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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

836800 WESTINGHOUSE CONTROLLERS REMANUFACTURED

LAMBDA LCS-E-5-OV USPP LCSE5OV

TELEMECANIQUE ATS-46C48N USPP ATS46C48N

ALLEN BRADLEY 8520-1S10A-BAT-EX4-T1-Y-4-5-7 USPP 85201S10ABATEX4T

CONTROL TECHNIQUES DXA-430 USPP DXA430

INDRAMAT HDS03.2-W100N-HS76-01-FW USPP HDS032W100NHS760

ITE SIEMENS HJD63B300L NSFP HJD63B300L

SIEMENS 6ES5-484-8AB11 USPP 6ES54848AB11

ALLEN BRADLEY 2707-V40P1 USPP 2707V40P1

Siemens 6ES5 928-3UB12 6ES59283UB12

Siemens SIMATIC 6ES5 095-8ME01 6ES5095-8ME01 S5-95U DP

SIEMENS 6ES5-497-4UB12 NSFP 6ES54974UB12

Siemens 6ES5 436-4UA11/6ES5436-4UA11 INPUT MODULE NIB

Siemens 12/24RC 6ED1052-1MD00-0BA4

Siemens EM232 6ES7232-0HB22-0XA0

SCHNEIDER DISCRETE VDC/VAC OUTPUT DAP 218/AS-BDAP-218

Square D 9001-KN-100SP

SIEMENS 6ES7 153-2BA00-0XB0 SIMATIC S7 DP SLAVE INTERFACE MODULE

WE SHIP SAME CISCO SPA-8XOC12-POS 8-PORT OC12/STM4 POS SHAR.ADAP. Fa

Siemens 6RA70 C98043-A1601-L4-16

SIEMENS TP270-10 6AV6545-0CC10-0AX0 Touch Glass

Schneider Modicon SECONDARY SUBRACK 5-SLOTS AS-HDTA-201 -

Schneider Modicon ASBDAP216Compact Out Module AS-BDAP-216

Schneider Modicon AS-B824-016 MODULE REPAIRED ASB824016

Schneider Modicon #NAME

Schneider Modicon AS-S911-800 ASS911800 Hot Standby Processor

Schneider Modicon AS-BDEP-220

Schneider Telemecanique Magelis Terminal XBTGT4330

SIEMENS 6ES7 131-4BD01-0AA0 ET200S INPUT MODULE

Rupert Neve Designs 543 Mono Compressor-Limiter DEMO UNIT

Siemens Digital Output Module 6ES5 456-4UA12 Version 1 Possibly

SIEMENS SINUMERIK 820 T 6FX1128-1BA00 WITH MODULE TESTED WARRANTY

Schneider Automation Communication Module TSXSCM2116 Ver. 2.3 WARRANTY

SIEMENS 6SN1-162-0EA00-0AA0 NSPP 6SN11620EA000AA0

SIEMENS 6SC6100-0GB12 6SC6 100-0GB12 SIMODRIVE Power Supply qty

SIEMENS 6FC5111-0CA04-0AA0 USPP 6FC51110CA040AA0

AllenBradley6182H-7KRH4DVersaViewCE700HPanelView.....

ALLEN BRADLEY W33 FNFP W33

ABB DSQC317 6MB MEMORY EXP BRD 3HAB2220-1 TESTED

Adtech - AX/4000 Mainframe w/5 modules

(Floor LOT) Allen Bradley Power Flex Drive 150F-251NBD NICE

KAIJO ELECTRIC 8801B-MR NSPP 8801BMR

ACTUS POWER NPSA-102MU-E9BS USPP NPSA102MUE9BS

FISHER ROSEMOUNT CL6011X1-BA1 USPP CL6011X1BA1

FANUC A05B-2301-C301 USPP A05B2301C301

SCHMERSAL LSS3002110 USPP LSS3002110

PPT VISION 661-0342-T10 NSFP 6610342T10

RELIANCE ELECTRIC 57C-404 NSPP 57C404

Siemens 6ES5 460-4UA11 6ES54604UA11

Siemens 6ES5-927-3KA13 NSFP 6ES59273KA13

SIEMENS 6ES5-430-4UA14 6ES54304UA14

Siemens 6ES5 482 7LA11 I/O MODULE 6ES5482 7LA11

Siemens S5 6ES5 453-4UA12 6ES5453-4UA12 Output

Siemens 7SJ6415-5EB21-1FE0/EE

Siemens 6ES7 321-7BH01-0AB0 6ES73217BH010AB0

Square D 8005 CP-50

NIM-211 Larscom A3 Network Interface Module NIM211

WS-SUP720 Cisco Supervisor Engine 720 Control processor

Siemens 6ES7131-4BF00-0AA0 6ES7 131-4BF00-0AA0 FreeShip

Siemens S7-200 EM231 RTD 6ES7 231-7PB22-0XA0 EM 231

Reliance 45C66A

Schneider Modicon GOULD PROGRAMMABLE CONTROLLER AS-584L-231 50Hz

Schneider Modicon AS-B352-000 NSFP ASB352000

Schneider Modicon AS-S908-000 USPP ASS908000

Schneider Modicon AS-B875-102 _ ASB875102 _ Analog Input

Schneider Modicon AS-B805-016/ASB805016 Input

MODICON AS-J470-000 ANALOG OUTPUT MEMORY MODULE Q1-5

SIEMENS PLC INPUT MODULE SIMATIC 6ES5 421-8MA12

Siemens 6ES5 454-4UA12 -FS- 6ES54544UA12

Siemens Power Supply Sitop Power 20 6EP1436-1SH013_6EP14361SH013_6EP1436-1SHO13

SIEMENS 6RA2116-6DD20-012mo warrantyFree EU ShippingInc UK VAT

WELLFLEET COMMUNICATIONS SSE 5410 MODULE

SIEMENS 6SN1118-0DG21-0AA0 _ 6SN11180DG210AA0 version D

SIEMENS Simodrive 611 6SN1118-0NJ01-0AA0 6SN1 118

SIEMENS 6FC5503-0AD00-0AA0 Free Shipping Worldwide

ADVANTECH PC-based Controller ADAM-4500 ADAM-4500-A NIB

Allen-Bradley 1771-0AD 12 to 120V AC Output Module

ABB ASEA CIRCUIT CARD DSMB127 DSMB 127 DSMB127 7K 57360001-HG/2 2668 184-584/2

Adept JR3 Factory Sealed 50/100 Force-Moment Sensor

6SE7032-6EG60-1AA1 SIEMENS MASTERDRIVE 260AMP 132kW 510-620VDC VECTOR CONTROL

HONEYWELL 1858-T79H0 USPP 1858T79H0

SYMAX 8030-CRM-232 USPP 8030CRM232

CUTLER HAMMER S801T18P3S USPP S801T18P3S

COMPUMOTOR APEX-6154 USPP APEX6154

NSK 7028A5TDBC7P4 NSFP 7028A5TDBC7P4

MITSUBISHI K3N-CPU-P2H USPP K3NCPUP2H

GE FANUC IC693CPU352 USPP IC693CPU352

Siemens 6ES5 262-8MA11 6ES52628MA11

Siemens 6ES5-482-4UA11/6ES5482-4UA11 I/O MODULEXLNT

SIEMENS 6ES5-312-3AB11/6ES5312-3AB11 INTERFACE MODULE NIB

SIEMENS S5-110 6ES5 380-7AA12 Timer Module S5-110 6ES53807AA12

Siemens 6ES5 464-8ME11 6ES54648ME11

Siemens 6FC5510-0BA00-0AA0 + 6FC5511-0CA00-0AA0

Siemens TP177 6AV6 640-0CA11-0AX1 Touch Glass + Film

Siemens 6ES5463-4UB12

Juniper Networks JX-2T1-RJ48-S Dual-port T/E1 Physical Interface Module PIM

ZIATECH ZT88CT60-S328 NSPP ZT88CT60S328

Siemens 6ES7 212-1BA01-0XB0 6ES7212-1BA01-0XB0

SIEMENS OP25 OP25/A 6AV3 525-1EA01-0AX0

PLC DIRECT D4-DCM

Schneider Modicon AS-B864-001/ASB864001

Schneider Modicon AS-584A-330 USPP AS584A330

Schneider Modicon AS-M780-032 USPP ASM78003 Memory Cartridge

Schneider Modicon AS-9492-001 USPP AS9492001

Schneider Modicon 984 Series 7 Slot Chassis AS-H819-007 surplus

Schneider Modicon /MODICON TSX COMPACT DTA 202/AS-HDTA-202 -

Siemens Texas Instruments U-05N Input Module U05N

Telemecanique Digital Operator Panel VL 1006366598

SIEMENS SIMATIC S7 SM332 ANALOG OUTPUT MODULE AO4 X 16 BIT 6ES7-332-7ND02-0AB0

SIEMENS 3SB02-P3G NSFP 3SB02P3G

SIEMENS SINUMERIK 840D/840Di/810D CYCLES AND PROGRAMMING GUIDE MANUAL NE

BOSCH/REXROTH/INDRAMAT RMK12.2-IBS-BKL RECO COMMUNICATION MODULE

SIEMENS SIMODRIVE 6SN1145-1AA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 [1]

SIEMENS PCB 6FC5357-0BA20-0AE0 GWE-570038962000 Nice

Advantech PCA-6741 PCA-6741L Card

Allen-Bradley 2711P-T7C4D8 Panelview Plus 6 6.5 Color Touchscreen

ABB 4" MAGNETIC FLOW METER 10DX43HCDE15P3B2DAA2132X3ABBC1 DIGITAL

ACCUTHERM THERMA CARE RA 090804

A4001-N ESD Target Set IEC 61000-4-2, 30dB Attenuator, SMA Cable

83402A, Agilent, Lightwave Source 300 kHz - 6 GHz, OPT 012, 6 MONTH

SIEMENS 6ES7-671-0CC01-0YX0 NSFP 6ES76710CC010YX1

ASEA BROWN BOVERI DSCA-125A USPP DSCA125A

APC SURT3000XLT USPP SURT3000XLT

MITSUBISHI A3A-CPU-R21 NSFP A3ACPUR21

INA PR14135 NSFP PR14135

ALLEN BRADLEY 22C-D045A103 USPP 22CD045A103

SIEMENS C98043-A1001-L.8 USPP C98043A1001L8

Siemens 6ES5-415-7AB11 NSPP 6ES54157AB11

SIEMENS 6ES5 464-8MA11 6ES54648MA11

SIEMENS 6ES5 700-2LA12 6ES5700-2LA12

Siemens PLC DIGITAL INPUT 6ES5 421-8MA12 6ES5421-8MA12

Siemens 6ES7 332-5HD01-0AB0 6ES73325HD010AB0 NIB

SIEMENS PLC EEPROM 6ES5 374-0AB11 6ES53740AB11

PVDM3-128 CISCO 128-CHANNEL HIGH-DENSITY VOICE AND VIDEO DSP MODULE

HAI 81A00-2WHZB ZIGBEE INTERFACE MODULE

USB INTERFACE MODULE PN UIM-2X

SIEMENS 6AV6545-0AA15-2AX0 TP070 touchscreen glass

Siemens LOGO 230RCo 6ED1052-2FB00-0BA6 NIB

Nemic-Lambda NNS15-5

Schneider Modicon Battery CELLS AS-5284-001

Schneider Modicon AS 884A 201 CONTROL MODULE

Schneider Modicon AS-E785-904 ASE785904 Fast Shipping

Schneider Modicon Gould AS-M485-004 PCB Rev B Board

Schneider Modicon AS-B814-108 MODULE 3 MON WARR

Schneider Modicon P810 PLC POWER SUPPLY MODULE AS-P810-001

Schneider/Modicon TM2AMI2HT in Box

Schneider PLC 140 ACO 13000 140ACO13000 NIB Sealed

SIEMENSPOWERMONITORPANELCAT4810E

Siemens 6AV6640-0CA01-0AX0 6AV6 640-0CA01-0AX0 SIMATIC TP170 Micro

SIEMENS SIMADYN D SP22 6DD1683-0CC0 REV B POWER SUPPLY MODULE

GE FANUC IC693CMM311R

SIEMENS SIMODRIVE Power Module 6SN1123-1AA00-0BA2 (6SN11231AA000BA2) NIB

SIEMENS Sinumerik 6FC5203-0AF00-0AA0 Operator Panel

SIEMENS MOORE 16210-1-3 RTM MARSHALLED RESISTANCE TEMPERATURE MODULE TERMINATION

ALLEN-BRADLEY P/N: 1492-CB3

AB 2098-IPD-HV050-DN SERVO DRIVE 460VAC 11/22 0-PK

AB-PANEL VIEW PLUS 1250, #2711P-RP1, SER-C, REV-A, 30 ,

A06B-0353-B831 FANUC SERVO MOTORS REMANUFACTURED

75 HP ELECTRIC MOTOR 3540 RPM 364TP VHS FOR IRRIGATION US Electric HO75S1SLG

RELIANCE ELECTRIC 801429-5SE USPP 8014295SE

ALLEN BRADLEY 2711-T10C8 FNFP 2711T10C8

ALLEN BRADLEY 1771-NIV1 USPP 1771NIV1

HONEYWELL 51400901-100 NSFP 51400901100

WESTINGHOUSE SPB100-1600 USPP SPB1001600

TOSHIBA VT130H3U2270 USPP VT130H3U2270

GETTYS 16-0071-35 USPP 16007135

Siemens 6ES5-234-1AD11 MEMORY MODULE 6ES52341AD11

SIEMENS 6ES5 375-0LD21 -- 6ES53750LD21

SIEMENS BOARD 6ES5-400-0AA11 6ES5 400 0AA11 6ES54000AA11 SPCB202 SIEMEN

Siemens 6ES5 951-7LB14/6ES5951-7LB14 P/S MODULE XLNT

SIEMENS 6ES5-240-1AA11 6ES52401AA11

Siemens MOBIC T8 6GK1611-0TA01-0AV0 Display Panel

RELIANCE ELECTRIC 57C-328 USPP 57C328

Texas Instruments 500-5009

Spirent Adtech AX/4000 401385 L3 OC3 Interface

VeriFone Vx570 Dial Terminal

Siemens C98043-A1682-L1-04

Modicon AS-W606-012

Schneider Modicon AUTOMATION AS WBXT 201

Schneider Modicon AS-B804-016 Output Module -NO BOX

Schneider Modicon AS-BDAP-211 NSFP ASBDAP211

Schneider Modicon AS-B875-002

Schneider Modicon Thermocouple Input Part AS-B883-200

Schneider Modicon B375 ANALOG INPUT MODULE AS-B375-001

Schneider MODICON AS-BADU-206

Schrack Seconet BX-AIM Germany Input Module EG072947-A\00

RELEASE SuperMicro X9DRD-IF Motherboard FULL MFR

SIEMENS 6ES5-470-8MB11/6ES5470-8MB11 OUTPUT MODULE NIB

SIEMENS SINUMERIK 880 6FX1121-2BA03 6FX11212BA03

Modicon / AEG Communication Processor Module AS-C921-101

SIEMENS Simodrive 611 E/R 6SN1146-1BB02-0CANIB

SIEMENS Sinumerik Module Modul DMP 6FC5111-0CA03-0AA2

SIEMENS CAT Caterpillar D6H & LGP II PARTS MANUAL CATALOG TRACTOR BULLDOZER 4RC 6FC 3306

AllenBradley1756-OB16EDigitalOutputModuleControlLogix

ALLEN BRADLEY SLC 500 OUTPUT MODULE 1746-OB8 SER A

ABB Robot IRB 6400R 2.5 / 150 - Control system S4C M99

A06B-0142-B084 FANUC SERVO MOTORS REMANUFACTURED

0.250" x 25" Vamco Servo Feeder Model: CFS-30II S/N: HDC42530PVPCL13

MODICON MM-PM21-200 USPP MMPM21200

ALLEN BRADLEY 150-A240NCDB USPP 150A240NCDB

ADEPT TECH 30332-12350 USPP 3033212350

GE FANUC IC752WTA055-GC USPP IC752WTA055GC

SOLA ELECTRIC 056-00300-0000-09 USPP 05600300000009

SIEMENS 6ES7-806-0CC00-0YE0 NSFP 6ES78060CC000YE0

ALLEN BRADLEY 8000-MB2Z USPP 8000MB2Z

Siemens 6ES5 941-7UB11 6ES59417UB11

Siemens Simatic Hi Speed Counter Module 6ES5-491-0LB11IP242A 6ES5-242-1AA32

SIEMENS 6ES5-521-8MA22 SERIAL INTERFACE MODULE 6ES55218MA22

Siemens 6ES5 441-8MA11/6ES5441-8MA11 OUTPUT MODULE 24VDC 0.5A XLNT

Siemens 2MB MMC 6ES7 953-8LL10-0AA0 6ES7953-8LL10-0AA0

Siemens EPROM 6ES5375-0LA21 6ES5 375-0LA21

SCHLEICHER MDA205-24VDC NSFP MDA20524VDC

Square D 9065-JA

SIEMENS 6SE7090-0XX84-0BD1 EXPANSION/INTERFACE MODULE SCB2 XLNT

WE SHIP SAME CISCO PVDM2-64 64-channel Packet Fax/Voice DSP Module

Siemens 6SE6400-0AP00-0AA1 6SE6 400-0AP00-0AA1 FreeShip

Siemens TP27-6 6AV3627-1NK00-0AX0

Schneider Modicon TSX COMPACT AS BDEP 254 BINARY

Schneider Modicon AS-BDAP-204 SEALED Compact Out ASBDAP204

Schneider Modicon AS-B827-032 ASB827032 32 Point 24VDC Input

Schneider Modicon AS-B828-016

Schneider Modicon AS-W804-002 NSPP ASW804002

Schneider Modicon AS-C921-101 COMM PROCESSOR GOOD TAKEOUT

Schneider PLC Output Module TSXDSZ32R5 In Box