CN103034180A - Novel automation electrical device for high purity graphite washing - Google Patents

Abstract

The invention provides a novel automation electrical device for high purity graphite washing. The novel automation electrical device for high purity graphite washing is a high purity graphite production line device. Procedures within every process and between processes are complex, manual operation mode and manual record are used in the prior art, which is not only waste in labour, low in equipment usage efficiency and low in output of per unit time, but also slow in fault finding and processing, seriously affecting the economic benefit. The high purity graphite washing novel automation electrical device is used for automatic controlling and managing the production process and uses current advanced industrial computer technology, namely programmable controller (PLC) technology and Ethernet technology. The process comprises the following steps: (1) decomposing every process of high purity graphite and high-carbon graphite, analyzing contact of within the process and between the process, using the PLC technology, controlling by software design, improving process automation level and improving the quality and economic benefit, (2) using the Ethernet technology to provide remote monitoring and management to production process, fault alarm and the like, according to the process requirement, designing a electrical schematic, programming a software, manufacturing equipment and providing remote monitoring and management.

Description

High purity graphite washing novel automatic electric device

One, technical field

The technology of this device belongs to the automatic control technology field

Two, background technology

1, adopting computer technology is Programmable Logic Controller technology and product, making software.

2, adopt ethernet communication and switch technology, set up the engineer station at central control room, carry out remote information management and monitoring.

3, under the process management software support of Siemens, the establishment monitoring software manages field data.

Three, summary of the invention

1, the high automation scheme of cost performance and reliability:

High-purity wash mill draining room is divided into two independent production lines that share three discharge pipes.Control system adopts the programmable logic controller (PLC) of the S7-400 of Siemens series, and the configuration monitoring picture adopts the software WINCC of form control center of Siemens Company's exploitation to make.

The object statistics that the production line in high-purity workshop need to be controlled is as follows:

1), valve quantity statistics:

2), need the I/O/simulating signal of collection:

3), hardware plan:

The built-in main frame of PLC0# central control board.

The PLCl# cabinet is placed slave station 1,2,3, No. 1 slave stations are 1 ET200M and 8 digital quantity input modules, and No. 2 slave stations are 1 ET200M and 8 digital quantity input modules, and No. 3 slave stations are 1 ET200M and 8 digital quantity input modules.

The PLC2# cabinet is placed slave station 4,5,6, No. 4 slave stations are 1 ET200M and 8 digital quantity input modules, and No. 5 slave stations are 1 ET200M and 8 digital quantity input modules, and No. 6 slave stations are 1 ET200M and 8 digital quantity input modules, and 1 SITOP power module.

The PLC3# cabinet is placed slave station 7,8,9, No. 7 slave stations are 1 ET200M and 8 digital quantity input modules, No. 8 slave stations are 1 ET200M and 8 digital quantity input modules, and No. 9 slave stations are 1 ET200M and 3 digital quantity input modules and 5 analog input modules, and 1 SITOP power module.

The PLC4# cabinet is placed slave station 10,11, No. 10 slave stations are 1 ET200M and 5 analog input modules, and No. 11 slave stations are 1 ET200M and 8 digital output modules, and 1 SITOP power module.

The PLC5# cabinet is placed slave station 12,13, No. 12 slave stations are 1 ET200M and 8 digital output modules, and No. 13 slave stations are 1 ET200M and 8 digital output modules, and 1 SITOP power module.

The PLC6# cabinet is placed slave station 14,15, No. 14 slave stations are 1 ET200M and 8 digital output modules, and No. 15 slave stations are 1 ET200M and 8 digital output modules, and 1 SITOP power module.

Main website is composed as follows:

Power module, this adopts this module input of PS30710A 120/230V AC output 24V DC power consumption 23W.

The CPU module, this adopts S7-417-2DP, and this CPU numerical quantities passage is supported 65536 I/O, and analog quantity is supported 4096 I/O, the maximum 12Mbit/s of transfer rate, DP slave station quantity is supported 124.

Communication module, adopt CP 343-1 with SIMATIC S7-300 be connected to Industrial Ethernet have 10/100 megabit per second complete/half-duplex transmission, band is useful on the self-induction function of automatic switch; RJ45 connects; Can realize multiple protocols of operation to host-host protocol TCP and UDP.

4), adopt the PROFIBUS-DP bus mode to carry out message exchange and processing between substation and the main website.

As the PROFIBUS of one of international standard for Fieldbus at field dominates such as industrial automation, transmission, chemical industry.Except the popular feature with fieldbus, PROFIBUS also has its unique advantage:

(1), bus transfer speed is high, reaches as high as 12Mbps;

(2), adopt principal and subordinate's polling mode, have definite transmission response time, can be applicable in the complex control system to the time requirement harshness;

(3), PROFIBUS satisfied from field layer to the requirement of factory management layer to network, wide application, product are various.Especially in the transmission industry, the product of nearly all famous producer is all supported PROFIBUS;

(4), multiple professional etiquette has guaranteed the versatility between the different manufacturers product.

5), adopt the communication module grind magnificent industrial computer and siemens switches, Siemens

Utilize ethernet technology, grind magnificent industrial computer by the CP communication module communication of switch and main website, reach with CPU in master station and carry out exchange message.

This design employing IPC-610/PCA-6010 installs display card additional at industrial computer and shows with the screen display of striding that realizes monitored picture

The technical characterstic of IPC:

(1), adopt all steel chemical industry cabinet meet " EIA " standard, strengthened anti-electromagnetic interference capability.

(2), adopt bus structure and modularity design technology.CPU and each functional module are all used the board plug type structure, and with the soft locking of depression bar, have improved shock resistance, anti-vibration ability.

(3), double fan is housed in the cabinet, malleation convection current air draft, and dirt filtrating screen is housed in order to dustproof.

(4), be furnished with highly reliably industrial power, and overvoltage, overcurrent protection are arranged.

(5), power supply and keyboard be all with electronic lock switch, can prevent illegal open and close and illegal keyboard input.

(6), has self-diagnostic function.

(7), can optionally match the I/O template.

(8), be provided with " house dog " timer, when barrier crashes for some reason, need not people's intervention and automatically reset.

(9), open good, compatible good, absorbed the repertoire of PC, can directly move the various application software of PC.

(10), configurable real time operating system, be convenient to scheduling and the operation of multitask.

(11), can adopt passive mother board (base plate), make things convenient for system upgrade.

The primary structure of IPC:

(1), all steel cabinet of all steel cabinet IPC is by standard design, shock resistance, anti-vibration, anti-electromagnetic interference (EMI), the passive backplane with the PC-bus compatibility can be installed in inside.

(2), the slot of passive backplane passive backplane is comprised of a plurality of slots of ISA and pci bus, the quantity of ISA or PCI slot and position have certain selection as required, this plate is four-layer structure, middle two-layer stratum and the bus plane of being respectively, this frame mode can weaken the phase mutual interference of logical signal on the plate and reduce source impedance.The base plate various integrated circuit boards of can pegging graft comprise CPU card, display card, control card, I/O card etc.

(3), industrial power is the AT Switching Power Supply, mean time between failures reaches 250,000 hours.

(4), the CPU card of CPU card: IPC has multiplely, can be divided into long card and half long card according to size, according to processor can be divided into 386,486,586, PII, PIII mainboard, visual oneself the needs of user are matched arbitrarily.Its principal feature is: working temperature 0-60 ℃; " house dog " timer is housed; Low-power consumption is 5V/2.5A when maximum.

(5), other accessories of other accessories: IPC are basically all compatible with PC, mainly contain CPU, internal memory, video card, hard disk, floppy drive, keyboard, mouse, CD-ROM drive, display etc.

The X212-2 switch is adopted in this design

With 12 10/100Mbit/s RJ45 interfaces, 2 100Mbit/s multimode optical fiber interfaces, the LED diagnostic function, the fault-signal demonstration, connection arranges button, the redundant power input, PROFINET IO design, network management can form redundancy loop, optional C-PLUG.

Transfer rate: the transfer rate of optics high-speed Ethernet port is 100Mbps.

Transmission mode: in IEEE 802.3 standards, the transmission mode of 100Base-FX is stipulated.

Because full-duplex mode and the transfer rate of optical delivery all can't be revised, therefore can't select auto negotiation.

Transmission medium: data transmission is undertaken by multimode optical fiber cable (FOC).Wavelength is 1310nm.

The core of employed multimode optical fiber cable is 50 or 62.5 μ m; Light source is LED.The external diameter of FOC is 125 μ m.

Transmission range: maximum transmitted scope (section length) is 3km.

Connector: cable connects by the BFOC socket.

This design adopts CP 343-1 communication module that SIMATIC S7-400 is connected to Industrial Ethernet 10/100Mbit/s, and complete/half-duplex transmission, band is for the self-induction function that automaticallyes switch between AUI, ITP and the RJ45 interface

General connection option is used for ITP, RJ45 and AUI

Adopt the multiple protocols of operation of ISO, TCP/IP and UDP host-host protocol

Adjustable Keep Alive function

The access list of configuration allows to enable for CP or controller access by TCP/IP with user and programmable controller arbitrarily.

2, adopt the trapezoidal language of PLC, carry out software programming, design, whole technological process is carried out robotization realize, control.

Software section adopts Siemens STEP7 programming, software by (OB1) main program block, (FC1～FC6, FC9) technological process program block, (FC20～FC22, FC24～FC30, FC33) process function program block, (FC40～FC45) condition judgment program block, (FC50, FC51) data operation program block and (DB1, DB2) data block form.

3, adopt the WINCC developing instrument, carry out software programming, design, whole technological process is carried out remote monitoring and management.

WINCC 6.2ASIA RT 65535 (64K point operation version) is adopted in this design

The Windows elements such as the menu of Siemens WinCC 6.2 and toolbar can be advanced in the user interface of application program by effective integration.Warning system has " report to the police and hide " function.Selectively some are reported to the police when having a large amount of warning message and hide, can obtain higher sharpness, this is specially adapted to relatively large factory.Also be integrated with simultaneously up-to-date database software Microsoft SQL Server 2005.Therefore, also can set up one now is used for by maximum 120000 concentrated archiving servers that the filing variable carries out the intensive data filing.In this process, can be a docking station with a Windows computer installation when needing, by its all current and historical data in can accessing database.And except can be used as a process visualization and operator station, a SIMATIC WinCC station can be that a SIMATIC all-in-service station is in order to effectively safeguard factory by configuration also now.WinCC is used for the visual of implementation procedure, and is operator's development graph user interface.1, WinCC allows the operator that process is observed.Process is presented on the screen in patterned mode.State in each process changes, all can update displayed.2, WinCC allows operator's control procedure.For example, the operator can or open valve from the pre-defined setting value of graphic user interface.3, in a single day critical process status occurs, will automatically send alerting signal.For example, if exceeded predefined limits value, will show a piece of news on the screen.When using WinCC to carry out work, both can the print procedure value, also can carry out electronic filing to process values.This is so that the documentation of process is more prone to and access production data in the past after allowing.The feature of WinCC can optimally be integrated into WinCC in user's the robotization and IT solution: 1, as the part of Siemens TIA concept (fully integrated robotization), WinCC can carry out work very in phase with the automated system that belongs to the SIMATIC Product Family.Simultaneously, also support the automated system of other manufacturer.2, by standard interface, WinCC can with other IT solution swap data, for example application program of MES and ERP layer (for example SAP system) or such as Microsoft Excel supervisor.3, open WinCC DLL (dynamic link library) allows the user to connect the program of oneself, thereby can control procedure and process data.4, can optimize customization WinCC, to satisfy the needs of process.Support large-scale configuration possibility, from single user system and client-server system until have the redundant distributions formula system of multiple servers.5, the WinCC configuration can be revised at any time, even also can revise after configuration is finished.This does not hinder already present project.

4, the main inventory of system hardware configuration (production line)

Sequence number	Title	Specifications and models
			1	Operator's console 1	1400W*750H*800D
2	Frame	6ES7 400-1JA01-0AA0
			3	CPU 414-2	6ES7 414-2XK05-0AB0
4	CP 443-1	6GK7 443-1EX20-0XE0
			5	Power supply	6ES7 407-0KA02-0AA0
6	Battery	6ES7 971-0BA00
			7	FEPROM	6ES7 952-1KM00-0AA0
8	PLC01	800*600*2200
			9	The SItop power supply	6EP 1336-3BA00
10	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0
			11	IM153-1	6ES7 153-1AA03-0XB0
12	Digital quantity input module	6ES7 321-1BL00-0AA0 (joining 40 needle connectors)
			13	The digital output module	6ES7 322-1BL00-0AA0 (joining 40 needle connectors)
14	PLC02	800*600*2200
			15	The SItop power supply	6EP 1336-3BA00
16	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0
			17	IM153-1	6ES7 153-1AA03-0XB0
18	Digital quantity input module	6ES7 321-1BL00-0AA0 (joining 40 needle connectors)
			19	The digital output module	6ES7 322-1BL00-0AA0 (joining 40 needle connectors)
20	PLC03	800*600*2200
			21	The SItop power supply	6EP 1336-3BA00
22	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0
			23	IM153-1	6ES7 153-1AA03-0XB0
24	Digital quantity input module	6ES7 321-1BL00-0AA0 (joining 40 needle connectors)
			25	The analog input module	6ES7 331-7KF02-0AB0 (joining 20 needle connectors)
26	PLC04	800*600*2200
			27	The SItop power supply	6EP 1336-3BA00
28	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0

[0073]

29	IM153-1	6ES7 153-1AA03-0XB0
			30	The analog input module	6ES7 331-7KF02-0AB0 (joining 20 needle connectors)
31	The digital output module	6ES7 322-1BL00-0AA0 (joining 40 needle connectors)
			32	PLC05	800*600*2200
33	The SItop power supply	6EP 1336-3BA00
			34	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0
35	IM153-1	6ES7 153-1AA03-0XB0
			36	Digital quantity input module	6ES7 321-1BL00-0AA0 (joining 40 needle connectors)
37	The digital output module	6ES7 322-1BL00-0AA0 (joining 40 needle connectors)
			38	PLC06	800*600*2200
39	The SItop power supply	6EP 1336-3BA00
			40	The DIN guide rail, 482mm	6ES7 390-1AE80-0XA0
41	IM153-1	6ES7 153-1AA03-0XB0
			42	Digital quantity input module	6ES7 321-1BL00-0AA0 (joining 40 needle connectors)
43	The digital output module	6ES7 322-1BL00-0AA0 (joining 40 needle connectors)

Four, description of drawings

1, Fig. 1: hardware configuration type selecting

1.: switch

2.: Ethernet

3.: operator station

4.: industrial computer

2, Fig. 2: control Software for Design FB(flow block)

3, Fig. 3: system hardware configuration

1.: the IO system

2.: the DP main station system

4, Fig. 4: device appearance structural drawing

1.: the cabinet top

2.: the element board top

3.: illuminating lamp

4.: illuminating lamp

5.: the cabinet top

6.: the dividing plate edge

7.: element board

8.: element board

9.: the back door

10.: element board

Element board

The Qianmen

The screen pack resistance

5, Fig. 5: components and parts schematic diagram in the cabinet

1.: the M frame

2.: switch

3.: operator station

4.: industrial computer

5.: the B01 frame

6, Fig. 6: B series frame schematic diagram

7, Fig. 7: electrical schematic diagram (part)

1.: No. 1 melting discharging request

2.: No. 2 melting discharging requests

3.: No. 3 melting discharging requests

4.: No. 4 melting discharging requests

5.: No. 5 melting discharging requests

6.: No. 6 melting discharging requests

7.: No. 7 melting discharging requests

8.: No. 8 melting discharging requests

8, Fig. 8:

1.: No. 9 melting discharging requests

2.: No. 10 melting discharging requests

3.: No. 11 melting discharging requests

4.: No. 12 melting discharging requests

5.: No. 1 leaching discharging request

6.: No. 2 leaching discharging requests

7.: No. 3 leaching discharging requests

9, Fig. 9: workshop cabinet picture group

10, Figure 10,11: the time of Siemens PLC C product and programming software and liquid level computing schematic diagram

11, Figure 12,13,14 monitored picture accompanying drawings

Five, embodiment

1, understand each technological process, comprehensive, overall system is carried out in the analysis process requirement.The statistical information point is matched the automated production of suitable producer.

2, preliminary software architecture, hardware configuration Selection and Design.

1), system software architecture design:

OB1: master routine tissue block

FC1: leaching process program piece

FC2: soda process program piece

FC3: reactor process program piece

FC4: automatic acid adding process program piece

FC5: assign storehouse process program piece

FC6: wash sour process program piece

FC9: quadratic acid reaction process program block

FC20: leaching function program piece

FC21: soda function program piece

FC22: reactor function program piece

FC24: assign storehouse function program piece

FC25: wash the acid function program block

FC26: quadratic acid response function program block

FC27: automatically add concentrated sulphuric acid function program piece

FC28: automatically add dilute sulfuric acid function program piece

FC29: Automatic-hydrogenation fluoric acid function program piece

FC30: automatic salt adding acid function program block

FC33: system failure function program piece

FC40: leaching is to soda condition judgment program block

FC41: soda is to reactor condition judgment program block

FC42: reactor is to dewaterer condition judgment program block

FC43: dewaterer is to assigning storehouse condition judgment program block

FC44: assign the storehouse to washing sour condition judgment program block

FC45: wash acid to normal-temperature reaction condition judgment program block

FC50: liquid level, temperature data operation program piece

FC51: time data operation program piece

DB1: liquid level, temperature simulation amount storage data block

DB2: time data storage data block

2), monitoring software design:

The monitoring software design has designed 23 pictures altogether, and on-the-spot monitoring and the information of management of needing has 3554.

3), system hardware configuration (accompanying drawing 3)

3, electrical principle design, device appearance structural design.

1), device appearance structural design (accompanying drawing 4)

2), components and parts schematic diagram (accompanying drawing 5,6) in the cabinet:

3), electrical principle diagram (Fig. 7,8)

4, manufacture, simulative debugging check.

5, site operation, debugging.

1), project profile

This project is that the high-purity wash mill in Chinese graphite application industry garden is controlled automatically.Totally 2 these outlines of production line are take article one apparatus for production line as example for native system, and second and article one are debugged equally.High-purity device scrubbing section robotization range of control is from the leaching can discharge valve to the storage tank material inlet valve of drying plant.

Main technique equipment has 12 melting cylinders, 6 leaching cans, 30 soda tanks, 6 reactors, 6 dewaterers, 6 slips to assign storehouse, 30 to wash that (wherein comprise 6 and be normal temperature acid reaction tank) filled with in acid, 5 covers add acid unit.

The opertaing device of native system comprises the major equipment of industrial computer, PLC system.All devices is installed in master-control room, and on-site signal and steering order etc. accesses corresponding PLC by cable or optical cable.

After the control system construction work installs, must work in coordination with each relevant departments and carry out total debugging of equipment and deliver for a check work.Automatic control system should be passed through strict system debug before formally coming into operation, could satisfy the requirement of safety in production, therefore write this interlock test run outline, and opertaing device relevant in the control system is tested, and had proposed inspection content and method.

The interlock test run of process equipment refers to each equipment in the process system, after finishing stand-alone debugging, works, heavily loaded combined debugging work empty by the equipment that technological requirement is carried out in system for making all devices harmoniously.The process equipment of participating in the interlock test run mainly contains: the PLC control system, 12 melting cylinders (R1～R12), 6 leaching cans (J1～J6), 30 soda tanks (XJ1-1～XJ1-15 and XJ2-1～XJ2-15), 6 reactors (F1～F6), 6 dewaterers (T1～T6), 6 slips are assigned storehouse (FP1～FP6), wash acid for 30 and fill with that (XS1-1～XS1-15 and XS2-1～XS2-15) be XS1-1 wherein, XS2-1, XS1-6, XS2-6, XS1-11, XS2-11 totally 6 be normal temperature acid reaction tank, 5 covers add the slip of acid unit and each equipment, acid, alkali, water, steam turnover valve, stirring motor, shift motor, liquid level gauge, thermometer etc.

The general contractor of each equipment should according to the unified plan of system interlink test run, be responsible for the separately interlock trial run work of equipment.The relevant systems such as power supply (containing relevant distribution), water supply, communication, broadcasting, fire-fighting must provide corresponding guarantee condition, to guarantee carrying out smoothly of interlock test run.

2), the purpose of unloaded interlock test run

Make process system under light condition, normally move by the process route of setting.For load interlock test run is got ready.Interlock between the single devices is confirmed.To mechanical, electrical, control, instrument, communication, etc. coordinate by production technology between the specialty and check.Further find the problems such as design, manufacturing, installation, propose solution and measures to rectify and reform.

3), the purpose of load interlock test run

(1), make process system under various load conditions, normally move by the process route of setting.

(2), inspection machine install after band material ruuning situation, the exposure device system problem that is in operation and exists as far as possible, and in time organize human and material resources is solved problem early during this period.

(3), improve that washing is produced, the ability of tissue, management and scheduling, each link relation of running of coordinating production.

4), equipment linkage test run discipline regulation

(1), non-interlock test run operating personnel must not enter interlock test run operation site.The operating personnel that participate in the interlock test run must not enter the perform region that has nothing to do with me.

(2), interlock test run operating personnel must wear test run operating personnel certificate, the anti-articles for use of labor of the dressing good regulation scene of being allowed for access.

(3), interlock test run operating personnel must be familiar with the responsibilities in this post, the work of grasping technology state and needing to do before work, and predict safely affirmation work etc., can work.

(4), the operation of interlock test run must obey the on-the-spot commander in chief's of test run unified command and scheduling, forbids polygon commander.

(5), interlock test run operating personnel must be energetic, ideological plane is concentrated, and obeys the on-the-spot commander in chief's of interlock test run instruction, strict implement operation standard and safety regulations, conscientiously operation.Forbid without authorization motor-car or without all kinds of switches of instruction random movement.

(6), interlock trial run work personnel must scrupulously abide by responsibility, before test run, conscientiously perform the regional every preliminary work of being in charge of separately, and the situation that will divide separately pipe unit notifies test run responsible officials at different levels at once, doubt instruction is had the right to offer one's comment and advise, in time report the higher level to command, carry out again work after understanding fully situation.

(7), this discipline is applicable to participate in all staff on board of interlock test run, comprises test run responsible officials at different levels.

5) robot control system(RCS) is debugged in earlier stage

Carrying out to carry out stand-alone debugging and unit uniting and adjustment to control system signal and relevant device before the unloaded uniting and adjustment of robot control system(RCS) and the load debugging, just can enter system integration and test after debugging is finished and load is debugged.Early stage debugging finish between automatic system and each tank the relevant devices such as valve, motor, liquid level gauge, thermometer between the correctness of interconnected relationship and the check of accuracy.By the debugging in early stage, the removal system mistake is striven for the once success of coordinated type car.

In the concrete equipment of debugging, must there be relevant device producer and installation company to participate in the debugging in early stage.Should guarantee in the early stage debugging that all devices major loop can not connect, only carry out input and checking, prevent any security incident.

The debugging scope:

1, hardware check

2, software inspection

3, equipment inspection

4, signal check

5, static debugging

6, dynamic debugging

Debugging is prepared:

1, collects design drawing and equipment data.Mainly comprise: each system schematic diagram, the backup system instructions, Siemens PLC C hardware description book, robot control system(RCS) I/O inventory is about measuring sensor and topworks's instructions.

2, new technology and equipment are investigated.

3, the equipment debugging of dispatching from the factory

4, be familiar with field apparatus and other control system

5, prepare debugging and use instrument and meter, such as four and half multimeters, screwdriver etc.

Commissioning requirements:

1, line inspection accuracy 100%

2, earthed system and stake resistance meet design code and Party A's requirement

3, the voltage fluctuation of 220V AC power and 48V direct supply is no more than positive and negatively 10%, and the voltage fluctuation of 24V direct supply is no more than positive and negative 15%

4, I/O passage accuracy 100%

5, the envelope test result is correct, and the dynamic test action is correct

6, backup system interlock protection devoting rate 100%, backup system drop into interlocking accuracy 100%PLC system debug purpose:

1, the Long-distance Control that guarantees all workshop appliances can be used, and feedback is correct

2, guarantee all correct inputs of sequence starting program

3, guarantee that all stored program controlled interlock logics are correct, guarantee used action in time without malfunction, without tripping PLC system debug condition:

1, system hardware installs, and host computer installs, and master station and follow station installs, and system possesses the energising requirement

2, on the spot measuring sensor installation, wiring is correct

3, on the spot topworks's installation, wiring is correct

4, the illumination of branch works and system electrical chamber is good

PLC system debug step:

1, feed cable inspection, the correctness of all power supplies of check system, namely according to design drawing to connecting system feed cable check, the power supply fetch bit is correct, the power supply access digit is correct, there are clear and definite sign and explanation in the cable both sides.

2, rack send electricity; at first all power switches of rack are placed the "off" position; turn-off the power supply that all enter rack; check whether wiring is correct on the electric power incoming line terminal; the feed voltage that whether has maloperation to cause in the control module cabinet, is extracted respectively the CPU module as requested; ethernet module and I/O module are to guarantee that the rack energising is the module burnout failure not to occur.Drop into total power switch at rack general supply place contact electric specialty and relevant speciality personnel.With multimeter measuring voltage value, its value is no more than the positive and negative 10% of ratings in module switch incoming power side, if error should be notified more greatly and send electric personnel to have a power failure to check, send electricity after qualified.

3, each module is sent electricity, and insert module is switched on successively, whether correctly observes its indicating status, perhaps with the engineer station module is carried out function and performance test.

4, I/O passage integrity checks, in the situation that disconnect all cables, carries out the integrity inspection with doing precision signal generator and the High Precision Multimeter input and output passage to the PLC system.

5, the analog input channel checks, sends the simulating signal that needs with the analog signals generator, checks displayed value engineer station or other programmable devices, record the input signal values and the output display value that do not have a passage, each passage detects three 0%, 50%, 100%.

6, the switching value input channel checks, with shorting stub shorting switch amount input signal, checks displayed value engineer station or other programmable devices.

7, the switching value output channel checks, export for the active switch amount, send the different instruction signal engineer station or other programmable devices, on the connection terminal of output channel, test the variation (voltage/no-voltage is arranged) of its output state with multimeter, export for the passive switch amount, send the different instruction signal engineer station or other programmable devices, test the variation of its output state with multimeter (logical lamp) at the connection terminal of output channel, for relay output, test (being placed on the 10M shelves apparent in view) with the nurse shelves difficult to understand of multimeter.

8, check cable connection, with multimeter or logical lamp all cables that access robot control system(RCS) are carried out Correctness checking.

9, measuring sensor inspection checks the inspection record of the measuring sensor relevant with robot control system(RCS).

, the inspection of topworks, topworks comprises motorized valve, motorized valve, pneumatic valve and motor etc. check its inspection record.

11., topworks operated from a distance test, after all topworkies carry out monomer debugging and finish, should carry out the operated from a distance test the engineer station, to guarantee that robot control system(RCS) is to the basic control function of topworks, at first in the robot control system(RCS) program, remove locking and the interlocking condition of topworks, this be primary also be necessary, otherwise when sending electricity or supplying gas in topworks, the interlock logic of robot control system(RCS) may make topworks's action.Its two pneumatic valve is supplied gas, and motorized valve send electricity, and the principle that motor send electricity will adhere to " whom who debugs is responsible for " is carried out.Forbid sticking to post the personnel that the engineer station carries out any operation and requires all to participate in debugging, until long-range test finishes, to prevent mishap.It is three when the engineer station carries out switch or start and stop to topworks, and personnel monitor and reporting facility action situation on the spot, and effectively 2. direction of operating should correctly 3. feedback signal should be consistent to judge 1. operated from a distance according to feedback signal.

12., software inspection and modification, the inspection of steering logic and modification, all steering logics should meet design and on-the-spot actual requirement, but because the factor of the aspects such as design alteration and device upgrade, so that former design section meets on-the-spot Secretary, the former actual mistake that do not have, but wrong on concrete configuration, so that can not realize former design idea, for the above problem that may occur, must check steering logic according to design drawing.

13., fixed value modification, jointly the definite value of robot control system(RCS) is made amendment with the Party A, pinpoint the problems and in time make amendment.

Static debugging:

Static debugging comprises three steps, the first interlock test, manually boot primary equipment and system, then make stand-by equipment and system be in stand-by state and Interlock Status, simulating a certain interlocking condition with signal generator on the spot, the said equipment and system are started automatically, and its result should meet system requirements and expected results, and requirement will check institute's interlocking condition.The second protection test manually boots primary equipment and system, is simulating a certain protective condition (trip condition) with the new generator on the spot, the said equipment is stopped rapidly or excises, and requires the protective condition of all devices is checked.The 3rd automatic control group test, an operation minute segment process robot control system(RCS) treats that all segmentation process systems tests are complete first, you go on foot order and walk to play all flow processs according to robot control system(RCS) to start process control system and be equipment in all process systems.

Dynamic test:

This test objective is that robot control system(RCS) is further adjusted, make robot control system(RCS) reach system fully and drop into requirement, for this reason, we must do following work, one, participate in the start-up course of visual plant, the problem that start-up course occurs is carried out technical Analysis, rationally change control logic, delay time and dynamic parameter etc.Its two, to implementing with the project that determine to increase and revise.

Before the uniting and adjustment, all devices producer reply equipment that supplies carries out hot-line test, and the motor machine should be able to continuous and steady operation 2 hours, and the electric valve actuating unit should be able to flexibility and reliability be changed, and all detector switches answer the installation site accurate.

6, the trial throw product stage.

Claims (6)

1. because the equipment in each work area is large and separation is too far away, therefore adopts and set up at the scene 15 substation patterns, carry out signals collecting, control outgoing management.

2. set up a main website at central control room, in main frame is arranged, adopt the DP bus mode, with each slave station communication, mutual exchange message, and process and controlled in main website.

3. set up long-range technological process monitoring station at Control Room, because distance between Control Room and central control room, adopt ethernet technology, set up as required the menu setecting mode, on same production line, select different flow processs to control the product of production different purity, and whole process is managed and monitors.

4. because there is two (containing) above same high purity graphite washing line at the scene, we adopt switch technology, respectively with industrial computer communication, two (containing) above production lines are managed and monitor.

5. adopt the PLC technology, according to the requirement of high purity graphite washing process, the soft and hardware scheme that the apolegamy cost performance is high, reliability is high, and carry out electrical principle design, technology controlling and process Software for Design, course controlling and managing Software for Design.

6. design outward appearance and the structure of this device, manufacture out this device, and come into operation.

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