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PK225PA,

PK225PA

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近几年，随着我厂生产规模的逐步扩大，就更加要求气体调节在生产中的稳定性和快速性，而目前传统的二次仪表已无法满足现有的控制需求。主要表现在：

　　1)过程自动化程度低，信息采集和反馈仍采用传统的二次仪表，致使数据采集缓慢、调节滞后，降低了系统运行的稳定性。

　　2)仪表内部信息储存量小，采集的压力、流量等数据无法长期保存，不便于日后生产工作的历史查询和分析。

　　3)系统可靠性低，需要配专人负责该系统的运行，造成了人工成本的上升。

　　鉴于以上三点，通过采用PLC(可编程控制器)控制系统，解决当前存在的问题。

　　1、PLC控制系统的特点及组成

　　PLC在现代工业控制领域中早己得到了广泛的应用。以PLC的控制功能而言，具有严谨、方便、易编程、易安装、可靠性高等优点。它通用性强，适应面广，特别在数字量输入/输出等逻辑控制领域有无可比拟的优点。PLC具有丰富的逻辑控制指令和应用指令，它提供高质量的硬件、高水平的系统软件平台和易学易编程的应用软件平台。另外，PLC即有自身的网络体系又有开放I/0及通讯接口，很容易组建网络并实现远程访问。

　　PLC采用Siemens公司生产的S7-300系列，由于现场的PLC系统与主控室的上位机距离较远(800米左右)，因此通讯系统需成对加装RS-485中继器，另外在现场增加TP27-10//触摸屏进行数据显示，确保系统运行的稳定性。

　　1.1系统结构及硬件配置

　　根据控制需求，CPU模块采用CPU314、数字量输入(DI)采用SM321模块，数字量输出(DO)采用SM322模块，模拟量输入(AI)采用SM331模块，模拟量输出(AO)采用SM332模块以及IM365等模块组成，IM365实现机架扩展，上位监控机采用SIEMENS公司CP5611网卡完成计算机与PLC之间的数据通讯。整个通讯网络采用MPI的通讯协议，从上位机上可对整个气体调节过程进行监控和操作。

　　1.2控制系统的功能实现

　　PLC程序的编制直接关系着供气系统能否正常工作，而程序设计的关键在于编程者对工艺系统的理解程度和程序编制技术的灵活应用。因此，在程序设计中首先考虑了供气压力调节系统的特点，将程序设计细化，分成多个程序模块，实行模块化编程。这样既可以方便的增加或删除程序模块，便于现场对工艺的调整，又可针对配套设备可控性对不同程序模块进行完善。

　　PLC的编程软件采用SIEMENS公司的SIMATICSTEP7V5.1软件平台用来完成硬件组态、地址和站址的分配以及编制整个生产过程的控制程序的。上位机监控软件采用国产软件组态王，全部采用汉化界面，便于系统的开发与操作，该系统运行于Windows2000中文平台，可实现对生产过程的全面监控，对重要参数形成历史记录，以报表或曲线的形式显示给操作人员。通过VB语言脚本，可以在主控室的上位机显示重要参数的历史趋势、实时趋势，实现压力调节的手自动切换、操作、压力的高、低限报警、流量数据的显示与累计，满足高生产率的调度需求。

　　1.3现场显示

　　现场采用TP27触摸屏进行参数显示、控制，触摸屏程序由组态软件来完成，人机界面采用中文菜单，界面友好，操作方便，功能较强，主要用于现场压力、流量、阀位的显示与操作。可作为操作人员现场操作的依据。

　　1.4工控机配置

　　工控机采用研华IPC-610，通过CP5611卡，完成S7-300PLC与工控机的通讯。主要完成下列任务：传送现场监控数据;运行监控;故障记录和排除提示;参数设置;生产数据管理和处理;图形化示教和离线编程。

　　2系统实现了供气系统的自动控制和监控，主要包括如下功能：

　　1)灵活的操作方式以及强大的系统控制功能：

　　系统可以实现上位机操作、控制柜触摸屏操作和就地手动操作;

　　2)报警功能：

　　当压力超过工艺要求，可在现场、就地实现高、低限压力报警;

　　3)简单、方便的参数设定：

　　压力调节阀的压力设定值、P、I、D等参数可以在上位机中设定。

　　2、系统控制功能

　　(1)过程控制的功能：

　　1)系统对供气压力实现了PID自动调节控制;

　　2)对所采集的模拟信号进行线性化、滤波、工程单位转换处理;

　　3)实现了流量信号的温、压补偿，提高了仪表的测量精度。

　　(2)逻辑控制

　　联锁逻辑控制实现开/关的控制，逻辑控制及用户自定义功能块等。系统实现了电磁阀控制以及参数越限报警等功能。

　　(3)人机接口

　　HMI系统中包含主工艺画面，各系统送气压力、流量，供气压力调节等多幅画面，画面直观、丰富，具备PID在线调节、在线显示调节曲线功能，包括过程量变化趋势的实时趋势曲线、历史趋势曲线。

　　(4)报表打印

　　以报表形式绘制报警记录、历史记录画面，调节间数据报表。实时趋势曲线和历史趋势曲线可随意设定时间段，打印在线趋势，历史趋势曲线。

　　3、软件设计

　　根据该系统具体情况，PLC系统软件设计过程中着重要考虑的是以下几个方面：

　　(1)数据采集及工程量转换

　　(2)PID算法

　　(3)流量温压补偿计算以及流量的累积计算

　　对于系统中的逻辑控制选用梯形图(LADDER)编程，直观、方便;对于PID回路控制流量温压补偿计算以及流量的累积计算部分则采用语句表(STL)编程，结构紧凑而又灵活。

　　PID调节是该系统中zui为重要的控制程序，因此特将PID算法作一重点介绍
 

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GFK-1534 Manual VersaMax Profibus-DP Network Communications

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2090-XXNPMP-16S25 MP-Series 25 m Length Power Cable

CBL-30-JP-06 AC power cord with 3-prong plug to flying lead. 6 feet

GF-0205 Connecting FlashCable to Fowler Maxcal / Digitrix.

IC200TBX214 Tool box, 14 point, (IC200UDR001) 24VDC In/Relay Out, AC powered (requires AC power), VersaMax SE (IC200SET001) with all software, cables and manuals. (IC640VPS002 and IC646MPM001)

IC646TBSPMPS700 Smart Process Monitoring Process+ server 700 loops

IC647NSJ000 Siemens MPI OPC Server

IC693ACC333 TBQC Base for IC693MDL340

IC752CAB202 AB Micrologix cable for DataPanel 150/160/240

IC800VMCP1100 Power cable for 1 kW VersaMotion servo motor- 10 meter

SLC/1746 System 1746-OX8 (8) ISOLATED RELAY OUTPUT - 5-250V AC, 5-125V DC

Industrial Computers 6189V-ACPSWS AC POWER SUPPLY ATX STANDARD (6180W WORKSTATION)

Application-specific products 1400-SP LOCAL DISPLAY POWERMONITOR SOFTWARE

Operator Interface 2711-B6C3L1 PV600 COLOR KEY&TOUCH, DH485 & RS232 PRINT

Support 9301-2SE2400ESS SUPT RENEWAL CONTRACT FOR 93012SE2400ES

Support 9307-EMCHTR SUPT REINSTATEMENT CONTRACT FOR 9307EMCHTENE

DeviceNet Products 1734-IB4 24V DC 4 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE250ZHU3R RSVIEW32 WORKS 300-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BNT60U3R UPGRADE: OUT-SUPT: RSBATCH 30 TO 60

Motion Control MPL-B330P-RJ24AA MOTOR,SERVO,4.18 NM,5000RPM,RSLVR,460V,BRK,6.8KG

Motion Control 2090-U3BK-D4403 BREAKOUT BOARD KIT,CONTROL,CN1,ULTRA 3000,3M

GFK-0712 Series 90 Digital Event Recorder User's Manual

IC646CXV000 X11Viewer Option for Windows 95 and Windows NT-Intel

MSCPX-312806W2 Marathon Exp CPU,566 MHz CPU, 128M, 6G, Win 2000, 2 PCI/ISA, 1 PCI, 1 ISA

PSPC-DC50/E-220L Prof Shop Floor SPC DC 50 User eSig 220v

20BC015A3AYNACC1 PowerFlex 700 AC Drive 20B

20F11FC085JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-IOSP CONKIT,K5500,I/O,SPRING TRM

2711P-RBK7 PanelView Plus Accessory

280-PWRM35H-M8 ArmorStart Three-Phase Power Media

CQM1-OC221 输出 8点.继电器 250V AC/24V DC 2A

1492-N37 TERM BLCK End Barrier

回路闭环控制模块 6ES7355-1VH10-0AE0 FM355S，4 回路闭环控制模块，8DI/8DO，4AI，2个 20pin 前连接器

行程开关 3SE53223SF23

TIA 博途 WinCC 选件 6AV2107-2KH00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 10 -> 25 Clients

1585J-M8HBJM-6 RJ45 Ethernet Media

1760-L12AWA Pico 12 Point AC Controller

188-K2C010 Miniature Circuit Breaker 1 A

194L-A16-1751 16 A 194L Load Switch

2090-CHBP8S8-12AA20 Kinetix 6000M IDM hybrid cable

2090-UXTBMP-18S15 MP-Series 15 m Length Brake Cable

BC647MPPU01 Logic Developer PLC Professional Upgrade with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTDV00150 GCC iFIX Std HMI 150 I/O Dev