Implementation Of A Modular And Flexible Manufacturing Auto-Production Line Based On PROFIBUS-DP For Education And Trianing

In the globalization, manufacturing has to face more consumers, organizations and individuals than ever and customization and personalization are increasingly important. Hence, product updates and changes in product requirements are more frequent and drastic. Fortunately, the model with multi-varieties and small-medium batches offers a good solution. Many manufacturing systems are created in this wave. Modular and flexible manufacturing system with the strength of modularization and flexibility, one of them, is able to deal with the production with high variety, small batch and short delivery periods well. Computer numerical control (CNC) machines are for the most part and workpieces are often manufactured by two or more machines in these systems, leading a fact that the basic information for production is scatered over these machines. Therefore, how to help the production information integrated into an interacting network accurately and timely become a concern with available centralized controls and production automation. It is PROFIBUS-DP (Process Field Bus-Decentralized Peripherials) that provides a solution to this problem.For THMSRM-5A, the system with a production line specialized for teching experiments, off-line auto-operations for its nine distributed S7-200 PLC (Programmable Logic Controller) stations were designed in this master’s thesis, respectively. And then PROFIBUS-DP was applied to combining them with one S7-300 PLC station. These activities were in following:Nine actuating mechanisms, namely nine pneumatic control circuits, which were configured by nine S7-200 stations including supply and inspection station, the manipulator for the supply and inspection station, the manipulator for the machining station, machining station, extracting station, picture detection station, handling station, assembly station and classification and storage station, were analyzed firstly, respectively, as well as their functions. Then every working process for each station was designed and their PLC programs were written by STEP7 Micro/Win V4.0 SP3. As a result, off-line auto-operations for each were at the light.It was a fact that these S7-200 stations can not only work without dependence, but, according to requests, be interconnected, to be a modular and flexible auto-production line for education and training. The hierarchical information integration frame by PROFIBUS-DP was adopted to configure the rock hardware, organize the communication network, and develop the relative program blocks for the S7-300 station with a control center and a circular conveyor through STEP7 V5.5 SP1. Thus a master-slave communication network based on PROFIBUS-DP in which the nine S7-200 stations were slaves while the only S7-300 station was the master was founded.Moreover, two human-machine interfaces (HMIs) were developed in the MT4523T by EV500_V1.7CHS to monitor and control all online stations visually. One was a splash screen utilized to observe slaves’ states about online, reset, waiting, and crash-stop; another was a supervisory control window for the circular conveyor to monitor its states and buffers, run or stop it, and make the guide rod of the buffer cylinder drawn back.The centralized controls, the auto-production line, and these two HMIs were made a test run successfully with all stations online. The result indicaded that this hierarchical PROFIBUS-DP frame for information integration is feasible and valid in the distributed field controls. In final, by WinCC Runtime V7.0+SP3 ASIA, fifty-two process values from the master station were archived with their being saved into SQL Server 2005 automatically and exported into a.CSV document that can be transformed into an Excel table. It showed, by this way, that acquiring real-time field information and storing it into the database is feasible and the information is able to be picked up or called by the upper management information system at a small price.Through these works, it was considered that this thesis is able to give basic supports for making information integration extended to execution layer, planning layer, a supply chain, and even to the higher.