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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(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?？勺鳛椴僮魅藛T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(guò)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(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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RSI Software Products 9301-2SE240JPU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-B60UB1R UPGRADE:OUT-SUPT:RSBIZWARE BATCH 60 UNTS TO BUNDLE

Motion Control MPL-A4520K-HJ22AA MOTOR,SERVO,6.10NM,4000RPM,ENCDR,230V,6.8KG

Motion Control 2090-UXNFM-S15 CABLE,ULTRA, DRIVE CN2 TO N/C,15M

CBL-1C-ET-30 Encoder Cable, MTR-1216, 1221 & 1231 Stepping Motors, 30 Ft.

IC630MDL310RR High Speed Counter Module

IC800SLCFLYV030 Flying Lead Cable, 1-5 kW SL Amplifier I/O to OCS or 3rd Party Controller, 3 Meters

OC647IFSETKTM iFIX Optn: System Extension Toolkit (M4 Part)

20AD5P0A3AYNAEC0 PowerFlex 70 AC Drive 5 A at 3 Hp 20A

20DD022A3EYNACASE PowerFlex 700S AC Drive 20D

20P41AB360RA0NNN PowerFlex DC Drive 230V AC 100 HP

2711C-CBL-AB03 PanelView Component Accessory

280-PWRM24B-M2 ArmorConnect 3-PH Power Media drop cable

SRT2-ID08 遠(yuǎn)程I/O端子（晶體管輸入）8點(diǎn)

1492-MCBA190 Miniature Circuit Breaker

1494V-DJ622-A-B-D-E NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44566BC45

工程組態(tài)編程軟件 6AV2103-2HX04-0BD5 SIMATIC WinCC 專業(yè)版 Powerpack 4096 PowerTags -> max. PowerTags V14

1585D-M4UBJM-5 1585D Ethernet Media Patchcord

1756-L72EROM ArmorControlLogix On Machine Controller

1799-COV20 Embedded I/O Plastic Cover

194E-FA16E-P11-PE 194E Load switch

2090-CFBM6DF-CBAA20 TL-Series 20m Feedback Cable

2090-SCNP5-0 Kinetix 5-5m Fiber Optic Cable

BC646MPM101 Logic Developer PLC Nano/Micro with Programming Cable with Proficy GlobalCare Complete

GC647APC001 GC PA Production Client

HMI-CCT-201 BACKLIGHT TUBE 10.5 inch Color STN (QPI2xxxxS2P) or TFT (QPI2xxxxC2P)

IC641VPD050 VersaPro Distributor Demo 50 Pack

IC647IFGLBLRLYSRVRM iFIX WebSpace Relay Server includes 25 Users

IC660EBR100 Electronic Assembly for IC660BBR100

IC697ACC700 Terminal Block, 40 Contacts (qty 6)

IC756WRE499E-28 Runtime License for Windows 100+ Users, Per User, English v2.8

FlexLogix System 1794-IE8K CONFORMAL COATED, ANALOG INPUT MODULE, 8 POINT

PLC-5/1771 System D6200-6.4.12JP PLC5 PROGRAMMING SW I/O CONFIG. MNL (JAPANESE)

Process Control 1757-SRC1 1757 REDUNDANCY MODULE CABLE - 1 METER, 3.28FT

Operator Interface 2711P-T10C4D2 PV PLUS 1000, TOUCH, ENET, DC PS, EXT MEM

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Support 2711-END1FRS SUPT RENEWAL CONTRACT FOR 2711END1FR

Support F1785-L46BSERE FIRMWARE UPGRADE FOR 1785-L46B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2304 RSVIEW32 WORKS 1500 WITH RSLINX SINGLE NODE

RSI Software Products 9701-VWSS000FRU3 RSVIEW SE 250 TO UNLTD DISP UPGRADE (FRENCH)

RSI Software Products 9399-RSBARG RSBATCH ARCHIVER REFERENCE GUIDE

Motion Control 1394C-SJT10-A MODULE,SYSTEM,10KW,SERVO,W/ANLG INTF,NO HIM

BC646MODEV10PK Motion Developer 10-pack Proficy Global Care Complete for the S2K Series Amplifiers/Controllers

IC300OCS057 MiniOCS with 2x20 LCD & 16 keypad & onboard IO (no expansion) 8 DC bs (pos/neg)without CsCAN, 8 DC Outputs (pos), 4 ISOLATED analog in (20mA), 2 ISOLATED analog out (20mA)

IC752WFB204 Display Station 2020 Series - w/ touch - 12.1" SVGA (800x600), Pentium 233 MHz, 64 MB RAM, 6.4 GB HD, expansion slots, Ethernet, floppy drive, CD ROM front access, built-in keypad, HMI for CNC, HSSB card, Win NT

MTR-3T21-G-R-B-M-S MTR series metric servo motor with resolver and brake and shaft seal

ZA06B-6136-H201 Beta Dual SVM1-20i FSSB Servo Amp,20/20A

20D-HEID-D0 PowerFlex 700S Heidenhain Encoder Board

20G1AGD361AA0NNNNN PowerFlex 755 AC Packaged Drive

25A-V4P8N104 PowerFlex 523 0.75kW (1Hp) AC Drive

2711P-T7C4D8 PanelView Plus Terminal

6SE6430-2UD31-8DB0 18.5KW

1492-L35 IEC Term Blck 16.1x100.5x51.8mm SPr Clp

1494C-CM13 Cable Mechanism

軟啟動(dòng)器 3RW44261BC44

附件 6ES7 954-8LL02-0AA0 存儲(chǔ)卡：256 MB

1585A-DD8JD Gigabit Ethernet Media

1746-RT29 SLC Replacement Terminal Block

1790D-T0B16 CompactBlock LDX 16 Point O/P Base Block

194E-A32-1753-6G 32 A 194E Load switch

20-PP12002 OPTICAL FIBER SET

2090-CSBM1DF-18AF12 Kinetix Cable Single DSL 2090-Series

20AC043F0AYNANC0 PowerFlex 70 AC Drive 43 A at 22 kW 20A

GC646MBPS99 Proficy GlobalCare Complete for ME Professional Development Suite - Site License

HE670RLY168 Discontinued Part. Check with GE IP on migration path.

IC600PM500RR CPU/DPU Power Supply, 115-230Vac

IC647HSTESEO100M eSignature Option for Historian - Enterprise Server 100 Points (M4 Key)

IC655CCM590RR RS-232/RS-422 Convertor Unit

IC694MDL230CA Conbal Coated Input module, 120VAC 8 point isolated.

IC756SDV010CS-99 DV Draw Development on Solaris Op Sys, Simplified Chinese, Version 9.9

MicroLogix 1500/1769 System 1769-IQ16F 1769 16 POINT HIGH SPEED 24VDC INPUT MODULE

PLC-5/1771 System 1785-ENET PLC-5 ETHERNET/IP EXPANSION MODULE FOR PLC-5

Distributed I/O 1794-TB3GK CONFORMALLY COATED, GROUNDED TERMINAL BASE 3-WIRE

Communications 9399-WGGUG RSSERVER FOR GE FANUC GENIUS I/O USER GUIDE

Support 9311-PCDR SUPT REINSTATEMENT CONTRACT FOR 9311PCD

Support 9358-BTDS30S SUPT RENEWAL CONTRACT FOR 9358BTDS30ENE

Support F1771-NXXSERB FIRMWARE UPGRADE FOR 1771-N SERIES I/O MODULE

RSI Software Products 9324-RLD200DEE RSLOGIX 5000 MINI, DEU

RSI Software Products 9301-RSVGEMENE RSVIEW32 GEMTOOL

RSI Software Products 9358-PLTM2200U1 UPGRADE: IN-SUPT: PLANTMETRICS 5 TO 10 WORKCELL

Motion Control 8720SM-022S2GAS3 22 KW/48 AMP, 750 VDC, AC MOTOR WITH SNS60 ENC.

840-RC-24 24" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200NAL211-24 Qty 24, 10 point PLC, (6) 24VDC in, (4) Relay Out, (1) Analog Input (0-10VDC, 8 bit), 24VDC Power Supply

IC697VAL318 Analog Output, Isolated, 8 channel, 12 bit, Current - 4 to 20mA. Removable terminal block, no cable required

MTR-1331-J-N-D-E-SRR MTR series NEMA 34 splashproof stepping motor

ZA06B-0062-B503#0100 B2/4000HVis High Voltage Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD156A3ANNANC1 PowerFlex 700 AC Drive 20B

20G11NE017AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-V6P0N103 PowerFlex 4M-1.1 kW (1.5 HP) AC Drive

140CFI00800 Quantum CABLEFAST, 模擬量輸入塊, 無(wú)保險(xiǎn)

294E-FD2P5Z-G1 Variable Frequency Drive

HL-5030 觸點(diǎn):1開/1閉,5A 250VAC機(jī)械壽命:1000萬(wàn)次?撞壓式 可調(diào)滾珠擺桿型

1492-SPM3B500 MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW40372BB04

中央處理單元 6ES7 212-1AE40-0XB0 CPU 1212C DC/DC/DC

150-F85NBRB SMC Flex Smart Motor Controller

1734-IT2I POINT I/O 2 Point Thermocouple Input

1783-HMS16TG4CGN Stratix 5400 20 Port Managed Switch

193-ER1A Remote Reset Solenoid

20-750-EMCBUS1-F8 PF750,FR8,IP00,EMC BUS, TERMINATION KIT

2090-CPWM7DF-14AA03 MP-Series 3m SpeedTec Standard Cable

2098-DSD-075-SE Ultra 3000 Servo Drive

GA646IFCLNTCRO100 GCA iFIX iClientTS Read Only 1 PK Runtime Version

GFK-2222 PACSystems CPU Reference Manual

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE, OUTPUT, QTY 10

IC647GE9C GE9:GE Fanuc Ethernet

IC647SGM001 Scheduler Series and Groups Module

IC693MDL646CA Conbal Coated Input module 24 VDC 16 point POS/NEG ogic. 1msec filtering.

IC756DVE010K-99 EO GECK (Graphical Editor Construction Kit) - Inb x87, Korean, Versi on 9.9

MSI-QUAL-UNL-43 Unltd Site Clients - Quality Mang-43

PLC-5/1771 System 1771-DS LATCHING INPUT MODULE, 10-27V DC, 8 INPUTS

Distributed I/O 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

Communications 1770-XE DATA HWY 15 PIN CONNECTOR KIT, (FEMALE)

Operator Interface 2727-M7P20D1Q3 MOBILEVIEW MACHINE TERMINAL MT750

Support 9305-RSVADFCPTR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCPT

Support 9515-RSAAMRCTS SUPT RENEWAL CONTRACT FOR 9515RSAAMRCTENE

EtherNet/IP Products 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE3400PTU5 RSVIEW32 RUNTIME 5K-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9515-RSCMP075ENE RSGUARDIAN MIGRATION PROMOTION, <=75 DEVICES

Motion Control 1326AB-B430G-S2L MOTOR,SERVO,460V,6.4NM,5000RPM,SINGL,IP67