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可编程序控制器是在继电器控制和计算机控制的基础上开发的产品,自60年代末,美国首先研制和使用可编程控制器以后,世界各国特别是日本和联邦德国也相继开发了各自的PLC(programmable logic controller),因此,与传统的继电器接触器控制系统相比较,笔者认为采用PLC实现鼠笼式异步电动机起制动控制是最明智的选择。下面就是笔者设计的采用PLC实现的鼠笼式异步电动机起制动控制电路的接线图、梯形图和指令程序,如图2和图3所示。
PLC控制逻辑与传统的继电器接触器控制系统基本一致,其工作过程如下:
起动时,按下起动按钮SB1,X400常开触点闭合,Y430线圈接通并自锁,KM1线圈接通,主触头吸合,电动机串入限流电阻R开始起动,同时Y430的两对常开触点闭合,当电动机转速上升到某一定值时,KS1的常开触点闭合,X402常开触点闭合,M100线圈接通并自锁,M100的一对常开触点接通Y432的线圈,KM3线圈有电主触头吸合,短接起动电阻,电机转速上升至给定值时投入稳定运行。
制动时,按下停机按钮SB2,X401常开触点断开Y430线圈,使KM1失电释放,而Y430的常闭触点接通Y431线圈,制动用的接触器KM2线圈通电,对调两相电源的相序,电动机处于反接制动状态。与此同时,Y430的常开触点断开Y432的线圈,KM3失电释放,串入电阻R限制制动电流。当电动机转速迅速下降至某一定值时,KS1常开触点断开,X402常开触点断开M100的线圈,M100的常开触点断开Y431线圈,KM2失电释放,电动机很快停下来。过载时,热继电器FR常开触点闭合,X403的两对常闭触点断开Y430和M110的线圈,从而使KM1或KM2失电释放,起到过载保护作用。
上述控制过程指令程序如下:
PLC与继电器接触器控制系统的比较
通过对鼠笼式异步电动机起制动的传统控制方法和PLC控制方法的比较,从某种意义上看,PLC控制是从继电器接触器控制发展而来的。两者既有相似性又有很多不同处。
1 二种方案的不同点
(1) PLC内部大部分采用“软”逻辑
继电器接触器控制全部用硬器件、硬触点和“硬”线连接,为全硬件控制;PLC内部大部分采用“软”电器、“软”接点和“软”线连接,为软件控制。
(2) PLC控制系统结构紧凑
继电器接触器控制系统使用电器多,体积大且故障率大;PLC控制系统结构紧凑,使用电器少,体积小。
(3) PLC内部全为“软接点”动作快
电器接触器控制全为机械式触点,动作慢,弧光放电严重;PLC内部全为“软接点”动作快。
(4) PLC控制功能改变极其方便
继电器接触器控制功能改变,需拆线接线乃至更换元器件,比较麻烦;PLC控制功能改变,一般只需修改程序便可,极其方便。
(5) PLC控制系统制造周期短
PLC控制系统由于结构简单紧凑,基本为软件控制,因此设计、施工与调试比继电器接触器控制系统周期短。
此外,由于PLC技术是计算机控制的基础上发展而来,因此,它的软硬件设置上有着传统的继电器接触器控制无法比拟的优势,工作可靠性极高。
2 PLC方案的设计要点
(1) 设置滤波
在PLC中一般都在输入输出接口处设置π形滤波器,它不仅可滤除来自外界的高频干扰,而且还可减少内部模块之间信号的相互干扰。
(2) 设有隔离
在PLC系统中CPU和各I/O回路(主要指数字口)几乎都设有光耦合器作隔离,以防止干扰或可能损坏CPU等。
(3) 设置屏蔽
屏蔽有两类:一类是对变压器采取磁场和电场的双重屏蔽,这时要用既导磁又导电的材料作为屏蔽层;另一类是对CPU和编程器等模块仅作电磁场的屏蔽,此时可用导电的金属材料作屏蔽层。
(4) 采用模块式结构
PLC通常采用积木式结构,这便于用户检修和更换模板,同时在各模板上都设有故障检测电路,并用相应的指示器标志它的状态,使用户能迅速确定故障的位置。
(5) 设有联锁功能
PLC中个各输出通道之间设有联锁功能。以防止各被控对象之间误动作可能造成的事故。
(6) 设置环境检测和诊断电路
这部分电路负责对PLC的运行环境(例如电网电压、工作温度、环境的湿度等)进行检测,同时也完成对PLC中各模块工作状态的监测。这部分电路往往是与软件相配合工作的,以实现故障自动诊断和预报。
(7)设置Watchdog电路
PLC中的这种电路是专门监视PLC运行进程是否按预定的顺序进行,如果PLC中发生故障或用户程序区受损,则因CPU不能按预定顺序(预定时间间隔)工作而报警。
(8) PLC的输入、输出控制简单
PLC是以扫描方式进行工作的,即PLC对信号的输入、数据的处理和控制信号的输出,分别在一个扫描周期内的不同时间间隔里,以批处理方式进行,这不仅使用户编程简单、不易出错,而且也使PLC的工作不易受到外界干扰的影响;同时PLC所处理的数据比较稳定,从而减少了处理中的错误;另外,PLC的输入、输出的控制较简单,不容易产生由于时序不合适而造成的问题。
由于PLC在设计制造时充分考虑到工业控制的现场环境问题,并采取了多层次、多种有效措施来提高工作可靠性,因此,采用PLC实现电机控制,特别是对工作环境条件较恶劣的工矿企业应该是一项明智之举。
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AMINCO 45-16433 Hydraulic Pump Adapter
Ridgid 1" EMT Hand Bender 8" Take-Up
KX-16 PARKER FINITE FILTER CONVERSION KIT KX16
Miller Valve Subplate 1/8" NPT 301
Miller Air Valve 3 Way 304 With Valve Subplate 1/8"NPT 301
Parker Gland Cartridge Kit For 1" Rod RG2AHl0101
Asco Solenoid Valve Rebuild Kit 162-893
Asco Solenoid Valve Rebuild Kit 69-657
Asco Solenoid Valve Rebuild Kit 168-219
Asco Solenoid Valve Rebuild Kit 68-101
Asco Solenoid Valve Rebuild Kit 69-555
Asco Solenoid Valve Rebuild Kit 164-225
Westinghouse IL 1250 1824 IT 4 Lever Loading Spring STL 2-3/8" OD x 2-3/4" LG
Westinghouse IL 1250 1824 IT 45 Dashpot Plunger Operating Piston
Mazander Engineered Equipment Filter KFSF9600-8-6UM
Signet P71058-3 pH Controller Touchpad M15160 Rev L
Parker 8Z(A)V6LRB CPI V-Series Needle Valve 1/2"Single Ferrule Tube Fitting Ends
Lot of 2 Westinghouse 506A099G01 Stationary Main Contact 2000A
United Conveyor S75AH Spray Nozzle 3/4" NPT
Guzzler 133-3470 Valve Flap
Timken T58689 Bearing Seal, Flinger
Crane Saunders Type A 1-1/4" Neoprene Valve Diaphragm Valve Class 125
Dow Saunders Type A 1-1/4" Neoprene Valve Diaphragm Valve Class 125
Worthington 22162 Water Slinger Lot of 2
Southern States PEA115100 Fuse Kit 100 Amp 115 KV
CAMCO 3" NPT Half Coupling 316 SST
Westinghouse 626C925056 Screw 1" DIA x 3-1/2" Long
CHESTERTON 60117 Seal Ring
Square D SP1175 Secondary Surge Arrester
Harris I-2589 Calorific Oxygen Regulator Single Stage 15 PSI
BRADY PSIDP-311-375 Y35180 Lot of 4 (400 count)
PX FILTRATION PXA25 Hydraulic Filter
Westinghouse 522A030G02 Brush Assy Electrical Ground Exciter End Lot of 2
GE Indicating Light LED 116B6708G44R53R4
Cutler-Hammer D23MR402 Type M Latched Relay Lot of 2
3/4" NPT 90* Stop Valve with 3/4" Compression and Bleed 200# Brass
199A1090P0004 Filter Element
Consolidated WC 87013 Lot Of 3 Shielded Bearing Consolidated Precision Bearings
Ridgid 500 Pipe Die Head 1/4"
JO BELL ZD-2WP Magnetic Proximity Switch
Westinghouse 1600702 Limit Switch
Dodge Positive Drive Pulley TL40L100-2012 Dyna-Sync Taper-Lock
Gates Super HC Belt O&HR V80 5VX900 15NX2290
Turbotechnology Services Corp. Compressor Tie Bolt Nut L.L. 3930446RE
Colonial Process Equipment 53444K3 Spring Rack Lot Of 2
Colonial Process Equipment 5320238D1 Leather CWP
Pall Trinity 1212937 Repair Kit
Siemens 3SX3 120 Actuator Assembly With Round Shaft
MOORE Nullmatic 10448-38 Upper Spring Seat Model 73-N-F
MOORE Nullmatic Controller 10637-8 Diaphragm Ring
Moore Nullmatic 14278-13 Nozzle
Lot of 2 Westinghouse 3530B91G01 O2 Probe Reflector SST
General Electric 323B7988P05 Carbon Brush 1-1/2 W x 1 Thk x 3-5/8 Lg 634
Schutte & Koerting Ball Flow Indicator Tube Max 200 PSI
REGO Products CV250BL 3-89 Brass Valve 1/4" NPT
REGO Products CV250B 12-87 Brass Valve 1/4" NPT
Radiant Illumination SK-PLQ Fluorescent Emergency Unit Ballast 120/277VAC
Lot of 2 Albany International Stainless Steel Spray Nozzle S674148401
3/4" PIPE TEE 3000 PSI SA-182 GR. F316 Stainless Steal Socket Weld Lot of 4
FOXBORO 00221739 Circular Chart Paper Range 0-12 Fits Foxboro 808386
1/2" Pipe Elbow 6000 PSI Socket Weld SA182 Gr. 304 Stainless Lot of 2
ITT Grinnell 1" Diaphragm Valve Stainless Body 1521 Size 1 CF8M Grade M
Telemecanique Contactor 120V ~ 50/60Hz 4KW/400V 5HP/460V LC1D09G7
Penn Troy Bicera 16 RD Service kit K16
Siemens Westinghouse 652D741007 Bushing 1.00 x .63
Hose Master MasterFlex 3/4" Male to 3/4" Male Braided 304 Stainless Steel Hose
Siemens Westinghouse 460B561064 Straight Pin .75 x 4.0
Siemens 3SE3 120-1B Position Switch with Lever Arm
P&H/Furnas 75D53735H Magnetic Coil Lot of 2
P&H R24285D1 Friction Disc NF-402 3493
P&H M05125R Friction Disc CIF6 2041
FAST HEAT CARTRIDGE F12-13 120V 25W Lot of 5
Clyde Bergemann Inc. 288286 11T 75P Hub-2IN CS Sprocket
Dialight 922-1526-525
Parker RG2AHL0135 1 3/8" Rod Cartridge Kit
GE Kepner 235A9848-1 SS 3/8" Series 1500 1522Y Check Valve
Emerson Power Transmission Kop-Flex Waldron Flex Gear Hub Coupling 1-1/2W FHUB
(7)Parker 66GTX-S 37* Flare Female Connector 3/8"Tube x 3/8"FNPT w/Sleeve Steel
Goulds 98233815001 2358 IS Cage Seal 2-7/16 x 3-3/8 for Model 5500
CORNING GLASS WORKS B6 MACBETH REFLEX GAUGE GLASS
Wallace & Tiernan Injector Suction Gauge 0-30 In Dial No 19959
General Electric Auxiliary Relay 12HGA11J52
YARWAY 951594 Repair Kit A-7 7331 Plain Flat Glass Mica Sealing Gasket
JERGUSON V 16756-8 Transparent Borosilicate Gage Glass
JERGUSON V 16757-8 Borosilicate Gage Glass
ITT 010-0000-30000-0RZ Valve Bonnet 1"
RACEFACE Chainring 104 44T 9 Speed RR104x44 5 Bolt J28990
Mansfield Green Poppet High Pressure Valve T-147
Dresser 0090-5025-632 2.375 Coupling Reducer x 1 1/2"
DeZurik 1072629 Butterfly Valve Seat 8"
Lot of 11 6PS-D20 Capacitors .002 600DC +/- 10% 220P
Schott Maxos 7 Borosilicate High Pressure Safety Sight Glass 280 x 34 x17
Fafnir 311KDD Z16 FS50000 Doubled Shielded Ball Bearing Made In The USA
Fafnir 311KDD C2 FS50000 Doubled Shielded Ball Bearing Made In The USA
GRINDEX PHASE SHIFTER CHANGES ROTATION OF PUMP WITH SWITCH 3 PHASE 32 AMPS
Potter Brumfield KUEP-11D15-24 Relay W/ 27E893 Socket 24VDC LOT OF 4
Parker 4-2 DBZ-B CPI Female Elbow 1/4" Single Ferrule Tube Fitting 1/8" FNPT (6)
Fisher FS-67CR-206 Pressure Regulator
Federal-Mogul 5305-KE Double Row Ball Bearing
Fafnir 5306WG Double Row Ball Bearing WIRELOC
Lot of 4 Parker 4 ETX-B 37* Flare Union Elbow 1/4" Tube with Sleeve Brass
(3) Parker 2-2 FTX-B 37* Flare Male Connector 1/8"Tube x 1/8"MNPT w/Sleeve Brass
Triplx Inc Lot of 2 Spiraseal Gasket IDP 230 Style SW 14.060" x 14.810" x .125"
Lot Of 4 Parker 4-4 FBZ-SS Male Connector 1/4T x 1/4M CPI Series 44FBZSS
Lot Of 2 Parker 6-4 HBZ-SS Reducing Union 3/8T x 1/4T CPI Series 64HBZSS
John Crane IT32 Mechanical Seal 1-1/8"DIA Rubber Gasket SS Body Type 1
Central 61-C10 6" Coupling With Gasket 6/168.3MM
Starrett 234B-15 Micrometer Standard 15"
Goodyear HY-T Wedge Belt Matchmaker ORS-SC 5VX1600
Westinghouse 9351-8 Power Positioner Diaphragm 3/4 ID x 3-1/4 OD Rubber Cupped
Lot Of 6 Parker 8-12 FBZ-B Brass Male Connector 1/2T x 3/4M CPI Series 812FBZB
MagneTek S150MLTLC3M-500K High Pressure Sodium Ballast Replacement Kit
Lot Of 2 Kellems ST-75-K Cord Grip
Fairchild EA-12154 Repair Kit
(3) Parker BS 4-4-4 JTX-SS 37* Flare Union Tee 1/4" Tube with Sleeve All Ends
Lot of 4 Parker 6-6 FHC-B Hex Coupler 3/8" FNPT x 3/8" FNPT Brass
Hagan Controls VA-448650 Mounted Positioner Beam & Bracket
John Crane HOU-2888-APLC Mechanical Seal Seat
Bailey Controls 4TB9515-0198 Liquid-Tite Fittings Kit
GE 2675081G27 Coil
Lot of 5 Allen-Bradley 700-N5 Surge Suppressor 150 VAC / VDC Series D
Gates Synchro Power Timing Belt 1000H150
StoneL 461074 Field Link Trip Cur. 04 Date 02/06/04
Elliott 5510-18 Turbo Brush Lot of 8
Westinghouse HFB3050L Breaker 600VAC 50A 3 Pole 4997D19G40
Gould G30T54 Heater Elements LOT OF 6
NIP Parker Brass Check Valve 5 PSI Cracking Pr. 3000 PSI Max Pr.Model 6M-C6L-5-B
Parker 4-4GBI2B Intru-Lok Flareless Female Connector 1/4"Tube x 1/4"FNPT (7)
TRW 5210M Double Row Ball Bearing
6" Coupling With Gasket C4 SPF
Solid State Controls 80-219800-90 Snubber PCB Circuit Board Assembly Rev C
Solid State Controls 80-219800-90 Snubber PCB Circuit Board Assembly
Lot Of 4 Gerbing 55-21201 Spider Coupling Insert Flexible Buna Rubber 3/4"
Timken 39250 Tapered Roller Bearing Made In The USA
Timken 1774 Tapered Roller Bearing
(3) Parker 4-4-4 JTX-SS 37* Flare Union Tee 1/4" Tube with Sleeve All Ends 26SS
SSAC Solid State Timer 30 Min Off 10-1000 Min On 120VAC 1Amp TSDR435B30M
NIB Parker 2 1/2" Viton Piston Seal Kit Model # PK2502A005
Helwig 2000319 Carbon Brushes Lot of 4
General Electric 2A405 Strip Heater 750 Watt
NEW Parker 1/8" Stainless Steel Needle Valve Part # 2F-V4LN-SS
NIB Parker Lot of 8 3/8" Brass Pipe Fitting Model 6-6 MCN-B
NIB Ridgid 1-1/4" NPT Right Hand Alloy Steel Mono Pipe Dies Model 50685
Milton Roy 268-A Gear Shaft
Westinghouse QC3030H 240 VAC 30 Amp 3 Pole CIRCUIT BREAKER
General Electric Programmable Controller IC610MDL175B
Parker 6-4 TRTXN-B Triple-Lok 37*Flare Tube End Reducer 3/8"x1/4" Brass Lot of 6
Crouse-Hinds 23176-A Explosion Proof Lamp Socket 660 Watt 220 Volt
Delco A5210 Lot Of 2 Inner Race Roller Bearing
Versa Products Inc. EZ-1-228L-A120 Multi-Purpose Solenoid Valve
TLT- Babcock 9182 Viton O-Ring 410x418x4mm 101-0127
Lot Of 2 Kellems 074-01-1342 Cord Grip
John Crane A9-2750-45-9051 Carbon Mating Ring 2-13/16"IDx3-1/4"ODx3/8"THK
Asco 027476-001-D Coil
Fafnir 200KLD Lot Of 4 Bearings
Pall Hydraulic Filter Element HC9600FDN8H
CATERPILLAR 3E-2246 Module Relay
WESTINGHOUSE 17G0183003 IL 1150 314 IT 33 Brass Clutch Collar
Dwyer Mercoid Air/Gas Pressure Control Switch Model # PGW-127-P1
NIB Square D Industrial Control Transformer Model # 9070T50D2
General Electric Psals Relay Model # CR120L022002
Moore Industries RBA/3W-100/SH1/117AC-EZ 93.03 Resistance Bulb Alarm RBA
Gates Hi-Power II V Belt O & H R V80 B97 Lot of 3
Guardian Electric 3HD-C-24D Box Frame Solenoid
GE 0116B6734G1 Indicator Light Type ET-17 110-139 Volts 227A240052
Johnson Controls 21-776 Coil Assembly for Robertshaw R427-20
Cutler Hammer D26MT Type M Pneumatic Time Delay Relay Series A1 1-180 Second
Rexnord 73889A22 B Flat Spray Nozzle
Edward Valve 444 Gate Valve 1/4"NPT 2000 WOG
Dodge 1A3.6B4.0-SH QD Sheave W/ Bushing 3/4" Bore SH 3/4 X
Spieth DSK 20.37 Clamping Sleeve
Maurey SDSX1-3/8 Split Taper Hub QD Sheave 1-3/8" Bore
Combustion Engineering 3A DWG 183A7744-1 Spiral Wound Flanged Gasket 10-1/2" ID
Volume International V9725-5 Black Wall Fixture W/ White Diffuser 1-60W Max
Graphalloy TS111733A-8 Bushing
(3) Parker 1/4MMS-B Male Branch Tee 1/4"NPTF All Ends Pipe and Port Series Brass
(4) Parker 4-4-4 JBZ-SS CPI Union Tee 1/4" Single Ferrule Tube Fitting all Ends
Allis-Chalmers 16-140-876-00-005 Fiber Seal Ring 4-5/8" OD x 4-3/16 ID x 1/2"
(5) Parker 4-4 EBZ-SS CPI Union Elbow 1/4" Single Ferrule Tube Fitting All Ends
Henry Vogt E-35651 R4 Gate Valve 1/4" Socket Weld SW2801 800 W.P. @ 850*
Henry Vogt E-35651 R1 Gate Valve 1/4" Socket Weld SW2801 800 W.P. @ 850*
Parker 14F13AB Miniature Air Filter 1/4"
Universal 12310-90-500-K High Pressure Sodium Lamp Ballast Kit 100 Watt
Westinghouse 3489A93G09 Disc & Shaft Relay Assy. for Type CVE Protective Relay
Delco RA99211 Roller Bearing Made In The USA
Fafnir 309K Single Row Ball Bearing
Fafnir 309PP Single Row Ball Bearing
SKF 5207 H Double Row Ball Bearing Made In The USA
B-Line 6" Pipe Roller Hanger Steel Yoke Galvanized Model B3110-6
Crouse-Hinds 50122-R (ML2075) Globe Red
NSK R6MC3E Ball Bearing Lot of 3
Flexonics Brass Tube to Pipe Adapter, 3/4" Compression x 1/2" MNPT
Parker 48CBZ-SS CPI Male Elbow 1/4"Single Ferrule Tube Fitting 1/2"MNPT Lot of 4
1/2" Threaded Square Head Plug Valve Three Port 150#
3/4" NPT 90* Stop Valve with 3/4" Compression 200# Brass
3/4" Pipe Elbow 3000 PSI SA182 GR. 316 Stainless Socket Weld Lot of 4
SKF SNW11x1.15/16 Adapter Assembly LOT OF 2
Yokogawa B9573YT Scanner Board
Robertshaw R471-1 Pneumatic Electric Relay 0-20PSI 30PSI MAX
NIB AMF Potter & Brumfield Relays 120 Vac Model KBPIIAG-120