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1. 制定設(shè)備運行方案
制定方案就是根據(jù)生產(chǎn)工藝的要求，分析各輸入、輸出與各種操作之間的邏輯關(guān)系，確定需要檢測的量和控制的方法，并設(shè)計出系統(tǒng)中各設(shè)備的操作內(nèi)容和操作順序。據(jù)此便可畫出流程圖。
2. 畫控制流程圖
對于較復(fù)雜的應(yīng)用系統(tǒng)，需要繪制系統(tǒng)控制流程圖，用以清楚地表明動作的順序和條件。對于簡單的控制系統(tǒng)，可省去這一步。
3. 制定系統(tǒng)的抗干擾措施
根據(jù)現(xiàn)場工作環(huán)境、干擾源的性質(zhì)等因素，綜合制定系統(tǒng)的硬件和軟件抗干擾措施，如硬件上的電源隔離、信號濾波，軟件上的平均值濾波等。
4. 編寫程序
根據(jù)被控對象的輸入輸出信號及所選定的PLC型號分配PLC的硬件資源，為梯形圖的各種繼電器或接點進(jìn)行編號，再按照軟件規(guī)格說明書(技術(shù)要求、編制依據(jù)、測試)，用梯形圖進(jìn)行編程。
5. 軟件測試
剛編寫好的程序難免有缺陷或錯誤。為了及時發(fā)現(xiàn)和消除程序中的錯誤和缺陷，需要對程序進(jìn)行離線測試。經(jīng)調(diào)試、排錯、修改及模擬運行后，才能正式投入運行。
6. 編制程序使用說明書
當(dāng)一項軟件工程完成后，為了便于用戶和現(xiàn)場調(diào)試人員的使用，應(yīng)對所編制的程序進(jìn)行說明，說明書應(yīng)包括程序設(shè)計的依據(jù)、結(jié)構(gòu)、功能、流程圖，各項功能單元的分析，PLC的IO信號，軟件程序操作使用的步驟、注意事項等。
PLC應(yīng)用系統(tǒng)設(shè)計實例
機械手控制系統(tǒng)設(shè)計
1. 工藝過程及控制要求
1) 工藝過程
圖6.1所示為一簡易物料搬運機械手的工藝流程圖。該機械手是一個水平垂直位移的機械設(shè)備，其操作是將工件從左工作臺搬運到右工作臺，由光耦合器VLC來檢測工作臺上有沒有工件。機械手通常位于原點，它的動作全部由氣缸驅(qū)動，而氣缸則由相應(yīng)的電磁閥控制。其中，上升下降和左移右移分別由雙線圈二位電磁閥控制，放松夾緊由一個單線圈二位電磁閥(稱為夾緊電磁閥)控制。
2) 控制要求
機械手整個搬運過程要求都能自動控制。在啟動過程中能切換到手動控制及自動控制或半自動控制(又稱單周期控制)，以便對設(shè)備進(jìn)行調(diào)整和檢修。圖6.2是機械手控制系統(tǒng)的邏輯流程圖。系統(tǒng)啟動之前，機械手處于原始位置，條件是機械手在高位﹑左位。
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NEW USG SOLFRUNT AMETEK PRESSURE GAUGE 0-30 PSI SB DIAPHRAGM 316L SST
Ametek Pressure Gauge 150894 4-1/2" -30 to 60 psi
AMETEK PRESSURE TRANSMITTER 88C002A2
AMETEK FORCE GAUGE GAGE MODEL T-10P-TC WITH FIXTURE
Lamb-Ametek #116158-01 36V 5.7 2 Stage Vacuum Motor
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Ametek/Lamb Electric 115334 2-Stage 7.2in Central Vacuum Motor 110in 12A 115V
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V36D28L0800 REPLACES AMETEK MOTOR 116883-00 120 VOLTS
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Ametek 2" P500 Utility Gauge
SV Allied Signal Aircraft Butterfly Valve, P/N 978558-2-1
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PANALARM Ametek ACS-8 8 PIN RELAY (New)
Ametek U.S. Gauage 600 PSI
Ametek Alpha-3 Air Sampler Portable Sampling Pump
SV Allied Signal Aircraft Butterfly Valve P/N 978558-2-1
AMETEK HUNTER SPRING FORCE GAUGE LO-1M 16 OUNCES
Ametek US Gauge 1980 155008 60 psi size 4 1/2
ametek rotron 1.45amp 20000rpm 28vol fan
Lot 4 Pittman Ametek Gear Motor Actuator Screw 24V DC 65:1 Ratio 10:1 GM9413G421
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AMETEK USG U.S. GAUGE 30 PSI 4 1/2" GAUGE 1/4 NPT NIB
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Ametek Power Instruments RPM Meter
Ametek Drexelbrook Sensing Element 700-0202-002
AMETEK ROTRON 48132-01 Blower Control, 5 A
USG Ametek Gauge 4-1/2" Liquid Filled
103T-AWD2-RB25C-E1C-KY-SP
ACCURAY 4-083182-001 REV CA I/O PC PCB PRINTED CIRCUIT BOARD MODULE CARD 58642
HONEYWELL ACCURAY BCMMST4A 60144916-001 SCANNER PCB CONTROL CIRCUIT BOARD 58693
ACCURAY 064860-003 FDI E SCANNER PRINTED CIR CONTROL BOARD CARD MODULE PCB 59056
ABB/ACCURAY 083898-010 ELECTROMETER RELAY 11PIN 600M OHMS TC=12MS PRE AMP 52939
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ACCURAY 6-053852-001 8301 2301 REGULATED HIGH VOLTAGE POWER SUPPLY 58666
ACCURAY 082132-001 082133-001 SCANNER CONTROL BOARD MODULE CARD 59053
ABB / ACCURAY 083898-010 ELECTROMETER RELAY 11PIN R600M OHM TC=12MS 58685
ABB/ACCURAY 083898-011 ELECTROMETER RELAY 11PIN R600M OHM TC=12MS E/C 58683
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ABB / ACCURAY 083898-011 ELECTROMETER RELAY 11PIN R600M OHM TC=12MS 58682
ABB / ACCURAY 083898-011 ELECTROMETER RELAY 11PIN 10000M OHM TC=100MS 52942
ACCURAY 086175-001 INPUT MODULE MOTHERBOARD ELECTRICAL CIRCUIT BOARD CARD 58013
ACCURAY MICROSCAN CALIPER CALIBRATION BLOCKS NA-B-8-082537-?001-A L13
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ACCURAY MICROSCAN CALIPER CALIBRATION BLOCKS NA-B-8-082537-?001-A L12
Accuray 028490 FTG BU. union?3/8 Tube (Part of 028490 Kit Air Compresor)
Dunlop AccuRay AccuRated Tires 1957 print Ad
ACCURAY OPERATOR CONTROL STATION INTERFACE ASSEMBLY W/ MONITOR + CONTROLS 57850
Accuray 64844-001 64844001 Process Interface Board
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Accuray 61595-003 61595003 Scanner in PWA
Accuray 61580-002 61580002 PC Board
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Accuray 83883-004 83883004 PC Board
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ACCURAY 086158-004 SIO6 A SCANNER CONTROL CIRCUIT BOARD MODULE CARD PC PCB 58615
Accuray 64829-003 64829003 PC Board
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Belmont 071A Accuray Dental Bitewing Intraoral X-Ray w/ Control Box & Mount
ACCURAY NA-B-8-083103 083892 TEMPERATURE CONTROLLER 10 POSITION 45C-80C 52932
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103T-AWD2-RB25C-E1C-KY-SP
SMX48RMBP2U X-Series 48V Ext battery Pack American Power Conversion-APC
APC SURTA1500XL 1500VA 1050W 120V SMART UPS BATTERIES
APC Metered Rack PDU AP7898
APC SU700RMNET USPP SU700RMNET
ABB Power Connection Board 58096652 SAFT 166 APC (3492)
APC Switched Rack PDU
SYBTU1-PLP APC Battery Module Assy.
APC RBC43 Replacement UPS Battery Cartridge 48VDC SUA2200RM2U SUA3000RM2U RBC-43
APC SMX48RMBP2U UPS External Battery Pack
APC Power Supply AWS1000L-2 Input 115V/230V
APC Smart-UPS 750VA/500W Tower UPS with LCD Display, RS-232 Serial, USB SMT750
APC AP7752 RACK ATS, 120V, 20A, L5-20
APC Smart-UPS X 750 VA Tower/Rack Mountable UPS SMX750
APC Smart-UPS SMT1500 1500VA LCD 120V 980W USB Retail
APC SMX48RMBP2U UPS External Battery Pack 48V DC 864Vah
BE750G APC Back-UPS ES 750 Battery Back-Up
APC SMART-UPS 1000VA LCD 230V 670 Watts SMT1000I
85130-60003 Agilent Adapter, 3.5mm NMD to APC-7
APC BP1400 USPP BP1400
Dicon PS-12-1-9-13/1?6-FC/APC
APC SMC15002U Smart UPS C 1500VA 2U LCD SMT1500-2U
APC Smart-UPS SC 1000VA Rack Mountable Tower 600W UPS 19.7 Mins Full Load SC1000
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APC Smart-UPS 1000VA 120V NAFTA USB & SERIAL SUA1000US
Genuine APC 864VAh UPS Replacement Battery Cartridge RBC105 APCRBC105 Open Box
APC SMT1000RM2U 1000VA Smart-UPS LCD RM 2U
APC SMT1500 1500VA Smart-UPS LCD 120V
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APC Smart-UPS SC 1500VA Rack-mountable Tower UPS SC1500
103T-AWD2-RB25C-E1C-KY-SP
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