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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(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。可作為操作人員現(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(guò)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(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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Motion Control Y-1003-2-H00AA MOTOR,SERVO,0.35 NM,4500RPM,ENCDR,230V,1.04KG

5004S Obsolete - Message Center. 1 Line, 15MM, Green VFD. SLAVE Unit. NEMA 4

IC200CHS122 I/O INTERPOSING FUSE STYLE, 16 PT EXPANSION

IC694MDL753 OUTPUT MODULE 12/24 VDC 0.5AMP 32 POINT POSITIVE LOGIC

MSI-WEB-2-43 Web or Excel Reping Clients 2 Pack-43

VSPCSE-ATNT VisualSPC SE Audit Trail Monitoring and Notification Tool.

20BD052A3AYNACC1 PowerFlex 700 AC Drive 52 A 40 Hp 20B

20G11LC1K5JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-E019N104 PowerFlex 40P 11 kW (15 Hp) AC Drive

140ESI06210C Quantum ASCII 接口模塊, RS232, 2通道, CC

291D-FAP-G1-3FR Direct Online Reversing Starte

MK4NJ-D2 NEW 24VDC，有反向二極管，4開(kāi)4閉，觸點(diǎn)5A 中國(guó)制

1492-SPM2C500 MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW30362BB04

電機(jī)啟動(dòng)器 3VU16403LS00

150-F251NBR SMC Flex Smart Motor Controller

1732E-16CFGM12P5QCR ArmorBlock 16 Point Configurable QC

1771-P5EK 1771 Power Supply

193-EEDP E1 Plus 3.2-16 A IEC Overload Relay

199-MSMA48 Surge Suppressor

2090-CPWM7DF-08AA90 MP-Series 90m Standard Power Cable

2097-F4 Kinetix 300/350 4.40 A Line EMI Filter

EDS-308-T C1 D2 8-port Unmanaged 10/100 Switch (-40 to 75 deg C op temp)

GFK-1504 Manual VersaMax Modules, Power Supplies, Carriers, and Cables

IC220ALG220 ANALOG IN, 15 BIT, VOLTAGE/CURRENT, 2CH (REQUIRES 1 IC220TBK061)

IC647CGMS00 GM Server Site License (not for general use)

IC647PRTOSIC Proficy Portal OSI PI Connector (M1 Key)

IC693DSM302RR Series 90-30 Motion Mate DSM302 Motion Controller, 2 Axes

IC756ADV001K-97 DV Development - AIX Op Sys Addt'l User, Korean, Version 9.7

MSI-IGC-43 7 Day x 24 Hour Support / GlobalCare-43

SLC/1746 System 1746-RT34 TERMINAL BLOCK FOR THE 1746-NT8 MODULE

Distributed I/O 1738-OB4EM8 24VDC 4 SOURCING OUTPUTS WITH M8 CONNECTORS

Communications 2760-A485 CONNECTOR, DH485 MULTIDROP FOR NEMA TYPE 1 DECODER

Operator Interface 2711-NP2 MOUNTING CLIPS PV600 KEY, 900, 1000

Support 9302-SCAR SUPT REINSTATEMENT CONTRACT FOR 9302SCA

Support 9324-RL5300ITR SUPT REINSTATEMENT CONTRACT FOR 9324RL5300IT

DeviceNet Products 2706-P44C INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE335DEU2R RSVIEW32 RUNTIME 300-5K UPGRADE OUT-SUPT(DE)

RSI Software Products 9371-DETPLUS DETAILER BONUS MODULE

Motion Control MPG-A025-031M22 MOTOR,SERVO,GEAR RATIO 31,100NM,168RPM,MULTI,230V

Silver Series 1785-V80B VME PLC5/80 CONTROLLER, 100K WORD SRAM

HE693RLY160 16 point, 5A Relay Output module for GE Fanuc high density Output module IC693MDL752. Requires HE690CBL102 or HE690CBL105 ribbon cable.

IC660BRD025 Genius 32point 5/12/24 Vdc Sink Block for Redundancy "T" Configuration

QPICGAE0000 10.4" Color TFT, GE Fanuc, Ethernet, CF Card, 110 VAC

ST-5252 STXi Serial Interface module RS-232 , 2 Channels,32 Bytes,

20BC205A0ANNANC0 PowerFlex 700 AC Drive 20B

20F1ANC140AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A5P0N114 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140DDI36400C Quantum DC IN 24VDC 6X16 SINK, CONFORMAL COAT

284D-FVD4P0B-N-R Cntl Mod. Variable Frequency Drive

E3S-5E4 5m,對(duì)射型 , 晶體管輸出80mA, 電源:12-24VDC

1492-SJMD5-12 IEC Term Blck 12 pole Side Jumper

人機(jī)界面 6AV6545-0BC15-2AX0 TP170B 觸摸屏，彩色，6 英寸，320? 240

6ES78331FA130YA8

1497B-A14-M14-0-N Control Power Transber

1606-XLS480E-3C Power Supply XLS 480 W Power Supply

1769-IA8I CompactLogix 8 Pt 120VAC D/I Iso Module

189-AL11 MCB Accessory Auxiliary Contact

194R-HM1 194R 100-400 A Operating Handle

2090-CPBM7DF-12AA30 MP-Series 30m Power and Brake Cable

2090-XXNPMP-16S20 MP-Series 20 m Length Power Cable

CBL-30-BT-30 Brake cable for MTR-3S or MTR-3N series servo motors with brake. 30 feet

GF-0203R Connecting FlashCable to Fowler (Chinese with RS-232).

IC200TBX210 Tool box, 10 point, (IC200NDR001) 24VDC In/Relay Out, 24VDC Powered (r equires an external 24VDC Power Supply), VersaMax SE (IC200SET001) wit h all software, cables and manuals (IC640VPS002 and IC646MPM001).

IC646TBSPMPS600 Smart Process Monitoring Process+ server 600 loops

IC647NSG000 Siemens AS511 OPC Server

IC693ACC332 TBQC Base for IC693MDL940

IC752CAB201 AB SLC500 cable for DataPanel 150/160/240

IC800VMCP1050 Power cable for 1 kW VersaMotion servo motor- 5 meter

SLC/1746 System 1746-OW8 RELAY OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-ACPS AC POWER SUPPLY ATX STANDARD

Application-specific products 1400-PD52A POWERMONITOR DISPLAY MODULE

Operator Interface 2711-B6C3 PV600 COLOR KEY&TOUCH, DH485 & RS232 PRINT

Support 9301-2SE2400ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400ES

Support 9307-EM8MGRS SUPT RENEWAL CONTRACT FOR 9307EM8MGRENE

DeviceNet Products 1734-IB2 24V DC 2 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE250ZHU2R RSVIEW32 WORKS 1500-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BNT60U3 UPGRADE: IN-SUPT: RSBATCH 30 TO 60

Motion Control MPL-B330P-RJ22AA MOTOR,SERVO,4.18 NM,5000RPM,RSLVR,460V,5.9KG

Motion Control 2090-U3BK-D4401 BREAKOUT BOARD KIT,CONTROL,CN1,ULTRA 3000,1M

GFK-0685 Series 90 PLC Flow Computer User's Manual

IC646CNU000 CIMPLICITY Client for Microsoft Windows User Package

MSCPX-312806NT Marathon Exp CPU,566 MHz CPU, 128M, 6G, Win NT, 2 PCI/ISA , 1 PCI, 1ISA

PSPC-DC50/E-220 Prof Shop Floor SPC DC 50 User eSig 220v

20BC015A3AYNACC0 PowerFlex 700 AC Drive 20B

20F11FC072JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-ENDCAP200 Kinetix 5700 DC Bus System End Cap

2711P-RBK12 PanelView Plus Accessory

280-PWRM35H-M4 ArmorStart Three-Phase Power Media

CQM1-IA121 輸入 8點(diǎn).100 –120V AC

1492-N30 TERM BLCK 50 Pole Side Jumper

快速進(jìn)給/爬行定位模塊 6ES7351-1AH01-0AE0 FM351，快速進(jìn)給/爬行定位模塊，以雙速電機(jī)實(shí)現(xiàn)閉環(huán)定位，8DI/8DO，15?針D?型編碼器接口，20pin前連接器

行程開(kāi)關(guān) 3SE53223SD23

TIA 博途 WinCC 選件 6AV2107-2KF00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 3 -> 10 Clients

1585J-M8HBJM-5 RJ45 Ethernet Media

1760-IB12XOW4IOF PicoGFX Analog Combination Module

188-K2B630 Miniature Circuit Breaker 63 A

194L-A12-1753 12A 194L Load Switch

2090-CHBP8S8-12AA09 Kinetix 6000M IDM Hybrid Cable

2090-UXTBMP-18S09 MP-Series 9 m Length Brake Cable

BC647MPP050 Logic Developer PLC Professional 50 pack with Proficy GlobalCare Complete with USB Hardware key

GC647IFPRSRUNLMT GCC iFIX Profsnl SCADA Unlmt Srv

IC200CHS102 I/O interposing disconnect style, 16 point expansion

IC646MSP005 Logic Developer State Professional 5 Pack

IC647IFSTRN00075K iFIX Standard HMI 75 I/O Runtime (M1 Kit Part)

IC670CHS003 I/O Base, Connector Style

IC697CSE925 State Logic CPU, 64MHz, 80486DX2

IC800SKCI030 Interface cable to connect an S2K auxiliary I/O connector to the 44A726268-001 terminal block. 3 meter

ControlLogix/1756 System 1756-OG16 0-5 VDC TTL OUTPUT (LOW TRUE) 16 PTS (20 PIN)

Industrial Computers 6182H-12BEH15B VVCE 1250, KEY/TOUCH, EXT MEM, CNET, AC

Process Control 1757-FIMUPG080 FIELDBUS LICENSE UPGRADE, 80 FIMS

Operator Interface 2711P-RGT12 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABOEMENS SUPT RENEWAL CONTRACT FOR 9355WABOEMEN

Support 9354-SS100R 9354-SS100 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 1788-CNF CONTROLNET LOGIX DAUGHTER CARD

RSI Software Products 9301-2SE2400PTE RSVIEW32 WORKS 32K (PORTUGUESE)

RSI Software Products 9355-WABSNEU3R UPGRADE: OUT-SUPT RSLINX SINGLE NODE TO RSLINX GW

Motion Control MPL-A330P-HK24AA MOTOR,SERVO,4.18NM,5000RPM,ENCDR,230V,BRK,6.1KG

Motion Control 2090-UXNBMP-18S01 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 1 MTR.

CBL-12-MPS-30 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 30 Ft.

IC600PB552RR PDT Prom Board

IC800SKCBVL100 Power/Brake Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 10 Meters

OC647IFESGRNUNLMTM iFIX Optn: ESig & ERec Unl I/O Runtime (M4 Part)

20AD052A3AYNAEC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A0EYNANBNE PowerFlex 700S AC Drive 20D