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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)控制領域中早己得到了廣泛的應用。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，適應面廣，特別在數(shù)字量輸入/輸出等邏輯控制領域有無可比擬的優(yōu)點。PLC具有豐富的邏輯控制指令和應用指令，它提供高質(zhì)量的硬件、高水平的系統(tǒng)軟件平臺和易學易編程的應用軟件平臺。另外，PLC即有自身的網(wǎng)絡體系又有開放I/0及通訊接口，很容易組建網(wǎng)絡并實現(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程序的編制直接關系著供氣系統(tǒng)能否正常工作，而程序設計的關鍵在于編程者對工藝系統(tǒng)的理解程度和程序編制技術的靈活應用。因此，在程序設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：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)設定：

　　壓力調(diào)節(jié)閥的壓力設定值、P、I、D等參數(shù)可以在上位機中設定。

　　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定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設計

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設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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HE660BGM424 Genius BASIC Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TJV000 CIMPLICITY?Tracker Display-Inb

QDA-EDT-001/L QuickDesigner Lite (download cable NOT included)

ST-3114 STXi analog b module 4 Channels, 0~20mA, 12-bit

20BC105A0AYNANC0 PowerFlex 700 AC Drive 20B

20F14NC260AN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B2P3F104 PowerFlex 4 0.4 kW (0.5 Hp) AC Drive

140CPS12420C Quantum LMS AC PS 115/230V RED CC

284D-FHD2P3B-10-CR-DB-SB DeviceNet Variable Frequency Drive

CJ1W-PA205R 電源單元100-240VAC,輸出能力：5A,5VDC

1492-RIFM20F-F120-2 Connection Products

上位網(wǎng)卡 6GK1561-1AA01 CP5611,PCI 卡，用于臺式機

變送器 3RS17001AD00

1497A-A10-M6-0-N Control Power Transber

1606-XLP100F Power Supply XLP 100 W Power Supply

1764-MM3 MicroLogix 1500 Memory Module

188-K4B200 Miniature Circuit Breaker 20 A

194L-HE6E-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF40 40 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S40 Kinetix Drives 40m Standard Cable

CA-870-2 Adapter for True Position probe to GP-3102NT GagePort.

GC647SES010 GCScheduler Server Medium

IC200PKG103 I/O starter kit DeviceNet NIU

IC646TBLCLT002 Proficy Troubleshooter for Inbligent Historian Standard, Enterprise and Corporate Clients Access 2 Users

IC647NCN020 CIMPLICITY HMI for CNC Additional Connection

IC690CBL714 Cable, Dual-port, Multi-drop SNP

IC698ACC720 Shielded double slot faceplate, package of six.

IC800VMA042 400 W VersaMotion servo amplifier

SLC/1746 System 1746-C9 36-INCH RACK INTERCONNECT CABLE

Industrial Computers 6181P-17TS2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH TFT

Application-specific products 9358-PBPC60ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 60 UNITS

Operator Interface 2711-K5A3L2 PV550 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9301-2SE2100PTS SUPT RENEWAL CONTRACT FOR 93012SE2100PT

Support 9500-CPAKPSENR SUPT REINSTATEMENT CONTRACT FOR 9500CPAKPSEN

ControlNet Products 9904-CNA10T CONTROLNET CNA10T ASIC (BOX OF 90)

RSI Software Products 9301-2SE2503ITE RSVIEW32 WORKS 100K WITH RSLINX (ITALIAN)

RSI Software Products 9358-BEPNT60U1R UPGRADE: OUT-SUPT: EPROCEDURE FOR NT 03 TO 60

Motion Control MPL-A520K-SK24AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,230V,BRK,13.9KG

Motion Control 2090-XXNPMP-14S30 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,30M

GC646MDA159 Proficy GlobalCare Complete for View Development /Runtime 1,500 I/O""

IC641SWM701 Logicmaster 90-70 S/W Dev. Pkg., 3.5"/5.25" disks + paper docs.

IC800SSI228RD2 28A, 230V, DeviceNet S2K Servo Controller for MTR Series Motors

PSPC-DC-220 Prof Shop Floor SPC DC 1 User 220v

20BB154A0AYNANC0 PowerFlex 700 AC Drive 20B

20DH105A0ENNANANE PowerFlex 700S AC Drive 20D

2198-DB20-F Kinetix 5500 20A Line Filter

2711P-K6C20A9 PanelView Plus 6 Graphic Terminal

280-PWRM35E-M12 ArmorStart Three-Phase Power Media

C20P-EDR-A C20P擴展，12點入， 8點出?（繼電器）.已停產(chǎn)，替換品：CPM1A-20EDR1

1492-MS6X12V21-30 Connection Products

數(shù)字量輸入/輸出模塊SM 6ES7 321-1FF01-0AA0 DI/8 110/230VAC，光電隔離，20pin 前連接器

行程開關 3SE53122SG12

運行版軟件 6AV2105-2HH04-0AC0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack Runtime Advanced 4096 PowerTags -> Runtime 專業(yè)版 4096 PowerTags V14

1585J-M8CBJM-10 RJ45 Ethernet Media

1756-PB75 ControlLogix 24V DC Power Supply

188-K1D010 Miniature Circuit Breaker 1 A

194E-Y100M-1753-6N 100 A 194E Load switch

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-WABDEE RSLINX PRO - GERMAN