I. Product Overview

The device combines the development of China’s industrial electrical automation application technology and device technology, and fully considers practicality and advancement. The device adopts a modular structure. The training hanging boxes include PLC host hanging components, frequency converter components, touch screen components, servo control components, physical control models, analog load hanging boxes and rich verification and demonstration devices. The training content includes PLC basic training, PLC comprehensive training, frequency converter recognition, operation, parameter setting and communication training, touch screen recognition, operation, application training, servo control training, network interface expansion, data collection, data display keyboard control, timer, interface training, etc. The training projects are rich and comprehensive, closely following the development trend of industrial automation.

II. Product Features

1. Modular structure, easy replacement of hanging boxes, convenient for organizing various training projects and expanding new training functions.
2. Suitable for pre-employment and pre-job comprehensive skills training, and suitable for senior workers’ skills training and assessment.
3. Can carry out small engineering project design, equipment selection, installation and commissioning, and operation simulation.
4. Only three-phase four-wire AC power supply is needed to put into use. It has rich training resources and strong comprehensiveness, effectively saving training rooms.
5. High safety. In addition to being equipped with voltage-type and current-type leakage protectors, the device is equipped with overload or short-circuit soft cut-off protection function monitored by a single-chip microcomputer throughout the process to ensure the safety of equipment and personnel.

III. Equipment Features

1. The training construction concept is one-time construction. This equipment adopts a universal wide expansion port. All I/O ports of the host can be led out through the photoelectric isolation transfer module (to protect the host components), which can be used for plug-in training and wire connection practical training.
2. The host is selected from the S7-1200 series PLC, which fully covers the common Siemens PLC types. The host can be connected to the training area through the parallel port for training. The learning concept from simplicity to complexity makes it easy for students to accept and learn more easily.
3. Adopt modular combined structure, including switch quantity, analog quantity, frequency conversion speed regulation, touch screen, communication module, etc., and is equipped with TIA industrial control configuration monitoring software to realize simulated and information-based training teaching.
4. Project training module: Use the current typical programmable controller and bus technology to complete the control of logic, simulation, process, movement, etc. in the simulation objects and physical models of typical cases in industrial production.
5. Understand the structure and characteristics of PLC Ethernet communication, and understand the structure and characteristics of PLC Profibus-DP bus communication;
6. Understand the use method of PLC digital input and output modules and analog input and output modules;
7. Master the basic programming methods of PLC and skillfully use basic programming languages;
8. Master the configuration programming method of touch screen;
9. Master the communication between PLC and frequency converter, touch screen;
10. Skillfully use PLC and various electrical accessories to form a PLC control system;
11. Skillfully use PLC and analog physical control objects to form various complex control systems;
12. Skillfully complete the Ethernet communication test experiment between PLCs;
13. Skillfully complete the frequency conversion debugging control experiment composed of PLC and frequency converter through Profibus-DP bus;
14. Master the use of PLC training teaching course APP software;

IV. Parameter Configuration

1. Electrical Automatic Control Circuit Installation, Commissioning and Maintenance Assessment Device

(1) Equipment Platform

 

Requirements: Equipped with 6 AC contactors and 1 thermal relay.

 

Configuration:

 

1. The main frame of the equipment is built with high-quality 128mm×34mm±1mm industrial aluminum profiles. The equipment layout area adopts a standard mesh plate made of 1.5mm thick high-quality steel plate through CNC machining, and the surface is treated with pickling, phosphating and high-temperature electrostatic spraying;
2. The bottom of the equipment is equipped with wheels, which is convenient for moving and placing the equipment;
3. Dimensions: ≥W1200D700H1800mm;

 

(2) Power Supply Box (can be used independently from the experimental platform)

 

Configuration:

 

1. AC output: Three-phase five-wire AC 380V±10%, single-phase three-wire AC 220±10%. Use automatic air switch to turn on and off the power supply, equipped with short-circuit protection system, leakage protection system, grounding protection and emergency stop protection.
2. DC regulated power supply: DC24V/2A or more, regulation accuracy 1%, with short-circuit soft current limiting and short-circuit self-recovery functions.
3. The power intelligent protector has phase loss, undervoltage, overvoltage, leakage, overcurrent, short circuit, surge protection functions and automatic reclosing function;
4. The leakage protection setting range can be set, and the leakage protection action time is not more than 0.1s;
5. The overvoltage protection range can be set, and the overvoltage protection action time does not exceed 5s;
6. The overcurrent protection range can be set, and the overcurrent protection action time does not exceed 5s; the short-circuit protection circuit is three times the rated circuit, and the overcurrent protection action time does not exceed 0.1s;
7. The protection device has lightning protection function, and no misoperation occurs in the high-voltage pulse test of 2KV between L and N;
8. Fault information can be saved for no less than 999 items;
9. The running state and fault state are indicated by indicator lights, which can display real-time voltage, current, leakage current and other parameters, and have sound and light alarm functions;
10. It has parameter modification and setting buttons to facilitate on-site modification and setting of protection parameters; it can realize remote DI and DO functions, which can be used for remote control of power supply and power control cabinet door opening detection and alarm; the main control device can have an RS485 interface to realize multi-device connection and communication.

 

(3) Control Module I

 

Configuration:

 

1. PLC: Adopt Siemens S7-1200 series host, CPU 1214C, compact CPU, DC/DC/DC, on-board I/O: 14 24V DC digital inputs; 10 24V DC digital outputs; 2 AI 0-10V DC, power supply: DC 20.4-28.8V DC, program/data memory 100 KB; digital expansion I/O 16 DI/16 DO, 16DI/16DO, 16DI 24V DC, sink current/source current, 16DO, relay 2A.
2. Frequency converter: Adopt Siemens G120C frequency converter, equipped with safety integrated STO PROFINET 6DI, 3DO, 2AI, 2AO, maximum 1F-DI PTC/KTY interface, USB and SD/MMC interface, protection grade IP20, light load power: 0.55KW, heavy load power 0.37KW.
3. Servo system: Adopt Siemens V90 series servo controller and servo motor, input voltage: 200-240V single-phase AC -15%/+10% 5.0A/3.0A 45-66, which can realize internal positioning block function, and has pulse position control, speed control and torque control modes.
4. Touch screen: Adopt Siemens KTP700 series touch screen, button/touch operation, 7″ TFT display, 65536 colors, PROFINET interface.
5. Stepper driver module: Two-phase stepper motor driver, which can positively set the current range of 1.0-4.2A, supply voltage DC18-48V, subdivision 1-128, pulse control type.

 

(4) Control Module II (can be used independently from the experimental platform)

 

Configuration:

 

1. Adopt 3mm aluminum alloy cuboid as the main structure, including multiple sets of intermediate relays, indicator lights, buttons and other modules;
2. The control circuit uses spring terminals;

 

(5) Sorting Task Module

 

Configuration:

 

1. Function: Simulate the automatic control of the production line. The frequency converter controls the conveying motor to realize the speed regulation function, and through the detection of optical fiber, photoelectric, metal, RFID and other sensors, the PLC controls the servo, stepping, and various cylinder actions to complete various functions.
2. Structure: The model bottom plate is made of 8mm thick aluminum plate processed and oxidized, with four black cast aluminum handles for easy handling. Above the bottom plate, there are annular conveyor belts, pneumatic manipulators, handling gantry frames, sorting mechanisms, frequency conversion motors, servo motors, stepping motors, various sensors and cylinders.
3. Main components:

1. Three-phase AC deceleration motor
   1. Rated voltage: 380V
   2. Power: 25W
   3. Reduction ratio: 1:50
   4. Incremental encoder TTL: 2500 increments/revolution
   5. Protection grade: IP65
2. Stepping motor
   1. Rated voltage: 3V
   2. Rated current: 2A
   3. Step angle: 1.8°
   4. Motor length: 49mm
   5. Holding torque: 0.48N.m
   6. Number of motor wires: 4 wires
   7. Step accuracy: 5%
   8. Insulation resistance: 100MΩ Min 500VDC
   9. Withstand voltage: 500V AC for 1 minute
   10. Radial runout: maximum 0.02mm (450g load)
   11. Axial runout: maximum 0.08mm (450g load)

• Industrial RFID reader
  1. Can support up to 1.5W radio frequency power;
  2. Sensing distance up to 20cm
  3. Overall length: 82mm;
  4. Front end diameter: 32mm;
  5. Adjustment distance outer diameter: 35/38mm;
  6. Wire length: 1500mm;

 

(6) Linear Motion Module

 

This device can be optionally equipped with a linear motion module for teaching the linear and positioning control of the motor. The module is divided into two parts: the transmission mechanism and the transmission motor. There are multiple configurations available for this module.

 

Transmission type: belt drive, screw drive. “Motor type: servo motor.

 

Training projects:

 

• Motor inching motion control
• Motor cycle motion control
• Motor positioning motion control

 

(7) Motor Group Module

 

Configuration:

 

1. Including stepping motor, servo motor, AC motor

 

Equipment Structure:
The training device stand is of metal structure. The I/O terminals of the PLC module of the training assessment device and the connection terminals between each common module and the PLC are all connected with safety sockets, and wires with safety plugs are used for circuit connection; the circuits of each command switch, photoelectric switch, sensor and indicator element are connected through terminal blocks. The combination of plug-in wire connection circuit and terminal connection circuit not only ensures the training, formation and consolidation of students’ basic skills, but also ensures the rapidity, safety and reliability of circuit connection.

 

Equipment Features:
① Manual/automatic control mode, for hardware detection and program verification.
② The open executive agency can be programmed according to different control schemes to form different executive systems, which is suitable for people at different levels to learn and program PLC. It can also be used for project design or research.
③ The product is open, and the overall mechanical structure is clearly visible.

 

(10) Computer Desk

 

Configuration:

 

1. Function: Industrial aluminum profile frame structure, single station, with computer host position and keyboard bracket, used to place programming computers.
2. Dimensions: not less than L600mm×W700mm×H780mm.
3. Desk body: The bottom of the desk body is equipped with universal wheels with brakes, which is convenient for moving and fixing.

 

(12) Main Assessment Content of Electrical Automatic Control Circuit Installation, Commissioning and Maintenance Assessment Device

 

Configuration:

 

1. Main assessment content:
   (1) Engineering creation, editing and downloading operation of touch screen;
   (2) Offline simulation application of touch screen;
   (3) Application of animation elements of touch screen;
   (4) Application of numerical value and text input display elements of touch screen;
   (5) Comprehensive application of touch screen system;
   (6) Wiring and debugging of stepping motor driver;
   (7) Parameter setting of stepping motor driver;
   (8) Pulse positioning control between stepping motor driver and PLC;
   (9) Wiring and debugging of servo motor driver;
   (10) Parameter setting of servo motor driver;
   (11) Pulse positioning control between servo motor driver and PLC;
   (12) Communication positioning control between servo motor driver and PLC;
   (13) PLC and RFID communication reading and writing programming debugging;
   (14) Wiring and debugging of frequency converter control motor;
   (15) Parameter setting of frequency converter;
   (17) PLC and frequency converter communication operation;
   (18) Wiring and debugging of sorting task model;
   (19) Design of operation control program for sorting task model;
   (20) Comprehensive application training of PLC, touch screen, frequency converter and servo system;
   (21) Check the composition of the double closed-loop DC speed regulation system, debug and analyze the double closed-loop DC speed regulation system;

 

(14) Tools and Instruments

 

Configuration:

 

1. Supporting equipment
   (1) Special screwdriver: used with spring terminals, 1 piece;
   (2) Large dual-purpose screwdriver, 6 inches, 1 piece;
   (3) Small dual-purpose screwdriver, 1 piece;
   (4) Ratchet cold-pressed terminal clamp, 1 piece;
   (5) Hexagon socket, medium long rod, 9-piece set, 1 set;
   (6) Stripping pliers, 6 inches, 1 piece;
   (7) Needle-nose pliers, 6 inches, 1 piece;
   (8) Toolbox, 10 inches, 1 piece;
   (9) Multimeter, UT39A+, 1 piece;
   (10) Safety helmet, thickened type, 1 piece;
   (11) Pay-off device, 5 kinds of wires, 1 set;
   (12) Bench vice, the width of the bench vice mouth should be greater than 75mm (cannot be installed by drilling), 1 piece;
   (13) Small air compressor, 24L-750W, 1 set;
   (14) Supporting wires, air pipes and connecting accessories, provided according to actual needs;