1606-XL480GP

1606-XL480GP
1606-XL480GP
1606-XL480GP


数控机床作为一种柔性的、能的自动化机床，很好地解决了复杂、精密、小批量和多品种的零件加工问题。随着数控机床设备在工业的广泛应用，其运行的性也显得愈发重要，的数控机床设备可以有效保护操作人员的人身，避免设备的频繁故障，提高企业的生产力水平。
　　为了提高设备的等级，某动力公司位于的生产基地于2012 年启动了设备防护改造工程，希望通过对机械加工设备的升级改造，避免由于设备功能的缺失或不完善可能导致的隐患，满足长远的 EHS目标，进一步提升企业的市场竞争优势。
　　先让们看看这家改造企业的背景：
　　该公司是一家多元化的动力管理公司，其生产的电力、流体动力和机械动力产品广泛应用于建筑、飞机、卡车、汽车、机械以及各种商业设施，年销售额超过200亿美元。此次改造的工厂是其位于的28个制造基地之一，主要生产各种液压弯头、接头和管件等产品。
　　三重挑战，如何个个击破?
　　本次整改项目共涉及65台套设备的机器改造，其中难度的是20台 MAZAK数控机床的系统改造。
　　先，作为企业生产的核心设备， MAZAK数控机床的改造方案稳妥，只可成功，不可失败。此外，MAZAK数控机床设备的使用率，设备每天工作16个小时，每小时开门20次，一年总计11.2 万次的开门次数，这要求所用方案可靠和耐久，可以耐长期高负荷的运行条件。
　　令企业头痛的是，原设备的PLC 系统代码被保护，由于不能获得原设备 PLC的代码，改造时无法对设备做内部改变，但同时又要满足数控系统机器的防护要求，新方案需要一个创新的设计思路。
　　总结来说，此次升级改造需要的不仅仅是系列产品，而是一个针对现有数控机床特点而设计的、完整的定制化解决方案。
　　好产品 ， 更要有好的解决方案!
　　凭借在美同类项目的成功应用经验，以及遍布各地的专业而快速的销售和执行队伍，罗克韦尔自动化针对工厂现有设备的具体情况，为其量身定制了系统升级方案。
　　改造前，数控机床设备的均采用单回路形式，改造目标是实现级别category 3。
　　先，罗克韦尔自动化的项目实施团队反复多次和工厂多个部门讨论，查找资料，吃透原机器结构和控制原理，熟悉机器的各种状态，包括：设置、数控编程、运行(手动和自动)、小批次和大批量、维护和调试状态等，新改造方案考虑上述各个方面。
　　在充分了解设备情况后，实施团队严格遵循机器标准(ISO 13849 和 IEC 62061)，增加防护系统并嵌入到现有系统中运行。
　　整体逻辑图如图1所示，新系统按照SIL 3标准来设计，新旧系统独立而又并列运行，而且并行的输入、串行的输出将新系统和旧系统的措施有机结合起来，这种冗余的结构设计是方案的一大亮点，保证了系统的稳定运行。
　　为保证改造方案的化，本次改造采用原型机试制和批量生产的方式。改造前，这些数控机床设备就在长期高负荷地运行，所以改造方案满足苛刻的运行条件，不适宜一开始就批量改造，所以用19号机器先行改造，运行2个月后，针对效果提出进一步改进措施，而后全部用更新后的方案批量改造。
　　机器的耐久和稳定运行是本次改造的重要目标，为达成该目标，除了采用冗余的系统架构外，实施团队还采取了一系列的措施，包括：浮动推拉门、防震设计、通风防尘设计和备用回退选项等。


1734-IV2 POINT I/O 2 Point Combination Module
750-348 Wago CANopen ECO fieldbus coupler D-SUB 10 kbaud 1 mBaud digital and a
103T-CWZJ2-RC16X-E1E-KN Combination Starter
100S-C37KD04C 37 A MCS Safety Contactor
20AB015A0AYNACG0 PowerFlex 70 15.3 A 5 Hp AC Drive
194R-KN30-1753-PY-A10 Non-Fused Fused Disconnect Switch
20DD027A3NYNANDAL PowerFlex 700S 27 A 20 Hp AC Drive
1492-CJM5-3 Center Jumper 5mm 3 Pole
1203-GK2 SCANport 24V DC Module
AMD PHENOM X4 955 QUAD CORE CPU MSI MOTHERBOARD 4GB DDR3 MEMORY RAM COMBO KIT
20DD065A0EYNANCNL PowerFlex 700S 65 A 50 Hp AC Drive
194E-E-PL11 AUXILIARY CONTACT BLOCK 25 - 100A
20BC015A3AYYACC1 PowerFlex 700 15.4 A 7.5 kW AC Drive
20BD4A0AYNADC1 PowerFlex 700 3.4 A 2 Hp AC Drive
103T-NX1D IEC Starter
100-C12Q400 12 A 100-C contactor
20DD650ACENNBCANE 650 A 500 Hp AC Drive
ASB807132 Modicon 24VAC Input Module AS-B807-132
20BC5A0AYNANA0 PowerFlex 700 3.5 A 1.5 kW AC Drive
140M-D8N-C10-KN-XC 140M Circuit Breaker
03 TRAILBLAZER COMMUNICATION MODULE COMMUNICATION ONSTAR OPT UE1
Allen Bradley 1734-OB8E 1734-0B8E Source Output Module in Factory Packaging
ABB AS Robotics Teach Pendant TPU2 3HNE-00311-1 Rev 13 349-3532-09
1494G-NX3 Industrial Grade Safety Switch
9305-RSVADFVCFRE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (FRENCH)
103S-FWD3-DC25C-R 18 - 25 A MCS Starter & Circuit Breaker
2090-CPWM4DF-14AF05 MP-Series 5 m Length Power Cable
20BC5A3AYYACC0 PowerFlex 700 3.5 A 1.5 kW AC Drive
2030-CH1200G ElectroGuard Bulletin 2030
ALLEN BRADLEY PROGRAMMING TERMINAL 1201-HAP SER. B FRN 1.07
100S-C85D22BC 85 A MCS Safety Contactor
1492-SP2D500 IEC 50 A Miniature Circuit-Breaker
191E-ANEJ3-CB40X-R00 2.5 - 4 A 191E Reversing EcoStarter w/CB
20BF082A0AYNANC0 PowerFlex 700 82 A 75 kW AC Drive
140U-H3C3-C60-MT H frame molded case circuit-breaker
9355-WABGWDEE RSLINX GATEWAY - GERMAN
103S-DTD2-DC16C-KY 10 - 16 A MCS Starter & Circuit Breaker
20F11FD034AA0NNNNN PowerFlex 753 AC Drive
6189-RW2 VVCE COMPACT FLASH 128MB W/ME
112-C12FBE1D-3-4G-6P-901-901T Fusible Disconnect Combination Starter
20AD014A3AYNACC1 PowerFlex 70 14 A 10 Hp AC Drive
1492-CABLE050CR Digital Cable Wiring System
140U-H2C3-C20-F-MT H frame molded case circuit-breaker
190E-DND2-DC10C-R11-S11-V 6.3 - 10 A 190E Eco Starter with CB
1494C-DJ644-A4-D1-E 400A Cable Operated Disconnect Kit
20BR125A0QYNAND0 PowerFlex 700 125 A 100 Hp.. AC Drive
1492-CABLE001X Digital Cable Wiring System
20-IP54RF-800 MECH ACC ROOF IP54/N12 FOR 800MM PF
112-C09FCD1C-1-6P Fusible Disconnect Combination Starter
ALLEN BRADLEY 2706-B21J8 SER F DATALINER PROGRAMMABLE MESSAGE DISPLAY 8K MEMORY
20DD1K0H0ENNBNANE PowerFlex 700S 1030 A 900 Hp AC Drive
1485C-P105N5-M5 DEVICENET THICK PATCHCORD
141A-B1210A 800 mm Length 12X10 mm Copper Busbar
100S-C30UD14C 30 A MCS Safety Contactor
ALLEN BRADLEY 1771-IAD INPUT MODULE
20AD5P0C3AYYAEG0 PowerFlex 70 5 A 3 Hp AC Drive
150-C85FAD-3-4R-6P-901 NEMA 85A 150 Motor Controller
23B-D012D104NN-P6T-S7-S18 23B AC Packaged Drive
1492-MS6X12HGND Wiring System 6mm x 12mm 80 Mkrs/Crd
191E-AND3-CB63C-A11 4 - 6.3 A 191E Reversing EcoStarter w/CB
1494C-DJ666-A4-B1-F 60A Cable Operated Disconnect Kit
9358-PBBK10R SUPT REINSTATEMENT CONTRACT FOR 9358PBBK10ENE RSBIZWARE BATCH FOR PROCESSLOGIX BACK-UP KEY (10 UNITS) SOFTWARE
2090-CPBM7DF-16AA09 9 m Length SpeedTec Standard Cable
194E-E32-TN NEUTRAL TERMINAL 25 - 32 AMP
190E-DND2-DC25S-KY-R 18 - 25 A 190E Eco Starter with CB
152H-F43FAD-42-1 Controller w/Fusible Disconn
20AC043A3AYNACG0 PowerFlex 70 43 A 22 kW AC Drive
20DD052A3EYNARABE 52 A 40 Hp AC Drive
1233X-ENB-A2M-6GP-49-90011 NEMA Pump Panel,Extra space,Cype
179168 KIT, GATE DRIVER PCB
20DJ385A3ENNBEASE PowerFlex 700S 385 A 300 Hp AC Drive
103S-ASD4-CC10B-KY-TE 6.3 - 10 A MCS Starter & Circuit Breaker
Allen Bradley SLC 500 Input Module 1746-1A16
2090-UXNPAN-16R01 CABLE,NON-FLEX, MOTOR POWER, N,R/A,16AWG,1M
20DK3852CENNBCANE PowerFlex 700S 385 A 400 Hp AC Drive
ALLEN BRADLEY 1746-OG16 SERIES C OUTPUT MODULE
140U-L-ELP4003 Circuit-Breaker Accessory
21VD011A3AYNAHC0AN 21V Fan & Pump Packaged Drive
100-C12VA01 12 A 100-C contactor
1492-GS3G080 3 POLE HIGH DEN. SLIM MINI.CB 8 A
112-C09FCD1C-6P IEC Enclosed Combination Starter
AB Allen Bradley AC Relay 700-PK400A1 Ser A
1494G-BF3N-203W NEMA 30A Enclosed Disconnect
150-F85FBD 150 Motor Controller
1775-MSA PLC-3/10 Memory Module
190S-AND2-CB16C-R10 1 - 1.6 A 190S Compact Comb Starter w/CB
2090-UXNFBY-S30 Y-Series 30 m Length Feedback Cable
1790D-T16BV0 DNET LDX, 24VDC, 16 UNIV. IN BASE, TERMINAL BLK
193-NCRID E1 Plus Remote Indication Display
100-NX201DM CONTACTOR
150-F25FBD-20D 150 Motor Controller
Allen-Bradley F-20598
2361-SPC02A CONTROL POWER FILTER, J-K CURRENT CODES
AIR-PWRINJ4 POWER INJECTOR 1140 / 1250 SERIES; SPARE
100-CSF47 24-240V AC Control Module
1492-LD4RB395 terminal block, resistor, 3.92M Ohms
1492-HWACAB025WA Honeywell Analog Cable Wiring System
AEG Modicon B872-002 Analog Input Module 7002D
8720MC-RFI80 SCHAFNER FN3100-80/35 FILTER FOR CE APPLICATIONS
9305-RSVADDCZHR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADDCZH RSVIEW32 ACTIVE DISPLAY SYSTEM DEDICATED CLIENT SOFTWARE (CHINESE)
20BD052A0NYNANN0 PowerFlex 700 52 A 40 Hp AC Drive
1394C-CONN-KEY KIT 1394 5&10KW POWER&SHUNT CONN W/KEY
140M-C2N-A16 Motor Circuit Protector
20AD027A3NYNANC0 PowerFlex 70 27 A 20 Hp AC Drive
20C60MCANNBNA0 PowerFlex 700H 460 A 250 kW AC Drive
1756-EN2T CLX HI-CAP ENET/IP MODULE - TP
140M-D8E-C10-XC 140M Circuit Breaker
20DM4162CENNBCANE PowerFlex 700S 416 A 400 kW AC Drive
20AD4A0AYNANG0 PowerFlex 70 3.4 A 2 Hp AC Drive
1492-MC5X8V31-40 Wiring System 5mm x 8mm 120 Mkrs/Crd
20G14GD186AA0NNNNN PowerFlex 755 AC Drive
190E-DND2-DC25X 18 - 25 A 190E Eco Starter with CB
150-C108NCD SMC-3 SOLID STATE MOTOR
20DD034A0NYNANCEK PowerFlex 700S 34 A 25 Hp AC Drive
Allen Bradley 2711P-RN6 /B PanelView Plus DH+/DHRIO/DH-4​85 Communication Module
20DE650A0ENNBNANE PowerFlex 700S 650 A 700 Hp AC Drive
190E-BND2-CB40X-KN 2.5 - 4 A 190E Eco Starter with CB
112-3AHDE1F IEC Enclosed Combination Starter
1492-MCS6X8 SNAP-IN MARKER CARD
Allen Bradley 1762-L40BXB Ser.C Rev.D
ALLEN BRADLEY 8000-IOABA USPP 8000IOABA
20BE041A0AYNAEC0 PowerFlex 700 41 A 40 Hp AC Drive
103S-GWD3-F5C-KN 32 - 45 A MCS Starter & Circuit Breaker
105-C09ABE1D Reversing Starter
MPG-A010-031M24 MOTOR,SERVO,GEAR RATIO 31,26NM,157RPM,MULTI,BRK
104-K09ZS02 IEC Reversing Contactor
1492-JD3RB620 terminal block, resistor, 61.9 Ohms
1485CF-P9N5-C DEVICENET THICK CORDSET
2711-NV6T ALLEN BRADLEY ANTIGLARE OVERLAY FOR PANELVIEW 1000 TOUCHSCREEN  
1492-M6X12V101-120 Wiring System 6mm x 12mm 120 Mkrs/Crd
23B-D024D104NN-P6T-S23 23B AC Packaged Drive
1000TR-CT1109000R GTRANE 110A STARTER ASSY
ABB S200-IB16 Input Module 16PT
20-750-I1-C750D710 PowerFlex 750 Inverter Assembly Kit
100S-C37KG14C 37 A MCS Safety Contactor
190S-ANP2-CB25C-KN-R-TE 190S Compact Comb Starter w/CB
9371-EDES2S SUPT RENEWAL CONTRACT FOR 9371EDES2 RSWIRE DESIGNER JIC AUTOCAD
112-C23FCDD1E-1 IEC Enclosed Combination Starter
1494G-BC3N NEMA 30A Enclosed Disconnect
103S-AWDJ3-CB63C-KN 4 - 6.3 A MCS Starter & Circuit Breaker
20AB042A3AYNAEC0 PowerFlex 70 42 A 15 Hp AC Drive
103S-AWZJ2-DB25C-KN MCS Starter & Circuit Breaker
ALLEN BRADLEY 1794-IF4I 1794IF4I SER A
1336-GF-SP4A XFRM CURRENT,GRND FAULT,(SA)1336STG,FRAM
Allen Bradley AC Output Module 1771-OAD/ B
109-C60ABXXX-1E Non-Reversing Starter
Allen Bradley 1771-OA 120VAC Output Module 8pt
20BB015A0NYNBNC0 PowerFlex 700 15.3 A 7.5 Hp AC Drive
ALLEN-BRADLEY SLC 500 1747-DCM communications module in good cond. series A
1492-CAB065J69 Digital Cable Wiring System
Allen Bradley 1771-OAD AC Output Module 1771OAD
ALLEN BRADLEY 280-MTR22-M3 NSPP 280MTR22M3
ALLEN BRADLEY AB Cat 771-OGD TTL OUTPUT MODULE 96042471 0gd
9303-23S0E80S SUPPORT RENEWAL CONTRACT FOR 9303-23S0E80
Allen Bradley 1784KT/B Comm Interface Module
20AC022F0AYNANC0 PowerFlex 70 22 A 11 kW AC Drive
190S-END3-FC10C-KY 190S Compact Comb Starter w/CB
Allen Bradley 8520-FOP Series F Operator Interface Panel Missing Button
ALLEN BRADLEY 2705-P21J1L PUSHBUTTON INTERFACE XLNT
140M-C-DFCRY EMERGENCY OFF Legend Plate
140U-R0H3-E20 2000 A Molded Case Circuit-Breaker
153H-F251FBD-54-1F-4G-4R-6P Controller w/Circuit Breaker
Allen Bradley 1746-IA8 Input Module AC Controller
9356-PRO2450U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO 32000 TAGS
109-C12ADE1P-3-4R-7-901 Non-Reversing Starter
1803-EEM20E4 EEM,32 PULSES, 24V DC, NEMA 4 ENCLOSURE
20AD2P1A0AYYANG0 PowerFlex 70 2.1 A 1 Hp AC Drive
9399-2SE32RUG RSVIEW32 RUNTIME USER GUIDE
20BD077A3NNNADC1 PowerFlex 700 77 A 60 Hp AC Drive
20DC125A0ENNANANE PowerFlex 700S 125 A 55 kW AC Drive
140U-H2C3-D12-MT H frame molded case circuit-breaker
140ESI06210 MODICON RS232 Module 140-ESI-062-10 TSX Quantum Interface
9356-PRO2350U3 UPGRADE: IN-SUPT: RSSQL STD.1500 TO PROF.5000 TAG
1492-M8X5V11-20 Wiring System 8mm x 5mm 160 Mkrs/Crd
100-NX212L10 50 A Definite Purpose Contactor
20AD2P1C3AYNNNG0 PowerFlex 70 2.1 A 1 Hp AC Drive
MPL-B320P-SJ22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,460V,4.0KG
1734-OB8E POINT I/O 8 Point Output Module
20BB080A0ANNANN0 PowerFlex 700 80 A 30 Hp AC Drive
140U-H2C3-0-MT H frame molded case circuit-breaker
ALLEN BRADLEY 1761 NET DNI INTERFACE MODULE DEVICENET
1609-D1000N Uninterruptible Power Supply
103S-EWZJ2-FC32CL-TE 23 - 32 A MCS Starter & Circuit Breaker
140M-C-AFA01 1 NC Contact Auxiliary Contact
2711P-T7C15B1 PV PLUS 700, TOUCH, CNET, AC PS, STD MEM INCL RS232, ETHERNET, USB
2706-P72CN2 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE 12 TO 24 CHAR, 7.2" OR 1.5"" HIGH. TRI-COLOR LED, NEMA 4
1489-A1C040 UL489 MINI CIRCUIT BIEC60947-2 MINI CIRC
150-C251NCR SMC-3 SOLID STATE MOTOR
20BR125M0ANNANC0 PowerFlex 700 125 A 100 Hp.. AC Drive
1492-CJCW6 Center Jumper Cover
1492-ACABLE100UB Analog Cable Wiring System
1492-CABLE150RTBR Digital Cable Wiring System
1494V-DN60-A Variable-Depth Disconnect Kit
20CH820N0ANNNNN0 PowerFlex 700H 820 A 450 kW AC Drive
1492-HWACAB100Z Honeywell Analog Cable Wiring System
190S-BNZJ2-CC10C-S11 190S Compact Comb Starter w/CB
1492-MS8X12VU61-70 1492-MS8x12 marker card Wiring System
140M-J2E-D25-MU MOTOR PROTECTION CIRCUIT BREAKER