Mastering Precision Control Technology of Fiber Sensors with S7-1200

Part One: Application Overview

In the field of modern industrial automation, fiber sensors have become key monitoring devices due to their high precision and anti-interference characteristics. This project will implement precise control and data acquisition of fiber sensors through the Siemens S7-1200 PLC. Readers will learn how to build a reliable industrial measurement system, which not only enhances technical capabilities but also lays a solid foundation for future career development in automation. This tutorial is suitable for university students and junior engineers in electronics and automation.

Part Two: Hardware Configuration

Hardware List:

1. Siemens S7-1200 CPU module
2. Fiber sensor (e.g., KEYENCE FU-77 model)
3. Power module (24V DC power supply)
4. Conversion interface module
5. Data acquisition connection cable

Hardware connection diagram:

Power → PLC power input → CPU module → Conversion interface → Fiber sensor

Key Parameters:

• PLC operating voltage: 24V DC
• Sensor response time: <1ms
• Measurement accuracy: ±0.1mm

Part Three: Program Design Ideas

The control system will be implemented through the following core processes:

1. Sensor signal acquisition
2. Data preprocessing
3. Threshold judgment
4. Output control

Program flowchart:

[Signal Acquisition] → [Data Preprocessing] → [Threshold Comparison] → [Execute Output]
       ↑_____[Exception Handling]_____↓

Key Technical Points:

• High-speed signal acquisition
• Digital filtering algorithm
• Real-time threshold judgment

Part Four: Program Code Implementation

PROGRAM Main
VAR
    SensorInput: BOOL;   // Sensor input signal
    AlarmOutput: BOOL;   // Alarm output
    Distance: REAL;      // Measured distance
    Threshold: REAL := 50.0;  // Threshold setting
END_VAR
// Main program logic
IF SensorInput THEN
    // Read sensor data
    Distance := ReadSensorData();
    // Threshold judgment
    IF Distance > Threshold THEN
        AlarmOutput := TRUE;  // Trigger alarm
    ELSE
        AlarmOutput := FALSE; // Turn off alarm
    END_IF
END_IF

Part Five: Debugging Methods

Common Problem Solutions:

1. Unstable signal

* Check wiring
* Adjust shielding

1. Large measurement error

* Calibrate the sensor
* Optimize the filtering algorithm

Debugging Suggestions:

• Use an oscilloscope to monitor signals
• Segment testing
• Keep a debugging log

Part Six: Function Expansion

Possible further expanded functions:

1. Data recording and analysis
2. Remote monitoring
3. Multi-sensor fusion
4. Intelligent early warning system

Application Fields:

• Precision manufacturing
• Warehouse logistics
• Medical equipment

Part Seven: Conclusion

This project demonstrates the fascinating world of industrial automation through precise control of fiber sensors with the S7-1200 PLC. Through practice, readers will master core skills such as PLC programming and sensor application. In the future, continuous learning and practice will make them excellent engineers in the field of automation.

Friendly reminder: While theoretical learning is important, practice is the only standard to test true knowledge. Let’s explore the infinite possibilities of technology through hands-on practice!

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