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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(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(yùn)行，造成了人工成本的上升。

　　鑒于以上三點(diǎn)，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(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。

　　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(duì)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(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(yùn)行于Windows2000中文平臺(tái)，可實(shí)現(xiàn)對(duì)生產(chǎn)過程的全面監(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(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?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)壓力超過工藝要求，可在現(xiàn)場、就地實(shí)現(xiàn)高、低限壓力報(bào)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(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，提高了儀表的測量精度。

　　(2)邏輯控制

　　聯(lián)鎖邏輯控制實(shí)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(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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2090-CFBM7DF-CEAF60 Kinetix 60m Flexible Cable

2090-UXNFBMP-S12 MP-Series 12 m Length Feedback Cable

BC646TDV999 Viewer Development System with Proficy GlobalCare

GC647IFESGRNUNLMT GCC iFIX Optn: ESig & ERec Unl I/O Run

IC200BEM002 PLC network communications Profibus-DP slave

IC646MED010 Proficy Machine Edition Demo 10 Pack - Does not include license - Does not include Supplemental CD

IC647IFPRRNUNLMTC iFIX Profsnl SCADA Unlimited Runtime (M1Component Part)

IC660TBD022 Terminal Assembly for IC660BBD022

IC697CMM711RR Communications Coprocessor, CCM2 and CCM3

IC800MCUB12160XERR Stepping MotorCube 50 oz-in, Pulse/Direction, Encoder Feedback

ControlLogix/1756 System 1756-IB16I 10-30 VDC ISOLATED INPUT 16 PTS (36 PIN)

Industrial Computers 6182H-7TRH4B VVCE 700, TOUCH, STD MEM, ENET, AC

Process Control 9358-PBNT10ENE RSBATCH NT FOR PROCESSLOGIX 10 UNITS

Operator Interface 2711P-RAK15 PVP1500/VVCE1500 KEY/COMBO TO PV1400E KEY ADAPTER

Support 9352-WPM100R SUPT REINSTATEMENT CONTRACT FOR 9352WPM100

Support 9351-AIXR SUPT REINSTATEMENT CONTRACT FOR 9351AIX

ControlNet Products 1786-TNCLXT4 CONTROLNET TNC 75 OHM TERMINATOR PLUG

RSI Software Products 9301-2SE235KOU1R RSVIEW32 WORKS 150-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9355-WABENE RSLINX PROFESSIONAL - ENGLISH

Motion Control MPL-A310F-SK24AA MOTOR,SERVO,1.58 NM,3000RPM,SINGL,230V,BRK,4.2KG

Motion Control 2090-DANFCT-S04 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 04M

BC647MODEV Motion Developer with Proficy GlobalCare Complete & H/W Key

IC5002TAW0000 12" Inbligence Industrial PC, Standard Series Win2000

IC800CBL065 Use IC800CBL068 for New Applications: B2/3000 and B6/2000 Motor Power Cable, 14 Meters

OC647HSTSCADA100 Proficy Historian for SCADA 100 pts

20AD014A3AYYADG1 PowerFlex 70 AC Drive 14 A at 10 Hp 20A

20DC125A0ENNANANE PowerFlex 700S AC Drive 20D

20G1AND415AA0NNNNN PowerFlex 755 AC Packaged Drive

25C-D024N104 PowerFlex 527 11kW (15Hp) AC Drive

280-MTRF22-M6 ArmorConnect Brake and Motor Cable

FX1S-14MR-001 主機(jī)8點(diǎn)入/ 6點(diǎn).出 繼電器輸出

1492-M5X10H81-90 Connection Products

1494H-BN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44446BC45

ET 200SP 6ES7136-6PA00-0BC0 故障安全型模塊F-PM-E 24VDC/8A PPM 標(biāo)準(zhǔn)型，基座單元類型C0

1585D-M4TBDM-12 Micro D-Code, QD Style Ethernet Media

1756-CP3 Logix Family RS232 Programmer Cable

1794-OA8 Flex 8 Point Digital Output Module

194E-CA32E-PE-TN 194E Load switch

2085-ECR Micro800 Expansion Module End Cap

2090-DANBT-18S03 TL-Series 3m Brake Cable

20AC5P0C0AYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MSS101 Proficy GlobalCare Complete for Logic Developer - State Standard w/Programming Cable

HE693THM409 4 ch. J, K, N, T, E, R, S, 0.5 deg C resolution, deg C/deg F engr. units

IC630MDL301RR 24Vdc Sink Input Module (16 points)

IC647HSTSS30KM-35 Historian v3.5 Standard Server 30000 Points (M4 Key)

IC660BLA021 Cover w/Label for IC660BBA021

IC695ALG616 Analog Input module, 16 channels single ended, 8 channels differential, channels are configurable for voltage and current. Can be configured for Current: 0 to 20mA, 4 to 20mA, +/- 20mA; Voltage: +/- 10V, 0 to 10V, +/- 5V, 0 to 5V, 1 to 5V. The ana

IC756WDV009E-23 DV Development Sys Visual Basic, English, Version 2.3

CompactLogix System 1769-IR6 6 CHANNEL RTD/RESISTANCE INPUT MODULE

PLC-5/1771 System 9399-FW5FBGR RSLGIX FRAMWRKS FUNCTION BUILD.GET'G RESULTS GUIDE

Distributed I/O 1799-MP20 PLASTIC MOUNTING PLATE/4 SCREWS-20 PT BOARD

Operator Interface 2711P-T6C3D PV PLUS 600 COLOR, TOUCH, DH485, DC PS

Support 9342-L2200R SUPT REINSTATEMENT CONTRACT FOR 9342L2200

Support 9358-PBPC03S SUPT RENEWAL CONTRACT FOR 9358PBPC03ENE

Support F1779-KFMRSERB FIRMWARE UPGRADE FOR 1779-KFMR COMMUNICATION MODUL

RSI Software Products 9301-2SE2103 RSVIEW32 WORKS 150 WITH RSLINX

RSI Software Products 9701-VWMR075AJPE RSV ME STATION RT 75 DISP -WINDOWS 2000 (JAPANESE)

RSI Software Products 9363-SNAPSHOT RSSNAPSHOT SOFTWARE

Motion Control 2098-DSD-075 DRIVE, 35/75A, ULTRA3000

A99L-0035-0001 Cable Grounding Clamp

IC200UEX636-24 Qty of 24, 6 channel Analog expansion. (4) Analog bs & (2) Analog outputs. 120/240

IC752DEM004 New DataPanel Demo consists of DataPanel 55 and DataPanel 160, DataDesigner and accessories.

MTR-3S23-G-R-0-N-S MTR series servo motor with resolver and shaft seal

ZA06B-0266-B200 Alpha 22/4000HVis servo motor with straight shaft and key

20BE011A0AYNANC0 PowerFlex 700 AC Drive 11 A at 10 Hp 20B

20G14ND156AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-D2P3 PowerFlex 520 0.75kW (1Hp) Power Module

140SDO95300S Quantum 安全型開關(guān)量輸出模板

FRN2.2G11S-4CX 4.2KVA 5.5A 2.2 KW 3相AC380V/50Hz/60Hz

1492-J4TW TERMINAL BLOCK

1492-SPM3D500 MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW40566BB34

CPU 模塊 6ES7 517-3AP00-0AB0 CPU 1517-3 PN/DP，2 MB 程序，8 MB 數(shù)據(jù)；2 ns；集成 X1: 2x PN 接口，X2: 1x PN 接口，X3:1x DP 接口

152H-C135XBD-50 SMC-3 Enclosed Motor Starter

1738-OB2EPM12 ArmorPoint 2 Point Output Module

1784-U2DHP Data Highway Plus Cable

193-NREC3ZZ E3 Plus Replacement Overload Relay

20-750-SPL1-F10 PowerFlex 750 FiberOptic Cable Spool Kit

2090-CSBM1DE-18AA01 Kinetix Cable Single DSL 2090-Series

20AB9P6A0AYNNNC0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSR00300 GCA iFIX Profsnl SCADA 300 I/O Srv

GP647IFESGSRUNLMT GCP iFIX Optn: ESig & ERec Unl I/O Srv

IC600BF912RR 230Vac Isolated Output Module (6 points)

IC647HSTCR1KM Collector Redundancy Option for Historian - Standard Server 1000 Points (M4 Key)

IC647TPD700 CIMPLICITY HMI ProServer 700 I/O Development & Runtime System

IC693PCM301LT Prog. Coproc. Mdl., 192 KB (47 KB Basic Prgm), w/Port Exp. Cbl. (LT)

IC756MDV000E-97 DV Development - Alpha OpenVMS Op Sys, English, Version 9.7

MicroLogix 1000/1761 System 1761-L32AAA 32 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-IL ANALOG INPUT MODULE

Distributed I/O 1792D-4BV0D 4 SINK/SOURCE INPUTS, 4 CONNECTORS

Communications 9300-RADM1 SERIES A REMOTE ACCESS MODEM (DESK TOP WITH CABLE)

Operator Interface D6190-6.5.15 CNTRLVW RAM 4MB ENHANCED MEMORY CARD(6190-MB14)MNL

Support 9356-SQLSAP250R SUPT REINSTATEMENT CONTRACT FOR 9356SQLSAP250

Support 1789-L10S SUPT RENEWAL CONTRACT FOR 1789L10

EtherNet/IP Products 9351-WESRT INTERCHANGE FOR WINDOWS RUNTIME

RSI Software Products 9301-2SE3500JPE RSVIEW32 RUNTIME 100K (JAPANESE)

RSI Software Products 9356-PRO2500U8 UPGRADE: IN-SUPT: RSSQL PROF.5000 TO 70000 TAG

Motion Control 0041-5069 N-3400 SHAFT SEAL KIT

44A735538 CPU323 Upgrade Kit latest revision

IC200CBL105 CABLE I/O NON-SHIELDED 2 CONNECTORS .5M

IC694ALG391 OUTPUT MODULE ANALOG 2 POINT CURRENT

MSI-SERVICES Professional services (Billed per hour)

VSPC32-IMP/GL VisualSPC Importer for Giddings and Lewis (OEM).

20BD034A0AYNANC0 PowerFlex 700 AC Drive 34 A at 25 Hp 20B

20G11GC072JA0NNNNN PowerFlex 755 AC Packaged Drive

22D-B024N104 PowerFlex 40P- 5.5 kW (7.5 HP) AC Drive

600558000 Quantum 電纜切割鉗

29011-061-06-R SCREW, M4 X 0.7 X 6MM PHMS

熱電偶/PT100輸入，電壓輸出，2個(gè)報(bào)警

1492-SPM2B160 MCB Supplementary Protector 16 A