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近幾年，隨著我廠生產規模的逐步擴大，就更加要求氣體調節在生產中的穩定性和快速性，而目前傳統的二次儀表已無法滿足現有的控制需求。主要表現在：

　　1)過程自動化程度低，信息采集和反饋仍采用傳統的二次儀表，致使數據采集緩慢、調節滯后，降低了系統運行的穩定性。

　　2)儀表內部信息儲存量小，采集的壓力、流量等數據無法長期保存，不便于日后生產工作的歷史查詢和分析。

　　3)系統可靠性低，需要配專人負責該系統的運行，造成了人工成本的上升。

　　鑒于以上三點，通過采用PLC(可編程控制器)控制系統，解決當前存在的問題。

　　1、PLC控制系統的特點及組成

　　PLC在現代工業控制領域中早己得到了廣泛的應用。以PLC的控制功能而言，具有嚴謹、方便、易編程、易安裝、可靠性高等優點。它通用性強，適應面廣，特別在數字量輸入/輸出等邏輯控制領域有無可比擬的優點。PLC具有豐富的邏輯控制指令和應用指令，它提供高質量的硬件、高水平的系統軟件平臺和易學易編程的應用軟件平臺。另外，PLC即有自身的網絡體系又有開放I/0及通訊接口，很容易組建網絡并實現遠程訪問。

　　PLC采用Siemens公司生產的S7-300系列，由于現場的PLC系統與主控室的上位機距離較遠(800米左右)，因此通訊系統需成對加裝RS-485中繼器，另外在現場增加TP27-10//觸摸屏進行數據顯示，確保系統運行的穩定性。

　　1.1系統結構及硬件配置

　　根據控制需求，CPU模塊采用CPU314、數字量輸入(DI)采用SM321模塊，數字量輸出(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實現機架擴展，上位監控機采用SIEMENS公司CP5611網卡完成計算機與PLC之間的數據通訊。整個通訊網絡采用MPI的通訊協議，從上位機上可對整個氣體調節過程進行監控和操作。

　　1.2控制系統的功能實現

　　PLC程序的編制直接關系著供氣系統能否正常工作，而程序設計的關鍵在于編程者對工藝系統的理解程度和程序編制技術的靈活應用。因此，在程序設計中首先考慮了供氣壓力調節系統的特點，將程序設計細化，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，便于現場對工藝的調整，又可針對配套設備可控性對不同程序模塊進行完善。

　　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、地址和站址的分配以及編制整個生產過程的控制程序的。上位機監控軟件采用國產軟件組態王，全部采用漢化界面，便于系統的開發與操作，該系統運行于Windows2000中文平臺，可實現對生產過程的全面監控，對重要參數形成歷史記錄，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顯示重要參數的歷史趨勢、實時趨勢，實現壓力調節的手自動切換、操作、壓力的高、低限報警、流量數據的顯示與累計，滿足高生產率的調度需求。

　　1.3現場顯示

　　現場采用TP27觸摸屏進行參數顯示、控制，觸摸屏程序由組態軟件來完成，人機界面采用中文菜單，界面友好，操作方便，功能較強，主要用于現場壓力、流量、閥位的顯示與操作。可作為操作人員現場操作的依據。

　　1.4工控機配置

　　工控機采用研華IPC-610，通過CP5611卡，完成S7-300PLC與工控機的通訊。主要完成下列任務：傳送現場監控數據;運行監控;故障記錄和排除提示;參數設置;生產數據管理和處理;圖形化示教和離線編程。

　　2系統實現了供氣系統的自動控制和監控，主要包括如下功能：

　　1)靈活的操作方式以及強大的系統控制功能：

　　系統可以實現上位機操作、控制柜觸摸屏操作和就地手動操作;

　　2)報警功能：

　　當壓力超過工藝要求，可在現場、就地實現高、低限壓力報警;

　　3)簡單、方便的參數設定：

　　壓力調節閥的壓力設定值、P、I、D等參數可以在上位機中設定。

　　2、系統控制功能

　　(1)過程控制的功能：

　　1)系統對供氣壓力實現了PID自動調節控制;

　　2)對所采集的模擬信號進行線性化、濾波、工程單位轉換處理;

　　3)實現了流量信號的溫、壓補償，提高了儀表的測量精度。

　　(2)邏輯控制

　　聯鎖邏輯控制實現開/關的控制，邏輯控制及用戶自定義功能塊等。系統實現了電磁閥控制以及參數越限報警等功能。

　　(3)人機接口

　　HMI系統中包含主工藝畫面，各系統送氣壓力、流量，供氣壓力調節等多幅畫面，畫面直觀、豐富，具備PID在線調節、在線顯示調節曲線功能，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，調節間數據報表。實時趨勢曲線和歷史趨勢曲線可隨意設定時間段，打印在線趨勢，歷史趨勢曲線。

　　3、軟件設計

　　根據該系統具體情況，PLC系統軟件設計過程中著重要考慮的是以下幾個方面：

　　(1)數據采集及工程量轉換

　　(2)PID算法

　　(3)流量溫壓補償計算以及流量的累積計算

　　對于系統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償計算以及流量的累積計算部分則采用語句表(STL)編程，結構緊湊而又靈活。

　　PID調節是該系統中zui為重要的控制程序，因此特將PID算法作一重點介紹
 

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194E-CA20-P11 194E Load switch

2080-OB4 Micro800 4 Point Source Output

2090-CSWM1DF-18AA25 Kinetix 25m Smartlink Single Cable

20AC5P0A0NYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MRC000 Proficy GlobalCare Complete for Logic PC & View Runtime 8,000 I/O

HE693STP110 Discontinued Part. Check with GE IP on migration path.

IC610MDL182RR Relay Output w/Removable Term. Block, w/LEDs (16 points)

IC647HSTSS1KM Historian Standard Server 1000 Points (M4 Key)

IC660BBR100RR Relay Block, Normally Closed

IC695ALG306 Isolated Thermocouple Input module provides six isolated differential thermocouple input channels. Each channel can be individually configured for inputs from: Thermocouple types: J, K, T, E, R, S, B, N, or C and Voltage: +/-150mV or +/-50mV. Module

IC756WDS000J-23 Dataviews Development Suite (All Windows Languages, Custom Editor Tool kit, Custom Datasource Toolkit, 1 yr SAFE), Japanese, Version 2.3

CompactLogix System 1769-OB16 16 POINT 24 VDC SOURCING OUTPUT MODULE

PLC-5/1771 System 1771-XB MODULE GROUP 1 SET OF 8 LABELS, FOR 8,16,32,PT I/O

Distributed I/O 1799-COV32 CLEAR PLASTIC COVER; 4 STAND-OFFS/SCREWS (32PT)

Operator Interface 2711P-K6M3A PV PLUS 600 GRAYSCALE, KEYPAD, DH485, AC PS

Support 9325-L3140S SUPT RENEWAL CONTRACT FOR 9325L3140

Support 9358-PBBK60R SUPT REINSTATEMENT CONTRACT FOR 9358PBBK60ENE

Support F1775-S4BSERA FIRMWARE UPGRADE FOR 1775-S4B PLC3 PROCESSOR MODUL

RSI Software Products 1789-L60 SOFTLOGIX5860 CONTROLLER W/16 SLOT VIRTUAL CHASSIS

RSI Software Products 9701-VWMR030AENE RSVIEW ME STATION RUNTIME 30 DISPLAY

RSI Software Products 9330-GC300U2R UPGRADE: OUT-SUPT: RSGUARDIAN CORE 24 TO 4096 NODE

Motion Control 2094-XNINV-1 230/460V INVERTER CONNECTORS UP TO 15A

A06B-6093-K001 Replacement Battery, Beta Series Amplifiers

IC200UEX212 28 point expansion. (16) 24VDC In, (12) Relay Out, 24VDC Power Supply (included IC200CBL501)

IC752COM102 Omron 25 pin cable for DataPanel 30/50

MTR-3N32-G-R-B-N-SRR Servo Motor Nema34 24V Brake, Seal

ZA06B-0158-B075#7008 A40/2000 servo motor with fan package and 64k serial encoder

20BD8P0A0NYYANC0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14NC367AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-A4P8 PowerFlex 520 0.75kW (1Hp) Power Module

TLXCDLUOFS33 Quantum LARGE OPC SOFTWARE

FRN1.5C1S-4C 2. 8KVA 3.7A 1.5KW 3相AC380V/50Hz/60Hz

1492-J4-B 4 square mm Feed-Through Terminal Block

1492-SPM3D200 MCB Supplementary Protector 20 A

軟啟動器 3RW40552BB35

SIMATIC HMI 系列面板 6AV2124-0XC02-0AX0 TP2200 精智 21.5 寸

150-SPPB4UR SMC-50 POWER POLE ASSEMBLY 180A

1738-IE2VM12 ArmorPoint 2 Point Input Module

1784-PCICS ControlNet PCI PC Comms Scanner Card

193-NCEC5CNT E3 Plus Replacement Connector

20-750-PNET PowerFlex 750 PROFINET IO Kit

2090-CSBM1DE-14AA01 Kinetix Cable Single DSL 2090-Series

20AB4P2A0AYNNNG0 PowerFlex 70 AC Drive 4.2 A at 1 Hp 20A

GA647IFPRDV00300 GCA iFIX Profsnl SCADA 300 I/O Dev

GP647IFESGDVUNLMT GCP iFIX Optn: ESig & ERec Unl I/O Dev

IC600BF902RR 24Vdc Sink Output Module (8 points)

IC647HSTCR10000KM Collector Redundancy Option for Historian - Standard Server 10,000,000 Points (M4 Key)