厦门莫格电气自动化有限公司

上胶机控制部分采用高稳定度可编程控制器-三菱FX1S小型PLC控制，电机驱动由三菱E540变频器驱动，手套由奥托尼的漫射光电开关检测，该机的定位由两只奥托尼0.1MM的光纤传感器检测，该机的主要工艺是由PLC控制，通过驱动四只电磁阀和一个单相电机的正反转来实现所有的工艺要求。该本具有步进，手动正反转调整位置等功能。

该机的工作过程如下(主机)：

首先将所要使用的机台处于自动状态，在按下启动键以后主机(一号机)，电机快速正转，在X0(光纤传感器)到位以后，电机减速，慢速前进，在X1(定位光纤传感器)到位以后，电机立即停止，与之同时顶模，顶链条开始工作(Y4工作)，在顶模到位后：

1,发出上胶指令给2-5号机台

2,主机判断是否有手套

主机判断是否有手套，如果没有则过程完成等待下一个过程。

如果有手套，则主机架，顶模，顶链条等工作，待下降到位后，刷胶刮刀下降，接着就是上胶，机头左转，左转完即上胶完成后，机架上升回到原位，顶模，顶链条退回，回到安全位置，最后就是胶从左到右将胶刮均匀，为下一次循环做作好准备，至此整个过程完成。

为了保证机器设备的安全，避免电机强制运行造成丝网板，定位等装置的损坏，主机PLC正常运行受各机台的PLC的安全位置联锁的控制，在自动和手动运行中各机台必须处于安全位置。

机台的安全位置包括以下内容：

1,刷胶主机架处于上面位置

2,顶模处于退回位置

3,顶链块处于缩回位置

本设备的主要部件由气缸推动。低振动，低噪声，效率高，各气缸的位置由气缸上安装的磁性开关检测输入PLC内部。

机台的联锁关系：

主机输出(Y12)一个检测信号，该信号为握手信号，依次传递。主机输出(Y12)的信号，输出到第二机台的PLC的输入点(X10)，第二机台PLC接收到X10有信号后先判断一下本机是否处于安全位置(安全位置如下要求)，如果处于安全位置则输出Y1，第二台的Y1信号送入到第三台的X10输入点，第三台接收到X10有信号后先判断一下本机是处于安全位置，如是处于则输出Y1：依次类推，当第六机台的PLC也接受到X10的信号时，输出Y1至第一台的X10，第一台在接受到第六台的信号后，并不是马上运行下一个回合，而是先判断一下主机是否做完上一个循环的所有工作，如果已完成，则开始下一个循环，如果没有完成的，则要等到把上个循环的步骤做完才能进入下个循环。

以上联锁中任何一个机台的位置都可能会影响到整个机器的行，在生产中多次碰到因为安全保护开关没有动作，造成整个机器不能运行的故障，机器不间歇的运行，机械长时间的磨损，都会给以后的使用造成很大的麻烦，如何才能快速的查找并排除故障？

常见故障主机手动/自动时都不能转动，

步骤如下：

机器运到故障时，不能确定在短时间解决的话先切断加热系统。

检查主机配电箱的电器是否正常，变频器是否跳闸？如果没有跳闸转第三步

主机的Y12输出指示灯是否亮起？如果亮起转第四步

检查第二台的X10是否有信号，如果没有信号则是第一台至第二台的线路故障。如X10有信号再检查Y1是否有输出，如果没有则就是第二台安全位置故障，如Y1有输出再转第五步

检查第三台的X10是否有信号，如果没有信号则是第二台到第三台的线路故障。如X10有信号再检查Y1是否有输出，如果没有则就是第三台安全位置故障，如Y1有输出则往后依检查。

当检查到六号机的X10有信号，Y1也有输出时，那就很可能故障点在一号机，检查一号机的X10是否有输入，如果有输入说明其它五个机台都是正常的，一号机本身有故障，故障的原因有多种，不光是安全位置的问题。

例如：起动或停止按钮断线，PLC输出点损坏，辅助小继电器接触不良等等，需要懂一定电气知识的才可以维修，不做详细说明。判断此设备的故障首先要知道是哪一台出了问题，X10和Y1是关键！

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