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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(yīng)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(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。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(yīng)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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IC5005TAW0000 15" Inbligence Industrial PC, Standard Series Win2000

IC800MCC23P050 Motor Cube Power Cable, 5 Meters

OC647IFAFLOVC iFIX Optn: SCADA Synchronization (M1Component Part)

20AD022A3AYNADC0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC1K0N0ENNBNANE PowerFlex 700S AC Drive 20D

20G1ANE192AA0NNNNN PowerFlex 755 AC Packaged Drive

25C-D2P3N104 PowerFlex 527 0.75kW (1Hp) AC Drive

280-PWRM22A-M14 ArmorConnect 14 Meter M22 Patchcord

FX1S-14MR-D 直流主機8入/6出 繼電器輸出

1492-M5X12V1-50 Connection Products

1494H-DA3H6 Safety Switch, 100 ,600V FUSE,Type 1

軟啟動器 3RW44452BC46

ET 200SP 6ES7138-6AA00-0BA0 TM Count 1x24V，高速計數(shù)模塊，基座單元類型A0

1585D-M4TBDM-35 Micro D-Code, QD Style Ethernet Media

1756-EN2TK CLX HI-CAP ENET/IP MODULE - TP

1794-OB8EP Flex 8 Point Digital Output Module

194E-CA63 194E Load switch

2085-OB16 Micro800 16 Point Source Output Module

2090-DANFCT-S04 TL-Series 4m Feedback Cable

ABICTAE0000/ABD 10.5 Inch Color TFT, TCP Label, 110VAC, with AB DataHighway Plus

GC646PCM025 GlobalCare Complete for Change Management 25 user pack

HE693THM889 8 ch. J, K, N, T, E, R, S, 0.5degC resolution, degC/F units, open circui t alarms

IC630MDL352RR 24Vdc Sink Output Module, 1 Amp (16 points)

IC647HSTSS500M-35 Historian v3.5 Standard Server 500 Points (M4 Key)

IC660BLA104 Cover w/Label for IC660BBA104

IC695ALG704CA Conbal Coated Analog Output Module,4 channel voltage/current. Module does not include terminal block.

IC756WDV009J-99 DV Development Sys Visual Basic, Japanese, Version 9.9

CompactLogix System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 9399-PLC5PG PLC 5, 6200 SERIES PROGRAMMING GUIDE

Distributed I/O D1794-6.5.12 FLEX I/O THRMCPLE/RTD/MILLIVLT INPUT MOD USER MANL

Operator Interface 2711P-T6M20D PV PLUS 600 GRAYSCALE, TOUCH, ETHERNET, DC PS

Support 6403-DDMCR 6403-DDMC SOFTWARE SUPPORT REINSTATEMENT

Support 9358-PBRE01S SUPT RENEWAL CONTRACT FOR 9358PBRE01ENE

Support F1779-KP5SERA FIRMWARE UPGRADE FOR 1779-KP5 COMMUNICATION MODULE

RSI Software Products 9301-2SE2104 RSVIEW32 WORKS 150 WITH RSLINX SINGLE NODE

RSI Software Products 9701-VWSB000ADEE RSVIEW SE STATION UNLIMITED DISPLAY (GERMAN)

RSI Software Products 9399-AIIG A I SERIES INSTALLATION GUIDE

Motion Control 2098-DSD-HV100X HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000 W/INDEXING

ABICTDE0000/ABR 10.5" Color TFT, TCP Label, 24Vdc, with AB Remote I/O, UL,cUL,CE, UL1604

IC220TBK082 I/O TERMINAL STRIP, 8 POSITION SPRING STYLE W/COLOR, QTY 10

IC752DPA262 Mature, order QuickPanel instead. DataPanel 1062IR with infrared touch. 10.4" VGA (640x480) active matrix TFT color display. Black bezel mounting from front of panel. Supports all WinCfg functionality.

MTR-3S33-G-R-0-E-ERR Servo Motor Nema34 Flg Explosion-Proof

ZA06B-0371-B577#7008 A1/3000 servo motor with 64k serial encoder

20BE052A0AYNANA0 PowerFlex 700 AC Drive 52 A 50 Hp 20B

20G14NE289AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PTG1-FB PowerFlex 520 Fr B Power Terminal Guard

2711P-RR128 PV Plus Logic Module 256 MB Ram Module

FRN30G11S-4CX 46 KVA 60 A 30KW 3相AC380V/50Hz/60Hz

1492-J6-OR 6 square mm Feed-Through Terminal Block

1492-TAIFM16-F-3 Connection Products

軟啟動器 3RW40736BB34

CPU 模塊 6ES7 512-1DK01-0AB0 CPU 1512SP-1 PN，200KB 程序，1 MB 數(shù)據(jù)；48 ns；集成 1x PN 接口 ( 可用 ET 200SP 總線適配器再拓展 2 個 PN 接口 )

153H-C135FBD-50 135 A Encl. Smart Mtr Ctrlr CB

1738-OW4M12 ArmorPoint 4 Point Output Module

1785-L80E PLC-5 Ethernet Processor

193-NVEC5VIM E3 Plus Voltage Input Replacement Module

20-COMM-K PowerFlex 20 CANopen Communication Kit

2090-CSBM1DE-18AF15 Kinetix Cable Single DSL 2090-Series

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GA647IFSTRN00075 GCA iFIX Std HMI 75 I/O Run

GP647IFPLRN00300 GCP iFIX Plus SCADA 300 I/O Run

IC600BF929RR 10-50Vdc Source Output Module with Lights (32 points)

IC647HSTCR40KM Collector Redundancy Option for Historian - Standard Server 40000 Points (M4 Key)

IC647TPR300 CIMPLICITY HMI ProServer 300 I/O Runtime System

IC693PIF400 High Perbance PC/AT Interface (PCIF) to Series 90-30 I/O with softw are

IC756MDV000K-99 DV Development - Alpha OpenVMS Op Sys, Korean, Version 9.9

MicroLogix 1000/1761 System 1761-CBL-AM00 CABLE: MICROLOGIX 1000 CONTROLLER TO PORT 2

PLC-5/1771 System 1771-NB4T HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-8BVT8D 8 SINK/SOURCE INPUTS, 8 SOURCING 0.5AMP OUTS

Communications 9351-AIXRT INTERCHANGE FOR AIX RUNTIME

Operator Interface D6190-6.5.20DE CONTROLVIEW STATIST. PROCESS CNTL USER MNL(GERMAN)

Support 9356-STD2350R SUPT REINSTATEMENT CONTRACT FOR 9356STD2350

Support 9392-CDRSENE DATADISC CD-ROM SUBSCRIPTION

EtherNet/IP Products 9355-WABSNENE RSLINX SINGLE NODE

RSI Software Products 9301-2SE3500KOU2 RSVIEW32 RUNTIME 1500-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAP250U1R UPGRADE: OUT-SUPT: RSSQL GATEWAY SAP TO SAP PREM

Motion Control TL-A130P-BJ34AA MOTOR, SERVO, 0.32NM, 5000RPM, 17BIT SERIAL FEEDBA

44A737558 Series 90-30 State Logic CSE313A,B,C Upgrade latest revision CSE313D

IC200CBL602 CABLE EXPANSION SHIELDED 2 CONNECTORS 2M

IC694MDL241 INPUT MODULE 24 VAC 16 POINT

MSI-UNIV-WEB-100-43 Univ Web(RTIP/Dash/Web/Excel) 100 Pak-43

VSPC32-MON50 VisualSPC Monitor, 50 license pack.

20BD034A3AYNANC0 PowerFlex 700 AC Drive 34 A at 25 Hp 20B

20G11GD052AA0NNNNN PowerFlex 755 AC Packaged Drive