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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(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(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?？勺鳛椴僮魅藛T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(cè)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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193-KC12 9.0-12.5 A IEC Bibllic Overload Relay

20-750-PH3-F10 PF755 FR10,IP00,24 VDC WIRE HARNESS

2090-CSBM1DE-10AF30 Kinetix Cable Single DSL 2090-Series

20AB4P2A0AYNNNC0 PowerFlex 70 AC Drive 4.2 A at 1 Hp 20A

GA647IFPRDV00150 GCA iFIX Profsnl SCADA 150 I/O Dev

GP647IFESGDV00900 GCP iFIX Optn: ESig & ERec 900 I/O Dev

IC600BF901RR Remote I/O Driver Module

IC647HSTCCP5M Historian Client Connection Pack 5 Users (M4 Key)

IC647TIDM TID:Texas Instrument Direct

IC693NIU004 Series 90-30 Ethernet NIU (Ethernet I/O)

IC756LDV010E-99 DV Draw Development on Inb/Linux RedHat Op Sys, English, Version 9.9

MicroLogix 1000/1761 System 1761-L10BWB 10 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-OWNA CONTACT OUTPUT MODULE 32 POINT (NORMALLY OPEN)

Distributed I/O 1791-N4V2 BLOCK I/O, 120V AC, 6 POINT ANALOG MODULE

Communications 1786-FSKIT V-PIN CONNECTOR KIT

Operator Interface 9399-RSVSPCGR RSVIEW32 SPC GETTING RESULTS GUIDE

Support 9356-PRO2350S SUPT RENEWAL CONTRACT FOR 9356PRO2350

Support 9324-RL0LDRENR SUPT REINSTATEMENT CONTRACT FOR 9324RL0LDREN

EtherNet/IP Products 9351-DKTS INTERCHANGE FOR MSL-DOS

RSI Software Products 9301-2SE3500FRU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (FR)

RSI Software Products 9356-PRO2500U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.70000 TAG

Motion Control N-4214-2-H00AA MOTOR,NEMA 42,14 LB-IN,4500 RPM

44A731203-G03 Upgrade Kit Genius IC660BBA023

IC200ALG331 Analog Output Module, 16 Bit Voltage/Current, 1500VAC Isolation, 4 Channels

IC693PWR321LT Power Supply, 120/240 Vac, 125 Vdc, Standard (LT)

Silver Series 9500-CPAKMENE CONTROLPAK RT - MEDIUM SYSTEM

VSPC32-ADMIN SP VisualSPC Administration Bundle includes Attributes, Analyst, Designer , Wizard, Importer and Reports.

20BD027A0AYNANC0 PowerFlex 700 AC Drive 27 A at 20 Hp 20B

20G11FD052AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D260A103 PowerFlex 400- 132 kW (200 HP) AC Drive

MA0329001 Quantum CONNECTOR SET,CASSETTE,W/BOOTS

285-BRCF25-M8 Source Brake Cordset Flex Cable

E6B2-CWZ1X 5VDC,線性驅(qū)動(dòng)輸出.600P/R

1492-SPM2B010 MCB Supplementary Protector 1 A

變頻器選件 6SE6 400-1PC00-0AA0 PC 至變頻器連接組件 MM420/440

電機(jī)啟動(dòng)器 3VU16400MN00

150-CF147 SMC-3 Accessory

1715-IF16 1715 16 Point Analog Input Module

1771-NBSC 1771 Analog Module

193-EC4EE E3 Plus 18-90 A Current Relay

198-WT2 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF09 MP-Series 9m Power Cable

2094-BL75S Kinetix Line Interface Module

DEMOCD00014 Proficy Shop Floor SPC - DEMO CD

GFK-0777 Analog-100 Brushless Servo Amplifier Instruction Manual

IC210DAR010 AC (85 to 264VAC) Power Source, 6 AC in/4out (Relay 8 Amp), Expandable, with LCD/Keypad

IC647ASC010 PA SDK 10 Pak

IC647PPSOF3 Proficy Process Systems Operator Console with iFIX - 3 Pak

IC693CPU313 5-Slot Base With Turbo CPU in base (.6 msec), 1K Registers, (12K Bytes User Program) Battery included

IC754VGI06SKD View Interm 6In STN Keypad DC GEF Ovrlay

MSI-DASHBOARD-10 Dashboard Client 10 Pack

SLC/1746 System 1746-R16 REPLACEMENT COVER & LABEL FOR CTLG # 1747-ASB

Distributed I/O 1734-OX2 24V DC COIL N.O./N.C. DPST RELAY MODULE

Application-specific products 1803-EEM30 EEM,48 PULSES, 24V DC

Operator Interface 2711-ND3 PANELBUILDER32 SOFTWARE

Support 9302-CTKR SUPT REINSTATEMENT CONTRACT FOR 9302CTK

Support 9381-PP250KENS SUPPORT RENEWAL CONTRACT FOR 9381PP250KEN

DeviceNet Products 1791D-0V16PX 24 VDC COMPACTBLOCK I/O EXPANSION, 16 OUT SINK

RSI Software Products 9301-2SE3350FRU2 RSVIEW32 RUNTIME 300-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9380-RSBCNS2 2-DAYS MISCELLANEOUS SERVICES FOR RSBATCH

Motion Control MPL-B880C-SJ22AA MOTOR,SERVO,110.0NM,1500RPM,SINGL,460V

Silver Series 1398-DDM-010 DRIVE,10A PEAK, ULTRA 200

HE660GGM100 RTU/Modbus slave device with (1) Genius + (1) RTU/Modbus port

IC646TPD150 Pro Server 150 I/O Point Development and Run Time System

QDA-UPD-001 QUICKDESIGNER ADV UPGRADE FROM 3.X

ST-3214 STXi analog b module 4 Channels, 4~20mA, 12-bit

20BC105A3ANNANC0 PowerFlex 700 AC Drive 20B

20F14NC302AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-B4P5F104 PowerFlex 4 0.75 kW (1 Hp) AC Drive

140CPS21400 Quantum 電源, 24 VDC, 可累加, 8A

284D-FHD2P3Z-10-CR-3 DeviceNet Variable Frequency Drive

CJ1W-ID211 16點(diǎn)輸入單元，24VDC

1492-RIFM20F-F24A-2 Connection Products

WinCC 上位監(jiān)控軟件 6GK1704-1CW63-3AA0 通用以太網(wǎng)卡 S7 驅(qū)動(dòng)

變送器 3RS17002AD00

1497A-A11-M6-3-N Control Power Transber

1606-XLP15E Power Supply XLP 15 W Power Supply

1764-RPLTB2 MicroLogix Replacement Part

188-K4B400 Miniature Circuit Breaker 40 A

194L-HE6I-175 IEC CONTROL AND LOAD SW ACTUATOR TYPE I

2090-CPBM7DF-10AA01 MP-Series 1m Standard Cable

2090-XXNPMP-10S01 MP-Series 1 m Length Power Cable

CB4N-0WPM-0140-AZ AHVi and AHVis Motor Brake Power Cable with Straight Connector, 14 M

GC647SLE999 GCScheduler Server Large

IC200PNS002 PROFINET Scanner (PNS) module interfaces a remote node of VersaMax modules to a PROFINET IO Controller. Two 100Mbps Multi-Mode fiber (MMF) ports. Requires Proficy Machine Edition 7.0.

IC646TBLCLT025 Proficy Troubleshooter for Inbligent Historian Standard, Enterprise and Corporate Clients Access 25 Users

IC647NDH000 CIMPLICITY HMI AB DH PLUS Driver

IC690CDR003 InfoLink For PLC Legacy Products CD, single user license

IC698CHS017 RX7i 17 Slot Rack Wall (Rear) Mount

IC800VMA202 2 kW VersaMotion servo amplifier

SLC/1746 System 1746-IA8 AC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-2P2KHDC VERSAVIEW 1200P NON DISPLAY COMPUTER 2 SLOT

Application-specific products 9358-PBPCNT30ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 30 UNITS

Operator Interface 2711-K5A5L1 PV550 MONOCHROME KEY, RS232 (DH485)

Support 9301-2SE2100ZHR SUPT REINSTATEMENT CONTRACT FOR 93012SE2100ZH

Support 9500-CPAKSENS SUPT RENEWAL CONTRACT FOR 9500CPAKSEN

ControlNet Products 9904-OSC CONTROLNET CNA10 OSCILLATOR (1000 PIECE REEL)

RSI Software Products 9301-2SE2503PTE RSVIEW32 WORKS 100K WITH RSLINX (PORTUGUESE)

RSI Software Products 9358-BEPNT60U3 UPGRADE: IN-SUPT: EPROCEDURE FOR NT 30 TO 60

Motion Control MPL-A540K-MK22AA MOTOR,SERVO,19.4 NM,4000RPM,MULTI,230V,16.5KG

Motion Control 2090-XXNPMP-16S01 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,1M

GC646MDC000 Proficy GlobalCare Complete for Logic Developer - PC & View Development/Runtime 8,000 I/O""

IC641SWP050 MS Windows SRTP/VME Host Drivers, Qty. 1

IC800SSI407RP2 7.2A, 480V, Profibus S2K Servo Controller for MTR Series Motors

PSPC-DC/E-220 Prof Shop Floor SPC DC 1 User eSig 220v

20BB192A0ANNANC0 PowerFlex 700 AC Drive 20B

20DH1K430ENNBNANE PowerFlex 700S AC Drive 20D

2198-DB80-F Kinetix 5700 80A Line Filter

2711P-K6C5A8 PanelView Plus 6 Graphic Terminal

280-PWRM35E-M2 ArmorStart Three-Phase Power Media

C60P-EDR-A C60P擴(kuò)展，32點(diǎn)入，28點(diǎn)出?（繼電器）.已停產(chǎn)

1492-MS6X12V51-100 Connection Products

數(shù)字量輸入/輸出模塊SM 6ES7 322-1BL00-0AA0 DO/32 24VDC，0.5A，晶體管輸出，光電隔離，40pin前連接器

行程開關(guān) 3SE53123SD13

運(yùn)行版軟件 6AV2105-2DD14-0AC0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack Runtime Advanced 512 PowerTags -> Runtime 專業(yè)版 512 PowerTags ASIA V14

1585J-M8CBJM-13 RJ45 Ethernet Media

1756-PBR2 ControlLogix Power Supply Bundle