1785-TAM
1785-TAM
1785-TAM
數控機床作為一種柔性的、能的自動化機床，很好地解決了復雜、精密、小批量和多品種的零件加工問題。隨著數控機床設備在工業的廣泛應用，其運行的性也顯得愈發重要，的數控機床設備可以有效保護操作人員的人身，避免設備的頻繁故障，提高企業的生產力水平。
為了提高設備的等級，某動力公司位於的生產基地於2012 年啟動了設備防護改造工程，希望通過對機械加工設備的升級改造，避免由於設備功能的缺失或不完善可能導致的隱患，滿足長遠的 EHS目標，進一步提升企業的市場競爭優勢。
先讓們看看這家改造企業的背景：
該公司是一家多元化的動力管理公司，其生產的電力、流體動力和機械動力產品廣泛應用於建築、飛機、卡車、汽車、機械以及各種商業設施，年銷售額超過200億美元。此次改造的工廠是其位於的28個制造基地之一，主要生產各種液壓彎頭、接頭和管件等產品。
三重挑戰，如何個個擊破?
本次整改項目共涉及65臺套設備的機器改造，其中難度的是20臺 MAZAK數控機床的係統改造。
先，作為企業生產的核心設備， MAZAK數控機床的改造方案穩妥，只可成功，不可失敗。此外，MAZAK數控機床設備的使用率，設備每天工作16個小時，每小時開門20次，一年總計11.2 萬次的開門次數，這要求所用方案可靠和耐久，可以耐長期高負荷的運行條件。
令企業頭痛的是，原設備的PLC 係統代碼被保護，由於不能獲得原設備 PLC的代碼，改造時無法對設備做內部改變，但同時又要滿足數控係統機器的防護要求，新方案需要一個創新的設計思路。
總結來說，此次升級改造需要的不僅僅是係列產品，而是一個針對現有數控機床特點而設計的、完整的定制化解決方案。
好產品 ， 更要有好的解決方案!
憑借在美同類項目的成功應用經驗，以及遍布各地的專業而快速的銷售和執行隊伍，羅克韋爾自動化針對工廠現有設備的具體情況，為其量身定制了係統升級方案。
改造前，數控機床設備的均採用單回路形式，改造目標是實現級別category 3。
先，羅克韋爾自動化的項目實施團隊反復多次和工廠多個部門討論，查找資料，吃透原機器結構和控制原理，熟悉機器的各種狀態，包括：設置、數控編程、運行(手動和自動)、小批次和大批量、維護和調試狀態等，新改造方案考慮上述各個方面。
在充分了解設備情況後，實施團隊嚴格遵循機器標準(ISO 13849 和 IEC 62061)，增加防護係統並嵌入到現有係統中運行。
整體邏輯圖如圖1所示，新係統按照SIL 3標準來設計，新舊係統獨立而又並列運行，而且並行的輸入、串行的輸出將新係統和舊係統的措施有機結合起來，這種冗餘的結構設計是方案的一大亮點，保證了係統的穩定運行。
為保證改造方案的化，本次改造採用原型機試制和批量生產的方式。改造前，這些數控機床設備就在長期高負荷地運行，所以改造方案滿足苛刻的運行條件，不適宜一開始就批量改造，所以用19號機器先行改造，運行2個月後，針對效果提出進一步改進措施，而後全部用更新後的方案批量改造。
機器的耐久和穩定運行是本次改造的重要目標，為達成該目標，除了採用冗餘的係統架構外，實施團隊還採取了一係列的措施，包括：浮動推拉門、防震設計、通風防塵設計和備用回退選項等。
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190S-DND2-DC16C-KY 10 - 16 A 190S Compact Comb Starter w/CB
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103T-ASJ2-RB40D-C2A-KN-TE IEC Combination Starter
2090-CPWM7DF-14AF07 MP-Series 7 m Length Power Cable
103S-FTZJ2-FC32B-SP 23 - 32 A MCS Starter & Circuit Breaker
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2090-XXTFMP-S04 MP-Series 4 m Length Feedback Cable
1494V-DR622-C-D-E 200A Variable-Depth Disconnect Kit
1769-OV16 16 POINT 24 VDC SINKING OUTPUT MODULE
1321-3RA1-C 1321 Power Component 1 A Line Reactor
20AD2P1A3AYNAEC1 PowerFlex 70 2.1 A 1 Hp AC Drive
1494GY-BF3N-98-414 NEMA 30A Enclosed Disconnect
1494G-CF3N-412 NEMA 60A Enclosed Disconnect
190S-AND2-CC10C-S11 190S Compact Comb Starter w/CB
1585J-M4UBJM-78 RJ45 Ethernet Media
20DD500B0ENNBDANK 500 A 450 Hp AC Drive
1492-CABLE040Q Digital Cable Wiring System
9324-RLD25U6ITE RSLOGIX 5000 LITE ITALIAN TO FULL UPGRADE
23B-D024DF04NN-P3T-S7-S18 23B AC Packaged Drive
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100-DS1-11 Contactor Auxiliary Contact Block
191S-AND3-CB10C-KY 191S Rev. Compact Starter w/CB
1485C-F30W5-N5 DeviceNet Physical Media
20G11TC910AN0NNNNN PowerFlex 755
2090-CPBM4DF-10AF90 MP-Series 90 m Length Cable
20DD8P0A3EYNANGNE PowerFlex 700S 8 A 5 Hp AC Drive
1732D-IB8M12 DEVICENET 24VDC 8 INPUT W/M12
1492-F3RE TERMINAL BLOCK 300V MAX
1492-CABLE080WH Digital Cable Wiring System
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140U-J6L3-D10-F J frame molded case circuit-breaker
1492-M6X12VU291-300 1492-M6x12 marker card Wiring System
150-C85FBD-3-4R-6P NEMA 85A 150 Motor Controller
21T-179615-905-3ZB LiquiFlo 2.0 Carrier Corp 608 A AC Drive
100-D630EB11 MCS Contactor
194R-F25-FC 25A NFC Fuse Carrier Rotary Disconnect
23B-D012D104NN 23B AC Packaged Drive
104S-C09KD210BC 9A MCS Safety Reversing Contactor
100-D115H11 115 A Contactor
20DC8P7A0EYYANBNE PowerFlex 700S 8.7 A 4 kW AC Drive
194E-KA63EX-P11-PE-6 Load Switch
ABM SBOKH/3.DF56 8-4S7167SBOKH?3DF5684S7167S?BORH/3.DF5630?68762001
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5150-RS 5150-MRS SERIES A 1 YEAR WARANTY
1492-HWACAB055UB Honeywell Analog Cable Wiring System
1494C-DRX666-A3 60A Cable Operated Disconnect Kit
190S-ANDJ2-CB16S-KN 1 - 1.6 A 190S Compact Comb Starter w/CB
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1497A-A6-M19-1-N MACHINE TOOL TRANSFORMER
103S-DSZJ2-CB63C-KY 4 - 6.3 A MCS Starter & Circuit Breaker
152H-3FBD-45-1-6P Controller w/Fusible Disconn Enclosed Mo
1492-CJLJ5-10-BL 1492 CENTER JUMPER-BLACK
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1336-BDB-KONE 1336 Kit
100S-C85UA14C 85 A MCS Safety Contactor
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107S-AWZJ3-CB10C 0.63 - 1 A Reversing Starter & Breaker
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194E-FA32EX-PE-P11-6 Load Switch
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9399-RSBVWUG RSBATCH VIEW USER'S GUIDE
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100S-C85VA14C 85 A MCS Safety Contactor
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1769-IM12 12 POINT 240 VAC INPUT MODULE
1492-CABLE005S Digital Cable Wiring System
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1494G-DF3R6-988 NEMA 100A Enclosed Disconnect
100S-C12KD32C 12 A MCS Safety Contactor
100-A75N3 Ser C Allen Bradley AB CONTACTOR 100A75N 3
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107T-ASJ3-QB10D-E1B-KN-TE Rev. Combination Starter
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190S-ANEJ1-CB63C 4 - 6.3 A 190S Compact Comb Starter w/CB
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150-C317NBR SMC-3 SOLID STATE MOTOR
190S-CND1-DC16C-KN 10 - 16 A 190S Compact Comb Starter w/CB
190S-FNKD3-FC32C 23 - 32 A 190S Compact Comb Starter w/CB
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141A-VU3300R Supply Module
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100-D95X11 95 A Contactor
140M-I8R-D15S-XCM 150 A Molded Case Circuit-Breaker
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1746-A10 10 SLOT CHASSIS-MODULAR HARDWARE STYLE
2706-D21J8 ALLEN BRADLEY
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2090-XXNFY-S01 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,1M
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20DC385N0ENNBCCNK 385 A 200 kW AC Drive
6189V-CPUPFM1 PERFORMANCE SBC (W/CPU AND COOLER) (1500W)
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1798-APB PROFIBUS DP ADAPTER
20AD4A3AYYACC0 PowerFlex 70 3.4 A 2 Hp AC Drive
100S-C30EJ22C 30 A MCS Safety Contactor
100-C30KL10 30 A 100-C contactor
1734-OE2V POINT I/O 2 Point Output Module
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103S-DTZJ2-CC25C 18 - 25 A MCS Starter & Circuit Breaker
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