全新的自動化包裝系統解決了哪些過時的技術問題?
發布時間：
2023-02-10 11:30
解決過時的技術問題是自動化包裝項目中有一種必然的發展趨勢。傳統的自動化包裝設備生產線所在的工廠區域每年必須保證全年無休的安全運行，因此，對其態度通常是“如果沒有故障，就不需要修理”。近年來，由于技術過時，制造商不得不對包裝系統進行升級。面臨的挑戰主要來自兩個方面：
It is an inevitable trend to solve the outdated technical problems in automatic packaging projects. The factory area where the traditional automatic packaging equipment production line is located must ensure the safe operation throughout the year. Therefore, the attitude towards it is usually "if there is no fault, there is no need to repair". In recent years, due to outdated technology, manufacturers have to upgrade the packaging system. The challenges are mainly from two aspects
1. 從來沒有一個好的停機時間窗口。
1. There has never been a good downtime window.
2. 系統需要在外觀和性能上與停機前完全一樣，以確保運行人員能夠接受該系統。
2. The appearance and performance of the system should be exactly the same as before shutdown to ensure that the operator can accept the system.
針對以上兩個方面的主要問題，一家面包生產線自動化包裝系統的升級解決了這些問題，升級了舊的控制系統，以控制和協調面包工廠的包裝區域。包裝系統由7 條生產線組成，每分鐘處理20箱以上。本次面包工廠的自動化包裝設備生產線的主要技術和策略是：
In view of the above two main problems, the automatic packaging system of a bread production line was upgraded to solve these problems. The old control system was upgraded to control and coordinate the packaging area of the bread factory. The packaging system consists of 7 production lines, handling more than 20 boxes per minute. The main technologies and Strategies of the automatic packaging equipment production line of the bread factory are as follows:
■ 通過預先識別已知的風險，制定緩解和應急計劃。
■ develop mitigation and contingency plans by identifying known risks in advance.
■ 對于老舊的項目，尤其是在時間至關重要的包裝應用中，升級系統時應密切注意序列時間。
■ for old projects, especially in packaging applications where time is critical, pay close attention to sequence time when upgrading the system.
■ 系統升級需要在所有生產設施之間進行跟蹤并保持一致性。
■ system upgrades need to be tracked and consistent across all production facilities.
該項目需要用4 個機架和超過60 個模塊來替換PLC 5/25，這些模塊通過遠程輸入/ 輸出（I/O）和過時的數據高速公路通信協議，連接到工廠的其余部分。舊的處理器和系統被可編程的自動化控制器和基于以太網的I/O 所取代。此外，還涉及到軟件轉換、更新現有（破爛不堪的）電氣設計文檔。
The project required the replacement of PLC 5 / 25 with four racks and more than 60 modules, which were connected to the rest of the plant via remote input / output (I / O) and outdated data highway communication protocols. The old processors and systems were replaced by programmable automation controllers and Ethernet based I / O. In addition, it involves software conversion and updating of existing (dilapidated) electrical design documents.
該項目的目標是更換所有硬件（現有處理器已滿，無法再對其進行編輯），測試新的I/O，并在啟動前確保現有功能的順利實現。由于項目基于硬件，并且缺少人機界面（HMI）屏幕，因此在上線之前無法對這類項目實現全面仿真以進行測試。為了降低啟動風險，項目團隊在代碼轉換、交叉檢查代碼、圖紙審查等質量管理方面格外小心。
The goal of the project is to replace all hardware (the existing processor is full and can no longer be edited), test the new I / O, and ensure the smooth implementation of existing functions before startup. As the project is based on hardware and lacks human machine interface (HMI) screen, it is impossible to fully simulate and test such projects before it is launched. In order to reduce the start-up risk, the project team takes extra care in quality management such as code conversion, cross check code, drawing review, etc.
停機時間選在了勞動節周末的3 天假日。電氣團隊從周六上午12 點開始接線，并在周日凌晨5 點結束。在周日，控制團隊完成了所有I /O 檢查，然后進行了功能測試。由于質量控制做的很好，代碼測試進行得很順利，經過漫長的一天，團隊最終完成了工作。這樣，就有星期一作為備用，可以進行更多測試，并有機會讓團隊休息。該系統在啟動爬坡（2 秒內從0 到60 mph）內進行了調試，與項目相關的總停機時間僅為20 分鐘。通過強有力的執行質量計劃、嚴格的驗收時間表和詳細的現場驗收測試清單，該項目的完成時間比預期提前，這為額外的測試留出了緩沖時間。
The downtime was selected on the 3-day holiday of the Labor Day weekend. The electrical team started wiring at 12 a.m. on Saturday and ended at 5 a.m. on Sunday. On Sunday, the control team completed all I / O checks and then conducted functional tests. Due to the good quality control, the code testing went smoothly, and after a long day, the team finally completed the work. That way, there's Monday as a backup, more testing and a chance to rest the team. The system was debugged within the start-up ramp (from 0 to 60 mph in 2 seconds), and the total project related downtime was only 20 minutes. Through a strong execution quality plan, strict acceptance schedule and detailed site acceptance test list, the completion time of the project is ahead of schedule, which provides buffer time for additional tests.
根據應用需求和環境的不同，自動化系統集成商需要為客戶考慮到所有可能出現的困難，先進的自動化包裝設備和控制技術可以幫助制造商實現包裝系統的集成和升級，幫助企業在最短的時間內，實現系統的平穩升級和高效運營。
According to the different application requirements and environments, automation system integrators need to consider all possible difficulties for customers. Advanced automatic packaging equipment and control technology can help manufacturers realize the integration and upgrading of packaging system, and help enterprises achieve smooth upgrading and efficient operation of the system in the shortest time.
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