罗克韦尔自动化提供免费软件RSNetWorx for DeviceNet 具有如下优点:
- 用于最小化调试一个系统的初始化启动时间, 节省项目成本
- 调试和解决网络设备问题, 由此减少网络故障时间和相关成本
- 检测网络设备需要的预防性维护, 避免系统瘫痪
Network Media Checker 用于测试安装的网络电缆是否断路和短路, 显示电缆断路和短路的距离, 识别和显示未接线的连接器, 测试全部电缆长度, 包括干线和支线。
可见专业工具对于智能MCC 的调试和维护是非常重要的。
智能MCC能提供非常丰富的测量和诊断信息, 需要一个功能强大的操作软件帮助调试、设置MCC, 同时显示相应的参数、报警信息、故障信息。
罗克韦尔自动化提供的专门的软件,提供马达控制中心和相关设备的监视窗口。MCC软件减少了代价不菲的 MCC监视画面软件的开发费用,提供了即插即用的解决方案,即便是计算机新手一样能够应付自如。下列要点给出了典型的集成智能型MCC软件的基本要求。
ü 熟悉的操作环境 – 软件运行在应用最为普遍的Windows操作系统下,保证操作的简单性。
ü 包含了初始化MCC所必需的特殊的文档资料- 每台MCC都是独一无二的。一旦安装完毕,应用程序应当能够调用特定的信息,调出与这台MCC相关的应用画面。
ü 起动网络通讯 - 组态并建立一个一体化的通讯网络通常是一件非常耗时的事情。但是在理想情况下,MCC制造商把用户特定的信息(根据用户定制或者标准的图纸),如节点地址、波特率等,下载到MCC产品中,然后对整个系统进行功能和通讯的准确性进行测试。在安装MCC 和软件时,用户只需要恢复原来的系统配置,使用软件来对预先组态好的设备进行轮询,并和用户数据库中的设备信息进行匹配。
ü 显示预先组态的画面,提供最为常见的参数 - 智能MCC软件可提取用户定义的数据文件,显示相关画面,下述预定以的软件画面非常有帮助:
v 正面视图 - 提供MCC 排布的实际布置形式,显示单元类型、铭牌信息、或者单元的状态。
v 单元视图 - 提供单元和网络设备的动态信息。最感兴趣的参数预先设置在画面中,在需要的时候可以进行修改。数据在画面上可用数字、模拟表头或者趋势图进行显示。
v 事件纪录 - 自动记录预设置或者用户定义的故障和报警信息,保持维护活动和设备更新的记录。
v 电子表格视图 - 比较理想的信息浏览工具。可以对相关的数据进行排序和过滤。
ü 在网络的任何一个层次上都可以进行数据存取-用户能够在任何一个层次的网络接入来读取MCC数据,例如 DeviceNet,ControlNet或者Ethernet。这一特性赋予用户极大的灵活性,即在不同的地点接入移动维护终端,或者是中控室,或者是工程师站。
ü 包含所有和用户相关的文档-综合的文档库软件提供了完整的文档集,用以最大限度地减少故障出现时找不到元件手册的情况。数据库允许用户添加或者改变,尤其是接线图。这些文档包括:
v 单元接线图
v MCC 柜面布置图
v 产品用户手册
v 备品备件列表
采用ArcShield技术的Centerline 2500 MCC, 当柜内发生燃弧故障时产生的巨大压力不会将柜门打开,能够最大程度地保护操作人员的人身安全。
压力释放机构示意较图
Pressure-Relief Top Plate
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Arc shield警告标签
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常规MCC |
AB智能MCC |
材料成本 |
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MCC柜体 |
1.24个电机回路, 2.抽屉式, 3.每个电机控制信号包括 DO: 电机启动, 电机停止, 启动指示, 停止指示, 电机故障指示, DI :电机故障 成本: ¥35,000 |
1.24个电机回路, 2.抽屉式, 3.无需控制信号线, 4.状态通过通讯在中控式集中显示
成本: ¥65,000 |
控制电线/电缆 |
1.控制电缆截面1.5MM2, 2.电气室至中控室距离平均为70M, 3.电缆为12芯阻燃,15元/米, 4.每柜需24根电缆对应相同数量电机回路。 成本: 24×70×15=¥25,200 |
1.平均每20面柜子需一根通讯电缆,70M长,10元/米。 2.通讯网关1块15000元/块。
成本: (70×10+15000)/20=¥785 |
电缆沟槽/管 |
1.电气室内20面MCC柜电缆共用一电缆桥架,500元/米, 2.电气室到中控室距离平均70米。
成本: 500×70/20=¥1,750 |
1.仅少量通讯电缆,无需单独敷设电缆桥架, 2.或敷设轻载型单层电缆桥架200元/米。
成本: 200×70/20=¥700 |
端子,中间继电器柜 |
1.每柜24电机回路, 2.每回路5路DO输出,需5只欧姆拉继电器35元/只, 3.每回路需10个凤凰端子1元/只(未考虑继电器柜壳成本)。 成本: 24×(5×35+10)=¥4,440 |
1.无需继电器柜
成本: ¥0 |
PLC/DCS设备 |
1.每柜24电机回路, 2.每回路需5路DO输出(启动及指示灯,停止及指示灯,故障指示灯,, 3.1路DI输入(电机故障)。 4.PLC模板为32路DI/DO, 85元/路 成本: 24×6×85=¥12,240 |
1.每柜24电机回路, 2.每回路需1点DI输入,做为智能保护器故障指示。 3.PLC模板为32路DI,85元/路。
成本: 24×85=¥2,040 |
成本总计(RMB) |
¥78,630 |
¥68,525 |
表一:
根据表一:
使用常规MCC方案,则每面MCC及相关成本估算如下:
MCC柜体单价+电线/电缆+电缆沟槽/管+端子,中间继电器柜+PLC/DCS设备+
=35,000+25,200+1,750+4,440+12,240
=78,630(元)
使用AB智能MCC方案,则每面MCC及相关工程成本估算如下:
MCC柜体单价+电线/电缆+电缆沟槽/管+端子,中间继电器柜+PLC/DCS设备+
=65,000+785+700+0+2,040
=68,525(元)
表二:
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常规MCC |
AB智能MCC |
生产人员成本 |
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|
|
使用常规MCC时,在每个电气室需1~2名人员。 5万元/人年,预计 50电气维检人员。 成本:
50×5=250万元 |
高度信息化和智能化,人员预计10名电气维检人员。 5万元/人年。 成本:
10×5=50万元 |
根据表二:
使用常规MCC方案,则每年生产维检人员成本估算如下:
=50×5
=250(万元)
使用AB智能MCC方案,则每年生产维检人员成本估算如下:
=10×5
=50(万元)
综合上述:
从每面MCC及相关工程成本,和每年生产维检人员成本考虑,使用AB智能器件的MCC均能节省投资,并且将电气控制技术水平提高到一个全新的高度。
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