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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(diǎn)，將程序設(shè)計細(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(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。可作為操作人員現(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)控數(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(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

　　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(bǔ)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(bǔ)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(diǎn)介紹
 

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GA647IFESGCLNTS GCA iFIX Optn: ESig & ERec iClientTS

GP-2102NT/OBG GagePort Digital NT 2-port b (Owens Brockway OEM)

IC5007TAX0110 PanelPC 17 inch Standard Unit with Windows XP and Stainless Steel Bezel

IC647HSTCC10000KM Calculation Collector for Historian - Standard Server 10,000,000 Points (M4 Key)

IC647SST001 Scheduler SAP Toolkit

IC693MDL742LT 12/24 Vdc Output, 1 Amp, Positive Logic (16 Points), Fused (LT)

IC756LDV000E-97 DV Development - Inb/Linux RedHat Op Sys, English, Version 9.7

Pico Controllers 1760-IB12XOB8 18 I/O EXPANSION MODULE, DC

PLC-5/1771 System 1771-OB 12-24V DC OUTPUT MODULE, 8 OUTPUTS

Distributed I/O 1791P-4B4P PROFIBUS 24 VDC CBLOCK I/O, 4 IN SINK 4 OUT SOURCE

Communications 6001-F1E SOFTWARE DRIVER FOR 1784-KT

Operator Interface 2706-PDHPK DH+ COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSB000AS SUPT RENEWAL CONTRACT FOR 9701VWSB000AENE

Support 9515-RSNHS500R SUPT REINSTATEMENT CONTRACT FOR 9515RSNHS500ENE

EtherNet/IP Products 2711P-K7C4D1 PV PLUS 700, KEYPAD, ENET, DC PS, STD MEM

RSI Software Products 9301-2SE340ITU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9356-PRO2350 RSSQL PRF VER WTH 5000 TG

Motion Control 1326AB-B740E-M2K7L MOTOR,SERVO,460V,50.0NM,3400RPM,MULTI,BRK,IP67

4162-L-8 4162 Continuous Lens Kit. For (8) 4162s

HMI-KPN-302/B QUICKPANEL KEYPAD FOR 10.5" BLANK

IC693CPU363 CPU 363 Module (240K Bytes configurable user memory)

SPS-50W Discontinue - POWER SUPPY 24VDC 2.1AMP UL, CUL, CE

AKD-P00607-NBEC-0000

AIMB-542VE-00A1E

PCM-3730

ElanVital EVM-3507-00

BTX-400P4

MC8041A

VPM-54416-32M

1492-SPM1D040-N MCB Supplementary Protector 4 A

通用型變頻器 6SE6 440-2UC33-7FA1 "37 KW,350 x 850 x 320"

電機(jī)啟動器 3VU13403MH00

150-C37FBD Encl. SMC-3 37 A Smart Motor Controller

1609-P10000E Uninterruptible Power Supply P UPS Acces

1771-CE 1771 I/O CHASSIS CBL FOR 1771-P2 P/S

193-EC1ZZ E3 9-5000 A Overload Relay

198-F3 IEC Mounting Foot Enclosure Accessory

2090-CPBM7E7-14AF20 MP-Series 20 m Length Cable

2094-AC05-M01-S Kinetix 6000 Integrated Axis Module

CP9I-0MEB-0140-AZ "A50HVis Sh Motor Power Cable, Straight Connector, 14 M"

GFK-0265 Series 90-70 PLC CPU Instruction Set Reference Manual

IC200UEX214 28 point expansion. (16) 24VDC In, (12) 24VDC Out, 24VDC Power Supply (includes IC200CBL501)

IC647APC001 PA Production Client

IC647PDCH050 Ruggedized PDC Historian Base with 5000 Tags

IC693CHS393 Base, Remote Expansion, 10 Slots (700 ft.)

IC754CSL06MTD Ctrl Loaded 6 In Mono Touch DC

KIT-GFS-356 RX3i Workshop Student Kit

SLC/1746 System D1746-UM026AENP SLC 500 8 CHANNEL ANALOG OUTPUT MANUAL

Distributed I/O 1734D-IA16 120 VAC 16 IN, DNET COMMS, SCREW

Application-specific products 1405-M620-400 MINI POWERMONITOR M620 400V

Operator Interface 2711-T10C20L1 PV1000 COLOR TOUCH, ENET & RS232 PRINT

Support 9301-2SE3400ZHS SUPT RENEWAL CONTRACT FOR 93012SE3400ZH

Support 9381-PA250ENR SUPT REINSTATEMENT CONTRACT FOR 9381PA250EN

DeviceNet Products 1790D-8BV8V DNET LDX, 24VDC,8 UNIV IN/8 SINK OUT BASE, D-SHELL

RSI Software Products 9301-2SE3303KOE RSVIEW32 RUNTME 1500 WITH RSLINX (KOREAN)

RSI Software Products 9358-PBANT60ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 60 UNITS

Motion Control MPL-B540K-SK24AA MOTOR,SERVO,19.4 NM,4000RPM,SINGL,460V,BRK,19.1KG

Motion Control 2090-UXLF-106 AC LINE FILTER,ULTRA,6 AMPS,1 PHASE

GQPL-DEM-C02 QUICKPANEL DEMO COLOR 12.1" GE LABEL

IC646MSP101 Logic Developer - State Professional w/Programming Cable

MTR-3T45-H-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-121F STXi b module 16 points, Positive Logic, 12V/ 24VDC (connector type)

SCXI-1122

PCI-1750

超微 X7DWE

GA-X48-DS5

CANON SC-01A AG9-0498-02

AT-COM/V53A2 C24B1000-0A

1492-RCDA2C40 Residual Current Device 40 A

存儲卡 6ES7952-1KM00-0AA0 FEPROM 存儲卡， 4M

變送器 3RS10 40-1GD50

1497-G-BAJK-0-N Control Circuit Transber

1606-XLDC40A 1606 Power Supply

1762-OB8 MicroLogix 8 Point Digital Output Module

188-K3D040-N Miniature Circuit Breaker 4 A

194L-HC6G-175 194L Control and Load Switch Actuator

2090-CPBM7DF-06AA40 MP-Series 40m Power and Brake Cable

2090-XXNPMF-10S90 MP-Series 90 m Length Cable

BC647TPD915 CIMPLICITY HMI ProServer 1500 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTKIT002 GlobalCare Complete - Proficy Portal Enterprise Edition Starter Kit 2 User Ver 3.0

IC200MDL742 Output 24VDC POS LOGIC 0.5 amp per point(2 group of 16) with ESCP 32 points

IC646PEW110 OpenProcess Engineering Workstation (700 I/O)

IC647MRA700 View Runtime 700 I/O with USB Hardware key

IC677DBO085 Profibus VersaMax IP Modular slave with (8) 24VDC outputs