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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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PLC-5/1771 System 1771-AM2 2 SLOT I/O CHASSIS ASSEMBLY

Distributed I/O 1790D-4R0 DNET LDX, 4 INPUT RTD BSE,D-SHELL CONN

Communications 1770-KF2 DATA HWY/DATA HWY+ ASYNCHRONOUS INTERFACE MODULE

Operator Interface 2727-M7P20D1P1 MOBILEVIEW MACHINE TERMINAL MT750

Support 9305-RSVADFCJPR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCJP

Support 9515-RSAAMPRVS SUPT RENEWAL CONTRACT FOR 9515RSAAMPRVENE

EtherNet/IP Products 2706-P43R INVIEW MESSAGE DISPLAY. 1 LINE, 20 CHARACTERS

RSI Software Products 9301-2SE3400PTU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9515-RSCHM200ENE RSMACC CHANGE MGMT FOR UP TO 200 DEVICES

Motion Control 1326AB-B430G-M2L MOTOR,SERVO,460V,6.4NM,5000RPM,MULTI,IP67

4161-2-24 BCD To 7 SEG Display . 2 Digit, 24VDC. Dust Seal

HMI-BEZ-403 BEZEL 10.5" (QPICxxx0000) STAINLESS STEEL

IC693APU301 Axis Positioning Module (APM), 1 Axis

QPLCGAE0000 12.1" Color TFT, Ethernet CF CARD, 110VAC

TGT-E000-0-1 Target series rack expansion module with rack ber cable for Nagel

SCC-AI03

PCL-818

EON-2V 021-100

PCI-4301

PCM-083

8001-4048

1492-SPM1C050 MCB Supplementary Protector 5 A

通用型變頻器 6SE6 420-2UD21-1AA1 "1.1 KW，73 x 173 x 149"

電機啟動器 3VU13401MC00

1497D-A9-M14-0-N Gen Purpose Transber

1608N-BP050A240V1 MiniDySC 25 Amp Bypass

1769-OW8I CompactLogix 8 Pt D/O Relay Iso Module

190S-DNKP2-DC16C 10-16 A Compact Comb Starter W/Ckt-Bkr

194R-NU400-1753 Disconnect non-fused NEMA 3 poles 400A

2090-CPBM7DF-16AF12 MP-Series 12m Cable

2090-XXTPMP-14S05 MP-Series 5 m Length Power Cable

CIMPONNODE300M CIMPLICITY Upgrade to On-Node 300 Tag Standard Edition Historian with Alarm & Event Option ??

GF-5003R Connecting FlashCable to Ametek Accuforce III, IV.

IC200UDR164 VersaMax Micro 64 point PLC,(40) 24VDC In, (24) Relay Out, 115/240VAC Power Supply. (1) serial port and (1)optional communication port.

IC647A30M A30:ABB Kent Taylor Mod 30

IC647PATMODB Proficy PAT - Modbus Slave Interface: Provides The Capability To Interact With Other Systems Via The Modbus Protocol

IC693BEM321RR I/O Link Interface Module (Master)

IC752SKT003RR Datapanel H Starter Kit: Includes Datapanel H (DPH000), download & co mmunication cables, WinCfg, user & programming manuals

IMC-200D-X-DRR IMC-D Series Ampless Servo Motor Controller, Standard

SLC/1746 System 1747-BAJMPR BATTERY JUMPER FOR PRGRMMABLE CONTROLLER

Industrial Computers 6189V-MRA17 RACK ADAPTER FOR 17" PLATFORMS

Application-specific products 1404-M605A-CNT 1404-M6 CONTROLNET PM3000 120/240V P.S.

Operator Interface 2711-K10C3 PV1000 COLOR KEY, DH485 & RS232 PRINT

Support 9301-2SE3200PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200PT

Support 9380-RSBVB2500S SUPT RENEWAL CONTRACT FOR 9380RSBVB2500

DeviceNet Products 1792D-4BVT4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

RSI Software Products 9301-2SE320JPU1R RSVIEW32 RUNTIME 150-300 UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BTDS30U1R UPGRADE: OUT-SUPT: RSBW TNG & SIMULATION 3 TO 10

Motion Control MPL-B4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,460V,8.2KG

Motion Control 2090-SCVP32-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 32.0

GQBH2D100S2P QUICKPANEL 6" STN HAND HELD BUNDLE GE LABEL

IC646MPS005 Logic Developer - PLC Standard - 5 pack

MTR-1350-E-A-E-S Stepping Motor Nema34, Parallel Wdg, Encoder, Splashproof

QPKCTDE0000 6 inch TFT QuickPanel with TCP label/ Ethernet/ Compact Flash/ 24VDC/ UL/cUL & CE Approvals

PXIe-6363

PCI-1735U

Enhanec ATX-752B

PCL-745

MATROX Meteor-Ⅱ MET2-MC/4/8F 751-0201

PPC-L128T

1492-PDL3111 175 A Power Distribution Block

模擬量輸入/輸出模塊 6ES7431-1KF10-0AB0 AI/8 14BIT，光隔離，U/I，THERMOEL/PT100

變送器 3RS10101CD00

1497-A-HXJX-0-N Control Circuit Transber

1585J-M8UBJM-25 RJ45 Ethernet Media

1761-L16NWB MicroLogix 1000 16 Point Controller

188-K3C010 Miniature Circuit Breaker 1 A

194L-E25-1753 25 A 194L Load Switch

2090-CPBM6DF-16AA07 TL-Series 7m Power and Brake Cable

2090-XXNFMP-S15 MP-Series 15 m Length Feedback Cable

BC647OPPSK01 OEM Edge Process M4 Key includes 1 physcial M4 key that authorizes Proficy Process System as well as all core products

GC647PATRX00 "Proficy PAT - Process Analytical Software Suite, Pharmaceutical - Assist Support"

IC200MDL140LT INPUT 120VAC (1 GROUP OF 8) 8PT (LT)

IC646NSL899 Proficy SQL 2008 - Processor License