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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(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(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、實(shí)時(shí)趨勢，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)對供氣壓力實(shí)現(xiàn)了PID自動(dòng)調(diào)節(jié)控制;

　　2)對所采集的模擬信號(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的實(shí)時(shí)趨勢曲線、歷史趨勢曲線。

　　(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)趨勢曲線和歷史趨勢曲線可隨意設(shè)定時(shí)間段，打印在線趨勢，歷史趨勢曲線。

　　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(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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CPM1-CIF11 外設(shè)口 RS422 適配器

1492-MR8X12V1-50 Connection Products

1495-N35 Electrical Interlock

行程開關(guān) 3SE53120SD12

運(yùn)行版軟件 6AV2105-0PA04-0AA0 SIMATIC WinCC Runtime 專業(yè)版 102400 PowerTags V14

1585J-M4TBJM-50 RJ45 Ethernet Media

1756-OF8H ControlLogix 8 Pt A/O I or V HART Module

188-K1C040-N Miniature Circuit Breaker 4 A

194E-HE13G-175 Load Switches Breter

2090-CFBM7DF-CEAA05 MP-Series 5m Servo Feedback Cable

2090-UXLF-106 Ultra Series 6A AC Line Filter

BC646PCN120 OP Operator Console Runtime S/W 300 I/O w/GC

GC647DMS025 GC DataMart 25 PA Connections

IC200ALG264CA Conbal Coated Analog b 15 bit current 15 channel

IC646IFCLNTCRO025M iFIX iClient Read Only 25 PK Keyless (M4 Part)

IC647IFPRDV00075M iFIX Profsnl SCADA 75 I/O Development (M4 Part)

IC660MPH509 Hand-Held Monitor Standalone Connector Kit (Qty 3)

IC697BEM761 Series 90-70 I/O Interface (Used with Series Six Plus PLC)

IC800BIHV020 BSVM1-20HVi Beta HVi 20 amp amplifier kit

ControlLogix/1756 System 1756-L55M24 LOGIX5555 PROCESSOR WITH 3.5MBYTE NV MEMORY

Industrial Computers 6182H-7BRH15B VVCE 700, KEY/TOUCH, STD MEM, CNET, AC

Process Control 9323-ATUNEENE LOOP TUNER FOR LOGIX5000 PIDE FUNCTION BLOCK

Operator Interface 2711P-K15C15B2 PV PLUS 1500, KEYPAD, CNET, AC PS, EXT MEM

Support 9240-WIN16SDKR SUPT REINSTATEMENT CONTRACT FOR 9240WIN16SDK

Support 6723-PCSS SUPPORT RENEWAL CONTRACT FOR 6723-PCS

Support F5130-RM2 FIRMWARE UPGRADE FOR 5130-RM2 PLC5250 PROCESSOR MO

RSI Software Products 9301-2SE2350ZHU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9351-OSF INTERCHANGE FOR DIGIAL UNIX

RSI Software Products 9399-WINIG WINDOWS-BASED PRODUCTS INSTALLATION GUIDE

Motion Control 8720MC-VA-B 460VAC VARISTOR

BC646MRE150 Logic PC & View Runtime (HRT) 150 I/O

IC300STP100 Stepper Indexer. Single axis, supports-type signals only (pulse train out, quadrature or Up/Down in)

IC754VKI12CTD Starter Kit - 12" Color-TFT QuickPanel View Intermediate, Touch, 24VDC

MTR-3T57-H-R-0-M-0RR Servo Motor Metric

20AD-DB1-D PowerFlex 70 Resistor Kit

20DC037A0EYNANASE PowerFlex 700S AC Drive 20D

20G1ANC260JA0NNNNN PowerFlex 755 AC Packaged Drive

25B-V6P0N104 PowerFlex 525 1.1kW (1.5Hp) AC Drive

280-M24F-M1 ArmorStart Three-Phase Power Media

FR-F740-18.5K 26.7KVA 35A 18.5KW 3相AC380V/50Hz/60Hz

1492-LG4Q IEC Term Blck 6.1x105x35.7mm Spr Clp

1494G-BF3N-203W-421 NEMA 1494G Enclosed Disconnect

軟啟動(dòng)器 3RW44366BC44

ET 200SP 6ES7132-6BF60-0AA0 DO 8x24VDC/0,5A 漏型輸出，基本型， 基座單元類型 A0

1585D-E4UBDE-3 Ethernet Media M12 Patchcord

1753-OW8 GuardPLC Relay Output Module

1794-IE8H Flex 8 Point Analog Input Module

194E-AA63E 194E Load switch

2080-LC30-48AWB Micro830 48 I/O Controller

2090-CSWM1DF-18AA07 Kinetix 7m Smartb Single Cable

20AC3P5A3AYNNNC0 PowerFlex 70 AC Drive 20A

GC646MQP001 Proficy GlobalCare Complete for View for QuickPanel

HE693RTD665 Discontinued Part. Check with GE IP on migration path.

IC610MDL105RR Thumbwheel Interface Module

IC647HSTSS10000KM Historian Standard Server 10,000,000 Points (M4 Key)

IC660BBD022RR 24Vdc Source I/O Block, 16 Circuit, Ph B

IC694PWR331 Power Supply 24 Vdc High Capacity.

IC756WDN009J-23 DV Development Sys VB, Java, C++, C, Japanese, Version 2.3

CompactLogix System

PLC-5/1771 System 1771-P6S POWER SUPPLY,SLOT (ONE SLOT), 8A, 220V AC

Distributed I/O 1798-OE2 FLEXARMOR 2 CHANNEL ANALOG OUTPUT MODULE

Operator Interface 2711P-B6M8D PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH+, DC PS

Support 9323-PI300DU UPGRADE: IN-SUPT: 6200-5250 BOTH TO AI-5250 BOTH

Support 9358-PB60S SUPT RENEWAL CONTRACT FOR 9358PB60ENE

Support F1772-SD2 FIRMWARE UPGRADE FOR 1772-SD2 PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD700NXDEE RSLOGIX 5000 PRO EDITION, GERMAN

RSI Software Products 9305-RSVADFVCITE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (ITALIAN)

RSI Software Products 9301-PCI2000MBP APPLICOM PCI2000MBP MODBUS PLUS INTERFACE

Motion Control 2094-BSP2 MODULE, SERVO SHUNT, 400/460V 200W DISSIPATION.

A06B-6050-K119 Connector Kit, B0.5 Motor Power

IC200UEX010 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240VAC Power Supply. (includes IC200CBL501)

IC752CBT060 Mature, order QuickPanel instead. DataPanel 320T CE (Color Expansion): 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory and PC/104 capability.

MTR-1N41-G-N-A-E-0RR Stepping Motor Nema42

ZA06B-0128-B675#7076 A6/3000 servo motor with IP67 sealing and brake and 64k serial encoder

20BD5P0A3AYNACD0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC085JA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E019 PowerFlex 520 11kW (15Hp) Power Module

771BSS47401 Quantum CONCEPT XL 版注冊軟件

FRN5.5E1S-2J 9.5KVA 25A 5.5KW 3相AC220V/50Hz/60Hz

6GT2091-1CH20

1492-SPM3D050-N MCB Supplementary Protector 5 A

軟啟動(dòng)器 3RW40281BB14

SIMATIC HMI 系列面板 6AV2123-2JB03-0AX0 KTP900 Basic PN 9 寸觸摸 + 按鍵

150-SF1R SMC-50 Frame B 24V DC Replacement Fan

1738-AENTR ArmorPoint Dual Port Adaptor

1783-ZMS4T4E2TGN ArmorStratix 5700 10 port managed switch

193-KA50 0.35-.50 A IEC Bibllic Overload Relay

20-750-P5-E510F500 PF750,Fr8,DC Input w Precharge,600/690V

2090-CPWM7DF-16AF25 MP-Series 25m Length Power Cable

20AB028A0AYNANC0 PowerFlex 70 AC Drive 28 A at 10 Hp 20A

GA647IFPLDV00300 GCA iFIX Plus SCADA 300 I/O Dev

GP647IFCLNTS005 GCP iFIX iClientTS 5 Additional Users

IC600BF814RR Type K Thermocouple Input Module (8 points)

IC647HSTCC40KM Calculation Collector for Historian - Standard Server 40000 Points (M4 Key)

IC647TDV000 CIMPLICITY HMI Server NO LIMIT Development & Runtime System

IC693MDL930LT Relay Output, Isolated, 4 Amp (8 Points) (LT)

IC756LDV001E64-925 DataViews Development on Inb Linux/Red Hat 64 bit, Addt'l User, English v9.25

Pico Controllers 1760-CONN-RJ45 INTRA-CBL CONNECT 10/PACK

PLC-5/1771 System 1771-OMD 220V AC OUTPUT MODULE, 16 OUTPUTS

Distributed I/O 1791-24AR BLOCK I/O, 120V AC, 32 POINT MODULE

Communications 1786-TNCLP4 CONTROLNET TNC COAXIAL CONN - PLUG TO PLUG

Operator Interface 9701-VWSTMDEE RSVIEW STUDIO FOR MACHINE EDITION (GERMAN)

Support 9701-VWSS250AS SUPT RENEWAL CONTRACT FOR 9701VWSS250AENE

Support 9324-RL0300DER SUPT REINSTATEMENT CONTRACT FOR 9324RL0300DE

EtherNet/IP Products 1747-L551 SLC 5/05 CONTROLLER

RSI Software Products 9301-2SE340ZHU5R RSVIEW32 RUNTIME 5K-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9356-PRO2450U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.32000 TAG

Motion Control F-6100-R-H04AA MOTOR/ENCODER/BRAKE

44A722981-011RR Color Adapter Card (W/M 1)

IC200ACC451 Simulator for VersaMax Micro 8 Inputs

IC693MDL310 120 Vac Output, 0.5 Amp (12 Points)

TRM-21006666 Connector, 20 Point Screw Terminal, S2K Digital I/O