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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(mǎn)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(xún)和分析。

　　3)系統(tǒng)可靠性低，需要配專(zhuān)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(kāi)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(kāi)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(xiàn)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(mǎn)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(xiàn)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(xiàn)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(kāi)/關(guān)的控制，邏輯控制及用戶(hù)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(huà)面，各系統(tǒng)送氣壓力、流量，供氣壓力調(diào)節(jié)等多幅畫(huà)面，畫(huà)面直觀、豐富，具備PID在線(xiàn)調(diào)節(jié)、在線(xiàn)顯示調(diào)節(jié)曲線(xiàn)功能，包括過(guò)程量變化趨勢(shì)的實(shí)時(shí)趨勢(shì)曲線(xiàn)、歷史趨勢(shì)曲線(xiàn)。

　　(4)報(bào)表打印

　　以報(bào)表形式繪制報(bào)警記錄、歷史記錄畫(huà)面，調(diào)節(jié)間數(shù)據(jù)報(bào)表。實(shí)時(shí)趨勢(shì)曲線(xiàn)和歷史趨勢(shì)曲線(xiàn)可隨意設(shè)定時(shí)間段，打印在線(xiàn)趨勢(shì)，歷史趨勢(shì)曲線(xiàn)。

　　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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IC210MDR124 12V DC Power Source, (12) 12VDC in/8 out (Relay, 8 Amp), (4) analog bs (the analog bs can be used as 24VDC bs, Expandable, with LCD/Keypad. The unit has built-in Modbus slave.

IC647BDD000 Batch Demo 25 Pack CD

IC647PRTEE100M Proficy Portal Enterprise Edition Client Pack 100 User (M4 Key)

IC693CPU352RR CPU 352 Module (4K I/O, 8 Racks, Floating Point Math)

IC754VSI12CTD View Intermediate 12 inch Color TFT Touch DC

MSI-EFF-10-43 Efficiency Mang Clients 10 Pack-43

SLC/1746 System 1746-RL57 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-OAP12

Distributed I/O 1734-RTBS REPLACEMENT IEC SPRING TERMINAL BLOCK

Application-specific products 9307-EM8MGRENE RSENERGYMETRIX MANAGER (0 - 8 METERS)

Operator Interface 2711-NB3 REAL TIME CLOCK

Support 9302-LLFS SUPT RENEWAL CONTRACT FOR 9302LLF

Support 9510-PBCENS SUPT RENEWAL CONTRACT FOR 9510PBCEN

DeviceNet Products 1784-PCD DEVICENET PCMCIA COMM CARD

RSI Software Products 9301-2SE3350U1R UPGRADE: OUT-SUPT: RSVIEW32 RUNTIME 150 TO 5000

RSI Software Products 9307-RSPRTD RSPOWER RT FOR AB PM1 PM2 POWER MONITORING DEVICES

Motion Control MPL-SSN-A8B8 KIT,SHAFT SEAL,FOR MPL-A8XX AND MPL-B8XX MTRS

Silver Series 1747-MNET MODULE,INTERFACE FOR PRGRMMABLE CONTROLLER

HE693DAC420 4ch., 4-20mA/0-20mA Analog Output, 2000Vac Isolation, 13-bit resolution

IC647WMI920 Workstation Interface (WSI) for PS/2, Series 90-70 Parallel/Serial

QPI211V0C2P QUICKPANEL COLOR 10.5" TFT VIDEO

ST-4212 STXi analog output module 2 Channels, 4~20mA, 12-bit

20BC170A0ANNACC0 PowerFlex 700 AC Drive 20B

20F1AGC205AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-D8P7H204 PowerFlex 4 3.7 kW (5 Hp) AC Drive

140DAI45300 Quantum 開(kāi)關(guān)量AC輸入,32點(diǎn),48VAC,8點(diǎn)成組隔離

284D-FVD2P3B-10-CR-EMI DeviceNet Variable Frequency Drive

WS02-CXPC1-E5.0 Windows版(2000/xp)

1492-RTB8P 8-Pole Push-In Style Rtb

WinCC 上位監(jiān)控軟件 6AV6381-1BF06-0DV0 "WinCC?V6.0 RT?64K?（64K 外部變量）"

變送器 3RS17221ET00

1497A-A9-M6-3-N 500VA 220x440-120V 60Hz w/Fuses CPT

1606-XLPRED 1606 Power Supply

1768-M04SE CompactLogix 4 Axis Motion Module

188-K4C630 Miniature Circuit Breaker 63 A

194R-B160-1753 Disconnect, Fused, Bs-Type, 160 A

2090-CPBM7DF-10AF09 MP-Series 9m Continuous-Flex Cable

2090-XXNPMP-14S05 MP-Series 5 m Length Power Cable

CBL-13-MP-10 Power cable for MTR-1220 or MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors. 10 feet

GC647WFL005 Proficy GlobalCare Complete for Proficy Workflow - 5 User License

IC200PWR202 POWER SUPPLY WITH EXPANDED 3.3VDC 12VDC INPUT

IC646TBLSS300 Proficy Troubleshooter for Inbligent Historian for Hist 300 Points

IC647NLS000 OPC Server

IC693ACC303 Memory Card, 32 KBytes, Use With HHP (qty 1)

IC698PSD300 RX7i Power Supply 300Watt 24VDC

IC800VMCB2030 Motor power and brake power cable for 2 kW VersaMotion servo motor- 3 meter

SLC/1746 System 1746-IV32 DC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-14PXPH VERSAVIEW NON-DISPLAY COMPUTER, 14 SLOT

Application-specific products 6556-SCBK SLC PROGRAMMABLE PRESS CONTROL KIT

Operator Interface 2711-T5A2L1 PV550 MONO TOUCH, DH485

Support 9301-2SE2300DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2300DE

Support 9307-10KMGDBPS SUPT RENEWAL CONTRACT FOR 930710KMGDBPENE

DeviceNet Products 1732D-IB8M12 DEVICENET 24VDC 8 INPUT W/M12

RSI Software Products 9301-2SE250ITU2R RSVIEW32 WORKS 1500-100K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-BNT03ENE RSBATCH 03 UNITS

Motion Control MPL-B310P-SJ22AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V,3.0KG

Motion Control 2090-XXNPY-16S05 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,5M

GFH-001 Servo Product Specification Guide (Alpha and Beta Series)

IC641SWP719 C Toolkit for Series 90-70 (Professional)

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

PSPC-DC10L Prof Shop Floor SPC DC 10 User

20BC011A0AYNAND0 PowerFlex 700 AC Drive 20B

20DM261N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H040-P-T K5500 FR1,2 control power con

2711P-RAAT7 PanelView Plus 7 Series Accessory

280-PWRM35G-M10 ArmorStart Three-Phase Power Media

CQM1H-CTB41 高速計(jì)數(shù)器板 4點(diǎn)3

1492-MS8X9 IEC 8 x 9 mm Marker Card

模擬量輸入/輸出模塊SM 6ES7 332-5HD01-0AB0 AO/4 通道，電壓、電流，光電隔離，20pin 前連接器

行程開(kāi)關(guān) 3SE53220SG23

運(yùn)行版軟件 6AV2105-4TT04-0AE0 SIMATIC WinCC Runtime 專(zhuān)業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 262144 PowerTags ->WinCC Runtime 專(zhuān)業(yè)版 262144 PowerTags V14

1585J-M8FBJM-5 RJ45 Ethernet Media

1756-SPESMNRM L7SP Energy Storage Module-Non Remove

188-K1D250-N Miniature Circuit Breaker 25 A

194E-Y32M-1753-6G 32A 3P LOADSW. IN M/THREAD BOX

2090-CFBM7E7-CEAF09 9 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S03 MP-Series 3 m Length Power Cable

BC646TRT915 Server 1500 I/O Runtime System with Proficy GlobalCare

GC647IFPLSR00075 GCC iFIX Plus SCADA 75 I/O Srv

IC200CBL602 Cable expansion shielded 2M 2 connectors

IC646MPS005 Logic Developer PLC Standard 5 Pack

IC647IFSCTSSPRT03M iFIX TS SCADA Support on SCADA -3 Clients (M4 Part)

IC670ALG230 Analog Input, Current, 8 Channel, Grouped

IC697CPU772RR CPU, 12 MHz, 2K Discrete I/O, Expandable Memory, Floating Pt

IC800PCUBC10S050 Powercube flying lead interface cable configured for 1000 steps/revolution and power save enabled. 5 meters

ControlLogix/1756 System 1756-OB8EI 10-30 VDC ISOLATED ELEC FUSED OUTPUT 8PTS (36 PIN)

Industrial Computers 6182H-10KEH6D VVCE 1000, KEYPAD, EXT MEM, RIO/DH, DC

Process Control 1757-FIMEXP035 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RBT7 PV PLUS 700 TOUCH REPLACEMENT BEZEL

Support 9355-WAB1OEMENR SUPT REINSTATEMENT CONTRACT FOR 9355WAB1OEMEN

Support 9351-VSRTR SUPT REINSTATEMENT CONTRACT FOR 9351VSRT

ControlNet Products 1785-L40C15 PLC-5/40C FOR CONTROLNET PHASE 1.5

RSI Software Products 9301-2SE2400FRU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (FR)

RSI Software Products 9355-WABJBENE RSLINX OEM/RSJUNCTIONBOX BUNDLE

Motion Control MPL-A320H-SJ22AA MOTOR,SERVO,2.26 NM,3500RPM,SINGL,230V,4.0KG

Motion Control 2090-DAPC-D0903 CABLE, NON-FLEX, CN3 SERIAL COMMUNICATIONS, 03M

CBL-114-1 Cable. Allen Bradley PLC5 Channel 0 (RS-232)

IC5008TBW2000 Discontinued - Order a BC5008TBW0000 & Appropriate CIM PE License

IC800PCUBC02S050 PowerCube Flying Lead Interface Cable, 200 Steps/Rev & Power Save Enabled, 5 Meters

OC647IFESGDV00075C iFIX Optn: ESig & ERec 75 I/O Development (M1Component Part)

20AD027A0AYYANC0 PowerFlex 70 AC Drive 27 A at 20 Hp 20A

20DC300A0ENNBNANE PowerFlex 700S AC Drive 20D

20G1ANF263JA0NNNNN PowerFlex 755 AC Packaged Drive

25C-E3P0N104 PowerFlex 527 1.5kW (2Hp) AC Drive

280-PWRM22B-M8 ArmorStart Three-Phase Power Media

FX2N-32MR-001 主機(jī)16入/16出?繼電器輸出

1492-M6X10 IEC 6 x 10 mm Marker Card

1494H-EF3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44466BC34

ET 200SP 6ES7193-6BP20-0BB0 基座單元 BU20-P12+A4+0B，類(lèi)型B0，直插式端子，帶4個(gè)AUX端子，適用于繼電器輸出模塊，20mm寬

1585D-M4TBJM-15 Micro D-Code, QD Style Ethernet Media

1756-ESMNSEK ControlLogix Energy Storage Module NSE

1794-OV16P Flex 16 Point Digital Output Module

194E-CA80E-TN-PE 194E Load switch

2090-CCMUSDS-48AA01 Kinetix 3 cable to 1203-USB 1m

2090-DANPT-16S12 TL-Series 12 m Length Power Cable

ABKSTDN0000/ABD 6 inch Color STN/ TCP Label/ 24VDC/ with AB DataHighway Plus/ UL/ cUL/ CE/ UL1604

GC646PCN110E Proficy GC for OP Operator Console Runtime S/W 700 I/O

HE800ACC019 Cage-clamp (screw) style I/O plug, 19-terminal. (Qty 1)

IC630PWR324RR 24Vdc Remote Power Supply Unit

IC647HSTSSEO10KM eSignature Option for Historian - Standard Server 10000 Points (M4 Key)

IC660BLD101 Cover w/Label for IC660BBD101

IC695CHS016CA RX3i 16 universal slots backplane with conbal coating.

IC756WET100J-23 Custom Editor Toolkit, Japanese, Version 2.3

CompactLogix System 1769-PB4 24VDC INPUT P0WER SUPPLY: 4A @ 5VDC 2A @ 24VDC

PLC-5/1771 System D1771-6.5.113 BASIC MODULE USER MANUAL

Process Control 1757-FFLD2 2 H1 / HSE FOUNDATION FIELDBUS LINKING DEVICE

Operator Interface 2711P-B7C4B2 PV PLUS 700, KEY/TOUCH, ENET, AC PS, EXT MEM