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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(wú)法滿足現(xiàn)有的控制需求。主要表現(xiàn)在：

　　1)過(guò)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(wú)法長(zhǎng)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(guò)采用PLC(可編程控制器)控制系統(tǒng)，解決當(dāng)前存在的問(wèn)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(wú)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(kāi)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(wèn)。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場(chǎng)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(duì)加裝RS-485中繼器，另外在現(xiàn)場(chǎng)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(duì)整個(gè)氣體調(diào)節(jié)過(guò)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(duì)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(chǎng)對(duì)工藝的調(diào)整，又可針對(duì)配套設(shè)備可控性對(duì)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(lái)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(guò)程的控制程序的。上位機(jī)監(jiān)控軟件采用國(guó)產(chǎn)軟件組態(tài)王，全部采用漢化界面，便于系統(tǒng)的開(kāi)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(duì)生產(chǎn)過(guò)程的全面監(jiān)控，對(duì)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(guò)VB語(yǔ)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(shì)、實(shí)時(shí)趨勢(shì)，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(chǎng)顯示

　　現(xiàn)場(chǎng)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(lái)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(chǎng)壓力、流量、閥位的顯示與操作�？勺鳛椴僮魅藛T現(xiàn)場(chǎng)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(guò)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(chǎng)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(guò)工藝要求，可在現(xiàn)場(chǎng)、就地實(shí)現(xiàn)高、低限壓力報(bào)警;

　　3)簡(jiǎn)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(guò)程控制的功能：

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

　　2)對(duì)所采集的模擬信號(hào)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(hào)的溫、壓補(bǔ)償，提高了儀表的測(cè)量精度。

　　(2)邏輯控制

　　聯(lián)鎖邏輯控制實(shí)現(xiàn)開(kāi)/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(huà)面，各系統(tǒng)送氣壓力、流量，供氣壓力調(diào)節(jié)等多幅畫(huà)面，畫(huà)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(guò)程量變化趨勢(shì)的實(shí)時(shí)趨勢(shì)曲線、歷史趨勢(shì)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(huà)面，調(diào)節(jié)間數(shù)據(jù)報(bào)表。實(shí)時(shí)趨勢(shì)曲線和歷史趨勢(shì)曲線可隨意設(shè)定時(shí)間段，打印在線趨勢(shì)，歷史趨勢(shì)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(guò)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(duì)于系統(tǒng)中的邏輯控制選用梯形圖(LADDER)編程，直觀、方便;對(duì)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(yǔ)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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284D-FHD4P0Z-10-CR DeviceNet Variable Frequency Drive

CJ1W-OC211 16點(diǎn)繼電器輸出單元

1492-RIFM40F Connection Products

WinCC 上位監(jiān)控軟件 6GK1713-5DB63-3AA0 DP-5613 驅(qū)動(dòng)

變送器 3RS17021CD00

1497A-A12-M7-0-N Control Power Transformer

1606-XLP30EQ AC or DC In 24VDC Out 30W Power Supply

1766-L32BWA MicroLogix 1400 32 Point Controller

188-K4C010 Miniature Circuit Breaker 1 A

194L-HE6N-178 #6 Handle (Breter)

2090-CPBM7DF-10AA05 MP-Series 5m Standard Cable

2090-XXNPMP-10S07 MP-Series 7 m Length Power Cable

CB6N-5WPM-0140-AZ "Brake cable for B0.4/5000is or B0.5/5000is or B1/5000is or BM0.5 or BM1 motor , 90 degree connector., 14 M"

GC647SPM001 GCScheduler Plus Module

IC200PWR001 POWER SUPPLY 24VDC INPUT

IC646TBLH002 Proficy Troubleshooter for Intelligent Historian 2 Seats

IC647NEF000 CIMPLICITY HMI FLOPRO/FLONET Communications Driver

IC690PWR024 Field Power Supply 24 VDC 5 Amps

IC698CHS217 RX7i 17 Slot Rack Rear I/O Mount

IC800VMACONCN2 VersaMotion amplifier CN2 encoder connector

SLC/1746 System 1746-IC16 DC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15BP2KHDC VERSAVIEW 15-INCH WORKSTATION, KEYPAD & TOUCH

Application-specific products 9358-PBVNT01ENE RSBATCH NT FOR PLX BATCH VIEW ADDITIONAL CLIENTS

Operator Interface 2711-K5A8L1 PV550 MONOCHROME KEY, DH+ & RS232 PRINT

Support 9301-2SE2200ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2200ES

Support 9501-RL0H150ENR SUPT REINSTATEMENT CONTRACT FOR 9501RL0H150EN

ControlNet Products 9904-XFMR CONTROLNET TRANSFORMER (BOX OF 110)

RSI Software Products 9301-2SE250DEU3R RSVIEW32 WORKS 300-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-BERP02ENE RSBIZWARE BATCH ERP - - (SPT. 1 - 3 BATCH SERVER)

Motion Control MPL-A540K-SK22AA MOTOR,SERVO,19.4 NM,4000RPM,SINGL,230V,16.5KG

Motion Control 2090-XXNPMP-16S05 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,5M

GC646MRB000 Proficy GlobalCare Complete for Logic PC Runtime 8,000 I/O""

IC641SWP054 HP-UX Host Communications Tool Kit (Ethernet SRTP)

IC800STI105D2 5 Amp S2K Series Stepper Amplifier/Controller with DeviceNet, 115 VAC

PSPC-DC10-220 Prof Shop Floor SPC DC 10 User 220v

20BB260A0AYNANC0 PowerFlex 700 AC Drive 20B

20DH300N0NNNBNANE PowerFlex 700S AC Drive 20D

2198-H008-ERS Kinetix 5500 6.3 Amp Servo Drive

2711P-K6M20A8 PanelView Plus 6 6 Grayscale Keypad AC

280-PWRM35E-M3 ArmorStart Three-Phase Power Media

CP1W-CIF11 CPU單元用RS-485可選板

1492-MS6X9V1-50 Connection Products

數(shù)字量輸入/輸出模塊SM 6ES7 322-1HF01-0AA0 "DO/8 繼電器，24VDC/230VAC,3A, 繼電器輸出，

行程開(kāi)關(guān) 3SE53123SG13

運(yùn)行版軟件 6AV2105-2KK14-0AC0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack Runtime Advanced 8192 PowerTags -> Runtime 專業(yè)版 8192 PowerTags ASIA V14

1585J-M8CBJM-19 RJ45 Ethernet Media

1756-PBXT ControlLogix 24V DC XT Power Supply

188-K1D040 Miniature Circuit Breaker 4 A

194E-Y16M-1753-4N 16 A 194E Load switch

2090-CFBM7E7-CDAF04 MP-Series 4 m Length Feedback Cable

2090-UXNFBMP-S60 MP-Series 60 m Length Feedback Cable

BC646TPD915 ProServer 1500 I/O Develop/Runtime System with Proficy GlobalCare

GC647IFGLBLCLN005M iFIX WebSpace 5 Additional Clients (GC Complete)

IC200CBL105 Cable I/O non-shielded 2 connectors .5M for connector-style carrier

IC646MPC101 Logic Developer PLC Configuration Tools with Programming Cable

IC647IFPRSR00150C iFIX Profsnl SCADA 150 I/O Server (M1Component Part)

IC660TBR100 Terminal Assembly for IC660BBR100

IC697CMM741RR Series 90-70 MMS/Ethernet Lan Interface

IC800MCUB12210XERR Stepping MotorCube 1000 oz-in, Pulse/Direction, Encoder Feedback

ControlLogix/1756 System 1756-IM16I 159-265 VAC ISOLATED INPUT 16 PTS (36 PIN)

Industrial Computers 6182H-10BEH4B VVCE 1000, KEY/TOUCH, EXT MEM, ENET, AC

Process Control 9358-PBNTK60ENE RSBATCH NT FOR PROCESSLOGIX BACK-UP KEY 60 UNITS

Operator Interface 2711P-RAT12E2 PVP/VVCE1250 TOUCH TO PV1200 TOUCH ADAPTER

Support 9352-WRA200R SUPT REINSTATEMENT CONTRACT FOR 9352WRA200

Support 9351-DKTSRTS SUPT RENEWAL CONTRACT FOR 9351DKTSRT

ControlNet Products 1786-FS10 200 MICRON CABLE ASSEMBLY 10 METERS (32.8 FT)

RSI Software Products 9301-2SE235ZHU1R RSVIEW32 WORKS 150-5K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9355-WABFRE RSLINX PRO - FRENCH

Motion Control MPL-A310P-MJ24AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,230V,BRK,4.1KG

Motion Control 2090-DANFCT-S20 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 20M

BC647MPP101 Logic Developer PLC Professional with Cable with Proficy GlobalCare Complete and a hardware key

IC5002TBX0000 12" Unbundled Intelligence Industrial Computer with WIN XP Performance Series

IC800FXMODEV fxMotion Developer software for the S2K Series Amplifier/Controllers

OC647IFABPPC iFIX Optn: Allen Bradley Productivity Pack (M1Component Part)

20AD022A0AYNANC0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC170A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANE144AA0NNNNN PowerFlex 755 AC Packaged Drive

25C-D1P4N104 PowerFlex 527 0.4kW (0.5Hp) AC Drive

280-PWRM22A-M10 ArmorConnect 10 Meter M22 Patchcord

FX1S-30MR-D 直流主機(jī)16入/14出 繼電器輸出

1492-M5X12V1-100 Connection Products

1494H-CN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44452BC45

ET 200SP 3RK7136-6SC00-0BC1 F-CM AS-i Safety 主站模塊，標(biāo)準(zhǔn)型，基座單元類型C0、C1

1585D-M4TBDM-3 Micro D-Code, QD Style Ethernet Media

1756-EN2F ControlLogix Enet/IP Fiber Optic Module

1794-OB32P Flex 32 Point Digital Output Module

194E-CA40EX-PE-TN 194E Load switch

2085-IRT4 Micro800 4 Channel TC/RTD Input Module

2090-DANFCT-S02 TL-Series 2m Feedback Cable

20AC5P0F0AYNNNC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646PCM005 GlobalCare Complete for Change Management 5 user pack

HE693THM884 8 ch. J, K, N, T, E, R, S, B, C 0.1degC res., degC/F units, 8 temp + ope n circ. alarms

IC630MDL325RR 115Vac Input Module (16 points)

IC647HSTSS500KM Historian Standard Server 500,000 Points (M4 Key)

IC660BLA101 Cover w/Label for IC660BBA101