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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(wú)法滿足現(xiàn)有的控制需求。主要表現(xiàn)在：

　　1)過(guò)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(wú)法長(zhǎng)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(guò)采用PLC(可編程控制器)控制系統(tǒng)，解決當(dāng)前存在的問(wèn)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(wú)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(kāi)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(wèn)。

　　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(guò)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(lái)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(guò)程的控制程序的。上位機(jī)監(jiān)控軟件采用國(guó)產(chǎn)軟件組態(tài)王，全部采用漢化界面，便于系統(tǒng)的開(kāi)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(guò)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(guò)VB語(yǔ)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(lái)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(guò)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(guò)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(jiǎn)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(guò)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(kāi)/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(huà)面，各系統(tǒng)送氣壓力、流量，供氣壓力調(diào)節(jié)等多幅畫(huà)面，畫(huà)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(guò)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(huà)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(guò)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(yǔ)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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IMC-78005661RR IMC Controller, Spec Order

SLC/1746 System 9399-WEGR RSEMULATE GETTING RESULTS GUIDE

Distributed I/O 1732D-IB8M8 DEVICENET 24VDC 8 INPUT W/M8

Application-specific products 1404-M805B-232-02 MASTER MODULE-PQ 232 COM-24V P/S-CLASS 0.2

Operator Interface 2711-T10C10 PV1000 COLOR TOUCH, DNET & RS232 PRINT

Support 9301-2SE3400ESS SUPT RENEWAL CONTRACT FOR 93012SE3400ES

Support 9381-P5KENR SUPT REINSTATEMENT CONTRACT FOR 9381P5KEN

DeviceNet Products 1790-T0B16X LDX I/O, 24VDC, 16 SOURCE OUT EXPANSION, TERM BLK

RSI Software Products 9301-2SE3300U1R RSVIEW RUNTIME 300 TO 1500 UPGRADE:OUT-OF-SUPPORT

RSI Software Products 9358-EPBKY60ENE RSBIZWARE EPROCEDURE BACKUP KEY 60 UNITS

Motion Control MPL-B520K-MK24AA MOTOR,SERVO,10.7 NM,4000RPM,MULTI,460V,BRK,13.9KG

Motion Control 9101-1476 MATING CONNECTOR KIT/J1 50 PIN MINI D(SOLDER CUP)

GQPJ-DEM-L02 QUICKPANEL JR. DEMO 5" LCD GE LABEL

IC646MRD150 Logic PC (HRT) 150 Tag Runtime System

MTR-3T23-G-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SNAP 3C5 PC Port is 9-pin male and port on CNC is 25-pin female. This is for ha rdware handshake communications.

PXIe-8431/8

PCI-6208V

NuPRO-E340

DEXON SYSTEMS LTD DX-702

METEOR2-MC/4 751-0201

D945GSEJT

1492-RAFB424 IEC Term Blck 10 x 110 x 44.8mm Spr Clp

連接器 6ES7492-1AL00-0AA0 48 針前連接器，用于信號(hào)、功能模板，螺釘型

變送器 3RS11011CD40

1497-E-M2-0-N Control Circuit Transber

1606-XL480EPT Power Supply XL 480 W Power Supply

1762-L24BXBR MicroLogix 1200 24 Point Controller

188-K3C500-N Miniature Circuit Breaker 50 A

194L-G3667 Add. Legend Plate For Size 4 Or 6 Bezels

2090-CPBM7DF-04AA90 MP-Series 90 m Length Cable

2090-XXNPMF-10S03 Kinetix Drives 3m Standard Cable

BC647SPR030 "Solution Provider Renewal < 30 keys includes up to 30 key flashes which could be M4 or M1, Global Care Complete (iGC SP1), and one

GC647PRTEE002 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 2 Users Ver 3.0

IC200MDL644 Input 5/12VDC POS/NEG logic (4 groups of 8) 32 points

IC646PCMS05 Proficy Change Management Electronic Signature Module 5 Pack

IC647MPS005 Logic Developer PLC Standard 5 Pack with USB Hardware key

IC676PBI008 IP67 Input Block - 24 VDC Positive Logic - 8 Pt - Profibus

IC697PWR711RR Power Supply, 120/240 Vac, 100 Watts

IC800SSI107RS1 7.2 amp 115/230 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-L30A 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPEH VVCE LOGIC MODULE, 256MB FLASH, 256MB RAM

Process Control 9399-SAPRG RSBATCH SERVER API REFERENCE GUIDE

Operator Interface 2711-B5A3L1 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20S SUPP RENEWAL CNTRCT FOR 9303-3CS0E20

Support 9371-RSWDI1R SUPT REINSTATEMENT CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P74CN2 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE2500ITU4 RSVIEW32 WORKS 150-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY10U1R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 03 TO 10

Motion Control MPL-A4530K-HK24AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,BRK,11KG

Motion Control 2090-UXPC-D0909 CABLE,9/9 POS,45 DEG D/STRAIGHT D,9M

CBL-3T-RD-30 Resolver Cable for MTR-3T Series Servo Motors, 30 Ft.

IC641HBR302 Max-ON "Extended" Software for 90-30 Hot Stand By Redundancy

IC800SLMCONKITV Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors without Brake

OC647TSSTDB000 Proficy Troubleshooter Connector: Tabular Database Read & Write

PXI-5402

PCE-5B13-08

PDSLA 945G

DSA628/328

IPC-6105P4

SYS7180CVE

1492-MCS5X10 IEC 5 x 10 mm Marker Card

1494V-LL3 DiISCONNECT SWITCH ACCESSORY

軟啟動(dòng)器 3RW44662BC44

運(yùn)行版軟件 6AV2104-3DD04-0AE0 SIMATIC WinCC Runtime Advanced 512 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-0M6 RJ45 Ethernet Media

1756-OB16EK ControlLogix 16 Point Digital Output

188-K1B400 Miniature Circuit Breaker 40 A

194E-FA80E-P11 194E Load switch

2090-CFBM7DF-CDAF09 MP-Series 9m Feedback Cable

2090-U5PM-D0909 Ultra 5000 9m Interface Cable

BC646MVSU02 View Standard Edition Upgrade from View for QuickPanel View Standard Edition with Proficy GlobalCare Complete

GC647AUR025 GC Universal Reporting Client 25 pak

IC200ACC414 The ACC414 is a long term battery for the VersaMax Micro 20, 23, 28, 40 and 64 point CPUs. The battery will backup upto 7 years.

IC646CSPR010 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 10X monitored KPIs

IC647IFPLSR00075M iFIX Plus SCADA 75 I/O Server (M4 Part)

IC660MLA105 Label for IC660BBA105 (Qty 100)

IC697ALG441RR Analog Input Expander, Voltage, 16 Channels

IC758WMM100 iGlobalCare Complete 21+ Users (same site): DataViews for Windows

FlexLogix System 1794-STRT1 FLEXLOGIX STARTER KIT

GuardPLC Systems 1753-PCSPAR RSLOGIX GUARD PLUS FOR GUARDPLC -PARALLEL HARDLOCK

Process Control 1757-UPGSIFZ UPGRADE FLAME SFGRD QUICKBUILDER I/F

Operator Interface 2711P-T12C6D1 PV PLUS 1250, TOUCH, RIO/DH, DC PS, STD MEM

Support 9220-TGS SUPT RENEWAL CONTRACT FOR 9220TG

Support 2755-LHS1R SUPT REINSTATEMENT CONTRACT FOR 2755LHS1

Support F1785-V30BSERE FIRMWARE UPGRADE FOR 1785-V30B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350KOU1 RSVIEW32 WORKS 150-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMDEE RSVIEW STUDIO FOR MACHINE EDITION (GERMAN)

RSI Software Products 9399-WABOUG RSLINX OEM USER GUIDE

Motion Control 8720MC- -HASP STANDARD PROGRAMING ONLY HIM

BC646MRB700 Logic PC Runtime 700 I/O

IC300OSW232 Cscape programming software (CD ROM), RS-232 programming cable, and complete software/hardware documentation.

IC754CKL06CTD Starter Kit, 6 TFT Ctrl Loaded, 24VDC"

MTR-3T45-I-R-B-M-0-MODRR Servo Motor Metric 24V Brake Mod=Key

PCI-6711

GENE-4310

IPC-6106P4

C806MCP

PCM-9362

CS250LM 5.1/12.1

1492-LD4RB333 Terminal Block, Resistor, 33.2K Ohms

1494F-L4 Door Hardware Kit

軟啟動(dòng)器 3RW44352BC36

ET 200SP 6ES7193-6AP00-0AA0 BA 2×SCRJ (用于PROFINET 高性能接口模塊，光纖接口）

1585D-E4TB-5 Micro D-Code, QD Style Ethernet Media