1785-TAM

1785-TAM
1785-TAM
1785-TAM


数控机床作为一种柔性的、能的自动化机床，很好地解决了复杂、精密、小批量和多品种的零件加工问题。随着数控机床设备在工业的广泛应用，其运行的性也显得愈发重要，的数控机床设备可以有效保护操作人员的人身，避免设备的频繁故障，提高企业的生产力水平。
　　为了提高设备的等级，某动力公司位于的生产基地于2012 年启动了设备防护改造工程，希望通过对机械加工设备的升级改造，避免由于设备功能的缺失或不完善可能导致的隐患，满足长远的 EHS目标，进一步提升企业的市场竞争优势。
　　先让们看看这家改造企业的背景：
　　该公司是一家多元化的动力管理公司，其生产的电力、流体动力和机械动力产品广泛应用于建筑、飞机、卡车、汽车、机械以及各种商业设施，年销售额超过200亿美元。此次改造的工厂是其位于的28个制造基地之一，主要生产各种液压弯头、接头和管件等产品。
　　三重挑战，如何个个击破?
　　本次整改项目共涉及65台套设备的机器改造，其中难度的是20台 MAZAK数控机床的系统改造。
　　先，作为企业生产的核心设备， MAZAK数控机床的改造方案稳妥，只可成功，不可失败。此外，MAZAK数控机床设备的使用率，设备每天工作16个小时，每小时开门20次，一年总计11.2 万次的开门次数，这要求所用方案可靠和耐久，可以耐长期高负荷的运行条件。
　　令企业头痛的是，原设备的PLC 系统代码被保护，由于不能获得原设备 PLC的代码，改造时无法对设备做内部改变，但同时又要满足数控系统机器的防护要求，新方案需要一个创新的设计思路。
　　总结来说，此次升级改造需要的不仅仅是系列产品，而是一个针对现有数控机床特点而设计的、完整的定制化解决方案。
　　好产品 ， 更要有好的解决方案!
　　凭借在美同类项目的成功应用经验，以及遍布各地的专业而快速的销售和执行队伍，罗克韦尔自动化针对工厂现有设备的具体情况，为其量身定制了系统升级方案。
　　改造前，数控机床设备的均采用单回路形式，改造目标是实现级别category 3。
　　先，罗克韦尔自动化的项目实施团队反复多次和工厂多个部门讨论，查找资料，吃透原机器结构和控制原理，熟悉机器的各种状态，包括：设置、数控编程、运行(手动和自动)、小批次和大批量、维护和调试状态等，新改造方案考虑上述各个方面。
　　在充分了解设备情况后，实施团队严格遵循机器标准(ISO 13849 和 IEC 62061)，增加防护系统并嵌入到现有系统中运行。
　　整体逻辑图如图1所示，新系统按照SIL 3标准来设计，新旧系统独立而又并列运行，而且并行的输入、串行的输出将新系统和旧系统的措施有机结合起来，这种冗余的结构设计是方案的一大亮点，保证了系统的稳定运行。
　　为保证改造方案的化，本次改造采用原型机试制和批量生产的方式。改造前，这些数控机床设备就在长期高负荷地运行，所以改造方案满足苛刻的运行条件，不适宜一开始就批量改造，所以用19号机器先行改造，运行2个月后，针对效果提出进一步改进措施，而后全部用更新后的方案批量改造。
　　机器的耐久和稳定运行是本次改造的重要目标，为达成该目标，除了采用冗余的系统架构外，实施团队还采取了一系列的措施，包括：浮动推拉门、防震设计、通风防尘设计和备用回退选项等。


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103S-EWD3-DC25C 18 - 25 A MCS Starter & Circuit Breaker
140M-C2E-C16-XL 140M Circuit Breaker
9358-MTRCK02U1R UPGRADE: OUT-SUPT: RSBW MATERIALTRACK 1 TO 03
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Allen Veiw MMI Model M1100
1762-RPLDIN2 REPLACEMENT DIN LATCHES FOR 1762 I/O
1492-ACABLE035Z Analog Cable Wiring System
9301-2SE3103ESE RSVIEW32 RUNTIME 150 WITH RSLINX (SPANISH)
20AD4A3AYNANG1 PowerFlex 70 3.4 A at 2 Hp AC Drive
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1494C-DN100-A3-B1-D 100A Cable Operated Disconnect Kit
1609-SDK1 1609 DIN Rail Kit UPS Accessory
1492-MS6X12H11-20 Wiring System 6mm x 12mm 80 Mkrs/Crd
1321-RWR55-EP Reflective We Reduction Device
100-3ZP00 43 A 100-C contactor
140M-J8P-D17-XN MOTOR CIRCUIT PROTECTOR
140M-C2E-B10-XC MOTOR PROTECTION CIRCUIT BREAKER
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107S-AWD3-DB40X-KN 2.5 - 4 A Reversing Starter & Breaker
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1492-81536-10 POLE CENTER JUMPER
109-C30FDXXX Non-Reversing Starter
1492-EF3 End Barrier
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20BD180A3AYNAEC1 PowerFlex 700 180 A 150 Hp AC Drive
1497-L-CXSX-0-N Control Circuit Transformer
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1109-BON-EEJ VAC STARTER 200A W/E10LR
1492-MS6X12H31-40 Wiring System 6mm x 12mm 80 Mkrs/Crd
2100-APP-CD LVMCC Documentation for 2100-APP-CD L
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1489-A3C020 UL489 MINI CIRCUIT BIEC60947-2 MINI CIRC
1497-A-CCJX-3-N Control Circuit Transformer
20AD027A3AYYAEC0 PowerFlex 70 27 A 20 Hp AC Drive
109-C16FDE1R-3-4R-901 Non-Reversing Starter
190S-DND2-DC16C-KY 10 - 16 A 190S Compact Comb Starter w/CB
1485T-P1E4-C1F-M4 KWIKLINK PWR DROP, MINI
103T-ASJ2-RB40D-C2A-KN-TE IEC Combination Starter
2090-CPWM7DF-14AF07 MP-Series 7 m Length Power Cable
103S-FTZJ2-FC32B-SP 23 - 32 A MCS Starter & Circuit Breaker
1102C-PK4N REPLACEMENT COIL ASSY FORVACUUM CONTACTR
2090-XXTFMP-S04 MP-Series 4 m Length Feedback Cable
1494V-DR622-C-D-E 200A Variable-Depth Disconnect Kit
1769-OV16 16 POINT 24 VDC SINKING OUTPUT MODULE
1321-3RA1-C 1321 Power Component 1 A Line Reactor
20AD2P1A3AYNAEC1 PowerFlex 70 2.1 A 1 Hp AC Drive
1494GY-BF3N-98-414 NEMA 30A Enclosed Disconnect
1494G-CF3N-412 NEMA 60A Enclosed Disconnect
190S-AND2-CC10C-S11 190S Compact Comb Starter w/CB
1585J-M4UBJM-78 RJ45 Ethernet Media
20DD500B0ENNBDANK 500 A 450 Hp AC Drive
1492-CABLE040Q Digital Cable Wiring System
9324-RLD25U6ITE RSLOGIX 5000 LITE ITALIAN TO FULL UPGRADE
23B-D024DF04NN-P3T-S7-S18 23B AC Packaged Drive
Beckhoff KL1702 4 channel 120-230VAC input module
100-DS1-11 Contactor Auxiliary Contact Block
191S-AND3-CB10C-KY 191S Rev. Compact Starter w/CB
1485C-F30W5-N5 DeviceNet Physical Media
20G11TC910AN0NNNNN PowerFlex 755
2090-CPBM4DF-10AF90 MP-Series 90 m Length Cable
20DD8P0A3EYNANGNE PowerFlex 700S 8 A 5 Hp AC Drive
1732D-IB8M12 DEVICENET 24VDC 8 INPUT W/M12
1492-F3RE TERMINAL BLOCK 300V MAX
1492-CABLE080WH Digital Cable Wiring System
ALLEN BRADLEY 6181P-17TSXPHX INDUSTRIAL COMPUTER INTERFACE MODULE XLNT
140U-J6L3-D10-F J frame molded case circuit-breaker
1492-M6X12VU291-300 1492-M6x12 marker card Wiring System
150-C85FBD-3-4R-6P NEMA 85A 150 Motor Controller
21T-179615-905-3ZB LiquiFlo 2.0 Carrier Corp 608 A AC Drive
100-D630EB11 MCS Contactor
194R-F25-FC 25A NFC Fuse Carrier Rotary Disconnect
23B-D012D104NN 23B AC Packaged Drive
104S-C09KD210BC 9A MCS Safety Reversing Contactor
100-D115H11 115 A Contactor
20DC8P7A0EYYANBNE PowerFlex 700S 8.7 A 4 kW AC Drive
194E-KA63EX-P11-PE-6 Load Switch
ABM SBOKH/3.DF56 8-4S7167SBOKH​3DF5684S7167S​BORH/3.DF5630​68762001
1485R-P6N5-F5 DeviceNet Physical Media
1494GX-BF3J6-1S-203W-420 NEMA 30A Enclosed Disconnect
5150-RS 5150-MRS SERIES A 1 YEAR WARANTY
1492-HWACAB055UB Honeywell Analog Cable Wiring System
1494C-DRX666-A3 60A Cable Operated Disconnect Kit
190S-ANDJ2-CB16S-KN 1 - 1.6 A 190S Compact Comb Starter w/CB
Allen Bradley Panelview 1000e 2711E-K10C6 A 2711EK10C6 A Operator Panel
21G1ALD710AN0NNNNN-HD-P3 PowerFlex Air Cooled 755 Packaged Drive
2090-SCEP1-0 Kinetix 1-1 m Length Fiber Optic Cable
1497A-A6-M19-1-N MACHINE TOOL TRANSFORMER
103S-DSZJ2-CB63C-KY 4 - 6.3 A MCS Starter & Circuit Breaker
152H-3FBD-45-1-6P Controller w/Fusible Disconn Enclosed Mo
1492-CJLJ5-10-BL 1492 CENTER JUMPER-BLACK
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1336-BDB-KONE 1336 Kit
100S-C85UA14C 85 A MCS Safety Contactor
1232X-DNA-6P-26R NEMA Pump Panel,Extra space,DS Type
32R1783-Nortel 10 Gigabit Uplink Ethernet Switch Module
103T-DWD2-RB40C-E1D-KY-SP IEC Combination Starter
107S-AWZJ3-CB10C 0.63 - 1 A Reversing Starter & Breaker
194L-HE6A-551 IEC CONTROL AND LOAD SW ACTUATOR, TYPE A
1585D-M4UBDM-40 Ethernet Media M12 Patchord
194E-FA32EX-PE-P11-6 Load Switch
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1790D-T8BV8V DNET LDX 24VDC,8 UNIV IN/8 SINK OUT BASE, TERM BLK
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9399-RSBVWUG RSBATCH VIEW USER'S GUIDE
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20DD022A3EYNA1DNL PowerFlex 700S 22 A 15 Hp AC Drive
100S-C85VA14C 85 A MCS Safety Contactor
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140M-C2E-A25-TE PROTECTOR,MOTOR 1600 AMP MAX
2711P-T7C6D1 PV PLUS 700, TOUCH, RIO/DH, DC PS, STD MEM INCL RIO, DH+, DH-485, RS232, ETHERNET, USB
20BE6P1A3AYNANC1 PowerFlex 700 6.1 A 5 Hp AC Drive
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2090-CFBM4DF-CDAF20 MP-Series 20 m Length Feedback Cable
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1769-IM12 12 POINT 240 VAC INPUT MODULE
1492-CABLE005S Digital Cable Wiring System
1747-L40C 40 I/O FIXED HARDWARE STYLE (24) DC SINK IN WITH HSC & (16) RELAY OUT, AC LINE POWER
1494G-DF3R6-988 NEMA 100A Enclosed Disconnect
100S-C12KD32C 12 A MCS Safety Contactor
100-A75N3 Ser C Allen Bradley AB CONTACTOR 100A75N 3
Allen Bradley Versiew Industrial Monitor 6186M-12PT Sealed 2010
1492-CAB050C62 Digital Cable Wiring System
194L-HE8I-175 IEC CONTROL AND LOAD SW ACTUATOR TYPE I
103T-AWDJ2-RB63C-D1C Combination Starter
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140U-J3D3-D20-QD J frame molded case circuit-breaker
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1321-3RA600-A 1321 Power Component 600 A Line Reactor
190S-CNP2-DC16C-KN 10 - 16 A 190S Compact Comb Starter w/CB
20DD730ACENNBCASE 730 A 600 Hp AC Drive
1492-SP3B300-N SUPP. PROTECTOR MINI CIRCUIT BREAKER
107T-ASJ3-QB10D-E1B-KN-TE Rev. Combination Starter
9306-4EXP01ENR SUPT REINSTATEMENT CONTRACT FOR 93064EXP01ENE DRIVEEXPLORER (VERSION 2.XX) SOFTWARE
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107T-AWD3-RC10B-C2B-KY Rev. Combination Starter
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20AD2P1A3AYNNNG1 PowerFlex 70 2.1 A 1 Hp AC Drive
190S-ANEJ1-CB63C 4 - 6.3 A 190S Compact Comb Starter w/CB
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190E-AND1-CB25C 1.6 - 2.5 A 190E Eco Starter with CB
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140M-F8T-C25-KY-MT MOTOR PROTECTION CIRCUIT BREAKER
150-C317NBR SMC-3 SOLID STATE MOTOR
190S-CND1-DC16C-KN 10 - 16 A 190S Compact Comb Starter w/CB
190S-FNKD3-FC32C 23 - 32 A 190S Compact Comb Starter w/CB
2090-XXNPMF-16S30 MP-Series 30 m Length Cable
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140U-K-OHE Operating Circuit-Breaker Accessory
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141A-VU3300R Supply Module
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103S-ATD2-CB25C-KN MCS Starter & Circuit Breaker
100-D95X11 95 A Contactor
140M-I8R-D15S-XCM 150 A Molded Case Circuit-Breaker
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1585D-E4UBDE-60 Ethernet Media M12, Patchcord
1746-A10 10 SLOT CHASSIS-MODULAR HARDWARE STYLE
2706-D21J8 ALLEN BRADLEY
2090-CPBM4DF-16AF03 MP-Series 3 m Length Pwr and Brake Cable
2090-XXNFY-S01 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,1M
190S-DND2-DC25C-R-TE 18 - 25 A 190S Compact Comb Starter w/CB
Allen-Bradley Panelview 1200 Operator Interface 2711-KC1
20DC385N0ENNBCCNK 385 A 200 kW AC Drive
6189V-CPUPFM1 PERFORMANCE SBC (W/CPU AND COOLER) (1500W)
20G11ND5P0AA0NNNNN PowerFlex 755 AC Drive
Analog Devices RTI-1225 Circuit Board Input Output I/O Card Processor
1798-APB PROFIBUS DP ADAPTER
20AD4A3AYYACC0 PowerFlex 70 3.4 A 2 Hp AC Drive
100S-C30EJ22C 30 A MCS Safety Contactor
100-C30KL10 30 A 100-C contactor
1734-OE2V POINT I/O 2 Point Output Module
20BD040A0AYNADD0 PowerFlex 700 40 A 30 Hp AC Drive
N-2302-1-F00AA MOTOR,NEMA 23,2 LB-IN,6000 RPM
Allen-Bradley 1771-OYL Reed Relay Contact Output Module - ATS 365 Warranty
20DD011A0EYNAEANE PowerFlex 700S 11 A 7.5 Hp AC Drive
103S-DTZJ2-CC25C 18 - 25 A MCS Starter & Circuit Breaker
1734-OE2C 24V DC 2 CHANNEL ANALOG CURRENT OUTPUT MODULE
2090-XXNPMP-16S02 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,2M
20BD248A3AYNACB0 PowerFlex 700 248 A 200 Hp AC Drive
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20DD077A0EYNANASE PowerFlex 700S 77 A 60 Hp AC Drive
103S-CWD3-CB25C-KY-V MCS Starter & Circuit Breaker
9355-WABOEMDEE RSLINX OEM - GERMAN
ALLEN BRADLEY 1771-IQ DC SELECTABLE INPUT MODULE
109-C16ADE1D-7 Non-Reversing Starter
100-DHF180 IEC Renewal Terminal Hardware