基于总线的移动式钢轨闪光焊机研制
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摘要
无缝线路的铺设为我国铁路的高速发展提供了有力保障,而钢轨焊接作为无缝线路铺设过程的关键环节,其作业质量和效率须依靠优质的焊接装备予以保证。闪光焊因其接头质量可靠、焊接效率高等优点,在线路作业中应用广泛。现场焊接中,由于焊机的频繁移动使控制柜与机头之间的控制电缆易于破损,容易出现故障,且维修困难,影响了作业效率。因此进行基于总线的焊机控制系统研制具有很好的工程应用价值。
本文在分析移动式交流闪光焊机结构、连接电缆故障问题以及前人工作的基础上,设计和完善了基于CC-Link现场总线的焊机控制系统,主要包括以下工作：1)结合钢轨闪光焊的工艺和闪光焊机系统的控制要求,对控制系统的硬件进行了系统设计：系统设计了基于总线通讯的控制系统供电系统；将整个系统分成了两个主要部分：控制柜处控制系统和机头控制系统,从而最大限度的减少了控制柜与机头的连线,并保证了机头操作的安全性；2)在系统设计的基础上,对设计了控制柜处控制系统和机头控制系统印制电路板,完善闪光焊机控制系统所需要的外部电路,制作了系统硬件平台；3)根据CC-Link总线协议,设定现场总线通讯参数,并利用SFC语言开发了系统的PLC控制软件,建立了基于CC-Link网络的移动式闪光焊机控制系统。
通过调试表明,基于CC-Link现场总线的控制系统在通讯速率、系统响应等性能方面能满足闪光焊机的控制需求,其应用较大程度的简化了设备的电气布线方式,提高了稳定性,达到了不改变原来闪光焊机工艺参数的基础上进行的闪光焊机的优化的目的。
The laying of continuous welded rail track is a strong guarantee for the rapid development of China's railway, the welding of the rail is the key link in the process of laying CWR, and the welding joint quality and the production efficiency have to rely on the quality of welding equipment. Flash butt welding is used wildly in field welding because of its connection quality and high efficiency. During the site welding, the welder frequently fails for the control cable's moving of between the control cabinet and the machine, and is repaired with difficulty, so the operational efficiency was affected. According to the reasons mentioned above, so it has a lot of engineering significance to do some research on welding machine control cable transformation.
On the basis of the analysis of mobile communication flash butt welding machine's structure and the connection cable fault, the welding machine control system based on the CC-Link field-bus was designed and improved. The work includes the following things:1) The hardware system was designed according to the flash butt welding process and the flash butt welding system control requirements.: the power supply system based on the bus communication control system was designed; and the whole system was divided into two main parts:the control system in the control cabinet and the control system around the machine head, so as to minimize the connection between control cabinet and machine head and ensure the safety of operation.2) The printed circuit boards of both parts of the system was designed, the external circuit of the control system was improved, and the hardware platform was produced.3) The PLC control system software had been developed by the SFC language, the communication parameters of the field-bus was set, and the mobile flash butt welding machine control system based the CC-Link bus was established.
The debugging showed that the communication speed and the response performance of the control system based the CC-Link field-bus could meet the control requirements of flash butt welding equipment, the device's electrical wiring could be simplified, the stability was improved, and the purpose of optimizing the flash butt welding machine without changing process parameters was achieved
本文在分析移动式交流闪光焊机结构、连接电缆故障问题以及前人工作的基础上,设计和完善了基于CC-Link现场总线的焊机控制系统,主要包括以下工作：1)结合钢轨闪光焊的工艺和闪光焊机系统的控制要求,对控制系统的硬件进行了系统设计：系统设计了基于总线通讯的控制系统供电系统；将整个系统分成了两个主要部分：控制柜处控制系统和机头控制系统,从而最大限度的减少了控制柜与机头的连线,并保证了机头操作的安全性；2)在系统设计的基础上,对设计了控制柜处控制系统和机头控制系统印制电路板,完善闪光焊机控制系统所需要的外部电路,制作了系统硬件平台；3)根据CC-Link总线协议,设定现场总线通讯参数,并利用SFC语言开发了系统的PLC控制软件,建立了基于CC-Link网络的移动式闪光焊机控制系统。
通过调试表明,基于CC-Link现场总线的控制系统在通讯速率、系统响应等性能方面能满足闪光焊机的控制需求,其应用较大程度的简化了设备的电气布线方式,提高了稳定性,达到了不改变原来闪光焊机工艺参数的基础上进行的闪光焊机的优化的目的。
The laying of continuous welded rail track is a strong guarantee for the rapid development of China's railway, the welding of the rail is the key link in the process of laying CWR, and the welding joint quality and the production efficiency have to rely on the quality of welding equipment. Flash butt welding is used wildly in field welding because of its connection quality and high efficiency. During the site welding, the welder frequently fails for the control cable's moving of between the control cabinet and the machine, and is repaired with difficulty, so the operational efficiency was affected. According to the reasons mentioned above, so it has a lot of engineering significance to do some research on welding machine control cable transformation.
On the basis of the analysis of mobile communication flash butt welding machine's structure and the connection cable fault, the welding machine control system based on the CC-Link field-bus was designed and improved. The work includes the following things:1) The hardware system was designed according to the flash butt welding process and the flash butt welding system control requirements.: the power supply system based on the bus communication control system was designed; and the whole system was divided into two main parts:the control system in the control cabinet and the control system around the machine head, so as to minimize the connection between control cabinet and machine head and ensure the safety of operation.2) The printed circuit boards of both parts of the system was designed, the external circuit of the control system was improved, and the hardware platform was produced.3) The PLC control system software had been developed by the SFC language, the communication parameters of the field-bus was set, and the mobile flash butt welding machine control system based the CC-Link bus was established.
The debugging showed that the communication speed and the response performance of the control system based the CC-Link field-bus could meet the control requirements of flash butt welding equipment, the device's electrical wiring could be simplified, the stability was improved, and the purpose of optimizing the flash butt welding machine without changing process parameters was achieved
引文
[1]贺颂,吕其兵.基于CC-LINK总线的移动式闪光焊机控制系统.成都市机械工程学会焊接分会.2010(11)
[2]贺颂.基于CC-LINK总线的移动式闪光焊机控制系统的研究.研究生学位论文.2011
[3]董卫国,刘奇梅.钢轨无缝线路焊接技术现状.焊接,2000(3)：37-39
[4]盛花.K190nK钢轨交流闪光焊机控制系统改造及焊接工艺研究.硕士学位论文.成都：西南交通大学,2006
[5]Lv Qi-bing, Dai Hong, Luo De-yang, Tan Ke-li. Optimization of Flash Butt Welding Parameters for Welding of U75V Rails.Journal of Southwest Jiaotong University.2006 v 41(2):210-213
[6]向朝.钢轨交流闪光焊质量检测与预测研究.西南交通大学硕士研究生论文.2006
[7]Fenn R, Lu Y. Real time welding quality control and assessment system. International Journal for the Joining of Materials,1997, Vol(9), No (3):94～98
[8]王会启.UN5-150钢轨交流闪光焊机研制.研究生学位论文.2006[9]陈雪芬.K1000焊机计算机系统及控制软件的研发.西南交通大学硕士学位论文.2011
[9]J. Wagner, C. Mitterer, M. Penoy, et al. The effect of deposition temperature on microstructure and properties of thermalCVDTiN coatings[J]. International Journal of Refractory Metals & Hard Materials,2008,26:120-126.
[10]张华俊.进口K900钢轨闪光焊机监测系统界面汉化及脉冲工艺研究.硕士学位论文.成都：西南交通大学,2006
[11]Xu Haili. The CC-Link based implementation of communication between PC and PLC [J]. Process Automation Instrumentation.2003,24(2):31-33
[12]黄诚.基于三菱PLC控制的CC-Link连接站的研究.硅谷.2010,03.22-23
[13]S. R. Dillon. Manufacturing Automation Protocol and Technical and ffice Protocols- Success through the OSI Model. In:proe.32nd IEEE Computer Society Int. Conf.,1987:80-81.
[14]J. D. Deeotignie. Some Future Directions in Fieldbus Research and Development. Fieldbus Technology, Systems Integration, Networking and Engineering. In:Proc. Fieldbus Conf,1988:308-312.
[15]冯梅,米玉华等.CC-Link现场总线的通信初始化方法及应用[C].第二届全国信息与电子工程学术交流会暨第十三届四川省电子学会曙光分会学术年会论文集.成都：第二届全国信息与电子工程学术交流会.2007：232-236
[16]Corvino, Lorenzo:Intrieri, Tonino. Electrical falsh-butt welding of rails in situ. Rail Engineering International,1989, vol.18(1):17-20
[17]Jonas Berge著.陈小枫,董景辰,曹迎东等译.过程控制现场总线——工程、运行与维护[M].清华大学出版社.2003：201—203
[18]林桂娟,宋德朝,陈明,周详发.基于CC-Link现场总线的远程智能监控系统.现代制造技术与装备.2010.108-110
[19]朱钱祥,汪伟,张琦.2011现场总线技术发展PLC&FA.2011:37-38
[20]Syh-Shiuh Yeh, Pau-lo Hsu. Analysis and design of integrated control for multi-axis motion system. Control Systems Technology, IEEE Transactions on,2003,11 (3):375～382.
[21]MITSUBISH ELECTRIC CORPORATION三菱Q大全手册.三菱电机,2002
[22]龚仲华,史建成等.三菱Fx/Q系列PLC应用技术.人民邮电出版社,2006
[23]侯浪.三菱QPLC应用技术研究.硕十学位论文.武汉：武汉理工大学,2008.5
[24]K.W.Gokhay. Designof PLC Control System. Electric Transmission, 2001(7).35-37
[25]MITSUB ISH IQ系列I/0模块用户手册.上海：三菱电自动化(上海)有限公司,2008
[26]武峰.可编程控制器PLC的基本原理及应用.电子世界,2002(11)45-47
[27]MITSUBISH ELECTRIC CORPORATION. QD75定位模块用户手册.三菱电机,2002
[28]MITSUBISH ELECTRIC CORPORATION.本菱QCPU用户手册(硬件设计/维护点检篇).上海：三菱电自动化(上海)有限公司,2007
[29]L. Borsi and E. Pavlik. The Concepts and Structures of Distributed Process Automation System. Process Autom, NO.2, PP.36-70,1980.
[30]Mitsubishi Electric Corporation. QCPU(Q Mode)/QnACPU Programming Manual(Common Instructions),2008
[31]郭丙君、黄旭峰.深入浅出PLC技术及应用设计.中国电力出版社,2008
[32]王英.模拟电子技术基础.西南交通大学出版社.2000
[33]王英.数字电子技术基础.西南交通大学出版社.2000
[34]YANG Jian, YUAN Hao. Design of industrial control system base on MITSUBISHI Q-PLC. LABORATORY SCIENCE,2010(4)
[35]三菱电机. QCPU/QnACPU编程手册编程参考手册(补充说明篇)[Z].2004
[36]三菱电机.QCPU/QnACPL编程手册编程参考手册(SFC指令篇)[Z],2004.04
[37]Xu Chang, Wei Hongyan, Zhu Mingwei. Design of the ControlSystem based on MitsubishiMotion ControlUnit forPipe Bender. PROCESS AUTOMATION INSTRUMENTATION,2008(10)
[38]MITSUBISH ELECTRIC CORPORATION. GX Configurator-QP操作手册.三菱电机,2002
[39]三菱电机.GX Developer Ver.7/Simulator Ver.6操作手册[Z],2002.04
[40]张还,李胜多.可编程序控制器原理及过程控制[M].中国电力出版社.2008：10
[41]K. W. Gokhay. Designof PLC Control System. Electric Transmission. 2001(7)
[42]胡俊达.大中型PLC控制系统的现场安装与调试中几个问题的讨论.电气自动化,2005(6).
[43]任好娟.钢轨焊接生产输送线现场控制系统网络开发.西南交通大学硕士毕业论文,2010.4
[44]MITSUBISH ELECTRIC CORPORATION. GX Configurator-QP操作手册.三菱电机,2002
[45]Hongguang Zhao, Chao He, Xi Zhang, Qibing Lv. Fault Diagnosis System Based on UN-150ZB Mobile Rail Flash Butt Welding. Interna tional Conference on Manufacturing Science and Engineering.2012
[46]何超,赵红光,吕其兵.钢轨精磨机砂轮对刀与磨削自动化[J].成都市机械学会焊接分会论文集,2011(12).
[47]张丹妮,骆德阳,冯文杰等.基于力控组态软件的百米焊轨生产线监控系统.西南交通大学学报增刊,2010.6
[48]Xi Zhang, Guoqing liu and Qibing Lv*. A Slicer Control System Based on PLC and Servo. Advanced Materials Research,2011.Vols.308-310: 1248-1251
[49]赵红光,何超,吕其兵.基于UN-150ZB钢轨闪光焊机的自诊断系统[J].现代焊接,2012(6).
[50]Ward-smith, Les. RAIL FLASH-BUTT WELDING IN THE SATS. South African mechanical engineer.1985,vol 35(1):9-10
[2]贺颂.基于CC-LINK总线的移动式闪光焊机控制系统的研究.研究生学位论文.2011
[3]董卫国,刘奇梅.钢轨无缝线路焊接技术现状.焊接,2000(3)：37-39
[4]盛花.K190nK钢轨交流闪光焊机控制系统改造及焊接工艺研究.硕士学位论文.成都：西南交通大学,2006
[5]Lv Qi-bing, Dai Hong, Luo De-yang, Tan Ke-li. Optimization of Flash Butt Welding Parameters for Welding of U75V Rails.Journal of Southwest Jiaotong University.2006 v 41(2):210-213
[6]向朝.钢轨交流闪光焊质量检测与预测研究.西南交通大学硕士研究生论文.2006
[7]Fenn R, Lu Y. Real time welding quality control and assessment system. International Journal for the Joining of Materials,1997, Vol(9), No (3):94～98
[8]王会启.UN5-150钢轨交流闪光焊机研制.研究生学位论文.2006[9]陈雪芬.K1000焊机计算机系统及控制软件的研发.西南交通大学硕士学位论文.2011
[9]J. Wagner, C. Mitterer, M. Penoy, et al. The effect of deposition temperature on microstructure and properties of thermalCVDTiN coatings[J]. International Journal of Refractory Metals & Hard Materials,2008,26:120-126.
[10]张华俊.进口K900钢轨闪光焊机监测系统界面汉化及脉冲工艺研究.硕士学位论文.成都：西南交通大学,2006
[11]Xu Haili. The CC-Link based implementation of communication between PC and PLC [J]. Process Automation Instrumentation.2003,24(2):31-33
[12]黄诚.基于三菱PLC控制的CC-Link连接站的研究.硅谷.2010,03.22-23
[13]S. R. Dillon. Manufacturing Automation Protocol and Technical and ffice Protocols- Success through the OSI Model. In:proe.32nd IEEE Computer Society Int. Conf.,1987:80-81.
[14]J. D. Deeotignie. Some Future Directions in Fieldbus Research and Development. Fieldbus Technology, Systems Integration, Networking and Engineering. In:Proc. Fieldbus Conf,1988:308-312.
[15]冯梅,米玉华等.CC-Link现场总线的通信初始化方法及应用[C].第二届全国信息与电子工程学术交流会暨第十三届四川省电子学会曙光分会学术年会论文集.成都：第二届全国信息与电子工程学术交流会.2007：232-236
[16]Corvino, Lorenzo:Intrieri, Tonino. Electrical falsh-butt welding of rails in situ. Rail Engineering International,1989, vol.18(1):17-20
[17]Jonas Berge著.陈小枫,董景辰,曹迎东等译.过程控制现场总线——工程、运行与维护[M].清华大学出版社.2003：201—203
[18]林桂娟,宋德朝,陈明,周详发.基于CC-Link现场总线的远程智能监控系统.现代制造技术与装备.2010.108-110
[19]朱钱祥,汪伟,张琦.2011现场总线技术发展PLC&FA.2011:37-38
[20]Syh-Shiuh Yeh, Pau-lo Hsu. Analysis and design of integrated control for multi-axis motion system. Control Systems Technology, IEEE Transactions on,2003,11 (3):375～382.
[21]MITSUBISH ELECTRIC CORPORATION三菱Q大全手册.三菱电机,2002
[22]龚仲华,史建成等.三菱Fx/Q系列PLC应用技术.人民邮电出版社,2006
[23]侯浪.三菱QPLC应用技术研究.硕十学位论文.武汉：武汉理工大学,2008.5
[24]K.W.Gokhay. Designof PLC Control System. Electric Transmission, 2001(7).35-37
[25]MITSUB ISH IQ系列I/0模块用户手册.上海：三菱电自动化(上海)有限公司,2008
[26]武峰.可编程控制器PLC的基本原理及应用.电子世界,2002(11)45-47
[27]MITSUBISH ELECTRIC CORPORATION. QD75定位模块用户手册.三菱电机,2002
[28]MITSUBISH ELECTRIC CORPORATION.本菱QCPU用户手册(硬件设计/维护点检篇).上海：三菱电自动化(上海)有限公司,2007
[29]L. Borsi and E. Pavlik. The Concepts and Structures of Distributed Process Automation System. Process Autom, NO.2, PP.36-70,1980.
[30]Mitsubishi Electric Corporation. QCPU(Q Mode)/QnACPU Programming Manual(Common Instructions),2008
[31]郭丙君、黄旭峰.深入浅出PLC技术及应用设计.中国电力出版社,2008
[32]王英.模拟电子技术基础.西南交通大学出版社.2000
[33]王英.数字电子技术基础.西南交通大学出版社.2000
[34]YANG Jian, YUAN Hao. Design of industrial control system base on MITSUBISHI Q-PLC. LABORATORY SCIENCE,2010(4)
[35]三菱电机. QCPU/QnACPU编程手册编程参考手册(补充说明篇)[Z].2004
[36]三菱电机.QCPU/QnACPL编程手册编程参考手册(SFC指令篇)[Z],2004.04
[37]Xu Chang, Wei Hongyan, Zhu Mingwei. Design of the ControlSystem based on MitsubishiMotion ControlUnit forPipe Bender. PROCESS AUTOMATION INSTRUMENTATION,2008(10)
[38]MITSUBISH ELECTRIC CORPORATION. GX Configurator-QP操作手册.三菱电机,2002
[39]三菱电机.GX Developer Ver.7/Simulator Ver.6操作手册[Z],2002.04
[40]张还,李胜多.可编程序控制器原理及过程控制[M].中国电力出版社.2008：10
[41]K. W. Gokhay. Designof PLC Control System. Electric Transmission. 2001(7)
[42]胡俊达.大中型PLC控制系统的现场安装与调试中几个问题的讨论.电气自动化,2005(6).
[43]任好娟.钢轨焊接生产输送线现场控制系统网络开发.西南交通大学硕士毕业论文,2010.4
[44]MITSUBISH ELECTRIC CORPORATION. GX Configurator-QP操作手册.三菱电机,2002
[45]Hongguang Zhao, Chao He, Xi Zhang, Qibing Lv. Fault Diagnosis System Based on UN-150ZB Mobile Rail Flash Butt Welding. Interna tional Conference on Manufacturing Science and Engineering.2012
[46]何超,赵红光,吕其兵.钢轨精磨机砂轮对刀与磨削自动化[J].成都市机械学会焊接分会论文集,2011(12).
[47]张丹妮,骆德阳,冯文杰等.基于力控组态软件的百米焊轨生产线监控系统.西南交通大学学报增刊,2010.6
[48]Xi Zhang, Guoqing liu and Qibing Lv*. A Slicer Control System Based on PLC and Servo. Advanced Materials Research,2011.Vols.308-310: 1248-1251
[49]赵红光,何超,吕其兵.基于UN-150ZB钢轨闪光焊机的自诊断系统[J].现代焊接,2012(6).
[50]Ward-smith, Les. RAIL FLASH-BUTT WELDING IN THE SATS. South African mechanical engineer.1985,vol 35(1):9-10