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中国矿业大学2008届本科生毕业设计 第13页翻译部分Developing a Hybrid Programmable Logic Controller Platform for a Flexible Manufacturing SystemKENVINJ.MCDERMOTT AND WENLONG ALBERT YAONew Jersey Institute of Technology, Newark, NJ 07102Abstract in this article, we act according to the programmable logical control electric circuit and the personal computer based on (personal computer machine) visual person - machine connection (MMI) and the data collection (direct action) the unit, designs and carries out a nimble processing system (flexible processing system) the implementation to control the platform. The flexible processing systems essential aspect lies in it to adapt in the operating process flexibility. The programmable controller provides the feasible solution flexibility processing system application the method, uses based on personal computers MMI/DAS, relies on the programmable logical controller to apply rapidly in the execution sequence control policy. With manages front end MMI/DAS the personal computer machine to make the visual operation contact surface, fills the powerful graph and the report tool. May or uses from personal computers information by a companys local area network the client - server technology to assign. At present, because has for the microcomputer technology and software programming technology foundation gathering, many users will discover that the programmable logical controller will be one saves the cost in the middle and small scale factory real-time control process the method, when particularly the use mixing method will supervise personal computers time. This articles main goal lies in the certificate programmable logic controller to rapid and the repeated control duty sensitivity, and to use the personal computer machine to provide the information automation the flowing and to accept the operator to operate the intention, therefore, is also provides for the user along with the request change, but changes unceasingly a monitoring process tool. 1. Introduced That in many kinds of product manufacturing industries, the production automations form is also flexible processing system (FMS) first proposed in the 1970s. After flexible processing systems appearance enhancement labor productivity, flexible processing systems quantity large scale growth (Gruver and Zimmers1984). The entire world as a result of global competitions enhancement, the production cycle reduces gradually, and the production cost increases day by day usual, the flexible processing system is composed of group of machines or another automated workstation, forms standardized the subsystem, for example numerical control machining center, robot, vision system and a process station and so on. And this material handling system interconnection usually (Malek1991) actuates through a computer. Each standardizations system needs a standardized the control system, its different spare part by single controller. All standardizations subsystem looked like in the past equally by the computer control. These controllers carry out their task under a higher horizontal controllers surveillance. To the system, two control devices and the information flow needs to automate. The flexible processing systems essential aspect lies in its ability to change along with the control duty. This flexibility can produce the components type including it quantity and the type, the executive command, as well as improves the partial routes to flow ability. Finally, the control platform should have ability to cause the information flowing automation。Usually, some 3 kind of control platform uses in the flexible processing system: Minicomputer, miniature electronic accounting machine and programmable logical controller (Malek1991). The minicomputer is very suitable complex, large-scale, continual, rules and regulations control application. The programmable logical controller uses in rapid and the repeated logical control. The personal computer (personal computer) is suitable for the man-machine interface function. First, the programmable logical controller replace relay, for in the industry environment inland transportation extension, it may easily by workshop engineer and the attendants, is serviced by the factory electrician. At present, because has the microcomputer technology and software programming technology foundation gathering, many users will discover that the programmable logical controller will apply in the middle and small scale factory real-time control process is saves the cost method, when particularly the use mixing method will supervise.This articles goal lies in the processing flexibility processing systems modernized technology. Proposed that the design and the data-acquisition system direct action the flexible processing system which and the personal computer controls for the programmable logical controller based on the visual person - machine connection (MMI) construction. Its structure is as follows: The first 2 parts start from the flexible processing systems description to introduce in the New Jersey engineering institute (NJIT) factory center level manufacture system. 3rd part of description flexibility processing systems operation. 4 parts and 5 parts demonstrated is the present programmable logical controller control and the personal computer gives the flexible processing system according to MMI/DAS in the NJIT application. 6 parts contain this programmable logical controller control and the personal computer the flexible processing system application superiority according to MMI/DAS the outline2. Flexible processing systems description 1.One about flexible processing system developments viewpoint as shown in Figure. It is composed of the following several parts: (Mac and Kamisetty1991; Mat, 1987). the S1 processing transmission system it is composed of 4 vehicles, A, B, C and D, the fixed equipment installs above each, to each workstation transportations two shift table, TT, TT2 and double feed way material.Processes system to develop a mix nimbly programmable logical controller platform the NASA 11 numerical control milling machines, the milling machine makes each different part according to the computer control. General Electric Company P50. A sharing robot uses for to load and unload as well as delivers in the numerical control milling machine and between the transporting stands and transports. It contains 5 computer programs which assigns by the programmable logical controller. The computer program control robot loading places delivers between the system and the car as well as the numerically-controlled machine tool and cars material. Finally two procedures are accepting or the rejection components complete. The part delivers stands this station including a gravity slanting slot, provides the unfinished raw material. This station also contains two type warehouses one accepts components rejection components computer vision system. The vision system provides the visible self-supervisory part. It is the menu actuation, 64 step density steps edge detection system. Drill hole machine has the automatic drill hole function IBM 7535 industry robot in brief, the flexible processing system has two kind of robots; first, the numerical control milling machine, another is the material shift expulsion system, supervises including the van and the limit switch and by General Electrics six programmable logical controller, by based on personal computers machine visual MMI/DAS monitoring vision system.3. operation description the flexibility processing systems action cycle carries on by the following way: (1) At first, transporting systems all four vans are spatial may use for raw material to install to deliver the station. the .(2)GE robot will put one after the other these four parts was swindled when these four vehicle laying aside material to these four vans they along the clockwise migration. Above first step and the second step is the flexible processing systems loading part.( 3) chart 2 demonstration is once after these four different parts are loaded the position which is accepted by four vans.(4) the van stops when the drill hole machine, the IBM robot drills various holes on the different surface. (5)GE robot transfers to the van, moves once more components vehicle on to X position, and loads into it located at on the numerical control machine tables fixed equipment.(6) the spare part is installed on the numerical control milling machine, these robots withdraw, milling machine milling these request part.(7) milling finished, the machinist moved from the milling machine fixes on milling machines spare part.(8) the robot places the end product on the identical transport vehicle.( 9) signal transmits to the visible photography examination part. (10) The signal direction robot accepts the components or the rejection components signal. (11) Robot moves a receive procedure, and the laying aside components or move a rejection procedure in a receive vessel to lay aside the components in a rejection vessel. (12)Robot to the components stands, and loads into new components the vehicle .Vehicle is issued the system, next circulation start step 3 arrive 13 step.(13) steps forms a flexible processing systems operating cycle.4. uses the programmable logical controller to control set of flexible processing system the flexibility processing systems control systems important characteristic to be as follows: Because systems trapezoidal chart logic capability system easy to form, and can adapt the change; By the similar way, the system is relatively easy to the procedure and the material; The system easy maintains, and overhauls reduces, because the online diagnosis may provide and point out the question then reduction service accurately; Obviously, the system is easy and computer connection. The programmable logic controller widely uses a multi-purpose industrial used computer in the industrial data processing. It can store up the instruction to sorts likely in such tool control function, adjustment, counting, control industry machine and process arithmetic, data manipulation and communication. The programmable logical controller is chosen carries out an item based on the following characteristic flexible processing systems control duty: Good reliability few space requirement and factory operating environment; Factory engineer or the technical personnel easy to maintain; If the control demand change, the procedure can change; Can with other computer network communication and the connection.In this application, the General Electric Company series 6 programmable logic controllers are loaded with a family memory bank, and I/O connection and following input and output interface: 8 port 120 volt exchange load module, 8 port 24 volt current load module, 8 port 120 volt exchange output module. the form 1 summarizes the programmable logical controller system surveillance and the control flexible processing system equipment. Like that kind of normal opening and the shutting down switch will use in a relay system. The starting switch abruption is NO, the stop switch is NC, the selection switch level provides by the chosen position closed contact. The inferior wire congress follows the normal plant to assure the security, and causes to overhaul the logical method. the flexibility processing system logic trapezoidal chart control procedure development, on the system uses an industry personal computer and special-purpose software package logic in Engineer GE work grasps 6 systems. 6 logical systems use for to expand the off-line or the connection online programmable logic controller provide renew the demonstration continuously the reference table and the program logic logical trapezoidal chart. This logic demonstrated that the mark characteristic winds through according to the stave, therefore the program execution may track. In ladder logical program according to 117 flexible processing system print., when is started, allows the van to transfer to the next station. Trapezoidal chart 20 logical, if inputs micros witch I0020 to put through or micros witch I0018 is closed or I0006 does not revolve, this time output port 00014 effective. Inputs the micros witch I0020 instruction vehicle in the correct position. Anther input port I0018 permission when system service the operator overthrows this condition. If another vehicle attends the station, inputs the port I0006 control vehicle to stand. The output port 00014 transmit a signal 440 to provide the energy to the solenoid, like this loosens the vehicle, so that it can the movement to the next station.5. Based on personal computers visual movement personnel connection unit because of the microprocessor technology and software techniques centralism, the microcomputer already became in the operator application very useful. The microcomputer moves MMI/DAS to have effective, the visualization to fill the useful cartography and to report tools operation connection. Can - serves the technical network from microcomputers information through the factory local area network or the use customer to carry on the transmission and the dissemination. MMI/DAS based on the personal computer vision to develop into the monitoring process and the lumber data. The MMI function is dual. First, it opens between the instruction character and a process window then demonstration on CRT the information which processes. It also allows the operator to revise the time retards the constant, or the warning determined, but has not exchanged the ladder logic, production change of demand. Next, it provides an automatic data logging equipment. It can establish approves, migration, as well as lumber assign from personal computers information through the local area network use client server technology. An application procedure through gives Windows to use a group of ready-made newest origin data, from programmable logical controller through - - the RS232 connection there based on software development personal computer. This method permits the personal computer union controller, the programming terminal, the movement man-machine connection, and data-acquisition system in identical unit. These provide some based on the personal computer MMI/DAS software actuate based on the image and the mouse to design systems control policy, with dynamic operation demonstration. Because the open style architecture characteristic, it provides the support for the user algorithm and the local area network connection technology.6. Summarizes the this special use programmable logic controller control and obtains systems flexible manufacture system platform by the personal computer machine foundation management operation connection unit and the data is the completely automatic flexibility manufacture system platform. Flexible manufacture systems Fang Zhan the tendency is the reasonable price in the situation has the more open system controls and the flexibility. Therefore, the size and equipments nature is deciding this result. This programmable logical controller and the personal computer mixing management control platform has provided a price effective real-time control and the information transmission automation solution for the middle and small scale factory processing equipment. This systems progress lay in it to achieve the control system reliability, the equipment maintainability, the software maintainability and the system flexible request. This automations DAS system can give the output change and the daily output report, the progress of work report and the equipment warning as well as renewal production data ability. 中文译文开发一个混合的可编程的逻辑控制器成为一个柔性加工系统平台KENVINJ.MCDERMOTT和 WENLONG ALBERT YAO新泽西技术研究所,Newark,07102摘要在这篇文章里,我们根据可编程逻辑控制电路和个人计算机基于(个人计算机机)的视觉人-机接口(MMI)和数据收集(直接作用)单位,设计并执行一个灵活的加工系统(柔性加工系统)的实施控制站台。柔性加工系统的关键方面在于它适应操作过程中的灵活性。可编程控制器提供可行的解决柔性加工系统 申请的方法,使用基于个人计算机的MMI/DAS,凭借可编程逻辑控制器迅速应用于执行顺序的控制策略。用经营MMI/DAS前端的个人计算机机做视觉操作界面,充满强有力的图形和报告的工具。来自个人计算机 的信息可以被一个公司的局域网或者使用客户机-服务器技术分配。目前,由于带有为微型计算机技术和软件编程技术的基础的会集,很多用户会发现可编程逻辑控制器在中小型工厂实时控制过程中是一个节省成本的方法,尤其是当使用混合法监督个人计算机的时候 。这篇文章的主要的目的在于证明可编程逻辑控制器对迅速和反复的控制任务的敏感性,并且为使用个人计算机机提供信息自动化的流动和接受操作者操作意图,因此,也就是为用户提供随着要求变化而不断变化的监控过程的一件工具。1 .介绍在多种产品制造业内,生产自动化的形式也是一个柔性加工系统(FMS),首先在20世纪70年代提出。自从柔性加工系统的出现提高劳动生产率之后,柔性加工系统的数量正大幅度增长(格鲁弗,1984)。整个世界由于全球竞争的增强,生产周期逐渐降低,并且生产成本日益增加。通常,柔性加工系统由一组机器或者另一个自动化工作站组成,形成标准化的子系统,例如数控加工中心,机器人,视觉系统和一个过程站等。这些材料处理系统相互连接并且通常通过一台计算机来驱动。每个标准化的系统都需要一个标准化的控制系统,其不同的零部件被单独的控制器单一控制。所有标准化的子系统都象往常一样被计算机控制。这些控制器在一个更高的水平控制器的监督下执行他们的任务。对系统来说,两台控制装置和信息流需要自动化。柔性加工系统的关键方面在于它的能力随控制任务去变化。这种灵活性包括它能生产出零件类型的数量和种类,执行命令,以及将部分路线改进到流程的能力。最后,控制平台应该有能力使信息的流动自动化。通常,有3 类控制平台在柔性加工系统里使用:小型计算机,微型电子计算机和可编程逻辑控制器。小型计算机很适合复杂的,大规模,连续,规章的控制应用。可编程逻辑控制器用于迅速和反复的逻辑控制。个人计算机(个人计算机)适于人机接口功能。首先,可编程逻辑控制器替换继电器,为了在工业环境内运转,它可以容易被车间工程师和维护人员修正,被工厂电工维修。目前,由于带有微型计算机技术和软件编程技术的基础的会集,很多用户会发现可编程逻辑控制器应用到中小型工厂实时控制过程中是一个节省成本方法,尤其是当使用混合法监督个人计算机的时。这篇文章的目的在于处理柔性加工系统的现代化技术。提出设计和数据获取系统直接作用给可编程逻辑控制器控制的柔性加工系统 和个人计算机 基于视觉人-机接口(MMI)的建设。它的结构如下:前2 部分从柔性加工系统的描述开始介绍在新泽西工学院(NJIT)工厂中心层的制造系统。第3 部分描述柔性加工系统的操作。4 部分和5部分显示的是目前可编程逻辑控制器控制和个人计算机 根据MMI/DAS给柔性加工系统在NJIT的应用。6部分包含这个可编程逻辑控制器控制和个人计算机根据MMI/DAS给柔性加工系统应用优势的概要。2. 柔性加工系统的描述1. 关于柔性加工系统发展的观点如图一所示。它由下列几个部分组成:(麦克德莫特,1991; 麦克德莫特,1987)。S1处理传达系统 它由4 辆车组成,A,B,C 和D,固定设备安装在每一个上面, 到每个工作站的运输的两份转移表,TT 、TT2 和双输送装置材料。图1为NASA11台数控铣床,铣床根据计算机控制制造每个不同的部分。通用电气公司P50 机器人,一个共享的机器人用来装卸在数控铣床与搬运系统之间以及递送站和搬运系统之间的材料。它包含由可编程逻辑控制器分配的5个计算机程序。计算机程序控制机器人装载放在递送系统和小车以及数控机床和小车之间的材料。 最后两个程序在接受或者拒绝零件完成。部分递送站,这个站包括一个重力斜槽沟,提供未加工原料。这个站也包含两种类型仓,一个是接受零件一个拒绝零件。计算机视觉系统,这个视觉系统提供可视的自动监视部分。 它是菜单驱动,64步灰度等级,边缘察觉系统。图1 钻孔机器。一个具有自动钻孔功能的IBM 7535工业机器人。总之, 柔性加工系统具有二类机器人,一是数控铣床,另一个是物料转移输送系统,包括搬运车及其限位开关和一个由通用电器公司的六台可编程逻辑控制器监督的、由基于个人计算机机的视觉MMI / DAS的监控视觉系统。3.操作的描述柔性加工系统的工作周期以以下的方式进行:1.最初,搬运系统的所有的四辆搬运车都是空的可以用来将原材料装到递送站。2.GE机器人将这四部分一个接一个地放到这四辆搬运车上当这四辆车放置物料时它们会沿顺时针移动。上面的第一步和第二步是柔性加工系统的装载部分。3.图2显示的是一旦这四个不同部分被装载后的被四辆搬运车所接受的位置。4.当搬运车停止在钻孔机器时,IBM 机器人在不同的面上钻各种各样的洞。5.GE机器人移到搬运车,将零件再次车上移动到X位置,并且把它装进位于数控机器桌子的固定设备上。6.一旦零部件被安装在数控铣床上,那些机器人撤回,铣床铣削那些要求的部分。7.铣削完毕之后,机器手从铣床移动固定在铣床上的零部件。 图28.机器人将成品放在同一个输送车上。9.信号发送到可视照相检测部分。10.视觉系统分析零件并且输出信号指引机器人接受零件或者拒绝零件信号。11.机器人运行一个接收程序并且放置零件在一个接收的容器内或者运行一个拒绝程序将零件放置在一个拒绝的容器里。12机器人到零件递送站并且把一个新的零件装进车。13.车被发布到系统,下一个循环开始。步3到步13步形成一个柔性加工系统的工作循环。4.用可编程逻辑控制器控制一套柔性加工系统柔性加工系统 控制系统的重要的特征如下:1.因为系统的梯形图逻辑能力系统容易成形并且能够适应变化;2.以相似的方式,系统对程序和资料相对容易;3.系统容易保持,并且检修减少,因为在线诊断可以提供并准确指出问题进而减少维修;4.显而易见,系统容易与计算机接口。可编程逻辑控制器广泛地在工业数据处理里使用一台多功能的业用计算机。它能把指示储存到排序那样的工具控制功能中去, 调节,计数,控制工业机器和过程的算术,数据操作和通讯。可编程逻辑控制器被选择执行一项基于下列特征的柔性加工系统控制任务: 1.可靠性;2.较少的空间要求和工厂操作环境;3.工厂工程师或技术人员易于维护;4.如果控制需求变化,程序能被重新改变 5.能够与其他的计算机网络沟通和连接 图3在这个应用中,通用电气公司系列6 台可编程逻辑控制器装有一家存储器银行,并且I/O接口与下列输入和输出接口:8端口120伏交流输入模块,8端口24伏直流输入模块,8端口120伏交流输出模块。图3总结可编程逻辑控制器系统监视和控制的柔性加工系统设备的程序,像那种正常开启和关闭的开关将在一个换班制内使用。启动开关断路为NO,停止开关为NC,选择开关电平提供被选择位置的闭触点。次导线大会遵循正常的植物保证安全并且使检修更合乎逻辑的方法。柔性加工系统逻辑梯形图控制程序发展,在GE工作工程师系统上使用一个工业个人计算机和专用软件包逻辑掌握6个系统。6个逻辑系统用来扩展离线或者连接在线的可编程逻辑控制器以提供连续更新显示的参考桌子和程序逻辑的逻辑梯形图。那些逻辑展示符号特征按梯级流过,因此程序执行可以被跟踪。图3 说明在梯子逻辑程序里按117柔性加工系统打印程序资料,。按20,当被开动时,允许搬运车移到下一个站。梯形图20种逻辑状态,如果输入微型开关I0020被接通或者微型开关 I0018被关闭或者I0006不运转, 此时输出端口00014有效。输入微开关I0020指示车在正确的位置。另一个输入端口I0018允许在系统维修时操作者推翻这种状态。如果另一辆车出席车站,输入端口I0006控制车去站。输出端口00014 发送一个信号对螺线管440提供能量,这样松开车,以便它能运动到下一个站。5.基于个人计算机 的视觉运行人员接口单位藉由微处理器技术和软件技术的集中,微机已经在操作员应用中变得非常有用。微机运行MMI/DAS前置器产生有效的、可视化的充满有用的绘图和报告工具的操作接口。来自微机的信息能够通过工厂局域网或者使用客户-伺候器技术的网进行发送和传播。基于个人计算机 视觉发MMI/DAS被发展成为监控过程和木材数据。MMI的功能是双重的。首先,它打开在操作符和过程之间的一个窗口然后展示在CRT上的被处理的信息。它也允许操作者修改时间,延迟常量,或者警报确定点而没有兑换梯子逻辑,生产要求改变。其次,它提供一个自动的数据登录设备。它能建立批,移动,以及木材报告。来自个人计算机的信息可以被通过局域网使用客户机服务器技术分配。一个应用程序通过给Windows使用一组现成的最新型的起源数据,从可编程逻辑控制器通过RS232接口那里的基于软件开发的个人计算机。这种方法允许个人计算机结合控制器,编程末端,运行人机接口,并且数据获取系统在同一单位内。那些基于个人计算机 MMI/DAS软件提供一些基于图像和鼠标驱动设计开系统的控制策略,和动态操作展示。由于开放式体系结构特征,它为用户算法和局域网接口技术提供支持。图4图4举例说明了一个针对柔性制造系统的典型的操作接口和数据获得
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