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1、汽车涂装全集成自动化系统 Automotive Painting Totally Integrated Automation System 配有安全传感器,可用性更高 Equipped with safety sensors, the availability of higher 汽车涂装车间的目标在于让德国人的珍爱看起来更加完美。 Auto Painting Workshop goal is to let the German's cherished look more perfect. 返修台必须消除诸如气泡等的细小缺陷。 Rework station must be elimin
2、ated, such as air bubbles and other small defects. 这就是 Ruesselsheim 厂的情形,它的涂装设施采用了传感器业最新技术以实现自动化控制。 This is the Ruesselsheim plant situation, and it's coating facilities in the sensor industry, using the latest technology in order to achieve automatic control. 其中,就有激光扫描器,它在现场总线级通过故障安全 Profisafe
3、行规与控制器进行通信。 Among them, there is laser scanner, it is through fail-safe fieldbus level Profisafe guild regulations to communicate with the controller. 总体上,该系统的可用性能提高到 99.85% 。 Overall, the performance of the system can be increased to 99.85%. 能直接通过控制器方便地参数化:通往横向传输机的提升装置的卷闸门处安装的 IQ-Sense 光式接近开关。 Dire
4、ctly through the controller to easily parameterized: the way to horizontal transmission machine upgrade device volume to install the gate of the IQ-Sense optical proximity switches. 在汽车工业,优化的生产解决方案必不可少, Ruesselsheim 的 Adam Opel 公司也不例外。 In the automotive industry, optimizing production solutions esse
5、ntial, Ruesselsheim of the Adam Opel company is no exception. 二十多年以来,该公司一直高度重视自动化控制技术。 20 Over the years, the company has attached great importance to automated control technology. 在 Ruesselsheim ,进行全威达系列的组装工作,也承担该系列产品各种各样的外涂装工作。 In the Ruesselsheim, Vectra wide range of assembly work, but also to u
6、ndertake the wide range of products outside the paint job. 其涂装设施占有一百多万立方米的封闭式空间,规模相当于一个足球运动场。 Its coating facility occupies more than 1 million cubic meters of enclosed space, equivalent to the size of a football stadium. 涂装车间拥有 3500 米长的输送线,其中, 1200 米连接至白车身总装线,约 800 米用于送走涂装完毕的汽车。 Painting Workshop i
7、s a 3500-meter-long transmission line, of which 1200 meters connected to the body in white assembly line, about 800 meters away for the finished painting cars. 这两条输送线之间,还有最多可存放 426 辆汽车的缓冲线。 Between the two transmission lines, as well as store up to 426 cars a buffer line. 该设施的设计日生产能力为 1495 辆汽车:两班制运行
8、的话,每小时可以涂装 108 辆汽车。 The facilities are designed daily capacity of 1495 vehicles: two-shift operation, then you can paint 108 cars per hour. 成功地挤身新领域 Successful crowd in new areas of 该设施的底层负责涂装缺陷的修饰工作,这也是在常规的滚筒输送线、水平输送线和链式输送线以外,另设提升装置的原因。 The bottom of the facility is responsible for modification of
9、coating defects, which is why in conventional roller conveyor line, the level of transmission line and the chain conveyor line outside the separate lifting equipment reasons. 最后一点需强调的是,西门子系列自动化设备传感器模块的智能互联,确保了这些部件之间的交互以及整个系统的工作与操作安全性。 The last point needs to be emphasized that the Siemens series of
10、intelligent automation equipment sensor module connected to ensure that the interaction between these components and the whole system in line with operational safety. 该系统的安全性、可靠性和可用性体现了“全集成自动化系统( TIA )”的最高水平,堪称典范。 The system's security, reliability and availability of the concept of "Totall
11、y Integrated Automation (TIA)" highest level, exemplary. 西门子也参预了其实施工作。 Simons also were involved in its implementation. “ 2003 年暑假该工厂停产期间,本地区的自动化和驱动技术水平完全改观。涂装设施技术支持经理 Albert Hoehn 负责该项目,他说,“对于我们,该系统是验证最新传感器和自动化设备的可靠性和功能性,并考察它 "2003 During the summer shutdown of the plant, the region the l
12、evel of automation and drive technology entirely different. Coating facility technical support manager, Albert Hoehn in charge of the project, he said," For us, the system is to verify the latest sensors and automation equipment reliability and functionality, and examine it 们在我公司其它方面应用的实验性项目。 O
13、ther aspects of their application in our company's experimental project. 由于 Opel 公司在 Ruesselsheim 已经成功地应用了自动化和控制技术达 24 年,因此,选择 Ruesselsheim 作为该项目的地点,不是随意的。 Since Opel in Ruesselsheim has been successfully applied automation and control technology for 24 years, therefore, select Ruesselsheim as t
14、he location of the project is not random. 结论是,我们的雇员获得了控制技术领域发展了近 30 年的最新技术,某种程度上,这些技术今天还在使用。 Conclusion is that our employees get to control the technology development for nearly 30 years of the latest technology, to some extent, these technologies still use today. “我们在该厂采用了各种控制技术,自继电器控制和远程机械控制和第一代
15、S5 与 S7 系统,直到现场总线技术与最现代化的 Ecofast 系统。”这对我们转向堪称典范的全集成自动化理念极为有利。 "We have the factory used a variety of control techniques, since the relay control and remote mechanical control and the first generation of S5 and S7 systems, until the field bus technology and the most modern Ecofast system."
16、 Which we turn to exemplary fully integrated automation concept is extremely beneficial. 通过 Profisafe ,激光扫描器直接连接至故障安全型 Simatic S7-400F 控制器,对卷闸门与横向输送机之间的区域进行 190° 的监控。 By Profisafe, laser scanner connected directly to fail-safe Simatic S7-400F controllers, on the roll and horizontal conveyor gat
17、e region between the 190 ° surveillance. 通过感应式接近开关和地板安装型信号发生器(右)控制横向输送线的运输板的速度、制动以及定位。 Through the inductive proximity switch and the floor mount signal generator (right) controls the horizontal transport board conveyor line speed, braking, and location. 输送机单元的 Ecofast 电机启动器(左)的结构符合 IP 67 规定,故可
18、以直接安装在驱动电机上。 Conveyor unit Ecofast starter motor (left) and structured to meet IP 67 requirements, it can be directly installed on the drive motor. 该试验项目专门解决车体前往三个返修台以及随后返回涂装车间的输送工作。 The pilot project to specifically address the body to the three rework station and the subsequent return to the deliv
19、ery of the work of paint shop. 将车体从上层输送系统送上运输板(输送托板)后,车身将在两层输送带之间全自动化地传输。 Transportation system will be sent to the upper body from the transport board (conveyor pallets), the body will be fully automated between the two conveyor belt to transfer. 控制器采用一台 Sicalis PMC7_CS ,以确保安全运转,并在统一的用户界面下,透明地监控所有过
20、程。 Controller uses a Sicalis PMC7_CS, in order to ensure safe operation, and unified user interface, transparent monitoring of all processes. Sicalis 平台统一的运作与诊断方案,支持集成化的、快速的安全故障检测功能,该点尤为有利。 Sicalis a unified platform for operation and diagnostics program to support integrated, fast fault detection s
21、afety feature, which is especially beneficial. 故障安全型 Simatic S7-416F 以远程主控制站的形式,协调安全保护系统的工作。 Fail-safe Simatic S7-416F to a remote master control station in the form, the coordination of security systems. 传感器,通向未来之路 Sensors, road to the future 尤其是对于传感器来说,现代化工厂出现了重大的创新。 Especially for sensors, the mo
22、dern factory there have been significant innovation. 由此,在提升装置卷闸门前部安装有一台 LS4 激光扫描器,使它通过 Profisafe (现场总线故障安全通信行规)直接与 Profibus DP 系统可编程逻辑控制器( PLC ) 通信,因而能同时利用 PLC 内集成的防护技术。 As a result, the Department of upgrading equipment roller shutters installed in front of a LS4 laser scanner, to make it through t
23、he Profisafe (fail-safe fieldbus communications OK rules) directly with Profibus DP-System Programmable Logic Controller (PLC) communications, which can simultaneously use protection technology integrated within the PLC. 该扫描器工作范围为 190° ,能监控该范围内精确划定的防护区域。 The scanner operating range of 190 °
24、;, be able to monitor the precise delineation of protection within the area. 这样,即使在 4 米以外,也能识别出穿黑衣服的人员。 Thus, even at 4 feet away, but also be able to identify the person dressed in black. 并将警报信息发送至 15 以外的人员或目标。 Alert messages will be sent to persons other than the 15 or objectives. 该系统采用的激光扫描器是全球第一
25、个 Profisafe 安装的该型号装置。 The system uses a laser scanner is the world's first installation of a Profisafe the model unit. 在它的旁边,设有三光束类别 4 光栅以及 4 个 IQ-Sense 光传感器,以实现最好的传输线旁人员安全性以及高度的应用灵活性。 Next to it, with three categories of four-beam grating, as well as four IQ-Sense optical sensors in order to ac
26、hieve the best transmission line next to the personnel safety and a high degree of application flexibility. 该文中, IQ-Sense 意味着组合传感器与控制器以构成系统仅需少量工作。 The article, IQ-Sense means that combined sensor and controller to form only a small amount of work the system. 单根双芯电缆,便可同时传输动力与数据,实现传感器 / 控制器模块一侧的最佳通信。
27、Dual-core single cable can also transmit power and data to achieve sensor / controller module side of the best communication. 通过 IntelliTeach 功能检测新目标便可校准 IQ-Sense 传感器,因此,该传感器技术的突出优点就是调试工作快捷、方便。 IntelliTeach function tests by the new target can be calibrated IQ-Sense sensor, so that the sensor techno
28、logy is the outstanding advantages of debugging quick and convenient. 且设置参数接下来可传送给其它任何一个传感器,能更一步节省时间。 And set the parameters then can be sent to any other one sensor can more step to save time. 此外, IQ-Sense 还支持按通道对系统进行诊 In addition, IQ-Sense also supports access to the system by attending 断,因而,更加安全:
29、能自动报告断线、短路、传感器 / 模块失调或故障,有助于避免故障,并将停机时间降至最少。 Broken, and therefore, more security: report automatically disconnected, short circuit, sensor / modules disorder or failure, help to avoid failure, and downtime to a minimum. 另一特点为,提升装置旁直接设置有两个 C40 封装形式的 IQ-Sense 光式接近开关,以控制安装于该处的卷闸门。 Another characterist
30、ic is to upgrade unit set directly next to the form of two C40 package, IQ-Sense Optical proximity switches to control the gate installed in the department's volume. 一旦检测到车体,传感器便定位并起动系统的电机启动器。 Once the body is detected, the sensor can locate and start-up system of motor starter. 与感应式接近开关不同,这些光电接
31、近开关可以检测出不同材质的物体,无论是金属还是其他材质。 Inductive proximity switch with a different, these photoelectric proximity switches can detect objects of different materials, whether metal or other material. 在横向输送带至返修站的路上,运输板上的感应式接近开关确保运输板的准确定位,以及必要的加速与制动。 In the horizontal conveyor belt to the rework station on the r
32、oad, the transport board, inductive proximity switches to ensure that the transport board accurate positioning, and the necessary acceleration and braking. 为此,需在输送带旁设置金属材质的信号发送器,当运输板路过时,供接近开关的感应式交变磁场检测,并触发相应的 PLC 通知信息。 To this end, need to set the metal conveyor belt next to the signal transmitter,
33、when the transportation board when passing for Inductive Proximity Switches alternating magnetic field detection, and trigger the corresponding PLC notification message. 完美结合透镜技术 The perfect combination of lens technology 为了分布式连接现场中的传感器,配置了 Simatic ET 200SF 站,它还能通过 Profisafe 行规与故障安全型 Simatic 控制器直接通信
34、。 In order to Distributed connection site of the sensor, equipped with Simatic ET 200SF station, it also through Profisafe guild regulations and fail-safe type Simatic controllers communicate directly. Ecofast 程序的智能电机启动器或变频器控制着输送带单元的驱动电机。 Ecofast program smart motor starter or inverter controls the
35、conveyor belt unit drive motor. 采用供电母线对驱动单元供电,而通信用电源则通过 Profibus DP 系统提供。 Bus-powered drive unit used on the electricity supply, while the communication with the power supply through the Profibus DP system. 故障或工作切换时,可通过电机启动器安全地切断各个组和一次回路。 Failure or work when switching motor starters can be safely c
36、ut off the various groups and a loop. 目前, Opel 还完成了该项功能针对其它应用的标准化工作。 At present, Opel has also completed the function of the standardization work for other applications. 由西门子非接触式 Moby I 运行识别系统实现传感技术与高层过程控制系统的集成,该系统长期以来就是 Opel 涂装设施的标准配置。 By Siemens Moby I run the non-contact sensing technology and id
37、entification systems to achieve high-level process control system integration, the system has long been standard Opel coating facility. 借助 Moby I 的数据媒体,能清晰地识别车身。 With Moby I data from the media, be able to clearly identify the body. 所用组件防护等级均高达 IP 67 ,它带来的优点极为明显,即能适应恶劣的工业环境。 Used for component prote
38、ction levels as high as IP 67, it brings the advantages of a very clear, that is able to adapt to harsh industrial environments. 例如,电机启动器无需再安装在控制柜内,而可以就近驱动电机直接安装。 For example, the motor starter no longer installed on the control cabinet, but can be installed close to a direct drive motor. 对于 Opel 来说
39、,除了技术功能以外,最重要的是技术合作商的一流服务:“在双班制工作期间,我们有时候,也包括异乎寻常的时间,需要合作商全方位的支持。西门子的服务支持令人称道,为该设施可用性自 85% 提升至 99.85% 做出了巨大的贡献。” Albert Hoehn 在描述该试验项目的成功经验时说。 For Opel, in addition to technical functions, the most important is first-class service provider of technical cooperation: "In the two-class system of w
40、ork, we sometimes also includes an unusual time, operators need to work together full support. Siemens service support is commendable, for the facilities, increase availability from 85% to 99.85% has made a great contribution. "Albert Hoehn description of the successful experience of the pilot
41、project, said. 这些被采用 Profisafe 组件( S7-416F , 417F 和 ET 200SF )已加入了 Opel 许可组件表,为其它欧洲工厂,如 Gliwice 和 Antwerp 使用这些组件建立了基础。 These were adopted Profisafe component (S7-416F, 417F and ET 200SF) has joined the Opel license component form, for other European plants, such as Gliwice and Antwerp to establish a
42、 foundation for the use of these components. / simatic-sensors 德语版发布于: 2005 年 SPS 汽车期刊 German version was released in: 2005 SPS Automotive Journal 汽车涂装全集成自动化系统配有安全传感器,可用性更高汽车涂装车间的目标在于让德国人的珍爱看起来更加完美。返修台必须消除诸如气泡等的细小缺陷。这就是 Ruesselsheim 厂的情形,它的涂装设施采用了传感器业最新技术以实现自动化控制。其中,就有激光扫描器,它在现场总线级通过故障安全 Profisafe 行
43、规与控制器进行通信。总体上,该系统的可用性能提高到 99.85%。能直接通过控制器方便地参数化:通往横向传输机的提升装置的卷闸门处安装的 IQ-Sense 光式接近开关。在汽车工业,优化的生产解决方案必不可少,Ruesselsheim 的 Adam Opel 公司也不例外。二十多年以来,该公司一直高度重视自动化控制技术。在 Ruesselsheim,进行全威达系列的组装工作,也承担该系列产品各种各样的外涂装工作。其涂装设施占有一百多万立方米的封闭式空间,规模相当于一个足球运动场。涂装车间拥有 3500 米长的输送线,其中,1200 米连接至白车身总装线,约 800 米用于送走涂装完毕的汽车。这
44、两条输送线之间,还有最多可存放 426 辆汽车的缓冲线。该设施的设计日生产能力为 1495 辆汽车:两班制运行的话,每小时可以涂装 108 辆汽车。成功地挤身新领域该设施的底层负责涂装缺陷的修饰工作,这也是在常规的滚筒输送线、水平输送线和链式输送线以外,另设提升装置的原因。最后一点需强调的是,西门子系列自动化设备传感器模块的智能互联,确保了这些部件之间的交互以及整个系统的工作与操作安全性。该系统的安全性、可靠性和可用性体现了“全集成自动化系统(TIA)”的最高水平,堪称典范。西门子也参预了其实施工作。“2003 年暑假该工厂停产期间,本地区的自动化和驱动技术水平完全改观。涂装设施技术支持经理
45、Albert Hoehn 负责该项目,他说,“对于我们,该系统是验证最新传感器和自动化设备的可靠性和功能性,并考察它们在我公司其它方面应用的实验性项目。由于 Opel 公司在 Ruesselsheim 已经成功地应用了自动化和控制技术达 24 年,因此,选择 Ruesselsheim 作为该项目的地点,不是随意的。结论是,我们的雇员获得了控制技术领域发展了近 30 年的最新技术,某种程度上,这些技术今天还在使用。“我们在该厂采用了各种控制技术,自继电器控制和远程机械控制和第一代 S5 与 S7 系统,直到现场总线技术与最现代化的 Ecofast 系统。”这对我们转向堪称典范的全集成自动化理念极
46、为有利。通过 Profisafe,激光扫描器直接连接至故障安全型 Simatic S7-400F 控制器,对卷闸门与横向输送机之间的区域进行 190° 的监控。通过感应式接近开关和地板安装型信号发生器(右)控制横向输送线的运输板的速度、制动以及定位。输送机单元的 Ecofast 电机启动器(左)的结构符合 IP 67规定,故可以直接安装在驱动电机上。该试验项目专门解决车体前往三个返修台以及随后返回涂装车间的输送工作。将车体从上层输送系统送上运输板(输送托板)后,车身将在两层输送带之间全自动化地传输。控制器采用一台 Sicalis PMC7_CS,以确保安全运转,并在统一的用户界面下,透明地监控所有过程。Sicalis平台统一的运作与诊断方案,
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