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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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IC754VSL06CTD 6 inch TFT QuickPanel View/ Loaded/ 24VDC

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SLC/1746 System 1746-RL59 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-IH16

Distributed I/O 1734-TB3SQ10 TEN 12-POSITION IP20 SPRING TERNIMAL BASES

Application-specific products 9307-EMDB1C RSEMETRIX ONE CLIENT LICENSE

Operator Interface 2711-NF1 FUNCTION KEY STRIP PV550

Support 9302-MGXS SUPT RENEWAL CONTRACT FOR 9302MGX

Support 9510-PBENS SUPT RENEWAL CONTRACT FOR 9510PBEN

DeviceNet Products 1784-PCID DEVICENET PCI BUS EXPLICIT MESSAGING CARD

RSI Software Products 9301-2SE3350U2R UPGRADE: OUT-SUPT: RSVIEW32 RUNTIME 300 TO 5000

RSI Software Products 9310-CPSBSLENE RSTESTSTAND ENTERPRISE AUTOMOTIVE BODYSHOP LIBRARY

Motion Control MPL-SSN-F165 KIT,SHAFT SEAL,FOR MPL-A5XXX AND MPL-B5XXX MTRS

Silver Series 1747-PTA1E MEMORY PAK - ENGLISH

HE693DNT750 DeviceNet slave module for Series 90-30.

IC648MNT016 Annual Software Maintenance for LM 90-70 Win95/NT Ethernet

QPI2D100L2P/B QUICKPANEL MONO 10.5" LCD BLANK

ST-4274 STXi analog output module 4 Channels, 4-20mA, 12bit, Sensor Connect

20BC170A0ANNANC0 PowerFlex 700 AC Drive 20B

20F1AGC205JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-V1P5H204 PowerFlex 4 0.2 kW (0.25 Hp) AC Drive

140DAI54000 Quantum 開關(guān)量 AC 輸入, 16點(diǎn), 115 VAC, 隔離

284D-FVD2P3B-10-RR-3 DeviceNet Variable Frequency Drive

E3JK-5M1 5m,分離式, 觸點(diǎn)輸出3A 電源:24-240V AC/DC

1492-RXIM4024-16R Connection Products

WinCC 上位監(jiān)控軟件 6AV6381-1BN06-0DV0 "WinCC?V6.0 RC?256?（256 個(gè)外部變量）"

6ES78220AA030YA7

1497B-A10-M14-0-N Control Power Transber

1606-XLS120E Power Supply XLS 120 W Power Supply

1769-ADN CompactLogix DeviceNet Adaptor Module

188-K4D020 Miniature Circuit Breaker 2 A

194R-B63-1753 BS88 194R Disconnect Switch

2090-CPBM7DF-10AF20 MP-Series 20m Continuous-Flex Cable

2090-XXNPMP-14S12 MP-Series 12 m Length Power Cable

CBL-14-ED-10 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series splashproof stepping motors connected to IMC or S2K. 10 feet

GC647WFL050 Proficy GlobalCare Complete for Proficy Workflow - 50 User License

IC200TBM001 I/O auxilary barrier style

IC646TBLSS500 Proficy Troubleshooter for Inbligent Historian for Hist 500 Points

IC647NMD000 CIMPLICITY HMI MODBUS PLUS Communications Driver

IC693ACC307 I/O Bus Terminator Plug

IC750CFL840RR PANELWARE 8-Line x 40-Character Graphic CFL Display

IC800VMCB2200 Motor power and brake power cable for 2 kW VersaMotion servo motor- 20 meter

SLC/1746 System 1746-OA8 AC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-7P2KH VERSAVIEW NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 6556-SCBK3 OMEGA - 5/03 CLUTCH/BRAKE AC KIT

Operator Interface 2711-T5A8L1 PV550 MONO TOUCH, DH+ & RS232 PRINT

Support 9301-2SE2300ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300ES

Support 9307-64MGDBCS SUPT RENEWAL CONTRACT FOR 930764MGDBCENE

DeviceNet Products 1732D-OB8EM12 DEVICENET 24VDC 8 0.5A OUTPUT W/M12

RSI Software Products 9301-2SE250ITU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-BNT03UB1R UPGRADE: OUT-SUPT: RSBATCH 03 UNITS TO BUNDLE

Motion Control MPL-B310P-SK22AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V

Motion Control 2090-XXNPY-16S09 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,9M

GFK-0256 MegaBasic Language Reference and Programmer's Guide

IC641VPH700 VersaPro Professional Edition - Windows Programming Software with Programming Cable for Series 90-70, Series 90-30, and VersaMax PLCs

IMC-316X-X-D IMC-D Series Servo Motor Controller, 6 Amp

PSPC-DC25-220 Prof Shop Floor SPC DC 25 User 220v

20BC011A0AYYANC0 PowerFlex 700 AC Drive 20B

20DM325N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H070-AD-T K5500 FR3 AC,DC Bus Connector

2711P-RAK12E PanelView Plus Accessory

280-PWRM35G-M2 ArmorStart Three-Phase Power Media

CQM1H-ABB21 絕對(duì)值編碼器 2點(diǎn)

1492-MUA2B-A7-A10 1772 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1AH02-0AE0 CP340，標(biāo)準(zhǔn)串行通訊模塊，RS232C 接口，最高19.2kbit/s,9 針 Sub-D 接口

行程開關(guān) 3SE53220SH21

TIA 博途 WinCC 選件 6AV2107-0CR00-0BB0 SIMATIC WinCC Sm@rtServer for SIMATIC Basic Panels

1585J-M8HB-2 RJ45 Ethernet Media

1756-SYNCH ControlLogix SynchLink Comms Module

188-K1D320-N Miniature Circuit Breaker 32 A

194E-Y40-1753-6G 40 A 194E Load switch

2090-CFBM7E7-CEAF15 15 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S15 MP-Series 15 m Length Power Cable

BC646TRT999 Viewer Runtime System with Proficy GlobalCare

GC647IFPLSR00300 GCC iFIX Plus SCADA 300 I/O Srv

IC200CBL615 Cable expansion shielded 15M 2 connectors

IC646MPS050 Logic Developer PLC Standard 50 Pack

IC647IFSCTSSPRT05M iFIX TS SCADA Support on SCADA -5 Clients OEM (M4 Part)

IC670ALG240 Analog Input, Current, 16 Channel

IC697CPU780RR CPU, Hot Standby Redundancy, 12K Disc. I/O, Exp Mem, Floating Pt

IC800PSHV018 PSM-18HVi 18 kW high voltage power supply kit for Alpha servos

ControlLogix/1756 System 1756-ON8 10-30 VAC 2 AMP OUTPUT 8 PTS (20 PIN)

Industrial Computers 6182H-10KRH15D VVCE 1000, KEYPAD, STD MEM, CNET, DC

Process Control 1757-FIMEXP065 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RDB12C PV PLUS 1250, KEY/TOUCH SCREEN DISPLAY MODULE

Support 9355-WABCENR SUPT REINSTATEMENT CONTRACT FOR 9355WABCEN

Support 9351-VSS SUPT RENEWAL CONTRACT FOR 9351VS

ControlNet Products 1785-L80C15 PLC-5/80C FOR CONTROLNET PHASE 1.5

RSI Software Products 9301-2SE2400FRU3 RSVIEW32 WORKS 150-32K UPGRADE IN-SUPT (FR)

RSI Software Products 9355-WABOEMENE RSLINX OEM - ENGLISH

Motion Control MPL-A320H-SK22AA MOTOR,SERVO,2.94 NM,3500RPM,SINGL,230V,4.1KG

Motion Control 2090-U3AE-D4401 CABLE,TWO AXISTO LOGIX 1756MOAE2 CARD,1M

CBL-116-1 Cable. Allen Bradley PLC5 1770-KF2 (RS-232)

IC5105KAN0000 15" Inbligence Industrial PC, Panel-C Series Win NT

IC800PCUBC04S050 PowerCube Flying Lead Interface Cable, 400 Steps/Rev & Power Save Enabled, 5 Meters

OC647IFESGDV00150C iFIX Optn: ESig & ERec 150 I/O Development (M1Component Part)

20AD027A3AYNACG0 PowerFlex 70 AC Drive 27 A at 20 Hp 20A

20DC300A0EYNBNCNK PowerFlex 700S AC Drive 20D

20L-GH10-A2 Hose Kit,(2)10 Ft X 1Inin,W/ Fit,1In Elb

25C-E6P6N104 PowerFlex 527 4kW (5Hp) AC Drive

280-PWRM22C-M025 ArmorStart Three-Phase Power Media

FX2N-128MT 主機(jī)64入/64出?晶體管輸出

1492-M6X10V1-100 Connection Products

1494H-EN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44466BC35

ET 200SP 6ES7193-6BP20-0DC0 基座單元 BU20-P6+A2+4D，類型C0，直插式端子，帶2個(gè)AUX端子，用于新負(fù)載組，20mm寬

1585D-M4TBJM-20 Micro D-Code, QD Style Ethernet Media

1756-HIST1G Historian ME 1 Gig in ControlLogix Rack

1794-OW8 Flex 8 Point Relay Output Module

194E-DA16E 194E Load switch

2090-CCPP8S8 Kinetix 6000M hybrid coupler cable

2090-DANPT-16S30 TL-Series 30 m Length Power Cable

ABKSTDN0000/SER 6 inch Color STN/ TCP Label/ 24VDC/ with HMI-CAB-C52 & HMI-CAB-C83/ UL/ cUL/ CE/ UL1604

GC646PEW110E Proficy GC for OP EWS Development Software 700 I/O

HE800ACC112 Cage-clamp (screw) style I/O plug, 12-terminal. (Qty 10)

IC640BSS303RR Series Six Interface Board

IC647HSTSSEO150KM eSignature Option for Historian - Standard Server 150000 Points (M4 Key)

IC660BLM506 Bus Terminator 150 Ohm (Qty 4)

IC695CMM004 RX3i serial communications module. Four isolated RS-232/485 port. Supports Serial Read/Write and Modbus Master/Slave. Requires Unversal Backplane.