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在企业搬迁工作中，原来在包装岗位有两台其他品牌的小型 PLC在使用，分别控制堆垛岗位和封切热缩岗位。目前该型号产品已经被淘汰，而在搬迁后发现，PLC上电无反应，必须要进行更新换代。
　　1　工艺原理
　　本包装设备，完成对本厂建材产品的包装，包装材料使用PE 热缩塑封膜。主要工艺步骤包括：①堆垛;②封切：对塑料膜进行切断和封口;③热缩：使PE膜加热收缩包裹产品。
　　2　方案选型
　　2.1 控制方案设计
　　针对本系统的特点，适合采用集成了IO点的小型PLC。而温度可以单独交给温控表进行控制，速度由变频器进行调节，为了提高系统操作性能，温控表和变频器与PLC进行MODBUS通信，交换数据。同时，PLC通过网线连接至中控室上位机，完成数据采集、显示和必要的操作。
　　2.2 PLC选型及IO表设计
　　根据现场设备汇总需要输入点13个，输出点12个，使用 S7-200 SMART系列的SR40型号CPU并设计IO表。
　　2.3 其它主要电气设备选型
　　另外选择了1台安川V1000变频器和2台山武SDC36温控表分别进行速度和温度的控制，它们都支持通过MODBUS通信协议与 S7-200 SMART进行通信。
　　2.4 确定通讯方案
　　(1)上位机以太网通信方案本工厂使用的上位机为亚控公司生产的组态王上位机组态软件，经过查找发现组态王已经更新了S7-200 SMART的驱动，驱动名称：S7 TCP.DLL，驱动版本：60.1.24.30。
　　(2)MODBUS通讯方案安川V1000变频器和山武SDC36温控表具有非常相似的指令结构，能够方便地接入系统。
　其中读取和写入的功能码分别是03H和10H。
　　3　编程与调试
　　3.1 IO控制程序编程与调试
　　塑封膜包装线中堆垛和封切工序的动作最为复杂，而且各动作也存在着逻辑关系，为了准确执行各封切动作，采用步进控制。其他的只采用普通的逻辑控制即可。
　　3.2 MODBUS通信程序编程与调试

Schneider Modicon Remote Processor Part AS-884A-101

Schneider Modicon MM-PM15-401 MMPM15401 MMPMMP003C

Schneider Electric Modicon Analog In 8 Input Expansion Module TM2AMI8HT

Siemens 6ES7 323-1BL00-0AA0 6ES73231BL000AA0

Siemens SITOP30 POWER SUPPLY 30AMP 480V 6EP1437-1SL01

Siemens 6ES5470-4UB12 Analog Output Module ~60 DAY WARRANTY~

SIEMENS SINUMERIK 840D/810D/FM-NC OPERATORS GUIDE MANUAL END USER DOCU NE

Honeywell Communication Module 620-0044 13832

SIEMENS 6SN1118-0NH00-0AA2 6SN11180NH000AA2

SIEMENS Simatic Simodrive Card C98040-A1087. .

SIEMENS 6FC5303-0AA02-0AA0 HANDWHEEL CONNECTION MODULE XLNT

Advantech POS-562 REV.A1

Allen-Bradley 1746-NO4V SLC 500 4-Ch Analog OUTPUT Module

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88138

ADEPT TECH 10330-15350 USPP 1033015350

(000 no lot) Fanuc PLC 10 s rack 7cards IC693CHS391C IC693CPU331S . PRISTINE

INDRAMAT CLM01.3-X-0-2-B-FW USPP CLM013X02BFW

TELEMECANIQUE ATV-58HD33N4ZU NSPP ATV58HD33N4ZU

EDWARDS MC4160-C14 NSFP MC4160C14

CUTLER HAMMER 92005401 USPP 92005401

PHOENIX CONTACT IBS-ISA-SC/486DX/I-T NSFP IBSISASC486DXIT

MODICON AS-521P-008 NSPP AS521P008

HONEYWELL 51305508-200 USPP 51305508200

Siemens 6ES5 312-3AB12 6ES53123AB12

Siemens 6ES5-526-3LF11 NSFP 6ES55263LF11

SIEMENS 6ES5-373-1AA61/6ES5373-1AA61 MEMORY SUBMODULE NIB

Siemens 6ES5 306-7LA11 -- 6ES53067LA11

Siemens 6ES5-490-7LB21

Siemens 6GK7443-1BX00-0XE0 in Box

Siemens TP27 HMI 6AV3627-1QL00-0AX0 6AV36271QL000AX0

Siemens 6ES5927-3SA11

Lenel LNL-1300 Single Reader Interface Module

Yaskawa 87820-15003-S202 PLC Module 8782015003 NIB

SIEMENS 6ES7 223-1HF00-0XA0 in Sealed Box

Siemens OP37 6AV3637-1LL00-0FX1 Membrane Keypad ping Worldwide

Reliance 0-49002-2

Schneider Modicon AS-B805-016 800 I/O MODULE NIB

Schneider Modicon AS-884A-311 USPP AS884A311

Schneider Modicon AS-P230-080 USPP ASP230080

Schneider Modicon AS-B266-000 USPP ASB266000

Schneider Modicon AS-8534-000 High/Low Density Connector -

MODICON TELEMECANIQUE TC2000 COMPACT INDUSTRIAL PC 3515 KPM

SIEMENS SIMATIC S7 DIGITAL INPUT MODULE 6ES7421-1BL01-0AA0

Siemens 6ES7 334-0KE00-0AB0 -FS- 6ES73340KE000AB0

Siemens Simatic PG-615 HandHeld Programmer 6ES56150UA11

Siemens 9350 9350DC-100-0NZZZA NIB Power Meter Display ION Profibus Access

SIEMENS Sinumerik MAC 3212 CRT to LCD Replacement Monitor

SIEMENS 6SN1123-1AB00-0CA2 6SN1 123-1AB00-0CA2 SIMODRIVE 611 Power Module

SIEMENS SIMODRIVE 6SN1123-1AA00-0HA1

SIEMENS ENCODER 6FC9320-3KA00

Advantech PCM-9370

ALLEN-BRADLEY 2711E-K10C6 PANELVIEW 1000E OPERATOR INTERFACE

ABB 6214BZ10110G SC BACK UP MEMORY MODULE CONTROLLER

Acterna CycloneATM IP Optimimizer With CPHY-155-SM INSTALLED

6AV2181-4MB10-0AX0 Starter Kit SIMATIC HMI Comfort KP1200

8520-MOP7 ALLEN BRADLEY MONITORS CRT

SIEMENS 6SE3-226-8DJ40 USPP 6SE32268DJ40

BAILEY CONTROLS IMASI-23 NSFP IMASI23

ASEA BROWN BOVERI SAFT-103-CON USPP SAFT103CON

MODICON 557VIC10200 NSFP 557VIC10200

INDRAMAT MDD093A-N-030-N2L-110GB0 USPP MDD093AN030N2L1B

ASEA BROWN BOVERI GNT0137200R0002 USPP GNT0137200R0002

TRIAD TR-18-8K-20 USPP TR188K20

Siemens 6ES5-450-3AA11 NSFP 6ES54503AA11

SIEMENS 6ES5 700-0LA11 6ES57000LA11

SIEMENS S5 6ES5 374-1KH215V Flash 256 kByte Memory 16Bit

Siemens S5 6ES5 955-3LF11 6ES5955 6ES595553LF11

Siemens 6ES7 972-0BA41-0XA0 6ES7972-0BA41-0XA0

Siemens S7 6ES7307-1BA00-0AA0

Siemens 335-37

Honeywell Interface Module Communicating Thermostat Telephone Access Module

WARRANTYSERIES A F/W REV 4.2

Siemens 6DS1730-8AA 6DS17308AA in box, seal opened,

Siemens LOGO! 24RCL PLC 6ED1 053-1HB00-0BA2

Omron 3G2A5-RM001-PEV1

Schneider Modicon AS-M680-008 8K 8 K RAM Memory Module

Schneider Modicon P800 POWER SUPPLY AS-P800-003

Schneider Modicon AS-H827-000 USPP ASH827000

Schneider Modicon GROUPE AS-HDTA-200 NNB

Schneider Modicon AS-BDEP-218

Schneider Modicon S201 S202 AS-201P-000 AS-202P-000 Board

TELEMECANIQUE Magelis HMI XBT-G2330 XBTG2330

SCHNEIDER Telemecanique Switch XB4 BVB1

SIEMENS/TEXAS INSTRUMENTS 2 AMP OUTPUT MODULE 505-3716

Siemens 6AV6 542-0AD15-2AX0 MP270 Simatic Multi Panel

SIEMENS SINUMERIK 6FC5203-0AF02-0AA0 MembraKeypad

GE FANUC CCM COMMUNICATIONS MODULE CATIC655CCM500C

SIEMENS Sinumerik Simodrive Drives Rack 6SC 6101-4A-Z

SIEMENS SIMODRIVE 6SN1146-1AB00-0BA2SINUMETIK 840D NCU-BOX 6FC52476FC5356 2KH

SIEMENS 16297-22 LIL BOARD KIT - NIB

Allen-Bradley Analog Output Module 1778-OFC

AB, ALLEN BRADLEY AC SERVO ULTRA SERIES 1398-DDM-150 AE

AC Motor Speed Control VFD - 60 HP - 480 Volt - Three Phase Input

A06B-0755-B921#C100 FANUC AC SERVO SPINDLE REMANUFACTURED

75HP 3600 RPM TEFC motor 365TS frame, 460/3/60 Rebuilt

RELIANCE ELECTRIC VZ3000-DASR-1 USPP VZ3000DASR1

ALLEN BRADLEY 6151-BBBACDAZABZ USPP 6151BBBACDAZABZ

ALLEN BRADLEY 2705-P11J1L USPP 2705P11J1L

INDRAMAT MDD-090C-N-030-N2L-110PB0 NSFP MDD090CN030N2L1A

YASKAWA ELECTRIC JANCD-SV02B NSPP JANCDSV02B

WESTINGHOUSE NB2800P-400 USPP NB2800P400

ITE SIEMENS JD23B400 USPP JD23B400

Siemens 6ES5-247-4UA31/6ES5247-4UA31 POSITIONING MODULE NIB

SIEMENS 6ES5 377-0AB41 6ES53770AB41

SIEMENS OP393-II 6ES5 393-0UA12 6ES5393-0UA12 FreeShip

Siemens BOARD 6ES5-410-0AA12 6ES5 410 0AA12 6ES54100AA12 SPCB205 SIEMEN

SIEMENS 6ES7 151-1CA00-0AB0 6ES7151-1CA00-0AB0 FreeShip

Siemens OP17 6AV3 617-1JC00-0AX1 Membrane Keypad

RELEASE SuperMicro X9SRL-F MB ※Check W/ Us for Availability FIRST※

Texas Instruments 505-6508

Sunpak Interface Module NE-1AF

TYAN THUNDER N6550EX S4989 S4989-SI AMD QUAD SKT 1207 SERVER BOARD S4989WG2NR-SI

Siemens CPU 221 6ES7 211-0BA23-0XB0 6ES7211-0BA23-0XB0

Modicon DR-1010-000

Schneider Modicon /Schneider AS-B875-102/ASB875102 NICE

Schneider Modicon ASB824016 SEALED 24 VDC True High Output Module AS-B824-016

Schneider Modicon AS-BDEP-216 NSFP ASBDEP216

Schneider Modicon AS-BDEO-216 16 Pt 24VDC Input ASBDEO216

Schneider Modicon -AS-521P-006

Schneider Modicon DEP 218/ AS-BDEP-218 DISCRETE INPUT MODULE

Schneider Telemecanique ATV28HYU29M2 Inverter 1.5K/2HP

SCHNEIDER MODICON AS-B805-016 115VAC INPUT MODULE

QLogic SANbox 9200 Switch 9000 SB9200-32B 31277-12

SIEMENS 6ES5-453-7LA11/6ES5453-7LA11 DIGITAL OUTPUT MODULE XLNT

SIEMENS 6DD1600-0AF0 Simadyn D CPU Controller

Mercedes-Benz Bluetooth Hands-Free Communication Module

SIEMENS Simodrive 6SN1123-1AA00-0AA1 6SN11231AA000AA1

SIEMENS SINUMERIK 840DE 6FC5357-0BB11-0AE0 NCU 571.2

SIEMENS /MOORE 39NIM421BAN APACS NIM MODULE 16194-32/02

ALLEN-BRADLEY VERSAVIEW 1500P CAT 6181P15NS2KH/B

Allen Bradley SLC 500 1746-NO41 1746-N041 Analog Output Module

ABB Robotics PS 90/6-57-P-LSS-4843 AC Servo Motor DanaherMotion 3 HAC 3403

A06B-0147-B084 FANUC SERVO MOTORS

0-49011-1 RELIANCE PLC MODULES REMANUFACTURED

NAMCO ER920-13812 NSPP ER92013812

ALLEN BRADLEY 1756-L61 FNFP 1756L61

ALLEN BRADLEY 1336-C010-EAD-SI USPP 1336C010EADSI

GENERAL ELECTRIC 7VXAS057CD08 USPP 7VXAS057CD08

STI 70016-1189 NSFP 700161189

SIEMENS 7SD5111-5CA02-1AA0/EF NSPP 7SD51115CA021AA0

BARBER COLMAN DYN2-40025-024-0-12 NSFP DYN240025024012

Siemens 6ES5 945-7UA23 -- 6ES59457UA23

Siemens Simatic S5 6ES5458-4UC11 6ES54584UC11

SIEMENS 6ES5-715-0BC50 USPP 6ES57150BC50

Siemens 6ES5 490-8MB11 Connector Assembly

SIEMENS 6AV6 545-0AA15-2AX0 TP070 touchscreen glass

Siemens KTP600 6AV6647-0AD11-3AX0 Touch Glass

S-4000S-3208 S-1608 = 48x16 Digital Stage I/O

Telemecanique ATV66D12M2

SIEMENS LMG-90 PRESSURE TRANSDUCER INTERFACE MODULE XLNT

Wago 758-876/000-112 WAGO-I/O-IPC-P14 Linux 2.6 codesys visu CANopen master

Siemens 6SE7038-6GL84-1JA1 6SE7 038-6GL84-1JA1 FreeShip

Modicon AS-M485-008

Schneider Modicon AS-B984-100C B984 I/O LOGIC SOLVER

Schneider Modicon AS-B865-001 8 Channel Register ASB865001 N833

Schneider Modicon AS-B864-001 USPP ASB864001

Schneider Modicon AS-P120-000 POWER SUPPLY

Schneider Modicon CONTROL MODULE AS 884A 21

Schneider Modicon AS-HDTA-201 Secondary Subrack 5 Slot

SCHNEIDER MODICON AS-BDAP-210 TSX OUTPUT MODULE

SIEMENS 6ES5 463-4UA12 ANALOG INPUT MODULE

Rigol Function/Arbitrary Waveform Generators DG3121A

SIEMENS A5E00159514 PANEL TOUCH SCREEN

SIEMENS SINUMERIK FM-NC/810D/DE/840D/DE 6FC5203-0AB11-0AA2

Reliance Communications Mem. Module Part 57413

SIEMENS Drive 6SN1123-1AA00-0BA1

SIEMENS SINUMERIK 840D/DE NCU 573.5 6FC5357-0BB35-0AE0 NIB

SIEMENS 6FC4600-1AS01 Free Ship

AllenBradley2711-K10G16/C2711K10G16Panelview

Allen Bradley Versa View 1500H 6189-RDT15CA 2711P-RN6 6182-15TEH6B

ABB IRB 1400 SER 14-20056 ROBOT S4C PLUS CNTRLR TEACH PENDANT W/ MATCHED SET

Advanced Energy VHF 2060 RF GENERATOR AMAT 0920-00056

(O2-1) 1 BLH ELECTRONIC C3P1 LOAD TRANSDUCER O2-1

MEASUREX 09806701 NSPP 09806701

ALLEN BRADLEY 1336F-B050-AA-EN-HASP-L6 USPP 1336FB050AAENHA1

GE FANUC IC800SSI216D2 USPP IC800SSI216D2

FANUC A16B-2100-0110 USPP A16B21000110

SIEMENS 6DS1220-8AA USPP 6DS12208AA

RELIANCE ELECTRIC 57C-330-B USPP 57C330B

SIEMENS 6SC-6100-0NA80 NSFP 6SC61000NA80

Siemens 6ES5 470-7LB12 6ES54707LB12

Siemens 6ES5-950-1AB61/6ES5950-1AB61 POWER SUPPLY NNB

SIEMENS 6ES5-441-5AA12 USPP 6ES54415AA12

Siemens 6ES5 955-3LC41 6ES59553LC41 Power Supply Module

Siemens S5 6ES5-464-8MA21

Siemens C98043-A1601-L4-17

Siemens 6ES5 464-8MF11 -FS- 6ES54648MF11

Square D 8030 CIM-101

ON Q Home 8 Port Network Interface Module 363486-01

WS-C2960-24TC-S CISCO 2960-24TC SWITCH- W/1YR - WSC296024TCS Fast

Siemens 6ES7331-7KB00-0AB0 NIB

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 , no box,

Saftronics CIMR-G3U47P5

Schneider Modicon ASMEEP001 Compact EEProm Card AS-MEEP-001

Schneider Modicon AS-B552-001 USPP ASB552001

Schneider Modicon AS-W801-012 3485-2400 REMAN W801012 34852400

Schneider Modicon AS-BDEP-218 PLC

Schneider Modicon AS-B827-032 Input Module

MODICON AEG PANELMATE PLUS OPERATOR INTERFACE MM-PM22-200 PARTS OR REPAIR

Siemens Digital Input Module 6ES5433-8MA11 MAYBE

SFP-GE-T 1000BASE-T SFP MODULE FOR CISCO NEBS 3 ESD

Siemens OP27 6AV3627-1JK00-0AX0

SIEMENS Sinumerik 6FC5111-0CA02-0AA2 DMP KOMPAKT 16A 24V/0.5 E-Stand A

STANDARD COMMUNICATIONS CELLULAR MODULE CMM8700-101

SIEMENS 6SN1123-1AA00-0AA0 Simodrive LT-Module

SIEMENS C98043-A1304-L C98043A1304L SIMODRIVE XLNT

SIEMENS 6FC5-247-0AA34-0AA1 NSFP 6FC52470AA340AA1

ADVANTECH SOM-A2552

ALLEN-BRADLEY 160-P1 PROGRAMMING TERMINAL KEYPAD ""

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88248

ADEPT TECH 10332-12410 NSPP 1033212410

(12) Dongan Transformers ES-10210.198, 1.5 kVA, 460vPri, 230vSec, 1 Phase

INDRAMAT DDS02.2-W200-B USPP DDS022W200B

TELEMECANIQUE TSX-P67425 USPP TSXP67425

EPSON E2C351S-UL USPP e2c351sul

CUTLER HAMMER D520FC1 NSFP D520FC1

RELIANCE ELECTRIC 0-51864-2 NSPP 0518642

MODICON AS-P530-OMA USPP ASP530OMA

INDRAMAT TRANS01-6/1-109-488-4800 USPP TRANS01611094884

Siemens 6ES5 318-8MB12 6ES53188MB12

Siemens 6ES5-535-3MA12 USPP 6ES55353MA12

SIEMENS 6ES5-374-2FH21 USPP 6ES53742FH21

Siemens 6ES5 373 1AA41 6ES5 373-1AA41 6ES53731AA41 Memory Module

Siemens 6GK1-543-0AA02/6GK15430AA02