Mitsubishi Q PLC application in fiber processing production line

1. Company introduction project equipment manufacturers for gaoan company, the company for the chemical fiber machinery factory is a big, FA products has been widely used, have certain popularity in the industry. The equipment is used for 5000 tons of fiber post processing production line project, its owner party for one day the waste-water. 2. Equipment instructions before the equipment is used for chemical fiber tensile, curl processing production, is mainly composed of spinning frame, eight stick thread machine, heat sink, the first draft, waterbath, second, drawing machine, steam box, the third drawing machine, folding machine, tension, winding machine, winding side panel motor, oil pump motor, vibration motor, circulating water pump, vibration test equipment. The scale of the I/O control for 103 points, the switch quantity input points to 61 points, the switch output for 39 points, analog input points to 3 points. Main control requirements for: chemical fiber yarn speed, draw ratio, steam and water temperature, related chain of logic control, etc. The system control is the key to guarantee the thread, on a lead, two, three led, curled up five synchronous motor speed. System configuration is shown in figure, the system adopts the Q series PLC controller of mitsubishi company as the main controller, the drive control for Emerson EV2000 inverter series, man-machine interface of F940GOT. System main configuration is as follows: low main controller: Q00CPU: speed and drawing ratio, given by the I/O module, detection field all the machine stop, limit switch and analog signal, such as complete chain control and alarm function. Low input module: QX40: complete the scene of the switch quantity control collection, low output module: QY10: complete switch output. Low input module: Q64AD: to complete the scene of the analog test. Low serial communication modules: QJ71C24N - R4: constitute inverter communication link. Low gear drive unit: Emerson EV2000 inverter series of the company. For space reasons, this paper describes the key design and implementation of this system, namely, guarantee the thread, on a lead, two, three led, crimp five synchronous motor speed. Customers based on the cost factor, drive drive unit to choose Emerson EV2000 inverter series, and constitute a main controller and the low-speed cheap communication based on RS485 communication medium link. Although godet, on a lead, two, three led, crimp 5 inverter USES the common dc bus operation mode, and install the incremental encoder speed closed loop in order to improve the precision of speed, crimping machine inverter with tension sensor to stabilize the control of the stretching tension, improve the fiber quality, but in the process of equipment start-stop process particularly in the run than adjusting speed and draft the process parameters such as real-time problems of low speed communication link is shown. On the design, although a communication module can be composed of 485 network, but because the traffic is very big, we must send the real-time motor speed instruction and start-stop information, at the same time also continue to read working parameters such as voltage, current, frequency of frequency converter, so if using a module, the communication cycle will increase, also does not achieve the effect of real-time. So we chose to use two pieces of 485 communication module, or four communication port to a guy at the same time, holding, holding, curled up four frequency communication, the guide wire and a leading share a communication port, communication in the next cycle. Considering the communication protocol frame length up to 18 bytes, under a 19200 bit/s transmission rate, the speed command response time is about 20 ms, the largest when the maximum speed of 200 m/Min, although godet lag slightly, but in the process is acceptable. This scheme can effectively solve the synchronous speed instruction ability, realize in the process of start and stop driving according to the instructions in the operation of the synchronous speed and speed adjustment when five motor speed of synchronization and fiber stretching tension uniform. Debugging situation and experience in actual debugging process, system in line with our forecast. But in communication debugging, we found that the Q series PLC in carrying multiple communication module system, the stability of communication and the length of PLC scan cycle. With the function of increasing, the continuous improvement of the program, scan cycle, the distribution scale increased as the when maximum scanning cycles greater than 25 ms, communication began to appear unstable phenomenon. Phenomenon: we use QJ71C24 dedicated communication instructions to accept the communication data, when greater than 25 ms scan cycle, at the same time communication of the four mouth, row at the end of the program is an occasional communication error, when to accept sign has jumped into the ON, said after data has been accepted, but to accept in the data area. Our four mouth procedures for communication at the same time order reversed found still, error occurs only in the order in the ranking of a mouth. Analysis reason: we think that is the communication timing problems, system accepts mark a jump and transmission of the system data are not synchronized, the system internal communications signs, communications buffer even before the data is transferred. So we judge prolong scan cycle can affect the communication sequence. Solution: downsizing programs to shorten or replace high speed PLC controller scan cycle. But because of the large amount of the system program, finally in order to guarantee the reliability of the system we replaced the CPU from Q00 Q02, improves the processing speed, lower the scan cycle below 10 ms, to solve problems. User feedback more than three months this system has been normal operation, the current system is very stable and reliable operation, technical indicators fully meet the design effect.
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