手工夹具阀岛技术控制方案

controlconceptwithvalveinmanualsub-assembly更改描述日期章节备注controlconceptwithvalveinmanualsub-assembly更改描述日期章节备注CreatedforModelS/LYFL.CompletepageDefinemanufacturerof24VPowerI/OModuleonvalvemanifoldwaspartlydeleted.Partlycontrolconceptwithvalveislandinmanualsub-assemblyfixture1页(page)/21页(total目录/tableof录/tableof 目1概述 2电气控制方案/Electricalcontrol 规定目录/tableof录/tableof 目1概述 2电气控制方案/Electricalcontrol 规定 标记/labelling PLC控制箱/PLCswitch 控制箱箱体/switchbox 操作面板/operator 24VDC供电/24VDCpower 总线系统/Field 3气动系统Pneumatic 气源处理单元Compressedairsupply ttwo-hand-startbutton） 压力开关Pressure 阀岛Modularvalve Festo阀岛/Festovalve 阀岛电源插头Plugforpowersupplyofvalve 夹具中的气缸Cylindersinthe 气动软管Compressedair 4元器件批准清单/Componentsrelease controlconceptwithvalveislandinmanualsub-assemblyfixture2页(page)/21页(total 概述ISO电磁阀，并通过可编程控制器进行控制的方案，如图1 概述ISO电磁阀，并通过可编程控制器进行控制的方案，如图1所示，包括气动系统和电气控制两部分。conventionalpneumaticvalvesandISO-solenoidvalves,whichiscontrolledbyPLC.Thecontrolconceptconsistsofpneumaticsystemandelectricalcontrolsystem(fig.1).1fig.1.controlconceptofmanualfixturewithvalveTheconceptdescribedinthisarticleisapplicableonlyforthemanualsub-assemblyequippedonlywithpneumaticcylindersasactuators.Theconceptisnotvalid,forexample,ifcontrolconceptwithvalveislandinmanualsub-assemblyfixture3页(page)/21页(totalmanualstationisequippedwithmotororsafetydevicesuchaslaserscannerformanualstationisequippedwithmotororsafetydevicesuchaslaserscannerforsafety使用保护等级IP65具有Interbus总线接口的阀岛，阀岛直接安装在现场。使用气动的双手按钮和急停按ValveislandisequippedwithINTERBUSinterfacewithprotectionclassIP65,andcanbeinstalledatthesite.Pneumatic2-hand-startbuttonsandemergencystopbuttonareinstalled.Personalsafetyisrealizedbypneumatics,andcorrespondingsignalsareconnectedthroughp(neumatic)/E(lectric)convertertotheelectricalcontrol 电气控制方案/Electricalcontrol2.1规定Relevantnationallaws,regulations,technicalnormsandrecognizedtechnicalregulationsshouldcompliedwithFurthermoretheeffectiveVW-regulationsforequipments(Betriebsmittelvorschriften)alsoshouldbeobserved。特别是以下准则：EspeciallytheregulationsdescribedasBV1.09锁、锁装置和油漆颜色/locklockdeviceandpaintingBV1.11电气气动工作安全/work电气装配与安装/electricalassemblyandinstallation(elektrischeMontageBV5.12电路资料/wiringsystemdocuments(Schaltungsunterlagen)BV5.13控制技术/controltechnology(Steuerungstechnik)DINEN60204-1/GB5226.1机械电气安全1/Safetymachinery—ElectricalequipmentofPart1:General (Elektrolastehheft)shouldbeabided 标记/labellingLabellingsystemshouldcorrespondwithVW-standardandSVW-specificlabelingcontrolconceptwithvalveislandinmanualsub-assemblyfixture4页(page)/21页(total2.3文档Uponfinal2.3文档Uponfinalacceptance,besides3setsoffinalversionpaperdocuments,originalfilesofdocumentsmustbehandedoverviadatamedia(e.g.CD).AllnecessaryfilesanddataforfurtherprocessingbySVWmustbeincludedondatamedia.Inthephaseofdesignandconstruction,andinthecourseofprojectexecution,thesupplierprovideintermediatedocuments,includingcorrespondingdataElectricaldrawingof24Vpowersupplydistributorboxisincludedindistributorcabinetofgeneralbusbarwhichthe24Vpowersupplydistributorboxisconnectedto.Oritwillbedrawnoutwithitsowndrawingnumber,thatis,thenameofdistributor2.4PLC控制箱PLCswitch子以及用于气/电转换的压力开关等。柜内需保证20%的裕量。ThePLC,fieldbusI/Omodules,fusecircuitbreaker,relayandpressureswitch(forthepurposeofpneumatic/electricalconversion）etc.areinstalledinPLCswitchbox.20%spaceshouldbereservedintheMinimum1setofPLCprogrammingsoftwareshouldbehandedoverforeachproduction控制箱箱体/switchboxRITTALboxwithE1-lockcomesintouseforswitchboxhousing.Color:RAL准备(参见项目电气材料批准清单)，如WERMA公司可自由安装的Φ57mm的LED信号指示灯(signalbeacon)200。为避免焊钳撞坏指示灯，不允许使用柱状灯，且指示灯须安装防撞保护。Greenhalfballindicatorlamp(seeproject-specificelectricalmaterialreleaselist)“weldingrelease”shouldbeinstalledonthetopofswitchboxtoindicatewhetherthefixtureisreadyforwelding,likefreestandingsignalbeacon200withΦ57mmfromWERMA.Inordertoavoiddestroyofindicatorlampbyweldinggun,signaltowerisnotallowed,andtheindicatorlampisprotectedfromcollision.controlconceptwithvalveislandinmanualsub-assemblyfixture5页(page)/21页(total电缆进线需用电缆接头聚酰胺(PG)进行电缆进线需用电缆接头聚酰胺(PG)进行密封，没有使用的电缆进口使用盲盖盖住进行ThecableholetotheboxshouldbesealedwithPG-screwfixing,ifcableholeisnotoccupied,itshouldbesealedwithblindcover.操作面板/operatorOperatorpanelisbuiltonfrontdoorofPLCswitchbox.Basedonthequantityofvalvesandinafixture,differenttypeofoperatorpanelcanbeQuantityofvalves(groupsofparallelcylinders)<=6,andcylindersdrivenbyeachvalveconventionaloperatorpanelcanbeQuantityofvalves(groupsofparallelcylinders)>6,orcylindersdrivenbyanyvalve>6,SBToperatorpanelfromSWACshouldputintouse.每只阀允许的气缸数量见气动部分规定。Thequantityofcylindersallowedtobedrivenbyapleaserefertothedefinitionin1)常规操作面板/conventionaloperator7SIRIUS3SB3系列的操作按钮/指示灯元件(带标记)。可ConventionaloperatorpanelisillustratedinFig.2,andSIRIUS3SB3seriesofbutton/indicatorelements（withLabels）fromSIEMENSarereleasedforconventionaloperatorpanel.Ifrequired,thehousingcanbeprovidedwithboring,theholeswhicharenotoccupiedshouldbecoveredwithcontrolconceptwithvalveislandinmanualsub-assemblyfixture6页(page)/21页(total图2、控制箱上图2、控制箱上的操作面Fig.2conventionaloperatorpanelbuiltinswitchTheconventionaloperatorpanelconsistsof5lines(Fig.2),frombottomtoline1:lamptestbutton,faultindicatorandoperationmodeselectionS23/S8controlconceptwithvalveislandinmanualsub-assemblyfixture7页(page)/21页(totalline2/3:cylinderbuttonsandline2/3:cylinderbuttonsandindicatorsforeachgroup第4行：零件检测指示灯line4partcontrolindicators5line5:cylinderfinalposition指示灯色标要求/Colorrequirementforindicator气缸工作位置(按钮＋指示灯)：蓝色/workingpositionofcylinder(button+indicator)气缸基本位置(按钮＋指示灯)：白色透明/basicpositionofcylinder(button+indicator):white故障指示灯：红色/faultindicator手动/自动选择按钮/灯测试按钮：黑色/selectiorswitchforoperationmode/lamptestbutton:UseserialoperatorpanelSBTseries4fromcontrolconceptwithvalveislandinmanualsub-assemblyfixture8页(page)/21页(totalFig.3Fig.3SWACoperatorpanelbuiltinswitchPressbuttonsandindicatorsonoperatorpanelshouldbearrangedaccordingtothesequence:lefttoright,frombottomtoSelectorswitchisusedforoperationmode“singlestroke”/”single3）双手按钮预选/2-hand-startbutton作手动夹具，在操作面板上安装E2锁。使用E2钥匙，可预选双手按钮的数量(参见图3)，直到最后一个Ifseveraloperatorsareplannedforafixture,several2-hand-startbuttonsshouldbeconsequentlyequipped.E2lockisplannedonoperatorpanelsothatthefixturecanbeoperatedincaseoperatorscontrolconceptwithvalveislandinmanualsub-assemblyfixture9页(page)/21页(totalarereduced.Thequantityof2-hand-startbuttonscanarereduced.Thequantityof2-hand-startbuttonscanbepreselectedwithE2-keytillthe2-hand-startbutton（seeFig.3）,sothatthefixturecanbeoperatedevenifonlyaoperatorAfterpreselectionofoperationmode“singlestroke”ontheoperatorpanel,press2-hand-startbutton,meanwhilepressthebuttonsonoperatorpanel,theclamps/cylinderscanbeoperatedmanually.Ormanualoperationisalsoavailable,if2-hand-startbuttonisjumpedwithE2-Keyandpressbuttonson onlyLEDisallowedtobeinstalledinthelamp“weldingrelease”andindicatorsonspaceonthefixtureisenough,theswitchbox,compressedairsupplyunitandmodularvalveterminalswillbeinstalledonthebaseplateofthefixture,compressedairsupplyunitandvalveislandissituatedundertheswitch 24VDC供电/24VDCpower24VDC供电。在分配箱的门上需安装主开关(Moeller的产品)E124VDCisrequiredbythesmall-sizedPLCinstalledinPLCswitchbox.Ifseveralfixturesavailableinaproductionarea,therequired24VDCforthesefixtureswillbesuppliedcentrallybyadistributorbox.Onthedooroftheboxmainswitch(fromMoeller)andE1-lockshouldbeinstalled.3-phaseprimaryswitchedpowersupplyunitisinstalledinthebox,andafusecircuitbreakerisplannedforeachfixture.电缆进线需用电缆接头聚酰胺(PG)进行密封，没有使用的电缆进口使用盲盖盖住进行ThecableholetotheboxshouldbesealedwithPG-screwfixing,ifcableholeisnotoccupied,itshouldbesealedwithblindcover. 总线系统/FieldInterbus现场总线系统。有总线能力的操作面板、阀岛等装置直接连接到总线系统。ThefieldbussystemINTERBUSwithcopperwirecomesintouseintheconcept.Operatorpanelcontrolconceptwithvalveislandinmanualsub-assemblyfixture10页(page)/21页(totalvalveislandetc.withfieldbusabilityvalveislandetc.withfieldbusabilityaredirectlyconnectedtoINTERBUSsystem.withoutfieldbusabilityare不超过2块；toI/Omodulesonvalveisland,andviaInterbusconnectoronvalveislandconnectedtoINTERBUSsystem.Premise:notmorethan2piecesofI/Omodulesareconnected.过Fieldline模块连接到现场总线系统。directlyviaFieldlinemodulestoINTERBUSsystem,ifmorethan2piecesofI/Omoduleslikelytobeconnectedtovalveisland(I/OmodulesonvalveislandwillnotbeInterbussystemwithpreassembledcopperwirecomesintouseinthesystem.Maximumonlyoneplugconnectorisallowedforanyinstallationwire(INI.wire).ThepositionofFieldlinemodulesshouldbeoptimizedinthefixturesothatinstallationwiresasshortaspossiblearerequired.Onlywire(freeofweldingsparks)canbeused,refertoThefieldbusI/OmodulestobeextendedinPLCswitchboxpleaserefertoproject-specificelectricalmaterialreleaselist.Note:IfInterbusbuscouplerisrequiredintheswitchbox,thebuscouplershouldbeequippedcopperwireFieldlineModuleandbuscable/powercableconnectedtoFieldlinemoduleshouldbeprotectedagainstweldingsparks.注意1.Fieldline模块保护等级IP65，总线电缆和电源插头使用有SpeedCon技术的快速接头；FieldlinemodulewithIP65buscableandpowercablearepreassembledwithM12-SpeedCon2、为保证良好的通讯质量，在夹具中只允许使用预制的总线电缆和电源电Inordertoguaranteethecommunicationquality,onlypreassembledbuscableandpowerareallowedtobeinstalledinthecontrolconceptwithvalveislandinmanualsub-assemblyfixture11页(page)/21页(totalElectricalcomponentswhicharenotdefinedElectricalcomponentswhicharenotdefinedinthearticle,pleaserefertoproject-specificmaterialreleaselistand3气动系统Pneumatic手工夹具阀岛技术气动系统Fig.4Exampleofpneumaticsysteminmanualfixturewithmodularvalve4为使用阀岛的手工夹具气动系统的例子。使用阀岛的手工夹具气动系统包括气源处理单元、Fig.4isanexampleofpneumaticsysteminmanualfixturewithmodularvalvemanifold.ThePneumaticsystemcontainscompressedairsupplyunit,pneumaticsafety（two-hand-startbutton,driveunit（includecylindersinthefixture,etc.）.FollowingVWstandardmustbeconformed:39V126039Vcontrolconceptwithvalveislandinmanualsub-assemblyfixture12页(page)/21页(total3.1气源处理单元Compressedairsupply39V3.1气源处理单元Compressedairsupply39V161305Compressedairsupplyunitshouldfollowthepneumaticstandard39V16130partInordertoguaranteethestabilityofpneumaticsystem,thecompressedairsupplyunitmustinclude:shut-offvalve,filterregulator（includethepressuregauge）,branchingmodular,pneumaticcontrol2/3startvalve,softstartvalve,pressuregaugeformaintenancepurpose.Ifnecessary,dryer,lubricatoralsoshouldbe5气源处理单元的例Fig.5Exampleofcompressedairsupply3.2气动安全元件（双手按钮、急停按钮）Pneumaticsafetyelement（emergencystop急停按钮和双手按钮使用气动的安全元件，按照气动标准执行（39V16130Pneumaticsafetyelements,thatis,emergencystopbuttonandtwo-hand-startbutton,willbeusedinthesystem,andshouldconformtopneumaticstandard（2-hand-startbuttonaccordingto39V16130part12）.PneumaticsignalsthroughpneumaticsafetyareconvertedtoelectricalsignalviaP/Econverter（pressureswitch）inthePLCswitchcontrolconceptwithvalveislandinmanualsub-assemblyfixture13页(page)/21页(total 压力开关PressureThe 压力开关PressureThepressureswitchinPLCswitchboxwillconvertthepneumaticsignalsfrompneumaticsafetytoelectricalones.3.3阀岛ModularvalveFesto阀岛FestovalveModularvalveterminalmanifoldType44withInterbusinterfacefromFestowillcomeinto断功能，如图6所示。ThemodularvalvemanifoldconsistsofInterbus-interfacemoduleandISOstandardvalveswithprotectionclassIP65anddiagnosticsfunction.SeeFig.Fig.6ModularvalvemanifoldType44withInterbusinterfacefrom口插座防护等级IP65。2Sub-DInterbus-connectorswithIP65（oneforincoming,theotherforoutgoing）andcontrolconceptwithvalveislandinmanualsub-assemblyfixture14页(page)/21页(totalsupplysocketfor24VDC（M18）aresupplysocketfor24VDC（M18）areavailableontheInterbus-interfaceNote:IfInterbusconnectorisnotoccupied,theconnectorshouldbecoveredwithprotective 气源输入/Airsupply：5~6bar。总线接点/Fieldbusnode：Interbus总线节点/Interbus防护等级/ProtectionSolenoidvalve:3differentspecificationsISO02型（18mm）550L/min 1型方便阀岛在工位上的安排（参见图。阀岛选型软件可从Festo公司免费获得。TheconfigurationtoolscanbereceivedfromFestofreeof7Fig.7Configurationtoolsformodularvalvecontrolconceptwithvalveislandinmanualsub-assemblyfixture15页(page)/21页(total阀岛电源插头Plugforpowersupplyof阀岛电源插头PlugforpowersupplyofvalvePlugforpowersupply24VDC（M18,4pin）ofvalveterminal（Fig.8阀岛24V电源插Fig.8Plugforpowersupply24Vofvalvepin124V电源/Systemsupplypin224V负载电源（电磁阀供给电源）/24Vloadsupply（forvalvepowersupply）pin3-0Vpin4-接地3.4夹具中的气缸CylindersintheVWKonzernlastenheft。气缸的位置传感器需选择电信号传感器。Cylindersinthefixturearereferredtoproject-specificcomponentslist,relevantstandardsshouldbeconformed（e.g.VWKonzernlastenheft）.Electricalpositionsensorshouldbeselectedcylindersinthe3.5气动软管CompressedairCompressedairhoseandcorrespondingconnectortobeusedinthefixtureshouldmeetrequirementofwelding4元器件批准清单/Componentsrelease电气材料/Electricalcontrolconceptwithvalveislandinmanualsub-assemblyfixture16页(page)/21页(total2.4.2操作面板/operatorSIRIUS3SB3系列/SiemensSIRIUS3SB3buttonandSWAC操作面板和附件SWACoperatorpanel2.4.2操作面板/operatorSIRIUS3SB3系列/SiemensSIRIUS3SB3buttonandSWAC操作面板和附件SWACoperatorpanelandcorresponding型号备注1MC2100-O-Operatorpanelsbt16(seriesFront-mountedversionwith16pushbutton/indicatingelementswithLED,incl.16E/A24V0,5A,2MC2101-O-Operatorpanelsbt32(seriesFront-mountedversionwith32pushbutton/indicatingelementswithLED,incl.16I/O24V0,5A,3MC2245-O-InterbusOPCbasemodulebtm245/32S4forconnectionseries4equipment,max.32Byte,withoutmedia4MC2930-H-WireconnectiontoInterbusbase序号型号备注13SB3644-红色指示灯indicator23SB3644-,33SB3645-金属按钮带兰色指示灯/metalbuttonwithindicator,43SB3645-金属按钮带透明指示灯/metalbuttonwithindicator,53SB3500-黑色选择开关/selector63SB3602-黑色按钮/buttonorder1AEcontrolconceptwithvalveislandinmanualsub-assemblyfixture17页(page)/21页(total 24VDC供电/24VDCpower24V电源分配箱/24Vdistributor24V电源/powerunit2.4.4总线系统/Fieldarticle1PLCwithEthernet- 24VDC供电/24VDCpower24V电源分配箱/24Vdistributor24V电源/powerunit2.4.4总线系统/Fieldarticle1PLCwithEthernet-ILC1502Branchterminalwithremotebusbranchwithcopperwire,completewithconnectorandlabelingfield板IBSIL24RB-T-3Interbusbuscoupler,copperconnection,completewithconnectorandlabelingfieldInterbusILIBBK-4Interbustwistcable,Standard(3x2xInterbus铜线双绞电缆，标准(3x2xIBSRBCMETER-5FieldlineModuleM12busFLMBKIBM12DI81TRIO- supply,3phasex130mmx152.5mm2TRIO- supply,3phasex130mmx190mm 1AEcontrolconceptwithvalveislandinmanualsub-assemblyfixture18页(page)/21页(totalcontrolconceptwithvalveislandinmanualsub-assemblyfixture19页(page)/21页(total6FieldlineModuleM12localbusdevice,16digiatalinputFLMDI167FieldlineModuleM12localcontrolconceptwithvalveislandinmanualsub-assemblyfixture19页(page)/21页(total6FieldlineModuleM12localbusdevice,16digiatalinputFLMDI167FieldlineModuleM12localbusdevice,8digitalinput,8digitaloutputFieldline模块，M12接口，本地总线，8个数字输入，8个数字输出，FLMDIO8/88ProtectivecapM12/M12PROT-9ZBFInterbusbuscable,shieldedM12B-coded,straightfemaleconnector,freeconductorend,5m连接器(孔式)，电缆另一端无接头，5Interbusbuscable,shieldedM12B-coded,straightfemalecon