5.电气操作及维护手册

操作和维护手册

Operating and Maintenance Manual

设备名称：门密封设备

Equipment Name: Door seal station

最终用户：上汽大众（宁波）公司

End User：SVW (NingBo) Company

图纸编号：Drawing No. : C4-E00-01E127121 C4-E00-01E127121

Version Date Description Comments

1.0 Operating and Maintenance English and Chinese

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前言

Preface:

在安装和开机试运行前必须完整地、深入地阅读本操作维护手册。阅读之后必须将本操作

指南妥善存放在每个工作人员可以随时取用的地方。只允许由专业人员安装和运行电气设备。

Before installing and operating this equipment, should to read and understand this manual. After using, please put this manual to the place where each working staff can find it easy. This operating and maintenance manual is only addressed to professional personnel.

原则上，电气版操作维护手册必须与设备机械、工艺和电气文档资料联系起来看。

In principle, Should make references to mechanical manual and technology document, together with this electrical operating and maintenance manual.

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目录Contents:

1 2 3 4 5 6 7 8 9 技术参数： TECHNICAL PARAMETERS (4)

安全说明SAFETY INSTRUCTIONS (5)

设备描述： STATION DESCRIPTION (6)

流程说明: WORKING FLOW DESCRIPTION (11)

电气设备部件说明 ELECTRICAL COMPONENTS DESCRIPTION (14)

可视系统的说明: VISUALIZATION DESCRIPTION (24)

设备的冷启动COLD START (40)

半自动模式SEQUENZ NOTORGA (42)

备注MEMO (43)

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1)技术参数：Technical parameters:

a)电气参数: Elctrical parameters:

生产商：Supplier: :大众祥源 ESC

制造年份：: 2016

2016 Manufacturing Date:

额定功率14千瓦Rating Power: 14 KW

电源

Power Supply: : TN-C / TN-C-S 3 x 400 V , PEN

频率: 50赫兹,

Frequency: 50Hz

保护级别:控制柜IP 54

IP Degree: 开关盒IP 54

2. Safety Instructions安全说明

? Keep free保持释放

o Panels操作台

o Emergency Push Buttons急停按钮

? Hold closed保持关闭

o Cabinet doors电器柜门

o Terminal boxes接线箱

? Check检查

o Nobody is in the safety area没有人在安全检测区域

o No material is in the working area工作区域没有材料物

? Conditions for the function功能条件

o Clean station工作站清洁

o Regards to the maintenance section of this manual.本手册维护部分的相关内容

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3.设备描述： STATION DESCRIPTION

2) Station Layout: The drawing above is an overview of this door sealing station. The

station consists of 7 substations. You can refer to the layout above for details. There are 4 turntables, 1 door type detection station and 2 centering stations. Each turn table equiped with 1 application plate.

上图所示的是这个门密封设备的总览：其中包括 7个子工作站，如上所示：包括 4个转 台，2个门对中工位和一个门型号检测工位。每个转台上安装有一个料盘。

111002DT---Turntable 1 123002DT---Turntable 2 134003DT—Turntable 3 146003DT---Turntable 4

122002FX---Centering station for front doors 145003FX---Centering station for rear doors 111002DT---转台 1 123002DT---转台 2 134003DT—转台 3 146003DT---转台 4

122002FX---前门对中工位 145003FX---后门对中工位

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3) The protection safety area for each turn table.每个转台的安全区域保护:

- Safety light curtains in the loading area can switch off the turn table.

安全光幕可停止转台旋转

- Safety laser scanner in the outer corner of the loading area which can switch off the turn table.

外侧角落的安全激光扫描仪可停止转台旋转.

- Safety laser scanner in the inner corner of the loading area which can switch off the turn table and power off the application plate. Also this

scanner can stop EHB.

内侧角落的安全激光扫描仪，该扫描仪可停止转台旋转，料盘气源切断

和吊具输送线的运行。

- Safety door to entrance the protection safety area

There is a control panel for each turn table, an E-stop push button is installed on this panel. At each safety door is an E-stop push button, too. This E-stops can stop the station and EHB.

每一个转台都有一个带有急停的操作面板，每一个急停都可以停止所有设备的运行，包括吊具输送设备。

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Switch off matrix停止矩阵

3)主要机械部件描述 Main mechanical device :

图片仅供参考，请以机械说明书为准。Pictures are only for reference, not the real scene.You should refer to mechanical manual for details.

转台

Turntable

对中工位

Centering station

车门检测

Door Type detection

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料盘：

Application Plate

EHB 吊架EHB hanger

4.流程说明: Working flow description:

This station is suitable to apply a seal to the front and rear doors of car. One application plate is for one door.

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该工作站为车门装配密封圈。每一个车门对应一个料盘。

The doors are transported to the station by P&F- conveyor, the P&F- hangers are fixed by the centering station when the hanger arrives at front door position or rear door position.

吊具输送线将门送至该站，该站的中心定位装置锁紧固定吊具。

After loading the seal into the plate by worker manually, the table turns the application plate to the door. The lifting device lifts the plate to the right height. A travelling device moves the plate to the door and the seal is pressed to the door by pneumatic cyclinder. The seal is equipped with adhesive strip.

当工人完成密封条的安装，转台将转至车门方向，升降装置到达相应的高度，水平移动至车门位置并将密封圈压入车门。密封圈带有粘性胶条。

For an intermediate time there are hangers with other type doors in the line. Because the seals are not for these doors, the hangers will go through the station without application.

有时吊具所带车门型号为其他型号车门，由于工作站不是为该车型工作的，所以该车型的吊具直接通过工作区域。

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车门密封粘装设备流程图: Working process flow diagram:

Plate locate at working area. Height adjustment is at middle position

Operator put the sealer to the plate

Adjust the height of plate by foot switch

Operator switch the clamps and press the button ”Press on unit go forward”

Press on unit go forward( 2 bars)

N

Check the sealer is Ok or not?

Operator press the button “press on unit go forward”

Y

Operator remove the thin film of sealer

Press on unit go backward

Reset light curtain and scanner

Turntable turns 180 degree.

Segment go forward

Height adjustment move to middle position after bottom

Press on unit go forward (6 bar)

N

EHB is at working position?

N

Y

Sealing time (20S)?

Segment go backward (Open).

Y

Press on unit go backward

Unlock plate

Segment go backward

Clamps go backward

Expanding unit go forward

Pusher go forward

Expanding unit go backward

N

Sensors detect the door? Lock plate

Pusher go backward

Y

Segment go forward

Close clamps

Height adjustment move to bottom position

Plate is at home position

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操作盘在放件区域 高度调整在中间位置

操作人员放入密封条并且 通过脚踏开

关移动高度调整装置

操纵人员换位手动夹紧装置并且

按下“压紧器向前”按键

压紧器向前

操作人员按下“向前压入”按键否

压紧器返回密封条

正常?

是

操作人员撕下密封条薄膜

操作人员应答安全区域

否

高度调整装置从底部移动至中间位置

对面操纵盘在初始位置？

没有操纵行走装置

段向前

旋转台旋转 180° 操作盘在粘装位置(EHB)

否

EHB 在工作位置？

是

否

粘装时间(20秒)过了？

段返回 压紧器返回

是

解锁操作盘

压紧器返回 段零压力（浮动的） 夹紧装置返回

操纵夹紧装置向前

行走装置向前

操作盘解锁 行走装置返回 操作盘锁定

否

传感器 顶料器返回 段向前

辨认车门？

是

操作盘在初始位置！

夹紧装置向前移动

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5.电气设备部件说明Electrical components description:

- 这里说明的设备由控制柜供电。所有的安全部件，诸如扫描器也同样由控制柜直接供电。

The power for all components is come from main cabinet. Also for the scanners.

- 1)设备控制系统采用西门子CPU 319F-3PN/DP。

The control system use Siemens CPU319F-3PN/DP

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2)采用Profisafe现场总线系统。I/O-区域被接线在Profisafe-ET200S and ET200 Pro在线-

模块上。它们各自布置在相应的接线盒内。

- The bus system use Profisafe. I/O are connected to the ET200s and ET200 Pro modules.

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3)旋转台上 FESTO-阀岛通过 FESTO-现场总线与Profinet 相连。The Festo valve island moudle is also connected to Profinet.

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4)设备的操作通过 4个西门子 TP1900 触摸屏执行。每个旋转台各自配置一个触摸屏。它们通过

PROFIBUS-DP 与 SPS 系统相连。对中站的操作也可通过板进行。There are 5 HMIs TP1900 for this station. Four HMIs are for the turntables and one HMI, on main cabinet, is for maintenance. These HMIs are connected to system via Profinet. Also the centering stations can be operated on the HMI-panel.

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4) 旋转台的驱动通过控制柜内的接触器实现。The contactors are used for controling turntable.

(转台控制电路图 Electrical circuit drawing of turn table )

5)料盘的高度控制采用西门子电机启动器来实现。这些启动器是安装在转台上的控制内。

The Siemens motor starters are used for height adjustment of the plates. These motor starters are mounted on the turntable.

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