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Application of SIMATIC S7-300 Programmable Controller in Combination Machine Tool
Injector is a crucial component of diesel internal combustion engines and stands as one of the top products in the oil pump nozzle industry. With the rapid growth of China's automotive sector, the demand for fuel injectors has evolved, requiring not only higher quantities but also improved quality. To meet these new demands, we have developed and manufactured a specialized machine tool designed for the precise processing of fuel injectors.
This machine tool features a complex mechanical structure, with power heads imported from France. It requires high-precision machining, a robust electrical control system, tight workpiece handling, and efficient production capabilities. To achieve the necessary functions—such as drilling, reaming, tapping, and compound drilling—we have implemented a SIEMENS SIMATIC S7-300 programmable controller along with an OP15 character operator panel for comprehensive electrical control.
The machine can operate in automatic, semi-automatic, and manual zero modes, allowing users to set parameters and monitor the running status in real time. In case of failure, the system promptly issues alarm information and accurately identifies the fault, ensuring quick resolution. This intuitive human-machine interface enhances user experience and operational efficiency.
The S7-300 controller uses a modular design that allows easy replacement of components and offers flexible configuration options. The STEP 7 BASIC software provides powerful programming tools, supporting various methods such as online debugging and monitoring of flags, timers, and counters. It also enables PLC fault diagnosis and data retrieval, making system maintenance more straightforward.
The OP15 operator panel directly displays status information, errors, and process variables, offering users a clear view of the machine’s operation and facilitating quick fault detection. The PROTOOL/LITE software is used to customize the OP15’s functions and interfaces, allowing for multiple display screens tailored to different tasks.
The OP15 communicates with the S7-300 via the MPI interface, using the user data area to exchange information. This integration ensures seamless interaction between the control system and the operator interface.
With this advanced hardware and software setup, the system’s software design benefits significantly. The machine tool’s programming follows a distributed approach, breaking the program into independent instruction blocks. Each block handles specific operations, improving modularity and maintainability.
The programming methods include ladder diagrams, statement lists, display blocks, parameter setting blocks, workbench execution blocks, auto-recovery blocks, and dynamic note adjustment blocks. These are organized and called by the main organization block OB1, ensuring smooth coordination across all functions.
After several years of operation, the machine has proven to be highly reliable, with excellent control accuracy and stable performance. It has greatly enhanced the automation level of injector manufacturing, reduced operator workload, and significantly improved overall production efficiency.