RAC3.5-150-460-A-OI-Z1-220高速線材軋線張力控制是線材自動控制中重要的一項(xiàng)技術(shù)，是衡量軋線自控系統(tǒng)的一項(xiàng)重要標(biāo)志。一般采用負(fù)荷法實(shí)現(xiàn)間接張力控制。張力數(shù)據(jù)的采集是間接張力控制系統(tǒng)重要環(huán)節(jié)，采集到的數(shù)據(jù)能否真實(shí)地反映現(xiàn)場的實(shí)際情況，是否可靠直接關(guān)系到后續(xù)控制的精度與穩(wěn)定性。在一般的PLC控制系統(tǒng)中，模擬量由于受到現(xiàn)場環(huán)境等的影響造成采集上來的信號不能充分反映現(xiàn)場的真實(shí)情況，信號進(jìn)入系統(tǒng)運(yùn)算后容易造成運(yùn)算超差，更有可能引起系統(tǒng)控制錯誤導(dǎo)致各種事故。由此可見模擬量控制的成功與否在很大程度上決定可控制系統(tǒng)的好壞。一般濾波控制只是簡單的把幾個采樣值進(jìn)行平均處理，有時造成的偏差較大，而且調(diào)試起來很不靈活，本文針對軋鋼現(xiàn)場的實(shí)際情況，介紹一套用于軋線PLC控制的模擬量信號采樣、濾波的方法。實(shí)現(xiàn)了自由靈活的信號處理。
2軋線PLC控制系統(tǒng)的組成:
RAC3.5-150-460-A-OI-Z1-220在我們設(shè)計調(diào)試的線材生產(chǎn)線中，一般采用SiemensS7-400PLC作為主控制器，粗、中軋機(jī)，預(yù)精軋機(jī)，吐絲機(jī)，夾送棍傳動采用SiemeNS直流調(diào)速裝置6RA70，精軋機(jī)采用交流變頻裝置。主軋線設(shè)兩個HMI，HMI與PLC通過以太網(wǎng)通訊，PLC與各傳動采用Profibus-DP網(wǎng)通訊，總體功能圖如下：
?。?）軋線張力控制的實(shí)現(xiàn)方法:
棒線材軋線張力控制一般采用間接張力控制方法，即利用軋機(jī)負(fù)荷反饋計算軋機(jī)的張力。本文控制方法為利用PLC與傳動裝置之間的Profibus-DP。
?。?）PLC內(nèi)部的信號濾波算法:
信號濾波在功能上分為輸入信號的采樣、儲存，數(shù)據(jù)分析處理、濾波，信號輸出等環(huán)節(jié)：
1）采樣、存儲環(huán)節(jié)：PLC系統(tǒng)接受模擬量信號后，首先進(jìn)行可控周期、可控數(shù)量的采樣，采樣采取FIFO算法，保證數(shù)據(jù)的實(shí)時性。保證在任何時間段內(nèi)采集存儲的的數(shù)據(jù)都是最新、最近的。
2）RAC3.5-150-460-A-OI-Z1-220數(shù)據(jù)處理排序環(huán)節(jié)：利用冒泡算法對采集的數(shù)據(jù)排序。
3）數(shù)據(jù)處理均值環(huán)節(jié)：去除N個最大值、最小值。對剩余的數(shù)據(jù)進(jìn)行均值處理?？刂瓶驁D如下：
3濾波系統(tǒng)功能詳細(xì)介紹:
考慮到數(shù)據(jù)采樣的連續(xù)性以及在特定的時間段內(nèi)要保留一定數(shù)量的連續(xù)的采樣數(shù)據(jù)，在系統(tǒng)中定義一個FIFO數(shù)據(jù)鏈表，采樣數(shù)據(jù)按照時間順序依次進(jìn)入鏈表，當(dāng)鏈表數(shù)據(jù)個數(shù)N（可調(diào)）一定時，那么著N個采樣值就是一段時間內(nèi)的連續(xù)采樣值。在采樣過程中從頻率根據(jù)具體情況進(jìn)行調(diào)整。采樣數(shù)據(jù)的最大值和最小值在采樣過程中有可能受到干擾，或者采集的數(shù)據(jù)與其它值有較大偏離，其采樣可靠度不如其他中間數(shù)據(jù)可靠，在運(yùn)算中將規(guī)定數(shù)量（可調(diào)）的最值除去。采用冒泡算法對數(shù)據(jù)排序，然后分別除去兩端的一定個數(shù)（可調(diào)）的最大值和最小值。最后剩余的數(shù)據(jù)均值處理。
4方案模塊化:
RAC3.5-150-460-A-OI-Z1-220本次應(yīng)用的特點(diǎn)就是將上述功能模塊化集中在一個功能塊FC中，任何時候只要調(diào)用此功能塊，就可實(shí)現(xiàn)采樣濾波功能，通過調(diào)整功能塊參數(shù)（爪子），可以實(shí)現(xiàn)可變頻率采樣，
可變數(shù)量采樣等數(shù)據(jù)濾波功能。本功能基于SiemensS7-400PLC系統(tǒng)設(shè)計，采用SCL編程語言，功能塊參數(shù)描述如下：
Input:
I_main：模擬量輸入信號
S_EN：功能允許信號
S_TRG：采樣允許信號
F_SEL：需要去除的最值個數(shù)
S_NO：采樣個數(shù)
S_ARR：采樣寄存器
Output:
O_main：濾波后信號輸出。
S_ok：采樣濾波計算正常。
調(diào)用此功能塊的程序如下：FC10為采樣功能塊
CALLFC10(
I_main:=MD300,
S_EN:=L20.0,
S_TRG:=L20.1,
F_SEL:=MW502,
S_NO:=MW504,
O_main:=MD404,
S_ok:=M506.0,
S_ARR:=DB10.ARR);
5應(yīng)用體會
RAC3.5-150-460-A-OI-Z1-220采用此濾波功能后，對速度相應(yīng)要求相對較慢的張力數(shù)據(jù)采集有較好的濾波效果。本功能可以方便地修改采樣周期，采樣個數(shù)，特殊值去除個數(shù)等，尤其便于根據(jù)具體情況進(jìn)行現(xiàn)場調(diào)試，提高現(xiàn)場工作效率。
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