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2022 華南展招展書
控制系統

圖爾克分布式案例技術的模塊化生產

  2022年04月15日  

導讀

  憑借IP67防護等級的分布式安全理念,圖爾克為某荷蘭設備制造商提供了優化支持。IO-Link與混合安全I/O模塊的組合,節省了大量的接線工作,因為整個安全架構可以安裝在控制柜外部。

  傳感器與執行器的電壓之間徹底的電隔離,可以實現在帶IO-Link接口的I/O集線器上,從而對執行器進行安全關斷。并可以為AWL顯示和評估數據的Lyla操作面板,提供重要的診斷數據。該項目證明了模塊化設備可以靈活的進行工作,并且能縮短交付和調試時間。

TBIL I/O集線器將焊接帽切割機的信號發送至IO-Link主站(在后臺實現此功能)

  任何使用模塊化配置來設計廚房的人,都會感受到優勢。這些獨立的模塊包括側面板、底板、后面板以及抽屜等。最后,還可以選擇不同風格的前面板、把手設計以及相應的操作臺。

  DIY廚房的例子,清晰顯示了在沒有標準化時,來談模塊化是不可想象的。只有在對間隙、尺寸、鉆孔以及水管或天然氣管路的連接進行規定時,才能實現模塊化生產的好處:廣泛的型號、更高的靈活性、更快的交付時間以及更合理的價格。

  該制造商AWL正是利用這種觀點,說服客戶接受模塊化機器理念。AWL在全球共有5個分支機構和超過750名員工,并憑借其在汽車行業的自動化焊接和連接線而聞名。主要的汽車制造商、供應商還有其他許多客戶都在生產線中使用他們的設備。

  2017年,某個跨學科團隊針對AWL的機器產品組合實施了模塊化理念,并逐步定義了M-Line的標準。首先,這需要在公司內部進行一定的說服工作。尤其是在從常規到模塊化生產布局的過渡階段,模塊化優勢還未凸顯出來。首先需要定義標準,而這通常會受到諸多因素的限制。

M-Line的不同模塊可以組合使用,構成完整的生產線

模塊化帶來靈活性并節省成本

  AWL設立的首個標準則是一系列產品的名稱:MLine既代表模塊化產品系列,又代表包含各個模塊的生產線。每個模塊的外殼是矩形鋼制框架,該框架經過設計以便安裝在符合ISO標準的容器內。這可以為運輸和調試設備節省時間和成本。由于模塊化設備可以使用合適的叉車在廠房內進行重新布置,因此客戶也可在未來輕松對系統進行擴展或轉換。

Lyla操作面板系統可采集和評估不同機器的數據,從而監測機器的運行和性能

模塊化需要標準

  除了基本框架外,AWL還定義了建造M-Line的3個核心模塊類型:一個是操作模塊,方便用戶插入組件和啟動進程;一個是分析模塊,包括轉臺和其他處理工件的裝置;一個是加工模塊,可以配合焊接機器人或機床等對工件進行加工。

目標:清空控制柜

  圖爾克的多協議以太網IO模塊為AWL提供了幫助,不論客戶偏好使用Profinet還是Ethernet/IP控制器都可以在每個M-Line模塊上使用相同的IO模塊。我們想要有盡可能多的標準化組件,以及在很大程度上的標準化控制柜。理想情況下,我們希望未來控制柜中只有PLC和電源。雖然還未達成該目標,但AWL模塊控制柜內現在已經騰出很多空間。圖爾克IP67混合型安全I/O模塊在此發揮了重要作用,它同時提供了普通信號和安全信號。

采用可擴展安全技術的IP67 IO-Link安全I/O

  AWL對圖爾克的模塊化IP67 IO-Link安全解決方案印象深刻:該解決方案的核心是TBPN混合安全I/O模塊。TBPN帶內置的安全控制器,可通過Profinet上的PROFIsafe與PLC通信。該模塊包含4個安全I/O、2個常規數字I/O和2個IO-Link端口。TBSB安全關斷箱與其中一個安全I/O連接,可以在嚴重情況下安全斷開執行器電壓V2。

  由于所有模塊的電源都通過安全關斷箱來提供,這確保了在緊急停機等情況下不會為任何執行器提供電源,且機器的任何部件都不會移動。而傳感器則通過V1供電,則保持連通狀態。這樣,控制器可以一直監測設備的狀態。焊帽切割機的傳感器和執行器與I/O集線器進行連接,并與圖爾克的TBEN-L-8IOL IO-Link主站通信。

  該IP67主站模塊提供4個符合Class A標準的IO-Link端口以及4個符合Class B標準的IO-Link端口,從而將傳感器電壓 (V1) 與執行器的電壓 (V2) 隔離開。因此,電源的斷開同樣通過IO-Link來實現。AWL已經在美國的類似項目上使用了圖爾克的TBIP模塊。該模塊與TBPN的硬件類似,但是使用EtherNet/IP和CIP-Safety通信。

模塊的整個安全技術通過TBPN(左下)運行。

IO-Link master(中下)通過安全箱( 中) 供電,從而確保在緊急情況下關閉Class B端口上的所有執行器

傳感器/執行器電壓的電隔離

  其他制造商也聲稱有能隔離V1和V2的模塊。然而,經過仔細鑒定便可以發現其所謂的“隔離”并不徹底,例如V1和V2會共用負極。若發生短路,是不被允許的。而這一簡單的隔離故障就足以使整個安全解決方案失去作用,原因之一就是無法確保徹底的電氣隔離。

清空控制柜:借助分布式I/O理念,模塊化機器的控制柜騰出了大量空間

IO-Link加快標準化

  使用IP67的安全產品和I/O集線器的解決方案為AWL節省了很多接線工作。作為IO-Link設備,集線器使用IO-Link協議將執行器和傳感器的數字信號傳輸至IO-Link主站,然后IO-Link主站通過以太網進一步將信號發送至控制器。另一個原因是雙向接口加快了M-Line的標準化。通過三線制電纜的信號傳輸消除了對特殊屏蔽電纜和專用電纜的需要。IO-Link還確保了更高的機器可用性:Lyla操作面板系統是M-Line的一部分,它可采集IO-LINK診斷數據和評估不同機器的數據,從而監測機器的運行和性能。

  “我們需要同樣能滿足我們要求的全球化合作伙伴,圖爾克正是我們的理想選擇?!?/P>

模塊化帶來靈活性并節省成本

  控制器層級的模塊化尚未開展。截至目前,每個控制項目仍需從零開始,只有基本模塊可以重復使用。無論如何,模塊化項目遠未結束。M-Line受到AWL客戶的廣泛認可,他們認為這些機器的可擴展能力是一項重大優勢。未來若需要增加輸出點位,可以使用模塊化方案靈活解決這一問題。這與廚房用具類似:需要改變時,只需將廚房用具取出,然后添加一些新模塊即可。

(來源:圖爾克)

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