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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(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，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(luò)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(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。可作為操作人員現(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(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(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(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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1585-C8PB-S100 Cable Spool Ethernet Media

1746-R13 SLC Replacement Covers and Labels

1790-T0W8X CompactBlock LDX 8 Expansion Block

194E-A16-1753-4G 16 A 194E Load switch

20-PP10023 WIRE MODIFICATION KIT REPL REV E & OLDER

2090-CSBM1DF-18AA35 Kinetix Cable Single DSL 2090-Series

20AC037F0AYNANC0 PowerFlex 70 AC Drive 20A

GC-FDT-DTM-SW1 FDT-DTM Software for use in FDT frame applications (shipping version). Existing DTM that communicates serially and is used primarily with MTL HART Multiplexers and Serial BIMs (8502 and 8505)

HE660BGM224 Discontinued Part. Check with GE IP on migration path.

IC600LR605RR 4K/1K Combined Memory

IC647HSTES3KM Historian Enterprise Server 2500 Points (M4 Key)

IC650ESS004RR Series Six Carrierband Lan Interface, Single Slot (MAP 30)

IC694BEM320 RX3i Communication Module, I/O Link Interface Module (Slave). Module uses RX3i high speed serial bus.

IC756SDV001CT-99 DV Development - Solaris Op Sys Addt'l User, Traditional Chinese, Vers ion 9.9

MicroLogix 1500/1769 System 1764-MM1 MICROLOGIX 1500 MEMORY MODULE

PLC-5/1771 System 1771-WHF FUSED WIRING ARM

Distributed I/O 1794-OE4K CONFORMAL COATED, ANALOG OUPUT MODULE, 4 POINT

Communications 9399-WAB32UGFR RSLINX USER GUIDE (FRENCH)

Support 6233-52VTLS SUPT RENEWAL CONTRACT FOR 623352VTL

Support 9358-BPMG01S SUPT RENEWAL CONTRACT FOR 9358BPMGR01ENE

Support F1771-IXESERC FIRMWARE UPGRADE FOR 1771-IXE I/O MODULE

RSI Software Products 9324-RLD0U6DEE RSLOGIX 5000 SERVICE ED TO FULL UPG, DEU

RSI Software Products 9301-2SE350PTU1R RSVIEW32 RUNTIME 32K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-MTRCK01ENE RSBIZWARE MATERIALTRACK (1 BATCH SERVER)

Motion Control 8720SM-018S2FAS1 18.5KW/41.4 AMP, 750 VDC, AC MOTOR WITH SRS60 ENC.

829-4-0 Thumbwheel Assembly. 4 Digit, 0 True. Dust Seal

IC200MDL643 INPUT 5/12VDC POS/NEG LOGIC (2 GROUPS OF 8) 16PT

IC697PCM711-MP Programmable Coprocessor Modified for use by OEMs

MTR-1324-N-A-E-SRR Stepping Motor Nema34 Splashproof

ZA06B-0032-B175#7008 B2/3000 servo motor with holding brake and 32k serial encoder

20BD125A0AYNAND0 PowerFlex 700 AC Drive 20B

20G11ND027AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF026-CL PowerFlex 4M EMC Filter Kit

110XCA28201 Momentum RS232 COMM CABLE 1M (OEM)

294E-FD1P5Z-G1 Variable Frequency Drive

S82K-10024 220VAC. 容量：100W輸出 24V 4.2A導(dǎo)軌安裝型。停產(chǎn)，可用S8VS-12024

1492-SPM3B160-N MCB Supplementary Protector 16 A

軟啟動器 3RW40262BB14

TS 模塊 6ES7 972-0EB00-0XA0 TS Adapter IE Basic

150-F625NBED SMC Flex Smart Motor Controller

1734-IE2C POINT I/O 2 Point Analog Input Module

1783-BMS20CGP Stratix 5700 20 Port Managed Switch

193-EMRZ01 E1 Plus 115V DC Remote Reset Solenoid

20-750-EMC1-F1 PF753 & PF755 FR 1 EMC CORES W PLATE

2090-CPWM7DF-12AA07 MP-Series 7m Power Cable

2098-DSD-020-DN Ultra 3000 Servo Drive

G-C440/OBG PC to GagePort Cable and Power Supply (25 pin for Owens Brockway OEM)

GFK-2142 Bus Conversion Unit Installation Guide

IC220STR001 MOTOR STARTER DIRECT, 1.5KW/400VAC

IC647EIMC EIM:Honeywell EIM 620

IC647SAX001 Scheduler Dynamics AX Toolkit

IC693MDL634LT 24 Vdc Input, Negative/Positive Logic (8 Points) (LT)

IC756DVE000K-97 EO GECK (Graphical Editor Construction Kit) - Unix, Korean, Version 9. 7

MSI-QUAL-2-43 Quality Mang Clients 2 Pack-43

PLC-5/1771 System 1771-A2B I/O CHASSIS ASSEMBLY, 8 SLOT

Distributed I/O 1790D-8BV8B DNET LDX ,24VDC,8 UNIV IN/8 SRCE OUT BASE, D-SHELL

Communications 1770-CD3 DATA HWY TWINAXIAL CABLE, 300 FT/91 M

Operator Interface 2711E-UT12ET10 PANELVIEW 1200E TOUCH TO 1000E TOUCH MIGRATION KIT

Support 9305-RSVADFCDES SUPT RENEWAL CONTRACT FOR 9305RSVADFCDE

Support 9324-RLDSFCER SUPT REINSTATEMENT CONTRACT FOR 9324RLDSFCE

EtherNet/IP Products 1756-EWEB CLX ENET/IP ENHANCED WEB SERVER MODULE

RSI Software Products 9301-2SE3400JPU3 RSVIEW32 RUNTIME 150-32K UPGRADE IN-SUPT (JP)

RSI Software Products 9371-RSWDI1U2R UPGRADE:OUT-SUPT:RSWIRE DES IED PROF ACAD TO STDAL

Motion Control 1326AB-B420H-M2K4L MOTOR,SERVO,460V,5.1NM,6000RPM,MULTI,BRK,IP67

2325-LV Greyline OS, 4 Line, (20) 5MM Chars, VFD, ASCII /Serial Interface, 10-30 VDC, NEMA 4

HMI-AGO-201 ANTI-GLARE OVERLAY 9"

IC693ACC335 Axis Terminal Block for the Motion Mate DSM302

QPK-DEM-S02 QUICKPANEL JR DEMO 6" STN

TGT-AI0V-16-0RR Target Analog Module 8 bs/8 outputs

20BC5P0A0AYNACC0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE099AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D1P4H204 PowerFlex 40- 0.4 kW (0.5 HP) AC Drive

140DDM39000C Quantum 開關(guān)量DC混合模塊,16點輸入,24VDC;8點輸出,

284E-FVD4P0Z-10-CRN EtherNet Variable Frequency Drive

TL-F20MY1 12mm,電感式,二線,常開200mA 電源:90-250VAC溝形

1492-SPM1C005-N MCB Supplementary Protector 0.5 A

通用型變頻器 6SE6 420-2UC21-1BA1 "1.1 KW，149 x 202 x 172"

電機啟動器 3VU13400ML00

1497D-A17-M14-0-N Gen Purpose Transber

1608N-003A240V1S 3 A Mini DySC Sag Corrector

1769-OF4CI CompactLogix 4 Pt A/O Current Module

190S-ANEJ2-CB40C-KN 2.5-4.0 A Compact Comb Starter W/Ckt-Bkr

194R-NE160-1753 Disconnect Non-Fused IEC 3 Poles 160A

2090-CPBM7DF-16AA60 MP-Series 60m Standard Cable

2090-XXTFMP-S30 MP-Series 30 m Length Feedback Cable

CFBA-0WPB-0140-AZ Encoder cable for BM0.5/4000 or BM1/4000 motors. 14 meter

GF-3610R Connecting FlashCable to CDI Torque Wrench (PET-M/S).

IC200UDR005 28 point PLC,(16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention. B attery not included.

IC646TRT075 75 I/O Point Runtime System

IC647PATCDI0 Proficy PAT - Driver For CDI

IC693APU300RR High Speed Counter (HSC)

IC752FPY000RR Industrial Floppy Drive in Case for Touch Displays

IMC-101-M-ST-T 10/100 baseT to multi-mode ST fiber converter (-40 to 75 deg C op temp)

SLC/1746 System 1746-P1 POWER SUPPLY - RACK MOUNT

Industrial Computers 6186-M20SS VERSAVIEW 20 INCH MONITOR, TEMPERED GLASS

Application-specific products 1404-M505A-RIO MASTER MODULE - PQ RIO COM