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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(mǎn)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(xún)和分析。

　　3)系統(tǒng)可靠性低，需要配專(zhuān)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(xiàn)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(mǎn)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。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(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(xiàn)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(xiàn)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(hù)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(xiàn)調(diào)節(jié)、在線(xiàn)顯示調(diào)節(jié)曲線(xiàn)功能，包括過(guò)程量變化趨勢(shì)的實(shí)時(shí)趨勢(shì)曲線(xiàn)、歷史趨勢(shì)曲線(xiàn)。

　　(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(xiàn)和歷史趨勢(shì)曲線(xiàn)可隨意設(shè)定時(shí)間段，打印在線(xiàn)趨勢(shì)，歷史趨勢(shì)曲線(xiàn)。

　　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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IC5008TAX0000 18" Unbundled Intelligence Industrial Computer with WIN XP Standard Series

IC800MCUB12310XN Stepping Motor Cube, 175 oz-in with Pulse/Direction, NEMA 23

OC647IFESGCLNTCRNM iFIX Optn: ESig & ERec iClient Runtime (M4 Part)

20AD022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC2P1A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANF171JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-E032N104 PowerFlex 527 22kW (30Hp) AC Drive

280-PWRM22B-M3 ArmorStart Three-Phase Power Media

FX2N-80MR-001 主機(jī)40入/40出?繼電器輸出

1492-M5X5V1-20S Connection Products

1494H-EA3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44462BC45

ET 200SP 6ES7193-6BP00-0BA1 基座單元 BU15-P16+A0+2B/T，類(lèi)型A1，直插式端子，帶有溫度測(cè)量，15mm寬

1585D-M4TBJM-1 Micro D-Code, QD Style Ethernet Media

1756-ESMCAPXT L7XT Energy Storage Module-Capacitor

1794-OM16 Flex 16 Point Digital Output Module

194E-CA80E 194E Load switch

2090-CCMDSDS-48AAP3 Comms Cable Kinetix 3 Drv to Drv 0.3m

2090-DANPT-16S05 TL-Series 5m Power Cable

ABKCTDE0000/DVN 6 inch TFT QuickPanel TCP w/DeviceNet 24VDC/ No Agency Approvals

GC646PCMSCH GlobalCare Complete for Change Management Scheduler

HE800ACC014 Cage-clamp (screw) style I/O plug, 14-terminal. (Qty 1)

IC630PWR314RR 24Vdc Power Supply Unit

IC647HSTSSEO100KM eSignature Option for Historian - Standard Server 100000 Points (M4 Key)

IC660BLD025 Cover w/Label for IC660BBD025

IC695CHS012CA RX3i 12 slot universal backplane. Conformal Coated.

IC756WET100E-99 Custom Editor Toolkit, English, Version 9.9

CompactLogix System 1769-PA4 120/240 VAC INPT. PWR SUPPLY 4A @ 5VDC, 2A @ 24VDC

PLC-5/1771 System D1771-6.5.108 TEMPERATURE CONTROL MODULE USER MANUAL

Process Control 1757-ABRIO PROCESS RIO SCANNER MODULE

Operator Interface 2711P-B7C15D2 PV PLUS 700, KEY/TOUCH, CNET, DC PS, EXT MEM

Support 6500-DSUTR SUPT REINSTATEMENT CONTRACT FOR 6500DSUT

Support 9358-PLTM2400S SUPT RENEWAL CONTRACT FOR 9358PLTM2400ENE

Support F1785-BCMSERA FIRMWARE UPGRADE FOR 1785-BCM COMMUNICATION MODULE

RSI Software Products 9301-2SE2200JPE RSVIEW32 WORKS 300 (JAPANESE)

RSI Software Products 9701-VWSB000ENU3 RSVIEW SE STATION 250 - UNLTD DISP UPGRADE

RSI Software Products 9399-CCUG CONTROLGUARDIAN USER'S GUIDE

Motion Control 2098-IPD-150 DRIVE, 65A/150A, ULTRA5000

AD641ECL720 ECLiPS Programming Software for the Series 90-70 CPU's, Serial, with OnTOP

IC300ADC120 4 channel Analog Inputs, Current (0-20mA, 4-20mA), 12 bit

IC752DSX000 Datapanel 160 - 240x64 LCD display with LED backlight. Includes integrated keypad for data entry. No touch capability. Various sizes of text, bitmaps, bar graphs, messaging. Supports limited PC/104 capability.

MTR-3S35-G-R-0-E-S MTR series servo motor with resolver and shaft seal

ZA06B-6077-K157 Noise filter for Alpha servo PSM-45HVi power supply module (required for CE)

20BE099A0ANNANC0 PowerFlex 700 AC Drive 99 A 100 Hp 20B

20G14NF263JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF027-CL PowerFlex 520 26.6A 230V EMC Filter Kit

2711P-RW1 PanelView Plus 64MB CompactFlash Card

FRN 7.5 P11S-4CX 1 4 KVA 16.5A 7.5KW 3相AC380V/50Hz/60Hz

1492-JD3-OR IEC 2-Ckt Feed-Through Blk 2.5mm

1492-W16S-G IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40746BB45

工藝型 CPU 6ES7 515-2TM01-0AB0 CPU 1511TF-1 PN，225 KB 程序，1 MB 數(shù)據(jù)；60 ns；集成 X1: 2x PN 接口，支持 IRT

153H-SC2FBD-54-BP Encl. SMC-50 Encl. Smart Motor Ctrlr CB

1746-F1 SLC Power Supply Fuse

1786-FS20 200 MICRON CBL ASSY 20 METERS (65.6 FT)

193-T1AB20 1.4-2.0 A IEC Bimetallic Overload Relay

20-FR09046 INSULATOR, DC+/-, FR9

2090-CSBM1DF-14AA02 Kinetix Cable Single DSL 2090-Series

20AC011F0AYNANC0 PowerFlex 70 AC Drive 20A

GA647TDV700 proficy GlobalCare Assist for CIMPLICITY HMI Server 700 I/O Development and Runtime System

GP647IFPRDV00900 GCP iFIX Profsnl SCADA 900 I/O Dev

IC600BF949RR 28K ASCII/Basic I/O Module

IC647HSTCS10KM Historian Enterprise Corporate Server 10000 Points (M4 Key)

IC647TRT700 CIMPLICITY HMI Server 700 I/O Runtime System

IC693PWR322 Power Supply, 24/48 Vdc, Standard. Battery not included. Battery is n ow included in the CPU backplane box.

IC756MDV010E-98 DV Draw Dvlpnt on Alpha OpenVMS, English, Version 9.8

MicroLogix 1000/1761 System 9399-RL50GRDE RSLOGIX 500 GETTING RESULTS GUIDE (GERMAN)

PLC-5/1771 System 1771-NIV1 HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-88HCCBL HIGH CURRENT BLOCK CABLE

Communications 9351-VS INTERCHANGE FOR OPENVMS

Operator Interface D6190-6.5.3 CONTROLVIEW GRAFIX EDITOR(6190-GFX)USER'S MNL

Support 9358-B60R SUPT REINSTATEMENT CONTRACT FOR 9358B60ENE

Support 9392-CDRSNLU UPGRADE TO ENGLISH/NETHERLANDS BUNDLE

RSI Software Products 9324-RL0100DEE RSLOGIX 500 STARTER GERMAN CD

RSI Software Products 9301-2SE3500U1 UPGRADE: IN-SUPT: RSVIEW32 RUNTIME 32K TO 100K

RSI Software Products 9356-STD2200U1R UPGRADE: OUT-SUPT: RSSQL STAND.150 TAG TO 300 TAG

Motion Control TL-SSN-2 KIT, SHAFT SEAL, TL-X2XX MTRS

44C742433-001 Cable, IC800ABK001 Battery Pack to Beta Amplifier, 2 Meters

IC200CHS015 I/O INTERPOSING SPRING STYLE

IC694MDL660 RX3i 24VDC Input Module 32 point. Module is supported by serial bus andis not limited to the universal base or expansion base. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block).

MSI-VALMET Valmet PaperLab Interface

VSPCSE-ADMIN VisualSPC SE Administration Bundle includes Attributes, Analyst, Desig ner, Wizard, Importer and Reports.

20BD040A3AYNAND0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JF650JN0NNNNN PowerFlex 755 AC Packaged Drive

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

140NOM21200C Quantum MB+ 網(wǎng)絡(luò)適配器, 1MB, 1MB+, 雙電纜, CC

290E-FAZ-G2 Direct Online Starter

MY4NJ 24VDC, 110VAC, 220VAC 4開(kāi)4閉 觸點(diǎn) 5A LED燈

1492-SPM2C130 MCB Supplementary Protector 13 A

軟啟動(dòng)器 3RW30272BB04

電機(jī)啟動(dòng)器 3VU16403MJ00

150-F201NBRB SMC Flex Smart Motor Controller

1732D-OB16M12MINI ArmorBlock 16 Point Output Block

1771-OZL 1771 Digital Output Module

193-EDN E1 Plus DeviceNet Module

199-FSMZ-1 Industrial Relay Diode Surge Suppressor

2090-CPWM7DF-08AA09 MP-Series 9m Standard Power Cable

2094-XNCON-2 Kinetix 6000 Connector Set

EDS-305-M-ST-T C1 D2 4-port 10/100, 1 port multi-mode ST fiber (-40 to 75 deg C op temp)

GFK-1192 Series 90-70 System Manual for Control Software Users

IC220ACC004 POINT LABELS BLANK QTY 1000

IC647BSU255 Batch Server Pak Upgrade (20 to 255 Units)

IC647PRTHE100C Proficy Portal Historian Edition Client Pack 100 Users (M1 Key)

IC693CPU367 CPU 367Module (240K Bytes configurable Supports Profibus DP Slave (Version 1 supported). One Profibus port and one RS-232 service port.

IC756ADV000K-98 DV Development - AIX Op Sys, Korean, Version 9.8

MSI-EFF-50-43 Efficiency Mang Clients 50 Pack-43

SLC/1746 System 1746-RT26 REPLACEMENT TERMINAL BLOCK - ANALOG OUTPUT

Distributed I/O 1738-IB8M12 24VDC 8 SINKING INPUTS WITH M12 CONNECTORS

Application-specific products D6300-6.9.1 REMOTE I/O MONITOR SW(6300,6310-MS)REFERENCE GUIDE

Operator Interface 2711-NL3 BACKLIGHT PV600 KEY & KEY&TOUCH SER B & EARLIER

Support 9302-REPR SUPT REINSTATEMENT CONTRACT FOR 9302REP

Support 9324-RL5300DER SUPT REINSTATEMENT CONTRACT FOR 9324RL5300DE

DeviceNet Products 1788-CN2DN CONTROLNET TO DEVICENET LINKING DEVICE

RSI Software Products 9301-2SE3353ESE RSVIEW32 RUNTIME 5K WITH RSLINX (SPANISH)

RSI Software Products 9326-AD25APENE APPLICATION MANAGEMENT ADD-ON 25 USER

Motion Control MPG-A010-031M22 MOTOR,SERVO,GEAR RATIO 31,26NM,157RPM,MULTI,230V

Silver Series 1769-L30 COMPACTLOGIX5330 PROCESSOR, 256 KBYTE MEMORY

HE693MIX800 Universal Analog Input module. Inputs for mV, V, mA, uA, RTD, and Thermocouple. See data sheet MAN0314 for details.

IC655MDL593RR 5/12 (TTL) Output (64 points)

QPI3D200C2P/B QUICKPANEL COLOR 10.5" TFT BLANK

ST-5111 STXi High Speed Counter module, 1 Channel, 24VDC 1.5MHz

20BC170A3AYNADC0 PowerFlex 700 AC Drive 20B

20F1AGD125AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A012N114 PowerFlex 40- 2.2 kW (3 HP) AC Drive

140DAI75300C Quantum 開(kāi)關(guān)量AC輸入,32點(diǎn),230VAC,8點(diǎn)成組隔離,CC

284D-FVD2P3Z-10-CR-3-SB DeviceNet Variable Frequency Drive

E3JK-D31 30cm,擴(kuò)散反射式,PNP晶體管輸出100mA，電源:10-30VDC

1492-SJ5B-24 IEC Term Blck 24 pole Side Jumper

人機(jī)界面 6ES7972-0CB20-0XA0 PC/MPI 卡,USB 接口