在高爐煉鐵企業中，上料系統是高爐不可缺少的部分，高爐上料有料車卷揚上料和傳輸帶上料兩種。卷揚料車上料機結構緊湊，占地面積小，對中小高爐有足夠的供料能力，且能實現自動控制。在中小高爐中廣泛采用料車卷揚上料。我們將偉創變頻器與西門子S7-200 PLC作為該套系統電氣控制部分，已在江西省新余市新鋼石灰窯廠1#、2#、3#、4#窯爐成功應用，2006年投產至今一切生產運作良好，系統穩定。

一 卷揚上料過程（本系統為單料車上料系統）

2.1 工作過程

高爐卷揚上料工作過程是：各種原料經過槽下自動配料后進入中間料斗，這時料車原點位置就處于料斗下面，料斗把原料放入斗車，通過稱重傳感器確定放料已足夠時，料斗自動關閉放料氣閥。（自動上料及稱重系統由其它公司提供）在爐頂準備好后，料車啟動。經過加速→勻速→一級減速→二級減速→到達卸料位置剎車制動→料車自動傾翻卸料→延時3S后→下行→勻速→一級減速→二級減速→到達原點剎車制動→等待裝料。如此往返運行。

2.2 工作特點

料車卷揚機是料車上料機的拖動設備,根據料車運行工作過程,其特點如下：

① 能夠頻繁啟動、制動、停車、反向、低頻力矩大鋼繩無抖動現象，過渡時間短。

② 系統工作穩定，無溜車現象。

③ 有失速、極限保護

④ 自動/檢修切換功能。即如電梯中的快/慢走車。

⑤ 系統有記憶功能。即運行中途停電后，PLC記憶當前料車位置，來電后可繼續運行。

二、系統配置

1、控制部分：

西門子S7-200PLC（40點）選用CPU224 CN系列外掛EM223 CN數字輸入/輸出模塊 （8點輸入/8點輸出）

TD-200文本顯示器 為用戶提供一個價格低廉、功能齊全的人機界面，可顯示中文故障記錄。及小車上、下極限位置調整。

偉創AC60-37KW變頻器一臺 可通過端子組合成多達15段速度

歐姆龍同軸編碼器（256脈沖點/轉）與電機同軸安裝 用于檢測料車行走位置

制動單元/制動電阻 由于系統制動頻繁，可考慮配置5KW/5歐姆線繞電阻3個串聯 制動單元選用VEICH-EC系列

2、拖動部分：

30KW 8極變頻電機，745r/min 減速比46:1、200W電動式抱閘、獨立電源散熱風扇

拖斗小車 自重1.5T，重車時可達4.5T

3、基本參考數據:整個行程37.5米、上限位36.25米、上極限位37米、下限位1米、下極限0.8米、上行減速位30米、下行減速位3米、上下行各有3段速、超速保護0.85米/秒、減速機轉一圈編碼器記為1.92米。

4、工作原理：所有的上行或下行限位、極限位、減速位、都由同軸編碼器檢測到多少點脈沖后傳送給PLC，PLC通過程序內設置的各段位置累計脈沖點數再發出信號控制變頻器和抱閘動作。電動抱閘延時1S打開，（防止重車下滑）停止時則與變頻器同時斷開。散熱風扇與抱閘同時動作。

MSD CMC 2 KW Micro-processor servo drive S3002M000007 Rev. A-2 Cleveland Machine

CSR MSD Micro-processor servo drive Cleveland Machine Controls 4 KW S3004M000000

Universal GSM 44mm x 32mm Tape Feeder

Universal GSM 56mm Multi Pitch SMT Feeder

Western Graphtec Thermal Arraycorder WR7700 4 Channel w/ Armor Box Case & Manual

Hepco 7900-LFA Lead Former 300-400-600 Center IC Former ; 7900 LFA Lead Forming

Banner EZ -Screen SLSCE30-600Q8 Safety Guard; 600mm defined area ; 0.1-18m range

Universal GSM 44mm Multi Pitch SMT Feeder

Electro-Lite Corporation ELC-410 UV Spot Cure System / Light Curing System

T&B Ansley Corporation Blue Macs Bench Press 779-3500

Control Concepts Universal Instruments Transformer LI-3-2100 45530902 208/230VAC

Universal GSM 32mm Multi Pitch SMT Feeder

Universal GSM 32mm x 16mm Tape Feeder

Universal GSM 32mm x 24mm Tape Feeder

Kollmorgen Platium Series Pulley and motor 00D12A02100-1

Electro Craft MCB Moving Coil Servo Motor 1450110

AMP tyco applicator, 690404-1, term 61279-1

Feeder Cart that holds Universal 4796B / Sanyo TCM Feeders UIC 3 Shelf on Wheels

Inarca Applicator Matr. 5551 , Art. 10381

Avago Technologies Encoder HEDS-5540-C11 for MPM

Applicator 6285703-A-645

Applicator 62885853-A-458

Applicator H-50597 DIODE ASSEMBLY

Applicator UNK

Blue M SW-17TA Single Wall Transite Gravity Oven

Dage BT22-LC41 Bond Pull Tester Arm 20 gram Pull Test Load Cell 20gm for BT22

Molex Applicator OSCM 1487 , crimper 1020-4A SPI 15

RSF Electronik Linear Encoder MSA 6708 ML 720mm 40um Linear Actuator Guide

Technitool Tech wand 2 vacuum assembly tool

EFD Model 800 Fluid Dispenser Dispensing System

HP 3468B Multimeter Benchtop Hewlett Packard ; Measure DC Volts, RMS AC Volts

Streckfuss A040 Pin Insertion Machine A 040 Solder Lugs Inserter

BMA TC-5 Laboratoroy Oven B-M-A Inc. TC-.5 Lab chamber

Sigma Systems Model 170 LN2 Temperature Chamber with CC-3 Controller

Applicator LR79193-97084

Siemens 141121 24mm/32mm Tape Feeder 24 / 32 mm

Die Set for Hepco 3000-2 - Lead form - Axial - Cut - Many to choose from

Square D NEMA Size 3 starter contact 600vac max 8502

Manual Ribbon Cable hand Press

Tripp Lite IS500 Isolation Transformer Isolator 500 Watt Noise Filtering Surge

Superior Electric Powerstat Variable Transformer 3PN116C : 120V Input, 0-140 Out

Sigma Systems Model 170C-3 LN2 Temperature Chamber with CC-3 Controller

Motron 2200RPM series 52872 M610V1RB

HP 5328B Universal Counter ; Hewlett Packard ; 100 Mhz

Ban Seok TAD-200S Barrel Control Dispenser Controller Total Application Dispense

Harting BC09990000248 Crimping Tool / Hand Crimper

Intel NetStructure 3130 VPN Gateway Networking

AMP ratcheting hand crimper set of 2 crimpers and includes one die set

Molex Crimp Tool Die Set ATP BB-275 ETC 19288

Molex Crimp Tool Die Set ATP M-675 ETC 19288

Universal GSM 24mm x 12mm Tape Feeder

Universal GSM 24mm x 16mm Tape Feeder

OMEGA OM-5000 Programmable Data Logger OM-5100

Topline QFP Lead Straightener PN 900000 Universal Template Reshape Re-Align Pins

Ring Thread Gage Many to choose 3 1/16 ; 2 1/2 ; 2 3/8 ; 2 5/16 ; 2 1/4 ; 2 3/16

Ring Thread Gage Many to choose from 1 15/16 ; 1 3/4 ; 1 11/16 ; 1 5/8 ; 1 9/16

Hakko 472B Desoldering Station Controller ; 472 B Rework System ; Desolder

Alfa Laval Saunders EC Piston Actuator 33750 and Module Remote indication 34219

Alfa Laval Saunders Module Remote Indication 34219 and EC Piston Actuator 33750

Intel NetStructure 7110 E-Commerce Accelerator

Ring Thread Gage Many to choose from 1 1/2 1 3/8 1 5/16 1 1/4 1 1/8 1 1/16

Ion Systems ZStat 6410 Auto Balance Ionizing air blower Ionizer

Plug Gage Thread Gage: Many to Choose from: 1 3/4" and 1.906-32NS

Package of 2 Hakko 936 ESD Safe Soldering Stations with 1 Hakko 907 Solder Iron

HP 6289A DC Power Supply ; Hewlett Packard ; 0 - 40 V ; 0 - 1.5 A

Siemens Schultz Aut 5 141091 PL EA 1 141096 Dual Lane Feeder 2x8mm Fit S Series

Swagelok Whitey Co. 133 SR Actuator 200 PSI Max 90* Spring Return

Scientech 365 Microprocessor Controlled Laser Power and Energy Meter

Fluoroware Diaphragm Valve CW16-1-D-01-SA1?6

Alfa Laval Saunders DN 50 Valve 34598

Ring Thread Gage Many to choose from ; 1" ; 1-14 ; 1-12 ; 1-18 ; 1-20 ; 15/16"

Plug Gage Thread Gage: Many to Choose from: 1 11/16"; 1 5/8; 1 9/16; 1 1/2 1 3/8

Dwyer Photohelic Series 3000MR Gauge 25 PSIG Max 3001MR

Licquid E Pulsator 196 gpd circulator

Siemens 141123 24mm/32mm Tape Feeder 24 / 32 mm Siemens MS SP HS Siplace Feeder

Alfa Laval Saunders DN 25 Valve 34597

Plug Gage Thread Gage: Many to Choose from: 1 5/16"; 1 1/4; 1 1/8; 1 1/16"

Siemens 141112 Tape Feeder 12/16mm W=12 W=16 P=4 P=8-12 Small Medium Large

Fluke 8010A Digital Multimeter 45 Hz - 50 kHz

Plug Pin Gage: Many to Choose from: GO-NO GO: Large; Vermont 1.905; 1.374; 1.185

Ring Thread Gage Many to choose from 7/8 and 13/16

Plug Gage Thread Gage: Many to Choose from: 1" ; 15/16" ; 1.000-20 ; 1.000-12

Intel Express 510T Switch with 1000SX Module for 500 Series Switches ES510T

Intel Express 510T Switch w/ stack interface module for 500 Series Switches

Swagelok SS-63TS12 Ball Valve - 2200 psi @ 100 degree F

AMP Crimper for Telephone Connectors Set of 2 crimpers 231652 cut and strip

Data Precision 2480R Benchtop Multimeter

Siemens 141105 / 1.3 Feeder 2x8mm dual lane tape feeder 2 x 8mm MS SP HS Siplace