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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(fù)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(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。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(yuǎn)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(jī)距離較遠(yuǎn)(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(jìn)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(jī)架擴(kuò)展，上位監(jiān)控機(jī)采用SIEMENS公司CP5611網(wǎng)卡完成計算機(jī)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(jī)上可對整個氣體調(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(xì)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(jìn)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(jī)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(jī)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(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(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(qiáng)大的系統(tǒng)控制功能：

　　系統(tǒng)可以實現(xiàn)上位機(jī)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(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(jìn)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(bǔ)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(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(bǔ)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(bǔ)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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RSI Software Products 9515-RSEOL056ENE RSMACC CONDITION MONITOR, 56XM & 8 ENWATCH

Motion Control 1326AB-B515G-M2L MOTOR,SERVO,460V,10.4NM,5000RPM,MULTI,IP67

4161-3-24-N12 BCD To 7 SEG Display . 3 Digit, 24VDC. NEMA 12

HMI-CAB-C113 CABLE TOYOPUC PC1

IC693CBL308 Cable, Single Connector, 1 Meter (Use with MDL652-653, MDL750-751)

QPM3D200B2P/B 6" Blue Monochrome Mini, Blank Label, 24Vdc

TGT-S00N-1-1 Target series system module with Devicenet

20BC8P7A0AYNANC0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF034JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-E012N104 PowerFlex 40- 7.5 kW (10 HP) AC Drive

140AVI03000C Quantum 模擬量輸入, 8通道, 雙極性, 多量程, CC

284E-FVD6P0Z-25-RR-3-DB1-SB EtherNet Variable Frequency Drive

E2E-X2D1-N NEW 2mm,電感式，兩線，常開 100 mA 電源：12-24VDC圓M8

1492-SPM1C100 MCB Supplementary Protector 10 A

通用型變頻器 6SE6 430-2UD27-5CA0 7.5 KW，185 x 245 x 195

電機(jī)啟動器 3VU13401ML00

150-C135NBR SMC-3 135A.. Smart Motor Controller

1608P-050A400V4S 50 A Pro DySC Sag Corrector

1769-RTB40AIO CMPLX L24 and L27 Replacement Part

191S-AND3-CB25C 1.6-2.5 A Compact Rev Starter W/Ckt-Bkr

194R-R12 194R Extended Length Operating Shaft

2090-CPBM7DF-16AF75 MP-Series 75 m Length Cable

2090-XXTPMP-16S04 MP-Series 4 m Length Power Cable

CP3B-0WEB-0070-AZ Shielded motor power cable for B8is motor (straight connector). 7 meters

GF-6050R Connecting FlashCable to Federal Pocket Surf.

IC200UEM001 Micro Plus 20/40/64 Ethernet module. The Ethernet module is compatible with SRTP and supports up to 4 connections. Module can also be configured for Modbus TCP (server).

IC647ABRC ABR:Allen Bradley RSLinx 7X

IC647PBB4P0 PPS Boiler Bookshelf - 4 pack

IC693CBK004 Cable Kit for High Density I/O Modules (includes CBL333 and CBL334)

IC754ACC06BEZ02 SS-Bezel for 6 Inch STN QP-View & Ctrl

IMC-313E-X-D 3 amp IMC enhanced servo motor controller

SLC/1746 System 1747-DTAM-E DATA TABLE ACCESS MODULE W/ ENGLISH USER'S MANUAL

Open Automation Systems 1784-PM02AETP03 1784-PM02AE TERMPANEL WITH 3 METER CABLE

Application-specific products 1404-M605B-CNT-02 1404-M6 CONTROLNET PM3000 CLASS 0.2 24V P.S.

Operator Interface 2711-K10G10L1 PV1000 GRAYSCALE KEY, DNET & RS232 PRINT

Support 9301-2SE3300ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE3300ES

Support 9380-RSBVBS SUPT RENEWAL CONTRACT FOR 9380RSBVB

DeviceNet Products 1792D-CB12JP MAXUM MEIDA BASE W/12MM CONNECTORS

RSI Software Products 9301-2SE3300ESE RSVIEW32 RUNTIME 1500 (SPANISH)

RSI Software Products 9358-EP10ENE RSBIZWARE EPROCEDURE 10 UNITS

Motion Control MPL-B4530K-SJ22AA MOTOR,SERVO,8.36 NM,4000RPM,SINGL,460V,8.2KG

Motion Control 2090-XB33-32 RESISTIVE BRAKE MODULE, 33A, 32 OHM

GQPI211V0C2P QUICKPANEL COLOR 10.5" TFT VIDEO GE LABEL

IC646MRA075 View 75 Tag Runtime System

MTR-1N31-I-E-D-S-0 Stepping Motor Nema34, Series Wdg, Encoder

QPLCTDE0000 12.1 inch Color TFT/ TCP/ Ethernet/ CF Card/ 24VDC/ UL/ cUL/ CE/ UL1604

20BC043A3AYNAEC0 PowerFlex 700 AC Drive 43 A at 22 kW 20B

20F11ND022AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF021-BL PowerFlex EMC Filter

2711P-RMCP PanelView Plus 7 Accessory

280S-PWRM35H-M1 ArmorStart Three-Phase Power Media

C200H-ID211 輸入單元, 8點, 12 - 24 VDC

1492-PDLC2 Power Distribution Block Accessory

通訊處理器 6ES7441-1AA04-0AE0 CP441-1，PtP-串行通訊，1 個通道，支持 3964RASCII 協(xié)議及打印機(jī)

變送器 3RS10201DD10

1497-B-BASX-3-N Control Circuit Transber

1585J-M8UBJM-6 RJ45 Ethernet Media

1761-L32BWA MicroLogix 1000 32 Point Controller

188-K3C040-N Miniature Circuit Breaker 4 A

194L-E32-1753 32 A 194L Load Switch

2090-CPBM7DF-02AA05 5 m Length DIN Power and Brake Cable

2090-XXNFN-S03 N-Series Universal Flying Lead Cable

BC647PSC025 Proficy Process Systems 250 I/O with Cimplicity

GC647PCM005 GlobalCare Complete for Proficy Change Management Server - 5 Concurrent Users

IC200MDL241 Input 240VAC (2 group of 8) 16 point.

IC646NTS025 Terminal Services - 25 Pack License

IC647MGS001 Proficy Maintenance Gateway Server

IC676CBLPBB050 IP67 Profibus Cordset - 5 Meters

IC697MEM732 Exp. RAM, 256K Bytes, Non-volatile Flash, 32 Bit (Used w/78X CPUs)

IC800SSI104D2RR 4.3A, 115/230V, DeviceNet S2K Servo Controller for S-Series Motors

ControlLogix/1756 System 1756-STRT3FR CONTROLLOGIX STARTER KIT FRENCH

Industrial Computers 6182H-15TEH6B VVCE 1500, TOUCH, EXT MEM, RIO/DH, AC

Process Control 1757-DNBUPG10 DEVICENET LIC UPG 10 DNB

Operator Interface 2711-B5A10L2 PV550 MONO KEY&TOUCH, DNET & RS232 PRINT

Support 9326-AD5WDS SUPT RENEWAL CONTRACT FOR 9326AD5WDENE

Support 9371-EIEC3R SUPT REINSTATEMENT CONTRACT FOR 9371EIEC3

ControlNet Products 1788-CN2FF CONTROLNET TO FIELDBUS LINKING DEVICE

RSI Software Products 9301-2SE2500DEU2 RSVIEW32 WORKS 1500-100K UPGRADE IN-SUPT (DE)

RSI Software Products 9358-BANT10U1 UPGRADE: IN-SUPT: RSBATCH ARCHIVER 03 TO 10

Motion Control MPL-A4520P-MK24AA MOTOR,SERVO,6.10 NM,5000RPM,MULTI,230V,BRK,9.5KG

Motion Control 2090-UXNPBMP-10S09 CABLE, 460V,NON-FLEX,MOTOR POWER,MP,10 GAUGE,9M

CBL-3C-L1D-FLY-10 S2K Feedback Cable, Special for 3rd Party Motors with Hall Commutating Encoders, Flying Leads, 10 Feet

IC641CTL170 Logicmaster 90-70 to Control 90-70 Upgrade

IC800SLM010N2BE25 100W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRPLSRUNLMTM iPower Option - Nwk Unlmt I/O Srv

20AD8P0A3AYYAEG1 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD065A0EYNANANK PowerFlex 700S AC Drive 65 A 50 Hp 20D

20P41AD1K3RA0NNN PowerFlex DC Drive 1328 A

2711P-B10C4A9 PanelView Plus Terminal

280-PWRM24G-M3 ArmorConnect 3-PH Power Media drop cable

NS12-TS00(B)-V1 彩色TFT LCD 分辨率：800×600點, 256色12.1英寸

1492-MCBA370 70 A UL489 Miniature Circuit Breaker

1494V-DS200 Disconnect Switch

軟啟動器 3RW44582BC46

運行版軟件 6AV6613-0AA00-0AL0 SIMATIC WinCC Advanced

1585D-M8UGJM-3 Gigabit Ethernet Media

1756-LSC8XIB8I ControlLogix 8 Point Counter Input

1799-ZCIOB 20 Point Embedded I/P/Output Comb Module

194E-FA32E-PD10-TN 194E Load switch

2090-CFBM7DD-CEAF03 Kinetix 3m Flexible Cable