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全新的自动化包装系统解决了哪些过时的技术问题?

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  解决过时的技术问题是自动化包装项目中有一种必然的发展趋势。传统的自动化包装设备生产线所在的工厂区域每年必须保证全年无休的安全运行,因此,对其态度通常是“如果没有故障,就不需要修理”。近年来,由于技术过时,制造商不得不对包装系统进行升级。面临的挑战主要来自两个方面:
  It is an inevitable trend to solve the outdated technical problems in automatic packaging projects. The factory area where the traditional automatic packaging equipment production line is located must ensure the safe operation throughout the year. Therefore, the attitude towards it is usually "if there is no fault, there is no need to repair". In recent years, due to outdated technology, manufacturers have to upgrade the packaging system. The challenges are mainly from two aspects
  1. 从来没有一个好的停机时间窗口。
  1. There has never been a good downtime window.
  2. 系统需要在外观和性能上与停机前完全一样,以确保运行人员能够接受该系统。
  2. The appearance and performance of the system should be exactly the same as before shutdown to ensure that the operator can accept the system.
  针对以上两个方面的主要问题,一家面包生产线自动化包装系统的升级解决了这些问题,升级了旧的控制系统,以控制和协调面包工厂的包装区域。包装系统由7 条生产线组成,每分钟处理20箱以上。本次面包工厂的自动化包装设备生产线的主要技术和策略是:
  In view of the above two main problems, the automatic packaging system of a bread production line was upgraded to solve these problems. The old control system was upgraded to control and coordinate the packaging area of the bread factory. The packaging system consists of 7 production lines, handling more than 20 boxes per minute. The main technologies and Strategies of the automatic packaging equipment production line of the bread factory are as follows:
  ■ 通过预先识别已知的风险,制定缓解和应急计划。
  ■ develop mitigation and contingency plans by identifying known risks in advance.
  ■ 对于老旧的项目,尤其是在时间至关重要的包装应用中,升级系统时应密切注意序列时间。
  ■ for old projects, especially in packaging applications where time is critical, pay close attention to sequence time when upgrading the system.
  ■ 系统升级需要在所有生产设施之间进行跟踪并保持一致性。
  ■ system upgrades need to be tracked and consistent across all production facilities.
  该项目需要用4 个机架和超过60 个模块来替换PLC 5/25,这些模块通过远程输入/ 输出(I/O)和过时的数据高速公路通信协议,连接到工厂的其余部分。旧的处理器和系统被可编程的自动化控制器和基于以太网的I/O 所取代。此外,还涉及到软件转换、更新现有(破烂不堪的)电气设计文档。
  The project required the replacement of PLC 5 / 25 with four racks and more than 60 modules, which were connected to the rest of the plant via remote input / output (I / O) and outdated data highway communication protocols. The old processors and systems were replaced by programmable automation controllers and Ethernet based I / O. In addition, it involves software conversion and updating of existing (dilapidated) electrical design documents.
  该项目的目标是更换所有硬件(现有处理器已满,无法再对其进行编辑),测试新的I/O,并在启动前确保现有功能的顺利实现。由于项目基于硬件,并且缺少人机界面(HMI)屏幕,因此在上线之前无法对这类项目实现全面仿真以进行测试。为了降低启动风险,项目团队在代码转换、交叉检查代码、图纸审查等质量管理方面格外小心。
  The goal of the project is to replace all hardware (the existing processor is full and can no longer be edited), test the new I / O, and ensure the smooth implementation of existing functions before startup. As the project is based on hardware and lacks human machine interface (HMI) screen, it is impossible to fully simulate and test such projects before it is launched. In order to reduce the start-up risk, the project team takes extra care in quality management such as code conversion, cross check code, drawing review, etc.
“全新的自动化包装系统”style="text-align:
  停机时间选在了劳动节周末的3 天假日。电气团队从周六上午12 点开始接线,并在周日凌晨5 点结束。在周日,控制团队完成了所有I /O 检查,然后进行了功能测试。由于质量控制做的很好,代码测试进行得很顺利,经过漫长的一天,团队最终完成了工作。这样,就有星期一作为备用,可以进行更多测试,并有机会让团队休息。该系统在启动爬坡(2 秒内从0 到60 mph)内进行了调试,与项目相关的总停机时间仅为20 分钟。通过强有力的执行质量计划、严格的验收时间表和详细的现场验收测试清单,该项目的完成时间比预期提前,这为额外的测试留出了缓冲时间。
  The downtime was selected on the 3-day holiday of the Labor Day weekend. The electrical team started wiring at 12 a.m. on Saturday and ended at 5 a.m. on Sunday. On Sunday, the control team completed all I / O checks and then conducted functional tests. Due to the good quality control, the code testing went smoothly, and after a long day, the team finally completed the work. That way, there's Monday as a backup, more testing and a chance to rest the team. The system was debugged within the start-up ramp (from 0 to 60 mph in 2 seconds), and the total project related downtime was only 20 minutes. Through a strong execution quality plan, strict acceptance schedule and detailed site acceptance test list, the completion time of the project is ahead of schedule, which provides buffer time for additional tests.
  根据应用需求和环境的不同,自动化系统集成商需要为客户考虑到所有可能出现的困难,先进的自动化包装设备和控制技术可以帮助制造商实现包装系统的集成和升级,帮助企业在最短的时间内,实现系统的平稳升级和高效运营。
  According to the different application requirements and environments, automation system integrators need to consider all possible difficulties for customers. Advanced automatic packaging equipment and control technology can help manufacturers realize the integration and upgrading of packaging system, and help enterprises achieve smooth upgrading and efficient operation of the system in the shortest time.