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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、實時趨勢，實現(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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MicroLogix 1500/1769 System D1764-UM001AUSP MICROLOGIX 1500 PROG. CONTROLLER USER MANUAL

PLC-5/1771 System 1771-P4S1 POWER SUPPLY, SLOT (ONE SLOT), 8A, 100V AC

Distributed I/O 1794-NM1 PANEL MOUNTING KIT FOR FLEX I/O

Operator Interface 2711P-B6M20A PV PLUS 600 GRAYSCALE, KEY/TOUCH, ETHERNET, AC PS

Support 9323-PA2GS SUPT RENEWAL CONTRACT FOR 9323PA2G

Support 9358-PB03R SUPT REINSTATEMENT CONTRACT FOR 9358PB03ENE

Support F1772-LZPSERC FIRMWARE UPGRADE FOR 1772-LZP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD6U7DEE RSLOGIX 5000 FULL TO PRO UPGRADE, GERMAN

RSI Software Products 9305-RSVADFCITE RSVIEW32 ACTIVE DISPLAY FLOATING CLIENT (ITALIAN)

RSI Software Products 9358-SYNSE10E SYNCHRONIZATION UTILITY (10)

Motion Control 2094-BC01-MP5 MODULE, INTEGRATED, 400/460V, 6KW CONV. 4A INV.

A06B-0153-B075#7076 A30/3000 Servo Motor, IP67 Sealing, 64K Serial Encoder

IC200UDR005 28 point; (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752CBT013RR Datapanel 320T ME (Mono Expansion)w/ Advanced software: 320x240 1/4 VGA Mono LCD with 386SX/40. Analog touch screen w/ text, bitmaps, bar graphs, real time clock. With 2M memory & PC/104. With Real Time Trends & Host Communications.

MTR-1N32-I-E-D-S-0RR Stepping Motor Nema34 Encoder

ZA06B-0116-B203 B1/6000is servo motor with 64k serial encoder

20BD481A3ANNNNC1 PowerFlex 700 AC Drive 20B

20G11TF370JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D024 PowerFlex 520 11kW (15Hp) Power Module

372SPU78001PDEV Quantum PROWORX 32 ONLINE OFFLINE SGL USER PKG

FRN0.1E1S-2J 0.3KVA 0.8A 0.1KW 3相AC220V/50Hz/60Hz

A20B-2902-0271 A20B-2902-0271/02B

1492-SPM3D020 MCB Supplementary Protector 2 A

軟啟動器 3RW40282BB04

SIMATIC 存儲卡 6ES7 954-8LE02-0AA0 12 MB

150-SD1NUR SMC-50 SOLID STATE MOTOR CONTROLLER 361A

1738-8CFGM8 ArmorPoint 8 Point Combination Module

1783-US6T2H Stratix 2000 6+2 port unmanaged switch

193-EXP-DIO-42-240 E300 240V AC Digital Expansion Module

20-750-NEMA1-F2 PowerFlex 750 Frame 2 Conduit Box Kit

2090-CPWM7DF-16AF04 MP-Series 4 m Length Power Cable

20AB015A0AYNANC0 PowerFlex 70 AC Drive 15.3 A at 5 Hp 20A

GA647IFESGSR00075 GCA iFIX Optn: ESig & ERec 75 I/O Srv

GP646IFCLNTCRO025 GCP iFIX iClient Read Only 50 PK Keyless Runtime Version

IC600BF804RR 115Vac/dc Input Module (8 points)

IC647HSTCC20000KM Calculation Collector for Historian - Standard Server 20,000,000 Points (M4 Key)

IC647TBLCPVC002 Virtual Campus for Proficy Troubleshooter and Cause+ - 2 Users

IC693MDL753LT 12/24 Vdc Output, Pos Logic (32 Pts) (LT)

IC756LDV000K-97 DV Development - Intel/Linux RedHat Op Sys, Korean, Version 9.7

Pico Controllers 1760-CBL-2M GFX 2 M CPU TO CPU CABLE

PLC-5/1771 System 1771-ODD 120VAC ISOLATED OUTPUT MODULE, 16 OUTPUTS

Distributed I/O 1791-0B16 BLOCK I/O, 24V DC, 16 POINT MODULE (16 OUTPUT)

Communications 1786-RPCD CNET COAXIAL HUB REPEATER

Operator Interface 2706-PRIOM REMOTE I/O COMMUNICATION MODULE FOR 2706-P4X

Support 9701-VWSS000AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSS000AENE

Support 9324-RL0100ESS SUPT RENEWAL CONTRACT FOR 9324RL0100ES

EtherNet/IP Products 2711P-K15C4B2 PV PLUS 1500, KEYPAD, ENET, AC PS, EXT MEM

RSI Software Products 9301-2SE340PTU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2350U7 UPGRADE: IN-SUPT: RSSQL PROF.1500 TO PROF.5000 TAG

Motion Control F-4050-Q-H04AN MOTOR,F-,NEMA 56C W/24V BRAKE,60 IN LB CONT.

4360-T 4360 WITH RS-232 OUTPUT

IC200ACC304 I/O CABLE CONNECTOR KIT QTY 2

IC693DNS201 DeviceNet Slave

TGT-E00A-2-0 Target Axis Expansion Module, 3' Rack Linker Cable

VDOCS-BOP Includes the following: (5) VisualDocs Office Seats (MasterControl Sea ts), VisualDocs Message Server, VisualDocs Data Import Utility, Web Co ntrol, Remote Installation and 5 Days of Professional Services

20BD014A3AYYANC1 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BF960JN0NNNNN PowerFlex 755 AC Packaged Drive

22C-CCC PowerFlex 400 C Frame Cover Kit

Quantum Remote I/O (S908-Coax.) 遠(yuǎn)程I/O系統(tǒng)

285-BRC25-M10D Source Brake Patchcord Cable, 10M, M25

H7EC-N 7位液晶顯示計數(shù)器，觸點(diǎn)輸入，計數(shù)速度30HZ/1KH可切換

1492-SPM1D100-N MCB Supplementary Protector 10 A

通用型變頻器 6SE6 440-2UD25-5CA1 5.5 KW,185 x 245 x 195

電機(jī)啟動器 3VU13403NL00

150-C43NCR SMC-3 43A Smart Motor Controller

1609-SBAT Bul 1609 UPS Standard 12VDC Battery

1771-IAD 1771 16 Point Digital Input Module

193-EC2PB E3 Plus 0.4-2.0 A Overload Relay

198-MS24 Start/Stop, On/Off Push Button Kit

2090-CPBM7E7-16AF15 MP-Series 15 m Length Cable

2094-AM01-S Kinetix 6000 Axis Module

CW0DT1005 Industrial Key Board for DuraTouch, QWERTY Keyboard, Elastomer Type

GFK-0487 Series 90 PCM Development Software (PCOP) User's Manual

IC200UEX636-24 Qty of 24, 6 channel Analog expansion. (4) Analog inputs & (2) Analog outputs. 120/240

IC647APXM APX:Moore APACS

IC647PFL300 Proficy Process Systems Standard Edition 3000 I/O with iFIX

IC693CHS398LT Base, Expansion, 5 Slots (LT)

IC754UEX001 VersaMax Micro Expansion I/O Interface for QP Control

MA15/D/2/SI AC15AMP PWR SRG PROTECT (240AC)

SLC/1746 System D1761-6.4 AIC + ADVANCED INTERFACE CONVERTER USER MANUAL

Distributed I/O 1734D-IB8XOW8 24 VDC 8 SINK IN 8 RELAY OUT, DNET COMMS, SCREW

Application-specific products 1803-EEM02 EEM,16 ANALOG, 4 TO 20 MA

Operator Interface 2711-T10G12 PV1000 GRAYSCALE TOUCH, PBUS & RS232 PRINT

Support 9301-2SE3500JPS SUPT RENEWAL CONTRACT FOR 93012SE3500JP

Support 9381-PEDEQPENR SUPT REINSTATEMENT CONTRACT FOR 9381PEDEQPEN

DeviceNet Products 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

RSI Software Products 9301-2SE330ITU1R RSVIEW32 RUNTIME 300-1500 UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-PBEPB30ENE RSBIZWARE BATCH & EPROCEDURE BNDLE PLX 30 UNITS

Motion Control MPL-B640F-MJ24AA MOTOR,SERVO,36.0NM,3000RPM,MULTI,460V,BRK

Motion Control 2090-UXLF-HV350 AC LINE FILTER,ULTRA,50 AMPS, 460V, 3 PHASE

GQSJ2D100S2P QUICKSTART KIT 5" STN GE LABEL

IC646NRV000 Report Manger Integrated Viewer