M470-2 D2778-C14

M470-2 D2778-C14
M470-2 D2778-C14
M470-2 D2778-C14

　使用模块化接线组件和机旁解决方案帮助轮胎设备制造商提高设备组装速度，使接线时间缩短 20%，同时使设备体积减小 25%。
　　位于俄亥俄州北坎顿的 RRR Development 是美一家客车、轻型卡车和工业轮胎装配机制造商，轮胎年产量超过 10 亿。该公司为 34 家轮胎工厂设计制造单一平台和多平台轮胎设备。
　　为保证这些企业及其终用户顺利达成目标，原始设备制造商不断投资新型技术。借助机旁控制解决方案和模块化接线技术，RRR 设计了一款新机器，使生产时间缩短了五天，加快了上市速度，还简化了终用户的安装、操作和维护工作。
　　为改善生产效率，RRR Development 工程人员研究了多种能够提高装配、拆卸和安装机械速度的接线方法。
　　“经过研究，们设计了一种带有分布式 I/O 架构的系统。”RRR Development 副总裁 Robert D. Irwin 说。
　　“在增加了几个用于安放分布式 I/O 模块的远程接线箱后，通过缩减主控制面板尺寸节省下来的费用很快就被抵消了。接线箱只是占用了机器周围的一大片空间，结果却无法实现预期的系统节约目标。”补充说。
　原始设备制造商 RRR Development 设计了支持模块化接线技术的 RRR 阶段轮胎成型机 (TBM)，使生产时间缩短了近五天。
　　RRR 工程师知道分布式 I/O 架构的一般概念可行，因此们请求罗克韦尔自动化帮助们将这个设想付诸实践。
　　“们说明了设计目标，就是希望能开发出一种既不需要 PLC 网络，也不需要额外的硬件和培训的模块化接线技术。”Irwin 说。
　　控制系统解决方案
　　为了融入新的接线技术，原始设备制造商RRR设计了阶段轮胎成型机 (TBM)。该机器将用于轮胎制造过程的核心部分，在此将所有材料一起卷成筒形。阶段完成后，机器将钢带和胎面放到第二阶段产品上，以便塑造出典型的轮胎形状。这款机器可以生产多种类型的轮胎，包括农用轮胎、客车轮胎、轻型卡车轮胎和摩托车轮胎，以往通常需要使用三种不同的机器才能实现这一目标。
　　为解决机器运动的同步问题，TBM 配备了罗克韦尔自动化的 Allen-Bradley® ControlLogix® 可编程自动化控制器 (PAC, www.rockwellautomation.com/go/tjcontrollogix)、Kinetix® 6000 伺服驱动器 (http://goo.gl/BcXwK6) 和 MP 系列低惯量 (MPL) 伺服电机 (http://goo.gl/BGlxQ0)。PAC 控制机器的顺序控制和运动控制，无需单独的运动控制器和各个功能的相关接线。
　　集成伺服驱动器有助于更加迅速地加速和减速机器，还能产生 250% 连续额定电流的转矩。该高峰值电流有助于缩小驱动器电源和轴模块的尺寸，缩小所需的面板空间。该控制解决方案还在 EtherNet/IP™ 上无缝集成了第三方气动阀。
　　机器设计成功的关键在于简化接线。“们非常希望通过使用一个简单的接线箱来减少人力和工作时间。”Irwin 解释说。
　　工程师通常将机器和控制柜设计成独立的单元，二者之间的互连需要大量的人力和接线。“像这种复杂机器的接线就涉及 17 个步骤。”Irwin 说。
　　为了使用单一控制平台进一步节省接线成本，RRR 选择了罗克韦尔自动化的紧凑型分布式 I/O 组件，这些组件可以直接安放在机器中。其中包括 Allen-Bradley 1667 PanelConnect™ 模块、898 分配器和系统电缆，可将所有 I/O 直接与控制器相连。通过使用方便的预制电缆和连接器，面板装配工人不需要 DIN 导轨和端子块即可将现场设备连接到 PAC，同时保证面板外壳的整体环保效果。

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