2019 PLC Program for PS2A

Date: 03/25/2023 Speaker: 谢刚

 目录
CONTENTS 01. 程序背景

02. 程序的架构

03. 现有架构优点

04. 使用过程的缺点

05. 其他应用的程序架构
PART
Station Component
01
About station in PLC

在 plc 程序中，将整机设备按照功能及区域划分为不
同的站，程序按照划分的站分开编写，每个站内部程
序结构基本一致
标准机型划分了 19 个站 LT 机型划分了 20 个站，每
个站使用相应的数字代码，下面分别简单介绍各个站 ,
方便设备程序维护人员能够在设备出问题时，知道去
哪里查看程序。具体每个站包含哪些器件参见说明书
12-11 图表
Station component instroduction1
150 Carcass drum station
下面分别简单介绍各个站 , 方便设备程序维护人员能够在设备出问题时，知道去哪里
查看程序。具体每个站包含哪些器件参见说明书 12-11 图表

S150
Carcass drum station
• Carcass drum device
-A Device
• Bead transfer ring - B
• Bead load device - C
• Stitcher - D

Program
 Station component instroduction2
130 and 510

S130
Belt drum station
PLC device
• Belt drum device
such as drum
rotate and BD
drum diameter

S510
BTR station
PLC device
• Tire crown transfer
ring
Station component instroduction3
152 Unloader station

S152
Unloader station
Device
• Remove tire device -
A
• Tire basktet -B
• All the execution
device and switch
PLC
Station component instroduction4
300 Common applier station

S300
Common applier
station
device
• Common convey
• All the execution
device and switch

PLC
Station component instroduction5
CD side servicer station

According to different material , the servicer station is create, every material have
one station .but servicer station does not include material Let-off device. Let-off
device have itself station . it is independent station.

S361
S312 S340
Breaker 1 servicer
PA servicer station BP servicer station
station

• All the Pa servicer • All the BP servicer • Breaker 1 convey

include innerliner include BP1 and BP2 and cut device
and SW supply supply and cut devce • All the execution
• All the execution • All the execution device and switch
device and switch device and switch
Station component instroduction6
CD side servicer station

S362
S380 S390
Breaker 1 servicer
JLB servicer Tread servicer station station

• JLB apply and cut • Tread cut and convey • Breaker 2 convey
device device and cut device
• All the execution • All the execution • All the execution
device and switch device and switch device and switch
Station component instroduction7
Material Let-off station
Every material Let-off device have itself station . it is independent station.
S410
Sidewall let-off
station
• Sidewall let-off
• All the execution
device and switch
S441
Bp2 let-off station
• Bp 2 let-off
• All the execution
device and switch
S411
Innerliner let-off
station
• Innerliner let-off
• All the execution
device and switch
S461
Breaker1 let-off
station
• Breaker 1 let-off
• All the execution
device and switch
S440
Bp1 let-off station
• Bp1 let-off
• All the execution
device and switch
S462
Breaker1 let-off
station
• Breaker 1 let-off
• All the execution
device and switch
Station component instroduction8
Material Let-off station2

S480 S490
JLB let-off station Tread let-off station

• JLB let-off • Tread let-off

• All the execution • All the execution
device and switch device and switch
PART
Station Program Structure
02
Station program structure overview
Every station program structure is the same . The description of every routine is as follow:
Name Description
R000_Main_Routine Call all the routines in the program at this station.
Copy the input used in the whole program to an input mapping table
(except in Ethernet communication).
R001_Initialization Initialize to the data of a certain program; initialization occurs when
supplying power, running PLC or requesting an initialization.
R005_Input All the input signal of the substation. Include, operation box switch signal,
detect switch signal and analog input signal.
R006_Safety All the running conditions relating safety in programs at the station.

R010_Machine_State_Management Recording the operation mode of the station and the status of state
machine.
R020_Fault_Handle Collect and record program errors at this station.
R030_HMI_Interface Message interface between the program at this station and the HMI.

R040_DATA Data calculation of the program at this station.

R050_Exchange_To_Other_Part Message interface between different actions.

R100_SFC_Management Process management at the station.

R101 to R199 Process and the conditions for fulfilling the process.
R200 to R300 EM_xxx Equipment module. Execute device,every one have one routine
R999_Output All the output signal of the substation. Include, valve control signal, light
control signal and analog output.
How to run
Start

When machine start ,This is Power on R020_Fault_Handle Collect

Program run routine Information from R200 to
R300 EM and itself.
Then sent the information to
All the R020 fault handle R010_Machine_State_Manag
reset Collect all the ement
Information
Y
Check err?
According to the err
N information from fault
handle ,Machine state
R010 management will change the
Step
Machine_State_ machine mode.
operation
Management Execute mode or others like
aborting
According to the command ,it
will also change the machine
Machine state mode ,
become Execute Maual or Auto
state
How to run
Command run routine

When command ,This is Machine Execute state

Program run routine
Maual command Auto command

R030 HMI R030 HMI

R005 input R005 input
Interface Interface

command command

R101 to R199
Actuator include R100 SFC
Equipment
all valve and Management
module
motor, motor
directly execute
Valve

R101 to R199
R999 output SFC program
and condition
PART
How to handle Problem
03
handle Problem in HMI

When machine stop, firstly need to

view the alarm in HMI
Step 1 select the err device such as A
Step 2 select alarm -B
Step 3 according to the information ,
then solve the alarm
Step 4 if have safety alarm ,it will tell
us what is safety alarm in Pic 2
Handle Problem in Program-manual mode
Manual mode
If we move the motor or valve , it
can not move ,we can find the
reason like the flow
Next page I will give an example
MOF
Step1
• Find the device routine in R200 to R300
• Check the AOI and check it for err such as GC RC1 RC2 fault
• AOI_MOTOR_2D1V for motor
Step2 • AOI_VALVE_2D1V for valve
• Monitor the tag Sxx _Drive_Diagnosis[x] such as
S510_Drive_Diagnosis[1]
• According to the tag ,we can make sure what is the err
Step 3
• According to the tag At the top of the routine we can find what is
the err
Step4
Handle Problem in Program-manual mode
manual operation Example 1
Fig1
Now I want move BTR to Taking
crown position . Like Pic 1 .but it
does not work.
How to know the reason?
Step 1 find the BTR motor module routine Fig2
(called BTR EM )in program.
According to the description for station
before, we can make sure BTR motor
belong to S510 station.
Step 2 Open BTR motor module
routine ,And find the EM AOI .
Handle Problem in Program-manual mode Fig5
manual operation Example 2

Step 2 Open BTR motor module

routine ,And find the EM AOI .
Now the AOI have the FLT_GC , like Fig3
Step 3 monitor the tag
‘S510_Drive_Diagnosis[1]’ like Fig4 and
Fig5.
Now we find the alarm ‘Fault 1’and ‘Fault 2’
Fig3 Fig4
Handle Problem in Program-manual mode
Example 3
Fig6
Step 4 Return to the EM routine ,in the
upper position wo can know what is the
fault 1 and fault 2.
‘S510_Drive_Diagnosis[1].Logic_GC_FLT
.1’ and ‘M_51001.GC_DW.1’ are in one to
one correspondence
It means that belt applicator is too high ,
more than 10, so move it to home position
,it will be ok
Fig7
In conclusion ,This is the step how
to handle the problem in program
when manual operation .
Handle Problem in Program-Auto mode
Auto mode without alarm

If machine stop ,when in

• Find the SFC routine in R100 to R199
production . If the state is still in Step1
auto mode, We can follow these
steps to solve the problem
• Open the routine and find which step the machine stop
Step2
Next page I will give an example

• Open the step(stop) condition routine, find the condition what make
the step stop
Step 3

• According to the condition ,do something to solve the

AMP reason .maybe make a adjustment for some switch ,or move the
Step4 other device to the required position
Handle Problem in Program -Auto mode Fig7
example1

Case 1:
Now the machine stop ,it need to load
bead. But the machine state is still auto.
Like Fig 7/8/9

Fig8

Fig9
Handle Problem in Program -Auto mode
example2

Step 1 find SFC routine that machine in

now ,like Fig 10 Fig10

Step 2 According to SFC routine ,we can

find that the process stopped at the first
step , And it is the variable
‘SFC_BL[1].TR_1’ that make process stop
 Handle Problem in Program -Auto mode
example3

Fig11
Step 3 Open the step(stop) condition
routine , Normally the condition routine on
the step routine ,so open the routine
‘R122_Transition_BL’
we can find the reason . It is the condition
‘B_BTR_SafetyPos’
SFC_BL[1].TR_1

Step 4 Go to cross reference for the tag.

Like fig12
In means BTR position should be less than
1060.

Fig12
Step 5 Move BTR to wait position , it will
be ok .if the BTR cannot move ,you can
follow the mentioned step that in manual
operation to solve the new problem .
 Handle Problem in Program – Auto mode
Auto mode
If machine stop ,when in
production . If the machine state
become to manual (the auto light
is off),and there is alarm in HMI.
We can follow these steps to
solve the problem
Next page I will give an example
AMF
• Find the station fault handle routine -- R020_Fault_Handle
Step1
• Open the routine and make sure which type it is
• In the routine ,it will categorize err message and sent it to R010 , then
machine will change work mode . Reference to Chart 1
Step2 • If the alarm is only from the routine , it does not matter with EM .it is
over ,otherwise go on
• Find the Aoi ‘AOI_FLT_Handle_Drive’ ,According to the message and
Step 3 monitor make sure it is from which EM
• Open the EM routine and find the err .like mentioned before MOF
Step4
• do something to solve the reason follow the MOF step
step5
 Handle Problem in Program -Auto mode
Fault level

Chart 1
Fault 0.x 1.x 2.x 3.x 4.x 5.x
level 1 1 1 2 2 3
state The machine will be emergency stop state , The station will become Only send
everyone will be stopped manual from auto .And the message
action will be stopped

Example S150_Station S150_Station S150_Station S150_Station S150_Station S150_Station

_Fault[0].0 _Fault[1].0 _Fault[2].0 _Fault[3].0 _Fault[4].0 _Fault[5].0
 Handle Problem in Program -Auto mode
Fig13
Example without alarm

Case 1:
Now the machine stop ,it need to load bead and stitch bp
splice. But the machine state is still auto.
Like Fig 13/14/15

Fig14

Fig15
Handle Problem in Program -Auto mode
Example without alarm Fig16
Step 1 find fault routine ,so
open fault handle of S150
station
like Fig 16
The signal
‘S150_Station_Fault[3].0’ is
on .so the carcass drum
station become manual and
alarm

Step 2 ‘S150_o_Drive_Logic_Fault’ means there is a

logic fault in S150 station .so the alarm is from EM. We
need find which one it is.
If it is like Fig17. we can get the reason directly. It is
‘ZS_RemoveDrum’ Fig17
Handle Problem in Program -Auto mode
Example without alarm Fig18

Step 3 Find the AOI, in the upper

position of the routine ,then
monitor the tag
‘S150_Drive_Logic_Fault’,
According to Fig 18, we can find
the EM .it is 15001
Then open EM15001 routine
Fig19
Handle Problem in Program -Auto mode
Example without alarm
Fig20
Step 4 Open EM15001
routine ,and do it As MOF mode
Monitor the tag
‘S150_Drive_Diagnosis[1]’

Fig21
Handle Problem in Program -Auto mode
Example without alarm

Step 5 According to
Fig22
Fig22,we find the switch.it is
magnet device return switch

Fig23
Handle motor Problem in Program -Auto mode
Servo and step motor Fig23 Fig24

If servo err we can monitor servo

state in plc ,like Fig23,
Check the motor servo screen is
also a good way ,
Then reference to the AB ‘Kinetix
5700 Servo Drives User Manual’ ,
We can solve the problem step by
step
Handle motor Problem in Program -Auto mode
Servo and step motor Fig25

Step motor is simple , we can

make a diagnosis through indicator
lighter on step motor dirve

Fig26
PART
明年工作计划
04
谢谢观看 敬请指导