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CR03302,

CR03302

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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
 

110-0002-04 415-0004-03-A

Alitronika AT2780 DVB-T/H/C

ARCNET AN-520BT

Ablecom PWS-0044-M

HPU4800ADA-100

COMI-LX504

1492-SPM3C040-N MCB Supplementary Protector 4 A

软启动器 3RW44366BC36

6ES78105CC000YM2

1497D-A12-M22-0-2 GEN PURPOSE TRANSFORMER

1606-XLSBUFFER48 Power Supply 48V DC Buffer Module

1769-L30ER CompactLogix 1 MB ENet Controller

190E-ANEJ1-CB25C 1.6-2.5 A Economy Starter W/Ckt-Bkr

194R-J60-1753S-PYN2 194R Disconnect Switch

2090-CPBM7DF-14AF20 MP-Series 20m Continuous-Flex Cable

2090-XXNPT-16S15 TL-Series 15 m Length Power Cable

CBL-3T-RD-10 Resolver cable for MTR-3T series servo motors. 10 feet

GF-0912RS-15/FOW Connecting FlashCable to Fowler Sylvac, Metronics, Mettler, Omega, Tol edo (FOW) - 15 ft.

IC200UAR014-24 Qty of 24, 14 point PLC, (8) 120VAC In, (6) Relay Out (2 at 10 amp & 4 at 2 amp), 120V/240VAC Power Supply

IC646TDV915 1500 I/O Point Development System

IC647NXV000 Proficy Tracker Order Execution Management Display

IC693ALG223LT Analog Input, Current, 16 Single Channels (LT)

IC752DDZ000 New DataDesigner editor, supports DataPanels 20, 30, 40, 50, 60, 85, 1 50, 160 and 240

IC800VMM20MBKSE25 2 kW VersaMotion medium inertia servo motor with 24 VDC holding brake (9.55 Nm)

SLC/1746 System 1746-QV OPEN LOOP VELOCITY CONTROL MODULE

Industrial Computers 6189V-SLCDRW CD DRIVE WRITEABLE (SLIM)

Application-specific products 1403-NSC COMMUNICATION MODULE FOR POWERMONITOR

Operator Interface 2711-K6C5L1 PV600 COLOR KEY, RS232 (DH485)

Support 9301-2SE2500R SUPT REINSTATEMENT CONTRACT FOR 93012SE2500

Support 9380-RSB500S SUPT RENEWAL CONTRACT FOR 9380RSB500

DeviceNet Products 1734-SSI SSI ABSOLUTE ENCODER INTERFACE

RSI Software Products 9301-2SE3200ESE RSVIEW32 RUNTIME 300 (SPANISH)

RSI Software Products 9358-BPC60U2 UPGRADE: IN-SUPT: RSBIZWARE PC PHASES 10 TO 60

Motion Control MPL-B430P-RK22AA MOTOR,SERVO,6.55 NM,5000RPM,RSLVR,460V

Motion Control 2090-SCEP5-0 SERCOS FBR CABL,CONN,ENCLOSURE ONLY PLASTIC,5.0M

GFK-1186 TCP/IP Ethernet Communications for the Series 90-30 PLC Station Manager Manual

IC646MDD075 Logic Developer PC (HRT) 75 Tag Runtime & Development System

MSP-RTD-IN1 Obsolete - 100W PT (-200 to 850C) in / Pulse out

QPI-COS-201 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: CANopen

PXIe-4082

PCI-7250

TC-PCIC01

ACE-832AP-RS

PM-1033

CBP-3064

1492-PD31123 380 A Power Distribution Block

中央机架 6ES7403-1TA01-0AA0 ER1 机架，18 槽，只能插信号模板

变送器 3RS17051FD00

TIA 博途数字化选件 6ES7823-0AA00-1AA0 SIMATIC ProDiag S7-1500 for 250 Supervisions

1585J-M8PBJM-5X 1585J Ethernet Media Cables

1760-MM2B Pico 12 or 18 Point Memory Module

188-K2D200 Miniature Circuit Breaker 20 A

194L-E12-3262 12A 194L Load Switch

2090-CNSSPSS-AA07 Kinetix 6000M network cable

2090-XXLF-TC3200 Kinetix Drives Line Filter

BC647OEM0111B OEM Edge Renewal Add't Key - iFIX

GC647IPWRSTRNUNLMTM iPower Option - Std Unlmt I/O Run Globalcare Complete part

IC200ERM001CA EXPANSION RECEIVER ISOLATED CONFORMAL COATED

IC646NGS000 Sharp TCP/IP Communications

IC647IPCC IPC:Honeywell IPC 620

IC670MDL643RR 5/12Vdc Pos/Neg Logic Input 16 pt. Grouped

IC697MDL341RR 120/240 Vac Isolated Output, 2 Amp (12 Points)

IC800SLCIZ010 Interface cable to connect any 30 Watt to 750 Watt SL series amplifier to terminal block. 1 meter

ControlLogix/1756 System 1756-DHRIO DH+/RIO BRIDGE/SCANNER MODULE

Industrial Computers 6182H-12TEH4B VVCE 1250, TOUCH, EXT MEM, ENET, AC

Process Control 1757-PFBUL100 PROFIBUS INTERFACE MODULE USAGE LICENSE

Operator Interface 2711P-RVAC REPLACMENT AC POWER TERMINAL BLOCK, QTY 10

Support 9357-DNETMDAD3S SUPT RENEWAL CONTRACT FOR 9357DNETMDAD3E

Support 9363-MAILMANR SUPT REINSTATEMENT CONTRACT FOR 9363MAILMAN

ControlNet Products 1734-232ASC POINT I/O RS232 ASCII INTERFACE

RSI Software Products 9301-2SE2403KOE RSVIEW32 WORKS 32K WITH RSLINX (KOREAN)

RSI Software Products 9358-B10U1 UPGRADE: IN-SUPT: RSBIZWARE BATCH 03 TO 10

Motion Control MPL-A430H-MJ24AA MOTOR,SERVO,6.55 NM,3500RPM,MULTI,230V,BRK,8.2KG

Motion Control 2090-UXNFBN-S30 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,N,30M

CBL-149 Cable.SIMATIC T.I. 535 Port 2 (RS-232)

IC610MDL111RR 24Vac/dc Source Input (8 points)

IC800SLA0752 750W, 230 VAC SL Servo Amplifier

OC647IFGLBLCLN020M-50 iFIX WebSpace 20 Additional Users (M4 key)

PXI-2544

W26361-W10-Z2-02-36

Hivertec HPCI-CPD534A

PCI-1756

FI-RBXAT-PEL02Z/4 FI-RBXAT-PEL02/3

PCI-9016

1492-MCAA220 20 A UL489 Miniature Circuit Breaker

1494U-LA36 1494U 30A-60A Aluminum Lugs

软启动器 3RW44552BC45

Safety Advanced V14 6ES7833-1FA14-0YK5 STEP 7 Safety Adv. V14 SP1 Upgrade SW DL

1585D-M4UBDM-5 Micro D-Code, QD Style Ethernet Media

1756-IT6I ControlLogix 6 Pt Isolated TC In Module

1797-OE8H FlexEx 8 Point Analog Output Module

194E-E40-3753 40 A 194E Load switch

2090-CFBM6DD-CCAA04 TL-Series 4m Feedback Cable

2090-SCEP0-2 Kinetix 0.2-0.2m Fiber Optic Cable

BC646MDA300 View Development/Runtime 300 I/O with Proficy GlobalCare Complete

GC647ADC001 GC PA Dashboard Client

HMI-CAB-C49 DOWNLOAD CABLE PROG TTL TO RS232

IC641SWP058 Windows 95/NT Host Drivers Tool Kit (SNP, Ethernet SRTP, EGD consume o nly)

IC647IFCLNTSRO001M iFIX iClientTS Read Only 1 PK (M4 Part)

IC660EBA105RR Current Source Analog Output, 115Vac/125Vdc Power, Elec Asm

IC695PSA140CA RX3i Conformal Coated 120/240VAC, 125VDC Multipurpose Power Supply is suitable for use in load-sharing and redundancy application.

IC756WRE099E-22 DataViews Runtime for Windows 50-99, Per User, English, Version 2.2

FlexLogix System 1794-OA8I 85-132V AC OUTPUT MODULE (ISOLATED), 8 POINT

PLC-5/1771 System D1785-6.5.13 PLC-5 PROTECTED PROCESSORS SUPPLEMENT MANUAL

Process Control 1757-PLXSIFR PLX HITACHI QUICKBUILDER INTERFACE

Operator Interface 2711P-K10C15B2 PV PLUS 1000, KEYPAD, CNET, AC PS, EXT MEM

Support 9310-WE5200R SUPT REINSTATEMENT CONTRACT FOR 9310WE5200

Support 2706-MB1S SUPT RENEWAL CONTRACT FOR 2706MB1

Support F1785-L40C15SERC FIRMWARE UPGRADE FOR 1785-L40C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE2300PTU1 RSVIEW32 WORKS 300-1500 UPGRADE IN-SUPT (PT)

RSI Software Products 9701-VWSCRAFRE RSVIEW SE VIEW CLIENT (FRENCH)

RSI Software Products 9399-PRTLUG RSPORTAL USER'S GUIDE

Motion Control 2098-DSD-HV150-SE HIGH VOLTAGE DRIVE, 34A/68A, ULTRA3000 W/SERCOS

BC646MDC150 Logic Developer - PC & View Development/Runtime 150 I/O

IC300MIX912 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc,0.5A pos. logic with ESCP) and 4 ISOLATED (500V) channels Analog Inputs, current (0-20ma, 4-20ma), 12 bit; 2 channels ISOLATED (500V) Analog Outputs, current (4-20ma)

IC752SKT005RR Datapanel 320T MEG Starter Kit: Includes Datapanel 320T Mono Expansion with 2 MB & Genius (CBT020), download & communication cables, WinCfg, user & programming manuals

MTR-3S88-G-R-0-E-SRR Servo Motor with Seal

PCI-6035E

Am5X86-P75-S

IPC-610H PCA-6006

ASUS华硕P5E64

LMB-868

BANDIT-VGA XR-M130-18500

1492-L10 IEC Term Blck 10x73.5x43.5mm Spr Clp

1492-XIM2024-16R Connection Products

软启动器 3RW44243BC44

通信模块 6GK7 543-1AX00-0XE0 CP 1543-1：RJ45，工业以太网 通讯模块

1585-C8CB-S600 Cable Spool Ethernet Media

1746-P1 SLC Rack Mounting Power Supply

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 运动控制卡 C-871

1492-SPM3B100 MCB Supplementary Protector 10 A

软启动器 3RW40271BB04

电机启动器 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

直流电源 6EP1436-3BA00 3 相 400-500VAC 输入，24VDC/20A 输出

电机启动器 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

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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

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