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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(jì)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(jì)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(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(jì)，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?？勺鳛椴僮魅藛T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(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(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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數(shù)字量輸入/輸出模塊SM 6ES7 321-1BL00-0AA0 DI/32 24VDC，光電隔離，40pin 前連接器

行程開關(guān) 3SE53122SE12

運(yùn)行版軟件 6AV2105-2DD04-0AC0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack Runtime Advanced 512 PowerTags -> Runtime 專業(yè)版 512 PowerTags V14

1585J-M8CBJM-0M6 RJ45 Ethernet Media

1756-PB72 ControlLogix 24V DC Power Supply

188-K1D005 Miniature Circuit Breaker 0.5 A

194E-Y100-1753-6G 100 A 194E Load switch

2090-CFBM7DF-CEAF40 Kinetix 40m Flexible Cable

2090-UXNFBMP-S07 MP-Series 7 m Length Feedback Cable

BC646TDV915 Server 1500 I/O Develop/Runtime System with Proficy GlobalCare

GC647IFESGRN00300 GCC iFIX Optn: ESig & ERec 300 I/O Run

IC200ALG620LT ANALOG INPUT 16 BIT RTD 4CH (LT)

IC646MDA700 View Development/Runtime 700 I/O

IC647IFPRRN00900K iFIX Profsnl SCADA 900 I/O Runtime (M1 Kit Part)

IC660TBA105 Terminal Assembly for IC660BBA105

IC697CHS791RR Series 90-70, 9 Slot Rack, Front Mount

IC800MCUB12160XDRR Stepping MotorCube 50 oz-in, DeviceNet

ControlLogix/1756 System 1756-IB16 10-31 VDC INPUT 16 PTS (20 PIN)

Industrial Computers 6182H-7TRH15B VVCE 700, TOUCH, STD MEM, CNET, AC

Process Control 9358-PBEPB60ENE RSBIZWARE BATCH & EPROCEDURE BNDLE PLX 60 UNITS

Operator Interface 2711P-RAK12E PVP/VVCE1250 KEY/COMB TO PV1200/1400E KEY ADAPTER

Support 9352-WM9300R SUPT REINSTATEMENT CONTRACT FOR 9352WM9300

Support 9330-RSRRTENR SUPT REINSTATEMENT CONTRACT FOR 9330RSRRTEN

ControlNet Products 1786-TNCL10 CONTROLNET TNC COAXIAL CONNECTOR - PLUG

RSI Software Products 9301-2SE235JPU2R RSVIEW32 WORKS 300-5K UPGRADE OUT-SUPT (JP)

RSI Software Products 9355-WABCEU2R UPGRADE: OUT-SUPT: 9351WKTS TO RSLINX C SDK CD

Motion Control MPL-A310F-SJ24AA MOTOR,SERVO,1.58 NM,3000RPM,SINGL,230V,BRK,4.1KG

Motion Control 2090-DANFCT-S02 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 02M

BC647MBS001 Machine Edition Standard Development Suite with Proficy GlobalCare Complete and a hardware key

IC320CGM562 PCI CsCAN Interface Board, 2 channel. Bundled with CsCAN OPC Server.

IC800CBL063 A30/3000 and A40/2000 Motor Power Cable, 14 Meters

OC647APS30050 CSense Predictive Soft Sensor 50 KPI's

PCIe-6353

HSB-681-02

PCA-6180E2

AT-FS708

PCA-6114P4E

PCL-727

1492-M5X10H51-60 Connection Products

1494H-BF3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動器 3RW44446BC44

ET 200SP 6ES7134-6PA00-0BD0 AI 電能測量，400VAC，標(biāo)準(zhǔn)型，基座單元類型 D0

1585D-M4TBDM-1 Micro D-Code, QD Style Ethernet Media

1756-CNBR ControlLogix Communication Module

1794-NM1 Flex I/O Accessories

194E-CA32E-P11 194E Load switch

2080-TRIMPOT6 Micro800 6 Point Trim Pot Plug-In

2090-DAIO-D5003 Kinetix 3m Non-Flex Cable

20AC5P0A3AYYAEC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MSS001 Proficy GlobalCare Complete for Logic Developer - State Standard

HE693TCUCBL Cable, for Thumbwheel Interface Unit, (6 ft.)

IC630CHS308RR Base Unit, 8 Slots

IC647HSTSS300M-35 Historian v3.5 Standard Server 300 Points (M4 Key)

IC660BCM501 Hand-Held Monitor Battery Charger

IC695ALG608 Analog Input module, 8 channels single ended, 4 channels differential, channels are configurable for voltage and current. Can be configured for Current: 0 to 20mA, 4 to 20mA, +/- 20mA; Voltage: +/- 10V, 0 to 10V, +/- 5V, 0 to 5V, 1 to 5V. The anal

IC756WDV000E-28 DataViews Development System for Visual Basic 1 User,English v2.8

CompactLogix System 1769-IF4 4 CHANNNEL ANALOG CURRENT/VOLTAGE INPUT MODULE

PLC-5/1771 System 9399-EVENTMSTRUG RSEVENTMASTER USER GUIDE

Distributed I/O 1799-DNETSCON 5-POSITION OPEN STYLE PLUG/LOCKING SCREWS FOR DN

Operator Interface 2711P-T6C20A PV PLUS 600 COLOR, TOUCH, ETHERNET, AC PS

Support 9325-S5255S SUPT RENEWAL CONTRACT FOR 9325S5255

Support 9358-PBEPB60R SUPT REINSTATEMENT CONTRACT FOR 9358PBEPB60ENE

Support F1779-KFLSERB FIRMWARE UPGRADE FOR 1779-KFL COMMUNICATION MODULE

RSI Software Products 9301-2SE2100PTE RSVIEW32 WORKS 150 (PORTUGUESE)

RSI Software Products 9701-VWMR075AENE RSVIEW ME STATION RUNTIME 75 DISPLAYS - WIN 2000

RSI Software Products 9361-PTLSEAT RSPORTAL SEAT LICENSE FOR GUARANTEED CONNECT

Motion Control 2098-DSD-030 DRIVE, 15A/30A, ULTRA3000

A81L-0001-0083#3C AC Line Filter, 5.4 KW

IC200UEX626-24 Qty of 24, 6 channel Analog expansion. (4) Analog bs & (2) Analog Outputs, 24VDC Power Supply (includes IC200CBL501)

IC752DEM001 Mature Products, order QuickPanel instead. DataPanel Demo Kit B

MTR-3S22-G-R-0-N-S MTR series servo motor with resolver and shaft seal

NI 9475

ROCKY-058HV

ADAM-4013

H8SGL-F

01-w3369f 30-50573-02

6064881C

1492-J4M IEC 1-Ckt Feed-Thru Blk Motor Conn 4mm

1492-SPM3D400 MCB Supplementary Protector 40 A

軟啟動器 3RW40562BB35

CPU 模塊 6ES7 518-4AP00--0AB0 CPU 1518-4 PN/DP，4 MB 程序，20 MB 數(shù)據(jù)；1 ns；集成X1: 2x PN 接，X2: 1x PN 接口，X3:1x 1000M 以太網(wǎng)接口，X4: 1x DP 接口

150B-SD3JBD-BP Encl. SMC-50 150B- Motor Controller

1738-OB16E25DS ArmorPoint 16 Point Output Module

1784-SD2 ControlLogix Secure Digital Card

193-NCXP-DIO-CNT E300 Digital Module Connectors

20-750-S PowerFlex 750 SAFE Torque-Off Opt module

2090-CSBM1DE-14AF15 Kinetix Cable Single DSL 2090-Series