We weld the workshop to factory of Volkswagen two of Shanghai, utilize SIMATIC products of Siemens Company, design and finish the automatic diagnosis and welder team control system of an equipment fault. Through a few years’ use, this system ran stably and reliably, basically achieved the goal of designing.

First. Weld the current situation analysis of the workshop

It enclose this car ago, after enclose, before baseplate,etc. part,and then spelling for having these parts spelt and lasted automobile bodies whole always, mended and weld, polish and form the final white automobile body finally, export and lacquer to the paint shop. This welds the workshop according to pressing the part – part – welding processing course always pieced together, production line it set up on six piece,respectively for before line enclosed, after line will enclose, before baseplate line, baseplate line, last line and be mend to last line always. It is joined that these six production lines are inflexible each other according to the production technology. That was mainly allocated in each worker location on these production lines is to weld the manipulator, weld the robot, some welders, pull rod are transmitted and transported automation equipment such as the car to make up in the sky more. Controlled various on these production lines to process the apparatus separately by 44 PLC of Taiwan Siemens Company, it make it coordinate each other it, run, make workshop not lasted for producing a white automobile body production the abilities of beat of the 56 seconds every continuously, automatic.

But when this workshop of production lines are put into operation, two main problems exist:

When some place on the apparatus breaks down, because unable to get rid of, cause whole production line shut down often quickly, or the whole workshop stops production, influence the workshop output and production beat seriously.

It is unstable that the welding quality of some solder joints will take place, can’t guarantee the quality of white automobile body.
Through making investigations and making a concrete analysis of, the main reason the above-mentioned problem happens is:
There are many apparatuses on the production line, facilities comparison is complicated, connect by the rigidity between the production line, if the machinery, hydraulic pressure or electricity trouble happen in a certain position will cause some production line to shut down, the maintenance personal should look for the course through the analysis of certain time, could find the trouble point, could fix a breakdown. During when the analysis of the trouble finds out and gets rid of, because has not buffered between the production line, production line in front shut down immediately, the following production line caused the empty worker’s location, this time is too long, will also cause the production line to shut down behind. It occupies a main one to be to analyze time of finding out in the time that analysis find out and get rid of of trouble.

Workshop this have 2,000 more than in all electric welding torch in work at the same time, easy to cause, supply power, press, fluctuate. If some electric welding torch rush, energize, weld in the intersection of voltage and low ebb, these solder joint weld unureally, quality is not good.
So, in order to analyze fast that looks for the trouble and guarantees the normal voltage is energized and welded, solve =The above-mentioned two questions, we set up the automatic diagnosis and welder team control system of this equipment fault for the workshop.

Two. Systematic hardware and software structure

Floor of the apparatus
Own PLC44 platform in common on six production lines of the whole workshop, is formed by S5-115U, S5-135U and S5-55U. These PLC can offer the state of running of the analytical equipment and analyse the relevant information of trouble point taking place to the system. But these PLC is scattered, diagnoses ability in fault-free. So, our system has set up the industrial bus Profibus network of two sections of scenes in the workshop, join these PLC separately. Make the system gather and gather the status information of the apparatus on the production line through on-the-spot PLC, diagnose the trouble in automatic analysis. The concrete method that the apparatus is incorporated into the power networks is, insert the Profibus net card CP5431 on each PLC, and connect on the industrial bus of a section of scene among them. see figures

The field engineer stands
The field engineer stands and sets up at the workshop scene, is made up of accusing of machine of six workers, correspond to six on-the-spot production lines of the workshop separately. Six Taiwan worker these accuse of, insert have the intersection of Profibus net card and CP5412 separately at the plane, through should block, connect at network of Profibus. Stand and can control the corresponding production line through the field engineer. see figures

Information exchange centre
The information exchange centre is formed by a S5-155U, is called main PLC of the system too. Through the industrial bus Profibus network of workshop scene on one hand, connect 44 PLCs on production line, gather and gather and analyze the trouble information for producing apparatus on the line; Connect with administration and supervision authorities of the system through industrial the intersection of Ethernet and H1 on the other hand, diagnose result send the intersection of office and computer to analyzing, diagnose his analysis the result is sent back field engineer’s station through the intersection of workshop and the intersection of scene and industrial network, Profibus of bus, while. see figures

Administration and supervision authorities
Systematic management includes the computers of workship director’s office and maintenance office, connects, makes administration and supervision authorities obtain the analysis result at present from the information exchange centre real-timely through industrial Ethernet H1 information exchange centre, and classify filing, form various report forms to this. see figures

Welder team control device
Set up a high and sensitive voltage monitoring instrument, the change of the voltage of monitoring the arc welding generator of the workshop and supplying power while working in real time, and send the result into the information exchange centre and deal with the welder team control information through the break procedure of S5- 155U, through the intersection of Prifibus-DP and way, convey PLC at the production line to at a high speed control signal, make corresponding welder put through to act as, can control electronically.

Software which the system disposes
CorosLSB/Win is the main software of system, mainly runs on the computer that administration and supervision authorities and field engineer stand, it is the main developing platform of system. COM5431 and COM143 system software is for managing the scene industrial bus Profibus and industrial Ethernet H1.

Three. Main purpose of the system
Gather the status information of running of apparatus on six production lines of the whole workshop
Because Profibus network is connecting on-the-spot PLC, the system can monitor and distinguish normal running, shutting down, trouble,etc. various states that every production equipment live in at present real-timely, and on the corresponding picture of the corresponding worker’s accusing of machine, reveal through the form of changing with different symbol, figure and color etc..

Analyze in real time that takes place in every trouble state and concrete position for producing apparatus on the line
Because Profibus network gathers the information on every production equipment, summary reaches concentrating on paying analyzing to synthesize on main PLCS5- 155U, the system can judge cranky type and place production line, worker’s location, position,etc. information of position of breaking down, send the judged result the corresponding worker machine to reveal subsequently, in order to point out a maintenance personal.

Analysis and statistics that are carried on about trouble information
Persons of management machine and the intersection of worker and person who accuse of under industrial the intersection of configuration and operating platform, CorosLSB/Win of software, at being systematic, can to from the intersection of trouble and information that main PLC send here, go on, classify, file, punish, go on, search in the intersection of apparatus and the intersection of servicing manual and database at the same time, find out the position where the trouble takes place, the reason why the trouble takes place and main method to fix a breakdown. Then this software records the time, position, reason and situation got rid of where the trouble take place in the file database of the apparatus, and form various report forms.

Energizing team control of welding voltage transformer controlled to the whole workshop by PLC
Utilize the characteristic of fast I/O of ProfibusDP, supplies power to the arc welding generator of the whole workshop the voltage is monitored, according to the arc welding generator team control principle, rank and energize and control to the arc welding generator controlled by PLC.

Four. Basic principle of system work
Diagnose the general method in automatic trouble
Weld the apparatus of the workshop to finish holding movements such as inserting, material loading, unloading and transporting,etc. of the work piece mostly through the cylinder and air cylinder. Preliminary statistics, this workshop, are distributed and amounted to 4,000 big and small cylinders and air cylinders on every production line, and the equipment fault mainly happens on the parts of cylinder and air cylinder, is shown as these jars are uncomplete. Following analysis is a cylinder movement situation, obtain the automatic trouble and diagnose the general method. Set up one cylinder take exercises Q forward =1,The cylinder reaches the front through certain sport time, then the front is close to the switch and have electric I_1 =1,Close to while being back switch lose electric I_2 =0. We set up a time-recorder T in system for this cylinder. When cylinder movement Q signals are sent out, this time-recorder begins to count, move in this cylinder that sets for in time T_set range, put correspondingly in place and is close to the switch and have the electricity, namely admit systematically this cylinder operates normally. If move in this cylinder in time T_set range, put correspondingly in place and is close to the switch and has not had the electricity, think systematically this cylinder breaks down. The result tabulation of automatic analysis of the system is as follows:

According to the above-mentioned method, the system, to each cylinder and air cylinder on the apparatus of the workshop, all distribute the time-recorder T in this apparatus PLC controller, and set up corresponding jar sports time T_set, diagnose in order to finish the automatic trouble.


Team control general method of the welder
There are four to supply power this workshop the voltage transformer supply power to the welder, because the welder is the single-phase electricity used. The workshop welder basically hangs in workshop on 12 single-phase electric wire roads separately evenly. The high and sensitive voltage monitoring instrument is monitoring these 12 single-phase electric wire ways separately. When monitoring the value that a circuit voltage among them is lower than presuming, apply to be cut off to main PLC. Cut off the procedure and check circuit voltage at first low something, deal with respectively:
There are in lining up in working range on circuit voltage,it last procedure according to range why craft permit, hang in welder of circuit this lining up, through the industrial bus of scene, control PLC on the apparatus, let the welder on this circuit energized and welded sequentially, make each one have enough electric current to work to weld.

The circuit voltage cuts off the procedure and notifies the apparatus PLC through the broadcast form of the industrial bus of scene in the range of shutting down, all welders hung in this circuit quit work, until the circuit voltage resumes in the normal range.

Five. Main function of the system and realizing the method
Systematic working way
Because most hardwares of the system adopt Siemens Company SIMATIC industry type products, round-the-clock normal work of a whole day of the security system. Especially it is S5-155U to adopt in the systematic information exchange centre, it is Profibus network that the workshop is adopted live, it is industrial Ethernet H1 that administration and supervision authorities adopt, all these have industrial products that can highly work under the abominable environment reliably, can long-term shutting down work. Can monitor the production line apparatus within a few years incessantly on the security system like this, gather apparatus information and production information, the timeliness, accuracy and integrality of data processing of the security system continuously.

Status information that the production equipment runs at present
Because the production process of the production line was controlled by PLC on the on-the-spot production line, and these PLC is all hung on Profibus, in this way information exchange centre, namely main PLC can gather the signal of all I/O of on-the-spot PLC through this network. The information exchange centre gathers and analyzes to the process of these signals, judge every present operation state for producing line every part of the whole workshop, and store the state of operation in the corresponding data piece DB in the information exchange centre. These run status information is with the information exchange centre main PLC at the same time And operation cycle breaks in real time. The engineer of the scene stands and the managerial computer passes Profibus and industrial Ethernet H1 respectively, visit the corresponding data piece in the information exchange centre, and get the production equipment and operate the status information at present, and then pass CorosLSB/Win dynamic figure picture, demonstrate the state of running of the production equipment at present vividly, vividly.

The equipment fault is diagnosed, analyzed and counted automatically
When the apparatus on the production line breaks down, information exchange can be monitored immediately through Profibu network centre. The information exchange centre judges cranky concrete content and position that happens according to four following respects, and reveal on the dynamic figure picture of the computer CorosLSB/Win that the field engineer stands and managerial in detail:
a.Experience that the on-the-spot maintenance personal offers;
b.Analyze the uncomplete signal of movements;
c.Emergence probability formed through historical record of the trouble;
d.Logic analysis of this apparatus PLC procedure.

The information exchange centre confirms the cranky type according to the properties of breaking down: Mechanical breakdown, electric apparatus trouble, hydraulic trouble, pneumatic trouble,etc.. The information exchange centre is according to breaking down and confirming the cranky grade to the influence degree of running of the apparatus: Want trouble, secondary trouble and main trouble. The information exchange centre points out and arranges so the method according to characteristic and maintenance record of breaking down. On the dynamic figure picture of the computer CorosLSB/Win that the field engineer stands and managerial, the intersection of trouble and type and arrange so method reveal the intersection of trouble and grade glimmer by different color form Cheng reveal in the form of characters.

The managerial computer counts the equipment fault, its content mainly includes:
a.Trouble information record of emergence of each apparatus weather;
b.The apparatus takes place according to the trouble the type goes on for week, moon, Ji He count every year;
c.Fault rate and opening rate of each apparatus;
d.Fault rate and opening rate of every production line;
e.Fault rate and opening rate of the apparatus of the whole workshop;
The workshop produces information automation statistically
Under the support that Profibus holds in place with a net, the system gathers the output information of every production line automatically, and store it in in the data piece of the information exchange centre. Form and make various of example to produce the statistical report form through CorosLSB/Win interface of the managerial computer:
Reveal the production beat of every production line and change the state in real time;

Reveal the production output of every production line and change the state, reveal the production output of every day changes the course in the same day and last seven days in real time;

Every day’s day shift and night production output record within one year of the workshop;

The workshop produces report form, monthly report form and annual report form of week of the output.
Team control of the welder
Monitor, go out of workshop, supply power at voltage lower than, power voltage normally as the intersection of voltage and monitoring device, the break on main PLC inputs the template 6ES5451-4UA13 Will receive the signal that the voltage monitoring device will be sent out, main PLC carves and enters and carries out and cuts off the service routine. Cut off the service routine according to the welder team control principle, through Profibus network, PLC to the apparatus sends out the working order, make every welder work in certain order.
Six. Conclusion and meaning
More feasible convenient means that this system so maintains offering to arranging to the apparatuses of users, have makeovered that kind of work method of diagnosing the trouble only according to the experience of the past. With the help of computer, so long as the production equipment is out of order happens, the systems can all confirm the concrete position of the trouble or position more accurately and rapidly, and offer and arrange so the method. Shorten trouble, find out and arrange greatly so so time, guarantee the apparatus can return to normal in the time as short as possible.

Because these system can realize and produce the output automation statistically, it needs sending a duplicate to the statistical work by hand of much time in the past to replace, have improved the automatic intensity of the production management of the workshop. At the same time this system also provided the means for producing dynamic deployment for workshop, find out about every production line of present workshop, every part of production status through administration and supervision authorities’ computer, can find the production bottleneck that may appear, make the workshop administrator produce adjustment in time.

The intersection of welder and team control unable to realize in China in the past, utilize PLC and the intersection of Profibus and technology welder team control of Siemens Company systematically now. Stabilizing and improving certain assurance of welding quality of this pair of arc welding generators.

Have succeeded in employing the technology of Siemens Company SIMATIC products in this system, among them Profibus on-the-spot bus and H1 industrial Ethernet technology play a key role in this system, they form every part of the system a entity; Main PLCS5-155U is by the collection, comprehensive analysis and conveying and can be paid reliably and accurately of the information of technological security system of the high, great storing amount of the running speed; The man-machine interface that CorosLSB/Win produces is fast, high in efficiency, and easy to use, use friendship and convenient.