1756-IT6I2
1756-IT6I2
1756-IT6I2
使用模塊化接線組件和機旁解決方案幫助輪胎設備制造商提高設備組裝速度，使接線時間縮短 20%，同時使設備體積減小 25%。
位於俄亥俄州北坎頓的 RRR Development 是美一家客車、輕型卡車和工業輪胎裝配機制造商，輪胎年產量超過 10 億。該公司為 34 家輪胎工廠設計制造單一平臺和多平臺輪胎設備。
為保證這些企業及其終用戶順利達成目標，原始設備制造商不斷投資新型技術。借助機旁控制解決方案和模塊化接線技術，RRR 設計了一款新機器，使生產時間縮短了五天，加快了上市速度，還簡化了終用戶的安裝、操作和維護工作。
為改善生產效率，RRR Development 工程人員研究了多種能夠提高裝配、拆卸和安裝機械速度的接線方法。
“經過研究，們設計了一種帶有分布式 I/O 架構的係統。”RRR Development 副總裁 Robert D. Irwin 說。
“在增加了幾個用於安放分布式 I/O 模塊的遠程接線箱後，通過縮減主控制面板尺寸節省下來的費用很快就被抵消了。接線箱只是佔用了機器周圍的一大片空間，結果卻無法實現預期的係統節約目標。”補充說。
原始設備制造商 RRR Development 設計了支持模塊化接線技術的 RRR 階段輪胎成型機 (TBM)，使生產時間縮短了近五天。
RRR 工程師知道分布式 I/O 架構的一般概念可行，因此們請求羅克韋爾自動化幫助們將這個設想付諸實踐。
“們說明了設計目標，就是希望能開發出一種既不需要 PLC 網絡，也不需要額外的硬件和培訓的模塊化接線技術。”Irwin 說。
控制係統解決方案
為了融入新的接線技術，原始設備制造商RRR設計了階段輪胎成型機 (TBM)。該機器將用於輪胎制造過程的核心部分，在此將所有材料一起卷成筒形。階段完成後，機器將鋼帶和胎面放到第二階段產品上，以便塑造出典型的輪胎形狀。這款機器可以生產多種類型的輪胎，包括農用輪胎、客車輪胎、輕型卡車輪胎和摩托車輪胎，以往通常需要使用三種不同的機器才能實現這一目標。
為解決機器運動的同步問題，TBM 配備了羅克韋爾自動化的 Allen-Bradley? ControlLogix? 可編程自動化控制器 (PAC, www.rockwellautomation.com/go/tjcontrollogix)、Kinetix? 6000 伺服驅動器 (http://goo.gl/BcXwK6) 和 MP 係列低慣量 (MPL) 伺服電機 (http://goo.gl/BGlxQ0)。PAC 控制機器的順序控制和運動控制，無需單獨的運動控制器和各個功能的相關接線。
集成伺服驅動器有助於更加迅速地加速和減速機器，還能產生 250% 連續額定電流的轉矩。該高峰值電流有助於縮小驅動器電源和軸模塊的尺寸，縮小所需的面板空間。該控制解決方案還在 EtherNet/IP? 上無縫集成了第三方氣動閥。
機器設計成功的關鍵在於簡化接線。“們非常希望通過使用一個簡單的接線箱來減少人力和工作時間。”Irwin 解釋說。
工程師通常將機器和控制櫃設計成獨立的單元，二者之間的互連需要大量的人力和接線。“像這種復雜機器的接線就涉及 17 個步驟。”Irwin 說。
為了使用單一控制平臺進一步節省接線成本，RRR 選擇了羅克韋爾自動化的緊湊型分布式 I/O 組件，這些組件可以直接安放在機器中。其中包括 Allen-Bradley 1667 PanelConnect? 模塊、898 分配器和係統電纜，可將所有 I/O 直接與控制器相連。通過使用方便的預制電纜和連接器，面板裝配工人不需要 DIN 導軌和端子塊即可將現場設備連接到 PAC，同時保證面板外殼的整體環保效果。
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