IC693CPU313***IC693CPU313***一、真空炉浇注主要采用以下两种生产工艺1、自动真空熔炼工艺:1.将自动/手动开关KS1切换到自动位置。将炉体开关KS2切换到Ⅰ＃炉。将真空/开关KS3切换到真空位置。2.系统送电。按下S06启H03灯亮。按下S30启动中频电源主回路,H39灯亮。按下S01启动机械泵H-70,H01H05灯亮(H05在故障时为快闪光状态），此时V0阀随H-70泵的启动而自动打开，H36灯亮。其他阀均处在关闭壮态。3.用双手同时按住S9和S10使模台T1上升，撞到上限位S39时，上限位指示灯H19亮。即刻松开双手。此时手动按下Ⅰ＃自动按钮S43,H37灯亮，使Ⅰ＃炉进入全自动状态。4.首先真空阀V1自动打开，H09灯亮，运行时H11为慢闪光。开到位后H11为常亮。(H11在故障时为快闪光）。炉体开始抽真空。待S39***2秒后接通K4使溢流阀DT0得电。5.真空抽到30mbar时膜式开关TRO动作，H30灯亮,罗茨泵ZJP600自动启动。H02H07灯亮。(H07在故障时为快闪光）。7.K07断开后，真空阀V1自动关闭到位，罗茨泵ZJP600自动停止运行。同时使破空阀V5自动打开。H17H15灯亮。8.当P时用双手按住M1电接点真空压力表真空指示到1000mbar时，H27灯亮。此时使模台T1自动下降，当撞到下限位S40时，H21灯亮。这时语音芯片XH1发出语音提示“进入下一道工序”。至此一个熔铸周期结束。2、自动保护熔炼工艺:1.将自动/手动开关KS1切换到自动位置。将炉体开关KS2切换到Ⅰ＃炉。将真空/开关KS3切换到位置。2.系统送电。按下S06启动液压站,H03灯亮。按下S30启动中频电源主回路,H39灯亮。按下S01启动机械泵H-70,H01H05灯亮(H05在故障时为快闪光壮态），此时V0阀随H-70泵的启动而自动打开，H36灯亮。其他阀均处在关闭壮态。3.用双手同时按住S9和S10使模台T1上升，撞到上限位S39时，上限位指示灯H19亮，即可松开双手。此时手动按下Ⅰ＃自动按钮S43,H37灯亮，使Ⅰ＃炉进入全自动状态。(注:以上1.2.3项均为手动操作)。4.首先V1阀自动打开，H09灯亮，运行时H11为慢闪光。开到位后为常亮。(H11在故障时为快闪光）。炉体开始抽真空。待S39***2秒后接通K4使溢流阀DT0得电。5.真空抽到30mbar时膜式开关TRO动作，H30灯亮,罗茨泵ZJP600自动启动。H02H07灯亮。(H07在故障时为快闪光）。的运行。7.待V1关闭到位后发出指令：V3充***阀自动打开，运行时H13慢闪光。到位时H13灯常亮。向炉内开始充***。8.充到40mbar时H29灯亮TR3发出指令：在关闭V3充气阀的同时，K07吸合中频开始自动加热，H43灯亮。加热到所设定的时间时,中频自动加热停止。9.中频自动加热接触器K07断开的同时：使V5阀自动打开破空。H17H15灯亮。10.当PM1电接点真空压力表真空指示1000mbar时发出指令：使模台T1自动下降，当撞到下限位S40时H21灯亮。并发出指令：XH1语音提示“进入下一道工序”。至此一个熔炼周期结束。两种浇注工艺在一个周期内自动控制，系统也可以切换到手动模式进行手动操作二、系统配置此系统采用西门子S7-300系列PLC，带有DP接口，并配备数字量I/O和模拟量I/O，PLC完成互锁控制，保障安全生产人机界面采用台湾斯美特12.1寸彩色触摸屏，并通过DP总线和PLC通讯，交换工艺参数，监控设备状态。三、部分控制界面图片图一：控制界面图二：真空度监视界面四、结束语由于真空炉采用自动化控制，温度控制、时间控制、真空度控制更加准确，保证了产品的质量，减少操作的复杂性，提高了设备的可靠性。SENTROL532-093-027USPP532093027PanasonicACServoMotorM***D042S1SFreeShipPanasonicACServoDriverMSDB3A2AAD02New0190-26756MITSUBISHISJ-4-V7.5-11TNSFPSJ4V7511TASEABROWNBOVERIHIEE300024R4NSFPHIEE300024R4FOXBORO202S-07-SSSFSS​ESNFUSPP202S07SSSFSSES​NFASEABROWNBOVERI6024BP10300CNSFP6024BP10300CPanasonicACServoMQDB012AAD(V3)ASEABROWNBOVERI1529F93A05USPP1529F93A05CUTLERHAMMERLD3500USPPLD3500PanasonicM***D082PJAACServoMotorALLENBRADLEY509-EOD-7NSFP509EOD7PANASONICM***A042A1AACSERVOMOTOR106V,2.5A,200Hz,3000r/min,0.4kWOUTPanasonicMatsushitaACSERVODRIVERMSD011P1EFreeShipASEABROWNBOVERI57360001-K/10USPP57360001K10TEXASINSTRUMENTSPLC2497435USPP2497435TEXASINSTRUMENTSPLC305-02BUSPP30502BTexasInstrumentsPM550-200ASEABROWNBOVERIEH450C-32VDC-TNSFPEH450C32VDCTSiemensTexasInstrumentsPLCController435-CPU405-15ABMU-55NUsedWorkingSIEMENS6DD-1610-0AG1USPP6DD16100AG1ALLENBRADLEY2705-EM11J1USPP2705EM11J1ALLENBRADLEY509-EOD-7NSFP509EOD7TEXASINSTRUMENTSPLC505-7339NSFP5057339METRAINSTRUMENTS611-0011-000USPP6110011000GENERALELECTRIC7VSDD08CD01USPP7VSDD08CD01ASEABROWNBOVERIACS601-0011-4-​000B1200801USPPACS60100114000​B1PERCEPTRON912-0010USPP9120010ASEABROWNBOVERIACS201-2P7-3-0​0-10USPPACS2012P730010YAMADAPUMPDP-10FUSPPDP10FTEXASINSTRUMENTSPLC305-CPUUSPP305CPUTEXASINSTRUMENTS5TI-1034-2USEDSEQUENCERMODULE5TI10342PanasonicMQDA013D1A+MQMA012C1Q100WServoDrive&Motorset(freeship)(AA01)ACSERVODRIVERPANASONICMATSUSHITAMSD021P1EA01WORKINGENDRESS&HAUSERFMR240-S3K1ALJ​AA4AUSPPFMR240S3K1ALJA​A4ASEABROWNBOVERIDSQT-239USPPDSQT239PERCEPTRON9110021USPP9110021TexasInstruments2497447PCBoardExpeditedshippingailableASEABROWNBOVERIRVS-6-100/120VNSFPRVS6100120VGALILMOTIONCONTROLSDMC-2130USPPDMC2130TEXASINSTRUMENTSPLC505-2590NSPP5052590PanasonicMQDB011AAD03ACServoDriver0190-19214workingASEABROWNBOVERIDSCA-125AUSPPDSCA125ASIEMENSTEXASINSTRUMENTS500-5031OUTPUTMODULETEXASINSTRUMENTSPLC505-RTUUSPP505RTUPERCEPTRON515-0108DIGITALSPOTLIGHTW/MOUNTFOXBORO130FD-NUSPP130FDNASEABROWNBOVERINDCU-21CUSPPNDCU21CTexasInstruments5TI-3100ASEABROWNBOVERI57287853USPP57287853OnePanasonicACServoMotorMBMK042BLAFreeShipASEABROWNBOVERI57171847USPP57171847ASEABROWNBOVERIACH401603032A0​BE0000USPPACH401603032A0​B1PROCESSCONTROLCORPC1247USPPC1247MOELLERELECTRICTPY3-415/480-1​10L-2BUSPPTPY3415480110L​2BHONEYWELL30752766-001NSPP30752766001NATIONALINSTRUMENTNI-CFP-2020NSFPNICFP2020TEXASINSTRUMENTSPLC505-7003USPP5057003RELIANCEELECTRIC0-51831-7NSFP0518317ALLENBRADLEY1756-EN2TRNSFP1756EN2TRPerceptronProcessorBoard495-0191FrameGrabber29400ALLENBRADLEY1336S-BRF50-AA​-EN-L6USPP1336SBRF50AAEN​LATexasInstrument500-584814ModuleI/Obase5005848A+TEXASINSTRUMENTSPLC510NSFP510ASEABROWNBOVERIYB560103-BNUSPPYB560103BNTEXASINSTRUMENTSPLC500-2101NSFP5002101SIEMENSTEXASINSTRUMENTSMONITORCVU100ALLENBRADLEY1785-CHBMNSPP1785CHBMTEXASINSTRUMENTSPLC505-6108AUSPP5056108AGORMANRUPP27781-035USPP27781035PanasonicACSERVOMOTORM***A082A1GFreeShip)