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近幾年，隨著我廠生產(chǎn)規(guī)模的逐步擴大，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)運行的穩(wěn)定性。

　　2)儀表內(nèi)部信息儲存量小，采集的壓力、流量等數(shù)據(jù)無法長期保存，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，需要配專人負責該系統(tǒng)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(tǒng)，解決當前存在的問題。

　　1、PLC控制系統(tǒng)的特點及組成

　　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，具有嚴謹、方便、易編程、易安裝、可靠性高等優(yōu)點。它通用性強，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。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)軟件平臺和易學易編程的應(yīng)用軟件平臺。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)并實現(xiàn)遠程訪問。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場的PLC系統(tǒng)與主控室的上位機距離較遠(800米左右)，因此通訊系統(tǒng)需成對加裝RS-485中繼器，另外在現(xiàn)場增加TP27-10//觸摸屏進行數(shù)據(jù)顯示，確保系統(tǒng)運行的穩(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實現(xiàn)機架擴展，上位監(jiān)控機采用SIEMENS公司CP5611網(wǎng)卡完成計算機與PLC之間的數(shù)據(jù)通訊。整個通訊網(wǎng)絡(luò)采用MPI的通訊協(xié)議，從上位機上可對整個氣體調(diào)節(jié)過程進行監(jiān)控和操作。

　　1.2控制系統(tǒng)的功能實現(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)計的關(guān)鍵在于編程者對工藝系統(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)計中首先考慮了供氣壓力調(diào)節(jié)系統(tǒng)的特點，將程序設(shè)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(xiàn)場對工藝的調(diào)整，又可針對配套設(shè)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(tài)、地址和站址的分配以及編制整個生產(chǎn)過程的控制程序的。上位機監(jiān)控軟件采用國產(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)運行于Windows2000中文平臺，可實現(xiàn)對生產(chǎn)過程的全面監(jiān)控，對重要參數(shù)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(shù)的歷史趨勢、實時趨勢，實現(xiàn)壓力調(diào)節(jié)的手自動切換、操作、壓力的高、低限報警、流量數(shù)據(jù)的顯示與累計，滿足高生產(chǎn)率的調(diào)度需求。

　　1.3現(xiàn)場顯示

　　現(xiàn)場采用TP27觸摸屏進行參數(shù)顯示、控制，觸摸屏程序由組態(tài)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(xiàn)場壓力、流量、閥位的顯示與操作。可作為操作人員現(xiàn)場操作的依據(jù)。

　　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(wù)：傳送現(xiàn)場監(jiān)控數(shù)據(jù);運行監(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)實現(xiàn)了供氣系統(tǒng)的自動控制和監(jiān)控，主要包括如下功能：

　　1)靈活的操作方式以及強大的系統(tǒng)控制功能：

　　系統(tǒng)可以實現(xiàn)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(xiàn)場、就地實現(xiàn)高、低限壓力報警;

　　3)簡單、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)對供氣壓力實現(xiàn)了PID自動調(diào)節(jié)控制;

　　2)對所采集的模擬信號進行線性化、濾波、工程單位轉(zhuǎn)換處理;

　　3)實現(xiàn)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(lián)鎖邏輯控制實現(xiàn)開/關(guān)的控制，邏輯控制及用戶自定義功能塊等。系統(tǒng)實現(xiàn)了電磁閥控制以及參數(shù)越限報警等功能。

　　(3)人機接口

　　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(diào)節(jié)間數(shù)據(jù)報表。實時趨勢曲線和歷史趨勢曲線可隨意設(shè)定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設(shè)計

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設(shè)計過程中著重要考慮的是以下幾個方面：

　　(1)數(shù)據(jù)采集及工程量轉(zhuǎn)換

　　(2)PID算法

　　(3)流量溫壓補償計算以及流量的累積計算

　　對于系統(tǒng)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(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算法作一重點介紹
 

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IC694MDL632CA Conformal Coated Input module 125 VDC 8 point NEG/POS logic.

IC756URT100 Unix DV Tools Runtime 100+, Per User

MicroLogix 1500/1769 System 1769-IR6 6 CHANNEL RTD/RESISTANCE INPUT MODULE

PLC-5/1771 System 1771-CX25 PLC-5 LOCAL CABLE

Distributed I/O 1797-CE3S BUS EXTENDER CABLE FOR BUS ISOLATOR - 3 FOOT

Communications D5000-6.4.21 REFERENCE MANUAL INTERCHANGE SOFTWARE

Support 9321-L2160R SUPT REINSTATEMENT CONTRACT FOR 9321L2160

Support 9358-EP03S SUPT RENEWAL CONTRACT FOR 9358BEPNT03ENE

Support F1771-SN FIRMWARE UPGRADE FOR 1771-SN MODULE

RSI Software Products 9324-RLD2U3PTE RSLOGIX 5000 MINI TO STD UP, PTE

RSI Software Products 9304-WVD256D WINTELLIGENT VIEW 256 DEVELOPMENT

RSI Software Products 9358-PLTM2500U1R UPGRADE: OUT-SUPT: PLANTMETRICS 5 TO 100 WORKCELL

Motion Control 8720SM-055S5PAS2 55 KW/116 AMP, 750VDC, AC MOTOR WITH SRM660 ENC.

995-4-0 Thumbwheel Assembly. 4 Digit. 0 True. Dust Seal

IC200TBX110 Tool box, 10 point (IC200NDR001) 24VDCIn/Relay Out, 24 P/S, VersaMax DataPanel DP45 with Programming software and cables, (IC640VPS00, IC752DDZ000, IC200CBL555)

IC698CHS117 RX7i 17 VME Slot Rack, Front Mount

MTR-1350-0-D-E-0RR Stepping Motor Nema34 Dbl Shft

ZA06B-0076-B503 B8/3000HVis servo motor with 24 VDC brake and 128k serial encoder

20BD248A0ANNANC0 PowerFlex 700 AC Drive 20B

20G11RC5P0AA0NNNNN PowerFlex 755 AC Packaged Drive

25-ENC-1 PowerFlex 525 Incremental Encoder

140XTS01209 Quantum CABLEFAST電纜, 大電流, 帶 QUANTUM I/O 端

294E-FD4P2Z-G1-SB Variable Frequency Drive

D4MC-5040 觸點:1開/1閉,10A 250VAC機械壽命:1000萬次 滾珠按鈕式（直角）

1492-SPM3C060 MCB Supplementary Protector 6 A

軟啟動器 3RW40361TB05

數(shù)字量輸入 / 直流輸出模塊 6ES7 223-1PL32-0XB0 SM 1223DI 16×24 V DC，DQ 16×RLY

150-FPP625B SMC Flex Repair Part

1734-OE4C POINT I/O 4 Point Analog Output Module

1783-HMS8TG8EG4CGR Stratix 5400 20 Port Managed Switch

193-ESM-I-60A-P E300/E200 60 Amp Sensing Module

20-750-HOOD1-F8 PowerFlex 750 Exhaust Hood Kit

2090-CPWM7DF-14AF04 MP-Series 4 m Length Power Cable

2098-DSD-HV050X-DN Ultra 3000 Servo Drive

GA646PME001 GlobalCare Assist for PCM Machine Edition Version 1 User

GP-0602NT-F3SB GagePort LVDT NT (Full Bridge for MD5/500AG) - Sales BOM.

IC5002TAX0110 PanelPC 12 inch Standard Unit with Windows XP and Stainless Steel Bezel

IC647HSTAE1250KM Alarm and Events Option for Historian - Standard Server 1,250,000 Points (M4 Key)

IC647SLE999 Scheduler Server Large

IC693MDL730RR 12/24 Vdc Output, 2 Amp, Positive Logic (8 Points)

IC756HDV001E-98 DV Development - HP/UX Op Sys Addt'l User, English, Version 9.8

MSI-SDK-2 SDK Connections 2 Pack

PLC-5/1771 System 1771-ID16K CONFORMALLY COATED, ISOLATED INPUT 120 V AC

Distributed I/O 1790P-T8BV8V PROFIBUS, 24VDC,8 IN/8 SINK OUT BASE,TERMINL BLOCK

Communications 1784-CP8 ADAPTER 62-PIN D-SHELL TO 3-PIN PHOENIX

Operator Interface 2727-TRSP1 MOBILVIEW TABLET SINGLE BAY BATTERY CHARGER

Support 9305-RSVADSESR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADSES

Support 9515-RSEOL024S SUPT RENEWAL CONTRACT FOR 9515RSEOL024ENE

EtherNet/IP Products 2711-B6C20 PV600 COLOR KEY&TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE3403ESE RSVIEW32 RUNTIME 32K WITH RSLINX (SPANISH)

RSI Software Products 9356-PRO2100 RSSQL PROFESSIONAL VERSION WITH 150 TAG LIMIT

Motion Control 1326AB-B520F-S2L MOTOR,SERVO,460V,13.1NM,3500RPM,SINGL,IP67

4161-4-5-N12 BCD To 7 SEG Display . 4 Digit, 5VDC. NEMA 12

HMI-CAB-ETH 6 feet, Ethernet Cross-over cable for direct connection to QuickPanel View & Control

IC693CMM301 Genius Communications Module, GCM (256 bits)

QSK2D100S2P QUICKSTART KIT 6" STN

TRM-21006671 9 point screw terminal AC power connector for 7.2 amp 230 VAC S2K

20BC8P7A3AYNAND0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF119JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E3P0N104 PowerFlex 40- 1.5 kW (2 HP) AC Drive

Quantum Analog Mixed Module 模擬量混合模板

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

E2E-X5Y1 5mm,電感式,二線,常開 300mA 電源:24-240VAC圓M18

1492-SPM1C250 MCB Supplementary Protector 25 A

通用型變頻器 6SE6 430-2UD38-8FB0 "90 KW,350 x 850 x 320"

電機啟動器 3VU13402MD00

150-C201NBD SMC-3 201A Smart Motor Controller

1608P-BP050A480V3 ProDySC 50 Amp Bypass

1770-CD2 Data Highway 200-200 ft Length Cable

193-DNCT DeviceNet Configuration Terminal

194R-R9 SHAFT, SQUARE, 10MM, FOR S3 HANDLE

2090-CPBM7E7-08AF15 15 m Length SpeedTec Extension Cable

2090-XXTPMP-16S60 MP-Series 60 m Length Power Cable

CP5A-1MPB-0140-AZ Mtr Power Cable, A30 & A40 Motors, 14 M

GF-959150 Connecting FlashCable to Mitutoyo Caliper (all except 500-2xx/500-50x/ 550-22x).

IC200UEX010 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240VAC Power S upply. (includes IC200CBL501)

IC647ADC025 PA Dashboard Client 25 Pak

IC647PCL300 Proficy Process Systems Standard Edition 3000 I/O with CIMPLICITY

IC693CBL316 Station Manager Serial Cable for Ethernet TCP/IP

IC754ACC15GAS Gasket for 15in QuickPanel View & Contro

IMC-316P-X-D 6 amp IMC enhanced servo motor controller with Devicenet

SLC/1746 System 9399-RL50GR RSLOGIX 500 GETTING RESULTS GUIDE

Open Automation Systems 1789-STRT1PT SOFTLOGIX 5800 STARTER KIT PORTUGUESE

Application-specific products 1404-M805A-DNT MASTER MODULE-PQ DNET COM-120/240V P/S