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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(diǎn)，將程序設(shè)計細(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(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)控數(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(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

　　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(bǔ)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(bǔ)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(diǎn)介紹
 

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25-PM2-D4P0 PowerFlex 520 1.5kW (2Hp) Power Module

2711P-RP8A PanelView Plus 6 700-1500 Logic Module

FRN3.7G11S-4CX 6.9KVA 9.0A 3.7 KW 3相AC380V/50Hz/60Hz

1492-J50 50 square mm Feed-Through Terminal Block

1492-SPM3D500-N MCB Supplementary Protector 50 A

軟啟動器 3RW40566BB44

CPU 模塊 6ES7 516-3AN01-0AB0 CPU 1516-3 PN/DP，1 MB 程序，5 MB 數(shù)據(jù)；10 ns ；集成 X1: 2x PN 接口，X2: 1x PN 接口，X3:1x DP 接口

152H-C135XBD-50-8L SMC-3 Pump Panel w/Line Prot.Module, FB

1738-OB8EM12 ArmorPoint 8 Point Output Module

1784-U2DN DeviceNet to PC USB Interface Cable

193-NREC5ZZ E3 Plus Replacement Overload Relay

20-750-UFB-1 PowerFlex 750 Univ Fdbk Option module

2090-CSBM1DE-18AA05 Kinetix Cable Single DSL 2090-Series

20AB9P6A3AYNACG0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSR00900 GCA iFIX Profsnl SCADA 900 I/O Srv

GP647IFPLDV00075 GCP iFIX Plus SCADA 75 I/O Dev

IC600BF913RR 10-50Vdc Sink Output Module

IC647HSTCR1KM Collector Redundancy Option for Historian - Standard Server 1000 Points (M4 Key)

IC647TPD700 CIMPLICITY HMI ProServer 700 I/O Development & Runtime System

IC693PCM301LT Prog. Coproc. Mdl., 192 KB (47 KB Basic Prgm), w/Port Exp. Cbl. (LT)

IC756MDV000E-97 DV Development - Alpha OpenVMS Op Sys, English, Version 9.7

MicroLogix 1000/1761 System 1761-L32AAA 32 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-IL ANALOG INPUT MODULE

Distributed I/O 1792D-4BV0D 4 SINK/SOURCE INPUTS, 4 CONNECTORS

Communications 9300-RADM1 SERIES A REMOTE ACCESS MODEM (DESK TOP WITH CABLE)

Operator Interface D6190-6.5.15 CNTRLVW RAM 4MB ENHANCED MEMORY CARD(6190-MB14)MNL

Support 9356-SQLSAP250R SUPT REINSTATEMENT CONTRACT FOR 9356SQLSAP250

Support 1789-L10S SUPT RENEWAL CONTRACT FOR 1789L10

EtherNet/IP Products 9351-WESRT INTERCHANGE FOR WINDOWS RUNTIME

RSI Software Products 9301-2SE3500JPE RSVIEW32 RUNTIME 100K (JAPANESE)

RSI Software Products 9356-PRO2500U8 UPGRADE: IN-SUPT: RSSQL PROF.5000 TO 70000 TAG

Motion Control 0041-5069 N-3400 SHAFT SEAL KIT

44A735538 CPU323 Upgrade Kit latest revision

IC200CBL105 CABLE I/O NON-SHIELDED 2 CONNECTORS .5M

IC694ALG391 OUTPUT MODULE ANALOG 2 POINT CURRENT

MSI-SERVICES Professional services (Billed per hour)

VSPC32-IMP/GL VisualSPC Importer for Giddings and Lewis (OEM).

20BD034A0AYNANC0 PowerFlex 700 AC Drive 34 A at 25 Hp 20B

20G11GC072JA0NNNNN PowerFlex 755 AC Packaged Drive

22D-B024N104 PowerFlex 40P- 5.5 kW (7.5 HP) AC Drive

600558000 Quantum 電纜切割鉗

29011-061-06-R SCREW, M4 X 0.7 X 6MM PHMS

熱電偶/PT100輸入，電壓輸出，2個報警

1492-SPM2B160 MCB Supplementary Protector 16 A

軟啟動器 3RW30161BB04

電機(jī)啟動器 3VU16401MN00

150-F108NBDD SMC Flex Smart Motor Controller

1715-TASOB8DE 1715 8 Point Termination Assembly

1771-NR 1771 Analog Module

193-EC5HG E3 Plus 60-302 A Overload Relay

198E-DA1488T IEC IP42/NEMA 1 Metal Hinged Enclosure

2090-CPWM6DF-16AA01 TL-Series 1m Standard Power Cable

2094-BSP2 Kinetix 6000 Shunt Resistor

DEMOCD00100 Demo CD - See comment

GFK-0854 Series 90 Sequential Function Chart Programming Language User's Manual

IC210EDR008 Expansion unit, 24V DC Power Source, (4) 24VDC in/(4) out (Relay, 8 Amp)

IC647AUR005 PA Universal Reporting Client 5 Pak

IC647PRTEE010C Proficy Portal Enterprise Edition Client Pack 10 Users (M1 Key)

IC693CPU340RR CPU 340 Module, (16K Bytes user memory), 10K Reg., 3 msec/K

IC754VKL06MTD Starter Kit 6 In Mono View Loaded 24 VDC

MSI-DASHBOARD-50-43 Dashboard Client 50 Pack-43

SLC/1746 System 1746-RL50 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-OA16

Distributed I/O 1734-VHSC24 24 VDC VERY HIGH SPEED COUNTER WITH SOURCE OUTPUTS

Application-specific products 9307-8MGDBCENE RSEMETRIX MGR(0-8 METERS),W/1MSSQL CLIENT LIC.

Operator Interface 2711-CBL-PM10 10METER RS232 CABLE, PV300MICRO TO SLC/PLC

Support 9302-H1R SUPT REINSTATEMENT CONTRACT FOR 9302H1

Support 9510-PB1000ENR SUPT REINSTATEMENT CONTRACT FOR 9510PB1000EN

DeviceNet Products 1799-DNETCON 5-POSITION OPEN STYLE PLUG FOR DN

RSI Software Products 9301-2SE3350KOU2 RSVIEW32 RUNTIME 300-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9307-EMCHTENE RSENERGYMETRIX CHARTPLUS

Motion Control MPL-B980C-MJ22AA MOTOR,SERVO,122.0NM,1500RPM,MULTI,460V

Silver Series 1398-DDM-150 DRIVE,150A,PEAK,ULTRA 200

HE693ADC410 4ch., +/-10Vdc Analog Input Module, 2000Vac Isolation, 14-bit resolution

IC646TRT915 1,500 I/O Point Runtime System

QPGCTDE0000 7/4" Color TFT, Ethernet, CF Card, 24VDC, UL, cUL, CE

ST-3704 STXi analog b module 4 Channels, RTD Connector Type

20BC140A0AYNANC0 PowerFlex 700 AC Drive 20B

20F14NF263JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D4P0F104 PowerFlex 4 1.5 kW (2 Hp) AC Drive

Quantum Digital Input Module 開關(guān)量輸入模板

284D-FHD7P6Z-25-CR-DB-SB DeviceNet Variable Frequency Drive

CJ1W-AD081-V1 8點(diǎn)模擬量輸入單元（1-5V,0-5V,0-10V,-10-10V,4-20MA）分辨率：1/8000

1492-RTB14N 14-Pole Screw Style Rtb Plug

WinCC 上位監(jiān)控軟件 6XV1840-2AH10 FC 標(biāo)準(zhǔn)電纜/每米

變送器 3RS17032AD00

1497A-A3-M8-3-N Control Power Transber

1606-XLP60EQ AC or DC Input 24 to 48VDC Out 60W PS

1768-EWEB CompactLogix Enhanced Web Server Module

188-K4C160 Miniature Circuit Breaker 16 A

194R-30-NJ 194R 30 Ampere 4th Power Pole Module

2090-CPBM7DF-10AA40 MP-Series 40m Standard Cable

2090-XXNPMP-10S60 MP-Series 60 m Length Power Cable

CBL-13-ED-10 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors connected to IMC or S2K. 10 feet

GC647SVB001 GCScheduler Visma Business Adapter

IC200PWR101LT POWER SUPPLY 120/240VAC INPUT (LT)

IC646TBLSS10K Proficy Troubleshooter for Inbligent Historian for Hist 10000 Points

IC647NGM000 CIMPLICITY HMI HONEYWELL IPC620 Communications

IC692MDR741RR 16 DC b/ 12 Relay Output 120 Vac PS

IC698CRE030 600mHz CPU, Ethernet, Redundancy

IC800VMCB100 Motor power and brake power cable for 200 W to 750 W VersaMotion servo motors- 10 meter

SLC/1746 System 1746-IO12DC COMBINATION MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15KSXPH VERSAVIEW 15-INCH WORKSTATION, KEYPAD

Application-specific products 6556-PA0PM1 CLUTCH/BRAKE KIT WITH ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-T5A10L1 PV550 MONO TOUCH, DNET & RS232 PRINT

Support 9301-2SE2200JPS SUPT RENEWAL CONTRACT FOR 93012SE2200JP