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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(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(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。

　　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(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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Motion Control MPL-B310P-MK22AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V

Motion Control 2090-XXNPMP-16S60 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,60M

GC646TDV700 Proficy GlobalCare Complete for Server 700 I/O Develop/Runtime System

IC641SWP303 LM 90-30/20/Micro Serial Software Demo Version, 3.5", 5.25" Format

IMC-200P-X-D IMC-D Series Ampless Servo Motor Controller, Enhanced, DeviceNet

PSPC-DC100-220L Prof Shop Floor SPC DC 100 User 220v

PXI-6733

PCM-3660

OC-64E0-IPRO0

GW-ERP2U700 (90+)

IAC-H672Z

PCI9054-AC50PI

1492-MS8X12V1-50 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-7KF02-0AB0 AI/8，電壓、電流、電阻、熱電阻、熱電偶，光電隔離，20pin 前連接器

行程開關(guān) 3SE53220SE23

運(yùn)行版軟件 6AV2105-4DD04-0AE0 SIMATIC WinCC Runtime 專業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 512 PowerTags -> WinCC Runtime 專業(yè)版 512 PowerTags V14

1585J-M8CBJM-60 RJ45 Ethernet Media

1756-RM2 ControlLogix Redundancy Enhanced Module

188-K1D130-N Miniature Circuit Breaker 13 A

194E-Y25M-1756-6G 25 A 194E Load switch

2090-CFBM7E7-CEAF01 1 m Length SpeedTec Extension Cable

2090-UXNFBY-S15 Y-Series 15 m Length Feedback Cable

BC646TRT000 Server Unlimited Runtime System with Proficy GlobalCare

GC647IFPLDVUNLMT GCC iFIX Plus SCADA Unlmt Dev

IC200CBL525 Series 90 SPN port, RS485 Cable to DataPanel 45/65/85

IC646MPP010 Logic Developer PLC Professional 10 pack

IC647IFPRSRUNLMTC iFIX Profsnl SCADA Unlimited Server (M1Component Part)

IC660TSD021 Terminal Assembly for IC660BBD021

IC697CPM924RR CPU, 64MHz, 12K Discrete I/O, 512K RAM (Expandable), 80486DX2

IC800PCUB00300 Powercube stepping motor power amplifier rated 12-48 VDC and 4 amp

ControlLogix/1756 System 1756-OB16D 19-30 VDC DIAGNOSTIC OUTPUT 16 PTS (36 PIN)

Industrial Computers 6182H-10BRH6D VVCE 1000, KEY/TOUCH, STD MEM, RIO/DH, DC

Process Control 9358-PBRENT01ENE RSBATCH NT FOR PROCESSLOGIX REPORT EDITOR

Operator Interface 2711P-RBK12 PV PLUS 1250 KEYPAD REPLACEMENT BEZEL

Support 9355-TKTOPCS SUPT RENEWAL CONTRACT FOR 9355TKTOPC

Support 9351-OSFRTS SUPT RENEWAL CONTRACT FOR 9351OSFRT

ControlNet Products 1786-RPFM CONTROLNET FIBER REPEATER - MEDIUM

RSI Software Products 9301-2SE2400DEU5 RSVIEW32 WORKS 5K-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9355-WABGWEU3R UPGRADE: OUT-SUPT RSLINX PROF TO RSLINX GW

Motion Control MPL-A320H-HJ24AA MOTOR,SERVO,2.94NM,3500RPM,ENCR,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S07 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MQP001 View Development for QuickPanels with Proficy GlobalCare Complete and a hardware key

IC5005TBX0000 15" Unbundled Inbligence Industrial Computer with WIN XP Perbance Series

IC800MCUB12210XE Stepping MotorCube 100 oz-in, Pulse/Direction, Encoder Feedback

OC647IFDBTKTM iFIX Optn: Database Dynamo Toolkit (M4 Part)

PCIe-8431/2 (RS485/422)

IB104+ TM5800-800M

ADLINK凌華M-322

AMCC 9590SE-16ML

DH-VRT-CG200

LV-676

1492-M5X5H1-50 Connection Products

1494H-DN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44456BC46

ET 200SP 6ES7193-6BP00-0BA0 基座單元 BU15-P16+A0+2B，類型A0，直插式端子，15mm寬

1585D-M4TBDM-80 Micro D-Code, QD Style Ethernet Media

1756-EN3TR ControlLogix Ethernet Motion Module

1794-OF4I Flex 4 Point Analog Output Module

194E-CA63EX-TN-PE 194E Load switch

2090-CBUSPSS Kinetix 6000M network bulkhead connector

2090-DANPT-16S01 TL-Series 1 m Length Power Cable

ABICTDE0000/DVN 10.5 inch Color TFT/ TCP Label/ 24VDC/ with DeviceNet/ UL/ cUL/ CE/ UL1604

GC646PCMS10 GlobalCare Complete for Change Management Electronic Signature Module 10 Pack

HE697THM160 Series 90-70 Thermocouple Input Module, 16 Channel

IC630MDL375RR 115/230Vac Output Module (16 points)

IC647HSTSS75KM Historian Standard Server 75000 Points (M4 Key)

IC660BLD021 Cover w/Label for IC660BBD021

IC695CBL001 Energy Pack Cable, 3 ft. (0.91m)

IC756WET100E-23 Custom Editor Toolkit, English, Version 2.3

CompactLogix System 1769-CRL3 3.28 FT (1M) RIGHT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRIT RSLOGIX 5 GETTING RESULTS GUIDE(ITALIAN)

Distributed I/O D1794-6.5.7 FLEX I/O THERM'CPL/MILLV'T MOD.1794-IT8 USR MANUAL

Operator Interface 2711P-T6M8D PV PLUS 600 GRAYSCALE, TOUCH, DH+, DC PS

Support 6411-SDSCR 6411-SDSC SOFTWARE SUPPORT REINSTATEMENT

Support 9358-PLTM2200S SUPT RENEWAL CONTRACT FOR 9358PLTM2200ENE

Support F1784-KTCX15SERA FIRMWARE UPGRADE FOR 1784-KTCX15 COMMUNICATION MOD

RSI Software Products 9301-2SE2200FRE RSVIEW32 WORKS 300 (FRENCH)

RSI Software Products 9701-VWSB000DEU3 RSV SE STATION 250 - UNLTD DISP UPGRADE (GERMAN)

RSI Software Products 9399-APSUM APS USER MANUAL FOR REL. 6.01

Motion Control 2098-IPD-010 DRIVE, 5A/15A, ULTRA5000

ABKSTDN0000/ABR 6" Color STN, TCP Label, 24Vdc, with AB Remote I/O,UL,cUL,CE,UL1604

IC300ACM200 Power Control Smart Stack. Input Range 120 three-phase Wye, 208V line to line

IC752DPJ000RR Datapanel J+, 256x64 LCD with EL backlight. Various sizes of text, bitmaps, bar graphs, real time clock. Includes an integrated keypad for data entry. No touch capability.

MTR-3S34-G-R-0-E-S MTR series servo motor with resolver and shaft seal

NI 9861

SYS7283VGA

ARK-14050

CI-7200

EmCORE-i741

801-8422-01

1492-JD3 2.5 mm Double Level Terminal Block

1492-W10-B IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40742BB45

CPU 模塊 6ES7 677-2AA41-0FM0 CPU 1515SP PC，4 GB RAM，16 GB CFAST， Windows 7 嵌入版 64 位 + HMI 2048PT

153H-C480XBD-59 SMC-3 Pump Panel w/Line Prot.Module, CB

1746-A7 SLC 7 Slots Chassis

1786-CP ControlNet Programming Cable

193-T1AA80 0.55-.80 A IEC Bibllic Overload Relay

20-DA1-B0 PowerFlex 700 115 V AC IO Kit

2090-CSBM1DF-10AF15 Kinetix Cable Single DSL 2090-Series