浇注机操作说明书

1、DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:1of982009-02-06OPERATING MANUAL操作手册操作手册Technical documentation技术资料技术资料PA-20-S Automatic Pouring MachinePA-20-S型自动浇注机型自动浇注机DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:2of982009-02-06Table of contents目录目录1OVERVIEW OF OPERA

2、TING ELEMENTS.7 总述1.1POURING CONTROL, GENERAL PLC/HARDWARE DESIGN.7 浇注控制, PLC/硬件总体设计1.2SOFTWARE EMPLOYED.8 软件的使用1.3CONTROL PANEL OVERVIEW.8 控制面板简介2MACHINE OPERATION.9 设备运行2.1PRINCIPLES OF THE CONTROLS FUNCTIONING.9 控制原理2.2CONTROLLING THE POURING PROCESS.9 浇注过程控制2.3OPERATING MODES.10 运行模式2.3.1Set-up

3、mode.10 调整模式2.3.2Manual mode.11 手动模式2.3.3Automatic mode.12 自动模式2.4ACTIVATING THE MACHINE.14 激活设备2.4.1Activating the machine control.14 激活设备控制装置2.5TASKS BEFORE COMMENCING PRODUCTION.16 生产前的准备工作2.5.1Weigh empty ladle.16 称重空浇包2.5.2Checking the inoculant container.19 检查孕育剂箱DOCUMENTATIONPA-20-SOPERATING

4、INSTRUCTIONSJob No.: 11 197page:3of982009-02-062.5.3Selecting operation with one ladle option.21 选择单浇包操作选项2.6REFERENCING THE DRIVES.22 参考驱动装置2.6.1Referencing the longitudinal drive.23 参考径向驱动装置2.6.2Referencing the cross drive.27 参考横向驱动装置2.6.3Referencing the tilting drive.32 参考倾倒驱动装置2.6.4Referencing t

5、he turning drive .37 参考旋转驱动装置2.6.5Referencing and calibrating the inoculation drive.41 参考和校准孕育剂驱动装置2.7FULLY AUTOMATIC MODE.45 全自动模式2.8LADLE HANDLING AND IRON FEED.48 浇包处理和铁水进给2.9THE MEANING OF THE IRON-FEED SIGNALS.48 铁水进给信号的含义2.10SEMI-AUTOMATIC MODE (ONLY TILTING DRIVE).49 半自动模式(仅限于倾倒驱动装置)2.11THE M

6、EANING OF THE MACHINE SIGNALS.49 设备信号的含义2.12PROCEDURE FOR SETTING THE POURING PARAMETERS.50 设定浇注参数的程序2.13DESCRIPTION AND SETTING OF POURING PARAMETERS.53 说明和设定浇注参数2.13.1Setting instructions for the pouring parameters.56 浇注参数的设定指导2.14PROCEDURE FOR POURING WITH INOCULANTS.58 随流孕育浇注的程序2.14.1Inoculation

7、 process monitoring.60 孕育剂过程监控2.15PROCEDURE FOR POURING WITH ADDITIONAL POURING.63DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:4of982009-02-06 伴随补充浇注的程序2.16DESCRIPTION OF POURING ABORTIONS.66 浇注失败的说明2.17SPECIAL FUNCTIONS.68 特殊功能3CONTROL PANEL OPERATING ELEMENTS.73 控制面板操作部件3.1EMERGEN

8、CY-STOP BUTTON + LAMP (NOS. 1 AND 2).73 急停开关 + 报警灯(1 号和 2 号)3.2BUTTON FOR LIFTING/LOWERING BARRIER 1 (NO. 15).74 升/降护栏的按钮(15 号)3.3BUTTON FOR LIFTING/LOWERING BARRIER 2 (NO. 16).74 升/降护栏的按钮(16 号)3.4MANUAL/AUTOMATIC SELECTOR SWITCH (NO. 4) .74 手动/自动的选择开关(4 号)3.5SET-UP KEY SWITCH (NO. 3).74 设定的钥匙开关(3 号

9、)3.6AUTOMATIC START BUTTON (NO. 5) .75 自动启动的按钮(5 号)3.7MUSHROOM BUTTON SEGMENT DEACTIVATION (NO. 6). .75 部分无效的蘑菇开关(6 号)3.8ACKNOWLEDGE MALFUNCTION BUTTON (NO. 7).75 确认故障的按钮(7 号)3.9HOOTER BUTTON (NO. 12).75 报警器的按钮(12 号)3.10HOOTER (NO. 11).76 报警器(11 号)3.11CONTROL LAMP FOR GIVING CLEARANCE FOR THE MOULDI

10、NG SYSTEM (NO. 17).76 移动造型线的控制灯(17 号)3.12SELECTOR SWITCH FOR GIVING CLEARANCE TO THE MOULDING SYSTEM (NO. 18) .76 移动造型线的选择开关(18 号)3.13CROSS MOVEMENT FORWARDS BUTTON (NO. 19).77 横向移动的前进开关(19 号)3.14CROSS MOVEMENT BACK BUTTON (NO. 20).77 横向移动的后退开关(20 号)DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.:

11、 11 197page:5of982009-02-063.15LONGITUDINAL MOVEMENT FORWARD BUTTON (NO. 21).78 径向移动的前进开关(21 号)3.16LONGITUDINAL MOVEMENT BACK BUTTON (NO. 22).78 径向移动的后退开关(22 号)3.17PICK-UP LID PICK-UP BUTTON (NO. 23).79 提升盖的提升开关(23 号)3.18DEPOSIT LID PICK-UP BUTTON (NO. 24).79 放置盖的提升开关(24 号)3.19PRG TILTING DRIVE BUTT

12、ON (NO. 25).79 PRG 倾倒驱动装置的按钮(25 号)3.20START POURING BUTTON (NO. 26) .80 开始浇注的按钮(26 号)3.21PICK-UP LADLE BUTTON (NO. 27).80 提升浇包的按钮(27 号)3.22END POUR BUTTON (NO. 28).81 结束浇注的按钮(28 号)3.23LIFT LADLE SIGNAL LAMP (NO. 29).81 提升浇包的信号灯(29 号)3.24JOYSTICK (FIVE-STAGE MASTER SWITCH) (NO. 30).81 操纵杆(五级总开关)(30 号

13、)3.25LOWER LADLE SIGNAL LAMP (NO. 31) .82 降低浇包的信号灯(31 号)4MONITORING SYSTEMS.83 监控系统4.1THE TEMPERATURE MEASURING SENSOR.83 温度测量传感器4.2CAMERAS.83 摄像头5POURING DATA ARCHIVING.84 浇注数据档案6DATA EXCHANGE .84 数据交换6.1HARDWARE COUPLING.84DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:6of982009-02-

14、06 硬件配合7PLANT CONTROL SYSTEM.85 设备控制系统8TELE-SERVICE.86 远程诊断9BASIC POSITION OF THE POURING MACHINE .86 浇注机的初始位置10LADLE MAINTENANCE .87 浇包的维护10.1THE LADLES.87 浇包11MACHINE MAINTENANCE .90 设备的维护12EMERGENCY SITUATIONS.94 紧急情况13SAFETY FACILITIES.94 安全装置13.1.1Barriers 1 and 2.95 1 号和 2 号护栏13.1.2Safety door

15、 at the manual pouring place.96 手动浇注位置的安全门13.1.3Sequence of safety door functions at the manual pouring place.96 手动浇注位置的安全门功能的14CHECKLIST.99 检查清单DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:7of982009-02-06Overview of operating elements总述总述1.1Pouring control, general PLC/hardware des

16、ign浇注控制, PLC/硬件总体设计ET stationelectronicscabinetET 站电气柜ET stationoperating consoleET 站操纵台ET stationmachine cabinetET 站设备电气柜PLCelectronicscabinetPLC 电气柜Frequency converterMachine cabinet:变频器设备电气柜:- Tilting drive倾倒驱动装置- Longitudinal drive径向驱动装置- Cross drive横向驱动装置- Inoculation drive孕育剂驱动装置Frequency conv

17、erterelectronics cabinet:变频器电气柜:- Turning drive旋转驱动装置DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:8of982009-02-061.2Software employed软件的使用-Windows XP (PC operating system) Windows XP (PC 操作系统)-Step 7 (PCL program coding) Step 7 (PCL 程序译码)-Step 7 Technology (controlling the Sinamics

18、frequency converter) Step 7 技术技术 (控制 Sinamics 变频器)-WinCC flexible (projecting operating device/touch panel) WinCC flexible (操作装置/触摸屏)-Graph 7 (PLC process-control program coding) Graph 7 (PLC 过程控制程序译码)-GLS2010 (visualization of the pouring data, process data) GLS2010 (浇注数据, 过程数据的可视化)-Siwarex FTA (sc

19、ales configuration programming) Siwarex FTA (比例配置编程)1.3Control panel overview 控制面板简介Control panel (example)控制面板(举例)The main control panel is for controlling the machines and additional equipments movements and functions.主控制面板用于控制设备和附加设备的动作和功能.DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197

20、page:9of982009-02-062Machine operation 设备操作设备操作2.1Principles of the controls functioning 控制原理The automatic pouring machine is employed at moulding plants for the fully automated pouring of grey or spheroidal cast iron components. Here, the ladles with molten iron are tilted by electronically control

21、led servo motors in such a way that the pouring stream is adapted to the moulds capacity and the feed funnel is always kept full. Cameras monitor the light intensity of the molten iron at different points of the pouring process and transfer the signals to the tilting drives control.在造型线上使用自动浇注机是为了全自

22、动浇注灰铸铁或者球墨铸铁铸件.通过电子控制的伺服电机将装满铁水的浇包进行倾倒,这样铁水就能根据铸型容积进行调整,浇铸系统始终保持充满的状态.摄像头监控浇注过程不同位置铁水的发光强度并将信号传输给倾倒驱动装置的控制装置.At the beginning of the pouring process, the full pouring ladle is taken from the rotary ladle changer and lifted for the first cast. The visual control system continuously monitors the width

23、 of the poured stream and the levels of iron in the feed funnel and thus determines the optimum tilting angle for each ladle. 开始浇注时,装满铁水的浇包从浇包旋转更换装置上取下并略微倾倒准备浇铸第一个铸件.可视控制系统不断地监控铁水流的宽度和浇口杯铁水的液面,这样就能决定每个浇包最佳的倾倒角度.When iron levels rise in the funnel and after the required casting weight has been achiev

24、ed, the ladle is tilted back slightly and is ready for the next cast.当浇口杯内铁水的液面上升,达到预设的铸件重量后,浇包就往回倾倒一些,准备浇注下一个铸型.The ladle changer has been designed as a rotary changer in order to achieve a considerably faster changing time than those offered by linear changing systems so that production at the fou

25、ndry is not held up by the process of iron replenishment.为了达到比线形更换系统更短的更换时间,浇包更换装置设计为旋转更换装置,这样的话生产就不会因为铁水补充而中断.The machine stands on a rail system with a gear rack enabling precise positioning along the casting line. This means that its possible to use up the molten iron in the event of interruption

26、s to production at the foundry by emptying the ladle into the stationary moulds.浇注机沿着造型线安装在齿轮齿条精确定位的轨道系统上.如果铸造厂生产突然中断的话,仍然可以用浇包内的剩余铁水浇入到静态的铸型中去.2.2Controlling the pouring process 浇注过程控制The pouring process: once pouring has been started in a controlled fashion (start pour 1,2,3), the pouring process

27、is controlled in such a way that it is stopped when the desired cast weight and set level have been achieved. The pouring cameras monitor actual levels in the funnel during the pouring process. If the actual level falls below a specified value (set level), the ladle will be tilted more; if the actua

28、l level exceeds the specified level (set level), the ladle will not be tilted as much, it may even be tilted back. 浇注过程:一旦浇注机以某种运行模式开始浇铸(开始浇注 1,2,3),浇注过程控制就是当铸件重量和铁水液面达到设定值的时候设备就停止.浇注摄像头监控浇注过程中浇口杯内实际的铁水液面. 如果实际的铁水的液面低于指定的液面(预设的液面),浇包就会继续倾倒;如果达到了指定的液面(预设的液面),浇包就不会继续倾倒,而是往回倾倒.DOCUMENTATIONPA-20-SOPERA

29、TING INSTRUCTIONSJob No.: 11 197page:10of982009-02-062.3Operating modes运行模式Next to the are themushroom button (emergency stop)signal lamp (red) (emergency stop)mode-selection switches for manual and automatic modesmushroom button locking (black) (segment deactivation)key switch jogging (set-up mode)

30、push button (black) (automatic start)signal lamp (yellow) (automatic)signal lamp (blue) (basic position)在蘑菇按钮(急停)、信号灯(红色) (急停)旁边是：手动模式和自动模式的模式选择开关蘑菇锁定按钮 (黑色) (局部暂停)钥匙开关点动 (调整模式)按钮(黑色) (自动启动)信号灯(黄色) (自动)信号灯(蓝色) (初始位置)2.3.1Set-up mode调整模式(Automatic - manual selector switch) (自动自动 手动手动 选择开关选择开关)Once th

31、e manual mode has been selected using the automatic manual selector switch, all drives and solenoid valves may be activated by simultaneously using the set-up key switch and the operating console in any sequence and without any safety interlocking.一旦使用自动 手动选择开关选择了手动手动模式,所有的驱动装置和电磁阀都会在任何步序和没有安全互锁的状态下

32、同时由调整钥匙开关和操作控制台激活.The pouring machines guards will, however, all remain active so that no movement that may be hazardous to people can be initiated when the guards are open.但是,浇注机的保护装置也全部激活,这是为了保证所有可能造成人身伤害的动作都不会启动.This operating mode was created to prevent operation using the valves emergency funct

33、ions (dangerous erroneous switching possible).建立这种操作模式是为了防止利用控制阀的应急操作(有危险错误的可能).2.3.2Manual mode手动模式(Automatic - manual selector switch) (自动自动 手动手动 选择开关选择开关)Manual mode allows all drives with solenoid valves to be activated with the restriction that hazardous movements will be prevented by the safet

34、y interlocking system.DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:11of982009-02-06手动手动模式允许所有带电磁阀的驱动装置都可以在由安全互锁系统防止造成人身伤害的状态下激活.Drives that have reached their end positions will also be switched to self-retention in this mode.在这种模式中, 当驱动装置到达最终位置时也能由自我保持自我保持控制.This prevents the devic

35、es from leaving their positions in the event of leaks in the hydraulics system.这样能防止在液压系统渗漏的情况下这些装置偏离位置.Manual operations自动模式In order to move the individual drives by hand 为了用手动方式分别移动的驱动装置This segment is stopped by the segment deactivation mushroom button 这个区域由局部暂停蘑菇按钮停止；The automatic manual selecto

36、r switch on the HvO will be set to manual. 在在 HvO 控制面板上的控制面板上的自动自动 手动手动 选择开关将设定为选择开关将设定为手动手动；Now the desired drives may be selected in the menu and moved with the corresponding buttons. The drive will stop when the button is released during the movement.现在可以在菜单中选择所需要的驱动装置并使用有关的按钮动作.在运动过程中,释放按钮时动作就将停

37、止.To return to automatic mode 回到自动模式the mushroom button must be released 必须释放蘑菇按钮；the automatic manual selector switch must be set to automatic 自动 手动 选择开关必须设定为自动；automatic mode for this segment is started with the start automatic button. 这个区域的自动模式由自动模式启动按钮启动；This also indicates whether and how the d

38、rives valves are controlled and in which position the drives are located.这也同时显示了驱动装置的控制阀是否处于控制和如何控制的情况,以及这些驱动装置所处位置.2.3.3Automatic mode 自动模式(Automatic - manual selector switch) (自动自动 手动手动 选择开关选择开关)ATTENTION!注意注意!Before starting the moulding system, make sure that neither people nor objects are locat

39、ed within the plant.在启动造型线之前在启动造型线之前,必须确保在设备内部没有人员和其他物品必须确保在设备内部没有人员和其他物品.DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:12of982009-02-06Checks must also be carried out to determine whether damage that could impair plant operation or pose risks to people has been caused to the plant s

40、ince it was last in operation.必须检查是否有造成设备损坏和导致人身伤害的动作必须检查是否有造成设备损坏和导致人身伤害的动作,因为在生产过程中这些动作会一因为在生产过程中这些动作会一直进行直进行.Automatic mode is selected by positioning the automatic manual selector switch to automatic and then activated when the start automatic button is pressed.将自动 手动 选择开关选择自动模式自动模式,然后按下自动模式启动按钮

41、激活.A warning signal (siren) will be sounded when the automatic system is activated. The pouring machine will commence to operate independently once this signal has stopped.激活自动系统时报警信号(报警器)会发出鸣叫.这种鸣叫停止后浇注机将自行开始工作.Automatic operation is indicated by signal lamps on the control panel (continuous light)

42、 and an all-round lamp in the pouring machines segment. 控制面板上的信号灯(连续灯连续灯)和浇注机的旋转灯表示设备处于自动模式.NOTE:注意：注意：In the event of a malfunction caused by a limit-switch monitor indicating parity (e.g. position top and position bottom are both occupied), it will not be possible to initiate automatic mode. The e

43、rror must be remedied and the malfunction acknowledged (on the console). 如果限位开关引起的故障在显示屏上显示对称(例如同时处于位置的顶部和底部),那就不能启动自动模式.必须纠正和确认故障(在控制台上).The tilting drive segment may be switched to semi-automatic using the tilting drive (PRG) button.倾倒装置可以使用tilting drive (PRG)按钮转换到半自动模式.The tilting drive segment m

44、ay be moved semi-automatically using various buttons. This includes, for example, start pouring or tilting back.倾倒装置可以使用不同的按钮进行半自动操作.这包括,例如,开始浇注或者倾倒退回.It is only possible to switch from fully automatic to semi-automatic when a pouring sequence has been completed. Pressing the PRG button will initial

45、ly only request semi-automatic execution. This state is indicated by flashing at a frequency of 2 Hz (rapid flashing) of the corresponding light signal. If semi-automatic mode is activated at the end of the machine cycle, the corresponding signal lamp will indicate this with a flashing frequency of

46、1 Hz (slow flashing). The signal lamp will light up continuously in fully automatic mode.只有在浇注过程结束以后才可能从全自动模式转换到半自动模式.按下 PRG 按钮只会初始要求半自动操作.这个状态以相应的灯光信号的 2 Hz (快速闪烁) 频率闪烁来显示.如果在设备循环结束时半自动模式已经被激活,相应的灯光信号将以 1 Hz (慢速闪烁)来显示.在全自动模式下灯光信号一直是亮着的.Fully automatic mode may be reactivated by pressing the PRG but

47、ton again. The control will then continue the automatic process at the place where the process was last interrupted. This means that the automatic step sequences will remain in the step they were in before they were interrupted by set-up, manual, semi-automatic mode. The step chain sequence will res

48、tart at precisely this point when fully automatic mode is reactivated from semi-automatic mode.全自动模式可以通过再次按下 PRG 按钮恢复. 控制装置将从上次被中断的地方开始继续进行.这就意味着全自动步骤顺序在被调整模式,手动模式,半自动模式中断之前会被保存在步骤中.这个步骤系列顺序将在从半自动模式恢复到全自动模式的时候精确地在这一个点上重新启动.DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:13of982009-02-0

49、6If fully automatic mode is interrupted by set-up or manual mode, the fully-automatic mode will only continue the step sequence and thus the automatic movements after being restarted when the interruption has been acknowledged with the START button. 如果全自动模式是被调整模式或者手动模式中断的话,全自动模式只会继续步骤顺序,因此, 自动移动只有在通

50、过 START 按钮确认中断后才能重新启动.If the machine is switched from fully automatic mode to manual or set-up mode, all movements will be immediately stopped (on conclusion of the quick-stop ramps). Only the tilting drive will keep tilting back if automatic mode is interrupted during the pouring process.In semi-au

51、tomatic mode, pressing the buttons for semi-automatic movement just briefly will suffice to set the corresponding movements in motion. 如果设备从全自动模式转换到手动模式或者调整模式,所有的移动都会立即停止(通过快停结束).如果在浇注过程中全自动模式中断的话,只有倾倒装置会继续倾倒退回的操作.在半自动模式中,只需要按下半自动移动的按钮就能启动相应的移动.In manual mode, the corresponding button for semi-autom

52、atic movement must be pressed until the drive stops by itself (e.g. longitudinal drive positioned for the next moulding box). The drive will stop immediately if the button is released before this.在手动模式中,必须按下半自动移动的相应按钮直到驱动装置自己停下来(例如径向驱动装置停在下一个砂箱的位置).如果在此之前就释放按钮的话,驱动装置会立即停止.The same applies to movemen

53、ts using the continuous movement buttons, but the drives will only stop at the limit switches at the end of their movements.相同的移动要求使用继续移动按钮,但是驱动装置只会在行程终点的限位开关处停止.2.4Activating the machine激活设备Main switch to ON. Switch on the PC for visualization. Launch the GLS2010 program and then the visualization

54、program. 打开主开关.打开 PC 显示屏.启动 GLS2010 程序和可视化程序.2.4.1Activating the machine control激活设备控制装置! ATTENTION! 注意注意!Before switching the machine on, make sure that people or the environment will not be put at risk!在启动设备之前,确认设备附近的人员没有危险!DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:14of982009-0

55、2-06Select machine control“ screen选择machine control“画面Press control on按下control onDOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:15of982009-02-062.5Tasks before commencing production生产前的准备工作2.5.1Weigh empty ladle空浇包称重Proceed to the weigh ladle screen. 回到weigh ladle画面Activate the machi

56、nes one- and two-hand control if this hasnt already been done.如果该操作已经完成的话,激活设备的单手和双手控制.Press button按下按钮DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:16of982009-02-06Delete the tare weight with the button in the service Siwarex FTA screen.在service Siwarex FTA 画面中使用 按钮去除皮重.The button w

57、ill change from green to grey. 按钮将从绿色转为灰色.Set the scales to zero with the button. The scales actual weight (gross) will now show 0.00 kg.使用 按钮将刻度设置为零. 刻度的实际重量 (毛重) 现在会显示为 0.00 公斤.Turn an empty ladle with lid into the machine and lift the tilting drive to tare position with the joystick. The ladle ma

58、y no longer be suspended in the rotary changer!旋转一个带着盖子的空浇包进入设备并使用操纵杆提升倾倒装置到皮重位置.浇包不能长时间悬挂在旋转更换装置上!When the ladle has been picked up, the scales actual value (gross) will display the weight of the empty ladle with lid. (Approx. 1660 kg.) 当浇包被提升后,刻度的实际值(毛重)将显示带着盖子的空浇包的重量. (大约 1660 公斤.)DOCUMENTATIONPA

59、-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:17of982009-02-06Press the button. If the tare process has been successful, the gross weight will be saved as the weight of the empty ladle. This may be indicated by the which will now be green. The empty ladle weight may be checked again in the Siwarex

60、FTA settings screen. 按下 按钮. 如果皮重称重成功, 毛重将以空浇包的重量被存储. 这个操作以 转为绿色作为标志. 空浇包的重量将在 Siwarex FTA settings 画面再次检查.Press button按下按钮DOCUMENTATIONPA-20-SOPERATING INSTRUCTIONSJob No.: 11 197page:18of982009-02-06The empty ladle may be hung back in the rotary changer after it has been weighed. This is done with