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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)絡體系又有開放I/0及通訊接口，很容易組建網(wǎng)絡并實現(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)結構及硬件配置

　　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)絡采用MPI的通訊協(xié)議，從上位機上可對整個氣體調節(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程序的編制直接關系著供氣系統(tǒng)能否正常工作，而程序設計的關鍵在于編程者對工藝系統(tǒng)的理解程度和程序編制技術的靈活應用。因此，在程序設計中首先考慮了供氣壓力調節(jié)系統(tǒng)的特點，將程序設計細化，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)場對工藝的調整，又可針對配套設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：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)設定：

　　壓力調節(jié)閥的壓力設定值、P、I、D等參數(shù)可以在上位機中設定。

　　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，供氣壓力調節(jié)等多幅畫面，畫面直觀、豐富，具備PID在線調節(jié)、在線顯示調節(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定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設計

　　根據(jù)該系統(tǒng)具體情況，PLC系統(tǒng)軟件設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，結構緊湊而又靈活。

　　PID調節(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 2090-XXNPY-16S05 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,5M

GFH-001 Servo Product Specification Guide (Alpha and Beta Series)

IC641SWP719 C Toolkit for Series 90-70 (Professional)

IMC-316E-X-D IMC-D Series Servo Motor Controller, Enhanced, 6 Amp

PSPC-DC10L Prof Shop Floor SPC DC 10 User

20BC011A0AYNAND0 PowerFlex 700 AC Drive 20B

20DM261N0ENNBNANE PowerFlex 700S AC Drive 20D

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2711P-RAAT7 PanelView Plus 7 Series Accessory

280-PWRM35G-M10 ArmorStart Three-Phase Power Media

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1492-MS8X9 IEC 8 x 9 mm Marker Card

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1756-SPESMNRM L7SP Energy Storage Module-Non Remove

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194E-Y32M-1753-6G 32A 3P LOADSW. IN M/THREAD BOX

2090-CFBM7E7-CEAF09 9 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S03 MP-Series 3 m Length Power Cable

BC646TRT915 Server 1500 I/O Runtime System with Proficy GlobalCare

GC647IFPLSR00075 GCC iFIX Plus SCADA 75 I/O Srv

IC200CBL602 Cable expansion shielded 2M 2 connectors

IC646MPS005 Logic Developer PLC Standard 5 Pack

IC647IFSCTSSPRT03M iFIX TS SCADA Support on SCADA -3 Clients (M4 Part)

IC670ALG230 Analog Input, Current, 8 Channel, Grouped

IC697CPU772RR CPU, 12 MHz, 2K Discrete I/O, Expandable Memory, Floating Pt

IC800PCUBC10S050 Powercube flying lead interface cable configured for 1000 steps/revolution and power save enabled. 5 meters

ControlLogix/1756 System 1756-OB8EI 10-30 VDC ISOLATED ELEC FUSED OUTPUT 8PTS (36 PIN)

Industrial Computers 6182H-10KEH6D VVCE 1000, KEYPAD, EXT MEM, RIO/DH, DC

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Motion Control 2090-DAPC-D0903 CABLE, NON-FLEX, CN3 SERIAL COMMUNICATIONS, 03M

CBL-114-1 Cable. Allen Bradley PLC5 Channel 0 (RS-232)

IC5008TBW2000 Discontinued - Order a BC5008TBW0000 & Appropriate CIM PE License

IC800PCUBC02S050 PowerCube Flying Lead Interface Cable, 200 Steps/Rev & Power Save Enabled, 5 Meters

OC647IFESGDV00075C iFIX Optn: ESig & ERec 75 I/O Development (M1Component Part)

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25C-E3P0N104 PowerFlex 527 1.5kW (2Hp) AC Drive

280-PWRM22B-M8 ArmorStart Three-Phase Power Media

FX2N-32MR-001 主機16入/16出?繼電器輸出

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1494H-EF3N Heavy Duty Non-Fus Safety Discon Switch

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1794-OV16P Flex 16 Point Digital Output Module

194E-CA80E-TN-PE 194E Load switch

2090-CCMUSDS-48AA01 Kinetix 3 cable to 1203-USB 1m

2090-DANPT-16S12 TL-Series 12 m Length Power Cable

ABKSTDN0000/ABD 6 inch Color STN/ TCP Label/ 24VDC/ with AB DataHighway Plus/ UL/ cUL/ CE/ UL1604

GC646PCN110E Proficy GC for OP Operator Console Runtime S/W 700 I/O

HE800ACC019 Cage-clamp (screw) style I/O plug, 19-terminal. (Qty 1)

IC630PWR324RR 24Vdc Remote Power Supply Unit

IC647HSTSSEO10KM eSignature Option for Historian - Standard Server 10000 Points (M4 Key)

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IC756WET100J-23 Custom Editor Toolkit, Japanese, Version 2.3

CompactLogix System 1769-PB4 24VDC INPUT P0WER SUPPLY: 4A @ 5VDC 2A @ 24VDC

PLC-5/1771 System D1771-6.5.113 BASIC MODULE USER MANUAL

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Operator Interface 2711P-B7C4B2 PV PLUS 700, KEY/TOUCH, ENET, AC PS, EXT MEM