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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)軟件平臺和易學(xué)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(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(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，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)時趨勢，實(shí)現(xiàn)壓力調(diào)節(jié)的手自動切換、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自動調(diào)節(jié)控制;

　　2)對所采集的模擬信號進(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(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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Operator Interface 2711P-T7C15B1 PV PLUS 700, TOUCH, CNET, AC PS, STD MEM

Support 6626-NMU2S 6626-NMU2 SOFTWARE SUPPORT RENEWAL

Support 8520-ODSR SUPT REINSTATEMENT CONTRACT FOR 8520ODS

Support F1785-L20C15SERD FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE220ITU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (IT)

RSI Software Products 9701-VWSB100DEU2 RSV SE STATION 100- SE SRV 100 DISP+CLIENT(GERMAN)

RSI Software Products 9399-HDWAREREFIT HARDWARE INTERFACE CONFIG. USER GUIDE(ITALIAN)

Motion Control 2098-DSD-HV100X-DN HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000 W/DNET,INDE

BC641VPN999 VersaPro Nano/Micro Edition Unlimited Seat Site License - Windows Programming Software for VersaMax Nano/Micro PLCs

IC300DIQ624 8 AC Inputs (120vac), 8 AC Outputs (80-250vac, 0.3A)

IC752GEN100 PC/104 Genius Card for models 160/240E

MTR-3S46-H-R-0-C-SRR Servo Motor Nema 56C with Seal

PCI-4472

SBC82631

PPC-177 PPC-177T-BARE-TE

DONJIN-D160A-BACK-CPCI

MMC-BDPV81INA

7129-0001 P65-MDDA8X64

1492-JG120 TERMINAL BLK

1492-WFB4 IEC Term Blck 8x47.6x41mm Screw

軟啟動器 3RW44223BC34

性能信號模塊 6ES7 522-5EH00-0AB0 DQ 16：數(shù)字量輸出模塊，晶體管 DQ16 X 24...48VUC/125VDC/0.5A, 35mm 模塊，不含前連接器

156-B32CB2 32 A Two-Phase Solid State Contactor

1746-N2 SLC Modular Card Slot Filler

1786-TPYR ControlNet Coaxial Right Angle Y-Tap

193-T1DC47P 35-47 A IEC Bibllic Overload Relay

20-IP20-800 IP 20 800MM DOOR

2090-CSBM1DF-14AF06 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNAEG0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT700 Proficy GlobalCare Assist for CIMPLICITY HMI Server 700 I/O Runtime System

GPA-100 GagePort Multiplexer, used to stack multiple GagePorts into a single s erial port.

IC600CM544RR 4K CMOS Logic Memory Module (for use in Model 600 or 6000)

IC647HSTCSEO10KM eSignature Option for Historian - Enterprise Corporate Server 10000 Points (M4 Key)

IC647WFL000 Proficy Workflow - Site License

IC694ACC003 Door labels for the IC694MDLxxx I/O modules. The kit includes two each of the following modules. IC694ACC300, IC694ACC310, IC694ALG220, IC694ALG221, IC694ALG222, IC694ALG223, IC694ALG390, IC694ALG391, IC694ALG392, IC694ALG442,IC694APU300, IC694APU3

IC756RDV001K-97 DV Development - Irix Op Sys Addt'l User, Korean, Version 9.7

MicroLogix 1200 System 1762-L40BWAR ML 1200 40DC/RLY/AC 2 PORT

PLC-5/1771 System 1771-LC3B LOOP CONTROLLER W/RTD OPTION, 120V AC SUPPLY

Distributed I/O 1794-IC16 FLEX 48 VDC INPUT MDL

Communications 9355-WABOEMESE RSLINX OEM - SPANISH

Operator Interface D6195-6.5.3 USER MANUAL CONTROLVIEW BUILDER

Support 9358-BEPB60R SUPT REINSTATEMENT CONTRACT FOR 9358BEPB60ENE

Support F1770-FLASH FIRMWARE UPGRADE FLASH UPDATE TOOL

RSI Software Products 9324-RL0300ITE RSLOGIX 500 STANDARD ITALIAN CD

RSI Software Products 9301-2SE3503ZHE RSVIEW32 RUNTIME 100K WITH RSLINX (CHINESE)

RSI Software Products 9358-HSTS2300U1R UPGRADE: OUT-SUPT: HISTORIAN 150 TO 1500 TAG

Motion Control W-4030-M-H00AB MOTOR,SERVO,WASHDOWN,BF,2.8 NM,3000RPM,12.0KG

5612 Greyline Micro MC. 4 Lines, (20) 5MM Chars. VFD. ASCII/Serial Interface. NEMA 4

IC200MDD840 MIXED 24VDC POS LOG INPUT GRP 20PT / OUTPUT RELAY 2.0A PER PT GRP 12PT

IC695PSA040 RX3I Power supply 120/240VAC and 125VDC 40 watts occupies two slots on system base

MTR-1220-E-A-E-0RR Stepping Motor Nema23 Encoder

cRIO-9075

AIMB-762G2

MOXA CP-104UL

7060T-300-VE-128M

YW-AM9126

105-00610-00

WSBC-Q450

1492-SPM2D200 MCB Supplementary Protector 20 A

軟啟動器 3RW30471BB14

電機(jī)啟動器 3VU16401CL00

150-F361FBD Encl. SMC Flex Smart Motor Controller

1732E-IR4IM12R ARMORBLOCK 4 POINT RTD INPUT

1771-WB 12 Point Terminal Field Wiring Arm

193-EEKZ E1 Plus 60-300 A Overload Relay

20-750-2263C-1R2T PowerFlex 750 24V Tran IO Option module

2090-CPWM7DF-10AA03 MP-Series 3m Servo Power Cable

2097-V32PR0 Kinetix 300 Servo Drive

ENSP1F5 Bulkhead Passthrough Connector, Female/Female

GFK-1885 ViewStation CE II ControlStation CE II Hardware User's Guide

IC220EBI002 VersaPoint Ethernet Standard Network Interface Unit. Supports Modbus TCP network communications. Requires (1) IC220TBK087.

IC647CSPR010 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 10X monitored KPIs

IC647PSF000 Proficy Process Systems 5000+ I/O with iFIX

IC693MDL231 240 Vac Isolated Input (8 Points)

IC756CDV000E-99 DV Development - Compaq True64 Op Sys, English, Version 9.9

MSI-MGMT-5 Production Management Clients 5 Pack

PLC-5/1771 System 1785-L40B PLC-5/40 CONTROLLER, 48K WORD SRAM

Distributed I/O 1738-VHSC24M23 24VDC VERY HIGH SPEED COUNTER WITH SOURCE OUT

Communications 1787-RSCABL 6FT (1.82 METERS) 9-9 PIN NULL MODEM RS-232 CABLE

Operator Interface 2711-NM15 10 MBYTE PC FLASH MEMORY CARD FOR PANELVIEW E

Support 9304-WVD128S SUPT RENEWAL CONTRACT FOR 9304WVD128

Support 9324-RLD25U6DEE RSLOGIX 5000 LITE GERMAN TO FULL UPGRADE

DeviceNet Products 2711-B5A10L3 PV550 MONO KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335KOU2R RSVIEW32 RUNTIME 300-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9371-EDESI1U4R UPGRADE: OUT-SUPT: RSWIRE DET IEC STD TO DES IEC

Motion Control MPG-B010-091S24 MOTOR,SERVO,GEAR RATIO 91,35NM,71RPM,SINGL,BRK

Silver Series 2711-K14C9 PV1400 COLOR KEY, RS232 (DH485) & RS232 PRINT

HE693STP100 One axis stepper bing module for Series 90-30

IC670CHS102 I/O Base, Box Style, Hot Insertion

QPI-PBS-202 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: Profibus Slave/ with memor y retention/ CE

ST-7188 STXi Potential Distribution module module, 0VDC and 24VDC 4 points

USB-9481

PCI-8164

WSB-9454-R12

TSZ1JTAG.1

AM386tmSX-40

PCI-5112

1492-SPM1B040-N MCB Supplementary Protector 4 A

6ED1055-1MB00-0BA1 LOGO!DM8 12/24R，4DI/4DO