可編程控制器簡稱為PLC，其以豐富的I/O接口模塊、高可靠性和強(qiáng)抗干攏能力廣泛應(yīng)用于工業(yè)自動(dòng)化控制。筆者曾參與我公司多項(xiàng)PLC控制系統(tǒng)的安裝、調(diào)試工作。因此，經(jīng)過對我公司多項(xiàng)工程的實(shí)踐與分析，篩選個(gè)別較具有代表性的例子，結(jié)合筆者多年的電氣維修、安裝及調(diào)試經(jīng)驗(yàn)，就PLC控制系統(tǒng)的設(shè)計(jì)提出若干意見，供同行參考。

1設(shè)計(jì)應(yīng)從小事著手，切實(shí)解決問題

　　1）PLC控制系統(tǒng)作為一個(gè)系統(tǒng)工程，設(shè)計(jì)時(shí)不能過分依靠PLC本體，使用外部繼電器能夠完成控制要求的，應(yīng)使用外部繼電器，例如時(shí)間繼電器控制。我公司水泥粉磨系統(tǒng)中細(xì)碎機(jī)及收塵風(fēng)機(jī)采用的是自藕降壓起動(dòng)，由于設(shè)計(jì)時(shí)取消外部時(shí)間繼電器，采用起動(dòng)信號直接輸入PLC，經(jīng)PLC內(nèi)部計(jì)時(shí)器輸出運(yùn)行信號，由于起動(dòng)時(shí)間難于精確確定及負(fù)荷變化將引起起動(dòng)時(shí)間變化，要想調(diào)整起動(dòng)時(shí)間較為困難（需要具備PLC編程知識及相關(guān)編程工具，一般用戶或電工不具備條件）。因此，采用PLC內(nèi)部計(jì)時(shí)器作為起動(dòng)時(shí)間控制，顯得頗費(fèi)周章，也不利于現(xiàn)場控制及日后維護(hù)。

　　2）在順序及聯(lián)鎖控制中，涉及平行并聯(lián)關(guān)系的機(jī)號，要考慮操作的便利，讓PLC能自動(dòng)選擇運(yùn)行機(jī)號，方便設(shè)備在運(yùn)行過程中能選擇其它設(shè)備運(yùn)行。如圖1（a）所示，聯(lián)鎖關(guān)系為四級。前兩級中有并列選擇運(yùn)行的機(jī)號（M1、M2和M3、M4、M5），能否自動(dòng)選擇需要運(yùn)行的設(shè)備，就顯得很重要。如何能實(shí)現(xiàn)自動(dòng)選擇呢？

將轉(zhuǎn)換開關(guān)SA撥到集中控制時(shí)，KA1吸合給PLC一個(gè)信號，讓PLC識別該臺機(jī)號需要運(yùn)行，而沒有選擇集中控制的機(jī)號則認(rèn)為暫時(shí)不運(yùn)行。

　　3）PLC程序設(shè)計(jì)要注意“防競爭”的處理，特別是在油站系統(tǒng)中主/備泵的啟動(dòng)。其主/備啟動(dòng)要求是：先啟動(dòng)主泵，幾秒后油壓無法達(dá)到設(shè)定值時(shí)，再啟動(dòng)備用泵；或者是主泵跳閘后，必須立即啟動(dòng)備用泵。如圖2所示：M2為防競爭處理，時(shí)間設(shè)為2s，即主泵啟動(dòng)2s后，油壓不能達(dá)到設(shè)定值時(shí)，備用泵啟動(dòng)，油壓夠后停止工作。（M2梯形圖及X003、X004防抖處理略）

AMAT Applied Materials 300mm XP Degas Reflector 0020-25373 new

Pentagon Technologies PT-0143-0011 RF Shield Endura 8" PVD New

AMAT Applied Materials 3060-00275 Vinton Sealed Ball Bearings Lot of 16 New

AMAT Applied Materials 0100-01765 I/O Interface Board Rev. 002 Used Working

AMAT Exhaust Temp Warning Retrofit Kit 170-10818-00 New

AMAT Applied Materials 0041-48869 Orienter Mount Plate New

AMAT Applied Materials 0100-90710 Vacuum Gauge Interface Board Rev.D working

AMAT Applied Materials 670794 Prom Board Used Working

KLA-Tencor 11102207 Basic Module PCB Assembly AMAT 0660-00786 Used

Daikin DUA19DNN01 Perfluoro Elastomer Seal O-Ring AMAT 3700-03715 Lot of 9 New

Infranor MH0606 P43 Servo Amplifier Drive Board Used Working

MKS Instruments AS00348-02 eDiagnostics System Interface Blue Box 4000x working

AMAT XR80 0100-01032 Vacuum Control Interlock Board Used Working

AMAT XR80 0100-01033 Rev. A Vacuum Control Interlock Board Used Working

AMAT Applied Materials 0100-90773 Rev. E Wafer Arm Servo Board Used Working

AMAT Optical Sensor Assy. 0190-03567 untested

Festo 214329-B Bilz Air Supply Box AMAT 0190-A8790 New

AMAT Applied Materials 0242-25144 7-Emitter Ionizer Bar Kit New

AMAT Applied Materials 0190-14224 Flex Distribution Panel Assembly new

Applied Materials AMAT 672544 Prom Board Used Working

Applied Materials AMAT RAM Memory Board 672532 Rev. C Used Working

AMAT Applied Materials 0030-76002 P5000 Mark II Front Cassette Bezel

AMAT Applied Materials 0100-09175 Interlock Board TEOS P5000 Precision 5000

AMAT Applied Materials 0040-79668 Wafer Carrier Used Working

AMAT Applied Materials 0041-33021 300mm HHXP Robot Axis-0 Magnet Hub new

AMAT Applied Materials 0100-90724 Rev. C Guiding Tube Board Used Working

AMAT Applied Materials 0200-40112 E-C 200mm Quartz Cover new

AMAT Applied Materials Quartz Chamber Slit Valve Insert 0200-40091 New

ETO ABX-X355 RF Generator Control PCB Rev. H Used Working

ETO ABX-X355 RF Generator Controller Board Rev. A Used Working

ETO ABX-X355 RF Generator Control PCB Used Working

Applied Materials AMAT 0010-35775 Actuator Assembly Kit New

Applied Materials AMAT 0200-09222 External Quartz Ring 8" New

AMAT 0100-90560 Rev. C Vacuum Control Interlock Board Used Working XR80

AMAT Applied Materials 0100-91085 Guiding Tube PCB Issue E XR80 Used Working

AMAT 0090-91594 Power Supply Module Board Used Working XR80

AMAT XR80 Applied Materials 0090-91271 Power Supply Rev.A working

AMAT Lower Preclean Shield 0040-61580 300mm New

AMAT 0100-00505 Vacuum Control Feedback Board Used Working XR80

Applied Materials AMAT 0200-00157-P1 Top ring 125MM New

AMAT Applied Materials 0020-40569 Conversion Plate Robot New

Applied Materials AMAT Cryo Port Bias Match Bracket 0021-41596 New

AMAT Applied Materials 0010-26750 Slit Valve Door new

AMAT O-Ring 15.955 x .275 Viton 3700-01482 Lot of 7 New

Applied Materials AMAT 300mm Chamber Controller Cover Kit 0240-30959 New

AMAT Applied Materials BES-9175-36C 50ft High Temp Chiller Hose DPS II New

AMAT Applied Materials 0100-90881 Vacuum Interlock Board Rev.B XR80 working

AMAT Applied Materials 0100-90880 Turbopump Interface Board Rev.A XR80 working

Applied Materials 25' KVM Harness Assembly 0140-14384 Lot of 3 New

AMAT XR80 0100-00505 Rev. A Vacuum Control Feedback Board Used Working

AMAT Applied Materials 0100-91082 XR80 Sensors Board Rev. D Used Working

AMAT Applied Materials XR80 X-Y Displacement & Splitter Box 0090-91586 Rev.C

AMAT Applied Materials 0020-41086 Centura Power Supply 0020-41218 working

AMAT 0100-90859 Rev. B I/V Converter Power Supply Board Used Working XR80

Applied Materials AMAT 0100-90861 Spin Scan Detector Board Used Working XR-80

Applied Materials AMAT 0100-90650 Wheel Current Board Used Working XR80

AMAT Applied Materials 0100-90071 Cryo Pump Temp Monitor Board Used Working XR80

AMAT 0100-00504 Vacuum Control Feedback Board Used Working XR80

Applied Materials AMAT 0100-90286 Beam Profiler Interface Board Working XR80

Applied Materials AMAT 0100-01366 Vibration Monitor Board Used Working XR80

Applied Materials AMAT 0020-81224 Arc Chamber New

AMAT 300mm Internal Membrane Clamp 0021-17972

AMAT Applied Materials 0190-33337 Heater Jacket Gemini Used Working

AMAT Applied Materials 10762200 75FT RF Cable 0620-02771 New

AMAT Applied Materials 0100-09134 DIO Fuse Board Rev. B Working P5000 Lot of 4

Opal 13811 Power Relay Board AMAT Applied Materials SEMVision Used Working

Opal SMC/M-Vacuum PCB Board 70317875200 Working AMAT SEMVision

MFD-1307 Applied Materials 75 FT DC Cable AMAT 0190-01559 New

D-Link DES-3528 28-Port Managed Switch xStack AMAT 0190-37330 New

AMAT Applied Materials PVD 6" Process Kit 0020-28064

Applied Materials AMAT Circuit Breaker 0680-01826 0680-02131 Lot of 2 New

Applied Materials AMAT Encore Feedthrough Insulator Pair 0200-02121 Lot of 2 New

Applied Materials AMAT SCR CAP SKT HD 6/32x 1/4L Hex 0021-08063 Lot of 24 New

Applied Materials AMAT Non-Seismic Securement Kit for 300mm 0240-52481 New

AMAT Endura 300mm Chamber Harness Assy 0140-06222 New

AMAT C/A Mainframe Interlock Main Cable 0150-04722 New

Applied Materials AMAT 75' DC Cable 0150-13757 New

AMAT Applied Materials 0100-01875 AC Distribution Board Used Working

AMAT Plate Blocker Assy. 150mm 0020-09316 new

AMAT PVD Robot Umbilica Harness Assy 0140-01893 New

AMAT MF to XFR Robot Harness Assembly 0140-76569 New

AMAT ORing ID: 9.984 CSD: .210 Lot of 12 3700-03048 New

AMAT Applied Materials 0100-18058 TC AMP INTLK Ultima PCB Assembly New

AMAT Applied Materials 0100-00313 Quantum Loadport Controller PCB Used Working

AMAT Applied Materials 0020-87128 300mm Tray Dome Controller new

AMAT Applied Materials 300mm PVD Chamber Cryo-Shield 0021-16035 new

AMAT Applied Materials 4200689 Air Manifold Assembly Used Working

AMAT Applied Materials 0010-51957 Water Manifold Assembly New Surplus

AMAT Applied Materials 0010-51957 Water Manifold Assembly 90° New Surplus

AMAT Applied Materials 0041-33571 DIW Distribution Manifold ECSA LDM New

AMAT Applied Materials 0041-34170 DIW Distribution Manifold ECSA LDM New

AMAT Applied Materials 1843623012 AC Servo Motor XBR-2310 AMAT 0010-70836 Used

AMAT Applied Materials 7-213729 AC Servo Motor XBR-2310 AMAT 0010-70836 Working

AMAT Applied Materials 3060-00835 Ball Bearing lot of 416 new

Applied Materials AMAT XR80 0100-90650 Rev. B Wheel Current Board Used Working

AMAT XR80 0100-90071 Rev. Y Cryo Pump Temp Monitor Board Used Working

AMAT Applied Materials 0100-90286 Beam Profiler Interface XR80 Used Working

AMAT Applied Materials XR80 Vacuum Control Feedback 0100-00504 Rev.A working

Applied Materials AMAT XR80 Arc Voltage Control Board 0100-90930 Used Working

Applied Materials AMAT XR80 0100-94006 Rev. A Spin Controller Board Used Working

AMAT XR80 Implanter Logic Board 0100-90875 working

AMAT Applied Materials 1843623012 AC Servo Motor XBR-2310 AMAT 0010-03907 Used

AMAT Applied Materials 221-7428E0 Spring Bellow Assembly WDX AMAT 0190-A9530 New

AMAT Applied Materials 0021-81146 300mm HDPCVD Telfon 18" Dome Ring new

AMAT Applied Materials 0021-34715 Low 300mm Cathode Liner new

Applied Materials AMAT Clip Silicon Sprayed 0040-96525 New

AMAT 0100-94006 Spin Controller Board Used Working XR80

AMAT 0100-94097 Rev. B Vibration Used Working XR80

AMAT 0100-90973 Rev. A Orienter Interlock Board Used Working XR80

AMAT 0100-91095 Rev. A Pneumatics Control Board Used Working XR80

AMAT Applied Materials Mainframe Interlock Cable 0150-04722 new

AMAT Applied Materials Network Module 9090-00491

AMAT Endura 6" PVD Process Kit 84-9502-280 in Keal Case

Applied Materials AMAT 0100-40027 Inverter Board Used Working XR80

Applied Materials AMAT 0100-90443 Spin Window Board Used Working XR80

Applied Materials AMAT 0100-90890 Spin/Scan INTLK Board Used Working XR80

AMAT 0100-90706 Rev. B Vacuum Manual Control Board Used Working XR80

Applied Materials AMAT 0200-09473-B Clamp Ring New

Applied Materials AMAT 0020-04277 Flange New

Applied Materials AMAT 0020-30700 Insert Polysulfone 125MM New

Applied Materials AMAT 0020-31488 Gas Distribution Plate New

AMAT Applied Materials 0190-76252 DeviceNet I/O Block DIP294 Used Working

MFD-3006 Applied Materials 50 FT DC Cable AMAT 0190-01560 New

AMAT XR80 0100-94102ITL Pressure Override PCB Board 0100-94102 working

AMAT Applied Materials A.C. Window Control 0090-00045

Applied Materials AMAT CONN ADPTR PNL MTG QDS-F/M 0720-04376 Lot of 7 New

AMAT Applied Materials 0200-08583 300mm PCII 2.0 Quartz Long Bushings lot of 18

AMAT Applied Materials 0242-18504 300mm PCII Adapter Installation Kit New

AMAT Applied Materials 0040-75563 Load Lock Roughing Manifold Used Working

AMAT Applied Materials 0021-15605 300mm Upper Shield Exhaust new

AMAT Applied Materials 0240-17388 Asst Dual RF/IF Tag Reader Kit New

AMAT FTG Vacuum Full Nipple NW25 Lot 3300-09057 new

Siemens Schmidbauer Transformer Pair AMAT XR80

AMAT Applied Materials XR80 Spin Window Card 0100-00970 Rev.A working

AMAT Applied Materials XR80 Switch Box 0010-91458 Rev.B working

AMAT Exhaust Ball Valve Wldmnt 210-17948-00 New

AMAT Applied Materials 0190-36511 DeviceNet I/O Block DIP294 Used Working

AMAT 0100-91040 Rev. D Vacuum Manual Control Board Used Working XR80

AMAT Applied Materials 3930-00256 IR Controller Box lot of 2 new

Applied Materials AMAT 0100-90177 Rev.C Vacuum Control Drive Board Working XR80

AMAT 0100-90178 Rev. J Vacuum Control Feedback Board Used Working XR80

Applied Materials AMAT 0200-00043 Quartz Ring New

Applied Materials AMAT 0200-09217 Quartz Ring 200MM New

Applied Materials AMAT 0200-36711-P1 Silicon Insert Ring 125MM New

Applied Materials AMAT 0020-82818 Aperture Plate New

Applied Materials AMAT 0020-98947 Electrode EH1 New

Applied Materials AMAT 0010-99166 Moving Clip New

AMAT 25 lb Weight Kit 0240-16987 300mm rebuilt

AMAT 300mm Retaining Ring, Grooved 0040-84056 new

AMAT Applied Materials 9321-02 DeviceNet Passive Drop Box 0190-16372 Lot of 3

Nemic-Lambda RWS30A-5 Power Supply YM-95-774 Used Working

AMAT Applied Materials DIP294-2 DeviceNet I/O Block 9090-00273 Working

AMAT Applied Materials 0100-01363 Signal Conditioning Board Producer SE Working

AMAT Applied Materials 0242-70297 Standard Insert Kit New Surplus

AMAT Applied Materials 0050-88513 Gas Lines 0050-88929 lot of 5 0050-88928 new

Applied Materials AMAT 300mm PCII Ceramic Pin Pedestal 0200-01904 Lot of 6 New

AMAT Applied Materials 0190-25467 Electric Lift 100lbs working

AMAT Applied Materials 0021-12855 300mm Housing Quartz Tube lot of 2 new

AMAT Applied Materials 0242-20638 300mm PVD Water Hardline Kit new

Applied Materials AMAT XP Robot ATM Inner Clamp 0040-83305 New

Applied Materials AMAT Endura 300mm Floor Exhaust Duct Manifold 0040-78134 New

Applied Materials AMAT Gas Line Extender 3/8" OD 300mm 0050-60372 New

Applied Materials AMAT PCII Pin Antenna 300mm 0200-07761 Lot of 12 New

AMAT LEL Field Replacement Kit, H2 170-11761-00 New

AMAT Fresh Water Flow Switch 342-62-003 New

AMAT Applied Materials 0190-22570 Transponder Reader TLG-I1-AMAT-R1 Used Working

AMAT Applied Materials 0190-11557 Particle Filter Assembly Used Working

T.E.M. Filter Co. TEM1515-8P Inline Gas Filter AMAT 4020-01206 New

AMAT Applied Materials 300mm Middle Purge SST Ring 0021-07586 New

AMAT Applied Materials 0240-18644 Mainframe PVD/PC Chamber Mounting Kit new

AMAT Applied Materials 0190-33044 Heater Jacket UAPM13565RSN-27?5 New

AMAT Applied Materials 0190-22543 Factory Interface Digital I/O Module Used

AMAT Applied Materials 50414731100 Safety High Voltage Cable Used Working

AMAT Applied Materials 0120-00415 G2/G3 Protection And Delatch PCB Used Working

AMAT Applied Materials 0190-33427 Heater Jacket UAPM13565RSN-27?7 New

AMAT Applied Materials 0190-33043 Heater Jacket UAPM13565RSN-26?9 New

AMAT Applied Materials 0190-33038 Heater Jacket UAPM13565RSN-27?4 New

AMAT Applied Materials 0190-33040 Heater Jacket UAPM13565RSN-27?3 New

AMAT Applied Materials Retaining Ring 200mm Kyron 1530 new

AMAT Applied Materials 3310-00139 Capacitance Pirani Gauge Used Working

AMAT 0020-26723 ball transfer load distribution plate new, sealed

AMAT Applied Materials 0010-28224 300mm MCA Heater SST Cover Kit 0010-28233 new

AMAT Applied Materials XR80 0100-90177 Rev.C Vacuum Control Drive Board Working

AMAT Applied Materials XR80 Charge Voltage Card 0100-90468 Rev.F working

AMAT XR80 0100-90860 Rev. I Beam Stabilizing Monitor Board Used Working

AMAT Applied Materials XR80 Vacuum Control Drive Card 0100-90177 Rev.C working

AMAT Applied Materials 0100-90944 Wafer Arm Gripper Interface Board Rev. A Used

Applied Materials AMAT XR80 Wafer Arm Position Board 0100-90491 Rev. A Used

AMAT Applied Materials 0190-14178 MAG-LEV Machine Controller Cable Used Working

AMAT Applied Materials AA2-03-15 Air Bearing 2450001 Lot of 5 New

AMAT Applied Materials 425556P-XA Chiller Cold Loop Coolant Hose AMAT 3400-02133

AMAT Applied Materials 0021-60948 2-Zone Lower Plate New