1 RAC2.2-200-380-A00-W1系統(tǒng)組成
某電廠化學(xué)水處理系統(tǒng)基礎(chǔ)設(shè)備具有良好的可控性，利用PLC和工業(yè)控制計(jì)算機(jī)對(duì)其進(jìn)行實(shí)時(shí)監(jiān)控管理，系統(tǒng)基本組成如圖1所示。
采用3臺(tái)西門子公司的SIMATICS5—115U可編程序控制器控制現(xiàn)場(chǎng)的一次設(shè)備，程控系統(tǒng)分為3套，依次為#1補(bǔ)給水處理單元、#2補(bǔ)給水處理單元、#3凝結(jié)水處理單元。
RAC2.2-200-380-A00-W1操作員站選用兩臺(tái)研華586工控機(jī)，軟件開發(fā)平臺(tái)選用美國(guó)Inblution公司的FIX5.5組態(tài)軟件。FIX5.5是一種能完成數(shù)據(jù)采集及控制、報(bào)警、圖形數(shù)據(jù)顯示等功能的完整工業(yè)自動(dòng)化軟件，該版本在WINDOWS或WINDOWSNT環(huán)境下運(yùn)行，采用了圖形用戶界面，相應(yīng)其內(nèi)部的圖形處理是基于第三代圖形技術(shù)。
數(shù)據(jù)通信系統(tǒng)采用SINECL2網(wǎng)，它把SIMATIC系列可編程序控制器以及工控機(jī)連成網(wǎng)絡(luò)。SNECL2是令牌總線網(wǎng)，網(wǎng)絡(luò)傳輸介質(zhì)是雙絞線或光纜。每個(gè)節(jié)點(diǎn)通過(guò)總線連接器連到總線網(wǎng)上，在本系統(tǒng)中，三臺(tái)PLC之間以及與兩臺(tái)工控機(jī)之間都實(shí)現(xiàn)了數(shù)據(jù)通訊。
系統(tǒng)結(jié)構(gòu)圖
圖1 系統(tǒng)結(jié)構(gòu)圖
RAC2.2-200-380-A00-W1該方案配置體現(xiàn)了分散控制系統(tǒng)的優(yōu)點(diǎn)，即控制功能分散，操作管理集中。控制功能分散意味著系統(tǒng)實(shí)時(shí)響應(yīng)快和系統(tǒng)危險(xiǎn)分散，操作管理集中便于集中管理，方案配置還具有冗余特性。
2 PLC及其程序設(shè)計(jì)
2.1 SIMATICS5-115U硬件組成及編程概要
可編程序控制器SIMATICS5-115U采用標(biāo)準(zhǔn)的模塊式結(jié)構(gòu)，電源、CPU、各種I/O模件都插在一塊母板上，并可以根據(jù)不同的I/O點(diǎn)數(shù)增加擴(kuò)展母板，輸入、輸出模件和存儲(chǔ)器的精細(xì)分級(jí)，使得這種裝置具有較強(qiáng)的配置適應(yīng)能力；通過(guò)通訊處理器和局部網(wǎng)，可方便地實(shí)現(xiàn)PLC之間及與計(jì)算機(jī)的通訊。
SIMATICS5-115U的編程語(yǔ)言是STEP5，有3種表達(dá)方法，即控制系統(tǒng)流程圖CSF，梯形圖LAD和語(yǔ)句表STL.其中語(yǔ)句表STL最接近于機(jī)器內(nèi)部的控制程序，功能也比前兩種方法豐富得多，因此在本系統(tǒng)實(shí)際編程應(yīng)用中全部采用語(yǔ)句表STL.
STEP5的最大特點(diǎn)是采用了結(jié)構(gòu)化編程方法，并提供大量標(biāo)準(zhǔn)功能塊如乘法功能塊FB242、通訊功能塊FB244等，使得編程工作大大簡(jiǎn)化，而且所編程序條理清晰，易于讀懂、修改和測(cè)試，這一優(yōu)點(diǎn)尤其在編制大型復(fù)雜程序時(shí)更能顯現(xiàn)出來(lái)。
RAC2.2-200-380-A00-W1要完成復(fù)雜任務(wù)，可以把整個(gè)程序分成一個(gè)個(gè)獨(dú)立的程序塊，STEP5有5種塊類型，即組織塊(OB)、程序塊(PB)、順序塊(SB)、功能塊(FB)和數(shù)據(jù)塊(DB)，其中組織塊(OB)用以管理用戶程序，形成了操作系統(tǒng)和控制程序之間的接口，所有其它類型塊在此被調(diào)用執(zhí)行。功能塊(FB)用于實(shí)現(xiàn)反復(fù)調(diào)用或者特別復(fù)雜的程序功能，這些功能塊可以是系統(tǒng)以標(biāo)準(zhǔn)功能塊的形式提供的，也可以由用戶自己編制。例如標(biāo)準(zhǔn)功能塊FB242就可以實(shí)現(xiàn)16位二進(jìn)制乘法功能、FB244可以實(shí)現(xiàn)CPU與通訊處理器之間的數(shù)據(jù)傳送，用到這些功能時(shí)可以直接調(diào)用這些功能塊。
2.2 SIMATICS5-115U大型程序的設(shè)計(jì)
以本系統(tǒng)#1補(bǔ)給水處理單元的控制程序?yàn)槔?，在組織塊OB1內(nèi)主要有下面幾條語(yǔ)句，完成各功能塊的無(wú)條件調(diào)用。
JUFB1(定義PLC1向兩臺(tái)工控機(jī)傳送的數(shù)據(jù))
JUFB2(定義兩臺(tái)工控機(jī)向PLC1傳送的數(shù)據(jù))
JUFB231(完成PLC1與兩臺(tái)工控機(jī)之間通訊的基本設(shè)置)
JUFB232(完成PLC1與PLC2、PLC3之間通訊的基本設(shè)置)
JUFB4(實(shí)現(xiàn)自動(dòng)控制及無(wú)擾切換功能)
JUFB3(氣動(dòng)門及電動(dòng)門控制)
JUFB10(實(shí)現(xiàn)模擬量處理功能)
JUFB11(報(bào)警處理)
RAC2.2-200-380-A00-W1在FB1、FB2內(nèi)主要將需要通訊的數(shù)據(jù)分別寫入某數(shù)據(jù)塊如DB10的相應(yīng)位，由此才能與通訊處理器中的變量取得一致。在FB231中調(diào)用兩個(gè)STEP5本身提供的標(biāo)準(zhǔn)功能塊FB244(發(fā)送數(shù)據(jù))、FB245(接收數(shù)據(jù))，再根據(jù)通訊處理器填寫一些必要的參數(shù)如接口、作業(yè)號(hào)等，從而實(shí)現(xiàn)數(shù)據(jù)通訊功能。在FB232內(nèi)按照通訊處理器分配的數(shù)據(jù)位，定義3臺(tái)PLC之間需要傳送的數(shù)據(jù)。在FB4內(nèi)根據(jù)生產(chǎn)工藝流程要求及操作規(guī)范，充分利用其它功能塊及I/O模塊傳送的數(shù)據(jù)，實(shí)現(xiàn)系統(tǒng)的自動(dòng)控制及無(wú)擾切換功能；針對(duì)多個(gè)被控對(duì)象相似的特點(diǎn)，分別編制了幾個(gè)有代表性的功能塊FB20、FB30、FB40，例如在FB4內(nèi)多次調(diào)用了FB20以便解決PLC內(nèi)某程序步時(shí)間和工控機(jī)畫面顯示時(shí)間保持一致的問(wèn)題，而且FB20內(nèi)又調(diào)用了乘法功能塊FB244.FB3根據(jù)FB4發(fā)出的自動(dòng)程序步指令去控制氣動(dòng)門、電動(dòng)門及泵等現(xiàn)場(chǎng)設(shè)備。FB10負(fù)責(zé)所有模擬量的處理，在此調(diào)用了開方功能塊FB5.FB11根據(jù)FB1RAC2.2-200-380-A00-W10轉(zhuǎn)換出來(lái)的數(shù)據(jù)，對(duì)模擬量進(jìn)行報(bào)警處理，在此一定要注意模擬量和PLC內(nèi)部數(shù)字量的對(duì)應(yīng)關(guān)系，以保證模擬量顯示和報(bào)警的準(zhǔn)確性。
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RAC2.2-200-380-A00-W1
RAC2.2
RAC3.5-200-460-L00-W1-220
RAC2.2-200-460-L00-W1
RAC2.3-200-460-A01-W1
RAC2.1-200-300
RAC3.5
RAC2.1
RAC1.2-250-380-A00-W1
RAC2.2-200-450-AP0-W1
RAC2.3-200-380-A00-300A
RAC3.1-150-460-AP0-W1-220
RAC3.1-150A
RAC3.5-150-460-A-OI-Z1-220
RAC3.5-150-460-L-00-WI
RAC3.5-150-460-A-0I-W1
RAC3.5-150-460-A-00
RAC3.5-150-460
RAC3.1-150-460-A-00
RAC2.2-250-460-A-00-WI
RAC2.2-200-460-A-00-W1
RAC2.2-200-460
RAC2.2-150-460-A-OO-WI
RAC2.2-150-460
RAC2.1-200-380A
RAC2.1-150-380-A00-W1
RAC2.1-150-380
RAC3.5-150-460-A00-W12
RAC2.2-150-380-A00-W1
RAC2.2-150-460-A00-W1
RAC2.2-200-380-A00-W1
RAC2.2-200-460-D00-W1
RAC2.2-250-380-A00-W1
RAC2.2-250-460-AP0-W1
RAC2.2-200-380-A00-Z1
RAC2.2-250-380-A00-Z1
RAC2.2-150-460-A00-Z1
RAC2.2-200-460-A00-Z1
RAC2.2-250-460-A00-Z1
RAC2.2-200-380-AP0-W1
RAC2.2-200-460-A00-W1
RAC2.2-250-460-A00-W1
RAC2.2-200-460-AP0-W1
RAC2.2-250-380-API-W1
RAC2.2-200-460-APD-W1
RAC2.2-150-380-AP0-W1
RAC2.2-200-380-A0I-W1
RAC2.2-150-380-A0I-W1
RAC2.2-250-380-A0I-W1
RAC3.1-100-460-A00-W1-220
RAC3.1-100-460-AP0-W1-220
RAC3.1-100-460-APD-W1-220
RAC3.1-100-460-A00-Z1-220
RAC3.1-150-460-A00-Z1-220
RAC3.1-100-460-API-W1-220
RAC3.1-100-460-A0I-W1-220
RAC3.1-100-460-D00-W1-220
RAC3.1-150-460-A00-W1-220
RAC3.1-150-460-AP0-W1-220
RAC3.1-150-460-APD-W1-220
RAC3.1-150-460-API-W1-220
RAC3.1-150-460-A0I-W1-220
RAC3.1-150-460-D00-W1-220
RAC2.2-250-380-A0S-W1
RAC2.2-200-380-A0S-W1
RAC3.1-150-460-A0S-W1-220
RAC2.2-150-380-A0D-W1
RAC2.2-250-380-A0I-Z1
RAC3.5-100-460-A00-W1-220
RAC3.5-150-460-A00-Z1-220
RAC3.5-100-460-A01-W1-220
RAC4.3-400-460-AP0-W1
RAC3.5-150-460-A00-W1-220
RAC3.5-150-460-A00-Z1-220
RAC3.5-150-460-A0I-W1-220
RAC3.1-150-460-100-W1-220
RAC2.1-150-460-A0I-W1-220
RAC3.5-200-460-L00-Z1-220
RAC3.6-150-460-L00-Z1-2
RAC2.3-250-460-L00-W1
RAC2.3-200-460-L00-W1
RAC2.2-200-460-A00-W1
RAC2.2-200-460-L00-W1
RAC3.5-200-460-L00-W1-220
RAC3.5-150-460-L00-W1-220
RAC3.1-150-460-A0I-Z1-220
RAC3.5-150-460-A01-W1-220
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GE FANUC IC660BBD120F *NEW*
GE FANUC IC697ALG320 ANALOG OUTPUT *NEW OUT OF A BOX*
FANUC A16B-3200-0040 MAIN CPU BOARD *USED*
GE FANUC IC660EBA105M *NEW IN BOX*
FANUC SERVO AMPLIFIER MODULE A06B-6080-H304 A06B6080H304
FANUC TEACH PENDANT BROKEN KNOB A05B-2301-C302
GE Fanuc A02B-0166-B001 POWER MATE MODELD
Fanuc Model # 3 DC Spindle Drive Motor, A06B-0820-B001, Used, WARRANTY
Fanuc power unit A20B-1000-0770-01
Fanuc Robotic CRT/KB Unit A05B-2051-C102
Sugino Selfeeder Drill Head MSX-113S Fanuc CNC Controlled Motor A06B-0313-B703-R
REBUILT FANUC SERVO MOTOR, MOD# A06B-0501-B006#0073 W/ 1 YEAR WARRANTY
NEW LISTING Fanuc A20B-1003-0750 / 05A, PC Board, Used, WARRANTY
Fanuc A06B-0128-B675#7008, Servo Motor, Reconditioned
FANUC SERVO AMPLIFIER A06-6058-H334,A16B-1100-0330/05B
GE Fanuc View Loaded IC754VSL06CTD-SN 6" Color TFT Touch, 2013 New sealed
Fanuc A17B-3300-0201 PCB F16M/T - SERVO AXIS CARD i - SERIES
Fanuc A05B-2301-C303 Teach Pendant P02120 Used
FANUC DC SERVO MOTOR A06B-0652-B201 20M
GE Fanuc Model 10S/3000 AC Servo Motor Type A06B-0317-B081#7008-R Fanuc LTD
FANUC EE-3505-710-001 PURGE MODULE - BRAND NEW - FREE SHIPPING!!!
FANUC * SER. A1 SERVO AMPLIFIER * A06B-6076-H001
FANUC Control Board A20B-1001-0560/01A and A16B-1010-0120/090 on A05B-2022-C001
Fanuc LTD A06B-6066-H006 Servo Amplifier
Fanuc A16B-2200-0141/09D Base2 with Sub CPU
GE Fanuc A02B-0162-C092 16" CRT/MDI Unit Operator Interface
FANUC ROBOTICS SERVO AMPLIFIER A06B-6066-H006
FANUC SERVO AMPLIFIER UNIT A06B-6093-H114
FANUC A16B-1212-0901 /16C POWER SUPPLY UNIT GOOD TAKEOUT
Fanuc A16B-2200-0090/06A Axis Control PCB - New
FANUC 5F AC SERVO MOTOR A06B-0342-B221
FANUC A20B-8100-0762/03A AUX AXIS CONTROL BOARD - NNB - FREE SHIPPING!!
Fanuc A97L-0118-0891 HS RV Reducer LRM100I Clean HD Systems CSF-20-80-2UH-SP
Fanuc A97L-0118-0890 # F25-100 HS RV Reducer HD Systems CSF-25-100-2UH-SP NEW
FANUC TEACH PENDANT A05B-2301-C372 DAMAGED KEYPAD
Fanuc A06B-0314-B002#7000 Servo Motor
GE FANUC IC697 ALG441C Expander Analog Voltage New
FANUC * CPU BOARD * A16B-3200-0071/03A
FANUC * CONTROL BOARD * A20B-2100-0421/03C
FANUC 1.4kW 6.0A MODEL aM6/3000AC SERVO MOTOR A06B-0162-B075
Fanuc Spindle Amplifier Module A06B-6102-H206
FANUC A16B-1010-0150/05A,A320-1010-T156/03 BOARD
FANUC A16B-1010-0150/06A,A320-1010-T156/03 BOARD
FANUC AC SERVO UNIT A06B-6089-H101 B A06B 6089 H101 A06B6089H101 2.2 A AMPS NEW
GE FANUC 44C741055-G01R06 OPERATOR PANEL 400MM SINK DRIVERS *XLNT*
GE FANUC SERVO POWER SUPPLY MODEL A20B-1000-0770-01
BENTLY NEVADA TRANSIENT DATA MGR 2100/00-01-10-01-00
Bently Nevada 2155/00-10-03-00-01-11-11-11-11-11-00 Transient Data Interface (TD
BENTLY NEVADA 3500 RACK WITH POWER SUPPLY AND MODULES 20/50/32/42M(3)/93
BENTLY NEVADA 3500 RACK W/ POWER SUPPLY MODULES 15/20/50/32/42M(4)/93 & I/Os
BENTLY NEVADA 3500 RACK W/ POWER SUPPLY MODULES 15/20/50/32/42M(4)/93 & I/Os
BENTLY NEVADA 2155/00-06-03-00-01-11-11-11-00-00-00 USPP 2155000603000111
BENTLY NEVADA TRANSIENT DATA MGR 2100/00-01-07-01-00
BENTLY NEVADA 3300/16-02-01-03-00-00-02 WITH 81564-01 NEW 330016020103000002
BENTLY NEVADA 3300/35-11-01-01-00-00 NSPP 3300351101010000
BENTLY NEVADA 72201-02-02-05-01-01-01 USPP 7220102020501010
BENTLY NEVADA TDX NET TRANSIENT DATA INTERFACE # 2155100-05-03-05-01-11-11-10
BENTLY NEVADA 3300/35-11-01-01-00-00 USPP 3300351101010000
BENTLY NEVADA 3500/50 3500
BENTLY NEVADA 3500/50 Tachometer Module
BENTLY NEVADA 3300/16-04-01-01-00-00-00 3300/16040101000000
BENTLY NEVADA 3300-50-01-01-01-00 USPP 33005001010100
Bently Nevada 103928-02 Sampler Card TDXnet PLC Transient Data Interface 5160
Bently Nevada 134652-01 Sampler TDXnet PLC Transient Data Interface 137305-01
NEW BENTLY NEVADA 3500 PROCESS MONITOR 3500/62
BENTLY NEVADA 3300/50-02-01-00-00 USPP 33005002010000
