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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(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(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。

　　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(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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IC756ADV010J-97 DV Draw Development on AIX Op Sys, Japanese, Version 9.7

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PLC-5/1771 System 1771-DMC1 CONTROL COPROCESSOR - MAIN MODULE

Distributed I/O 1738-IE2CM12 24VDC 2 ANALOG CURRENT INPUTS WITH M12 CONNECTORS

Communications 1770-KFDG DEVICENET RS-232 ADAPTER W/GLOBAL 9V

Operator Interface 2711-NV5 ANTIGLARE OVERLAY PV600 KEY & KEY&TOUCH

Support 9302-TIDR SUPT REINSTATEMENT CONTRACT FOR 9302TID

Support 9324-RL5LDRENR SUPT REINSTATEMENT CONTRACT FOR 9324RL5LDREN

DeviceNet Products 2706-P92C INVIEW MESSAGE DISPLAYS

RSI Software Products 9301-2SE335FRU2R RSVIEW32 RUNTIME 300-5K UPGRADE OUT-SUPT (FR)

RSI Software Products 9371-EDES1U2 UPGRADE: IN-SUPT: RSWIRE DTLR JIC/ACAD TO DES STD

Motion Control MPG-A025-091S22 MOTOR,SERVO,GEAR RATIO 91,100NM,62RPM,SINGL,230V

Silver Series 2711-K14C1 PV1400 COLOR KEY, RIO & RS232 PRINT

HE693RTM705 RTU / Modbus master module for Series 90-30 with 1 RS-232 port, 1 RS-485 port, supports Report by Exception.

IC670ALG320 Analog Output Current/Voltage 4 Pt. Grouped

QPI-DEM-CV2 QUICKPANEL DEMO 10.5" VIDEO

ST-5641 STXi 1 Channels, Pulse Out module, 0.5A/24V, Source, 20Khz

20BC205A3AYNANC0 PowerFlex 700 AC Drive 20B

20F1ANC170JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B012F104 PowerFlex 40 2.2 kW (3 Hp) AC Drive

140DDI85300C Quantum 開關(guān)量DC輸入,32點(diǎn),10-60VDC,4組隔離,CC

284D-FVD4P0Z-10-CR-SB DeviceNet Variable Frequency Drive

E3S-LS10C4S 10CM距離設(shè)定型，晶體管輸出80mA, 電源:12-24VDC

1492-SPM1B005 MCB Supplementary Protector 0.5 A

人機(jī)界面 6AV6545-0AG10-0AX0 MP270B 觸摸面板，256 色，10.4 英寸, 640? 480

6ES73317KB024AB2

1497B-A5-M12-0-N Control Power Transber

1606-XLS480F-3 480VAC 600VDC In 48 to 56VDC Out 480W PS

1769-IF4XOF2 CompactLogix 6 Pt A/I and A/O Module

189-AR20 MCB Accessory Auxiliary Contact

194R-HM4-NFPA1 194R Internal Operating Handle

2090-CPBM7DF-14AA04 MP-Series 4m Standard Cable

2090-XXNPMP-16S90 MP-Series 90 m Length Power Cable

CBL-38-MP-10 Power cable for MTR-3S80 series servo motors. 10 feet

GF-0231R Connecting FlashCable to Brown & Sharpe Digit Cal Mark IV.

IC200TBX240 Tool box, Micro 40, operator interface and software. Includes (IC200UDD040) 24VDC In/24VDC Out, requires 24VDC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP 45 (IC200DTX450) with Proficy programming

IC646TBSPMPW002 Smart Process Monitoring Process+ Web Clients 2 Pack

IC647NSL025 Proficy SQL 2005 - 25 Client Access Licenses (order as separate item, not an option)

IC693ACC337 TBQC Base for IC693MDL654/655/752/753

IC752CBT013RR Datapanel 320T ME (Mono Expansion)w/ Advanced software: 320x240 1/4 VG A Mono LCD with 386SX/40. Analog touch screen w/ text, bitmaps, bar g raphs, real time clock. With 2M memory & PC/104. With Real Time Trends & Host Communications.

IC800VMCP2050 Power cable for 2 kW VersaMotion servo motors- 5 meter

SLC/1746 System 1746-NI16I (16) ANALOG INPUT MODULE, +/- 20 MA

Industrial Computers 6189V-CPUPFM2 PERFORMANCE SBC (W/CPU AND COOLER) (1400R)

Application-specific products 1403-CF001 2 X 1 M F LINK FOR POWERMONITOR

Operator Interface 2711-B6C8L1 PV600 COLOR KEY&TOUCH, DH+ & RS232 PRINT

Support 9301-2SE2400ITS SUPT RENEWAL CONTRACT FOR 93012SE2400IT

Support 9307-EMRTR SUPT REINSTATEMENT CONTRACT FOR 9307EMRTENE

DeviceNet Products 1734-IV4 24V DC 4 CHANNEL SOURCE INPUT MODULE

RSI Software Products 9301-2SE3100DEE RSVIEW32 RUNTIME 150 (GERMAN)

RSI Software Products 9358-BNTK10ENE RSBATCH BACK-UP KEY 10 UNITS

Motion Control MPL-B330P-SJ24AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,460V,BRK,6.1KG

Motion Control 2090-U3CK-D44 CONNECTOR KIT 44 PIN D SUB, CNTRL I/O INTERFACE CN

GFK-0731 ECLIPS (State Logic) Programming for Series 90-70 PLC User's Guide

IC646FXMU10 Proficy Change Management 10 Users System

MSC-RTD-C Obsolete - 100W PT (-200 to 850C) in / 4-20 mA out

PSPC-DCL Prof Shop Floor SPC DC 1 User

20BC015A3AYNAND0 PowerFlex 700 AC Drive 20B

20F11FD014AA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-PWR70 CONKIT,K5500,FR3 POWER

2711P-RBT7 PanelView Plus Accessory

280A-EXT1 ArmorStart w/ Terminator Resistor Cable

CQM1-OD213 輸出32點(diǎn).晶體管NPN 24V DC 100mA

1492-N44 TERM BLCK High Rise MTG Rail

連接電纜 6ES7368-3BB01-0AA0 IM360/361 連接電纜， 1m

變送器 3RS18001AP00

TIA 博途 WinCC 選件 6AV2107-0LB00-0BB0 SIMATIC WinCC DataMonitor for Runtime Professional 1 Client

1585J-M8MBJM-5 RJ45 Ethernet Media

1760-L12BBB-ND Pico 12 Point DC Controller

188-K2C060 6 A Miniature Circuit Breaker

194L-A20-1753 20A 194L Load Switch

2090-CNSRPRS-AA03 Kinetix 6000M Network Cable

2090-UXTBMP-18S40 MP-Series 40 m Length Brake Cable

BC647MQP001 Machine Edition View for Quick Panel 1 user with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTRN00075 GCC iFIX Std HMI 75 I/O Run

IC200CPU001 CPU 34K user configurable user memory, 1.80MSEC/K Boolean one RS232 and one RS485 serial ports

IC646MVD000 ME View View OPC Driver License w/o Global Care and Software Key

IC647IFSTRN00300K iFIX Standard HMI 300 I/O Runtime (M1 Kit Part)

IC670GBI002RR Genius Bus Interface Unit (BIU)

IC697HSC700RR High Speed Counter

IC800SKCPZ100 Power cable to connect an S2K to any 30 - 750 Watt S-series servo motor. 10 meters

ControlLogix/1756 System 1756-M02AE 2-AX SERVO,ANALOG/ENC-ICP

Industrial Computers 6182H-12BRH15B VVCE 1250, KEY/TOUCH, STD MEM, CNET, AC

Process Control 1757-PFBEXP002 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RL7C PV PLUS/VVCE 700 BACKLIGHT REPLACEMENT

Support 9355-WABOEMITS SUPT RENEWAL CONTRACT FOR 9355WABOEMIT

Support 9354-SS505R 9354-SS505 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 1734-IB8 24V DC 8 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE2400U1R UPGRADE: OUT-SUPT: RSVIEW WORKS 1500 TO 32K

RSI Software Products 9357-CNETMDAD3E RSNETWORX MD FOR CONTROLNET ADD-ON

Motion Control MPL-A330P-SJ24AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,230V,BRK,6.1KG

Motion Control 2090-UXNBMP-18S90 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 90 MTR.

CBL-138-2 Cable. Allen Bradley SLC500 1747-KE (RS-232)

IC600WD005 I/O Cable, 5 feet (1.5m)

IC800SKCFLY030 Cable, S2K Aux. I/O Connector to Flying Leads, 3 Meter

OC647IFESGSR00300M iFIX Optn: ESig & ERec 300 I/O Server (M4 Part)

20AD065A0AYNANG0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A

20DC650N0ENNBNANE PowerFlex 700S AC Drive 650 A 355 kW 20D

20P21AD027RA0NNN PowerFlex 27 A DC Drive

2711-NC13 PanelView 5 m Operate Comms Print Cable

280-PWRM22F-M2 ArmorStart Three-Phase Power Media

FX2N-1PG-E 定位模塊

1492-MC5X10 IEC 5 x 10 mm Marker Card

1494U-D100 1494U 100A Switch and Mechanism

軟啟動(dòng)器 3RW44536BC44

SIMATIC STEP 7 V14 6ES7822-0AA04-0YE5 Upgrade SIMATIC STEP 7 基本版 V11..V13 -> V14 浮動(dòng)授權(quán)

1585D-M4UBDF-12 1585D Ethernet Media Patchcord

1756-IF16K ControlLogix 16 Point Analog Input

1794-TBNK Flex Terminal Base

194E-E16-PE 194E Earthing-Grounding Terminal

2090-CFBM4DF-CDAF12 MP-Series 12m Feedback Cable

2090-KPBE7-06AA MP-Series Power and Brake Connector Kit

BC5005TBX0000 15 Inch Inbligence Industrial Computer - Bundled - Perbance Series - w/ Windows XP

GC646TRT050 Proficy GlobalCare Complete for Server 50 I/O RUNTIME SYS

HMI-BEZ-205 Stainless Steel Bezel: 12.1 inch (QPL2xxxx-C2P)/ NEMA 4X