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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(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(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(guó)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(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/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(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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2711P-B7C22A9P-B PanelView Plus 7 Graphic Terminal

280-PWRM35C-M1 ArmorStart Three-Phase Power Media

CPM1A-DA002 4 路模擬量輸出 分辨率1/4000 轉(zhuǎn)換速率2.5ms/CH 每個(gè)輸出通道可獨(dú)立設(shè)置量程輸出：-10～10V 0～10V 0～5V 0～20mA 1～5V 4～20mA

1492-MR6X8 IEC 6 x 8 mm Marker Card

1495-J6 CONTACT,AUXILIARY FOR STRTOR CONTACTOR

行程開關(guān) 3SE53120SB11

運(yùn)行版軟件 6AV2105-0FA04-0AA0 SIMATIC WinCC Runtime 專業(yè)版 2048 PowerTags V14

1585J-M4TBJM-3 RJ45 Ethernet Media

1756-OF4 ControlLogix 4 Point A/O I or V Module

188-K1C020-N Miniature Circuit Breaker 2 A

194E-G3707 194E 52 mm Metal Load Switch Shaft

2090-CFBM7DF-CEAA01 MP-Series 1m Servo Feedback Cable

2090-UXBK-D1501 Ultra series 1m Cable Breakout Board Kit

BC646OEM0401 OEM Edge Renewal - Historian

GC647DMS001 GC DataMart 1 PA Connection

IC200ALG262 Analog b 15 bit current differential 8 channel

IC646IFCLNTCRO010C iFIX iClient Read Only 10 PK Keyless (M1Component Part)

IC647IFPLSRUNLMTC iFIX Plus SCADA Unlimited Server (M1Component Part)

IC660MLD120 Label for IC660BBD120 (Qty 100)

IC697BEM731RR Series 90-70 Genius I/O Bus Controller

IC800APK080 SVU1-80 Alpha series 80 amp amplifier kit

ControlLogix/1756 System 1756-L55M13 LOGIX5555 PROCESSOR WITH 1.5MBYTE MEMORY

Industrial Computers 6182H-7BEH4B VVCE 700, KEY/TOUCH, EXT MEM, ENET, AC

Process Control 9358-BHIST01ENE RSBIZWARE BATCHHISTORIAN - 3 UNITS

Operator Interface 2711P-B15C6B2 PV PLUS 1500, KEY/TOUCH, RIO/DH, AC PS, EXT MEM

Support 9240-MON16R SUPT REINSTATEMENT CONTRACT FOR 9240MON16

Support 6310-MSS 6310-MS SOFTWARE SUPPORT RENEWAL

Support F1794-ACNR15SERB FIRMWARE UPGRADE FOR 1794-ACNR15 I/O MODULE

RSI Software Products 9301-2SE2350U3 UPGRADE: IN-SUPT: RSVIEW32 WORKS 1500 TO 5000

RSI Software Products 9351-DKTSRT INTERCHANGE SOFTWARE FOR MS-DOS RUNTIME

RSI Software Products 9399-WGGUG RSSERVER FOR GE FANUC GENIUS I/O USER GUIDE

Motion Control 8720MC-MCM SPARE MAIN CONTROL MODULE KIT

BC646MRD300 Logic PC Runtime (HRT) 300 I/O

IC300RCS210 Remote Control Station (OCS without Keypad and display) Supports up to 4 SmartStack I/O Boards, full ladder instruction set, and CsCAN Networking.

IC754VKB06MTD Starter Kit - 6" Monochrome QuickPanel View Basic, Touch, 24VDC

MTR-3T55-I-R-B-M-0RR Servo Motor Metric 24V Brake

20AC8P7F0AYNANC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC030A3NYNACGNE PowerFlex 700S AC Drive 20D

20G1ANC205JA0NNNNN PowerFlex 755 AC Packaged Drive

25B-E6P6N104 PowerFlex 525 4kW (5Hp) AC Drive

280-FAM35F Field Attachable Receptacle, Female, M35

FR-F740-5.5K 8.8 KVA 11.5A 5.5KW 3相AC380V/50Hz/60Hz

1492-LG35 IEC Term Blck 16.1x100.5x51.7mm Spr Clp

1494F-V1 Combination Starter Door Hardware

軟啟動(dòng)器 3RW44362BC45

ET 200SP 6ES7132-6BH00-0BA0 DO 16x24VDC 標(biāo)準(zhǔn)型，基座單元類型 A0

1585D-E4UBDE-10 Micro D-Code, QD Style Ethernet Media

1753-L28BBBP GuardPLC 1600 Safety Controller

1794-IE12 Flex 12 Point Analog Input Module

194E-AA40E 194E Load switch

2080-LC30-16QWB Micro830 16 I/O Controller

2090-CSWM1DF-18AA03 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNAEG0 PowerFlex 70 AC Drive 20A

GC646MPSS50 Proficy GlobalCare Complete for Logic Developer - PLC Standard 50 Seat Site License

HE693RLY110 8 point, 8A Isolated Relay Module, 2 NO/NC, 6 NO

IC610CPU105RR Series One Plus CPU, 700 Words, Expandable to 1.7K Words

IC647HSTSC50KM Server to Server Collector for Historian - Standard Server 50000 Points (M4 Key)

IC660BBD020RR 24/48Vdc Source I/O Block, 16 Circuit, Ph B

IC694PWR321 Power Supply 120/240 VAC 125 VDC Standard

IC756WDN009E-27 DataViews Development System Visual Basic Java C++ & Native C English v2.7

MicroLogix 1500/1769 System 1769-RL1 REPLACEMENT DOOR LABELS FOR DISC. I/O (2 PER KIT)

PLC-5/1771 System 1771-P5E POWER SUPPLY, SLOT,8A,24V DC (EMI ENHANCED)

Distributed I/O 1798-IB8 FLEXARMOR 8 POINT 24 VDC SINKING INPUT MODULE

Operator Interface 2711P-B6M3D PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH485, DC PS

Support 9323-PA2JR SUPT REINSTATEMENT CONTRACT FOR 9323PA2J

Support 9358-PB10S SUPT RENEWAL CONTRACT FOR 9358PB10ENE

Support F1772-LZSERB FIRMWARE UPGRADE FOR 1772-LZ PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7FRE RSLOGIX 5000 FULL TO PRO UPGRADE, FRENCH

RSI Software Products 9305-RSVADFVCDEE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (GERMAN)

RSI Software Products 9301-PCI1500PFB APPLICOM PCI1500PFB PROFIBUS INTERFACE

Motion Control 2094-BM01 MODULE, AXIS, 400/460V, 9A INV.

A06B-0158-B075#7008 A40/2000 Servo Motor, Fan Package, 64K Serial Encoder

IC200UDR010 28 point; (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 24VDC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752CBT023RR Datapanel 320T MEG (Mono Expansion w/Genius) w/ Advanced s/w: 320x240 1/4 VGA Mono LCD with 386SX/40 processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Comms. With Genius PC/104.

MTR-1N33-N-A-S-0-MOD MTR series NEMA 34 stepping motor with parallel winding connection and special 0.5 inch diameter shaft

ZA06B-0116-B503#0100 B1/6000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD5P0A0AYNANC0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G11TF460JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D2P3 PowerFlex 520 0.75kW (1Hp) Power Module

372SPU78401LPTE Quantum LEGACY PRODUCT UPGR TO 10 USER CLIENT

FRN0.75E1S-2J? 1.9KVA 5A 0.75KW 3相AC220V/50Hz/60Hz

A06B-6035-H321

1492-SPM3D030-N MCB Supplementary Protector 3 A

軟啟動(dòng)器 3RW40281BB05

"

150-SD2NUR SMC-50 SOLID STATE MOTOR CONTROLLER 420A

1738-ADN18 ArmorPoint DeviceNet Network Adaptor

1783-US7T1H Stratix 2000 7+1 port unmanaged switc

193-EXP-PS-DC E300 DC Expansion Power Supply

20-750-NEMA1-F5 PowerFlex 750 Frame 5 Conduit Box Kit

2090-CPWM7DF-16AF09 MP-Series 9m Length Power Cable

20AB022A0AYNANC0 PowerFlex 70 AC Drive 22 A at 7.5 Hp 20A

GA647IFESGSR00900 GCA iFIX Optn: ESig & ERec 900 I/O Srv

GP647IFCLNTCDV GCP iFIX iClient Dev

IC600BF808RR Interrupt Input Module (8 points)

IC647HSTCC250KM Calculation Collector for Historian - Standard Server 250000 Points (M4 Key)

IC647TBLCPVC025 Virtual Campus for Proficy Troubleshooter and Cause+ - 25 Users

IC693MDL760 Solenoid Valve Output (11 Points)/ 24VDC Output ,0.5 Amp, Positive Log ic (5 Points)

IC756LDV001E-925 "DataViews Development on Inb Linux/Red Hat, Addt'l User, English v9.25"

Pico Controllers 1760-CBL-INT03 PICO-LINK CONNECTIVITY CBL .8M 1 PCS/PACK

PLC-5/1771 System 1771-ODZ 120V AC OUTPUT MODULE (4 COMMONS)

Distributed I/O 1791-16A0 BLOCK I/O, 120V AC, 16 POINT MODULE (16 INPUT)

Communications 1786-TCT2BD1 CONTROLNET TNC IP67 T-TAP/BNC STRAIGHT

Operator Interface 2706-PSW1 INVIEW MESSAGING SOFTWARE.

Support 9701-VWSS025AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSS025AENE

Support 9324-RL0100FRS SUPT RENEWAL CONTRACT FOR 9324RL0100FR

EtherNet/IP Products 2711P-K15C4D2 PV PLUS 1500, KEYPAD, ENET, DC PS, EXT MEM

RSI Software Products 9301-2SE340PTU5R RSVIEW32 RUNTIME 5K-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2450 RSSQL PR0 VERS WTH 32000

Motion Control F-4075-R-H00AN MOTOR,F-,NEMA 56C,82 IN LB CONT.

4362-H 4362 WITH 0-10 OR 4-20 mA OUTPUT

IC200ACC404 Spare parts kit. Two terminal strips and four plastic doors and four covers

IC693DSM314 Series 90-30 DSM314 Motion Controller, 1-4 axis

TGT-S000-1-1 Target System Module with 2 MB RAM

VDOCS-OFF5 VisualDocs Office (5) seats