FESTO模块化生产系统的柔性化研究
摘要
MPS(模块化生产系统)是一种工业自动化生产系统。通过模块化的思想将生产系统分成功能各异的模块,这些模块都可独立完成生产工艺中的某一个流程。所有模块都安装有标准通信装置,可以在生产过程中进行实时通信。通过分析工件的生产工艺流程,结合每个模块的功能和特点,按照稳定、简便的原则选择需要的模块,组合成一个系统,完成生产任务。这就是模块化生产系统。模块化生产系统的标准化、柔性化这两个特点使得该生产系统在现代制造业中的应用越来越广泛。
德国FESTO公司生产的MPS系统共有九个模块,根据工件的生产流程,可完成供料、传输、加工、检测等工艺过程。该系统为单一工件供料模式,可对不同颜色的工件进行识别。供料模块是MPS中的第一个模块,它由料仓、推送机构、摆臂机构组成,主要完成为下一单元输送工件的工作。整个工作的完成以气泵提供的气压为动力源,通过PLC控制阀岛来完成各个部件的动作。
经过分析,原MPS系统有一定的局限性,如对零件尺寸、形状的变化要求范围小、柔性差等,若对MPS进行柔性化、扩大零件尺寸范围,并且对后续的几个模块进行适当调整,即可使MPS的功能改进,系统的利用率和效率得到提高。因此,本文根据生产和柔性化的要求,针对供料模块的功能,设计了圆形料盘结构、楔形传送结构,将料盘内部用隔板成相对独立的空间。圆形料盘内的隔板推动工件运动,实现了模块工作连续性；隔板之间的角度可调整,实现了系统柔性化；楔形传送结构实现了不同尺寸工件最后停至不同位置,便于机械臂提取。同时,本文还进行了上位机和PLC联接与通讯的研究,利用组态王软件设计人机窗口和监控界面,构建供料模块监控系统,通过上位机中的监控界面,工作人员可观察模块的运行情况。
总之,改进后的MPS系统其柔性得到提高,随着工件尺寸的改变,系统只需根据工件直径调节料盘中隔板间的夹角,并在监控界面输入相关尺寸,即可实现后续工序内容；通过监控系统则可以观察模块运行是否正常,在故障时及时停止模块运行,满足了MPS的自动化要求。
MPS(Modular Production System) is a kind of industrial automation system. The system was separated according to modularization method into different module with different function. These modules can finish a task by itself. All of the modules have communication device which can communicate with each other. By analyzing the technological process, a production system would be made up according to stable and expedient principle. This is the mean of MPS. Standardization and flexibility are two features of MPS which make MPS widely used in modern manufacturing industry.
The MPS of FESTO contain nine modules. FESTO MPS can board part, machining part and detection part and so on. The mode of supplying parts is single. This system can distinguish the color of parts. Boards module is the first one in the MPS. It contains silo, push mechanism, rocker arm. The main job of this module is offering part for the next module. The power of the system is an air pump.
Through the analysis, MPS have a limitation on the size and shape. If expansion the machining range and adjust other modules, MPS can machine more kinds of parts and improve the availability and efficiency. So, on basis the requirement of production and flexibility, the tray was designed to be rounded and the conveyor was designed to be wedge. The baffle separate the tray to a number of part. The baffle push work to the assigned place. By adjusting the angle between baffles, MPS improve flexibility. In the meantime, the communication between host computer and the PLC was studied. The man-machine interface was made up with configuration software, then supervisory system was built. The real-time condition can be reacted in that interface.
In a word, the flexibility of the modified MPS was improved. When the size of part changed, the follow-up process can be completed by adjusting the angle between baffles and input the size into supervisory interface. The working condition can be seen in the supervisory system. The system can be stopped when there is a bug. So, the automation of MPS was fulfilled.
德国FESTO公司生产的MPS系统共有九个模块,根据工件的生产流程,可完成供料、传输、加工、检测等工艺过程。该系统为单一工件供料模式,可对不同颜色的工件进行识别。供料模块是MPS中的第一个模块,它由料仓、推送机构、摆臂机构组成,主要完成为下一单元输送工件的工作。整个工作的完成以气泵提供的气压为动力源,通过PLC控制阀岛来完成各个部件的动作。
经过分析,原MPS系统有一定的局限性,如对零件尺寸、形状的变化要求范围小、柔性差等,若对MPS进行柔性化、扩大零件尺寸范围,并且对后续的几个模块进行适当调整,即可使MPS的功能改进,系统的利用率和效率得到提高。因此,本文根据生产和柔性化的要求,针对供料模块的功能,设计了圆形料盘结构、楔形传送结构,将料盘内部用隔板成相对独立的空间。圆形料盘内的隔板推动工件运动,实现了模块工作连续性；隔板之间的角度可调整,实现了系统柔性化；楔形传送结构实现了不同尺寸工件最后停至不同位置,便于机械臂提取。同时,本文还进行了上位机和PLC联接与通讯的研究,利用组态王软件设计人机窗口和监控界面,构建供料模块监控系统,通过上位机中的监控界面,工作人员可观察模块的运行情况。
总之,改进后的MPS系统其柔性得到提高,随着工件尺寸的改变,系统只需根据工件直径调节料盘中隔板间的夹角,并在监控界面输入相关尺寸,即可实现后续工序内容；通过监控系统则可以观察模块运行是否正常,在故障时及时停止模块运行,满足了MPS的自动化要求。
MPS(Modular Production System) is a kind of industrial automation system. The system was separated according to modularization method into different module with different function. These modules can finish a task by itself. All of the modules have communication device which can communicate with each other. By analyzing the technological process, a production system would be made up according to stable and expedient principle. This is the mean of MPS. Standardization and flexibility are two features of MPS which make MPS widely used in modern manufacturing industry.
The MPS of FESTO contain nine modules. FESTO MPS can board part, machining part and detection part and so on. The mode of supplying parts is single. This system can distinguish the color of parts. Boards module is the first one in the MPS. It contains silo, push mechanism, rocker arm. The main job of this module is offering part for the next module. The power of the system is an air pump.
Through the analysis, MPS have a limitation on the size and shape. If expansion the machining range and adjust other modules, MPS can machine more kinds of parts and improve the availability and efficiency. So, on basis the requirement of production and flexibility, the tray was designed to be rounded and the conveyor was designed to be wedge. The baffle separate the tray to a number of part. The baffle push work to the assigned place. By adjusting the angle between baffles, MPS improve flexibility. In the meantime, the communication between host computer and the PLC was studied. The man-machine interface was made up with configuration software, then supervisory system was built. The real-time condition can be reacted in that interface.
In a word, the flexibility of the modified MPS was improved. When the size of part changed, the follow-up process can be completed by adjusting the angle between baffles and input the size into supervisory interface. The working condition can be seen in the supervisory system. The system can be stopped when there is a bug. So, the automation of MPS was fulfilled.
引文
[1]顾建新,郑国君、朱万贵、崔梁萍.面向大批量定制生产的模块化制造系统[J].组合机
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[2]罗振璧,盛伯浩,赵晓波,等.快速重组制造系统[J].中国机械工程,2009,11(3)：300 303.
[3]Beaty, R.T., Mass customisation, Manufacturing Engineer[J] 1996(5):217-220.
[4]G.G.Rogers,L.Bottaci. Modular production systems:a new manufacturing paradigm[J].Journal of Intelligent Manufacturing,2007,8(2):147-148.
[5]阳文辉,从计算机技术的发展看工业自动化的发展现状和趋势[J].煤炭技术,2011,5：21-22.
[6]Rogers,G.G, Bottaci, L,Modular production system:anew manufacturing paradigm[J]. Journal of Intelligent Manufac-turing,2007(8):147～156
[7]蔡宗琰,严新民.计算机辅助可重构制造系统设计[J].计算机辅助设计与图形学学报,2002,14(2)：125—129.
[8]Hongjian Cao, Hui Zhangb,Maosong Liu2.Global Modular ProductionNetwork:From System Perspective[R]2011 International Conference on Power and Engineering Application.2011.
[9]周聪霞.MPS模块化生产系统的开发及研究[D].沈阳：沈阳理工大学,2007.
[10]Mariagrazia Dotoli;Maria Pia Fanti;Agostino M.Mangini;Walter Ukovich. Identification of the unobservable behavior of industrial automation systems by Petri nets[J]. Control Engineering Practice,2011,19(9):95-98.
[11]刘增辉.模块化生产加工系统应用技术[M].北京：电子工业出版社：2005：2-5.
[12]赵维佳,冼钊龙.监控组态软件的研究与应用[J].工业控制计算机,2006,19：(10).
[13]张宏林.PLC应用开发技术与工程实践[M].北京：人民邮电出版社,2007：6-12.
[14]刘光起,周亚夫.PLC技术及应用[M].北京：化学工业出版社,2008：8-15.
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[16]程周.PLC技术与应用[M].福州：福建科学技术出版社,2004：6-10.
[17]吴亦锋.可编程控制器原理与应用[M].福州：福建科学技术出版社,2004.7-11.
[18]温照方.可编程控制器教程[M].北京：北京理工大学出版社,2002：3-13.
[19]Bai Jing-jing, Zhang Zi-Xian, Bao Chun-Hong.The Design and Application of Sewage Treatment Automation System Based on S7-300 PLC[J].Communications in Computer and information Science,2011,225(2):179-486.
[20]刘艳梅,任双艳,李一波.S7-300可编程控制器教程[M].北京：人民邮电出版社,2008：10-20.
[21]阳胜峰S7-300PLC编程与应用从入门到提高[R].北京：PLC World.2009.
[22]Xingqiao Liu, Jiao Geng, Shaoqing Teng.A fuzzy-PID controller with adjustable factor based on S7-300 PLC[M]. International Journal of Modeling Identification and Control, 2009,7 (4):10-13.
[23]顾伟康.传感器技术与应用[M].杭州：浙江大学出版社,2006：1-7.
[24]张岩,胡秀芳.传感器应用技术[M].福州：福建科技出版社,2004：1-3.
[25]吴敏.多传感器信息处理系统的研究[D].西安：西安科技大学,2009.
[26]杨爽.基于ZigBee技术页岩油加氢工艺压力监控系统的研究与设计[D].长春：长春工业大学,2011.
[27]程鹏,程江,闫冠.压电式压力广安器热冲击效应的实验研究[J].传感器与微系统,2006,25(2)：27-29.
[28]张建荣,林知秋.基于S7-300的料仓料位自动化监控系统[J].矿业研究与开发,2010,30(1)：74-76.
[29]赵一洁,段晨东,程婷.基于S72PLC的工业以太网设备监控系统设计[J].计算机测量与控制,2010,18(12)：23-27
[30]袁海亮.基于PLC与组态王在蔬菜发酵系统中的研究[D].天津：天津科技大学,2009.
[31]华文瀚.立体车库存取车机械装置及其控制系统的研究开发[D].成都：西南交通大学,2010.
[32]闫明,赵殿礼,张春来.基于PLC和组态王的船舶辅助锅炉燃烧器的设计[J].大连海事大学学报,2008,34：81-82.
[33]石晓妹,王香婷,丁平.基于PLC的井下变电所在线监测监控系统的设计[J].电气应 用,2010,29(16)：62-65.
[34]庄宪骥.基于S7-200自来水管网监控系统设计[D].太原：中北大学,2009.
[35]任凤娟.基于西门子PLC的实验室网络控制系统的研究[D].成都：西华大学,2009.
[36]Ooba,Y. Model Elevator System Development for Student Experiment applying PLC and DC Motor Drive [J].Report of Researches-Nippon institute of Technology,2005,32(2):41-42.
[36]周晓旭.基于PLC和组态软件的自动生产线设备开发[J].数字技术与应用,2010,18：9]-93.
[37]何平良.125MN挤压机运垫控制系统设计研究与应用[D].长沙：中南大学,2009.
[38]付志刚.铝塑门窗锯床控制系统及下料优化方法的研究[D].哈尔滨：东北林业大学,2008.
[39]陈长亮.基于PLC与FPC变频调速系统的研究[D].武汉,武汉理工大学,2009.
[40]张建森.PLC控制在普通机床轧辊磨床进给传动中的应用[J].电子世界,2012,3：49-50.
[41]Gao,D. Based ON Force Control and PLC for Supervisory System of Meter-stator Dipped Lacquer[J].CONTROL AND AND AUTOMATION,2005,9:31-32.
[42]邓利红.基于变频器与PLC的载货节能环保电梯设计[J].煤炭技术,2012,1：23-26.
[43]Deng ChangQi,Li,Bin. The Design of Program for NTC Automatic Tool Change Based on S7-300[J]. Key Engineering Materials,2011,1076(46):322-324.
[44]李建国.基于PLC的气动机械手的改装设计[J].液压与气动,2011,8：21-22.
[45]聂国伦,白生威.基于PLC技术的矿井提升机位置与速度控制系统设计[J].2011,32(04)：158-]59.
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[47]秦常贵.基于PLC的步进电动机的正反转及调速控制[J].2011,32(8)：186-187.
[48]彭芳S7-200PLC在顺序控制系统中的应用[J].2011,30(7)：25-26.
床与自动化加工技术,2003,(1)：1-3.
[2]罗振璧,盛伯浩,赵晓波,等.快速重组制造系统[J].中国机械工程,2009,11(3)：300 303.
[3]Beaty, R.T., Mass customisation, Manufacturing Engineer[J] 1996(5):217-220.
[4]G.G.Rogers,L.Bottaci. Modular production systems:a new manufacturing paradigm[J].Journal of Intelligent Manufacturing,2007,8(2):147-148.
[5]阳文辉,从计算机技术的发展看工业自动化的发展现状和趋势[J].煤炭技术,2011,5：21-22.
[6]Rogers,G.G, Bottaci, L,Modular production system:anew manufacturing paradigm[J]. Journal of Intelligent Manufac-turing,2007(8):147～156
[7]蔡宗琰,严新民.计算机辅助可重构制造系统设计[J].计算机辅助设计与图形学学报,2002,14(2)：125—129.
[8]Hongjian Cao, Hui Zhangb,Maosong Liu2.Global Modular ProductionNetwork:From System Perspective[R]2011 International Conference on Power and Engineering Application.2011.
[9]周聪霞.MPS模块化生产系统的开发及研究[D].沈阳：沈阳理工大学,2007.
[10]Mariagrazia Dotoli;Maria Pia Fanti;Agostino M.Mangini;Walter Ukovich. Identification of the unobservable behavior of industrial automation systems by Petri nets[J]. Control Engineering Practice,2011,19(9):95-98.
[11]刘增辉.模块化生产加工系统应用技术[M].北京：电子工业出版社：2005：2-5.
[12]赵维佳,冼钊龙.监控组态软件的研究与应用[J].工业控制计算机,2006,19：(10).
[13]张宏林.PLC应用开发技术与工程实践[M].北京：人民邮电出版社,2007：6-12.
[14]刘光起,周亚夫.PLC技术及应用[M].北京：化学工业出版社,2008：8-15.
[15]胡成龙,何琼.PLC应用技术[M].武汉：湖北科技出版社：2008：3-5.
[16]程周.PLC技术与应用[M].福州：福建科学技术出版社,2004：6-10.
[17]吴亦锋.可编程控制器原理与应用[M].福州：福建科学技术出版社,2004.7-11.
[18]温照方.可编程控制器教程[M].北京：北京理工大学出版社,2002：3-13.
[19]Bai Jing-jing, Zhang Zi-Xian, Bao Chun-Hong.The Design and Application of Sewage Treatment Automation System Based on S7-300 PLC[J].Communications in Computer and information Science,2011,225(2):179-486.
[20]刘艳梅,任双艳,李一波.S7-300可编程控制器教程[M].北京：人民邮电出版社,2008：10-20.
[21]阳胜峰S7-300PLC编程与应用从入门到提高[R].北京：PLC World.2009.
[22]Xingqiao Liu, Jiao Geng, Shaoqing Teng.A fuzzy-PID controller with adjustable factor based on S7-300 PLC[M]. International Journal of Modeling Identification and Control, 2009,7 (4):10-13.
[23]顾伟康.传感器技术与应用[M].杭州：浙江大学出版社,2006：1-7.
[24]张岩,胡秀芳.传感器应用技术[M].福州：福建科技出版社,2004：1-3.
[25]吴敏.多传感器信息处理系统的研究[D].西安：西安科技大学,2009.
[26]杨爽.基于ZigBee技术页岩油加氢工艺压力监控系统的研究与设计[D].长春：长春工业大学,2011.
[27]程鹏,程江,闫冠.压电式压力广安器热冲击效应的实验研究[J].传感器与微系统,2006,25(2)：27-29.
[28]张建荣,林知秋.基于S7-300的料仓料位自动化监控系统[J].矿业研究与开发,2010,30(1)：74-76.
[29]赵一洁,段晨东,程婷.基于S72PLC的工业以太网设备监控系统设计[J].计算机测量与控制,2010,18(12)：23-27
[30]袁海亮.基于PLC与组态王在蔬菜发酵系统中的研究[D].天津：天津科技大学,2009.
[31]华文瀚.立体车库存取车机械装置及其控制系统的研究开发[D].成都：西南交通大学,2010.
[32]闫明,赵殿礼,张春来.基于PLC和组态王的船舶辅助锅炉燃烧器的设计[J].大连海事大学学报,2008,34：81-82.
[33]石晓妹,王香婷,丁平.基于PLC的井下变电所在线监测监控系统的设计[J].电气应 用,2010,29(16)：62-65.
[34]庄宪骥.基于S7-200自来水管网监控系统设计[D].太原：中北大学,2009.
[35]任凤娟.基于西门子PLC的实验室网络控制系统的研究[D].成都：西华大学,2009.
[36]Ooba,Y. Model Elevator System Development for Student Experiment applying PLC and DC Motor Drive [J].Report of Researches-Nippon institute of Technology,2005,32(2):41-42.
[36]周晓旭.基于PLC和组态软件的自动生产线设备开发[J].数字技术与应用,2010,18：9]-93.
[37]何平良.125MN挤压机运垫控制系统设计研究与应用[D].长沙：中南大学,2009.
[38]付志刚.铝塑门窗锯床控制系统及下料优化方法的研究[D].哈尔滨：东北林业大学,2008.
[39]陈长亮.基于PLC与FPC变频调速系统的研究[D].武汉,武汉理工大学,2009.
[40]张建森.PLC控制在普通机床轧辊磨床进给传动中的应用[J].电子世界,2012,3：49-50.
[41]Gao,D. Based ON Force Control and PLC for Supervisory System of Meter-stator Dipped Lacquer[J].CONTROL AND AND AUTOMATION,2005,9:31-32.
[42]邓利红.基于变频器与PLC的载货节能环保电梯设计[J].煤炭技术,2012,1：23-26.
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