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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。可作為操作人員現(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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1790-7CMCBL CompactBlock LDX Expansion Cable

194E-A100-1753-6G 100 A 194E Load switch

20-PP10002 CABLE L1,L2, L3, FR10, PF700H, PF700S

2090-CSBM1DF-18AA12 Kinetix Cable Single DSL 2090-Series

20AC037A3AYNADC0 PowerFlex 70 AC Drive 20A

GC-8461-SW-MT Modbus (RTU, ASCII, TCP, Enron)

HE300GEN200 Genius interface board for AV300/DV300 Drives

IC600KD516RR Mini OIT - Touch

IC647HSTES1KM Historian Enterprise Server 1000 Points (M4 Key)

IC648MNT076 Annual Software Maintenance for LM 90-70 Standard Serial Communication s

IC694ALG442CA Conformal Coated Analog Input module, 4 in and 2 out. Voltage and current supported.

IC756SDV000J-98 DV Development - Solaris Op Sys, Japanese, Version 9.8

MicroLogix 1200 System 1762-RPLDIN2 REPLACEMENT DIN LATCHES FOR 1762 I/O

PLC-5/1771 System 1771-WB FIELD WIRING ARM, 12 TERMINALS, GOLD PLATED

Distributed I/O 1794-IF2XOF2I ISOLATED ANALOG COMBO MODULE

Communications 9399-WAB32LUGES RSLINX LITE USER GUIDE (SPANISH)

Support 6223-5VDLR SUPT REINSTATEMENT CONTRACT FOR 62235VDL

Support 9358-BPC10R SUPT REINSTATEMENT CONTRACT FOR 9358BPC10ENE

Support F1771-ILSERB FIRMWARE UPGRADE FOR 1771-IFE I/O MODULE

RSI Software Products 9324-RLD000PTE RSLOGIX 5000 SERVICE EDITION, PTG

RSI Software Products 9301-2SE350JPU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-HSTS2500U3 UPGRADE: IN-SUPT: HISTORIAN 1500 TO 70K TAG

Motion Control 8720SM-015S2ECS1 15 KW/48 AMP, 380 VAC, AC MOTOR WITH SRS60 ENC.

829-1-AC Thumbwheel Assembly. 1 Digit, AC Logic. Dust Seal

IC200MDL330 OUTPUT 120VAC 0.5A PER PT ISOLATED 16PT

IC697CMM799RR Replacement Part, MAP 30 Modem, Broadband, All Channels

MTR-1324-E-D-E-0RR Stepping Motor Nema34 Encoder

ExpressCard-8420/2

HSC-1462CLDN

UDIOCODES TRUNKPACK-100

ESX180

WY580-T4

NOVA MC8043P

MELEC 運(yùn)動(dòng)控制卡 C-871

1492-SPM3B100 MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40271BB04

電機(jī)啟動(dòng)器 3VU16403CR00

150-F60NBR SMC Flex Smart Motor Controller

1734-IA2 POINT I/O 2 Point Digital Input Module

1783-BMS10CL Stratix 5700 10 Port Managed Switch

193-EIOGP-22-240 E300/E200 240V AC Control Module

20-750-DB1-D2 PowerFlex 750 Frame 2 DB Resistor Kit

2090-CPWM7DF-10AF60 MP-Series 60 m Length Power Cable

2098-DSD-005X-NV1 Ultra 3000 Servo Drive

G-0001-A 6 Foot Gage Extension Cable

GFK-2079 PMC IDE Hard Disk Adapter User's Manual

IC220PWR003 POWER TERMINAL, FUSED W/DIAG 24VDC (REQUIRES 1 IC220TBK087)

IC647DNP000 DNP3 Master Protocol for Unlimited points

IC647ROC050M ROC:Fisher Remote Operations Controller for 250 Units

IC693MDL390RR 120/240 Vac Isolated Output, 2 Amp (5 Points)

IC756CNU001 Architecture Change/Addt'l User - Intel x86

MSI-PROD-UNL-43 Unltd Site Clients - Product Mang-43

PLC-5/1771 System 1771-SN SUB I/O SCANNER MODULE

Distributed I/O 1790-T8A0X LDX I/O, 110V AC, 8 INPUT EXPANSION, TERMINAL BLK

Communications 1785-TR10BF AUI TO F.OPTIC ENET TRANS

Operator Interface 2711E-NF3 FUNCTION KEY LEGEND INSERTS, PV1200 & PV1200E

Support 9305-RSVADDCJPR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADDCJP

Support 9324-RLD600S SUPT RENEWAL CONTRACT FOR 9324RLD600ENE

DeviceNet Products 9355-WABOEMENE RSLINX OEM - ENGLISH

RSI Software Products 9301-2SE3400ITU1 RSVIEW32 RUNTIME 1500-32K UPGRADE IN-SUPT (IT)

RSI Software Products 9371-RSWD2 RSWIRE DESIGNER/JIC PROFESSIONAL PACK

Motion Control 1326AB-B410J-M2L MOTOR,SERVO,460V,2.7NM,7250RPM,MULTI,IP67

2224 Greyline OS, 2 Line, (20) 5MM Chars, Backlit Supertwist LCD. ASCII /Serial Interface, NEMA 4

HE800ACC006 Cage-clamp (screw) style I/O plug, 6-terminal. (Qty 1). May be used as an alternative to the standard SmartStack plugs which are spring-clamp style.

IC693ACC302 High capacity battery pack. The new Auxiliary Battery Pack (IC693ACC302) will enable Series 90-30 & Series 90-70 CPUs (except CPU374) to go up to 75 months (shelf life of 10 years ) of RAM memory backup w/no power & the CPU374 backup=15 mo

QPK2D101S2P QUICKPANEL 6" STN COLOR WITH CE MARK

TGT-000A-2-0 Target series 2-axis motion control module

SCC-SG03

TAHOMA TECH 10118B

INTERFACE PCI 8521S

100-79-0810-00

SC I486

MK620-MCT01

1492-SPM1B400 MCB Supplementary Protector 40 A

直流電源 6EP1436-3BA00 3 相 400-500VAC 輸入，24VDC/20A 輸出

電機(jī)啟動(dòng)器 3VU13400MD00

1497D-A15-M21-0-22 GEN PURPOSE TRANSFORMER

1607-XT200D2A ArmorPower Dual 24VDC Output 91W PS

1769-OB16 CompactLogix 16 Pt 24VDC D/O Module

190S-AND2-CB25C-KN-V 1.6-2.5 A Compact Comb Starter W/Ckt-Bkr

194R-N30-1753-PBS1 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA09 MP-Series 9m Standard Cable

2090-XXTFMP-S05 MP-Series 5 m Length Feedback Cable

CBL-T7-MB-20 Power/brake cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 20 feet

GF-3022R Connecting FlashCable to Ametek Accuforce II Cadet.

IC200UDD240 VersaMax Micro 40 point PLC,(24) 24VDC In, (16) 24VDC Sink Outputs, 24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retention. Battery no

IC646TPR300 ProServer 300 I/O Point Runtime System

IC647PATABB0 Proficy PAT - Driver For Ethernet-Coupled Abb Bomem Ftir Spectrometers

IC693ALG442CA Conformal Coated Analog module, four in and two out.

IC752DSX000RR Datapanel 160 - 240x64 LCD display with LED backlight. Includes integ rated keypad for data entry. No touch capability. Various sizes of t ext, bitmaps, bar graphs, messaging. Supports limited PC/104 capabili ty.

IFIXONNODE100M iFIX Upgrade to On-Node 100 Tag Standard Edition Historian with Alarm & Event Option, M4 Key

SLC/1746 System 1746-BAS BASIC MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6186-M17SS VERSAVIEW 17 INCH MONITOR, TEMPERED GLASS

Application-specific products 1404-M505A-000 MASTER MODULE - PQ

Operator Interface 2711-T6C5L1 PV600 COLOR TOUCH, RS232 (DH485)

Support 9301-2SE3100JPS SUPT RENEWAL CONTRACT FOR 93012SE3100JP

Support 9380-RSBARR SUPT REINSTATEMENT CONTRACT FOR 9380RSBAR

DeviceNet Products 1734-TBSQ10 10 MODULES BASES W/ REMOVABLE IEC SPRING TERMINALS

RSI Software Products 9301-2SE3200U1R RSVIEW RUNTIME 150 TO 300 UPGRADE:OUT-OF-SUPPORT

RSI Software Products 9358-BPCNT60ENE RSBATCH PC-BASED PHASES 60 UNITS

Motion Control MPL-B4520P-RK24AA MOTOR,SERVO,6.1 NM,5000RPM,RSLVR,460V,BRK

Motion Control 2090-SCVG100-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,100.0M