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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(lǐng)域中早己得到了廣泛的應(yīng)用。以PLC的控制功能而言，具有嚴謹、方便、易編程、易安裝、可靠性高等優(yōu)點。它通用性強，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。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)軟件平臺和易學易編程的應(yīng)用軟件平臺。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(luò)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(guān)系著供氣系統(tǒng)能否正常工作，而程序設(shè)計的關(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)計中首先考慮了供氣壓力調(diào)節(jié)系統(tǒng)的特點，將程序設(shè)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(shè)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(wù)：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(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(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(guān)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(shè)定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設(shè)計

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設(shè)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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MSI-MGMT-5-43 Production Mang Clients 5 Pack-43

PLC-5/1771 System 1785-L40C15 PLC-5/40C FOR CONTROLNET PHASE 1.5

Distributed I/O 1738-ADN12 DEVICENET ADAPTER M12

Communications 1787-TCABL T-STYLE CABLE FOR 1770-KFD 6 FT (1.82 METERS)

Operator Interface 2711-NR4 19-INCH RACK MOUNT KIT

Support 9304-WVD256R SUPT REINSTATEMENT CONTRACT FOR 9304WVD256

Support 9324-RLD25U6ENE RSLOGIX 5000 LITE ENGLISH TO FULL UPGRADE

DeviceNet Products 2711-K5A10 PV550 MONOCHROME KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE335KOU3R RSVIEW32 RUNTIME 1500-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9371-EDESI1U5 UPGRADE: IN-SUPT: RSWIRE DET IEC/ACAD TO DES IEC

Motion Control MPG-B025-031M22 MOTOR,SERVO,GEAR RATIO 31,100NM,156RPM,MULTI,460V

Silver Series 2711-T14C1 PV1400 COLOR TOUCH, RIO & RS232 PRINT

HE693STP101 same as STP100E w/optical isolation, independent accel/decel

IC670MDL233 120VAC 8 PT Isolated Input

QPI-PSL-201 Communication Adaptor Module for 7.5", 10", 12" QP4's

ST-7241 STXi Expansion Field Power Distribution module, 5, 24, 48, AC 10 Amp no LED status

USB-9861

PIO-16/16L（PCI)

MSC-3870-ROMOE

NComputing Xtenda X300

ECB-642

GALIL RIO-47100

1492-SPM1B050 MCB Supplementary Protector 5 A

6ED1055-1CB00-0BA0 LOGO!DM8 24，4DI/4DO

6ES73325HB014AB2

1497B-A9-M15-0-N Control Power Transber

1606-XLSBAT1 1606 7 Ah UPS Battery Power Supply

1769-IT6 CompactLogix 6 Pt Thermocouple Module

190-PB Circuit-Breaker Disconnect Accessory

194R-J30-1753-PYS1 194R Disconnect Switch

2090-CPBM7DF-14AA60 MP-Series 60m Standard Cable

2090-XXNPMP-8S60 MP-Series 60 m Length Power Cable

CBL-3C-RD-30 Resolver cable for MTR-3S or MTR-3N series servo motors. 30 feet

GF-0800-3 Connecting FlashCable to DataMyte 518 Gap & Flushness, GSE, RS Technol ogies.

IC200UAA003 14 point PLC, (8) 120VAC In, (6) 120VAC Out, 120V/240VAC Power Supply

IC646TBSPMSW005 Smart Process Monitoring SPC+ Web Clients 5 Pack

IC647NUU000 CIMPLICITY HMI Upgrade Process Fee

IC693ALG221 Analog Input, Current, 4 Channels

IC752CGE202 SNP CMM cable for DataPanel 150/160/240

IC800VMM04LBKSE25 400 W VersaMotion servo motor with 24 VDC holding brake (1.27 Nm)

SLC/1746 System 1746-NR8 8 CHANNEL RTD INPUT MODULE

Industrial Computers 6189V-DVICBL5 DIGITAL VIDEO CABLE 6186 5M

Application-specific products 1403-LM01B MASTER MODULE FOR POWERMONITOR

Operator Interface 2711-K6C16 PV600 COLOR KEY, DF1 & RS232 PRINT

Support 9301-2SE2500ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500ES

Support 9380-RSB10000S SUPT RENEWAL CONTRACT FOR 9380RSB10000

DeviceNet Products 1734-IE2C 24V DC 2 CHANNEL ANALOG CURRENT INPUT MODULE

RSI Software Products 9301-2SE3103FRE RSVIEW32 RUNTIME 150 WITH RSLINX (FRENCH)

RSI Software Products 9358-BPC10U1 UPGRADE: IN-SUPT: RSBIZWARE PC PHASES 03 TO 10

Motion Control MPL-B420P-SJ22AA MOTOR,SERVO,4.74 NM,5000RPM,SINGL,460V,5.0KG

Motion Control 2090-S-BLHD SERCOS FIBER CABLE BULKHEAD ADAPTOR 2 PER

GFK-0846 Pro-Log GRI Genius I/O Interface for the Allen-Bradley PLC Reference Manual

IC646MDB159 Logic Developer 1500 Tag Runtime & Development System

MSDIS-1211 Discontiuned, Marathon 12", HiBrite Display, Keypad and Touch

PSPC-MONITOR50 Prof Shop Floor SPC Monitor 50 User

PXIe-2727

CONTEC COM-2(PCI)H

486/5X86

CP-168EL

ANRITSU MU530001A4 SCAN-MES04

PII-15S-K

1492-NM40BL TERM BLCK End Barrier

微存儲卡 6ES7953-8LG11-0AA0 MMC 微存儲卡 128K 用于 S7-300/C7/ET200S IM151CPU,3.3V NFLASH

變送器 3RS18002AP00

TIA 博途 WinCC 選件 6AV2107-0GA00-0BB0 SIMATIC WinCC Logging for Runtime Advanced

1585J-M8PBJM-20X 1585J Ethernet Media Cables

1760-L18DWD-EX Pico 18 Point Controller

188-K2D005 Miniature Circuit Breaker 0.5 A

194L-E12-1754 12A 194L Load Switch

2090-CNSSPRS-AA04 Kinetix 6000M network cable

2090-XNSM-W Kinetix Safe Off Header Connector Kit