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FP-DI-300,

FP-DI-300

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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
 

IC650AEL003RR Series Six Controller Board with Faceplate (MAP30) **

IC695ALG704 Analog Output Module, 4 channels,that is configurable for voltage and current, configured for Current: 0 to 20mA, 4 to 20mA; Voltage: +/- 10 VDC, 0 to 10VDC per channel non isolated. Up to 16 bit resolution. Requires high capacity terminal block IC

IC800SKCPZ050 Power cable to connect an S2K to any 30 - 750 Watt S-series servo motor. 5 meters

Pico Controllers 1760-L12AWA-NC 12 I/O PICO CONTROLLER, AC

PLC-5/1771 System 1771-AM1 1 SLOT I/O CHASSIS ASSEMBLY

Distributed I/O 1738-OV4EM12 24VDC 4 SINKING OUTPUTS WITH M12 CONNECTORS

Application-specific products 1404-M605B-232 MASTER MODULE - PQ 24V POWER SUPPLY 232 COM

Operator Interface 2711P-RTFC REPLACEMENT MOUNTING LEVERS, QTY 8, PVP400/600

Operator Interface 2706-PRIOP REMOTE I/O COMMUNICATION MODULE FOR 2706-P22R

Support 9701-VWSS000AS SUPT RENEWAL CONTRACT FOR 9701VWSS000AENE

Support 9324-RL0100FRR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100FR

EtherNet/IP Products 2711P-K15C4D1 PV PLUS 1500, KEYPAD, ENET, DC PS, STD MEM

RSI Software Products 9301-2SE340PTU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (PT)

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Motion Control F-4075-R-H00AA BRUSHLESS MOTOR/ENCODER

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IC693DSM302 Series 90-30 Motion Mate DSM302 Motion Controller, 2 Axis

TGT-S000-1-0 Target System Module

VDOCS-BSF Includes the following: (5) VisualDocs ShopFloor Seats (includes integ rated viewer) and (2) VisualDocs Administration Seats (includes integr ated viewer)

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140CRP93100 Quantum RIO 处理器接口, S908 Head, 单电缆，本地（总站）

285-BRC25-M12 Source Brake Cordset Cable

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Motion Control MPL-B640F-SJ24AA MOTOR,SERVO,36.0NM,3000RPM,SINGL,460V,BRK

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490NOR00005 Networks Ethernet MTRJ/MTRJ 5M Opt

284-MTRS22-M3 ArmorStart Spare Parts

C200H-SP001 占空单元

1492-RCDA4C40 Residual Current Device 40 A

6ES7153-2AR02-0XA0 IM153-2 冗余组，由 2 IM153-2 基本型和一个 IM153/IM153 总线模板组成

变送器 3RS11 40-1GW60

1497-K-AXSX-0-N Control Circuit Transformer

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GC647PSC200 "GlobalCare,####CIMPLICITY# Proficy##### 2000# I/O"

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IC647MX1C MX1:Leeds and Northrup Max1

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IC800SSI407RP2RR 7.2A, 480V, Profibus S2K Servo Controller for MTR Series Motors

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Support 9306-4PXP01R SUPT REINSTATEMENT CONTRACT FOR 93064PXP01ENE

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ControlNet Products 2711P-K7C15B2 PV PLUS 700, KEYPAD, CNET, AC PS, EXT MEM

RSI Software Products 9301-2SE2500U2R UPGRADE: OUT-SUPT: RSVIEW32 WORKS 1500 TO 100K

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FR-F740-S132K 198KVA 260A 132KW 3相AC380V/50Hz/60Hz

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1494G-EF3J6-98-412-414 NEMA 1494G Enclosed Disconnect

软启动器 3RW44432BC45

ET 200SP 6ES7134-6GB00-0BA1 AI 2xI 2/4 线制 标准型，基座单元类型 A0、A1

1585D-F4UB-5 1585D Ethernet Media Cordset

1756-A4 ControlLogix 4 Slots Chassis

1794-IF8IHNFXT Flex XT 8 Point Analog Input Module

194E-CA00E 194E Load switch

2080-LC50-48AWB Micro850 48 I/O EtherNet/IP Controller

2090-CSWM1DF-18AA15 Kinetix 15m Smartlink Single Cable

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GC646MRA700 Proficy GlobalCare Complete for View Runtime 700 I/O

HE693SNP940 Discontinued Part. Check with GE IP on migration path.

IC610MDL129RR 115Vac Input w/Removable Term. Block (16 points)

IC647HSTSS1250KM Historian Standard Server 1,250,000 Points (M4 Key)

IC660BBD101 Block 115Vac I/O Low Leakage 8 Circuits

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IC756WDS000CT-22 Dataviews Development Suite (All Windows Languages, Custom Editor Tool kit, Custom Datasource Toolkit, 1 yr SAFE), Traditional Chinese, Versi on 2.2

CompactLogix System 1769-IM12 12 POINT 240 VAC INPUT MODULE

PLC-5/1771 System 1770-XY AA LITHIUM BATTERY FOR ORIGINAL PLC-5 & PLC-2/05

Distributed I/O 1798-DFTP2 DEVICENET 18MM FIELD TERMINATION PLUG

Operator Interface 2711P-K6C5D PV PLUS 600 COLOR, KEYPAD, RS232, DC PS

Support 9323-S5300R SUPT REINSTATEMENT CONTRACT FOR 9323S5300

Support 9358-PBA60S SUPT RENEWAL CONTRACT FOR 9358PBA60ENE

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RSI Software Products 9324-RLDSFCE RSLOGIX 5000 SEQUENCIAL FUNCTION CHART OPTION

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1492-J35-B IEC 1-CKT FEED-THROUGH BLK

1492-SPM3D100-N MCB Supplementary Protector 10 A

软启动器 3RW40381BB05

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150-SPPB1BR SMC-50 POWER POLE ASSEMBLY 90A

1738-IA2M12AC4 ArmorPoint Input Module

1784-CP11 PLC-5 Communication Cable

193-KB32 2.3-3.2 A IEC Bimetallic Overload Relay

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GP647IFESGCLNTCDV GCP iFIX Optn: ESig & ERec iClient Dev

IC600BF831RR 10-50Vdc Input Module with Lights (32 points)

IC647HSTCCP100M Historian Client Connection Pack 100 Users (M4 Key)

IC647TDV935 CIMPLICITY HMI Server 35,000 I/O D&R System

IC693MDL940RR Relay Output, 2 Amp (16 Points)

IC756LDV001K-97 DV Development - Intel/Linux RedHat Addt'l User, Korean, Version 9.7

Pico Controllers 1760-STARTL12BWB PICO DC STARTER PAK

PLC-5/1771 System 1771-OVN LOW-TRUE OUTPUT MODULE, 32 OUTPUTS, 10-30V DC

Distributed I/O 1791-8BR BLOCK I/O, 24V DC, 16 POINT MODULE

Communications 1786-FS100 200 MICRON CABLE ASSEMBLY 100 METERS (328 .1 FT)

Operator Interface 9399-2SE32GRIT RSVIEW32 GETTING RESULTS GUIDE (ITALIAN)

Support 9356-PRO2100S SUPT RENEWAL CONTRACT FOR 9356PRO2100

Support 9324-RL0300ITR SUPT REINSTATEMENT CONTRACT FOR 9324RL0300IT

EtherNet/IP Products 1785-L20E ETHERNET/IP PLC-5/20 CONTROLLER, 16K WORD SRAM

RSI Software Products 9301-2SE3500ESU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9356-PRO2450U8 UPGRADE: IN-SUPT: RSSQL PROF.5000 TO 32000 TAGS

Motion Control N-2304-1-F00AA MOTOR,NEMA 23,4 LB-IN,6000 RPM

44A730464-G18 Connector Kit, B2, B6 & A6 Motor Power

IC200ALG321 ANALOG OUTPUT 12 BIT VOLTAGE 0-10V 4CH

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

Silver Series 2711E-T14C6 PANELVIEW 1400E TOUCHSCREEN TERMINAL 14" COLOR CRT

VMEM-SVR VisualMEM Admin Bundle, core components.

20BD022A3AYNAND0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FD011AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D072A103 PowerFlex 400- 37 kW (50 HP) AC Drive

ASMBII004 Quantum DROP CBL 140FT

285-BRCF25-M10 ArmorConnect Brake and Motor Cable

E6A2-CW3C 5-12VDC,集电极开路输出30VDC 30mA,2相,100P/R,200P/R

1492-SPM1D400-N MCB Supplementary Protector 40 A

变频器选件 6SE6 400-0BP00-0AA0 BOP 操作面板 420/440

电机启动器 3VU16400MG00

150-C9NCD SMC-3 9A Smart Motor Controller

170-PW85 Bulletin 100-C Accessory

1771-IQ16 1771 16 Point Digital Input Module

193-EC3ZZ E3 Plus 9-5000 A Overload Relay

198-TD1 IEC Control Circuit Enclosure Accessory

2090-CPWM4DF-16AF02 MP-Series 2 m Length Power Cable