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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(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(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(guó)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(duì)生產(chǎn)過程的全面監(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(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。可作為操作人員現(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/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(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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IC647HSTESEO2000KM eSignature Option for Historian - Enterprise Server 2,000,000 Points (M4 Key)

IC655MDL525RR 115/230Vac Input (16 points)

IC694MDL330 Output module 120/240 VAC 2amps 8 Points.

IC756SDV010K-97 DV Draw Development on Solaris Op Sys, Korean, Version 9.7

MicroLogix 1500/1769 System 1769-OV16 16 POINT 24 VDC SINKING OUTPUT MODULE

PLC-5/1771 System 1771-ACN15 CONTROLNET 1.5 AND BEYOND, 1771 I/O ADAPTER

Distributed I/O 1794-PS13 85-264 VAC TO 24 VDC 1.3A POWER SUPPLY

Communications D1785-6.5.2 DH PLUS RS-232-C INTERFACE MDL(1785-KE)USER'S MNL

Support 9313-L5225S SUPT RENEWAL CONTRACT FOR 9313L5225

Support 9358-CTATRENR SUPT REINSTATEMENT CONTRACT FOR 9358CTATREN

Support F1771-QDCSERA FIRMWARE UPGRADE FOR 1771-QDC I/O MODULE

RSI Software Products 9324-RLD250ITE RSLOGIX 5000 LITE EDITION ITALIAN

RSI Software Products 9301-WK15GEMENE RSVIEW32 WORKS1500 WITH GEMTOOL/SECSHOST/RSLINX

RSI Software Products 9358-PLTM2400U1R UPGRADE: OUT-SUPT: PLANTMETRICS 5 TO 50 WORKCELL

Motion Control 8720SM-037S4KAS3 37 KW/76.1AMP, 750 VDC,AMP AC MOTOR WITH SNS60ENC.

9450-SX-C Protocol Converter. 3 Serial & 1 Bidirect Parallel Port with Clock/Calendar

IC200TBM001 I/O AUXILIARY BARRIER STYLE

IC697VRM015 Reflective Memory with 256Kbyte memory & 512 transfer FIFO. 170MBaud fiber optic network. Supports up to 256 nodes over 2,000 meters

MTR-1337-N-A-E-0RR Stepping Motor Nema34

ZA06B-0075-B203 B8/3000is servo motor with 128k serial encoder

20BD180A3ANNACC0 PowerFlex 700 AC Drive 20B

20G11RC015AA0NNNNN PowerFlex 755 AC Packaged Drive

25-COMM-P PowerFlex 520 Profibus Comm Adaptor

140XCA10215 Quantum CABLEFAST電纜, 大電流, 50針D型,5M

294E-FD4P2P-G1-3-SB Variable Frequency Drive

D4D-2120N 觸點(diǎn):1開/1閉,6A 250VAC機(jī)械壽命:1500萬次?撞壓式 ，停產(chǎn)，用D4NA-4122

1492-SPM3C020-N MCB Supplementary Protector 2 A

軟啟動(dòng)器 3RW40362BB05

數(shù)字量輸入模塊 6ES7 221-1BH32-0XB0 SM 1221 DI 16x24 V DC

150-FPP25B SMC Flex Repair Part

1734-OB4 POINT I/O 4 Point Digital Output Module

1783-HMS8S4CGN Stratix 5400 12 Port Managed Switch

193-ESM-I-30A-C23 E300/E200 30 Amp Sensing Module

20-750-FLNG1-F2 PowerFlex 750 NEMA 1 Flange Adaptor Kit

2090-CPWM7DF-14AA30 MP-Series 30m SpeedTec Standard Cable

2098-DSD-HV030-SE Ultra 3000 3kW with SERCOS Servo Drive

GA646PCMS01 GlobalCare Assist for Change Management Electronic Signature Module (Single)

GFZ-0087 Series 90-70 and Genius Bus Controller Troubleshooting Pocket Guide

IC5000P256RM PanelPC 256MB RAM Option

IC647HITC HIT:Hitachi S10

IC647SI5M SI5:Siemens SI5

IC693MDL655 24 Vdc Input, Neg/Pos Logic, 1 ms, (32 pts)

IC756HDV000J-99 DV Development - HP/UX Op Sys, Japanese, Version 9.9

MSI-S95 S95 XML Interface

PLC-5/1771 System 1771-IBN HIGH-TRUE INPUT MODULE, 10-30V DC, 32 INPUT

Distributed I/O 1790D-TN4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE, TERM BLOCK

Communications 1784-CP15 CABLE ASSY, 10 FT/3.2 M

Operator Interface 2727-RY1 MOBILEVIEW STYLUS WITH TETHER (5 PACK)

Support 9305-RSVADFVCFRS SUPT RENEWAL CONTRACT FOR 9305RSVADFVCFR

Support 9515-RSCHM200R SUPT REINSTATEMENT CONTRACT FOR 9515RSCHM200ENE

EtherNet/IP Products 2706-PENETM ETHERNET/IP COMMUNICATION MODULE FOR 2706-P4X

RSI Software Products 9301-2SE3400ZHE RSVIEW32 RUNTIME 32K (CHINESE)

RSI Software Products 9515-RSMSVRENE RSMACC SERVER AND RSMACC CLIENT ACTIVATION

Motion Control 1326AB-B520E-M2K5L MOTOR,SERVO,460V,13.0NM,3000RPM,MULTI,BRK,IP67

4161-4-24-.8 BCD To 7 SEG Display . 4 Digit, (.8") 24VDC. Dust Seal

HMI-CAB-C120 CABLE GE FANUC 90/30 CPU 351/352/363, RJ11 Serial Port

IC693CBL312 Cable, I/O Expansion, 0.15 Meters, Shielded

QSI2D100L2P QUICKSTART KIT 10.5" MONO LCD

TRM-21006664 7point screw terminal connector for 4.3/5/7.2 amp S2K controller extended digital I/O

20BC8P7A0AYNAND0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF046JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E019N104 PowerFlex 40- 11 kW (15 HP) AC Drive

140ACO02000C Quantum 模擬量輸出, 4通道, 4-20mA, 通道隔離, CC

284E-FVD7P6Z-25-CR-3-DB-SB EtherNet Variable Frequency Drive

E2E-X10D1-N NEW 10mm, 電感式,兩線,常開100mA 電源:10-30VDC圓M30

1492-SPM1C130-N MCB Supplementary Protector 13 A

通用型變頻器 6SE6 430-2UD31-8DB0 18.5 KW,275 x 520 x 245

電機(jī)啟動(dòng)器 3VU13401MP00

150-C16NBD SMC-3 16A Smart Motor Controller

1608P-100A400V3E 100 A Pro DySC Sag Corrector

1769-RTBN10 CompactLogix 10 Pin Terminal Block

191S-ANEJ3-CC10C-KN 6.3-10.0 A Compact Rev Starter W/Ckt-Bkr

194R-R3 Operating Shaft

2090-CPBM7E7-08AF02 2 m Length SpeedTec Extension Cable

2090-XXTPMP-16S09 MP-Series 9 m Length Power Cable

CP3B-0WPB-0140-AZ Power cable for B8/3000is motor. 14 meters

GF-905409/SW Connecting FlashCable to Mitutoyo Caliper with Data Read Switch (all e xcept 500-15x/ 500-17x, 551 & 552 series).

IC200UEO108 VersaMax Micro Expansion 8 Output Expansion 24VDC Sink Output, 24VDC Power Supply (includes IC200CBL501)

IC647ACL001 PA Redundant Key

IC647PBBFT0 PPS Boiler Bookshelf - Fire Tube

IC693CBL302 I/O Base expansion 50 feet (15 meters), continuous shield with built in terminator.

IC754ACC06MNT Mounting Clips (4) & PWR Connector/ 6 inch QuickPanel View & Control

IMC-313P-X-DRR IMC-D Series Servo Motor Controller, Enhanced, DeviceNet, 3 Amp

SLC/1746 System 9399-APSQS APS QUICK START GUIDE FOR REL 6.01

Open Automation Systems 1746-BAS-T BASIC MODULE (HIGH SPEED)

Application-specific products 1404-M605B-RIO MASTER MODULE - PQ 24V POWER SUPPLY RIO COM

Operator Interface 2711-K10G14 PV1000 GRAYSCALE KEY, MBUS & RS232 PRINT

Support 9301-2SE3300FRS SUPT RENEWAL CONTRACT FOR 93012SE3300FR

Support 9381-P10KENR SUPT REINSTATEMENT CONTRACT FOR 9381P10KEN

DeviceNet Products 1792D-CB18P MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

RSI Software Products 9301-2SE3300FRE RSVIEW32 RUNTIME 1500 (FRENCH)

RSI Software Products 9358-EP30ENE RSBIZWARE EPROCEDURE 30 UNITS

Motion Control MPL-B4530K-SK24AA MOTOR,SERVO,8.36 NM,4000RPM,SINGL,460V,BRK

Motion Control 2090-XXNRB-14F0P7 RBM TO DRIVE CABLE, .66M

GQPI31200C2P QUICKPANEL COLOR 10.5" TFT GELABEL

IC646MRA300 View 300 Tag Runtime System

MTR-1N32-I-E-D-S-0 Stepping Motor Nema34, Series Wdg, Encoder

QSI31200E2P Starter Kit: 9 inch Monochrome EL/ TCP Label/ 110VAC/ No Agency Approvals

20BC043A3AYNAND0 PowerFlex 700 AC Drive 43 A at 22 kW 20B

20F11ND040AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF026-CL PowerFlex EMC Filter

2711P-RN10H PV Plus 700 to 1500 Dnet Comms Module

28171-071-09-R TAPTITE HEX HD WASH #8-32X.375

C200H-IA122 輸入單元,16點(diǎn), 100 -120 VAC

1492-PDM3111 115 A Power Distribution Block

通訊處理器 6GK7443-1GX11-0XE0 CP443-1 IT，以太網(wǎng)，ISO，TCP/IP

變送器 3RS10201DW20

1497-C-AXSX-0-N Control Circuit Transformer

1585J-M8VBJM-1 RJ45 Ethernet Media

1761-NET-ENI MicroLogix and SLC Communication Adaptor

188-K3C080 Miniature Circuit Breaker 8 A

194L-E40-1756 40 A 194L Load Switch

2090-CPBM7DF-02AA15 15 m Length DIN Power and Brake Cable

2090-XXNFT-S03 Kinetix Drives 03m Standard Cable

BC647PSC200 Proficy Process Systems 2000 I/O with CIMPLICITY with Global Care

GC647PCM050 GlobalCare Complete for Proficy Change Management Server - 50 Concurrent Users

IC200MDL244 Input 240VAC isolated 8 point

IC646NUU000 HMI Functional Upgrade Transaction Processing Fee