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近幾年，隨著我廠生產規模的逐步擴大，就更加要求氣體調節在生產中的穩定性和快速性，而目前傳統的二次儀表已無法滿足現有的控制需求。主要表現在：

　　1)過程自動化程度低，信息采集和反饋仍采用傳統的二次儀表，致使數據采集緩慢、調節滯后，降低了系統運行的穩定性。

　　2)儀表內部信息儲存量小，采集的壓力、流量等數據無法長期保存，不便于日后生產工作的歷史查詢和分析。

　　3)系統可靠性低，需要配專人負責該系統的運行，造成了人工成本的上升。

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

　　1、PLC控制系統的特點及組成

　　PLC在現代工業控制領域中早己得到了廣泛的應用。以PLC的控制功能而言，具有嚴謹、方便、易編程、易安裝、可靠性高等優點。它通用性強，適應面廣，特別在數字量輸入/輸出等邏輯控制領域有無可比擬的優點。PLC具有豐富的邏輯控制指令和應用指令，它提供高質量的硬件、高水平的系統軟件平臺和易學易編程的應用軟件平臺。另外，PLC即有自身的網絡體系又有開放I/0及通訊接口，很容易組建網絡并實現遠程訪問。

　　PLC采用Siemens公司生產的S7-300系列，由于現場的PLC系統與主控室的上位機距離較遠(800米左右)，因此通訊系統需成對加裝RS-485中繼器，另外在現場增加TP27-10//觸摸屏進行數據顯示，確保系統運行的穩定性。

　　1.1系統結構及硬件配置

　　根據控制需求，CPU模塊采用CPU314、數字量輸入(DI)采用SM321模塊，數字量輸出(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實現機架擴展，上位監控機采用SIEMENS公司CP5611網卡完成計算機與PLC之間的數據通訊。整個通訊網絡采用MPI的通訊協議，從上位機上可對整個氣體調節過程進行監控和操作。

　　1.2控制系統的功能實現

　　PLC程序的編制直接關系著供氣系統能否正常工作，而程序設計的關鍵在于編程者對工藝系統的理解程度和程序編制技術的靈活應用。因此，在程序設計中首先考慮了供氣壓力調節系統的特點，將程序設計細化，分成多個程序模塊，實行模塊化編程。這樣既可以方便的增加或刪除程序模塊，便于現場對工藝的調整，又可針對配套設備可控性對不同程序模塊進行完善。

　　PLC的編程軟件采用SIEMENS公司的SIMATICSTEP7V5.1軟件平臺用來完成硬件組態、地址和站址的分配以及編制整個生產過程的控制程序的。上位機監控軟件采用國產軟件組態王，全部采用漢化界面，便于系統的開發與操作，該系統運行于Windows2000中文平臺，可實現對生產過程的全面監控，對重要參數形成歷史記錄，以報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顯示重要參數的歷史趨勢、實時趨勢，實現壓力調節的手自動切換、操作、壓力的高、低限報警、流量數據的顯示與累計，滿足高生產率的調度需求。

　　1.3現場顯示

　　現場采用TP27觸摸屏進行參數顯示、控制，觸摸屏程序由組態軟件來完成，人機界面采用中文菜單，界面友好，操作方便，功能較強，主要用于現場壓力、流量、閥位的顯示與操作。可作為操作人員現場操作的依據。

　　1.4工控機配置

　　工控機采用研華IPC-610，通過CP5611卡，完成S7-300PLC與工控機的通訊。主要完成下列任務：傳送現場監控數據;運行監控;故障記錄和排除提示;參數設置;生產數據管理和處理;圖形化示教和離線編程。

　　2系統實現了供氣系統的自動控制和監控，主要包括如下功能：

　　1)靈活的操作方式以及強大的系統控制功能：

　　系統可以實現上位機操作、控制柜觸摸屏操作和就地手動操作;

　　2)報警功能：

　　當壓力超過工藝要求，可在現場、就地實現高、低限壓力報警;

　　3)簡單、方便的參數設定：

　　壓力調節閥的壓力設定值、P、I、D等參數可以在上位機中設定。

　　2、系統控制功能

　　(1)過程控制的功能：

　　1)系統對供氣壓力實現了PID自動調節控制;

　　2)對所采集的模擬信號進行線性化、濾波、工程單位轉換處理;

　　3)實現了流量信號的溫、壓補償，提高了儀表的測量精度。

　　(2)邏輯控制

　　聯鎖邏輯控制實現開/關的控制，邏輯控制及用戶自定義功能塊等。系統實現了電磁閥控制以及參數越限報警等功能。

　　(3)人機接口

　　HMI系統中包含主工藝畫面，各系統送氣壓力、流量，供氣壓力調節等多幅畫面，畫面直觀、豐富，具備PID在線調節、在線顯示調節曲線功能，包括過程量變化趨勢的實時趨勢曲線、歷史趨勢曲線。

　　(4)報表打印

　　以報表形式繪制報警記錄、歷史記錄畫面，調節間數據報表。實時趨勢曲線和歷史趨勢曲線可隨意設定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設計

　　根據該系統具體情況，PLC系統軟件設計過程中著重要考慮的是以下幾個方面：

　　(1)數據采集及工程量轉換

　　(2)PID算法

　　(3)流量溫壓補償計算以及流量的累積計算

　　對于系統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償計算以及流量的累積計算部分則采用語句表(STL)編程，結構緊湊而又靈活。

　　PID調節是該系統中zui為重要的控制程序，因此特將PID算法作一重點介紹
 

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RSI Software Products 9301-2SE3350ITU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (IT)

RSI Software Products 9307-8MGDBCENE RSEMETRIX MGR(0-8 METERS),W/1MSSQL CLIENT LIC.

Motion Control MPL-B960B-SJ24AA MOTOR,SERVO,102.0NM,1000RPM,SINGL,460V,BRK

Silver Series 1398-DDM-019X-DN DRIVE,30A PEAK, ULTRA 100 W/DNET,INDEX

HE670ADC830 Field Control Analog Input Module, 8 Ch, 0 to 10Vdc and +/-10Vdc, 400Vdc Channel to Channel Isolation, 1000Vdc Channel to Bus Isolation, 12Bits, 11Bits + Sign

IC646TPR000 Pro Server Unlimited I/O Point Run Time System

QM1204COA QUICKMARQUEE 1 X 20 4.8" OR 2 X 40 2.1" TRICOLOR

ST-3428 STXi analog input module 8 Channels, 0~10V, 12bit

20BC125A0ANNANC0 PowerFlex 700 AC Drive 20B

20F14NC456JA0NNNNN PowerFlex 753 AC Packaged Drive

22A-B8P0N104 PowerFlex 4 1.5 kW (2 Hp) AC Drive

140CPS41400C Quantum 電源, 48/60 VDC, 可累加, 8A, CC

284D-FHD4P0Z-N-R-3 Cntl Mod. Variable Frequency Drive

CJ1W-OD201 8點晶體管輸出單元漏型

1492-RIFM40F-2 Connection Products

WinCC 上位監控軟件 6GK1713-5CB63-3AA0 S7-5613 驅動

變送器 3RS17021DD00

1497A-A13-M6-0-N 2000VA 240x480-120V 60Hz CPT

1606-XLP36C Power Supply XLP 36 W Power Supply

1766-L32BWAA MicroLogix 1400 32 Point Controller

188-K4C020 Miniature Circuit Breaker 2 A

194L-HE8G-175 194L Control and Load Switch Actuator

2090-CPBM7DF-10AA07 MP-Series 7m Standard Cable

2090-XXNPMP-10S09 MP-Series 9 m Length Power Cable

CBL-12-ED-03M-RA Right angle encoder cable for Motorcube. 3 meters

GC647SPR001 GCScheduler Desktop Pro 1 user

IC200PWR001LT POWER SUPPLY 24VDC INPUT (LT)

IC646TBLH005 Proficy Troubleshooter for Intelligent Historian 5 Seats

IC647NET000 CIMPLICITY HMI MMS Ethernet Communications Driver

IC690PWR124 Field Power Supply 24 VDC 10 Amps

IC698CMX016 PACSystems RX7i Control Memory Xchange 16MB Memory

IC800VMACONCN3 VersaMotion amplifier CN3 communication connector

SLC/1746 System 1746-IG16 DC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

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

Application-specific products 6556-MLCBK MICRO LOGIX C/B KIT AC

Operator Interface 2711-K5A8L2 PV550 MONOCHROME KEY, DH+ & RS232 PRINT

Support 9301-2SE2200ESS SUPT RENEWAL CONTRACT FOR 93012SE2200ES

Support 9501-RL0H150ENS SUPT RENEWAL CONTRACT FOR 9501RL0H150EN

ControlNet Products 9904-XTAL CONTROLNET 60.00 MHZ CRYSTAL (500 PIECE REEL)

RSI Software Products 9301-2SE250DEU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-BERP02U1 UPGRADE: IN-SUPT: RSBW BATCH ERP 1 TO 3 SERVER

Motion Control MPL-A540K-SK24AA MOTOR,SERVO,19.4 NM,4000RPM,SINGL,230V,BRK,19.1KG