Article(id=1199810037230174880, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, articleNumber=1009-5438(2022)06-0068-04, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1661356800000, receivedDateStr=2022-08-25, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1763986604267, onlineDateStr=2025-11-24, pubDate=1671897600000, pubDateStr=2022-12-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1763986604267, onlineIssueDateStr=2025-11-24, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1763986604267, creator=13701087609, updateTime=1763986604267, updator=13701087609, issue=Issue{id=1199810028623458694, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='6', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1763986602216, creator=13701087609, updateTime=1764034375076, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200010402584163079, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200010402584163080, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1199810028623458694, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=68, endPage=71, ext={EN=ArticleExt(id=1199810037729297087, articleId=1199810037230174880, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Application of S120 Frequency Converter in Reform of Servo Control for Gang Saw, columnId=1187100786392711543, journalTitle=Science & Technology of Baotou Steel, columnName=Equipment and Automation, runingTitle=null, highlight=null, articleAbstract=

The spindle of gang saw, running and positioning of baffle trolley are driven by four Siemens servo motors as well as the control system is 611U frequency converter. The Siemens 611U frequency converter has gone out of production, so the spare parts purchase is difficult and manufacturing cost is high. The spare parts of S120 frequency converter that is widely used in field are universal and it is with easy maintenance. A lot of downtime caused by main drive system failure could be avoided by using the S120 system as backup system of 611U system to synchronize data and switch flexibly so as to avoid affecting productions. After adopt the new S120 system as backup system, the safe operations of production line is ensured, production capacity and maintenance efficiency of equipment are improved as well as the equipment is upgraded and reformed so that the service life and cycle are extended.

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管排锯主轴和挡板小车运行和定位由4台西门子伺服电机驱动,控制系统为611U变频器。西门子611U变频器已停产,备件采购困难且造价高昂。现场广泛使用的S120变频器,备件通用,维护方便。用S120系统作为611U系统备用系统,进行数据同步,灵活切换,可以避免因为主传动系统故障导致大量的停机时间影响产线生产。采用新的S120系统做备用系统后,保证了生产线的安全运行,提高了产能和设备保养维护效率,同时对设备进行了升级改造,延长了使用寿命和周期。

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屈 波(1984-),男,内蒙古包头市人,工程师,现从事电气设备点检工作。

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屈 波(1984-),男,内蒙古包头市人,工程师,现从事电气设备点检工作。

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屈 波(1984-),男,内蒙古包头市人,工程师,现从事电气设备点检工作。

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测试编号 钢级材质 管坯直径
/mm
壁厚
/mm
每排根数 最快生产
节奏/s
每小时下
冷床根数
排数 每台锯每小时
切割排数
设计每小时
切割排数
1 20G 377.0 14.0 3 45 80.0 26.6 6.6 7.7
2 9Cr1MoW 377.0 15.0 3 45 80.0 26.6 6.6 4.4
3 27SiMn 457.0 60.0 2 45 51.4 25.7 6.4 6.2
4 27SiMn 457.0 57.0 2 45 51.4 25.7 6.4 6.2
5 30CrMo 325.0 8.4 3 45 80.0 26.6 6.6 9.3
6 P110 244.5 8.9 5 45 80.0 16.0 4.0 4.8
), ArticleFig(id=1200024822819418441, tenantId=1146029695717560320, journalId=1185652524569653253, articleId=1199810037230174880, language=CN, label=表1, caption=

生产节奏数据

, figureFileSmall=null, figureFileBig=null, tableContent=
测试编号 钢级材质 管坯直径
/mm
壁厚
/mm
每排根数 最快生产
节奏/s
每小时下
冷床根数
排数 每台锯每小时
切割排数
设计每小时
切割排数
1 20G 377.0 14.0 3 45 80.0 26.6 6.6 7.7
2 9Cr1MoW 377.0 15.0 3 45 80.0 26.6 6.6 4.4
3 27SiMn 457.0 60.0 2 45 51.4 25.7 6.4 6.2
4 27SiMn 457.0 57.0 2 45 51.4 25.7 6.4 6.2
5 30CrMo 325.0 8.4 3 45 80.0 26.6 6.6 9.3
6 P110 244.5 8.9 5 45 80.0 16.0 4.0 4.8
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S120变频器在排锯伺服控制改造中的应用
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屈波 , 陈亮 , 郭强 , 方飞
包钢科技 | 设备与自动化 2022,48(6): 68-71
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包钢科技 | 设备与自动化 2022, 48(6): 68-71
S120变频器在排锯伺服控制改造中的应用
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屈波, 陈亮, 郭强, 方飞
作者信息
  • 内蒙古包钢钢管有限公司, 内蒙古 包头 014010
  • 屈 波(1984-),男,内蒙古包头市人,工程师,现从事电气设备点检工作。

Application of S120 Frequency Converter in Reform of Servo Control for Gang Saw
Bo Qu, Liang Chen, Qiang Guo, Fei Fang
Affiliations
  • Inner Mongolia Baotou Steel Tube Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
出版时间: 2022-12-25
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管排锯主轴和挡板小车运行和定位由4台西门子伺服电机驱动,控制系统为611U变频器。西门子611U变频器已停产,备件采购困难且造价高昂。现场广泛使用的S120变频器,备件通用,维护方便。用S120系统作为611U系统备用系统,进行数据同步,灵活切换,可以避免因为主传动系统故障导致大量的停机时间影响产线生产。采用新的S120系统做备用系统后,保证了生产线的安全运行,提高了产能和设备保养维护效率,同时对设备进行了升级改造,延长了使用寿命和周期。

611U变频器  /  S120变频器  /  停机时间  /  备用系统  /  维护效率

The spindle of gang saw, running and positioning of baffle trolley are driven by four Siemens servo motors as well as the control system is 611U frequency converter. The Siemens 611U frequency converter has gone out of production, so the spare parts purchase is difficult and manufacturing cost is high. The spare parts of S120 frequency converter that is widely used in field are universal and it is with easy maintenance. A lot of downtime caused by main drive system failure could be avoided by using the S120 system as backup system of 611U system to synchronize data and switch flexibly so as to avoid affecting productions. After adopt the new S120 system as backup system, the safe operations of production line is ensured, production capacity and maintenance efficiency of equipment are improved as well as the equipment is upgraded and reformed so that the service life and cycle are extended.

611U frequency converter  /  S120 frequency converter  /  downtime  /  backup system  /  maintenance efficiency
屈波, 陈亮, 郭强, 方飞. S120变频器在排锯伺服控制改造中的应用. 包钢科技, 2022 , 48 (6) : 68 -71 .
Bo Qu, Liang Chen, Qiang Guo, Fei Fang. Application of S120 Frequency Converter in Reform of Servo Control for Gang Saw[J]. Science & Technology of Baotou Steel, 2022 , 48 (6) : 68 -71 .
管排锯是利用圆盘锯机将成排的钢管按照产品参数要求的长度,在挡板小车处对齐,主机夹紧后用圆盘锯进行切割,一组钢管切割为数段。伺服电机控制系统就是按照产品参数要求,精确定位挡板,确保每排钢管切割后符合工艺要求,定位精度为毫米级。
管排锯主轴和挡板小车运行和定位由4台西门子伺服电机驱动,控制系统为611U变频器。西门子611U变频器已停产,备件采购困难且造价高昂,所以用其他控制系统替代611U变频器迫在眉睫。鉴于设备系统主体由西门子PLC和西门子电机构成,同时现场使用的S120变频器较多,备件充足,为保证系统兼容性,决定采用S120变频器进行改造。两套设备进行数据同步,灵活切换,从而实现互相备用。
西门子S120变频技术在大型钢铁企业生产线得到了很好的应用,实现了很多控制功能。强大的软件便于调试与操作,与PLC组成的自动控制系统,控制简单,精确度高,完全满足生产工艺的要求。
钢管公司460分厂设计能力如表1所示。以27SiMn钢Φ457 mm×60 mm无缝管为例,当出料节奏为45 s,每排3支管时冷床每小时能下26排管,每台锯每小时需要切6到7排管,受壁厚和切割效率的影响,排锯设计能力为每小时切6.2排管,当一台锯出现故障时,便无法满足轧线需求,而造成堵料停产。
表1数据比对,可以发现目前大多数钢种生产时,当所有锯机同时开动时基本能满足生产要求,但排除掉精整换锯片、倒废料的时间后,当其中1台锯机出现故障时必然对轧线的生产节奏产生影响。只有个别钢种排锯实际能力能满足3台锯切管1台锯停机,多数情况下4台排锯都是满负荷生产,因此就要求降低排锯的故障时间和故障率。
一般传动故障导致的停机时间都较长,处理耗时也多。因此当出现变频器故障时先切换备用系统保证生产,再去处理原系统故障,排除故障后投入使用,可以节省大量故障时间,保证现场生产需求。
611U变频器已停产,市场上的产品数量少且采购价格高。购买一块控制板都需要上万元,而且采购周期长。由于现场普遍使用的都是S120变频器,备件通用,采购费用低,修复维护方便,所以改造为S120系统可以节省大量备件费用,延长设备使用寿命,提高生产效率。
用一套西门子PLC300和S120变频器系统建立控制系统,通过DP总线与锯机PLC系统通讯[1],进行数据交换和设备驱动。
该系统传动由一块6SL3330-6TTE35-5AA3-Z回馈整流单元、两块CU320驱动、两组6SL3130-7TE28-0AA3电源模块、4组6SL3120-1TE26-0AA3逆变单元组成。控制部分由一组S7-300系列PLC组成,通过DP网络通讯。硬件网络组态通讯如图1所示。
在变频器中输入电机相关参数,核对变频器功率单元型号,选择驱动电机类型并且输入电机数据,配置电机编码器数据,完成位置控制的基本参数配置。进行电机静态辨识(伺服控制方式不建议对电机进行动态辨识),设置变频器通讯报文格式。电机空载测试正常。
变频器与PLC控制器通过Profibus-DP网络通讯,主要控制的信号包括变频器启动停止P840、激活MDI方式P2647、位置给定值P2042、速度给定值P2043、设定数据传输信号P2650。重要的变频装置返回数据有变频器工作状态字、实际位置值、实际速度值、故障代码、报警代码[2]
插入驱动单元CU320,选择版本号、通讯方式后,自动读取驱动装置。操作软件进行自动组态,并选择“SERVO”,组态完成后,进入离线调试。组态框架截屏图如图2所示。
打开Configure DDS驱动配置(图3),按照向导提示逐步配置驱动,按照提示输入电机参数及编码器参数和控制方式。
通过使用Traversing Blocks“程序步”模式可以自动执行一个完整的定位程序,也可实现单步控制;各程序步之间可通过数字量输入信号切换,但只有当前程序步执行完后下一程序步才有效[3]
在S120中提供了最多64个程序步供使用,程序步执行步骤如下。
(1)项目导航栏中选择Traversing Blocks模式,设定开关量输入点DI3用于激活程序步功能。
(2)不拒绝任务P2641=1、没有停止命令P2640=1运行过程中可通过断开与P2640的外部开关发出停止命令,则轴将以减速度P2620减速停车。若断开联接与P2641的外部开关发出拒绝任务命令,则轴将以最大减速度P2573减速停车。
(3)按工艺需要设定各个程序步参数,程序步代号决定程序的执行顺序。
(4)通过6个数字量输入点的不同组合选择需要的程序步。
(5)闭合DI1(ON/OFF1)运行,闭合DI3激活Traversing方式(P2631=1有效),轴按设定步骤运行。
将锯机的切割数据发送到备用系统,再传到变频器Traversing Blocks块。实现定位数据与原系统同步。切割数据传输到功能块后,变频器将按照Traversing Blocks内的数据按照指令顺序驱动伺服电机进行移动与定位。
备用系统切换程序。第一步:停原系统传动电源,然后送备用系统传动电源;第二步:通过上位机操作界面操作备用程序和原始程序切换,切换后PLC指令会控制继电器驱动接触器实现对外部驱动线路的切换。对应程序如图4所示。
改造前,当变频器模块出现故障时,检查更换一个611U模块,耗时1~2 h,调试参数耗时0.5~1 h。改造后出现故障时切换S120变频器,可以不停机直接恢复生产,因此节省的故障停机时间至少3 h以上。
当其他3台锯机出现故障时,有备用系统的锯机切换到S120变频器后,将原有611U控制系统的元件拆除后用于更换出现故障的元器件。这就相当于购买了一整套611U备件,节省了备件费用。
采用新的S120系统做备用系统后,保证了生产线的安全运行,提高了产能和设备保养维护效率,同时对设备进行了升级改造,延长了使用寿命和周期。
(1)经过现场测试改造后S120控制系统可以替换原611U控制系统,实现原系统全部功能,运行稳定,满足现场需求。
(2)出现故障时随时可进行系统切换,保证现场生产。切换后对故障单元进行离线检修、更换,不影响现场生产。
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2022年第48卷第6期
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  • 接收时间:2022-08-25
  • 首发时间:2025-11-24
  • 出版时间:2022-12-25
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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