贴片瓷介电容微器件装配联动机控制系统的研究与实现
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摘要
随着先进控制技术的发展,国内企业也在设备生产与改造中大量的应用了这些技术。论文针对广东南方宏明电子科技股份有限公司贴片瓷介电容微器件生产线改造项目,根据装配联动机的控制要求,设计开发了一套基于PROFIBUS-DP现场总线的自动控制系统,实现了改造后系统的自动化。
本文首先在理论上对现场总线控制系统进行了全面的探讨,介绍了现场总线的网络结构、特点以及五种典型的现场总线,并且尤为深入的对PROFIBUS现场总线进行了阐述。然后根据装配联动机实际应用的需要,从综合自动化控制系统的完整性、可靠性、开放性及可扩充性几个方面,比较分析了DCS、现场总线、工业以太网等工业应用网络的连接方式,提出基于PROFIBUS现场总线网络的通信方案。并根据装配联动机的工艺动作,制订整个装配过程自动控制系统的总体设计方案和具体实施细节。本文着重讨论装配联动机控制系统的软硬件结构、通讯组网以及它们的应用,并详细的分析了主从站之间的数据通信,使系统达到了较高的控制精度,提供了完成控制任务既方便又经济的解决方案。
论文分析了装配联动机回流焊炉的温度控制要求,根据其控制特点提出将常规PID控制与模糊控制相结合的控制策略,通过参数自整定模糊PID控制算法的设计、研究和MATLAB仿真实验,验证模糊自整定PID控制算法的有效性和精确性,保证贴片瓷介电容微器件的焊接质量。
论文还对监控系统的发展和MCGS组态监控软件进行介绍,并设计基于嵌入式技术的人机交互界面,完成装配联动机生产现场设备的三维实时监控,实现现场设备故障点的准确定位和故障的及时处理。
基于本文研究设计开发的装配联动机自动控制系统己投入实际运行,运行情况表明:系统性能稳定、人机界面友好、操作简便、生产效率比原来提高了8倍,能满足电容微器件装配联动机安全高效运行的要求。
With the development of advanced control technology in foreign countries, it has been applied widely in equipment production and reconstruction in domestic corporation. This paper is aimed at the reconstruction project of chip ceramic capacitor production line of Guangdong South Hong Ming electronic science and technology co., Ltd to design a set of automatic control system based on PROFIBUS-DP fieldbus according to control demand of assembly-linking machine. After the reconstruction it realized the complete automation of the system.
First of all, this Paper discusses the fieldbus control system comprehensively in theory, introduces the network structure of fieldbus, its features as well as five kinds of typical field bus. The paper elaborates on the PROFIBUS fieldbus. And then, considering the actual demand of assembly-linking machine, this Paper compares and analyzes the connecting ways of DCS, fieldbus, industrial Ethernet from the field of automatic control system’s integrality, reliability, extendibility and open capability, and puts forward a communication network scheme based on PROFIBUS fieldbus. What’s more, this paper formulates the overall design scheme of automatic control system and detailed implementation. The paper emphasizes on the Hardware and software of assembly-linking machine’s control system, communications network and its application. The system reaches a high control precision and provides convenient as well as economic Solutions to finish the control task.
The paper analyzes the requirement of assembly-linking machine’s reflow furnace PID control and fuzzy control according to its control features. It demonstrates the validity and puts forward control strategy of combining normal and accuracy of Fuzzy-PID control by means of Parameter self-adjusting Fuzzy-PID control’s design, investigation and MATLAB Simulation experiment, and ensures jointing quality of chip ceramic capacitor.
What’s more, this paper introduces development of monitoring system and MCGS configuration monitoring software, designs Man-machine interface based on embedded technology, accomplishes three-dimensional real-time monitoring of assembly-linking machine’s scene production equipment and realizes the concise orientation of malfunction and its timely treatment.
The automatic control system has been put into use, the result shows: Performance of the system is stable, the man-machine interface is friendly, the operation is easy, and the efficiency is increased by 8 times. It makes the assembly-linking machine operate safely and effectively.
本文首先在理论上对现场总线控制系统进行了全面的探讨,介绍了现场总线的网络结构、特点以及五种典型的现场总线,并且尤为深入的对PROFIBUS现场总线进行了阐述。然后根据装配联动机实际应用的需要,从综合自动化控制系统的完整性、可靠性、开放性及可扩充性几个方面,比较分析了DCS、现场总线、工业以太网等工业应用网络的连接方式,提出基于PROFIBUS现场总线网络的通信方案。并根据装配联动机的工艺动作,制订整个装配过程自动控制系统的总体设计方案和具体实施细节。本文着重讨论装配联动机控制系统的软硬件结构、通讯组网以及它们的应用,并详细的分析了主从站之间的数据通信,使系统达到了较高的控制精度,提供了完成控制任务既方便又经济的解决方案。
论文分析了装配联动机回流焊炉的温度控制要求,根据其控制特点提出将常规PID控制与模糊控制相结合的控制策略,通过参数自整定模糊PID控制算法的设计、研究和MATLAB仿真实验,验证模糊自整定PID控制算法的有效性和精确性,保证贴片瓷介电容微器件的焊接质量。
论文还对监控系统的发展和MCGS组态监控软件进行介绍,并设计基于嵌入式技术的人机交互界面,完成装配联动机生产现场设备的三维实时监控,实现现场设备故障点的准确定位和故障的及时处理。
基于本文研究设计开发的装配联动机自动控制系统己投入实际运行,运行情况表明:系统性能稳定、人机界面友好、操作简便、生产效率比原来提高了8倍,能满足电容微器件装配联动机安全高效运行的要求。
With the development of advanced control technology in foreign countries, it has been applied widely in equipment production and reconstruction in domestic corporation. This paper is aimed at the reconstruction project of chip ceramic capacitor production line of Guangdong South Hong Ming electronic science and technology co., Ltd to design a set of automatic control system based on PROFIBUS-DP fieldbus according to control demand of assembly-linking machine. After the reconstruction it realized the complete automation of the system.
First of all, this Paper discusses the fieldbus control system comprehensively in theory, introduces the network structure of fieldbus, its features as well as five kinds of typical field bus. The paper elaborates on the PROFIBUS fieldbus. And then, considering the actual demand of assembly-linking machine, this Paper compares and analyzes the connecting ways of DCS, fieldbus, industrial Ethernet from the field of automatic control system’s integrality, reliability, extendibility and open capability, and puts forward a communication network scheme based on PROFIBUS fieldbus. What’s more, this paper formulates the overall design scheme of automatic control system and detailed implementation. The paper emphasizes on the Hardware and software of assembly-linking machine’s control system, communications network and its application. The system reaches a high control precision and provides convenient as well as economic Solutions to finish the control task.
The paper analyzes the requirement of assembly-linking machine’s reflow furnace PID control and fuzzy control according to its control features. It demonstrates the validity and puts forward control strategy of combining normal and accuracy of Fuzzy-PID control by means of Parameter self-adjusting Fuzzy-PID control’s design, investigation and MATLAB Simulation experiment, and ensures jointing quality of chip ceramic capacitor.
What’s more, this paper introduces development of monitoring system and MCGS configuration monitoring software, designs Man-machine interface based on embedded technology, accomplishes three-dimensional real-time monitoring of assembly-linking machine’s scene production equipment and realizes the concise orientation of malfunction and its timely treatment.
The automatic control system has been put into use, the result shows: Performance of the system is stable, the man-machine interface is friendly, the operation is easy, and the efficiency is increased by 8 times. It makes the assembly-linking machine operate safely and effectively.
引文
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[8]李正军.现场总线与工业以太网及其运用系统设计.北京:人民邮电出版社,2006,3-95
[9] McFarland, Andy. Fieldbus Review. Sensor Review.1997,17(3):204-210
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[11]高明嶂.现场总线的发展趋势.仪器仪表用户,2005,12(6):160-161
[12]周勇,张广川.基于基金会现场总线的控制系统.工业控制计算机,2005,18(11):16-18
[13]顾洪军.工业企业网与现场总线技术及应用.北京:人民邮电出版社,2002,12-15
[14]朱松梅,朱志松.LonWorks总线在楼字自动化系统中的应用.自动化技术与应用,2005,24(5):51-53
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[19]王文建.基于CAN总线的现场设备控制管理系统.自动化博览,2005,22(5):38-39,42
[20]许庆星.现场总线控制系统及应用.电气时代,2000,(8):6-9
[21]孙喜田.关于我国现场总线技术发展策略的思考.自动化与仪器仪表,2000,(5):1-3
[22]王德志.基于现场总线技术的井下铁路信号PLC联锁控制系统研究与应用:[硕士学位论文].阜新:辽宁工程技术大学,2003:2-4
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[24]刘文文.PROFIBUS现场总线实时性能研究:[硕士学位论文].西安:西安电子科技大学, 2007:11-12
[25]况群意.基于Profibus现场总线控制的闸门监控系统的开发:[硕士学位论文].武汉:武汉理工大学,2004:14-16
[26]SIEMENS.SIMATIC PROFIBUS接口部件.2000,(3):5-23
[27]Hua Pang; Long Wang; Jialin Ma. Research of Monitoring and Configuration Platform in Foundation Fieldbus Control System. IEEE International Conference on Integration Technology (ICIT '07), 2007: 756-759
[28]魏军.PROFIBUS总线技术研究及监控系统的实现:[硕士学位论文].南京:南京航空航天大学,2004:19-20
[29]沈爱弟,林叶春,郑华耀.现场总线控制系统实验装置的开发与应用.实验室研究与探索, 2005,24(9):23-26
[30]叶彬强.Profibus-PA现场总线技术研究和应用.石油化工自动化,2005,(5):64-67
[31]Telecommunication Networks Group, Technical University Berlin. Analysis of the PROFIBUS Token Passing Protocol over Wireless Links. Proceedings of the 2002 IEEE International Symposium on Industrial Electronics (ISIE 2002), Vol.1:56-60
[32]唐济扬.现场总线(Profibus)技术应用指南.中国现场总线(Profibus)专业委员会, 1998:21-35
[33]孙鹤旭,梁涛,云利军.Profibus现场总线控制系统的设计与开发.北京:国防工业出版社, 2007,23-25
[34]俞琦.自适应模糊PID在自动下芯机控制系统中的应用研究:[硕士学位论文].合肥:合肥工业大学,2004:37-38
[35]曾光奇,胡君安,王东,刘春玲.模糊控制理论与工程应用.武汉:华中科技大学出版社, 2006,57-95
[36]张磊,范维浩.MPI网络技术在水厂中的应用.计算技术与自动化,2002,21(4):40-44
[37]G.Nakagawa, S.Sasaki, N.Yamamoto, et al.High Power and High Sensitivity PLC Module using a Novel Corner-illuminated PIN Photodiode. 1997 Electronic Components and Technology Conference: 607-613
[38]左立健.设备故障诊断技术的应用实例.自控与监测,2005,(1):54-55
[39]韩思亮,汤建新,马皓.PLC远程监控与故障诊断系统设计与实现.工业仪表与自动化装置, 2005,(1):23-26
[40]文乔.利用PLC设计故障诊断系统.PLC、工控机与集散控制系统,2004,(6):46-48
[41]夏建亭.回流焊温度分布曲线图.电子工艺技术,1998,19(3):106-107
[42]Maeda M, Murakami S.A. Design of fuzzy logic controller. Information Sciences, 1988, (45):315-330
[43]关学忠,高杉,增凡军.锅炉燃烧器模糊PID复合控制器的设计.工业控制与应用, 2003,22(7):53-56
[44]闻新,周露,李东江.MATLAB模糊工具箱的分析与应用.北京:科学出版社,2001,35-46
[45]黄洪钟.机械设计模糊优化原理及应用.北京:科学出版社,1997,76-78
[46]石辛民,郝整清.模糊控制及其MATLAB仿真.北京:清华大学出版社,北京交通大学出版社, 2008,48-49
[47]MCGS工控组态软件参考手册.北京:北京昆仑通态自动化软件科技有限公司,2002:1-100
[48]王兰香,基于Profibus-DP现场总线技术的设备组态研究:[硕士学位论文].北京:华北电力大学,2006:24-29
[49]吴作明,工控组态软件与PLC运用技术.北京:北京航空航天大学出版社,2007,1-6
[50]李丹.MCGS监控组态软件在密地选矿厂破碎车间的应用:[硕士学位论文].昆明:昆明理工大学,2004:20-22
[2]于凌宇.世界片式元器件产业发展走势.世界产品与技术,2000,(5):12-14
[3]温和荣.一个有价值的经验之谈SMT贴装机的选择购.世界电子元器件,1997,(5):2-7
[4]鲜飞.SMT设备的最新发展趋势.电子与封装,2008,8(4):8-11
[5]考旭东.基于DCS的先进控制方法在醋酸乙烯生产过程中的应用:[硕士学位论文].哈尔滨:黑龙江大学,2007:6-7
[6]权万锋.基于PROFIBUS的水洗牵伸机组自动控制系统设计:[硕士学位论文].燕山:燕山大学,2006:2-3
[7]龙凯.基于PROFIBUS的PLC控制系统的设计研究:[硕士学位论文].武汉:武汉科技大学, 2008:12-15
[8]李正军.现场总线与工业以太网及其运用系统设计.北京:人民邮电出版社,2006,3-95
[9] McFarland, Andy. Fieldbus Review. Sensor Review.1997,17(3):204-210
[10]白焰.现场总线控制系统的体系结构及其应用问题分析.中国电力,2002,20(2):59-62
[11]高明嶂.现场总线的发展趋势.仪器仪表用户,2005,12(6):160-161
[12]周勇,张广川.基于基金会现场总线的控制系统.工业控制计算机,2005,18(11):16-18
[13]顾洪军.工业企业网与现场总线技术及应用.北京:人民邮电出版社,2002,12-15
[14]朱松梅,朱志松.LonWorks总线在楼字自动化系统中的应用.自动化技术与应用,2005,24(5):51-53
[15]冯池斌,吴波.Profibus现场总线技术.自动化与仪器仪表,2002,(2):1-4
[16]于浩洋.Profibus现场总线概述.自动化与仪表,2002,(2):18-21
[17]H.Kleines, K.Zwoll, M.Drochner, J.Sarkadi.Integration of Industrial Automation Equipment in Experiment Control Systems via PROFIBUS-developments and Experiences at Forschungszentrum Julich. IEEE Transactions on Nuclear Science, 2000, 47(4): 229-235
[18]G.B.Lohiya, S.N.Talbar.Design of Profibus Compatible Smart Transmitter. 1998 IEEE Region 10 International Conference on Global Connectivity in Energy, Computer, Communication and Control(TENCON '98),Vol.2:365-368
[19]王文建.基于CAN总线的现场设备控制管理系统.自动化博览,2005,22(5):38-39,42
[20]许庆星.现场总线控制系统及应用.电气时代,2000,(8):6-9
[21]孙喜田.关于我国现场总线技术发展策略的思考.自动化与仪器仪表,2000,(5):1-3
[22]王德志.基于现场总线技术的井下铁路信号PLC联锁控制系统研究与应用:[硕士学位论文].阜新:辽宁工程技术大学,2003:2-4
[23]张浩,谭克云,朱守云.现场总线与工业以太网应用技术手册(第一册).上海:上海科学技术出版社,2001,70-85
[24]刘文文.PROFIBUS现场总线实时性能研究:[硕士学位论文].西安:西安电子科技大学, 2007:11-12
[25]况群意.基于Profibus现场总线控制的闸门监控系统的开发:[硕士学位论文].武汉:武汉理工大学,2004:14-16
[26]SIEMENS.SIMATIC PROFIBUS接口部件.2000,(3):5-23
[27]Hua Pang; Long Wang; Jialin Ma. Research of Monitoring and Configuration Platform in Foundation Fieldbus Control System. IEEE International Conference on Integration Technology (ICIT '07), 2007: 756-759
[28]魏军.PROFIBUS总线技术研究及监控系统的实现:[硕士学位论文].南京:南京航空航天大学,2004:19-20
[29]沈爱弟,林叶春,郑华耀.现场总线控制系统实验装置的开发与应用.实验室研究与探索, 2005,24(9):23-26
[30]叶彬强.Profibus-PA现场总线技术研究和应用.石油化工自动化,2005,(5):64-67
[31]Telecommunication Networks Group, Technical University Berlin. Analysis of the PROFIBUS Token Passing Protocol over Wireless Links. Proceedings of the 2002 IEEE International Symposium on Industrial Electronics (ISIE 2002), Vol.1:56-60
[32]唐济扬.现场总线(Profibus)技术应用指南.中国现场总线(Profibus)专业委员会, 1998:21-35
[33]孙鹤旭,梁涛,云利军.Profibus现场总线控制系统的设计与开发.北京:国防工业出版社, 2007,23-25
[34]俞琦.自适应模糊PID在自动下芯机控制系统中的应用研究:[硕士学位论文].合肥:合肥工业大学,2004:37-38
[35]曾光奇,胡君安,王东,刘春玲.模糊控制理论与工程应用.武汉:华中科技大学出版社, 2006,57-95
[36]张磊,范维浩.MPI网络技术在水厂中的应用.计算技术与自动化,2002,21(4):40-44
[37]G.Nakagawa, S.Sasaki, N.Yamamoto, et al.High Power and High Sensitivity PLC Module using a Novel Corner-illuminated PIN Photodiode. 1997 Electronic Components and Technology Conference: 607-613
[38]左立健.设备故障诊断技术的应用实例.自控与监测,2005,(1):54-55
[39]韩思亮,汤建新,马皓.PLC远程监控与故障诊断系统设计与实现.工业仪表与自动化装置, 2005,(1):23-26
[40]文乔.利用PLC设计故障诊断系统.PLC、工控机与集散控制系统,2004,(6):46-48
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