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近幾年，隨著我廠生產(chǎn)規(guī)模的逐步擴大，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，需要配專人負責該系統(tǒng)的運行，造成了人工成本的上升。

　　鑒于以上三點，通過采用PLC(可編程控制器)控制系統(tǒng)，解決當前存在的問題。

　　1、PLC控制系統(tǒng)的特點及組成

　　PLC在現(xiàn)代工業(yè)控制領(lǐng)域中早己得到了廣泛的應用。以PLC的控制功能而言，具有嚴謹、方便、易編程、易安裝、可靠性高等優(yōu)點。它通用性強，適應面廣，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。PLC具有豐富的邏輯控制指令和應用指令，它提供高質(zhì)量的硬件、高水平的系統(tǒng)軟件平臺和易學易編程的應用軟件平臺。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)并實現(xiàn)遠程訪問。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場的PLC系統(tǒng)與主控室的上位機距離較遠(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//觸摸屏進行數(shù)據(jù)顯示，確保系統(tǒng)運行的穩(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實現(xiàn)機架擴展，上位監(jiān)控機采用SIEMENS公司CP5611網(wǎng)卡完成計算機與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，從上位機上可對整個氣體調(diào)節(jié)過程進行監(jiān)控和操作。

　　1.2控制系統(tǒng)的功能實現(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，將程序設(shè)計細化，分成多個程序模塊，實行模塊化編程。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)運行于Windows2000中文平臺，可實現(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顯示重要參數(shù)的歷史趨勢、實時趨勢，實現(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觸摸屏進行參數(shù)顯示、控制，觸摸屏程序由組態(tài)軟件來完成，人機界面采用中文菜單，界面友好，操作方便，功能較強，主要用于現(xiàn)場壓力、流量、閥位的顯示與操作?？勺鳛椴僮魅藛T現(xiàn)場操作的依據(jù)。

　　1.4工控機配置

　　工控機采用研華IPC-610，通過CP5611卡，完成S7-300PLC與工控機的通訊。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大的系統(tǒng)控制功能：

　　系統(tǒng)可以實現(xiàn)上位機操作、控制柜觸摸屏操作和就地手動操作;

　　2)報警功能：

　　當壓力超過工藝要求，可在現(xiàn)場、就地實現(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)對供氣壓力實現(xiàn)了PID自動調(diào)節(jié)控制;

　　2)對所采集的模擬信號進行線性化、濾波、工程單位轉(zhuǎn)換處理;

　　3)實現(xiàn)了流量信號的溫、壓補償，提高了儀表的測量精度。

　　(2)邏輯控制

　　聯(lián)鎖邏輯控制實現(xiàn)開/關(guān)的控制，邏輯控制及用戶自定義功能塊等。系統(tǒng)實現(xiàn)了電磁閥控制以及參數(shù)越限報警等功能。

　　(3)人機接口

　　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算法作一重點介紹
 

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Motion Control MPL-B520K-MK24AA MOTOR,SERVO,10.7 NM,4000RPM,MULTI,460V,BRK,13.9KG

Motion Control 9101-1476 MATING CONNECTOR KIT/J1 50 PIN MINI D(SOLDER CUP)

GQPJ-DEM-L02 QUICKPANEL JR. DEMO 5" LCD GE LABEL

IC646MRD150 Logic PC (HRT) 150 Tag Runtime System

MTR-3T22-G-R-B-M-S MTR-Series Servo Motor, Resolver, Metric, 24V Brake, Seal

SNAP 2C5 PC Port is 25-pin male and CNC port is 25-pin female. This is for Xon/ Xoff communications.

20BC056A3AYNANA0 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11NE041AA0NNNNN PowerFlex 753 AC Packaged Drive

22-XCOMM-DC-BASE PowerFlex External Comm Enclosure

140CPU43412U Quantum Unity Quantum 43412 CPU

281D-F12Z-10C-CRW ArmorStart Direct Online RVSG Starter

C200H-ID215 多點I/O單元, DC輸入 24VDC 32點

1492-QP5-6 IEC 6 pole Plug-in Connection Block

連接電纜 6ES7468-1BF00-0AA0 IM 電纜，5m

變送器 3RS11011CD30

1497-E-BASX-3-N Control Circuit Transber

1606-XL480EP Power Supply XL 480 W Power Supply

1762-L24BXB MicroLogix 1200 24 Point Controller

188-K3C500 Miniature Circuit Breaker 50 A

194L-G3576 194L IP66 Noryl Plastic Enclosure

2090-CPBM7DF-04AA60 MP-Series 60m Power and Brake Cable

2090-XXNFY-S30 Y-Series 30 m Length Feedback Cable

BC647SPR010 Solution Provider Renewal < 10 keys includes up to 10 key flashes which could be M4 or M1, Global Care Complete (iGC SP1)

GC647PRTDB2 GlobalCare Complete - Proficy Portal DB2 Connector Ver 3.0

IC200MDL643LT INPUT 5/12VDC POS/NEG LOGIC (2 GROUPS OF 8) 16PT (LT)

IC646PCMS01 Proficy Change Management Electronic Signature Module (Single)

IC647MPS001 Logic Developer PLC Standard with USB Hardware key

IC676CBLPWM100 IP67 Power Cordset - 10 Meters - Male Connector w/Leads

IC697PWR711FFM Power Supply, 120/240 VAC, 100 Watts, FM Approved

IC800SSI107RP2RR 7.2A, 115/230V, Profibus S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L20F 20 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RDT7C VVCE 700, TOUCH SCREEN DISPLAY MODULE

Process Control 9399-RSPCPHPG RSBATCH PC-BASED PHASES PROGRAMMER'S GUIDE

Operator Interface 2711-B5A3 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20R SUPP REINSTATEMENT CNTRCT FOR 9303-3CS0E20

Support 9371-RSWD2S SUPT RENEWAL CONTRACT FOR 9371RSWD2

ControlNet Products 2706-P74CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE2500ITU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY10ENE RSBIZWARE BATCH BACK-UP KEY 10 UNITS

Motion Control MPL-A4530K-HK22AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,8.2KG

Motion Control 2090-UXPC-D0903 CABLE,9/9 POS,45 DEG D/STRAIGHT D,3M

CBL-3T-RD-20 Resolver Cable for MTR-3T Series Servo Motors, 20 Ft.

IC641HBR301 Max-ON "Standard" Software for 90-30 Hot Stand By Redundancy

IC800SLM500M2XE25 5000W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647TSSOSI000 Proficy Troubleshooter Connector: OSIsoft PI Source

20AE3P9A0AYNNNC0 PowerFlex 70 AC Drive 3.9 A at 3 Hp 20A

20DD2P1A0EYNANASE PowerFlex 700S AC Drive 20D

20P41AE540RA0NNN PowerFlex 540 A DC Drive

2711P-B6C20A8 PanelView Plus 6 6 Color Key/Touch AC

280-PWRM35A-M30 ArmorConnect 3-PH Power Media trnk cable

CPM1A-40CDR-A-V1 40點主機 AC100-220V 24點入，16點繼電器輸出

1492-MCGAT250 Ground Fault Circuit Breaker

1494V-LK DiISCONNECT SWITCH ACCESSORY

軟啟動器 3RW44662BC34

運行版軟件 6AV2104-3BB04-0AE0 SIMATIC WinCC Runtime Advanced 128 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-0M3 RJ45 Ethernet Media

1756-OB16E ControlLogix 16 Point D/O Module

188-K1B320-N Miniature Circuit Breaker 32 A

194E-FA80E 194E Load switch

2090-CFBM7DF-CDAF07 MP-Series 7m Feedback Cable

2090-U5PM-D0903 Ultra 5000 3m Interface Cable

BC646MVSU01 View Standard Edition Upgrade from QuickDesigner with Proficy GlobalCare Complete

GC647AUR010 GC Universal Reporting Client 10 Pak

IC200ACC405 VersaMax Micro 64 and Micro 40 spare parts kit. Kit includes (5) Micro 64 terminal blocks, (5) Micro 40 terminal blocks and (5) Micro 64 terminal block covers.

IC646CSPR005 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 5X monitored KPIs

IC647IFPLSR00075K iFIX Plus SCADA 75 I/O Server (M1 Kit Part)

IC660MLA104 Label for IC660BBA104 (Qty 100)

IC697ALG441RR Analog Input Expander, Voltage, 16 Channels

IC758WMM100 iGlobalCare Complete 21+ Users (same site): DataViews for Windows

FlexLogix System 1794-STRT1 FLEXLOGIX STARTER KIT

GuardPLC Systems 1753-PCSPAR RSLOGIX GUARD PLUS FOR GUARDPLC -PARALLEL HARDLOCK

Process Control 1757-UPGSIFZ UPGRADE FLAME SFGRD QUICKBUILDER I/F

Operator Interface 2711P-T12C6D1 PV PLUS 1250, TOUCH, RIO/DH, DC PS, STD MEM

Support 9220-TGS SUPT RENEWAL CONTRACT FOR 9220TG

Support 2755-LHS1R SUPT REINSTATEMENT CONTRACT FOR 2755LHS1

Support F1785-V30BSERE FIRMWARE UPGRADE FOR 1785-V30B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350KOU1 RSVIEW32 WORKS 150-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMDEE RSVIEW STUDIO FOR MACHINE EDITION (GERMAN)

RSI Software Products 9399-WABOUG RSLINX OEM USER GUIDE

Motion Control 8720MC- -HASP STANDARD PROGRAMING ONLY HIM

BC646MRB700 Logic PC Runtime 700 I/O

IC300OSW232 Cscape programming software (CD ROM), RS-232 programming cable, and complete software/hardware documentation.

IC754CKL06CTD Starter Kit, 6 TFT Ctrl Loaded, 24VDC"