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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(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(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。

　　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(duì)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(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(tái)，可實(shí)現(xiàn)對(duì)生產(chǎn)過程的全面監(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(shí)趨勢，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?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)壓力超過工藝要求，可在現(xiàn)場、就地實(shí)現(xiàn)高、低限壓力報(bào)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(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，包括過程量變化趨勢的實(shí)時(shí)趨勢曲線、歷史趨勢曲線。

　　(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)趨勢曲線和歷史趨勢曲線可隨意設(shè)定時(shí)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(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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GP-0602NT-F13SB GagePort LVDT NT (Full Bridge for Schaevitz LBB 100 Series) - Sales BO M.

IC5002CAC0002 12in Inbligence PanelClient w/ CIMP TS

IC647HSTAE100KM Alarm and Events Option for Historian - Standard Server 100000 Points (M4 Key)

IC647SIEM SIE:Siemens 3964r

IC693MDL660 24VDC Input Module 32 point. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 springclamp style terminal block).Terminal block is sold seperaby. Input filter time is configurable 0.5ms, 1.0ms, 2.0ms, 5.0ms, 10.0ms, 50.0ms

IC756HDV001CS-99 DV Development - HP/UX Op Sys Addt'l User, Simplified Chinese, Version 9.9

MSI-SDK-10-43 SDK Connections 10 Pack Ver 4.3

PLC-5/1771 System 1771-ID ISOLATED INPUT MODULE, 120V AC/DC, 6 INPUT

Distributed I/O 1790P-TN4C0 PROFIBUS,4 INPUT ANALG CURRENT BASE,TERMINAL BLOCK

Communications 1784-CP5 CABLE ASSY, 10FT/3.20M, 1784-KTK1 (15-PIN D-SHELL)

Operator Interface 2727-TRB7 MOBILEVIEW REPLACEMENT BATTERY

Support 9305-RSVADSDES SUPT RENEWAL CONTRACT FOR 9305RSVADSDE

Support 9515-RSEOL016R SUPT REINSTATEMENT CONTRACT FOR 9515RSEOL016ENE

EtherNet/IP Products 2711-K5A20 PV550 MONOCHROME KEY, ENET & RS232 PRINT

RSI Software Products 9301-2SE3400ZHU5 RSVIEW32 RUNTIME 5K-32K UPGRADE IN-SUPT (ZH)

RSI Software Products 9515-RSNHS100ENE RSMACC NETWORK HEALTH FOR 100 NETWORKS

Motion Control 1326AB-B520F-M2K5L MOTOR,SERVO,460V,13.1NM,3500RPM,MULTI,BRK,IP67

4161-4-24-N12 BCD To 7 SEG Display . 4 Digit, 24VDC, NEMA 12

HMI-CAB-C96 CABLE TOSHIBA MX, EX

IC693CBL325 Cable, Terminal Board Connections for DSM302, 3 Meters

QSJ2D100L2P QUICKSTART KIT 5" MONO LCD

TRM-21006668 Devicenet connector for IMC controller

BP023-000017-2C

SCHM315-059070 315-0600628

Meteor2-CL/32

HPCI-14S12U NUPRO-852 NuPRO-A301

ARBOR HiCore-i6313

8001-4020

1492-SPM1C160-N MCB Supplementary Protector 16 A

通用型變頻器 6SE6 430-2UD34-5EB0 "45 KW,275 x 650 x 245"

電機(jī)啟動(dòng)器 3VU13401NL00

150-C19NBD SMC-3 19A Smart Motor Controller

1608P-200A415V4S 200 A Pro DySC Sag Corrector

1769-SM2 Compact IO To DSI Communication module

193-CBCT2 E3 Plus Ground Fault Current Sensor

194R-R6 Operating Shaft

2090-CPBM7E7-08AF07 7 m Length SpeedTec Extension Cable

2090-XXTPMP-16S25 MP-Series 25 m Length Power Cable

CP4B-1MPB-0140-AZ Power cable for AC12/2000 motor. 14 meters

GF-937244 Connecting FlashCable to Mitutoyo Caliper (500-2xx/500-50x/550-22x/551 -22x/552-xxx)

IC200UER508 Isolated 5 amp, 8 point relay output expansion module, requires 24VDC power supply. Module is not UL approved.

IC647ADC002 PA Dashboard Client 2 Pak

IC647PCL050 Proficy Process Systems Standard Edition 500 I/O with CIMPLICITY

IC693CBL311 I/O cable for DSM324 24V I/O or APM I/O to the 44A726268-001 terminal block. 3 meters

IC754ACC12BEZ01 SS-Bezel for 12 Inch TFT QP-View & Ctrl

IMC-316D-X-DRR IMC-D Series Servo Motor Controller, DeviceNet, 6 Amp

SLC/1746 System 9399-CCUG CONTROLGUARDIAN USER'S GUIDE

Open Automation Systems 1789-STRT1ES SOFTLOGIX 5800 STARTER KIT SPANISH

Application-specific products 1404-M805A-232-02 MASTER MODULE-PQ 232 COM-120/240V P/S-CLASS0.2

Operator Interface 2711-K10G16 PV1000 GRAYSCALE KEY, DF1 & RS232 PRINT

Support 9301-2SE3300JPS SUPT RENEWAL CONTRACT FOR 93012SE3300JP

Support 9381-P1KENR SUPT REINSTATEMENT CONTRACT FOR 9381P1KEN

DeviceNet Products 1792D-KPLT KEMPF INTERFACE PLATE

RSI Software Products 9301-2SE3300ITU1 RSVIEW32 RUNTIME 300-1500 UPGRADE IN-SUPT (IT)

RSI Software Products 9358-EP30U2R UPGRADE: OUT-SUPT: RSBIZWARE EPROCEDURE 10 TO 30

Motion Control MPL-B4540F-MK24AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,460V,BRK

Motion Control 9101-0327 CONNECTOR KIT, MOTOR POWER, F/H-6X, STRAIGHT

GQPI3D200E2P QUICKPANEL 9" EL GE LABEL

IC646MRB150 Logic PC 150 Tag Runtime System

MTR-1N42-H-E-A-E-S Steping Motor Nema42, Parallel Wdg, Encoder

SA07-020 MATRIX Basic Training (3.5 days)

PXIe-6556

(R)PEB-4720-LVDS-SV RHMB0393

X9DRH-IF

SURFEXPRESS/PCIE SD282

LPCI-3488A

PEAK635VL-100

1492-PLOTADPT IEC X-Y Plotter Ultra Fine Pen Adapter

定位模塊 6ES7 451-3AL00-0AE0 FM451 定位，rapid traverse/creep speed,3 軸

變送器 3RS10301DD20

1497-C-M2-0-N Control Circuit Transber

1606-XL120E-3 Power Supply XL 120 W Power Supply

1762-IF4 MicroLogix 4 Point Analog Input Module

188-K3C130-N Miniature Circuit Breaker 13 A

194L-G2864R Control Knob Red

2090-CPBM7DF-04AA03 MP-Series 3 m Length Pwr and Brake Cable

2090-XXNFT-S15 Kinetix Drives 15m Standard Cable

BC647PSF050 Proficy Process Systems 500 I/O with iFIX with Global Care

GC647PME005 GlobalCare Complete for Proficy Change Management Server Machine Edition Version - 5 Concurrent Users

IC200MDL330LT OUTPUT 120VAC 0.5A PER PT ISOLATED 16PT (LT)

IC646NWV010 WebView - 10 Pack License

IC647MMPM MMP:Modicon Modbus Plus

IC676CBLPBM100 IP67 Profibus Cordset - 10 Meters - Male Connector w/Leads

IC697MSC701RR Series 90-70 Demonstration Case

IC800SSI104RS1 4.3 amp 115/230 VAC S2K servo controller for MTR series motors

SoftLogix System 1789-SLOTL SOFTLOGIX STARTER KIT DOCUMENTATION SET

Industrial Computers 6182H-15TRH6D VVCE 1500, TOUCH, STD MEM, RIO/DH, DC

Process Control 9399-RSBACLRG RSBATCH ACTIVE X CONTROLS LIBRARY REF. GUIDE

Operator Interface 2711-B5A15L2 PV550 MONO KEY&TOUCH, CNET & RS232 PRINT

Support 9303-23S0E40R SUPPORT REINSTATEMENT CONTRACT FOR 9303-23S0E40

Support 9371-EPCO3S SUPT RENEWAL CONTRACT FOR 9371EPCO3

ControlNet Products 9355-WABGWENE RSLINX GATEWAY - ENGLISH

RSI Software Products 9301-2SE2500ESU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-BANT60ENE RSBATCH ARCHIVER 60 UNITS

Motion Control MPL-A4530F-HK22AA MOTOR,SERVO,8.36NM,2800RPM,ENCRD,8.2KG

Motion Control 2090-UXNPBMP-14S30 CABLE,460V,NON-FLEX,MOTOR POWER,MP,14 GAUGE,30M

CBL-3C-RD-20 Resolver Cable, MTR-3S & MTR-3N Series Servo Motors, 20 Ft.

IC641CTL936 CIMPLICITY Control Developer Tooolkit

IC800SLM040N1XE25 400W, 115 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder