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近幾年，隨著我廠生產規(guī)模的逐步擴大，就更加要求氣體調節(jié)在生產中的穩(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、調節(jié)滯后，降低了系統(tǒng)運行的穩(wěn)定性。

　　2)儀表內部信息儲存量小，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即有自身的網絡體系又有開放I/0及通訊接口，很容易組建網絡并實現(xiàn)遠程訪問。

　　PLC采用Siemens公司生產的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)結構及硬件配置

　　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網卡完成計算機與PLC之間的數(shù)據(jù)通訊。整個通訊網絡采用MPI的通訊協(xié)議，從上位機上可對整個氣體調節(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過程的控制程序的。上位機監(jiān)控軟件采用國產軟件組態(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，滿足高生產率的調度需求。

　　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，供氣壓力調節(jié)等多幅畫面，畫面直觀、豐富，具備PID在線調節(jié)、在線顯示調節(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，結構緊湊而又靈活。

　　PID調節(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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IC647HSTSC20KM Server to Server Collector for Historian - Standard Server 20000 Points (M4 Key)

IC660BBA103 Block 115Vac/125Vdc Thermocouple Input 6 Channels

IC694MDL753CA Output module, 12/24VDC POS logic, 32 points. Interface uses Fujitsu connector.

IC756WDJ009J-23 DV Development Sys VB and Java, Japanese, Version 2.3

MicroLogix 1500/1769 System 9399-RL50GRIT RSLOGIX 500 GETTING RESULTS GUIDE (ITALIAN)

PLC-5/1771 System 1771-CT 1771 I/O CHASSIS CABLE FOR 1771-P4S, 6S POWER SPLY

Distributed I/O 1797-PS2E2 24 VDC IN QUAD-EX OUT POWER SUPPLY, IS CONN, ATEX

Operator Interface 2711P-B6C5A PV PLUS 600 COLOR, KEY/TOUCH, RS232, AC PS. INCL U

Support 9323-PA1SS SUPT RENEWAL CONTRACT FOR 9323PA1S

Support 9358-MTRCK01R SUPT REINSTATEMENT CONTRACT FOR 9358MTRCK01ENE

Support F1772-LXSERA FIRMWARE UPGRADE FOR 1772-LX PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD600DEE RSLOGIX 5000 FULL EDITION, GERMAN

RSI Software Products 9305-RSVADDCJPE RSVIEW32 ACTIVE DISPLAY DEDICATED CLIENT(JAPANESE)

RSI Software Products 9358-SCHENE RSBIZWARE SCHEDULER SERVER

Motion Control 2094-AC09-M02 MODULE, INTEGRATED, 200/230V, 6KW CONV. 15A INV.

A06B-0143-B175#7076 A12/3000 Servo Motor, IP67 Sealing, Holding Brake, 64K Serial Encoder

IC200UDD120 28 point PLC,(16) 24VDC In, (12) 24VDC Out ESCP(2 at 1.0 amp and 10 at 0.70 amp), 24VDC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752CAB101 AB SLC500 cable for DataPanel 30/50

MTR-1480-E-A-E-SRR Stepping Motor Nema42 Encoder Splashproof

ZA06B-0115-B175#0008 BM0.5/4000 servo motor with brake and 32k serial encoder

20BD3P4A3AYNANA0 PowerFlex 700 AC Drive 3.4 A at 2 Hp 20B

20G11TD710AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-B062 PowerFlex 520 15kW (20Hp) Power Module

372SPU47101V26 Quantum Concept 軟件,S 版本,V2.6

FRN?15E1S-4C 22 KVA 30 A 15KW 3相AC380V/50Hz/60Hz

1747-BA

1492-SPM3C500-N MCB Supplementary Protector 50 A

軟啟動器 3RW40461TB04

模擬量輸出信號板 6ES7 241-1CH30-1XB0 CB 1241 RS485

150-SC3NBR SMC-50 SOLID STATE MOTOR CONTROLLER 320A

1734-VTM POINT I/O Voltage Terminal Module

1783-US14T2S Stratix 2000 14+2 port unmanaged switch

193-ESM-VIG-60A-E3T E300/E200 60 Amp Sensing Module

20-750-MNT2-F10 PF755 FR10,IP00,PANEL MOUNTING KIT

2090-CPWM7DF-16AA30 MP-Series 30m Servo Power Cable

20A-EMC01 PowerFlex 70 Ferrite Core Kit

GA647IFESGDV00900 GCA iFIX Optn: ESig & ERec 900 I/O Dev

GP-2104NT/OBG GagePort Digital NT 4-port b (Owens Brockway OEM)

IC5007TBX0110 PanelPC 17 inch Perbance Unit with Windows XP and Stainless Steel Bezel

IC647HSTCC10KM Calculation Collector for Historian - Standard Server 10000 Points (M4 Key)

IC647SVW001 Scheduler Desktop View Client

IC693MDL751RR 12/24 Vdc Output, Positive Logic (32 Points)

IC756LDV000J-912 DataViews Development on Inb Linux/Red Hat 32 bit Op Sys, Japanese v9.12

Pico Controllers 1760-IB12XOW4IOF 12 DC IN 4 RELAY OUT AIAO

PLC-5/1771 System 1771-OBDSK CONFORMALLY COATED, CURRENT LIMITING OUTPUT MODULE

Distributed I/O 1791R-16B0 RIO 24VDC COMPACTBLOCK, 16 IN SINKING, BASE

Communications 1786-BNCJ CONTROLNET BNC COAXIAL CONNECTOR

Operator Interface 2706-PDNETM DEVICENET COMMUNICATION MODULE FOR 2706-P4X

Support 9701-VWSB100AS SUPT RENEWAL CONTRACT FOR 9701VWSB100AENE

Support 9311-SL25R SUPT REINSTATEMENT CONTRACT FOR 9311SL25

EtherNet/IP Products 2711P-K10C4D1 PV PLUS 1000, KEYPAD, ENET, DC PS, STD MEM

RSI Software Products 9301-2SE340JPU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (JP)

RSI Software Products 9356-PRO2350U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.5000 TAG

Motion Control F-4030-Q-H00AA BRUSHLESS MOTOR/ENCODER

4261A-4-N4 7 SEG Panel DISP. 4 Digit. ASCII/Serial Interface. Quick CONN W/Protocol CONV. NEMA 4

IC200ACC003 "EZ PROGRAM STORE, CPU RS485 PORT UPDATE DEVICE

IC693CPU500 Series 90-30 Cscape CPU supports 1,024 I/O. The processor can be programmed the same as the OCS products over the built-in network that supports CsCAN or DeviceNet Slave.

TGT-000A-4-0 Target 4-Axis Motion Control Module

VDNC-ADM VisualDNC Administrator includes VisualDNC Edit and VisualDocs Adminis trator.

20BD014A3AYNACD0 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BD960AN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B033N103 PowerFlex 400- 7.5 kW (10 HP) AC Drive

140XBP01600 Quantum 背板, 16槽

285-BRC22-M6D Source Brake Patchcord Cable, 6M, M22

H3CR-F8-300 AC100-240V，0.05S-300h可調，2時間設定?二開二閉?觸點：5A

1492-SPM1D060-N MCB Supplementary Protector 6 A

通用型變頻器 6SE6 440-2UD17-5AA1 0.75KW,73 x 173 x 149

電機啟動器 3VU13403MM00

150-C3NBD SMC-3 3A Smart Motor Controller