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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(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(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。可作為操作人員現(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(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(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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RSI Software Products 9324-RL01U3ESE UPGRADE: IN-SUPT: SPANISH RS500 STARTER TO RS500

RSI Software Products 9301-2SE3500ZHE RSVIEW32 RUNTIME 100K (CHINESE)

RSI Software Products 9356-STD2350U2R UPGRADE: OUT-SUPT: RSSQL STD 300 TO STD 5000 TAG

Motion Control Y-1003-2-H04AA MOTOR,SERVO,0.35 NM,4500RPM,ENCDR,230V,BRK,1.2KG

510-1000-041 POWER SUPPLY 24VDC 2AMP

IC200CPU001LT CPU 12K USER PROG 1.80MSEC/K BOOLEAN ONE RS232 AND ONE RS485 SERIAL PORTS (LT)

IC694MDL930 OUTPUT MODULE RELAY 4AMP 8 POINT ISOLATED

MSI-WEB-25-43 Web or Excel Reping Clients 25 Pack-43

VSPCSE-IMP10 VisualSPC SE Importer, 10 license pack.

20BD052A3AYNAEC0 PowerFlex 700 AC Drive 52 A 40 Hp 20B

20G11LC910AN0NNNNN PowerFlex 755 AC Packaged Drive

22D-E3P0H204 PowerFlex 40P 1.5 kW (2 Hp) AC Drive

Quantum Communication Accessories 網(wǎng)絡(luò)通訊及附件

291D-FAZ-G1-3FR Direct Online Reversing Starte

MK4NJ-CR NEW 220VAC，有阻容吸收回路，4開4閉，觸點(diǎn)5A 中國制

1492-SPM2D005 MCB Supplementary Protector 0.5 A

軟啟動器 3RW30371BB04

電機(jī)啟動器 3VU16400CH00

150-F251NCDB SMC Flex Smart Motor Controller

1732E-16CFGM12QCR ArmorBlock 16 Point Configurable QC

1771-P6S 1771 Power Supply

193-EEED E1 Plus 5.4-27 A IEC Overload Relay

199-MSMV1 Surge Suppressor

2090-CPWM7DF-08AF05 5 m Length SpeedTec Pwr and Brake Cable

2097-F6 Kinetix 300/350 15.0 A Line EMI Filter

EN84-2481-3040M 1000 ft., Proplex Stranded Ethernet Cable

GFK-1534 Manual VersaMax Profibus-DP Network Communications

IC220ALG320 ANALOG OUT, 16 BIT, VOLTAGE/CURRENT, 1CH (REQUIRES 1 IC220TBK203)

IC647CGMV00 GM Viewer Site License (not for general use)

IC647PRTPRFYC Proficy Portal SQL Connector for use with other Proficy products (M1 Key)

IC693DSM324 DSM324 motion controller module for Series 90-30

IC756ADV001K-99 DV Development - AIX Op Sys Addt'l User, Korean, Version 9.9

MSI-MAINT-43 5 Day x 9 Hour Support-43

SLC/1746 System 1747-KY1 REPLACEMENT KEYS FOR SLC 5/03, /04, /05 PROCESSORS

Distributed I/O 1738-OB8EM8 24VDC 8 SOURCING OUTPUTS WITH M8 CONNECTORS

Communications 2760-SFC2 PROTOCOL CARTRIDGE FOR A-B DH485 MULTI-DROP DEVICE

Operator Interface 2711-NV3K ANTIGLARE OVERLAY PV900 KEY

Support 9302-SMDR SUPT REINSTATEMENT CONTRACT FOR 9302SMD

Support 9324-RL5300PTR SUPT REINSTATEMENT CONTRACT FOR 9324RL5300PT

DeviceNet Products 2706-P72CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE335ESU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (ES)

RSI Software Products 9371-EDBA3 RSWIRE DESIGNER DATABASE OPTION

Motion Control MPG-A025-031S22 MOTOR,SERVO,GEAR RATIO 31,100NM,168RPM,SINGL,230V

Silver Series 1789-SL51 SOFTLOGIX5 NT-BASED CONTROLLER, 1 COMM CHANNEL

HE693RTD601 RTD Input, 6 channel, 3-wire, 0.125癈 res., -100 to +260癈 range (Pt-100)

IC660ERD020 Genius 24/48Vdc Source Electronics Module for Redundancy "T" Output Configuration

QPI-COS-201 QUICKPANEL CANOpen

ST-5351 STXi SSI Interface module 1 CH; 62.5K, 100K, 125K,250K,500K,1M,2Mbps

20BC205A0AYNANC0 PowerFlex 700 AC Drive 20B

20F1ANC140JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A8P0F104 PowerFlex 40 1.5 kW (2 Hp) AC Drive

140DDI67300C Quantum 開關(guān)量DC輸入,24點(diǎn),125VDC,3組隔離,CC

284D-FVD4P0B-N-R-3-DB-EMI Cntl Mod. Variable Frequency Drive

E3S-2E4 2m,對射型 , 晶體管輸出80mA, 電源:12-24VDC水平安裝

1492-SJS TERM BLCK Side Jumper INSLG Sleeve

人機(jī)界面 6AV6545-0CA10-0AX0 TP270-6 觸摸屏，256 色，5.7 英寸，320? 240

6ES78331FC000YM2

1497B-A14-M15-0-N Control Power Transber

1606-XLS480E-D Power Supply XLS 480 W Power Supply

1769-IF16C CompactLogix 16 Pt A/I Current Module

189-AL20 MCB Accessory Auxiliary Contact

194R-HM1-N1 194R 100-400 A Operating Handle

2090-CPBM7DF-12AA40 MP-Series 40m Power and Brake Cable

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

CBL-30-JP-06 AC power cord with 3-prong plug to flying lead. 6 feet

GF-0205 Connecting FlashCable to Fowler Maxcal / Digitrix.

IC200TBX214 Tool box, 14 point, (IC200UDR001) 24VDC In/Relay Out, AC powered (requires AC power), VersaMax SE (IC200SET001) with all software, cables and manuals. (IC640VPS002 and IC646MPM001)

IC646TBSPMPS700 Smart Process Monitoring Process+ server 700 loops

IC647NSJ000 Siemens MPI OPC Server

IC693ACC333 TBQC Base for IC693MDL340

IC752CAB202 AB Micrologix cable for DataPanel 150/160/240

IC800VMCP1100 Power cable for 1 kW VersaMotion servo motor- 10 meter

SLC/1746 System 1746-OX8 (8) ISOLATED RELAY OUTPUT - 5-250V AC, 5-125V DC

Industrial Computers 6189V-ACPSWS AC POWER SUPPLY ATX STANDARD (6180W WORKSTATION)

Application-specific products 1400-SP LOCAL DISPLAY POWERMONITOR SOFTWARE

Operator Interface 2711-B6C3L1 PV600 COLOR KEY&TOUCH, DH485 & RS232 PRINT

Support 9301-2SE2400ESS SUPT RENEWAL CONTRACT FOR 93012SE2400ES

Support 9307-EMCHTR SUPT REINSTATEMENT CONTRACT FOR 9307EMCHTENE

DeviceNet Products 1734-IB4 24V DC 4 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE250ZHU3R RSVIEW32 WORKS 300-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BNT60U3R UPGRADE: OUT-SUPT: RSBATCH 30 TO 60

Motion Control MPL-B330P-RJ24AA MOTOR,SERVO,4.18 NM,5000RPM,RSLVR,460V,BRK,6.8KG

Motion Control 2090-U3BK-D4403 BREAKOUT BOARD KIT,CONTROL,CN1,ULTRA 3000,3M

GFK-0712 Series 90 Digital Event Recorder User's Manual

IC646CXV000 X11Viewer Option for Windows 95 and Windows NT-Inb

MSCPX-312806W2 Marathon Exp CPU,566 MHz CPU, 128M, 6G, Win 2000, 2 PCI/ISA, 1 PCI, 1 ISA

PSPC-DC50/E-220L Prof Shop Floor SPC DC 50 User eSig 220v

20BC015A3AYNACC1 PowerFlex 700 AC Drive 20B

20F11FC085JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-IOSP CONKIT,K5500,I/O,SPRING TRM

2711P-RBK7 PanelView Plus Accessory

280-PWRM35H-M8 ArmorStart Three-Phase Power Media

CQM1-OC221 輸出 8點(diǎn).繼電器 250V AC/24V DC 2A

1492-N37 TERM BLCK End Barrier

回路閉環(huán)控制模塊 6ES7355-1VH10-0AE0 FM355S，4 回路閉環(huán)控制模塊，8DI/8DO，4AI，2個 20pin 前連接器

行程開關(guān) 3SE53223SF23

TIA 博途 WinCC 選件 6AV2107-2KH00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 10 -> 25 Clients

1585J-M8HBJM-6 RJ45 Ethernet Media

1760-L12AWA Pico 12 Point AC Controller

188-K2C010 Miniature Circuit Breaker 1 A

194L-A16-1751 16 A 194L Load Switch

2090-CHBP8S8-12AA20 Kinetix 6000M IDM hybrid cable

2090-UXTBMP-18S15 MP-Series 15 m Length Brake Cable

BC647MPPU01 Logic Developer PLC Professional Upgrade with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTDV00150 GCC iFIX Std HMI 150 I/O Dev