纸厂复卷机自动化培训教材(中)课件.ppt

1、1QDW/T 7300复卷机复卷机自动化培训教材自动化培训教材（中）（中）2E-stop trip wire when tripped switch is at“0”position and orange light is lit.EMERGENCY STOP Position=033SAFETY DEVICES=04 Safety locksSafety lock of safety doors.4SAFETY DEVICES=04 Safety locks5 Winder has one light curtain/safety beam at 卷取部分(04S720)Safety bea

2、m-the purpose is to prevent dangerous movements of devices when someone inside the 卷取部分 area.Prevention is hardwired and it disconnects power supply of device if safety circuit not resetted.Safety beam system consists of the following parts:sender/receiver part mirror element safety relay(in PC10)an

3、d circuit+reset button 卷取部分 safety beam prevents 踢辊器,rider roll and service hatch movements if not reset.Status light is red(at the top of the sender part)when safety circuit is open and relay not reseted and green when circuit is ok and relay reseted.Safety beam can be acknowledged at panel CP12.Sa

4、fety circuit (beam)OKif green light1/2SAFETY DEVICES=04 Safety beam6Safety beam circuits open and not reseted.Safety beam circuits ok and reset.Safety beam safety relay in PC10SAFETY DEVICES=04 Safety beam2/27FIELD EQUIPMENTSnINDUCTIVE SENSORSnPHOTOCELLSnABSOLUTE ENCODERSnANALOG SENSORS8INDUCTIVE SE

5、NSORSBrand of sensors:nTurcknBi15-CK40-AP6X2-H1141(15mm,NO)nBi8-M18-VP4X-H1141(8mm NO/NC)nBi15-CP40-VP4X2(15mm,NO/NC)nIFMnIM 5057(15mm)nFestonSMT-8F-PS-24V-K-0,3-M12(cylinder limit switch)IFM:IM5057TURCK-Bi15-CK40-AP6X2-H1141-the most common sensor type used in the windersTURCK-Bi8-M18-VP4X-H1141FES

6、TO-SMT-8F-PS-24V-K-0,3-M12TURCK-Bi15-CP40-VP4X29WEB CUTTING DEVICESensor:13S219 DS and 13S227 OS-Web cutting device auxiliary cylinder 1 closeduIndicates when cutting device under rear drum is up/close position(near rear drum)uGives permission to cutting device up/down movementuSTEP 7 Block FC1310DS

7、 CORE LOCK CLOSE(16S126)DS CORE LOCK OPEN(16S128)nIndicates when drive side core lock is close and open positionnGives permission to core guiders up and down movementnClose position is interlock to winders run permission.nSTEP 7 Block FC16DS CORE LOCK11RIDER ROLL LOCK CLOSE OS(19S122)nIndicates when

8、 rider roll lock(s)is closed(=down position).RIDER ROLL LOCKRIDER ROLL LOCK CLOSE DS(19S127)12BELT JOINT AT OS(20S412)BELT JOINT AT DS(20S417)nIndicates when knife transfer belt joint are either Operation/Drive side end.KNIFE TRANSFER BELTBelt joint13nAlarm is given to Slitting station operation pan

9、el CP15 when OS/DS sensor detect belt jointnDuring automatic knife transfer belt joint centered automatic by software.nSemiauto knife transfer when alarm occurs belt joint must be operated manually by using switch to opposite directionKNIFE TRANSFER BELTBelt jointAlarm window at CP15 operating scree

10、n14TAMBOUR COUPLING CLOSED(22S117)TAMBOUR COUPLING OPEN(22S119)nIndicates when tambour coupling is open and in closed position.nControlling possible only when unwinder is in center positionnClose position is interlock to winders run permission.nSTEP 7 Block FC22TAMBOUR COUPLING22S119Sensors location

11、 under cover22S11715SAFETY FENCE UP POSITION(25S120)SAFETY FENCE DOWN POSITION(25S122)SAFETY FENCE MIDDLE POSITION(25S124)n25S120 Indicates when safety fence is at up position.Gives permission for 踢辊器 to move forward/backward.n25S122 Indicates when safety fence is at down position.Down position is i

12、nterlock for winder Run permission.n25S124 Indicates when safety fence go through middle position.During down-movement when middle position reached safety fence reducing speed automatically.nSTEP 7,FC25SAFETY FENCE25S12225S12425S12016SAFETY FENCE LOCK OPEN OS(25S213)SAFETY FENCE LOCK OPEN DS(25S217)

13、nIndicates when safety fence locks are at open and close position.nGives permission to roll nip safety fence down control movement.nStep7 FC25 Network 3SAFETY FENCE LOCKS17SAFETY FENCE LOCK OPEN OS(25S213)SAFETY FENCE LOCK CLOSE OS(25S215)SAFETY FENCE LOCK OPEN DS(25S217)SAFETY FENCE LOCK CLOSE DS(2

14、5S219)SAFETY FENCE LOCKS25S21325S21518TAMBOUR SHAFT LOCKED DS(28S225)TAMBOUR SHAFT LOCKED OS(28S216)nIndicates when tambour locks are closed and also reel spool is detected.nGives permission to tambour coupling close-control.nWhen reel spool is detected coupling close function does not work if drive

15、 system are not readynClose position is interlock to winders run permission.nSTEP 7 Block FC28TAMBOUR LOCKS19CORE LOADING LIFTER36S819OS CORE LIFTER UP LIMIT(36S819)DS CORE LIFTER UP LIMIT(36S823)nIndicates when Core lifter at 踢辊器 is up positionnInterlocking for 踢辊器 eject/return movement.nStep 7 blo

16、ck FC31536S82320CORE LOADING LIFTERCORE LIFTER AT DOWN LIMIT(36S814)nIndicates when Core lifter at 踢辊器 is down position against coresnInterlocking for core lifter down movement.nStep 7 block FC31536S81421ROLL STOPPER94S113ROLL STOPPER AT UP POSITION(94S113)nIndicates when Roll stopper are at up posi

17、tionnInterlocking for 踢辊器 ejecting when Set Change sequence 22PHOTOCELLS23WEB BREAK SENSOR(06S120)nDiffuse reflection sensornIndicates when there is no web in the windernWhen sensor detect it gives fast stop command to drive system(30s).nSTEP 7 Block FC5nDrives PLC also controls web break by using t

18、ension actual signal:when winder speed 30m/min and tension 70%smaller than setpoint then web break activates and winder stops using fast stop command and ramp.nHydraulic brakes goes close in web break,tooPHOTOCELLS24ROLL AT ROLL STOPPER(94S116)nRetro-reflective sensorn94S116 detect rolls at roll sto

19、pper.It is used only Automatic Set Change Sequence.n94S116 gives permission to eject rolls out when there is no rolls at roll stopper.nSTEP 7 Block FC94ROLL STOPPER25Photoelectric proximity switchesnDiffuse reflection sensors(Sick)26胶机CORE EDGE DETECTION BEFORE GLUING(36S614)nPhoto-electric proximit

20、y switchn36S614 detect cores before gluing.It is used only Core Loading sequence.n36S614 gives permission to load cores inside WindernSTEP 7 Block FC31836S61427胶机喷嘴处检测纸芯光电开关(36S618)nPhoto-electric proximity switchn36S618 detect cores at gluing 喷嘴.It is used only at Core Loading sequence.n36S618 enab

21、les glue spray to cores when Core loading sequence is on.n36S618 is used for calculation of the core set lenght.nSTEP 7 Block FC31836S618NOTE!IF SENSOR IS COVERED BY DUST,LENGHT CALCULATION OF THE CORES NOT WORK PROPERLY.28CORE FEEDING CONVEYOR ENDSTOPPERCORE FEEDING CONVEYOR FULL(36S121)nPhoto-elec

22、tric proximity switchn36S121 detect cores when cores are against End Stopper.It is used only at Core Loading sequence.n36S121 enables Core lifter down movement when Core loading sequence is on.nSTEP 7 Block FC92,FC309 and FB9236S121LocationNOTE!IF SENSOR IS COVERED BY DUST,CORE LOADING SEQUENCE MAY

23、NOT WORK PROPERLY.THEN SEQUENCE BYPASS CORE LOADING FUNCTION.29绝对值编码器30uThe encoder is equipped with two LEDs in the connection hood:one red LED(BF)for indicating errors and one green LED(STST)for indicating status information.uWhen the encoder starts up both LEDs flash briefly.uThere are also led d

24、isplay indicating the sensors node numberuNormal operation is when RED LED is OFF and GREEN LED is on.Then parameter setting and configuration were successful and encoder is running.绝对值编码器31CH58 Profibus trouble shooting绝对值编码器32CH58 Profibus trouble shooting绝对值编码器33uTo Recalibrate sensor go to WinCC

25、 Diagnostic Page and press CTRL+L.uLOGIN:?uPASSWORD:?uSelect Sensor calibration pageButton background colour is red when maintenance mode is selected!绝对值编码器34uMeasuring distance from winder centerlineuCalculation winder CPU:FB17OS/DS 纸芯锁定位 17B227/17B223 绝对值编码器35CALIBRATION:1.Go to WinCC Diagnostic P

26、age2.Click onto the Sensor Calibration button3.Select from pop-up MAINTENANCE mode4.Close core locks5.Move the core lock so that the surface which is against the core is located 150mm from the drums edge towards the Winder.6.Reset the encoder.7.Exit from MAINTENANCE-mode150mm Rear drum OS/DS core lo

27、ck position 17B227/17B223 Danger of damage or injury!In maintenance mode,device interlockings are removed,so be extremely cautious when controlling devices in this mode!150mm 绝对值编码器36uMeasuring post spreader angleuCalculation Winder CPU:FB27CALIBRATION:1.Go to WinCC Control Page2.Click onto the Sens

28、or Calibration button3.Select from pop-up MAINTENANCE-mode4.Reset the encoder when the post spreader actuator shaft length is:nWinder 1=196mmnWinder 2=189mm5.Exit from MAINTENANCE-modeCalibration at winder pitPOST SPREADER ANGLE 27B126Danger of damage or injury!In maintenance mode,device interlockin

29、gs are removed,so be extremely cautious when controlling devices in this mode!Abs.encoder at OS绝对值编码器37uMeasuring reel spool vertical positionuCalculation Winder CPU:FB26 Nw 4CALIBRATION:1.Go to WinCC Control Page2.Click onto the Sensor Calibration button3.Select from pop-up MAINTENANCE-mode4.Reset

30、the encoder when the spool vertical movement shaft is against stopper.5.Exit from MAINTENANCE-modeCalibration against stopperWEB DIRECTION(Reel spool vertical position)26B313Danger of damage or injury!In maintenance mode,device interlockings are removed,so be extremely cautious when controlling devi

31、ces in this mode!绝对值编码器38uMeasured the distance from the Winder centerline comparing that to the OS Core Lock positionuMust be positioned always same distance from the Winder centerline than OS core lock.uCalculation Winder CPU:FC311CALIBRATION:1.Go to WinCC Diagnostic Page2.Click onto the Sensor Ca

32、libration button3.Select from pop-up MAINTENANCE-mode4.Control End Stopper forward(to DS direction)as long it stops mechanically.5.Reset the Encoder 6.Exit from MAINTENANCE-modeDanger of damage or injury!In maintenance mode,device interlockings are removed,so be extremely cautious when controlling d

33、evices in this mode!CONVEYOR END STOPPER POSITION 36B623绝对值编码器39Danger of damage or injury!In maintenance mode,device interlockings are removed,so be extremely cautious when controlling devices in this mode!nMeasured the length of the cores which feeded inside Winder by using Core loading sequencenC

34、alculation Winder CPU:FC314CALIBRATIONnEncoder resetting automatically during the 胶机胶机 when the core stopper goes up.Can be manually resetted from the WinCC:1.Go to WinCC Diagnostic Page2.Click onto the Sensor Calibration button3.Select from pop-up MAINTENANCE-mode4.Reset the Encoder 5.Exit from MAI

35、NTENANCE-modeCORE FEEDING CONVEYOR POSITION 36B126绝对值编码器40uMeasuring roll diameter=the distance between rider roll position and OS core guider positionCore guiders and rider roll linear sensor 15B315(OS),15B323(DS)uTwo magnets,length 2700mmuCalculation Winder CPU:FB18,FB15 and FB121x1 x10 LINEAR ABS

36、OLUTE ENCODERS41Core guiders and rider roll linear sensor 15B315(OS),15B323(DS)LINEAR ABSOLUTE ENCODERS42Core guiders and rider roll linear sensor 15B315(OS),15B323(DS)LINEAR ABSOLUTE ENCODERSMagnet for measuring core guider position OS and DSMagnet for measuring Rider roll position OS and DS43卷取部分

37、diameter calculation(calibration):FB121(RW Diameter)Network 31.Install new sensor approximately at the same place where old one was.2.If new sensor was installed STEP7 hardware configuration must be download again.3.After every set measure finished roll diameter(using stee ruler).4.If diameter does

38、not match then do following steps:1.Adjust”GuideOffset”constant value during next set.If real diameter is bigger than“PrevRollDia”change“GuideOffset”value smaller.nFor example:Measured Diameter is 1042mm but“PrevDia”is 1044mm.Change“GuideOffset”value from 76.0 to 74.0.1.Check and measured next set a

39、nd change“GuideOffset”value again if necessary.LINEAR ABSOLUTE ENCODERS44Knife Position MeasurementAbsolute position of each knife pair(bottom knife)is measured by Temposonic linear encoder.System is not sending any diagnostics information of the encoder and therefore the incorrect operation should

40、be observed by the operators.Encoder is very vulnerable to shocks and rough handling.For example a bend or knock in the encoder bar could be damege sensor.In that case,the encoder must be replaced.If the encoder seems to send incorrect knife positions or is not sending any value at all,the power sup

41、ply and bus connections must be checked.Control unit and connection plugs are located in the drive side frame(TB32).If new sensor is installed STEP7 hardware configuration must be downloaded again.Slitting motor(bottom knife)position 20B1325LINEAR ABSOLUTE ENCODERSMagnet for measuring position of the bottom knife.45ANALOG SENSORS