目录
项目 1 智能制造发展与应用状况分析 ····································································· 1
1.1 项目描述 ······························································································· 1
1.1.1 工作任务 ······················································································ 1
1.1.2 任务要求 ······················································································ 2
1.1.3 学习成果 ······················································································ 2
1.1.4 学习导图 ······················································································ 2
1.2 工作任务书 ···························································································· 2
1.3 知识准备 ······························································································· 3
1.3.1 智能制造的概念 ············································································· 3
1.3.2 智能制造的应用领域 ······································································· 4
1.4 任务实施 ······························································································· 7
1.5 任务评价 ······························································································· 8
1.6 任务拓展 ······························································································· 9
项目 2 智能生产线的布局规划 ············································································· 11
2.1 项目描述 ······························································································ 11
2.1.1 工作任务 ····················································································· 11
2.1.2 任务要求 ····················································································· 11
2.1.3 学习成果 ····················································································· 11
2.1.4 学习导图 ···················································································· 12
2.2 工作任务书 ·························································································· 12
2.3 任务实施 ····························································································· 13
2.3.1 生产线的模型导入 ········································································ 13
2.3.2 智能生产线布局规划表 ·································································· 31
2.4 任务评价 ····························································································· 31
2.5 任务拓展 ····························································································· 32
项目 3 智能生产线的整体设计与规划 ··································································· 34
3.1 项目描述 ····························································································· 34
3.1.1 工作任务 ····················································································· 34
3.1.2 任务要求 ····················································································· 34
3.1.3 学习成果 ····················································································· 34
3.1.4 学习导图 ····················································································· 35
3.2 工作任务书 ·························································································· 35
3.3 知识准备 ····························································································· 36
3.3.1 智能生产线的设计原则 ··································································· 36
3.3.2 智能生产线设计的一般流程 ····························································· 36
3.3.3 夹爪的选型原则 ············································································ 37
3.3.4 气缸的选型原则 ············································································ 37
3.3.5 传感器的选型原则 ········································································· 38
3.4 任务实施 ····························································································· 39
3.4.1 客户需求与生产工艺分析 ································································ 39
3.4.2 智能生产线的布局及三维建模 ·························································· 39
3.4.3 工序、生产节拍的确定 ··································································· 41
3.4.4 智能生产线的虚拟仿真验证 ····························································· 41
3.4.5 按照客户需求下单采购设备 ····························································· 60
3.4.6 智能生产线的现场调试 ··································································· 61
3.4.7 智能生产线的维护与维修 ································································ 61
3.4.8 智能生产线设计说明书 ··································································· 61
3.5 任务评价 ····························································································· 62
3.6 任务拓展 ····························································································· 63
项目 4 智能生产线的认知 ··················································································· 64
4.1 项目描述 ····························································································· 64
4.1.1 工作任务 ····················································································· 64
4.1.2 任务要求 ····················································································· 64
4.1.3 学习成果 ····················································································· 65
4.1.4 学习导图 ····················································································· 65
4.2 工作任务书 ·························································································· 65
4.3 知识准备 ····························································································· 66
4.3.1 智能生产线功能介绍 ······································································ 66
4.3.2 智能生产线的工艺流程 ··································································· 67
4.4 任务实施 ····························································································· 67
4.4.1 智能生产线的结构认知 ··································································· 67
4.4.2 智能生产线的关键技术认知 ····························································· 69
4.4.3 智能生产线的主要元器件认知 ·························································· 71
4.4.4 智能产线的物料流和信息流分析 ······················································· 72
4.4.5 智能生产线认知说明书 ··································································· 73
4.5 任务评价 ····························································································· 74
4.6 任务拓展 ····························································································· 75
项目 5 智能生产线的操作 ·················································································· 76
5.1 项目描述 ····························································································· 76
5.1.1 工作任务 ···················································································· 76
5.1.2 任务要求 ···················································································· 77
5.1.3 学习成果 ···················································································· 77
5.1.4 学习导图 ···················································································· 77
5.2 工作任务书 ·························································································· 77
5.3 知识准备 ····························································································· 78
5.3.1 智能生产线安全操作规程 ······························································· 78
5.3.2 安全标识认识 ·············································································· 79
5.4 任务实施 ····························································································· 80
5.4.1 开机前的智能生产线检查 ······························································· 80
5.4.2 智能生产线的上电初始化操作流程 ··················································· 83
5.4.3 智能生产线的操作模式 ·································································· 84
5.4.4 智能生产线的 Default 模式 ······························································ 85
5.4.5 智能生产线的 MES 模式 ································································· 87
5.4.6 智能生产线的急停操作流程 ···························································· 96
5.4.7 智能生产线操作说明书 ·································································· 98
5.5 任务评价 ····························································································· 99
5.6 任务拓展 ···························································································· 100
项目 6 智能生产线的安装 ················································································· 101
6.1 项目描述 ···························································································· 101
6.1.1 工作任务 ··················································································· 101
6.1.2 任务要求 ··················································································· 101
6.1.3 学习成果 ··················································································· 101
6.1.4 学习导图 ··················································································· 101
6.2 工作任务书 ························································································· 102
6.3 知识准备 ···························································································· 103
6.3.1 智能生产线的主要部件 ································································· 103
6.3.2 各类传感器的安装注意事项 ··························································· 103
6.3.3 各类气缸的安装注意事项 ······························································ 104
6.3.4 电磁阀的安装注意事项 ································································· 104
6.4 任务实施 ···························································································· 104
6.4.1 打开模型并进入“机电概念设计”应用模块 ······································ 104
6.4.2 电气柜的组装 ············································································· 105
6.4.3 传输带的组装 ·············································································· 110
6.4.4 支架机构的组装 ··········································································· 126
6.4.5 控制模块的组装 ··········································································· 129
6.4.6 滑台的组装 ················································································· 133
6.4.7 移动轴的组装 ·············································································· 137
6.4.8 输出单元的整体组装 ····································································· 147
6.5 任务评价 ···························································································· 153
6.6 任务拓展 ···························································································· 154
项目 7 智能生产线调试准备 ··············································································· 155
7.1 项目描述 ···························································································· 155
7.1.1 工作任务 ···················································································· 155
7.1.2 任务要求 ···················································································· 155
7.1.3 学习成果 ···················································································· 156
7.1.4 学习导图 ···················································································· 156
7.2 工作任务书 ························································································· 156
7.3 知识准备 ···························································································· 157
7.3.1 智能生产线信号点位测试 ······························································· 157
7.3.2 智能生产线调试的流程说明 ···························································· 157
7.4 任务实施 ···························································································· 158
7.4.1 智能生产线调试前的安全检查 ························································· 158
7.4.2 智能生产线调试前的资料准备 ························································· 158
7.4.3 智能生产线调试前的信号点位测试 ··················································· 159
7.4.4 智能生产线调试准备手册 ······························································· 160
7.5 任务评价 ···························································································· 160
7.6 任务拓展 ···························································································· 161
项目 8 智能生产线单站点调试 ············································································ 163
8.1 项目描述 ···························································································· 163
8.1.1 工作任务 ···················································································· 163
8.1.2 任务要求 ···················································································· 164
8.1.3 学习成果 ···················································································· 164
8.1.4 学习导图 ···················································································· 164
8.2 工作任务书 ························································································· 164
8.3 知识准备 ···························································································· 165
8.4 任务实施 ···························································································· 167
8.4.1 钻孔单元的 MCD 设置 ·································································· 167
8.4.2 虚拟 PLC 的建立 ·········································································· 196
8.4.3 TIA 博途环境的搭建 ····································································· 198
8.4.4 外部信号的通信 ·········································································· 204
8.4.5 钻孔单元的虚拟调试 ···································································· 206
8.5 任务评价 ···························································································· 207
8.6 任务拓展 ···························································································· 208
项目 9 智能生产线综合调试 ·············································································· 209
9.1 项目描述 ···························································································· 209
9.1.1 工作任务 ··················································································· 209
9.1.2 任务要求 ··················································································· 210
9.1.3 学习成果 ··················································································· 210
9.1.4 学习导图 ··················································································· 210
9.2 工作任务书 ························································································· 210
9.3 知识准备 ···························································································· 211
9.3.1 智能生产线的工艺流程 ································································· 211
9.3.2 智能生产线虚实联调的步骤 ··························································· 212
9.3.3 I/O Link 通信 ·············································································· 212
9.4 任务实施 ···························································································· 216
9.4.1 智能生产线的 MCD 设置 ······························································· 216
9.4.2 OPC Link 的设置 ········································································· 258
9.4.3 TIA 博途环境的搭建 ····································································· 259
9.4.4 MCD 外部信号配置 ······································································ 265
9.4.5 MCD 信号映射 ············································································ 265
9.4.6 智能生产线的虚实联调 ································································· 268
9.5 任务评价 ···························································································· 269
9.6 任务拓展 ···························································································· 270
项目 10 智能生产线的维护与维修 ······································································· 271
10.1 项目描述 ·························································································· 271
10.1.1 工作任务 ·················································································· 271
10.1.2 任务要求 ·················································································· 271
10.1.3 学习成果 ·················································································· 271
10.1.4 学习导图 ·················································································· 271
10.2 工作任务书 ······················································································· 272
10.3 知识准备 ·························································································· 273
10.3.1 维护与维修的概念 ······································································ 273
10.3.2 维护与维修基本知识 ··································································· 273
10.3.3 智能生产线维护的常见方式 ·························································· 274
10.3.4 智能生产线的维护方式和内容 ······················································· 274
10.3.5 维护与维修的安全注意事项 ·························································· 276
10.4 任务实施 ··························································································· 276
10.4.1 智能生产线的维护保养 ································································ 276
10.4.2 仓储单元的故障分析与记录总结 ···················································· 277
10.4.3 智能生产线的维护手册 ································································ 278
10.4.4 智能生产线的维修手册 ································································ 279
10.5 任务评价 ··························································································· 279
10.6 任务拓展 ··························································································· 280
项目 11 智能生产线的验收与交付 ······································································· 282
11.1 项目描述 ··························································································· 282
11.1.1 工作任务 ·················································································· 282
11.1.2 任务要求 ·················································································· 282
11.1.3 学习成果 ·················································································· 282
11.1.4 学习导图 ·················································································· 282
11.2 工作任务书 ························································································ 283
11.3 知识准备 ··························································································· 284
11.4 任务实施 ··························································································· 284
11.4.1 智能生产线验收前的项目需求清单 ················································· 284
11.4.2 培训方案的制作与实施 ································································ 285
11.4.3 培训记录与成本核算 ··································································· 287
11.4.4 智能生产线交付清单 ··································································· 288
11.5 任务评价 ··························································································· 289
11.6 任务拓展 ··························································································· 290
参考文献 ········································································································· 292

宋志刚，工学硕士，副教授，广东省高等学校“千百十工程”培养对象，液压与气动控制工高级考评员，工业机器人系统运维员技师，中国机电一体化技术应用协会培训专委会副主任。曾获校长教学质量奖，中国机电职业教育行业教学名师，深圳职业技术学院教书育人标兵，优秀教师等荣誉称号。主要参与国家精品课程和国家精品资源共享课《液压与气动技术》及国家职业教育专业教学资源库《液压与气压控制》课程的建设工作。在“机械科学与技术”、“液压与气动”等刊物上发表论文15余篇，主编出版教材5部，其中1部“十四五”职业教育国家规划教材，1部数字化教材；获得8项机电一体化类专利授权，3项软件著作权和6项作品著作权等。