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1、Design of a Special PLC for Garbage TruckVld.2No.1,March2011StnnNo.5DesignofaSpecialPLCforGarbageTruck13oGAO(高波),Xiao-meiI1AN(栾晓梅)(CollegeofInformationandElectricalEngineering.ShandongUniversityofScienceandTechnology,(ngdao266510,China)AbstractASlcialPLCisdesignedfortheeontrolsystemofgar?-bagetruck,
2、basedOilthefeatureandapplicationsofvehiculardectri-caldevice.ThepIJrp0seisdevelopingakindofmatureproductstocontrolthehydraulicsystem.Thegeneraldesignplansaredescribed,indetail,andthedesignmintsareanalyzedandstnnmarized.KeywoldsPLC;gwbage臼cf(;singlechip;4ffcularelectronicsManuscriptNlm】ber:16748042(2
3、011)01001304dio:10.3969/j.issn.16748042.2011.O1.041IntroductionWiththerapiddevelopmentofsocialeconomy,ur.banenvironmentalsanitationandrefusetransportequip.mentarerequiredtobeincreasinglyimproved.InsOmenaediunlandlargecitiesofourcountry,convertiblegar.bagetrucksaregraduallyeliminated,andreplacedbycom
4、pressionrefusecollector,rolloffgarbagetruck,etc.Atpresent,someofcompressionrefusecollectormanufacturersformtheirownproductionanddevelop.mentcapacitythroughdigestingandabsorbingimportedtechnology,orbyimitationandappropriateinnovation,butsomeofthekeYcomponentssuchashydraulicsystemandcontrolsystemetc.n
5、eedtobeimported.amongthem,controlsystemsalladoptimportedspecialprogram-mablelogiccontroller(PLC)oruniversalPLC,itscostishigherandtherearesomedefectsinthesystemt.Therefore,basedonexistingtechnology,accordingtotheworkingconditionandcontrolrequirementofgar.bagetruck,thetopicofgarbagetruckspecialprogram
6、mablelogiccontrollerdesignisraised,thepur/xistode.signahighspecialty,low-cost,andhigh-reliabilitypro-grammableloglccontroller,andrealizeitsindustrializa.tioninordertoreplaceimportedproducts.Themainresearchcontentsinclude:1)Hardwareofspecialprogrammablelogiccontroller.whichcanbeusedonallkindsofgarbag
7、etruckprod.ucts;2)Hand-holdwritingwhichcanwriteandreadpro.gramonsite;3)Softwaresystem,whichincludessystemmonitorprogramandladderlogicprogrammingsystem.2ThegeneraltechnologyschemeThemainfunctionofspecialPLCforgarbagetruckReceived:20100813Q耵_啊H唱author:13oGAO(gb005)istocontrolelectromagneticvalvestorea
8、chthepmxofcontrolmanipulatoraccordingtobuttonoperationorderofoperatorandcombinationwiththesignalstatefromswitchessuchastravelswitchesandproximityswitches.Programmablelogiccontrollerissuppliedwithpowerbytruckbatteryorgenerator.Atpresent,thecontrolsystemisanindependentsystem.whichnodatacommunicationne
9、edsfunctionintheprcwessofwork;thereservedcom.municationinterfaceisconvenientfordownloadinguserprogramsfromhostcomputerorhandholdprogrammer.Inthefuturedevelopment,theplcwillprobablyneedtocommunicatewithothersystemsormaincontrollerofve.hicle,whichconstitutesabuscontrolsystemorachievesditalcontrol.Theb
10、asiccompositionofPLCisshowninFig.1Fig.1BasiccomtxitionofPLC14JournalofMeasurementScienceandInstrumentationNo.120l11)HardwarepartHardwarepartisthecorepartwhichdistinguishesspecialPLCfromuniversalPLC.thepartprocessesvehi.clepowersupply,processesinputandoutputaccordingtothedemandofvehicleequipment,also
11、includesCPUmoduleandcommunicationmodule.2)Softwarepart111esoftwarepartisdividedintosystemmonitorpro.gramanduserprogram.Systemmonitorprogramembedinasinglechipreadsriserprogramafterinitialization,andexecuteCorrespondinginput,output1nstructions,etc.ac-Cordingtouserprogramtoachievetheultimatefunctionofp
12、rogrammablelogicController.3)ProgrammingsystemProgrammingsystemisthatusereditsuserprogramonhostcomputerwithladderdiagramorinstructionlist,thenuserprogramcanbecompiledintohexformatanddownloadedtoPLChardwareorhandholdprogrammer.2.2ThebasicfunctionofprogrmnrblelogiccontrollerAccordingtotheapplicationre
13、quirementsoffieldprogrammablecontrol,thebasicfunctionofprogramma.blelogicControllerdesignedisdividedintoinputprowess.rag,userprogramScan,outputprocessing,andalsoin-cludesauxiliarypowerprocessingandCommunicationfunction.TheblockdiagramofbasicfunctionisshowninFig.2.Fig.2Blockdiagramofbasicfunction1)In
14、putprocessingBeforeprogramisexecuted.theon/offstatesofalJinputterminalsarereadtoinputimageregister.Intheprocessofexecution,IoDortsreceivethestatechangesofinputports,buttheContentofinputimageregisterisun-changed,thechangescannotbereaduntilthenextscanperiod.Inaddition,input19ortsshouldreadstatemanytim
15、esatthesainescanperiodinordertoremovetheimpactofinterference.JUserprogramscanprocessingForordersstoredinuserprogrammemory,theon/offstatesofrelatedsoftcomponentsarereadfrominputimageregister,thenoperationinorderstartsfromthefirststep,resultiswrittenintotherelevantimageregistereverytime,therefore,thec
16、ontentofeveryimageregister(exceptinputrelay)isConstantlychangingwithprogramexecution.3)OutputprocessingAftertheendofinstructionexecution,theon/offstatesofoutputimagereglsteraretransportedtooutputlatchregisterandbecomeactualoutputofprogrammablelogicController.Aboveinput/outputmodeiscalledbulkinput/ou
17、tputmode.3ProgrammablelogiccontrollerhardwaredesignI11eCoreofprogranmblelogicControlleradoptsseriessinglechip,whichDOssesses128Kbytesofin-systemprogrammaNeFIash,upto8O00stepscanbestored,thereadingandwritingtimesistenthousand.111eFRAMmemoryisusedtobeadata-holdingregisteronpower-off,whichcanrealizehig
18、hspeeddatareadandwrite,maximunlbusfrequencyis1MHz,thereadingandwritingtimesis10,datacanberetainedupto45yearsonpoweroff.AccordingtothequestionthatuniversaJPLChaspooradaptabilitytoharshcircumstances.aspecialhand.holdprogrammerisdeveloped,whichfunctionistostoreandwriteprograms.Atthetimeofstorage,hostco
19、mputerwritesuserprogramstoprogrammableASHatthesamewaytooperateprogrammablelogicController.ForhostComputer,therearenodifferencestowriteprogramsbetweentoprogrammablelogicControllerandtohand.holdprogrammer.Whenprogramiswritten,handholdprogrammerisconnectedtoPLCandsuppliespowerthroughtheserialport.Userc
20、ontrolsprogramtobewrit,Vl01.213oGAO,Xiao-meiLUANtentoprograrnmablelogiccontrollerthroughbuttons.Forprogrammablelogiccontroller,thereisnodifferencetowriteprogramsbetweenwithhostcomputerorwithwriter.1herefore.thecoreofhandholdprogrammeradoptsthesameplanandcomponentsasprogrammablelogiccontroller,thesin
21、glechipprogramincreaseswritingfunc.tionbasedonprogrammablelogiccontrollermonitorprogram.workloadofdesignisgreatlysimplified.Theworkingrangerequirementofvehiclepowersupply1swider,atthemstantofenginestarting,waveshockislarger,forthisreason,powersupplymoduleusesintegratedandwiderangeisolatedDdDCmodulew
22、hichisspeciallyusedforvehicularelectroniccircuits,alsousestransientvoltagesuppressorandPP丁Ctyperesettablefuse,theModulecanachievereliablepowerconversionandensurethatthecoreCPUworksstablYandpreventr1_一powersourcereversalconnections引.3.20ModuleI/OmodulecanbedividedintotwotyF,es:onetypeisbuttonormechan
23、icaltravelswitchsigna1.anothertypeiselectronicproximityswitchsigna1.Fortheformer,signalscanbedirectlyaccessedtophotocouplerafteracur.rentlimiting.Forthelatter,thetypeofswitchsienalmustbetakenintoaccount,thatis,thetypeisPNPorNPN.whichisthequestionofcurrentflowdirection.SomeuniversalPLCcanaccepttwo-wa
24、ycurrentsignalsthroughinternalprocessing,thatistheinputoOMportcanacceptpositivesignalornegativesigna1.Comprehensivelyconsideredfactorssuchascostandreliabilityetc.colnlTlOnanodeleakageinputisused,thatis,suitableforcommonNPNsensor.3.3Outputmoduleofprogrammablelogiccontrol-lerforgarbagetruckOutputmodul
25、eofprogrammablelogiccontrollerforgarbagetruckisthekeyfactorwhichdecidesthestabilityandreliabilityoftheirlongtermoperation.I1hecontrolobjectisDCelectromagnetofelectromagneticvalve.workcurrentislargerandthereareshocksatthetimeofstart.Toensurereliablework,maximumoutputcontrolcurrentshouldreach610A.Matu
26、reproductsinforeigncountriesgenerallyusespecialcontactrelaysforautomobile.butmaximumoutputsPLCnedsareuptotwentyroads,sothesizeandweightofrelaysoccupyalargershare.Withthedevelopmentofelectronictechnology.highpowerM0Stubeshavebeeninoreandmorewidelyapplied,itcanmeetneedsofresistancetoshockcurrentandhas
27、advantagessuchaslonglire,goodreliability,ef.fectiveprotectionofloads.self-recovery.smallsizeandsoon.ThefuturedevelopmenttrendwillgraduallymakeMOStubesreplacecontactrelays.Atpresent,packagetyperelayappliedinvehicularelectronichasappeared.Therefore,thisdesignalsoadoptstheplanthatMOStubeisadriver,after
28、mature,fortheplan,engineeringverificationwillbecarriedout.3.4CommunicationmoduleBeingdifferenttouniversalPLC.applicationcondi.tionofPLConvehicularissingle.Tosimplifydesign.ac.cordingtopresentuserequirements,RS232interfaceisonlyretainedandachievedownloadingandreadofuserladderprogram(connectionwithhos
29、tcomputerorsceneprogrammer),attheSanletime,theinterfaceisacommunicationinterfacewhichconnectsuserprogramwithotherSerialdevices.Asavehicleproduct.thefuturedevelopmenttrendisthatCANbusisusedtoachieverealtimecommunicationanddatatransmission,whichconstitutesabuscontrolsystem.Therefore.aftertherealizatio
30、nofpracticality,thatwillbetheaimofthenextprod.uctdevelopment.4ProgrammingsystemandmonitorprogramThesoftwaredesignofprogrammablelogiccontro1.1ercontainsladderdiagramprogrammingsystemofhostcomputerandmonitorprogramwithinasinglechip.Thefunctionisasfollows:Programmingsystemconvertsuserprograminputtedthr
31、oughladderdiagramorinstructionlistintohexformatdata;downloadinguserprogramtouserprogrammemorythroughSenalports;monitorpro?gramwithinasinglechipcircularlyreadsuserprogramandpertormscorrespondingoperationssuchasmput,output,logiccalculationandsoonaccordingtoitsimplicationinordertocompleteuserfunction.T
32、hisisacomparativelygeneralway,thatis,theplanadoptedbydesignatpresent.ThespecificdesignprocessisnoIongerdescribedindetail1,.Anotherwayisonlytoadoptprogrammingsystemofhostcomputer.Userprogramwillbedirectlyconvertedintosinglechipexecutableprogramaccordingtoafixedmodel,thendownloadedtosinglechipprograms
33、torageareaandimplemented.Thiswayhastheadvantagesofsimpleprogram,goodstabilityandsoon,butsomeset.tingsneedtobemadeaccordingtotheCPUtypeofPLCwhenprogramisdownloaded,whichmaycausesoftiepuzzlesforthefieldengineeringandtechnicalpersonnelwhousePLC.5PLCsystemtestThedesignpurlxofswxfialPLCisdevelopingakindo
34、fmatureproductswhichCanreplaceexistingimportproducts.So,itisnecessarytotestPLCaccordingtona-tionalstandardsanduserneeds,accuratetechnicaIindexisobtainedinordertofurtherimprovedefaults.Inaddit.iontorequirementssuchasworkinghours(theworktimesofrelays),inputpowersupplyindicator,controlJournalofMeasurem
35、entScienceandImtrumentationNo.12011objectsandsoon,PLCproducta/soshouldcarryoutothertests.PLCstabilityoflong-termworkistestedonconditionofhi【ghtemperatureorlowtemperature.I,ausegarbagetruckworksoutdoorsandenvironmenttempera-tureshavelargedifferenceswitidifferentworkcities,itshighandlowtemperatureperf
36、ormancemustbeensured.ThepC)seistotesttheeffectoftemperaturealternatingoilworkstabilityandmechanicalproperties.5.3VibrationtestThepurposeistotesttheeffectofsinemechanicalvibrationinfluenceonPLCcircuitboardelectricalandmechanicalpropertiesunderdifferentfrequencies.ForthePLCmountedonmobilevehicle,thisi
37、sanimportantindex.5.4DroptestThepurposeistotestthedamagedropcausesOllconditionofpackagingornon-packaging.Asaproductdevelopment,servicelifeofslxcia/programmablelogiccontrollershouldbenolassthantenyears,thePLCcanadapttotheharshtropicalorcoldoutdoorclimate,forthisreason,theplcmustbetestedstrictlyandcom
38、prehensivelytoensurethecorrectnessofdesignandeventuallybecomesaqualifiedproductforUSers6ConclusionAftercompletionofthedesign.accordingtotheex.istingimportedgarbagetrucktechnology,itscontrolpro-gramhasbeenrewrittenandcarriedoutfunctionalverifi.cationtest;testresultprovesthattheprogramcallmeettheFIC._
39、,Osofcontro1.Next.1ong-termworkstabilityandreliabilitywillbeverifiedunderavarietyofworkingcon.ditions.andthenbatchproductionwillbeachievedinor.dertoreplaceimportedproducts.ThroughthedesignandproductionofspecialPLC.experienceandtechnicalinthisrespectareaccumulated.whichwillpromoteindustri.alizationof
40、domesticprogrammablelogiccontroller.5.5Electromagneticcompatibilitytestingl1JInaccordancewithnationalstandards,eligibleinsti.tutionscarryoutperformancetestforelectrostaticdis.LzJcharge,electromagneticradiation,instantimpact,surgeprotection,conductedinterference,voltagefluctuations,F31aperiodicover-v
41、oltagetestandsoon.TheworkstabilityandreliabilityofPLCcanbeensuredundertheenviron-4mentofcarpowersupply.5.6Hvoltageinsulationtest_5_ThepurposeistotesthighvoltageinsulationpefformanceXiang-deMengg,Li-shunLi,JanqingZhan,etal,200r7.De-signofself-loadingandunloadingcontrolsystembasedonPC.MMernMnufacturin
42、gEngiruring,2:1O6-1O7.Xiac-mingPi,Zhen-weiHe,20o6.1design0fhydraulicpres一$33/systemandPLCoontrolsystmaat,outtheback-loadingsqueeaerefusecollector.A/hineryn&Nlanufacture,8:123_124.GI】ixinFan.2002.Thedevdolxnmtofspedalf)LC.RailzoayLocomotiveandRingStock,l:1618.W锄一junYan,1996.TheDevdopmentofaSpecialP0聊m甚.bleLogicGtroller.tion.ZhejiangUniversity,Hmgzoa.XiWang,2003.Design0fself-protectioncircuitonautodectronicequipments.AutoE/ectrz?Parts,4:9-11.
