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Application of SIMATIC S7-300 Programmable Controller in Combination Machine Tool
Injector is a critical component of diesel internal combustion engines and plays a vital role in the oil pump nozzle industry. As China's automotive sector continues to grow, the demand for fuel injectors has increased significantly, not only in volume but also in quality. To meet these evolving requirements, we have developed and manufactured a specialized combination 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 demands high precision in machining, a robust electrical control system, tight tolerances during workpiece processing, and high production efficiency. To achieve the required functions—such as drilling, reaming, tapping, and compound drilling—we have implemented a SIEMENS SIMATIC S7-300 programmable controller combined with an OP15 character operator panel. This setup enables full electrical control of the machine, supporting automatic, semi-automatic, and manual zero modes. Users can easily set parameters and monitor the machine’s operational status in real time.
In case of any malfunction, the system promptly issues alarm signals and accurately identifies the fault, ensuring quick resolution. The intuitive human-machine interface enhances usability and improves overall system performance. The S7-300 controller uses a modular DIN rail design, allowing for easy replacement of components. Its powerful STEP 7 BASIC software supports multiple programming methods, enabling online debugging, monitoring of flags, timers, and counters, and efficient PLC fault diagnosis.
The OP15 operator panel provides direct display of process variables, error messages, and system status, making it easier for operators to monitor machine conditions and locate faults. The PROTOOL/LITE software is used to customize the panel’s interface, allowing for various display screens tailored to specific tasks. Communication between the OP15 and the S7-300 is achieved through the MPI interface, with data exchanged via the user-defined data area.
With this advanced hardware and software configuration, the system benefits from a well-structured and efficient software design. The machine tool’s programming follows a distributed approach, dividing the program into independent blocks, each responsible for a specific operation group. These blocks include ladder diagrams, instruction lists, display blocks, parameter settings, workbench execution, auto-recovery, and dynamic adjustment functions. All are called by the main organization block OB1 to ensure coordinated and reliable operation.
After years of continuous use, the system has proven to be highly reliable, accurate, and efficient. It has significantly improved the automation level of injector manufacturing, reduced operator workload, and enhanced overall productivity.