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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(fù)責(zé)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(dāng)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(yán)謹(jǐn)、方便、易編程、易安裝、可靠性高等優(yōu)點。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(xué)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(yuǎn)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(jī)距離較遠(yuǎn)(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(jìn)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(jī)架擴(kuò)展，上位監(jiān)控機(jī)采用SIEMENS公司CP5611網(wǎng)卡完成計算機(jī)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(jī)上可對整個氣體調(diào)節(jié)過程進(jìn)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(xì)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(jìn)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(jī)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(jī)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(jìn)行參數(shù)顯示、控制，觸摸屏程序由組態(tài)軟件來完成，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(jī)配置

　　工控機(jī)采用研華IPC-610，通過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(qiáng)大的系統(tǒng)控制功能：

　　系統(tǒng)可以實現(xiàn)上位機(jī)操作、控制柜觸摸屏操作和就地手動操作;

　　2)報警功能：

　　當(dāng)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(jī)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(jìn)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(bǔ)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(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(bǔ)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(bǔ)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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GA647IFCLNTSRO100 GCP iFIX iClient Read Only 1 PK Keyed Runtime Version

GP-2102NT GagePort Digital NT 2-port b

IC5005TBX0130 PanelPC 15 inch Perbance Unit Deluxe with Windows XP and Stainless Steel Bezel

IC647HSTAE5KM Alarm and Events Option for Historian - Standard Server 5000 Points (M4 Key)

IC647SSE004 Scheduler Server Small

IC693MDL741LT 12/24 Vdc Output, 0.5 Amp, Negative Logic (16 Points) (LT)

IC756HDV010K-99 DV Draw Development on HP/UX Op Sys, Korean, Version 9.9

Pico Controllers 1760-MM2 MEMORY MODULE FOR 18 I/O PICO CONTROLLER

PLC-5/1771 System 1771-OA 120V AC OUTPUT MODULE, 8 OUTPUTS

Distributed I/O 1791D-N4CV2X 24 VDC CB I/O EXPANSION, ANALOG COMBO, 4 IN/2 OUT

Communications 1785-KA3 PLC-2 DATA HWY PLUS COMMUNICATION ADAPTER MODULE

Operator Interface 2706-PCNETP CONTROLNET COMMUNICATION MODULE FOR 2706-P22R

Support 9701-VWMR075AS SUPT RENEWAL CONTRACT FOR 9701VWMR075AENE

Support 9515-RSNHS100R SUPT REINSTATEMENT CONTRACT FOR 9515RSNHS100ENE

EtherNet/IP Products 2711P-K6M20A PV PLUS 600 GRAYSCALE, KEYPAD, ETHERNET, AC PS

RSI Software Products 9301-2SE340FRU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (FR)

RSI Software Products 9356-PRO2300U5 UPGRADE: IN-SUPT: RSSQL PROF.150 TO 1500 TAG

Motion Control 1326AB-B740C-M2K7L MOTOR,SERVO,460V,53.0NM,2200RPM,MULTI,BRK,IP67

4162-L-2 4162 CONTINUOUS LENS KIT. FOR (2) 4162s

HMI-KPN-201/B QUICKPANEL KEYPAD FOR 5" & 6" BLANK

IC693CPU352LT CPU 352 Module (240K Bytes configurable user memory, 4K I/O, 8 Racks, Hardware FLOATING POINT MATH), two built-in Serial Ports .22msec/K (LT)

SPS-120W 24 VDC PS, 5.0A, 85-265 VAC Input

TRM-21006691 9 point screw terminal AC power connector for S2K stepper controller

20BD011A3NYNACD0 PowerFlex 700 AC Drive 20B

20G11BC1K6JN0NNNNN PowerFlex 755 AC Packaged Drive

22B-V6P0C104 PowerFlex 40 1.1 kW (1.5 Hp) AC Drive

140XBP00300 Quantum 背板, 3槽

284R-360P500-M05 360 Ohm Dynamic Brake Resistor

面板安裝，觸點:5A

1492-SPM1D020-N MCB Supplementary Protector 2 A

通用型變頻器 6SE6 440-2UC31-5DA1 "15 KW,275 x 520 x 245"

電機(jī)啟動器 3VU13403MD00

150-C317NBD SMC-3 317A Smart Motor Controller

1609-EXBAT External Battery Housing

1770-XYV PLC-5 Battery

193-EC1JG E3 84-420 A Overload Relay

195-GL01 Auxiliary Contact Block, Side Mounting

2090-CPBM7E7-14AF07 MP-Series 7 m Length Pwr and Brake Cable

2093-PRS4 Kinetix 2000 4 Axis Slim Power Rail

CP9B-0WPB-0140-AZ Power cable for B2/4000is or B4/4000is motors. 14 meters

GFK-0255 Series 90 Programmable Coprocessor Module & Support Software User's Manual

IC200UEX211-24 Qty of 24, 28 point expansion. (16) 24VDC In, (12) Relay Out, 120V/24 0AC Power Supply (includes IC200CBL501)

IC647AMK0441 PA Media Kit v4.4.1

IC647PCMSCH Proficy Change Management Scheduler

IC693CHS392 Base, Expansion, 10 Slots

IC754CKL06MTD Starter Kit 6 In Mono Ctrl Loaded 24 VDCVDC

KIT-GFS-350 QP View & Control Workshop Student Kit

SLC/1746 System D1746-6.7 SLC 500 RTD/RESISTANCE INPUT MOD USER MANUAL

Distributed I/O 1732P-OB8EM8 PROFIBUS 24VDC 8 0.5A OUTPUT W/M8

Application-specific products 1404-M805B-RIO-02 MASTER MODULE-PQ RIO COM-24V P/S-CLASS 0.2

Operator Interface 2711-T10C16 PV1000 COLOR TOUCH, DF1 & RS232 PRINT

Support 9301-2SE3400PTS SUPT RENEWAL CONTRACT FOR 93012SE3400PT

Support 9381-PA2500ENR SUPT REINSTATEMENT CONTRACT FOR 9381PA2500EN

DeviceNet Products 1790D-0V16 DNET LDX I/O, 24VDC, 16 SINK OUT BASE, D-SHELL

RSI Software Products 9301-2SE3303ESE RSVIEW32 RUNTIME 1500 WITH RSLINX (SPANISH)

RSI Software Products 9358-PBA60ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 60 UNITS

Motion Control MPL-B540K-MK24AA MOTOR,SERVO,19.4NM,4000RPM,MULTI,460V,BRK,19.1KG

Motion Control 9101-1779 CABLE, ADAPTOR,50 POS, PCB TO J1 D PLUG

GQPK-DEM-L02 QUICKPANEL JR DEMO 6" MONO LCD GE LABEL

IC646MRE300 Logic PC & View (HRT) 300 Tag Runtime System

MTR-3T43-J-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-1114 STXi b module 4 points, Positive Logic, 5VDC

20BC072A3AYNACC0 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11RC015AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A1P4N113 PowerFlex 4- 0.2 kW (0.25 HP) AC Drive

140CPU65150C Quantum CC QUANTUM PROCESS- UNITY W/ 1024/7

281E-F23Z-25D-CR-3FR ArmorStart Direct Online RVSG Starter

C200H-DA001 模出單元,2路12位?D/A 4-20mA/1-5V/0-10V 可選

1492-RCDA2A40 Residual Current Device 40 A

存儲卡 6ES7952-0KF00-0AA0 FEPROM 存儲卡， 64K

變送器 3RS11202DD20

1497-F-M4-0-N Control Circuit Transber

1606-XL960E-3S Power Supply XL 960 W Power Supply

1762-MM1RTC MicroLogix 1200 with RTC Memory Module

188-K3D020-N Miniature Circuit Breaker 2 A

194L-HC4A-825 Actuator For Control Switch

2090-CPBM7DF-06AA15 MP-Series 15m Power and Brake Cable

2090-XXNPMF-10S25 Kinetix Drives 25m Standard Cable

BC647TPD075 CIMPLICITY HMI ProServer 75 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE010 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 10 Users Ver 3.0

IC200MDL740LT OUTPUT 12/24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT (LT)

IC646PCN110 OpenProcess Operator Console (700 I/O)

IC647MRA150 View Runtime 150 I/O with USB Hardware key

IC677CBLY006 IP67 Sensor/actuator cable, 3-pos., PUR halogen-free black, straight M12 Y-socket, on 2x angled M12 connector, cable length: 0.6 meters

IC697PWR732RR Replacement Power Supply, 125 Vdc, 60 Watts

IC800SSI216RD2 16 amp 230 VAC Devicenet S2K servo controller for MTR series motors

SLC/1746 System 1747-L511 SLC 5/01 CONTROLLER, 1K MEMORY - DH 485

Industrial Computers 6189-RW2 VVCE COMPACT FLASH 128MB W/ME

Application-specific products 9358-PB30ENE RSBIZWARE BATCH FOR PROCESSLOGIX 30 UNITS

Operator Interface 2711-B5A8L1 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

Support 9303-3CS0E80S SUPP RENEWAL CNTRCT FOR 9303-3CS0E80

Support 9391-SDHEHR 9391-SDHEH SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 2711-B5A15L2 PV550 MONO KEY&TOUCH, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOE RSVIEW32 WORKS 100K (KOREAN)