Design of PASSIM winding machine electrical control system based on IPC-PLC

The original electrical control system of the PASSIM cigarette making unit consisted of a local PLC and logic circuit board, which had low anti-interference capability, high failure rate, and was prone to false rejection and missed rejection, resulting in low production efficiency and high raw material consumption. To address these issues, a new electrical control system based on IPC-PLC was designed. This system uses an industrial control computer (IPC) as the core of the entire system, a programmable logic controller (PLC) for process control, and PROFIBUS-DP bus for data communication between different systems. It also utilizes EtherCAT industrial Ethernet and TwinCAT real-time systems to achieve cigarette quality inspection and weight control functions. After the upgrade, the PASSIM cigarette making unit operates stably and reliably, accurately detecting and rejecting substandard cigarettes online in real time. The effective operating rate of the unit increased from 90% to over 95%, reducing the consumption of raw materials and improving the automation and networking of equipment management and data acquisition.