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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/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(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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MSI-QUAL-SV-43 Quality Mang Server Software-43

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(jī)啟動(dòng)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

AFB1212VHE

1492-PDEN3 Power Distribution Block Adapter Plate

模擬量輸入/輸出模塊 6ES7431-1KF00-0AB0 AI/8 13BIT，光隔離，U/I

變送器 3RS10002CK20

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

1585J-M8UBJM-20 RJ45 Ethernet Media

1761-L16NWA MicroLogix 1000 16 Point Controller

188-K3C005-N Miniature Circuit Breaker 0.5 A

194L-E25-1752 25 A 194L Load Switch

2090-CPBM6DF-16AA05 TL-Series 5m Power and Brake Cable

2090-XXNFMP-S12 MP-Series 12 m Length Feedback Cable

BC647OPPMK01 OEM Edge Plant Apps M4 Key includes 1 physical M4 key that authorizes Proficy Plant Apps as well as all core products

GC647PATPIRO Proficy PAT - Pirouette Interface: Provides The Capability To Interface Proficy Rx To Infometrix? Pirouette Chemometrics Software -

IC200MDL140 Input 120VAC (1 group of 8) 8 point.

IC646NSL825 Proficy SQL 2008 - 25 CALs using Client Access licensing model

IC647MELC MEL:Mitsubishi Melsec

IC676ACC002 Protective Caps - Male (For unused I/O connectors and/or outgoing bus & power connectors) - Qty 5

IC697MEM715 Expansion RAM, 128K Bytes, CMOS (Used w/77X CPUs and PCM)

IC800SSD216S1RR 16A, 230V, S2K Servo Drive for S-Series Motors

ControlLogix/1756 System D1756-UM011AENP CONTROL LOGIX MULTI-VENDOR INTERFACE MODULE DH UM

Industrial Computers 6182H-15KRH4B VVCE 1500, KEYPAD, STD MEM, ENET, AC

Process Control 1757-DNBUL35 DEVICENET USAGE LICENSE, 35 DNB MAX

Operator Interface 2711-START300 STARTER KIT PV300 KEY(PV300, PB32&DOWN/OP CABLES)

Support 9326-AD25WDS SUPT RENEWAL CONTRACT FOR 9326AD25WDENE

Support 9371-EDETISAR SUPT REINSTATEMENT CONTRACT FOR 9371EDETISA

ControlNet Products 1797-TCAP CONTROLNET EX TAP (DUMMY) TERMINATOR (5 PIECES)

RSI Software Products 9301-2SE240PTU5R RSVIEW32 WORKS 5K-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-BA60U1 UPGRADE: IN-SUPT: RSBIZWARE ARCHIVER 03 TO 60

Motion Control MPL-A4520K-SK24AA MOTOR,SERVO,6.10 NM,4000RPM,SINGL,230V,BRK,9.5KG

Motion Control 2090-UXNPAMP-8S30 CABLE,230V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,30M

CBL-30-BT-30 Brake Cable, MTR-3S & MTR-3T Series Servo Motors with Brake, 30 Ft.

IC640HWP710 Series 90 Workstation Intf. (XT/AT) w/LM 90-70, Parallel/Serial

IC800SLCPZ100 Power Cable, 30-750 W SL Servo Motor, 10 Meters

OC647IPWRCLNDVM iPower Option - Dev Client

PXI-2598

siweisoft SW-8028

Fujitsu Siemens W26361-W64-X-04

GIN-3800V

SSC-6X86H

數(shù)據(jù)采集卡 3440506400

1492-MCBA2H80 80A Miniature Circuit Breaker

1494V-DJ644-D-E NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44576BC45

運(yùn)行版軟件 6AV2103-4FH04-0AE5 SIMATIC WinCC V7.0..V7.3 RC 2048 ->WinCC 專業(yè)版 4096 PowerTags V14 Combo 和 WinCC RT 專業(yè)版 2048 PowerTags

1585D-M8UGDM-4 Gigabit Ethernet Media

1756-L74K ControlLogix 16 MB Controller

1799-DNETSCN2R Embedded I/O DeviceNet Connector

194E-FA32-P11 194E Load switch