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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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Process Control 1757-FIMUPG010 FIELDBUS LICENSE UPGRADE, 10 FIMS

Operator Interface 2711P-RGK15 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABITR SUPT REINSTATEMENT CONTRACT FOR 9355WABIT

Support 9354-LN100S 9354-LN100 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1784-PCIC CONTROLNET PCI BUS MESSAGING CARD WITH

RSI Software Products 9301-2SE2400KOE RSVIEW32 WORKS 32K (KOREAN)

RSI Software Products 9355-WABSNEU1 UPGRADE: IN-SUPT: RSLINX SINGLE NODE TO RSLINX OEM

Motion Control MPL-A320P-SK22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,230V,4.1KG

Motion Control 2090-U5PM-D0903 CABLE, ULTRA5000 TO PANELVIEW 300 MICRO DF-1, 3M

CBL-12-MP-10 Power Cable, MTR-1216, 1221, or 1231 Stepping Motor, 10 Ft.

IC600KD512RR Color Operator Interface Terminal, 12" CRT

IC800SGM450M2KE25 4500W, 230V S-Series Servo Motor, 322 in-lb (36.4 Nm)

OC647IFESGRN00300C iFIX Optn: ESig & ERec 300 I/O Runtime (M1Component Part)

20AD040A3AYNAEC0 PowerFlex 70 AC Drive 40 A at 30 Hp 20A

20DC590N0ENNBDANE PowerFlex 700S AC Drive 590 A 315 kW 20D

20LD1K2N0ENNXNW0WA PowerFlex 700L AC Drive 20L

2706-PCABLE1 InView Programing and Downloading Cable

280-PWRM22D-M4 ArmorStart Three-Phase Power Media

FX2N-16EYR 擴(kuò)展16出 繼電器輸出

1492-M6X12VR1-20 Connection Products

1494R-N19 200 A/400 A Multi-Tap Lug Adaptor Kit

軟啟動(dòng)器 3RW44476BC44

ET 200SP 6ES7193-6SC00-1AM0 基座單元屏蔽組件

1585D-M4UBDE-0M3 1585D Ethernet Media Patchcord

1756-IB16D ControlLogix 16 Point D/I Module

1794-TB3GS Flex Terminal Base

194E-E100-1753-6N 100 A 194E Load switch

2090-CFBM4DD-CDAA03 MP-Series 3 m Length Feedback Cable

2090-K6CK-D26M Kinetix 6000 Low Profile Connector Kit

ADP-SCM-STF-M SC to ST multi mode adapter

GC646TDV000 Proficy GlobalCare Complete for Unlimited I/O Point Runtime / Development System.

HE800CBL212 I/O Extension Cable, 12-pin, 2.0m. For use in conjunction with TRM512

IC640MWS901RR Workmaster System/ 1-35 inch Disk Drive

IC647HSTSSEO40KM eSignature Option for Historian - Standard Server 40000 Points (M4 Key)

IC660BRD021 24/48VDC SINK BLOCK FOR RDCY

IC695CRU320 1Ghz CPU with 64Meg of memory 2 SERIAL PORTS (occupies two slots on system base) redundant CPU. External high capacity battery IC693ACC302 required. The CRU320 supports both Genius LAN and Ethernet LAN. Dual Genius LAN is supported by an applicati

IC756WET200K-23 Custom Datasource Toolkit, Korean, Version 2.3

CompactLogix System 1769-STRT2DE COMPACTLOGIX STARTER KIT GERMAN

PLC-5/1771 System D1771-6.5.27 DIRECT COMMUNICATION MODULE(1771-DCM)USER'S MNL

Process Control 1757-PLXNA RECIPE MANAGER

Operator Interface 2711P-K7C4D2 PV PLUS 700, KEYPAD, ENET, DC PS, EXT MEM

Support 6556-SPLSR SUPPORT REINSTATEMENT CONTRACT FOR 6556SPLS

Support 8100-HSKARS SUPT RENEWAL CONTRACT FOR 8100HSKA

Support F1785-L11BSERD FIRMWARE UPGRADE FOR 1785-L11B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2203KOE RSVIEW32 WORKS 300 WITH RSLINX (KOREAN)

RSI Software Products 9701-VWSB025FRU1 RSV SE STATION 25 - SE SRV 25 UPG (FRENCH)

RSI Software Products 9399-FW5FBGR RSLGIX FRAMWRKS FUNCTION BUILD.GET'G RESULTS GUIDE

Motion Control 2098-DSD-150-DN DRIVE, 65A/150A, ULTRA3000 W/DEVICENET

BC5008TBN0000 18 Inch Intelligence Industrial Computer - Bundled - Performance Series - w/ Windows NT

IC300DIM210 8 DC Inputs (12/24vdc, pos/neg logic).

IC752ECD550 Display Station 1493 - 14" XGA (1024x768) resistive touch screen, Pentium 133, 32MB, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT

MTR-3S45-G-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6093-K001 Replacement serial encoder battery for Beta series amplifiers

20BH140A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TD740AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-A2P5N114 PowerFlex 523 0.4kW (0.5Hp) AC Drive

2711P-T10C4D9 PanelView Plus Terminal

FRN280P11S-4CX 400KVA 520A 280KW 3相AC380V/50Hz/60Hz

1492-JD4C 4 square mm Double Level Terminal Block

1492-W6 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40766BB45

性能信號(hào)模塊 6ES7 521-1BH50--0AA0 DI 16：數(shù)字量輸入模塊，源型，DI 16x 24VDC SRC BA, 35mm 模塊，不含前連接器

156-B30BV1 30 A Contactor

1746-IB8 SLC 8 Point DC Input Module

1786-TNCL10 ControlNet Media TNC Connector Plug

193-T1BC30 24.5-30.0 A IEC Bimetallic Ovld Relay

20-HIM-A5 PowerFlex Architecture Class HIM

2090-CSBM1DF-14AA20 Kinetix 20m Smartlink Single Cable

20AC015C3AYNANC0 PowerFlex 70 AC Drive 20A

GA647TPR915 Proficy GlobalCare Assist for CIMPLICITY HMI ProServer 1500 I/O Runtime System

GP647IFSTDVUNLMT GCP iFIX Std HMI Unlmt Dev

IC600CB524RR Arithmetic Control Module

IC647HSTCSCCP25M Historian Enterprise Corporate Client Enterprise Connection Pack 25 Users (M4 Key)

IC647UDCC UDC:Honeywell UDC Controllers

IC693UAA007RR 28 pt AC In/AC Out, AC Power Supply

IC756RDV000K-99 DV Development - Irix Op Sys, Korean, Version 9.9

MicroLogix 1200 System 1762-L24BWA MICROLOGIX 1200, 24 PT.

PLC-5/1771 System 1771-CFMK CONFORMALLY COATED, CONFIGURABLE FLOW METER

Distributed I/O 1794-IB10XOB6 10/6 24VDC COMBO

Communications 9355-WABGWFRE RSLINX GATEWAY - FRENCH

Operator Interface D6190-6.5.9 CONTROLVIEW NETWORKER(CAT.NO.6190-NET)USER'S MNL

Support 9358-BCMPN01R SUPT REINSTATEMENT CONTRACT FOR 9358BCMPN01ENE

Support F1403-MMVER2X FIRMWARE UPGRADE FOR 1403-MMV POWERMONITOR MODULE

RSI Software Products 9324-RL01U3PTER UPGRADE: OUT-SUPT: PORTUGUESE RS500 START TO RS500

RSI Software Products 9301-2SE3503DEE RSVIEW32 RUNTIME 100K WITH RSLINX (GERMAN)

RSI Software Products 9358-HSTCLTENE RSBIZWARE HISTORIAN SINGLE USER RUN TIME CLIENT

Motion Control Y-2012-2-H00AA MOTOR,SERVO,1.35 NM,4500RPM,ENCDR,230V,2.31KG

5401 Greyline Micro MC. 2 Lines, (20) 5MM Chars. LCD. Quick Connect. NEMA 4

IC200DTX450 Operator Interface with up to 200 stored messages. 2 x 16 character LCD backlight display and 6 function keys

IC695CHS016 RX3i BASE 16 SLOTS

MSI-WEB-UNL-43 Unltd Site Clients - Web or Excel Rep-43

VSPCSE-OPC10 Secure Edition OPC Client Option includes VisualSPC Importer (licensin g is per client PC), Support for up to 10 Points/Tags.

20BD065A0AYNAND0 PowerFlex 700 AC Drive 65 A 50 Hp 20B

20G11LE825JN0NNNNN PowerFlex 755 AC Packaged Drive

22F-A011N113 PowerFlex 4M- 2.2 kW (3 HP) AC Drive

490NRP25300 Quantum 光纖中極器,MBPL

291E-FAP-G1 Direct Online Reversing Starte

P2CF-08 導(dǎo)軌安裝型，

1492-SPM2D070 MCB Supplementary Protector 7 A

軟啟動(dòng)器 3RW30382BB14

電機(jī)啟動(dòng)器 3VU16400CQ00

150-F317NBDB SMC Flex Smart Motor Controller

1732E-IB16M12 ArmorBlock 16 Point Input Block

1771-RTP1 1771 Remote Terminal Panel

193-EEGF E1 Plus 18-90 A Overload Relay

20-750-1132C-2R PowerFlex 750 Series 24V DC EIO Kit

2090-CPWM7DF-08AF25 MP-Series 25m Continuous-Flex PWR Cable

2097-R6 Kinetix 300/350 75 Ohm Shunt Resistor

ENP2115M010 Male Industrial/Male Industrial, 1 meter

GFK-1687 User Manual-Mini OCS Hardware Manual

IC220BEM485 RS-485 Communications Module interfaces serial I/O devices to a VersaPoint I/O Station. Requires a NIU that supports PCP services, not compatible with IC220EBI002 Ethernet NIU. Supports the following protocols Transparent, End-to-end, Dual buffer,

IC647CSPC005 Proficy Cause+ for Intelligent HMI/SCADA Client Enabler - 5X CALs

IC647PSC000 Proficy Process Systems 5000+ I/O with CIMPLICITY

IC693MCD001 Beta series servo demo case

IC756ADV010J-99 DV Draw Development on AIX Op Sys, Japanese, Version 9.9

MSI-MGMT-100 Production Management Clients 100 Pack