内容分析ab plc学习

10/25/20221CommonControlsSoftware-2(CCS-2)Section16-HardAutoWelding(Revised12/8/2003)10/25/20222AdvancedorganizerSection1

CCS-2IntroductionSection2

LogixOverviewSection3

PanelViewSection7

DevicesSection8

DiagnosticsSection9

ActionsSection1Section10

ScrollistSection16

HardAutoWeldingSection1Section11

CellLogicSection1Section12

StationLogicSection13

RobotConceptsSection1Section14

RobotLogicSection1Section15

RobotLogic2Section6

InterlocksSection5

ProgramsSection4

Naming10/25/20223LearningobjectivesUponcompletionofthisreportthelearnerwillbeableto:ExplaintheuseofweldschedulesExplainthespecificationsthatareinvolvedinweldingDescribehowthePLCinterfaceswiththeweldcontrollerExplainhowtowritelogictoperformhardautomaticwelding10/25/20224HardAutomaticWeldingGMtopurchasecommonweldcontrollersacrossALLunitsNodivisional/plantspecificweldcontrollersWeldControllerspurchasedacrossmanyprojectsatsignificantlyreducedcostWeldControllerseasilyreallocatedbetweenprojectsNext10/25/20225WeldingspecificationsWS1-GMCommonWeldingPrinciplesSectionAisresistancespotweldingWS2-NACommonWeldingSpecifications(furtherinfotocomeiningslide)SectionA:ResistanceWelderControlWS4-CommonresistanceweldingverificationproceduresRS4-RobotinterfacespecificationIncludesweldcontrolinterfaceCommoninterfacebetweenhardautomaticweldingandroboticwelding10/25/20226WeldControllerRulesofProcessWeldControllerareprovidedas:SinglePack:1SCRTri-Pack:3SCR’sSix-Pack:6SCR’sWeldcontrollercanbesharedacrossstationswithinthesamecell,providedthestationdoesnothaveanoperatorinterface.Anoperatorcontrolledstationmusthavecompletecontroloftheweldcontroller.Next10/25/20227WS2AWeldingSpecification(ResistanceWelderControl)WeldingTechnicalSpecification(“Out-of-the-box”content)DeviceNetcommunicationforallcontrolsignalsRS-485orethernetforupload/downloadsupportInterfaceSpecificationDefinesHardwireInterfaceToMainControlPanelProvidesthe“NotE-Stop”SignalDefinesReceptacle/Cable/Pin-outReferencesRS-4forCableDiagramDefinesApplicationSignals(DeviceNet)inconjunctionwithRS-4DedicatedDeviceNetChannelCellto/fromWeldControllerNext10/25/20228WS2AWeldControllerSignals-PLCtoWeldControllerWeldControllertoPLCWeldSchedule1-31NoAlertRequestWeldModeOnApproachingCapChangeFaultResetCapChangeRequestEnableContactorSaverPressure0-15RequestPressureReadPressureInitiateWeldNoFaultCapsChangedWeldModeOnProcessCompleteScheduleInProgressStepperResetTipDressRequestContactorOpenNext10/25/20229WeldingProgramOrganizationOneprogramforEveryweldcontroller.

Consistsofthefollowing:MappingRoutinesParameterConfigurationRoutineDriverRoutineforSpecificWeldControlModelandManufacturerDiagnosticRoutineWeldStationprogramcontainsthefollowingtypesofroutines:WeldgrouproutineOneroutineforeveryweldstepinthesequenceWeldActionRoutineAgroupofactionrungsforeveryweldgunwhichcyclesforaweldstepIfaweldguncyclesatmultipleweldsteps,therewillbearoutineforeachinstancetheweldguncycles.WeldCommonRoutineCollectstheinformationfromeachweldsteptopassontothewelddriverLogicforcommonweldsupport.(i.e.enableweldmode,enableweldtimers,etc.)Next10/25/202210WeldControllerprogramlogicEachweldcontrollerhasitsownprogramTheprogramnamematchestheweldcontrollername–AA100WC01ThesearetheroutinesthatarelocatedintheweldcontrollerprogramNext10/25/202211B001_MapInputsIdentifytheDeviceNetnodeoftheweldcontrollerAlsocontainsgeneralweldcontrollerconfigurationsettingsNext10/25/202212B001_MapInputsIdentifytheDeviceNetnodeNextChangearrayreferencetonodenumberChangearrayreferencetotwotimesnodenumber10/25/202213B001_MapInputsConfigurewhetherSCRisusedinthecell.NextChangeOTEtoOTUwhenNOTused.10/25/202214B002_MapOutputsIdentifytheDeviceNetnodeoftheweldcontrollerNext10/25/202215B002_MapOutputsIdentifytheDeviceNetnode–MUSTbethesameasB001_MapInputsNextChangearrayreferencetotwotimesnodenumber10/25/202216B004_ParametersSettheMessageOffsetfortheweldcontrollersdiagnosticsSettheprogram’sstringnamefordisplayonthePanelViewNext10/25/202217Z3**_*WeldControllerConfigurationSpecificDriverSpecifictoeachweldcontrollerconfiguration.(1Pack,3Pack,6Pack)Specifictodifferentversionsoftheweldcontrollerspecification.(WS2,WS2A-RevA)Specifictodifferentvenders.Allvendor&weldcontrollerspecificlogicinthisroutineThisrequiresthereplacementofonlyoneroutinewhenchangingtoadifferentweldcontrollerNext10/25/202218WeldNamingConventionsControllerScopedTagsAA###WC##OneperWeldControllerPassinformationbetweentheweldcontrollerprogramandthestationprogramAA###WC##PVOneperWeldControllerPassinformationbetweentheweldcontrollerprogramandthePanelviewNext10/25/202219WeldingStationLogicThereisonecommonroutineperstation,whichcollectstheinformationfromthevariousactionroutinestocoordinatecommunicationtotheweldcontroller.NextWeldstepconsistsofaroutinetocollecttheinformationforallweldgunsthatprocessonthatstep.Eachweldgunthatprocessesataweldstepcontainsanactionroutine.

10/25/202220WeldNamingConventionsWeldStationProgramScopedTagsG###OneperWeldGunInformationabouttheweldgun.W#G###OneperWeldGunperWeldStepInformationabouttheweldgunforaparticularweldstep.Weld#OneperWeldStepInformationaboutallweldsforastepWC##OneperWeldControllerAliasforAA###WC##WeldTimersOneperStationEnableTimerstocyclethroughtheweldscheduleWeldModeOneperStationTogglestheselectionofweldmodeonandoffNextWeldStationProgramScopedTags*WGxxxOneperWeldGunInformationabouttheweldgun.*WxWGxxxOneperWeldGunperWeldStepInformationabouttheweldgunforaparticularweldstep.WeldxOneperWeldStepInformationaboutallweldsforastep*WCxxOneperWeldControllerAliasforAA###WC##WeldTimersOneperStationEnableTimerstocyclethroughtheweldscheduleWeldModeOneperStationTogglestheselectionofweldmodeonandoff*Note:ForReferenceOnly,refertotheGeneralMotorsMechanicalDesignStandardsdocumentMD-1(ComponentNaming)whencreatingthesetags10/25/202221Exercise1Time:15min.Objective:Addaweldcontrollerprogrambycopyingbetweentwoprojects,renameprogramsandtagsaftercopy,pointtagalias’stointerlocktags.Directions:Opentheexerciseproject“Sec16Exercise1.ACD”andthereferenceproject“Sec16Reference.ACD”inRSLogix5000.Copyandpastethefollowingcontrollertagsfromthereferenceprojecttotheexerciseproject(procedureissimilartocopyingtagsinthesameproject):AA100WC01AA100WC01PVCopyandpastethefollowingprogramtagsfromthereferenceprojectStationWeldingprogramtoStationAA010programtagdatabaseintheexerciseproject(procedureissimilartocopyingtagsinthesameproject):Weld1WeldModeWeldTimersWC01Next10/25/202222Exercise1(cont’d)Directions:CopyandpastetheAA100WC01programfromthereferenceprojecttotheexerciseproject(procedureissimilartocopyingprogramsinthesameproject).Renamethefollowingintheexerciseproject:ControllertagAA100WC01toAA010WC01ControllertagAA100WC01PVtoAA010WC01PVProgramAA100WC01toAA010WC01Note:Thetagsarerenamedaftercopyingtheprogramsothatprogramtagalias’sandlogicwouldverifyaftercopy.Otherwisethetagalias’sandaddressreferenceswouldneedtobecorrected.CheckandcorrectAA010programtags:Doubleclickonthe“AliasFor”columntitletosorttagsbyalias.Verifythealias’sWC01isstillpointingtotheAA010WC01controllertag.CheckandcorrectAA010WC01programtags:Doubleclickonthe“AliasFor”columntitletosorttagsbyalias.Verifythealias’sWCandPVarestillpointingtotheAA010WC01andAA010WC01PVcontrollertags.CorrecttheCelltagaliastopointtoAA010Cell.Next10/25/202223Exercise1(cont’d)Directions:CheckandcorrectweldcontrollerDeviceNetaddressmapping:CorrectDeviceNodeaddressmappingrungsintheMapInputandMapOutputroutines,thenodeaddressforthiscontrollerisNode21CorrecttheCOPandFLLinstructionslengthfrom1to2onDeviceNetI/Omappingrungs,thisisrequiredfora3or6packweldcontroller,changesneedtobemadeinbothMapInputsandMapOutputsroutines.CorrectdiagnosticmessagerungsandrungcommentsinMapInputroutinewithnewnodeaddress,node21.VerifythethemessagenumbersarenotduplicatedbycrossreferencingthekAlarmcontrollertag.Verifyandsavetheexerciseproject.Next10/25/202224Exercise2Time:30min.Objectives:CopyandpasteweldactionandweldcommonroutinesProgramweldingpromptingSearchandReplacetagcommentsintheprogramtagdatabase

Backgroundinformation:Forthepurposesofthisexercisethefollowingwillapply

“1stWeld”actionincludestwoweldgunsC940WG01&C940WG02WeldGunC940WG01valvelocatedinvalvemanifoldPM1,valve7WeldGunC940WG02valvelocatedinvalvemanifoldPM1,valve8WeldGunC940WG01locatedonAA010WC01SCR1firesusingschedule1WeldGunC940WG02locatedonAA010WC01SCR2firesusingschedule1Clamp1andClamp2andClamp3mustbeclosedbeforetheweldingcanbeinitiated

Next10/25/202225Exercise2(cont’d)Opentheexerciseproject“Sec16Exercise2.ACD”andthereferenceproject“Sec16Reference.ACD”inRSLogix5000.Makenoteofthefollowing:Thereferenceprojectcontainsmanyprogramsandunscheduledprograms.ThisexercisewillbeusingtheStationWeldingprogramasthereference.CopyandpastethefollowingtagsfromthereferenceprogramtagdatabasetotheexerciseAA010programtagdatabase:WG104WG106W1WG104W1WG106Copyandpastethefollowingroutinesfromthereferenceprojecttotheexerciseproject:S030_1stWeldS035_InitW1WG104S040_InitW1WG106monNext10/25/202226Exercise2(cont’d)RenamethefollowingAA010programtags:WG104toC940WG01WG106toC940WG02W1WG104toW1C940WG01W1WG106toW1C940WG02Renamethenewroutinesintheexerciseprojecttoamorespecificnameandmatchthesequenceorder:S035_InitW1WG104toS035_InitW1C940WG01S040_InitW1WG106toS040_InitW1C940WG02Verifynewsequenceroutinesareinproperorderaccordingtothenewmachinesequence,theweldingtakesplaceafterClamps3areclosed. IntheexerciseprojectS030_1stWeldroutinedothefollowing:RemoveTBDbitontheWeld1.ToolRdyrungandaddXICp,pandp. IntheexerciseprojectS035_InitW1C940WG01routinedothefollowing:Correctthescrolllistrung,changethescrollisttextIDto20Correctthescrolllisttextvalueto20Correcttherungcommenttoreflectthenewscrollisttexttrigger,andweldgunnumberNext10/25/202227Exercise2(cont’d)Onthemotionpromptrung,addapromptforClamp3byaddinganoutputbranchwithXIOpandaOTLClamp3.Close.Prompt. IntheexerciseprojectS040_InitW1C940WG02routinedothefollowing:Correctthescrolllistrung,changethescrollisttextIDto21.Correctthescrolllisttextvalueto21Correcttherungcommenttoreflectthenewscrollisttexttrigger,andweldgunnumberOnthemotionpromptrung,addapromptforClamp3byaddinganoutputbranchwithXIOpandaOTLClamp3.Close.Prompt. Intheexerciseprojectmonroutinedothefollowing:Correctthefollowingweldgunvalveaddressrungs:WeldgunC940WG01isPM1V7S14WeldgunC940WG02isPM1V8S14ChangesourcevalueinMoveinstructiononrung3to1,toinitiateschedule1onAA010WC01.SCR1.ChangesourcevalueinMoveinstructiononrung4to1,toinitiateschedule1onAA010WC01.SCR2.Changevalveaddressonrung13tonewvalveaddressforC940WG01,PM1V7S14.Next10/25/202228Exercise2(cont’d)Changevalveaddres