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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(wú)法滿足現(xiàn)有的控制需求。主要表現(xiàn)在：

　　1)過(guò)程自動(dòng)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(chǔ)存量小，采集的壓力、流量等數(shù)據(jù)無(wú)法長(zhǎng)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(guò)采用PLC(可編程控制器)控制系統(tǒng)，解決當(dāng)前存在的問(wèn)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(wú)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(tái)和易學(xué)易編程的應(yīng)用軟件平臺(tái)。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(wèn)。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場(chǎng)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(duì)加裝RS-485中繼器，另外在現(xiàn)場(chǎng)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(gè)通訊網(wǎng)絡(luò)采用MPI的通訊協(xié)議，從上位機(jī)上可對(duì)整個(gè)氣體調(diào)節(jié)過(guò)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(duì)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(gè)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(chǎng)對(duì)工藝的調(diào)整，又可針對(duì)配套設(shè)備可控性對(duì)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(tái)用來(lái)完成硬件組態(tài)、地址和站址的分配以及編制整個(gè)生產(chǎn)過(guò)程的控制程序的。上位機(jī)監(jiān)控軟件采用國(guó)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(tái)，可實(shí)現(xiàn)對(duì)生產(chǎn)過(guò)程的全面監(jiān)控，對(duì)重要參數(shù)形成歷史記錄，以報(bào)表或曲線的形式顯示給操作人員。通過(guò)VB語(yǔ)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(shì)、實(shí)時(shí)趨勢(shì)，實(shí)現(xiàn)壓力調(diào)節(jié)的手自動(dòng)切換、操作、壓力的高、低限報(bào)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(chǎng)顯示

　　現(xiàn)場(chǎng)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(lái)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(chǎng)壓力、流量、閥位的顯示與操作?？勺鳛椴僮魅藛T現(xiàn)場(chǎng)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(guò)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(chǎng)監(jiān)控?cái)?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(dòng)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(dòng)操作;

　　2)報(bào)警功能：

　　當(dāng)壓力超過(guò)工藝要求，可在現(xiàn)場(chǎng)、就地實(shí)現(xiàn)高、低限壓力報(bào)警;

　　3)簡(jiǎn)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(guò)程控制的功能：

　　1)系統(tǒng)對(duì)供氣壓力實(shí)現(xiàn)了PID自動(dòng)調(diào)節(jié)控制;

　　2)對(duì)所采集的模擬信號(hào)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(hào)的溫、壓補(bǔ)償，提高了儀表的測(cè)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(bào)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(guò)程量變化趨勢(shì)的實(shí)時(shí)趨勢(shì)曲線、歷史趨勢(shì)曲線。

　　(4)報(bào)表打印

　　以報(bào)表形式繪制報(bào)警記錄、歷史記錄畫面，調(diào)節(jié)間數(shù)據(jù)報(bào)表。實(shí)時(shí)趨勢(shì)曲線和歷史趨勢(shì)曲線可隨意設(shè)定時(shí)間段，打印在線趨勢(shì)，歷史趨勢(shì)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(guò)程中著重要考慮的是以下幾個(gè)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(duì)于系統(tǒng)中的邏輯控制選用梯形圖(LADDER)編程，直觀、方便;對(duì)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(yǔ)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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CBL-14-ET-20 Encoder cable for MTR-1300 or MTR-1N series splashproof stepping motor. 20 feet

GF-0188 Connecting FlashCable to Federal Micro Maxum Indicator.

IC200TBX014 Tool box, 14 point, (IC200UDR001) 24VDC In/Relay Out, AC Powered. (requires AC power) Programming software, manuals and cables (IC640VPS002 and IC646MPM001) provided.

IC646TBPAS010 Production Accounting Server 10 mass balance streams

IC647NMKJAP CIMPLICITY HMI Japanese Media Kit

IC693ACC311 Terminal Blocks (qty 6)

IC750LCD220RR PANELWARE 2-Line x 20-Character LCD Dislplay

IC800VMCB3100 Motor power and brake power cable for 3 kW VersaMotion servo motor- 10 meter

SLC/1746 System 1746-OB16E ELECTRONICALLY PROTECTED DC OUTPUT MODULE

Industrial Computers 6155R-7SXPH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBM33 SLC PROGRAMMABLE PRESS CONTROL 16 POINT KIT

Operator Interface 2711-B6C10 PV600 COLOR KEY&TOUCH, DNET & RS232 PRINT

Support 9301-2SE2300ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300IT

Support 9307-8MGDBCS SUPT RENEWAL CONTRACT FOR 93078MGDBCENE

DeviceNet Products 1734-PDN DEVICENET INTERFACE MODULE

RSI Software Products 9301-2SE250JPU3R RSVIEW32 WORKS 300-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BNT10UB1 UPGRADE: IN-SUPT: RSBATCH 10 UNITS TO BUNDLE

Motion Control MPL-B320P-MK22AA MOTOR,SERVO,2.94 NM,5000RPM,MULTI,460V

Motion Control 2090-XXNPY-16S25 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,25M

GFK-0466 Logicmaster 90 Series 90-30 and 90-20 Programming SW User's Manual

IC641VPP950 VersaPro Professional Edition 50 Seat Site License - Windows Programming Software for Series 90-70, Series 90-30 and VersaMax PLCs

MSC-C-V Obsolete - 4-20 mA in / 0-10 Vout

PSPC-DC25/E-220L Prof Shop Floor SPC DC 25 User eSig 220v

20BC011A3AYNANC0 PowerFlex 700 AC Drive 20B

20DM920N0ENNBNANE PowerFlex 700S AC Drive 920 A 900 kW 20D

2198-H070-D-T K5500 FR3 DC Bus Connector

2711P-RAK6 PanelView Plus Accessory

280-PWRM35G-M30 ArmorConnect 3-PH Power Media trnk cable

CQM1-PA203 電源. 100 - 240V AC

1492-N1 TERM BLCK Breakaway MTG Rail

通訊處理器CP 6ES7 341-1CH01-0AE0 CP341，標(biāo)準(zhǔn)串行通訊模塊，RS422/485 接口，最高 76.8kbit/s,15 針 D 型接口,可加載 ModbusRTU及 DataHighway 驅(qū)動(dòng)

行程開關(guān) 3SE53221SB21

TIA 博途 WinCC 選件 6AV2107-0CA00-0BB0 SIMATIC WinCC Sm@rtServer for Runtime Advanced

1585J-M8HBJM-0M4 RJ45 Ethernet Media

1756-TBS6H ControlLogix 36 Pin Spring TRM Block

188-K1D500-N Miniature Circuit Breaker 50 A

194E-Y40M-1753-6N 40 A 194E Load switch

2090-CHBIFS8-12AA03 Kinetix 6000M IPIM Hybrid Cable

2090-UXNPBMP-10S15 MP-Series 15 m Length Power Cable

BC647MBP001 Machine Edition Professional Development Suite with Proficy GlobalCare Complete and USB Hardware key

GC647IFPRDV00150 GCC iFIX Profsnl SCADA 150 I/O Dev

IC200CHS002 I/O carrier box style

IC646MPTS99 GE Compare Unlimited Seat Site License

IC647IFSTDV00150C iFIX Standard HMI 150 I/O Development (M1Component Part)

IC670ALG320 Analog Output, Current/Voltage, 4 Channel, Grouped

IC697CPU788RR CPU, 100 Triplex (voted) I/O, GMR Redundancy

IC800S2KDEM1 S2K encoder-based case demo with 4.3 amp Devicenet controller and Motorcube

ControlLogix/1756 System 1756-OX8I N.O./N.C. ISOLATED RELAY OUTPUT 8 PTS (36 PIN)

Industrial Computers 6182H-10KRH6D VVCE 1000, KEYPAD, STD MEM, RIO/DH, DC

Process Control 1757-FIMUL010 FOUNDATION FIELDBUS FIM MODULE USAGE LICENSE

Operator Interface 2711P-RDK12C PV PLUS 1250, KEYPAD DISPLAY MODULE

Support 9355-WABENR SUPT REINSTATEMENT CONTRACT FOR 9355WABEN

Support 9351-WESS SUPT RENEWAL CONTRACT FOR 9351WES

ControlNet Products 1756-CNBR CONTROLNET REDUNDANT BRIDGE MODULE

RSI Software Products 9301-2SE2400ITU2 RSVIEW32 WORKS 300-32K UPGRADE IN-SUPT (IT)

RSI Software Products 9355-WABOEMITE RSLINX OEM - ITALIAN

Motion Control MPL-A320P-HK22AA MOTOR,SERVO,2.94NM,5000RPM,ENCDR,230V,4.0KG

Motion Control 2090-U3AE-D4430 CABLE,TWO AXISTO LOGIX 1756MOAE2 CARD,30M

CBL-120 CABLE. ALLEN-BRADLEY SLC100/150 PROG. PORT (RS-422)

IC600CP612RR 13" Series Six Plus CPU 24Vdc Power Supply (8 Slots)

IC800S2K4DSTRKIT S2K Series Controller Starter Kit, 4.3 Amp with DeviceNet

OC647IFESGDV00900C iFIX Optn: ESig & ERec 900 I/O Development (M1Component Part)

20AD027C3AYYANC0 PowerFlex 70 AC Drive 27 A at 20 Hp 20A

20DC3P5A0EYNANCNK PowerFlex 700S AC Drive 20D

20L-GH30-B1 Hose Kit,(2)30 Ft X 0.75In Dia.,W/ Fit

25C-V2P5N104 PowerFlex 527 0.4kW (0.5Hp) AC Drive

280-PWRM22C-M14 ArmorStart Three-Phase Power Media

FX2N-32MT 主機(jī)16入/16出?晶體管輸出

1492-M6X12C Connection Products

1494R-N10 Lug Kit

軟啟動(dòng)器 3RW44472BC34

ET 200SP 6ES7133-6CV15-1AM0 基座單元蓋板，15mm寬

1585D-M4TBJM-30 Micro D-Code, QD Style Ethernet Media

1756-IA16 ControlLogix 16 Pt D/I 120V AC Module

1794-TB2 Flex Terminal Base

194E-DA20E-PE-TN 194E Load switch

2090-CDNFDMP-S30 MP-Series 30 m Length Feedback Cable

2090-K2CK-D15M Kinetix 2000 Feedback Connector Kit

AD641ECL721 ECLiPS Programming Software for the Series 90-70 SLP with OnTOP

GC646PME010 GlobalCare Complete for PCM Machine Edition Version 10 User

HE800ACC512 DIN-rail mount Terminal Block, 12-pin. Compatible with most SmartStac k Analog I/O.

IC640HWC316 LM 90-30 Enet TCP/IP for Win 95/98/NT, w/cables, CD Docs

IC647HSTSSEO20000KM eSignature Option for Historian - Standard Server 20,000,000 Points (M4 Key)

IC660BLR101 Cover w/Label for IC660BBR101

IC695CPE305CA Conbal Coated. CPE305 single slot CPU, 1.1Ghz processor,5 Meg user memory, 1 RS-232 port (IC693CBL316 cable), 1 Ethernet port (SRTP Programmer support only) and a USB master port upload/download only. Ships with Energy PAC IC695ACC400).

IC756WET200E-26 Custom Datasource Toolkit, Eng, v2.6

CompactLogix System D1769-UM008AENP COMPACT 8-BIT LO RESOLU. ANLG I/O COMB USER MANUAL

PLC-5/1771 System D1771-6.5.122 SPI PROTOCOL INTERFACE MODULE CONCEPTS MANUAL

Process Control 1757-PLX52 PROCESSLOGIX CPU

Operator Interface 2711P-K7C15B1 PV PLUS 700, KEYPAD, CNET, AC PS, STD MEM

Support 6556-SABS SUPPORT RENEWAL CONTRACT FOR 6556-SAB

Support 9358-PLTMCLTS SUPT RENEWAL CONTRACT FOR 9358PLTMCLTENE

Support F1785-KA5SERA FIRMWARE UPGRADE FOR 1785-KA5 COMMUNICATION MODULE

RSI Software Products 9301-2SE2200ZHE RSVIEW32 WORKS 300 (CHINESE)

RSI Software Products 9701-VWSB000JPU3 RSV SE STATION 250 - UNLTD DISP UPGRADE (JAPANESE)

RSI Software Products 9399-EDS2UG RSWIRE SYSTEM USER'S MANUAL

Motion Control 2098-DSD-010-DN DRIVE, 5A/15A, ULTRA3000 W/DEVICENET

BC5002TBX0000 12" Bundled Inbligence Industrial Computer with WIN XP Perbance Series

IC300CBF010 FOX Fiber Cable Pair, 10.0M

IC752DVT160 VT100 firmware on DataPanel 160 allows DataPanel to be used as terminal includes graphic support

MTR-3S43-H-R-0-E-SRR Servo Motor with Seal

ZA06B-6089-H711 External regeneration resistor with fan rated 8 ohm 800 Watt for Alpha SVU1-130 amplifier

20BE9P0A0AYNAND0 PowerFlex 700 AC Drive 9 A 7.5 Hp 20B

20G14TC750JN0NNNNN PowerFlex 755 AC Packaged Drive

25-RF8P0-BL PowerFlex 520 8.0A 600V EMC Filter Kit

2711P-T10C21D8S-B PanelView Plus 7 Standard 1000 Brandless

FRN 5 5P11S-4CX 8 5 KVA 112A 55KW 3相AC380V/50Hz/60Hz

1492-JD3FB 2.5 square mm Double Level Fuse Block

1492-W3-Y IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40756BB45

安全 CPU 模塊 6ES7 516-3FN01-0AB0 SIMATIC S7-1500F，CPU 1516F-3 PN/DP，中央處理單元，帶有：1.5 MB 工作存儲(chǔ)區(qū)，5MB 數(shù)據(jù)存儲(chǔ)區(qū)

156-B25AB2 25 A Contactor

1746-HSCE SLC High Speed Module

1786-RPFRL CNet Fiber Ring Long Distance Repeater

193-T1AC12 9.0-12.5 A IEC Bibllic Overload Relay

20-FR09824 RECTIFIER MOD SUB-AS.(WITH BRK) FR9 400V

2090-CSBM1DF-14AA10 Kinetix Cable Single DSL 2090-Series