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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(wú)法滿足現(xiàn)有的控制需求。主要表現(xiàn)在：

　　1)過(guò)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(wú)法長(zhǎng)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(guò)采用PLC(可編程控制器)控制系統(tǒng)，解決當(dāng)前存在的問(wèn)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(wú)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(kāi)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(wèn)。

　　PLC采用Siemens公司生產(chǎn)的S7-300系列，由于現(xiàn)場(chǎng)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(chǎng)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(guò)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(chǎng)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(lái)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(guò)程的控制程序的。上位機(jī)監(jiān)控軟件采用國(guó)產(chǎn)軟件組態(tài)王，全部采用漢化界面，便于系統(tǒng)的開(kāi)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(guò)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(guò)VB語(yǔ)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(shì)、實(shí)時(shí)趨勢(shì)，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(chǎng)顯示

　　現(xiàn)場(chǎng)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(lái)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(chǎng)壓力、流量、閥位的顯示與操作?？勺鳛椴僮魅藛T現(xiàn)場(chǎng)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(guò)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(chǎng)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(guò)工藝要求，可在現(xiàn)場(chǎng)、就地實(shí)現(xiàn)高、低限壓力報(bào)警;

　　3)簡(jiǎn)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(guò)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(cè)量精度。

　　(2)邏輯控制

　　聯(lián)鎖邏輯控制實(shí)現(xiàn)開(kāi)/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(huà)面，各系統(tǒng)送氣壓力、流量，供氣壓力調(diào)節(jié)等多幅畫(huà)面，畫(huà)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(guò)程量變化趨勢(shì)的實(shí)時(shí)趨勢(shì)曲線、歷史趨勢(shì)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(huà)面，調(diào)節(jié)間數(shù)據(jù)報(bào)表。實(shí)時(shí)趨勢(shì)曲線和歷史趨勢(shì)曲線可隨意設(shè)定時(shí)間段，打印在線趨勢(shì)，歷史趨勢(shì)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(guò)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(yǔ)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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IC640HWP310 Series 90 Workstation Intf. (XT/AT) w/LM 90-30/20 Serial

IC800SLCPVL100 Power Cable, 3500W and 5000W SL Servo Motor, 10 Meters

OC647IFXPESPC-50 iFIX for Embedded XP SPC Blocks Option V5.0

20AD8P0A0AYNANC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD034A0EYNANANE PowerFlex 700S AC Drive 20D

20P41AD027RA0NNN PowerFlex 460V AC 15 HP DC Drive

2711C-T6M PanelView Comp C600 Graphic Terminal

280-PWRM24E-M24 ArmorStart Three-Phase Power Media

NT631C-ST152B-EV2 彩色TFT LCD分辨率：640×480點(diǎn), 8色 10.4英寸.

1492-MCBA2H60 60 A UL489 Miniature Circuit Breaker

1494V-DJ644-A-B-D1-E-F NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44576BC44

運(yùn)行版軟件 6AV2102-4AA04-0AE5 SIMATIC WinCC Advanced V14 Upgrade WinCC flexible 2008 Advanced -> WinCC Advanced V14 Combo

1585D-M8UGDM-20 Gigabit Ethernet Media

1756-L73SXT Logix 5573SXT Automation Controller 8/4M

1799-D16U16VL 32 Point Embedded I/P/Output Comb Module

194E-FA20E-PD10-TN 194E Load switch

2090-CFBM7DD-CEAA09 MP-Series 9m Servo Feedback Cable

2090-SCVP25-0 Kinetix 25-25m Fiber Optic Cable

BC646MPPU01 Logic Developer PLC Professional Upgrade with Proficy GlobalCare Complete

GC647AQC001 GC PA Quality Client

HMI-CCT-405 Backlight for the 12.1 inch Color TFT (QPLCxxE0000)

IC641VPS300 VersaPro Standard Edition - Windows Programming Software for Series 90 -30 and VersaMax PLCs

IC647IFPLDV00075K iFIX Plus SCADA 75 I/O Development (M1 Kit Part)

IC660EBS103RR 115Vac/125Vdc Low Leak Isol I/O, w/o Failed Sw Diag, Elec Asm

IC697ACC726 Top PWA Cover, CPU-Style, (Quantity 6)

IC756WRJ049J-27 Runtime License Windows 25-49 Users Japanese v2.7

FlexLogix System 1794-OF4I ISOLATED ANALOG OUTPUT MODULE, 16 BIT, 4 POINT

PLC-5/1771 System D6200-6.4.6RU PLC5 PROG. SW CONFIG.& MAINTENANCE MNL (RUSSIAN)

Process Control 1757-UPGNG PLX SERVER BATCH REPORT UPGRADE

Operator Interface 2711P-B12C4B1 PV PLUS 1250, KEY/TOUCH, ENET, AC PS, STD MEM

Support 6001-F2ES SUPT RENEWAL CONTRACT FOR 6001F2E

Support 2711-ND2DES SUPT RENEWAL CONTRACT FOR 2711ND2DE

Support F1785-L60CSERD FIRMWARE UPGRADE FOR 1785-L60C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE230JPU1R RSVIEW32 WORKS 300-1500 UPGRADE OUT-SUPT (JP)

RSI Software Products 9701-VWSS025LENE RSVIEW SE SERVER 25 W/RSLINX ENTERPRISE

RSI Software Products 9399-RSRGR RSRULES GETTING STARTED GUIDE

Motion Control 1394C-SJT22-C MODULE,SYSTEM,22KW,IMCS,NO RIO,NO AXIS,LI

BC646MPP005 Logic Developer - PLC Standard Bundled 1 Year SAFE - 5 Pack

IC300OCS072 OCS with 2x20 LCD Display and with 16-key keypad. Built in I/O no expansion. 16 DC Inputs (12/24vdc), 12 DC Outputs (5/12/24vdc, 0.5A neg. logic with ESCP). With CAN network interface

IC752WFC575 CONTROLSTATION DS2050 15" 566MHz/128MB RAM WNT

MTR-3T23-G-R-B-M-SRR Servo Motor Metric 24V Brake, Seal

ZA66L-6001-0023#L300R0 A22/3000HVi & A12/4000HVis & A22/4000HVis, Fiber Optic Command Cable, 30 CM

20D-PUB-IN1-EN PF700S,F0-6 INSTALLATION PUB KIT,ENGLISH

20G1AJD545AN4NNNNN PowerFlex 755 AC Packaged Drive

25B-A8P0N114 PowerFlex 525 1.5kW (2Hp) AC Drive

2711PC-B4C20D8 PV Plus 6 400 Color Key Touch Terminal

6SE6430-2UD41-3FB0 132KW

1492-L3QS-W Side-By-Side 2Ckt Feed-Through Blk,2.5mm

1494C-CMX7 Cable Mechanism

軟啟動(dòng)器 3RW44263BC36

備品備件 6ES7 591-1BA00-0AA0 CPU 顯示面板：CPU 1515,1516,1517 和 1518

1585BT-M8UBBM-10 1585 Ethernet Media Patchcord

1747-C11 SLC Replacement Cable

1790D-T4R0 CompactBlock LDX Input Base Block

194E-A40-1753-6G 40 A 194E Load switch

20-PP60010 FIBER OPTIC CBL SET FR9 PF700H PF700S

2090-CSBM1DF-18AF40 Kinetix Cable Single DSL 2090-Series

20AC072A0AYNANC0 PowerFlex 70 AC Drive 72 A at 37 kW 20A

GC646MDA159 Proficy GlobalCare Complete for View Development /Runtime 1,500 I/O

HE693ASC900 64K ASCII BASIC Module w/two RS-232 and one RS-485 port, EEPROM

IC600PM542RR High Capacity I/O Rack Power Supply, 24Vdc

IC647HSTESEO2000KM eSignature Option for Historian - Enterprise Server 2,000,000 Points (M4 Key)

IC655MDL525RR 115/230Vac Input (16 points)

IC694MDL330 Output module 120/240 VAC 2amps 8 Points.

IC756SDV010K-97 DV Draw Development on Solaris Op Sys, Korean, Version 9.7

MicroLogix 1500/1769 System 1769-OV16 16 POINT 24 VDC SINKING OUTPUT MODULE

PLC-5/1771 System 1771-ACN15 CONTROLNET 1.5 AND BEYOND, 1771 I/O ADAPTER

Distributed I/O 1794-PS13 85-264 VAC TO 24 VDC 1.3A POWER SUPPLY

Communications D1785-6.5.2 DH PLUS RS-232-C INTERFACE MDL(1785-KE)USER'S MNL

Support 9313-L5225S SUPT RENEWAL CONTRACT FOR 9313L5225

Support 9358-CTATRENR SUPT REINSTATEMENT CONTRACT FOR 9358CTATREN

Support F1771-QDCSERA FIRMWARE UPGRADE FOR 1771-QDC I/O MODULE

RSI Software Products 9324-RLD250ITE RSLOGIX 5000 LITE EDITION ITALIAN

RSI Software Products 9301-WK15GEMENE RSVIEW32 WORKS1500 WITH GEMTOOL/SECSHOST/RSLINX

RSI Software Products 9358-PLTM2400U1R UPGRADE: OUT-SUPT: PLANTMETRICS 5 TO 50 WORKCELL

Motion Control 8720SM-037S4KAS3 37 KW/76.1AMP, 750 VDC,AMP AC MOTOR WITH SNS60ENC.

9450-SX-C Protocol Converter. 3 Serial & 1 Bidirect Parallel Port with Clock/Calendar

IC200TBM001 I/O AUXILIARY BARRIER STYLE

IC697VRM015 Reflective Memory with 256Kbyte memory & 512 transfer FIFO. 170MBaud fiber optic network. Supports up to 256 nodes over 2,000 meters

MTR-1337-N-A-E-0RR Stepping Motor Nema34

ZA06B-0075-B203 B8/3000is servo motor with 128k serial encoder

20BD180A3ANNACC0 PowerFlex 700 AC Drive 20B

20G11RC015AA0NNNNN PowerFlex 755 AC Packaged Drive

25-COMM-P PowerFlex 520 Profibus Comm Adaptor

140XTS00203 Quantum CABLEFAST電纜, 帶 QUANTUM I/O 端子, 0.9M

294E-FD4P2P-G1-SB Variable Frequency Drive

D4D-2121N 觸點(diǎn):1開(kāi)/1閉,6A 250VAC機(jī)械壽命:1000萬(wàn)次?撞壓式,高度可調(diào),停產(chǎn)，用D4NA-412G替代

1492-SPM3C030 MCB Supplementary Protector 3 A

軟啟動(dòng)器 3RW40362TB05

數(shù)字量輸出模 6ES7 222-1HF32-0XB0 SM 1222DQ 8 x RLY

150-FPP317B SMC Flex Renewal Part

1734-OB4E POINT I/O 4 Point Digital Output Module

1783-HMS8SG4CGN Stratix 5400 12 Port Managed Switch

193-ESM-I-30A-C55 E300/E200 30 Amp Sensing Module

20-750-FLNG1-F3 PowerFlex 750 NEMA 1 Flange Adaptor Kit

2090-CPWM7DF-14AA40 MP-Series 40m SpeedTec Standard Cable

2098-DSD-HV030X Ultra 3000 3kW Servo Drive

GA646PCMS01 GlobalCare Assist for Change Management Electronic Signature Module (Single)

GFZ-0087 Series 90-70 and Genius Bus Controller Troubleshooting Pocket Guide

IC5000P256RM PanelPC 256MB RAM Option

IC647HITC HIT:Hitachi S10

IC647SI5M SI5:Siemens SI5

IC693MDL655 24 Vdc Input, Neg/Pos Logic, 1 ms, (32 pts)

IC756HDV000J-99 DV Development - HP/UX Op Sys, Japanese, Version 9.9

MSI-S95 S95 XML Interface

PLC-5/1771 System 1771-IBN HIGH-TRUE INPUT MODULE, 10-30V DC, 32 INPUT

Distributed I/O 1790D-TN4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE, TERM BLOCK

Communications 1784-CP15 CABLE ASSY, 10 FT/3.2 M

Operator Interface 2727-RY1 MOBILEVIEW STYLUS WITH TETHER (5 PACK)

Support 9305-RSVADFVCFRS SUPT RENEWAL CONTRACT FOR 9305RSVADFVCFR

Support 9515-RSCHM200R SUPT REINSTATEMENT CONTRACT FOR 9515RSCHM200ENE

EtherNet/IP Products 2706-PENETM ETHERNET/IP COMMUNICATION MODULE FOR 2706-P4X

RSI Software Products 9301-2SE3400ZHE RSVIEW32 RUNTIME 32K (CHINESE)

RSI Software Products 9515-RSMSVRENE RSMACC SERVER AND RSMACC CLIENT ACTIVATION

Motion Control 1326AB-B520E-M2K5L MOTOR,SERVO,460V,13.0NM,3000RPM,MULTI,BRK,IP67

4161-4-24-.8 BCD To 7 SEG Display . 4 Digit, (.8") 24VDC. Dust Seal

HMI-CAB-C120 CABLE GE FANUC 90/30 CPU 351/352/363, RJ11 Serial Port

IC693CBL312 Cable, I/O Expansion, 0.15 Meters, Shielded

QSI2D100L2P QUICKSTART KIT 10.5" MONO LCD

TRM-21006664 7point screw terminal connector for 4.3/5/7.2 amp S2K controller extended digital I/O

20BC8P7A0AYNAND0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF046JN0NNNNN PowerFlex 753 AC Packaged Drive