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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用軟件平臺。另外，PLC即有自身的網(wǎng)絡體系又有開放I/0及通訊接口，很容易組建網(wǎng)絡并實現(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)的靈活應用。因此，在程序設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?？勺鳛椴僮魅藛T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：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)設定：

　　壓力調(diào)節(jié)閥的壓力設定值、P、I、D等參數(shù)可以在上位機中設定。

　　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定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設計

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設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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20-750-PH1-F8 PF755 FR8,IP00,24 VDC WIRE HARNESS

2090-CSBM1DE-10AF09 Kinetix Cable Single DSL 2090-Series

20AB2P2A3AYNNNC0 PowerFlex 70 AC Drive 20A

GA647IFPLSRUNLMT GCA iFIX Plus SCADA Unlmt Srv

GP647IFESGDV00150 GCP iFIX Optn: ESig & ERec 150 I/O Dev

IC600BF843RR 4-20mA Analog Input Module (8 channels)

IC647HSTCCP2M Historian Client Connection Pack 2 Users (M4 Key)

IC647TIAM TIA:Texas Instrument Unib PC Adapter

IC693MLX000 Series 90-30 I/O Modules Label Kit (various quantities)

IC756LDV010E-97 DV Draw Development on Inb/Linux RedHat Op Sys, English, Version 9.7

MicroLogix 1000/1761 System

PLC-5/1771 System 1771-OWK CONFORMALLY COATED, CONTACT OUTPUT MODULE

Distributed I/O 1791-IOVX BLOCK I/O, 24V DC, 128 PT MODULE

Communications 1786-FS60 200 MICRON CABLE ASSEMBLY 60 METERS (196.8 FT)

Operator Interface 9399-PWRGR RSPOWER GETTING RESULTS GUIDE

Support 9356-PRO2300S SUPT RENEWAL CONTRACT FOR 9356PRO2300

Support 9324-RL0700NXR SUPT REINSTATEMENT CONTRACT FOR 9324RL0700NXENE

EtherNet/IP Products 9351-AIX INTERCHANGE FOR AIX

RSI Software Products 9301-2SE3500ESU5 RSVIEW32 RUNTIME 5K-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9356-PRO2500U1R UPGRADE: OUT-SUPT: RSSQL STD.150 TO PROF.70000 TAG

Motion Control N-3412-2-H00AA MOTOR,NEMA 34,12 LB-IN,5500 RPM

44A730464-G26 Connector Kit, Brake (all motors except B0.5) or A40 Motor Fan

IC200ALG327 ANALOG OUTPUT 13 BIT VOLTAGE 12CH

IC693PTM101 Power Transducer Module (includes module, interface, 1m cable)

Silver Series 9323-L3300D A.I SERIES PLC-3 OFFLINE/ONLINE PROGRAMMING

VSPC-SRV/SQL VisualSPC MS SQL Server Interface (Version 7.0 or greater).

20BD027A0AYNANA0 PowerFlex 700 AC Drive 27 A at 20 Hp 20B

20G11FD034AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D170A103 PowerFlex 400- 90 kW (125 HP) AC Drive

520402000 Quantum 遠程I/O分支器終端電阻

285-BRCF25-M4 Source Brake Cordset Flex Cable

E6B2-CWZ3E 5-12VDC,電壓輸出,負載電流20mA, 3相,1000P/R,2000P/R

1492-SPM1D630-N MCB Supplementary Protector 63 A

變頻器選件 6SE6 400-0EN00-0AA0 Encoder 脈沖編碼器計數(shù)模塊

電機啟動器 3VU16400ML00

150-CA20 Smart Motor Controller Accessory

1715-C2 1715 2 m Length Backplane Extender Cable

1771-IXE 1771 8 Point Input Module

193-EC4DD E3 Plus 9-45 A Current Relay

198-WT1 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF07 MP-Series 7m Power Cable

2094-BL50S Kinetix Line Interface Module

DEMOCD00013 iWorkinstruction DEMO CD

GFK-0772 PCM C Function Library Reference Manual

IC210CBL002 PDA to Durus Controllers Transfer Cable

IC647ASC005 PA SDK 5 Pak

IC647PPSOCF Proficy Process Systems Operator Console with iFIX

IC693CPU311RR Base 5 - slot with CPU311

IC754VGF08CTD View Loaded 8In Color TFT Touch DC GEF

MSI-DASHBOARD Dashboard Client

SLC/1746 System 1746-R15 REPLACEMENT RETAINER CLIP FOR MODULES

Distributed I/O 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE

Application-specific products 1803-EEM21E4 EEM,32 PULSES,24V DC,8 ANALOG,4 TO 20 MA, NEMA 4

Operator Interface 2711E-T10C6 PANELVIEW 1000E TOUCHSCREEN TERMINAL, 10.4" FLAT

Support 9302-BLDS SUPT RENEWAL CONTRACT FOR 9302BLD

Support 9381-PP250KENR SUPPORT REINSTATEMENT CONTRACT FOR 9381PP250KEN

DeviceNet Products 1791D-0B16PX 24 VDC BLOCK I/O EXPANSION, 16 OUT SOURCE, RTB

RSI Software Products 9301-2SE3350FRU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9358-PBVNT01ENE RSBATCH NT FOR PLX BATCH VIEW ADDITIONAL CLIENTS

Motion Control MPL-B880C-MJ24AA MOTOR,SERVO,76.0NM,1500RPM,MULTI,460V,BRKE

Silver Series 1398-DDM-009X-DN DRIVE,15A PEAK, ULTRA 100 W/DNET,INDEX

HE660CGM424 Genius "C" Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TPD075 Pro Server 75 I/O Point Development and Run Time System

QDA-EDT-SITE QuickDesigner Site License

ST-3134 STXi analog b module 4 Channels, 0~20mA, 14-bit

20BC105A3ANNACC0 PowerFlex 700 AC Drive 20B

20F14NC260JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B2P3N104 PowerFlex 4- 0.4 kW (0.5 HP) AC Drive

140CPS21100C Quantum 電源, 24 VDC, 獨立, 3A, CC

284D-FHD2P3Z-10-CR DeviceNet Variable Frequency Drive

CJ1W-II101 I/O控制單元，擴展機架用

1492-RIFM20F-F24-2 Connection Products

微處理器的PCI卡 6GK1561-3AA01 CP5613,有微處理器的 PCI 卡

變送器 3RS17001CD00

1497A-A11-M6-0-N Control Power Transber

1606-XLP15A Power Supply XLP 15 W Power Supply

1764-MM3RTC MicroLogix 1500 with RTC Memory Module

188-K4B250 Miniature Circuit Breaker 25 A

194L-HE6E-375 Actuator Handle For Load Switch

2090-CPBM7DF-08AF60 60 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S60 Kinetix Drives 60m Standard Cable

CB1N-1WPM-0140-AZ Brake cable Alpha and Beta series motor s. 14 meters (replaces 44C742238-004 cable)

GC647SGM001 GCScheduler Series and Groups Module

IC200PKG104 VersaMax Ethernet NIU starter kit with I/O.