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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，具有嚴謹、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?？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(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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194E-AA63 194E Load switch

2080-LC30-24QWB Micro830 24 I/O Controller

2090-CSWM1DF-18AA06 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNNEG0 PowerFlex 70 AC Drive 20A

GC646MPTS99 Proficy GlobalCare Complete GE Compare

HE693RTD660 6 channel RTD b module for Series 90-30 with 700VDC bus-isolation and 0.05C resolution.

IC610MDL104RR 24Vdc Sink In, Relay Out (4 In/4 Out)

IC647HSTSC75KM Server to Server Collector for Historian - Standard Server 75000 Points (M4 Key)

IC660BBD022 Block 24Vdc Source I/O 16 Circuits, 2/3 Wire Sensor Compatible

IC694PWR330CA Conbal Coated Power Supply 120/240VAC 125VDC, added capacity.

IC756WDN009J-22 DV Development Sys VB, Java, C++, C, Japanese, Version 2.2

MicroLogix 1500/1769 System 1769-RTBN18 REPLACEMENT 18 PIN NEMA TERMINAL BLOCK (1 PER KIT)

PLC-5/1771 System 1771-P6R POWER SUPPLY,REDUNDANT,SLOT,8A,220V AC

Distributed I/O 1798-IE4 FLEXARMOR 4 CHANNEL ANALOG INPUT MODULE

Operator Interface 2711P-B6M8A PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH+, AC PS

Support 9323-PA2SS SUPT RENEWAL CONTRACT FOR 9323PA2S

Support 9358-PB60R SUPT REINSTATEMENT CONTRACT FOR 9358PB60ENE

Support F1772-SD FIRMWARE UPGRADE FOR 1772-SD PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7PTE RSLOGIX 5000 FULL TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9305-RSVADFVCFRE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (FRENCH)

RSI Software Products 9301-PCI2000ETHP APPLICOM PCI2000ETH ADDITIONAL PROTOCOL

Motion Control 2094-BNCON-1 460V CONVERTER CONNECTORS UP TO 15KW

A06B-6050-K115 Connector Kit, B2, B6 and A6 Motor Encoder

IC200UEX009 14 point expansion. (8) 120VAC In, (6) Relay Out (2 at 10 amp and 4 at 2 amp), 120/240VAC Power Supply. (includes IC200CBL501)

IC752CBT053RR Datapanel 320T CB (Color Base) with Advanced software: 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications.

MTR-1N41-G-N-A-E-0 MTR series NEMA 42 stepping motor with parallel winding connection and encoder

ZA06B-0128-B675#7008 A6/3000 servo motor with brake and 64k serial encoder

20BD5P0A3AYNACC1 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC085AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E012 PowerFlex 520 7.5kW (10Hp) Power Module

771BSS47201 Quantum CONCEPT M 版注冊服務(wù)

FRN2.2E1S-2J 4.1KVA 11A 2.2KW 3相AC220V/50Hz/60Hz

A20B-0005-0611

1492-SPM3D040-N MCB Supplementary Protector 4 A

軟啟動器 3RW40281TB04

SIMATIC HMI 系列面板 6AV2123-2GA03-0AX0 KTP700 Basic DP 7 寸觸摸 + 按鍵

150-SD3NBR SMC-50 SOLID STATE MOTOR CONTROLLER 520A

1738-ADNX ArmorPoint DeviceNet Network Adaptor

1783-ZMS16TA ArmorStratix 5700 16 port managed switch

193-KA25 0.16-.25 A IEC Bibllic Overload Relay

20-750-NEMA1-F7 PowerFlex 750 Frame 7 Conduit Box Kit

2090-CPWM7DF-16AF15 MP-Series 15m Length Power Cable

20AB022C3AYNANC0 PowerFlex 70 AC Drive 22 A at 7.5 Hp 20A

GA647IFPLDV00075 GCA iFIX Plus SCADA 75 I/O Dev

GP647IFCLNTCRO001 GCP iFIX iClient Read Only 5 PK Keyless Runtime Version

IC600BF811RR 5VTTL/10-50Vdc Input Module

IC647HSTCC30KM Calculation Collector for Historian - Standard Server 30000 Points (M4 Key)

IC647TBPC TBP:Texas Instrument Transparent Byte Protocol

IC693MDL930 Relay Output, Isolated, 4 Amp (8 Points)

IC756LDV001E-98 DV Development - Inb/Linux RedHat Addt'l User, English, Version 9.8

Pico Controllers 1760-CBL-INT300 INTRA-CBL 100M NONTERM

PLC-5/1771 System 1771-OGD TTL OUTPUT MODULE

Distributed I/O 1791-16BC BLOCK I/O, 24V DC, 32 POINT MODULE

Communications 1786-TNCJI4 CONTROLNET TNC COAXIAL CONN - ISOL JACK TO JACK

Operator Interface 2707-MVMNT MICROVIEW HAND-HELD PANEL MOUNT ADAPTER

Support 9701-VWSS100AS SUPT RENEWAL CONTRACT FOR 9701VWSS100AENE

Support 9324-RL0100PTR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100PT

EtherNet/IP Products 1738-AENT ETHERNET ADAPTER

RSI Software Products 9301-2SE340ZHU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9356-PRO2450U2 UPGRADE: IN-SUPT: RSSQL STD.300 TO PROF.32000 TAG

Motion Control F-6100-R-H00AA BRUSHLESS MOTOR/ENCODER

4363-T 4363 WITH RS-232 OUTPUT

IC200ACC450 Simulator for VersaMax Nano. 6 Inputs

IC693MDL230LT 120 Vac Isolated Input (8 Points) (LT)

TRM-21006664 Connector, 7 Point 4.3/5/7.2 Amp S2K Extended Digital I/O (S1 Modules)

VMEM-FETN FOCAS1 Ethernet connection license for VisualMEM. Requires FOCAS1 Eth ernet hardware for CNC available from GE Fanuc

20BD022A0AYNANB0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FC030JA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D017F103 PowerFlex 400 7.5 kW (10 Hp) AC Drive

140CRA93100C Quantum RIO 站適配器, S908 RIO, 單電纜, CC

285-BRC25-M1D Source Brake Patchcord Cable, 1M, M25

H7CR-AV 電源:AC100-240V, 0-999999次,

1492-SPM1D160-N MCB Supplementary Protector 16 A

通用型變頻器 6SE6 440-2UD33-0EB1 "30 KW,275 x 650 x 245"

電機啟動器 3VU13401TD00

150-C60NBR SMC-3 60A Smart Motor Controller

1692-ZG4444 24 V DC Electronic Circuit Protection

1771-IFE Analog Input Module

193-EC3DE E3 Plus 9-45 A Overload Relay

198-N1 IEC Closing Enclosure Accessory

2090-CPWM4DF-10AF30 MP-Series 30 m Length Power Cable

2094-ANINV-2 Kinetix 6000 Connector Set

DEMOCD00001 Proficy iFIX DEMO CD

GFK-0644 Series 90-70 I/O Link Interface Module User's Manual

IC200UEX826 VersaMax Micro 4 channel Thermocouple/mV b and 2 channels of analog output expansion module. Supports Type K,J,E,S,T,B,N,-/+50mV,-/+100mV bs, 12bit resolution bs and 0 to 10VDC or 0 to 20mA outputs. Power source required for expansion mo