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1.1起重機簡介
起重機是一種用來起重與空中搬運重物的機械設備，廣泛應用于工礦企業(yè)、車站、港口、倉庫、建筑工地等部門。它對減輕工人勞動強度、提高勞動生產(chǎn)率、促進生產(chǎn)過程機械化起著重要作用，是現(xiàn)代化生產(chǎn)中不可缺少的工具。起重機包括橋式、門式、梁氏和旋轉式等多種，其中以橋式起重機的應用最廣。
橋式類起重機又分為通用橋式起重機、冶金專用起重機、龍門起重機與纜索起重機等。
橋式起重機是橋架在高架軌道上運行的一種橋架型起重機，又稱天車。橋式起重機的橋架沿鋪設在兩側高架上的軌道縱向運行，起重小車沿鋪設在橋架上的軌道橫向運行，構成一矩形的工作范圍，就可以充分利用橋架下面的空間吊運物料，不受地面設備的阻礙。
1.1.1普通橋式起重機組成部分
（1） 橋架（又稱大車）
橋架是起重機的基本構件，由主梁、端梁、走臺等部分組成。
（2） 大車移動機構
大車移動機構由大車拖動電動機、聯(lián)軸節(jié)、減速器、制動器及車輪等部分。整個橋式起重機在大車移動機構拖動下沿車間長度方向的導軌移動。
（3） 小車
小車安放在橋架導軌上，可沿車間寬度方向移動。小車移動機構由小車電動機、制動器、聯(lián)軸節(jié)、減速器、車輪等部分組成。
（4） 提升機構
提升機構由提升電動機、提升減速器、制動器、卷筒、靜滑輪、吊鉤等部分組成。提升電動機經(jīng)聯(lián)軸節(jié)、制動輪與減速器聯(lián)接，鋼絲繩另一端裝有吊鉤。當卷筒轉動時，吊鉤就隨鋼絲繩在卷筒上纏繞而上升或下降，對于起重量在15t以上的提升機構，一般配備兩套吊鉤上隨著卷筒而獲得上下運動，隨著小車在寬度方向獲得左右運動，隨著大車沿車間長度方向作前后運動，所以就實現(xiàn)了重物在垂直、縱向、橫向三個方向的運動，將重物移動到車向的任一位置。
（5） 駕駛室
駕駛室是操縱起重機的吊艙，駕駛室一般固定在主梁一端的下面，也有少數(shù)裝在小車下方隨小車移動，駕駛室內有小車、大車、提升機構的控制裝置及保護裝置。
1.1.2橋式起重機的工作原理
起重機由大車電動機驅動沿車間兩邊的軌道作縱向前后運動； 小車及提升機構由小車電動機驅動沿橋架上的軌道作橫向左右運動；在升降重物時由起重電動機驅動作垂直上下運動，實現(xiàn)重物在垂直、橫向、縱向三個方向的運動。
1.1.3遙控控制
傳統(tǒng)起重機得控制方法采用凸輪控制器或采用主令控制器與磁力控制屏控制，凸輪控制器和主令控制器均安裝在起重機駕駛室內，操作人員離控制對象比較遠，常因此判斷不準造成定位不準，甚至造成失誤。基于此采用遙控控制裝置，這樣就使操作人員可以在適當?shù)淖鳂I(yè)面利用手中的遙控器發(fā)出控制命令，很方便地控制起重機的工作。
1.2起重機遙控系統(tǒng)的發(fā)展概況
50年代，各類工業(yè)用遙控系統(tǒng)在歐美開始出現(xiàn)。
60年代，以德國HBC為代表的遙控系統(tǒng)制造商開發(fā)了專用于起重機控制的遙控系統(tǒng)，被認為是企業(yè)減少勞動力，實現(xiàn)自動控制的良好途徑。當時歐洲的制造業(yè)、建筑業(yè)等人手不足的現(xiàn)象越來越嚴重，遙控系統(tǒng)的使用漸漸引起人們的重視。
70年代初，采用了與時分制周期傳送方式并用的方法，增加了操作指令，并實現(xiàn)了設計、制造的標準化。
70年代末，采用了當時最先進的CMOS電路，研制出了周期循環(huán)數(shù)字方式的遙控系統(tǒng)，可靠性和安全性有個很大提高。
80年代，采用了集成電路，開發(fā)出了可靠性更高，可持續(xù)的遙控系統(tǒng)。
90年代初，采用了微處理器和大規(guī)模集成電路，使遙控系統(tǒng)的發(fā)展又上了一個新臺階。
近年來，又研制出了具有自動跳頻技術、自動頻率管理技術和各類總線輸出的遙控系統(tǒng)。
1.3起重機遙控控制的優(yōu)點
在科學技術不段發(fā)展的今天，無線遙控技術應用已經(jīng)十分廣泛，大到人造衛(wèi)星，小到家用的空調器、電視機、音響等都使用遙控技術來進行操作。遙控技術的發(fā)展被認為是一種現(xiàn)代化的標志，它可以充分使人從繁雜的體力勞動中解放出來，隨心所欲地從遠距離進行控制，如：電視機的遙控可以使人隨意地躺坐來變換喜歡的電視節(jié)目，使人享受充分的休息。遙控技術的發(fā)展使人們享受著科學的魅力。由于遙控技術可以減低勞動強度、提高勞動生產(chǎn)率及提高作業(yè)的安全性等方面起著積極的作用，在工業(yè)自動化控制中的遙控技術的應用已愈來愈被人們重視。
日常生活中我們使用的無線遙控發(fā)射方式多數(shù)為紅外線型，因其成本低，易于人們接受。但由于該控制方式受發(fā)射距離、方向和條件的限制，局限性較大，應用在工業(yè)無線控制領域就顯不足。而目前廣泛用于工業(yè)無線控制領域的遙控裝置，主流是以無線信號進行傳輸?shù)姆绞健?
以下就起重機用無線遙控系統(tǒng)自身特點、發(fā)展概況、使用優(yōu)勢和遙控系統(tǒng)分類進行簡單介紹。
1.3.1起重機使用遙控系統(tǒng)具有以下幾個優(yōu)點
（1）.節(jié)省人力
a. 對于橋式、門式起重機及汽車起重機等裝卸設備，其操作掛鉤可由一人承擔，操作者可直視操作，不需要指揮。
b. 對于工作效率低的起重機設備，一人可同時管理多臺起重機設備。
c. 可在起重機操縱同時，完成與其關連的輸送帶、加料器、搬運車等其它設備控制和管理。
（2).提高工作效率
a. 由于操作者與地面指揮由一人承擔，操作者可自行判斷，進行作業(yè)，提高了作業(yè)的準確性及工作效率。
b. 避免了過去操作人員與地面指揮之間的誤解，適用于設備組裝等精密安裝作業(yè)。
c. 省去了司機上、下起重機的所帶來的諸多不便。
（3).環(huán)境安全的提高
在有毒氣體、高溫、多粉塵和危險的作業(yè)場地，可選擇環(huán)境好、且安全的位置進行操作，操作者的人身安全得到保護，作業(yè)條件得到改善。
（4）準確的檢查故障
1.3.2起重機用無線遙控系統(tǒng)特點
（1） 可靠性。
遙控系統(tǒng)一旦發(fā)生故障，將影響生產(chǎn)正常運行。因此其系統(tǒng)及系統(tǒng)的硬件必須具有高度的可靠性。
（2） 安全性。
遙控系統(tǒng)是起重機械的控制裝置，如果動作有誤，將發(fā)生物損、人傷的事故。因此必須保證遙控系統(tǒng)的百分之百的安全，具有操作者應能直接進行緊急停車和系統(tǒng)自動急停的安全保護。
（3）抗干擾性強。
能夠不受電焊、電爐及起重機變頻器等的電磁雜波干擾，能夠在小范圍內同時多臺使用，互不干擾。
（4）能在惡劣環(huán)境中使用。
必須具有較強的防塵、防煤氣、耐油、抗沖擊等性能。
輕小型便于操作。
（5）發(fā)射系統(tǒng)由操作者攜帶進行操作，故應體積小、重量輕、攜帶方便。
1.4現(xiàn)有橋式起重機遙控控制缺陷
起重機的遙控控制還未完全普及，其主要原因歸結為目前的遙控接口電路。目前主流遙控接口電路為繼電器—接觸器控制。 起重機的電氣傳動系統(tǒng)多采用繞線式交流電動機，由凸輪控制器直接控制或由主令控制器發(fā)布控制命令給繼電器——接觸器式系統(tǒng)，來切除電機轉子外串電阻的方式進行調速，并且操作完全集中在吊車的駕駛室中進行，傳統(tǒng)遙控操作方式存在以下問題：
1）遙控操作改變了原起重機的運行性能。
為使遙控操作簡便，遙控操作按鍵一般較少，相應地接收機輸出接點也少。一般的起重機均有大車、小車、主鉤和副鉤四個機構，每個機構至少需要遙控器有7個控制點，加上啟動、急停、點動及主鉤快下，則遙控器至少需要32個控制點，接受機需要32個單速按鍵或24個單雙速按鍵，要實現(xiàn)全部功能，操作者須同時操作兩個以上按鍵，操作者即感到操作繁忙，又會造成操作者混亂，形成安全隱患，故遙控器通常設置的輸出點較少，所以用繼電器接觸器接口只能實現(xiàn)原起重機的部分功能，通常各機構以快慢速運行，失去了原起重機五檔調速性能，所以對遙控技術的應用形成了障礙。
2)可靠性差。
繼電器-接觸器接口電路須有繼電器柜，特別是復雜的繼電器控制是最易出現(xiàn)故障的環(huán)節(jié)。兩種接口電路需要接觸器柜，由于起重機經(jīng)常處于頻繁點動等重任務下工作，因此增加了接觸器線圈的損壞，觸點燒損或熔焊、接線松動等故障，尤其是觸點熔焊有可能造成成人身和設備損害的重大事故，因此可靠性差。
3)遙控改造量大，電工維修困難。
兩種接口電路都需要將遙控接口電路串接與原起重機的保護電路中，部分并接在各機構控制的主電路中，因此遙控系統(tǒng)需要很多引出導線，這不僅增加了遙控改造施工的工作量，而且也給日后電工維修系統(tǒng)造成困難。
1.5本課題設計的意義
橋式起重機已在冶金行業(yè)內廣泛使用，由于行業(yè)特點，冶金企業(yè)中的橋式起重機常常在高溫、多粉塵、有毒氣和危險環(huán)境中工作，在橋式起重機的駕駛室進行操作的作業(yè)條件很差，駕駛員的人身安全得不到有效保障。并且有的吊車安裝位置距離地面有30—40m，由于視線不清楚，吊車操作時必須由地有地面人員的指揮才能進行，但有時由于指揮配合不當，存在著很大的事故隱患。
起重機遙控操作，它改善了操作者的操作環(huán)境，拓寬了人員的視野，增加了操作人員的人身安全，減少了操作人員數(shù)量，調高了生產(chǎn)效率。
本文以10t橋式起重機為例，以S7-200PLC+遙控器+減速電機組成作為遙控接口電路進行系統(tǒng)硬件、軟件的設計。由該接口電路組成的遙控系統(tǒng)具有安全可靠、操作簡單、維護方便、系統(tǒng)成本低。可實現(xiàn)原起重機全部控制功能。
1.6系統(tǒng)控制的基本思路
充分利用原凸輪控制器控制方式的操作簡單、維護容易、工作可靠和PLC控制功能強大的特點．將原凸輪控制器的方向盤去掉，安裝聯(lián)軸器，再裝上減速電機，由PLC控制電機的正反方向運行，起重機的運行命令由遙控器發(fā)射器發(fā)出．接收機收到命令后傳給PLC，利用PLC強大的編程功能實現(xiàn)遙控器的功能擴展.根據(jù)按下按鍵的時間長短.控制電機運行的轉角，實現(xiàn)各機構的調速，根據(jù)檢測元件實現(xiàn)機構的限位和零位控制。用PLC+減速電機+ 凸輪控制器+遙控器系統(tǒng)實現(xiàn)遙控，可用簡單的操作實現(xiàn)起重機的全部功能。
1.7系統(tǒng)控制要求
(1)系統(tǒng)能實現(xiàn)起重機原有的全部調速功能；
(2)遙控啟動時各機構凸輪控制器必須在零位：
(3)各機構分別用2個按鍵實現(xiàn)正反方向及調速的控制：
(4)各機構減速時按下相反方向按鍵機構減速至零位為止，不能反向啟動；若要反向啟動，需機構到零位后放開反向鍵，然后再按一次即可；
(5)點動控制時，各機構最高運行在第2擋，放開鍵后自動回到零位；
1.1 crane profile
crane is a used to lifting and air carrying heavy loads of machinery, equipment, widely used in industrial and mining enterprises, station, port, warehouse, construction sites and other departments. It to reduce labor intensity and improve labor productivity and promoting production process mechanization plays an important role in modern production, is the indispensable tools. Crane including bridge type and gantry, LiangShiHe rotary and so on many kinds of, among them with bridge crane's most widely used.
Bridge type class crane and divided into general bridge crane, metallurgy special crane and longmen crane and cable crane, etc.
Bridge crane bridge in elevated rail running on a bridge cranes, also called cranes. Bridge crane along the bridge on both sides laying in the orbit of an elevated along the longitudinal operation, lifting car on the shelf in bridge laying track horizontal operation, constitutes a rectangular scope of work, can make full use of bridge in the Spaces below hoisting the materials, not to suffer ground equipment obstacles.
1.1.1 ordinary bridge crane component
(1)Bridge (also called cart)
Bridge is the basic components, the crane girder, girders, walking machine components.
(2)Cart mobile mechanism
By cart mobile mechanism cart drag motors, couplings, reducer, brake and wheel etc parts. The whole bridge crane mobile mechanism under the cart along the length direction drag the guide moving workshop.
(3)car
Car in bridge guide rail, can move along the workshop width. By car motor car mobile mechanism, brakes, couplings, reducer, wheels components.
(4)Hoisting mechanism
Hoisting mechanism ascension motors, ascending reducer, brakes, drum, static pulley, hooks components. Ascension by coupling, brake wheel motors with reducer connection, and the other end wire rope with hook. When the drum rotating, hook with the wire rope in rolling around and rising or falling, for lifting weight in the ascension of 15t above, the general equipped with two sets of organization on the hook won movement up and down with rolling across the width, along with the car, get along with left movement cart ront-rear movement length direction workshop, so will achieve weight in vertical, vertical, horizontal three directions movement, a move to any position to the car.
(5)cab
The cabin is manipulating crane, cab in general fixed pod girder end of below, also have a few outfit in the car with the car moving, cab below inside car, cart, hoisting mechanism control devices and protection device.
1.1.2 bridge crane principle of work
Crane cart motor drives by the workshop on both sides of the orbit around longitudinally sports; Vehicles and hoisting mechanism by car motor drives on the shelf along the bridge about make lateral movement track; When lifting heavy objects in by lifting motor drives, realize the vertical movement up and down in the vertical, horizontal, weight of longitudinal three directions sport.
1.1.3 remote control
Traditional crane must adopt CAM controller or control method by using the command controller and magnetic control panel control, CAM controller and Lord command controller are installed in crane operators driving indoor is far away from the control object, often so judgment not cause positioning prohibit, even cause errors. Based on this using remote control device, thus gives operators can be in the hands of the appropriate coolie in a controlled command, remote control easily control crane work.
1.2 crane development survey of remote control system
In the 1950s, the various industrial control system in Europe and America began to appear.
In the 1960s, HBC in Germany as a representative of the remote control system manufacturer develops the special-purpose in crane remote-control system, considered firms to reduce labor, a good way for the realization of automatic control. At that time Europe as the manufacturing and construction short-handed phenomenon more and more serious, the use of remote control system gradually attracted people's attention.
By the early 1970s, when transmitted TNSS with the method with periodic way, increased operating instructions, and realized the design, the manufacture of standardization.
In the late 1970s, adopted the most advanced CMOS circuit, developed a cycle of remote control system of digital mode, reliability and safety have a greatly improved.
In the 1980s, adopted integrated circuits, developed a higher reliability, sustainable remote control system.
By the early 1990s, the microprocessor and large scale integrated circuits, make remote control system development and on a new level.
In recent years, and developed with automatic frequency hopping technology, automatic frequency management technology and various bus output remote control system.
1.3he advantages of crane remote control
In science and technology for development today, wireless remote control technology application has been very extensive, big to satellite, small to household air-conditioner, TV, acoustics are using remote control technology to operate. The development of remote control technology was considered a modern symbol, it can be fully make people from multifarious physical labor liberated from a distance, follow one's inclinationsly control, such as: TV remote control can make people sit to transform lie freely favorite TV program, make the person enjoy sufficient rest. Remote control technology development makes people enjoy a scientific charm. Due to control technology can reduce labor intensity, improve labor productivity and improve the safety of homework plays an active role in industrial automation control, the application of the control technology already more and more attention by people.
In daily life we use wireless remote control means of transmission for infrared linetypes, most for its low cost and easy people accept. But as the control mode, direction and distance by launching the constraint of larger, application, limitations in industrial wireless control field shows insufficient. And now it is widely used in the industry of wireless control areas remote control device, the mainstream is the way for transmission wireless signals.
Under with wireless remote control system of crane characteristics, advantages and development situation, use simple introduction of remote control system classification.
1.3.1 cranes use remote control system has the following a few advantages
(1). Save manpower
For bridge type and gantry crane and automobile crane, loading and unloading equipment, its operation can be borne by one link operator may look operation, need not command.
For work efficiency low crane equipment, one can also manage multiple crane equipment.
But in crane, complete with manipulating and associated conveyer, plus other equipment van distributor, control and management.
(2). Improving work efficiency
Due to the operator and the ground control by one bear operator may decide, and assignments, improve the working efficiency and accuracy of the assignments.
Avoid the past operators and ground command misunderstandings among, apply to equipment assembling etc. Precise installation work.
Tell the driver, under a crane brings a lot of inconvenience.
(3). Environmental safety improvement
In toxic gases, high temperature, dust and dangerous work site, optional choose good environment, and safe operation, the position of the operator's personal safety protected, operation conditions improve.
(4) accurate inspection fault
1.3.2 With wireless remote control systemcrane characteristics
Reliability.
Remote control system once breaks down, will affect the normal operation of production. So the system and hardware must have high reliability.
Safety.
Remote control system of crane control device, if the action that will happen is wrong, the accident loss, wounded. Therefore must ensure that remote control system of 100 percent security, with the operator should be able to direct the emergency stop and automatically abrupt stop safety protection.
(3) strong anti-jamming.
Can not be electric welding, such as electric and crane inverter electromagnetic clutter interference, can in the small scope and multiple use, not interfere with each other.
(4) can use in bad environment.
Must have strong dustproof, gas, oil resistance, impact resistant properties.
Light and small operation is convenient.
(5) launch system is operated by the operator, reason should carry small volume, light weight, easy to carry
1.4 existing bridge crane remote control flaw
Crane's remote control are not completely popularization, the main reason boils down to the current remote control interface circuit. At present the mainstream remote control interface circuit for relays - contactor controlling. Crane electric drive system used more winding type ac motor, the CAM controller directly control or by Lord command controller release control command to relay - contactor system, to resection of motor rotor resistance of the way, and the operation speed totally on the crane in the cockpit, the traditional remote operation way has the following questions:
1) remote operation changed the original crane's performance.
To make remote operation is simple, remote control buttons generally less, correspondingly receiver output contacts are also less. General crane cart, car, are main hook and vice hook four agencies, each agency needs at least remote seven points, plus start, abrupt stop and point move and main hook fast, the remote control under need at least 32 points, accept machines need to be 32 single speed buttons or 24 dual speed key, to realize the full function, the operator must operating simultaneously two or more buttons, the operator that feel operation busy, and will cause confusion, forming operator safe hidden trouble, so remote usually set the output points less, so use relay contactor interface can realize the partial function of the crane, usually agencies to speed speed operation, lost original crane five timings.this performance, so the application of remote control technology to form the obstacles.
2) poor reliability.
Relays - contactor interface circuit must have relay ark, especially complex relay control is the most easy to malfunction link. Two kinds of interface circuit need contactor ark, often in frequent points because crane and other heavy work under dynamic task, hence increasing contactor coils damage, the contacts burning or welded, wiring looseness fault, especially contacts as welding is likely to cause damage to personal and equipment into a major accident, so poor reliability.
3) remote GaiZaoLiang big, electrical maintenance difficulties.
Two kinds of interface circuit all need will pick up and remote control interface circuit string of original crane protection circuit, part and taken up in institutions in the main circuit control, so remote control system requires a lot of lead wire, it not only increased workload of remote modification construction, but also for future electrician maintenance system cause difficulties.
1.5 The significance of this topic design
Bridge crane has been widely used in metallurgical industry, because within the profession characteristic, metallurgical enterprise bridge crane is often in high temperature, much dust, poisonous gas and danger of working environment, in bridge crane operation homework cab driver bad conditions, without effective safeguard the personal safety. And some crane installation position has 30 - from the ground, because 40m sight is not clear, crane operation must have the ground staff by the command, but sometimes can proceed with improper, due to command the exist great potential accident.
Crane remote operation, it improved operator operating environment, and widened the field of vision, personnel increased operating personnel's personal safety and reduce the operating personnel quantity, raise the efficiency.
Taking 10t bridge crane, for example, with s7-200 PLC + remote + deceleration motor as a remote control interface circuit of the system hardware and software design. Composed by the remote control system of interface circuit with safe and reliable, simple operation, easy maintenance, low cost of a system. The crane can realize all control function.
1.6The basic thought of system control
Make full use of the original CAM controller control mode of simple operation, easy maintenance, reliable and PLC control powerful features. Will the original CAM controller, installed coupling, remove the steering wheel gear motor on reload, controlled by PLC motor running, the positive and negative direction by remote control run command crane. Receiver transmitter after receiving orders issued to PLC, using PLC powerful programming function realizes remote function expansion. According to press the button. Control the length of time the motor running corner, realize the agencies, according to the detection speed limit and the organization components control zero. Use PLC + decelerating motors + CAM controller + remote control system implement remote control, simple operation to realize the crane can all the functions.
1.7 system control requirements
(1) the system can realize all the speed adjustment crane original;
(2) remote start-up agencies CAM controller must in zero:
(3) agencies respectively with two buttons realize the positive and negative direction and speed control:
(4) agencies deceleration press the opposite direction key institutions slow to zero so far, cannot reverse launched; If want to reverse startup, need to institutions to zero, then reverse key after release can; click again
(5) the point start control, agencies operating in the second highest block, let go back to zero; automatic key
The second chapter PLC technology introduction
1. PLC overview
Programmable program controller (Programmable Controler), also known as PLC (Programmable Controler) questions, is to Programmable Logic controller. The use of computer architecture, mainly including the CPU, memory, input and output interface and module, communication interface and module, the programmer and power six parts. As shown in figure 4.1 shows, PLC, by bus structure internal instructions and data transmission. External various switch signals, the analog signals, sensor test various signals are as PLC, input variables, by PLC external input terminals their input into the internal registers, by PLC internal logic operations or various other operational treatment to output terminals, as the output variables of PLC, carry out various control field devices
2. The performance index of programmable controller
Programmable controller performance index is more, different manufacturer programmable controller product technical performance each are not identical, each have characteristics. Usually can use the following several performance indicators are described herein.
(1). The I/O points
The I/O points refers to programmable controller composition control system can access the maximum number of input and output signals, can programmable controller external input and output terminals number. Usually, in total points, input and output points, points than input and output point not an alternative.
(2). Scanning speed
General with executive 1000 steps needed time to measure the instruction, the unit for