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近幾年，隨著我廠生產(chǎn)規(guī)模的逐步擴(kuò)大，就更加要求氣體調(diào)節(jié)在生產(chǎn)中的穩(wěn)定性和快速性，而目前傳統(tǒng)的二次儀表已無法滿足現(xiàn)有的控制需求。主要表現(xiàn)在：

　　1)過程自動(dòng)化程度低，信息采集和反饋仍采用傳統(tǒng)的二次儀表，致使數(shù)據(jù)采集緩慢、調(diào)節(jié)滯后，降低了系統(tǒng)運(yùn)行的穩(wěn)定性。

　　2)儀表內(nèi)部信息儲(chǔ)存量小，采集的壓力、流量等數(shù)據(jù)無法長期保存，不便于日后生產(chǎn)工作的歷史查詢和分析。

　　3)系統(tǒng)可靠性低，需要配專人負(fù)責(zé)該系統(tǒng)的運(yùn)行，造成了人工成本的上升。

　　鑒于以上三點(diǎn)，通過采用PLC(可編程控制器)控制系統(tǒng)，解決當(dāng)前存在的問題。

　　1、PLC控制系統(tǒng)的特點(diǎn)及組成

　　PLC在現(xiàn)代工業(yè)控制領(lǐng)域中早己得到了廣泛的應(yīng)用。以PLC的控制功能而言，具有嚴(yán)謹(jǐn)、方便、易編程、易安裝、可靠性高等優(yōu)點(diǎn)。它通用性強(qiáng)，適應(yīng)面廣，特別在數(shù)字量輸入/輸出等邏輯控制領(lǐng)域有無可比擬的優(yōu)點(diǎn)。PLC具有豐富的邏輯控制指令和應(yīng)用指令，它提供高質(zhì)量的硬件、高水平的系統(tǒng)軟件平臺(tái)和易學(xué)易編程的應(yīng)用軟件平臺(tái)。另外，PLC即有自身的網(wǎng)絡(luò)體系又有開放I/0及通訊接口，很容易組建網(wǎng)絡(luò)并實(shí)現(xiàn)遠(yuǎn)程訪問。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場的PLC系統(tǒng)與主控室的上位機(jī)距離較遠(yuǎn)(800米左右)，因此通訊系統(tǒng)需成對加裝RS-485中繼器，另外在現(xiàn)場增加TP27-10//觸摸屏進(jìn)行數(shù)據(jù)顯示，確保系統(tǒng)運(yùn)行的穩(wěn)定性。

　　1.1系統(tǒng)結(jié)構(gòu)及硬件配置

　　根據(jù)控制需求，CPU模塊采用CPU314、數(shù)字量輸入(DI)采用SM321模塊，數(shù)字量輸出(DO)采用SM322模塊，模擬量輸入(AI)采用SM331模塊，模擬量輸出(AO)采用SM332模塊以及IM365等模塊組成，IM365實(shí)現(xiàn)機(jī)架擴(kuò)展，上位監(jiān)控機(jī)采用SIEMENS公司CP5611網(wǎng)卡完成計(jì)算機(jī)與PLC之間的數(shù)據(jù)通訊。整個(gè)通訊網(wǎng)絡(luò)采用MPI的通訊協(xié)議，從上位機(jī)上可對整個(gè)氣體調(diào)節(jié)過程進(jìn)行監(jiān)控和操作。

　　1.2控制系統(tǒng)的功能實(shí)現(xiàn)

　　PLC程序的編制直接關(guān)系著供氣系統(tǒng)能否正常工作，而程序設(shè)計(jì)的關(guān)鍵在于編程者對工藝系統(tǒng)的理解程度和程序編制技術(shù)的靈活應(yīng)用。因此，在程序設(shè)計(jì)中首先考慮了供氣壓力調(diào)節(jié)系統(tǒng)的特點(diǎn)，將程序設(shè)計(jì)細(xì)化，分成多個(gè)程序模塊，實(shí)行模塊化編程。這樣既可以方便的增加或刪除程序模塊，便于現(xiàn)場對工藝的調(diào)整，又可針對配套設(shè)備可控性對不同程序模塊進(jìn)行完善。

　　PLC的編程軟件采用SIEMENS公司的SIMATICSTEP7V5.1軟件平臺(tái)用來完成硬件組態(tài)、地址和站址的分配以及編制整個(gè)生產(chǎn)過程的控制程序的。上位機(jī)監(jiān)控軟件采用國產(chǎn)軟件組態(tài)王，全部采用漢化界面，便于系統(tǒng)的開發(fā)與操作，該系統(tǒng)運(yùn)行于Windows2000中文平臺(tái)，可實(shí)現(xiàn)對生產(chǎn)過程的全面監(jiān)控，對重要參數(shù)形成歷史記錄，以報(bào)表或曲線的形式顯示給操作人員。通過VB語言腳本，可以在主控室的上位機(jī)顯示重要參數(shù)的歷史趨勢、實(shí)時(shí)趨勢，實(shí)現(xiàn)壓力調(diào)節(jié)的手自動(dòng)切換、操作、壓力的高、低限報(bào)警、流量數(shù)據(jù)的顯示與累計(jì)，滿足高生產(chǎn)率的調(diào)度需求。

　　1.3現(xiàn)場顯示

　　現(xiàn)場采用TP27觸摸屏進(jìn)行參數(shù)顯示、控制，觸摸屏程序由組態(tài)軟件來完成，人機(jī)界面采用中文菜單，界面友好，操作方便，功能較強(qiáng)，主要用于現(xiàn)場壓力、流量、閥位的顯示與操作。可作為操作人員現(xiàn)場操作的依據(jù)。

　　1.4工控機(jī)配置

　　工控機(jī)采用研華IPC-610，通過CP5611卡，完成S7-300PLC與工控機(jī)的通訊。主要完成下列任務(wù)：傳送現(xiàn)場監(jiān)控?cái)?shù)據(jù);運(yùn)行監(jiān)控;故障記錄和排除提示;參數(shù)設(shè)置;生產(chǎn)數(shù)據(jù)管理和處理;圖形化示教和離線編程。

　　2系統(tǒng)實(shí)現(xiàn)了供氣系統(tǒng)的自動(dòng)控制和監(jiān)控，主要包括如下功能：

　　1)靈活的操作方式以及強(qiáng)大的系統(tǒng)控制功能：

　　系統(tǒng)可以實(shí)現(xiàn)上位機(jī)操作、控制柜觸摸屏操作和就地手動(dòng)操作;

　　2)報(bào)警功能：

　　當(dāng)壓力超過工藝要求，可在現(xiàn)場、就地實(shí)現(xiàn)高、低限壓力報(bào)警;

　　3)簡單、方便的參數(shù)設(shè)定：

　　壓力調(diào)節(jié)閥的壓力設(shè)定值、P、I、D等參數(shù)可以在上位機(jī)中設(shè)定。

　　2、系統(tǒng)控制功能

　　(1)過程控制的功能：

　　1)系統(tǒng)對供氣壓力實(shí)現(xiàn)了PID自動(dòng)調(diào)節(jié)控制;

　　2)對所采集的模擬信號進(jìn)行線性化、濾波、工程單位轉(zhuǎn)換處理;

　　3)實(shí)現(xiàn)了流量信號的溫、壓補(bǔ)償，提高了儀表的測量精度。

　　(2)邏輯控制

　　聯(lián)鎖邏輯控制實(shí)現(xiàn)開/關(guān)的控制，邏輯控制及用戶自定義功能塊等。系統(tǒng)實(shí)現(xiàn)了電磁閥控制以及參數(shù)越限報(bào)警等功能。

　　(3)人機(jī)接口

　　HMI系統(tǒng)中包含主工藝畫面，各系統(tǒng)送氣壓力、流量，供氣壓力調(diào)節(jié)等多幅畫面，畫面直觀、豐富，具備PID在線調(diào)節(jié)、在線顯示調(diào)節(jié)曲線功能，包括過程量變化趨勢的實(shí)時(shí)趨勢曲線、歷史趨勢曲線。

　　(4)報(bào)表打印

　　以報(bào)表形式繪制報(bào)警記錄、歷史記錄畫面，調(diào)節(jié)間數(shù)據(jù)報(bào)表。實(shí)時(shí)趨勢曲線和歷史趨勢曲線可隨意設(shè)定時(shí)間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設(shè)計(jì)

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設(shè)計(jì)過程中著重要考慮的是以下幾個(gè)方面：

　　(1)數(shù)據(jù)采集及工程量轉(zhuǎn)換

　　(2)PID算法

　　(3)流量溫壓補(bǔ)償計(jì)算以及流量的累積計(jì)算

　　對于系統(tǒng)中的邏輯控制選用梯形圖(LADDER)編程，直觀、方便;對于PID回路控制流量溫壓補(bǔ)償計(jì)算以及流量的累積計(jì)算部分則采用語句表(STL)編程，結(jié)構(gòu)緊湊而又靈活。

　　PID調(diào)節(jié)是該系統(tǒng)中zui為重要的控制程序，因此特將PID算法作一重點(diǎn)介紹

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Operator Interface 2711-T6C1L1 PV600 COLOR TOUCH, RIO & RS232 PRINT

Support 9301-2SE3100FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE3100FR

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DeviceNet Products 1734-RTBS REPLACEMENT IEC SPRING TERMINAL BLOCK

RSI Software Products 9301-2SE3200KOE RSVIEW32 RUNTIME 300 (KOREAN)

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QPI31200E2P/B 9 inch Monochrome EL/ Blank Label/ 110VAC/ No Agency Approvals

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21G1ABD710AN2NNNNN-ND-L1-P5 PowerFlex Air Cooled 755 Packaged Drive

2711P-RDT7CM PanelView Plus Display Module

280E-FN-25-C ArmorStart Direct Online Starter

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IC800SLCBVL050 Power/Brake Cable, 3500W and 5000W SL Servo Motors with Brake, 5 Meters

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IC752SKT011 DataPanel 240E Starter Kit: includes Datapanel 240E (BDT100), download & Communication cables, DataDesigner, user & programming manuals

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25A-E027N104 PowerFlex 523 18.5kW (25Hp) AC Drive

2711P-T6M5A8 PanelView Plus 6 6 Gray Touch AC RS232

6SE6440-2UD35-5FB1 55KW

1492-L2-Y 1-Ckt Feed-Through Blk 1.5mm

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1746-R15 SLC Replacement Retainer Clip

1790-T8A0X CompactBlock LDX 8 Expansion Block

194E-A16-PD10 194E 1 NO-EB Auxiliary Contact Block

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GC646CFG100 Proficy GlobalCare for VersaPro Remote IO Manager

HE660CGM224 Discontinued Part. Check with GE IP on migration path.

IC600LR616RR 8K/8K Combined Memory

IC647HSTES5000KM Historian Enterprise Server 5,000,000 Points (M4 Key)

IC651ENS042 Series 90-70 TCP/IP Ethernet LAN Software

IC694BEM331 RX3i Genius Bus Controller (supports I/O and Datagrams). Module connectsto the serial bus. Requires CPU firmware 2.9 or higher and requires Proficy Machine Edition Version 5.00 SP1A Logic Developer-PLC, Hot Fix 1or later for configuration.

IC756SDV001E-925 "DataViews Development on Solaris Op Sys, Addt'l User, English v9.25 "

MicroLogix 1500/1769 System 1764-MM2 MICROLOGIX 1500 16K MEMORY MODULE

PLC-5/1771 System 1771-WI THERMOCOUPLE WIRING ARM FOR IXE, 18 TERMINALS

Distributed I/O 1794-ID2 2-CHANNEL INCREMENTAL ENCODER INPUT MODULE

Communications 9399-WAB32UGPT RSLINX USERS GUIDE (PORTUGUESE)

Support 6233-5VDLS SUPT RENEWAL CONTRACT FOR 62335VDL

Support 9358-BPMG02S SUPT RENEWAL CONTRACT FOR 9358BPMGR02ENE

Support F1771-KA2 FIRMWARE UPGRADE FOR 1771-KA2 COMMUNICATION MODULE

RSI Software Products 9324-RLD0U6ESE RSLOGIX 5000 SERVICE ED TO FULL UPG, UPG

RSI Software Products 9301-2SE350PTU3R RSVIEW32 RUNTIME 300-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-MTRCK02U1 UPGRADE: IN-SUPT: RSBW MATERIALTRACK 1 TO 03

Motion Control 8720SM-018S2FAS3 18.5KW/41.4AMP,750 VDC,AMPAC MOTOR WITH SNS60 ENC.

829-4-AC Thumbwheel Assembly. 4 Digit, AC Logic. Dust Seal

IC200MDL650 INPUT 24VDC POS/NEG LOGIC (4 GROUPS OF 8) 32PT

IC697VAL132 Analog Input, 12bit, 32 channel single ended or 16 channel differential, 0-20ma. Module has removable terminal block, no cable required

MTR-1324-N-D-E-0RR Stepping Motor Nema34 Nema34

ZA06B-0033-B175#7008 B3/3000 servo motor with holding brake and 32k serial encoder

20BD125A3ANNAEC0 PowerFlex 700 AC Drive 20B

20G11ND040AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF039-CL PowerFlex 4M EMC Filter Kit

110XCA28203 Momentum RS232 COMM CABLE 6M (OEM)

294E-FD1P5Z-G1-3-SB Variable Frequency Drive

WLCA2-2N 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1500萬次?撞壓式 滾珠擺桿型單惻動(dòng)作

1492-SPM3B200-N MCB Supplementary Protector 20 A

軟啟動(dòng)器 3RW40261BB05

TS 模塊 6ES7 972-0MD00-0XA0 TS Module ISDN

150-F780NBE SMC Flex Smart Motor Controller

1734-IE4C POINT I/O 4 Point Analog Input Module

1783-BMS20CL Stratix 5700 20 Port Managed Switch

193-EOS-SCS E300 Control Station

20-750-EMC1-F3 PowerFlex 750 Frame 3 EMC Kit

2090-CPWM7DF-12AA12 MP-Series 12m Power Cable

2098-DSD-020X Ultra 3000 2kW Servo Drive

G-C441/E PC to GagePort Cable and Power Supply (9-pin for European 220v)

GFK-2193 Series 90-30 PROFIBUS Slave Module User's Manual

IC220STR003 MOTOR STARTER REVERSING, 1.5KW/400VAC

IC647ERPW000 Open Enterprise

IC647SCDK001 Scheduler API Developers Kit

IC693MDL640RR 24 Vdc Output, Positive Logic (16 Points)

IC756DVE000K-99 EO GECK (Graphical Editor Construction Kit) - Unix, Korean, Version 9. 9

MSI-QUAL-25-43 Quality Management Clients 25 Pack Ver4.3

PLC-5/1771 System 1771-A3B I/O CHASSIS ASSEMBLY,12 SLOT,19 RACK MOUNTABLE

Distributed I/O 1790D-T0A6 DNET LDX , 120V AC, 6 OUTPUT BASE, TERMINAL BLOCK

Communications 1770-CD5 DATA HWY TWINAXIAL CABLE, 500 FT/152 M

Operator Interface 2711E-UTCT10 PANELVIEW 1200 TOUCH TO 1000E TOUCH MIGRATION KIT

Support 9305-RSVADFCENS SUPT RENEWAL CONTRACT FOR 9305RSVADFCEN

Support 9324-RLDSTXER SUPT REINSTATEMENT CONTRACT FOR 9324RLDSTXE

EtherNet/IP Products 1761-NETENIW ETHERNET INTERFACE W/WEB FOR MICROCONTROLLER

RSI Software Products 9301-2SE3400KOE RSVIEW32 RUNTIME 32K (KOREAN)

RSI Software Products 9371-RSWDI2U1R UPGRADE: OUT-SUPT: RSWIRE DET IEC ACAD TO PRF PACK

Motion Control 1326AB-B420H-S2K4L MOTOR,SERVO,460V,5.1NM,6000RPM,SINGL,BRK,IP67

26005592 Target Replacement Fan Tray Assembly

HMI-AGO-203 ANTI-GLARE OVERLAY 5"

IC693ACC340 Redundant Power Supply Base (RPSB) with 0.1 meter cable to connect to Power Supply Adapter module. Supports any Series 90-30 power supply.

QPKSGDN0000 6" Color STN, GE Fanuc Label, No Ethernet, CF, 24Vdc,UL,cUL,CE,UL1604

TGT-AI0V-8-0RR Target Analog Module 4 inputs/4 outputs

20BC5P0A0AYNANC0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE192AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D1P4N104 PowerFlex 40- 0.4 kW (0.5 HP) AC Drive

140DDM69000 Quantum 開關(guān)量DC混合模塊,4點(diǎn)輸入,125VDC;4點(diǎn)輸出

284E-FVD4P0Z-10-DRN-DB1-SB-EMI EtherNet Variable Frequency Drive

E2E-CR8C1 0.8mm,電感式,三線,常開5-100mA NPN電源:10-30VDC圓M4

1492-SPM1C010 MCB Supplementary Protector 1 A

通用型變頻器 6SE6 420-2UC21-5BA1 "1.5 KW，149 x 202 x 172"

電機(jī)啟動(dòng)器 3VU13400MM00

1497D-A17-M21-0-2 1EN PURPOSE TRANSFORMER

1608N-012A208V1S 12 A Mini DySC Sag Corrector

1769-OF4VI CompactLogix 4 Pt A/O VoltageModule

190S-ANEJ2-CB63D-KN-R11-S20 4.0-6.3 A Compact Comb Starter W/Ckt-Bkr

194R-NE250-1753 Disconnect Non-Fused IEC 3 Poles 250A

2090-CPBM7DF-16AA90 MP-Series 90m Standard Cable

2090-XXTFMP-S40 MP-Series 40 m Length Feedback Cable

CFDA-0WPB-0140-AZ "AHVi, AHVis, Bis and BHVis Series Motor Encoder Feedback Cable, Straight Connector, 14 M"

GF-3791R Connecting FlashCable to Sartorius, Fairbanks Scale.

IC200UDR006 28 point PLC, (16) 12VDC In, (12) Relay Out, 12VDC Power Supply. Batt ery (IC200ACC403) is required for long term data rentntion and Real Ti me Clock. Battery not included.

IC646TRT300 300 I/O Point Runtime System

IC647PATEHFT Proficy PAT - Driver For Ethernet-Coupled Hamilton Sundstrand Analect Ftir Spectrometers

IC693APU301RR Axis Positioning Module (APM), 1 Axis, requires (1) or (2) CBL311

IC752GEN100 PC/104 Genius Card

IMC-105D-1-D 5 amp IMC stepping motor controller with Devicenet

SLC/1746 System 1746-P3 POWER SUPPLY - RACK MOUNT

Industrial Computers 6189V-MBA BENCH/TABLE TOP ADAPTER FOR 6186 MONITORS

Application-specific products 1404-M505B-232 MASTER MODULE - PQ 24V P/S 232 COM

Operator Interface 2711-K10C14L1 PV1000 COLOR KEY, MBUS & RS232 PRINT

Support 9301-2SE3200ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200ES

Support 9380-RSBOCXS SUPT RENEWAL CONTRACT FOR 9380RSBOCX

DeviceNet Products 1792D-0VT16E 16 SINKING 0.5 AMP OUTPUTS, 8 CONNECTORS