连续挤压生产线计算机监控系统的研究
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摘要
可编程序控制器(PLC)以其高可靠性，高稳定性，编程简单，易于使用，广泛应用于现代工业企业生产线过程控制中。但PLC没能给操作者提供动态的生产线状态参数显示和报表输出，而工业控制计算机有着十分丰富的商品软件支持，可以开发出用户直观方便的图形操作界面。工控机与可编程控制器联合使用已经成为当前工业自动化发展的方向和趋势之一。
TLJ300铜连续挤压生产线是我校联杰科贸公司自行研制生产的连续挤压成套设备，在国内处领先地位，但与国外的同类设备相比，在设备的自动化水平上还存在着一定差距。主要体现在庞大的控制台，开关、按钮繁多，接线复杂。另外，设备挤压腔温度及挤压轮转速的控制完全靠工人凭经验手动调节，控制误差大，精度低。为了进一步提高劳动生产率和设备的自动化水平，降低劳动强度，研制了连续挤压生产线自动监控系统。
本文提出一种用工控机和可编程控制器对连续挤压生产线进行联合监控的方法。该系统是对生产线原控制系统的改进，其采用工业控制计算机作为上位机，组态软件作为用户可以定制功能的软件平台，对整个生产线进行实时监控以及状态参数的显示。采用控制功能稳定可靠的可编程控制器作为下位机，对生产线各信号进行采集、具体执行上位机命令，并对生产线进行顺序逻辑控制，以及挤压温度的实时控制等。
经过改进后的控制系统，实时控制作用由稳定可靠的PLC不依赖于上位机独立完成。在控制算法的选择上，由于温度的控制具有非线性、时变及滞后等特点，难以建立精确的数学模型，通过分析和比较各种控制算法，选用模糊控制作为本系统的控制算法，模拟人工完成对挤压温度的实时控制。
系统仿真与调试结果表明：整个计算机监测系统运行稳定可靠，温度模糊控制器控制效果良好，具有较强的鲁棒性。整个计算机监控系统满足了预先制定的监控要求。
The Programmable Logic Controller ( PLC ), owing to its high reliability, high stability , and easiness in programming and using, has been extensively used in the process control system of production line in the modern industry enterprises. But the PLC cann't provide the user with the dynamic display of production line's state messages or the output of the report forms, however utilizing the industrial computer( EPC ) , the users can develop convenience graphical interfaces, with the support of numerous software. Nowadays, it has already become one of the directions that combining PLC with IPC to the development of industry automation.
The TLJ300 copper Continuous Extrusion Forming (CONFORM) production line made in our college has achieved the lead position in domestic similar equipment. But when it compared with the similar product made in abroad, the technology gap still exists in automatic control system, which mainly include the large control panel, the great plenty of switchs and the complexity of wire connection. Otherwise, the controlling of the extrusion cavity's temperature and the extrusion wheel's rotate velocity is completely depended on the workers' experience, which result in the big errors and low precision. In order to further increase the efficiency and to enhance the grade of the automatic control system , the CONFORM production line's computer supervisory control system is developed.
In this paper, an integrate method of supervising and controlling the CONFORM production line which uses PLC and IPC is introduced. This system is the improvement of it's original control system, which uses IPC as the upper computer and uses the configuration software as the users' customization operation flat in which the line's real-time control and the state display is performed. As the reliability and stability of the PLC, it is used to acquire data, execute the upper computer's commands, perform the logic control and the real-time control of the extrusion cavity's temperature etc.
After reform, the control functions are executed only by the PLC itself and independent of the upper computer. As far as the control method is concerned, the fuzzy control is chosened to simulate the manual work, because the temperature has the non-linear, inertia and hysteresis characters, which lead to the difficulty of establishing an accurate math model.
The results of system simulation and debugging show that the computer supervision system runs steadily and reliably, also, the performance of the temperature fuzzy control system is excellent, which has a better robust capability. The whole computer supervisory control system has met the anticipative requirements.
TLJ300铜连续挤压生产线是我校联杰科贸公司自行研制生产的连续挤压成套设备，在国内处领先地位，但与国外的同类设备相比，在设备的自动化水平上还存在着一定差距。主要体现在庞大的控制台，开关、按钮繁多，接线复杂。另外，设备挤压腔温度及挤压轮转速的控制完全靠工人凭经验手动调节，控制误差大，精度低。为了进一步提高劳动生产率和设备的自动化水平，降低劳动强度，研制了连续挤压生产线自动监控系统。
本文提出一种用工控机和可编程控制器对连续挤压生产线进行联合监控的方法。该系统是对生产线原控制系统的改进，其采用工业控制计算机作为上位机，组态软件作为用户可以定制功能的软件平台，对整个生产线进行实时监控以及状态参数的显示。采用控制功能稳定可靠的可编程控制器作为下位机，对生产线各信号进行采集、具体执行上位机命令，并对生产线进行顺序逻辑控制，以及挤压温度的实时控制等。
经过改进后的控制系统，实时控制作用由稳定可靠的PLC不依赖于上位机独立完成。在控制算法的选择上，由于温度的控制具有非线性、时变及滞后等特点，难以建立精确的数学模型，通过分析和比较各种控制算法，选用模糊控制作为本系统的控制算法，模拟人工完成对挤压温度的实时控制。
系统仿真与调试结果表明：整个计算机监测系统运行稳定可靠，温度模糊控制器控制效果良好，具有较强的鲁棒性。整个计算机监控系统满足了预先制定的监控要求。
The Programmable Logic Controller ( PLC ), owing to its high reliability, high stability , and easiness in programming and using, has been extensively used in the process control system of production line in the modern industry enterprises. But the PLC cann't provide the user with the dynamic display of production line's state messages or the output of the report forms, however utilizing the industrial computer( EPC ) , the users can develop convenience graphical interfaces, with the support of numerous software. Nowadays, it has already become one of the directions that combining PLC with IPC to the development of industry automation.
The TLJ300 copper Continuous Extrusion Forming (CONFORM) production line made in our college has achieved the lead position in domestic similar equipment. But when it compared with the similar product made in abroad, the technology gap still exists in automatic control system, which mainly include the large control panel, the great plenty of switchs and the complexity of wire connection. Otherwise, the controlling of the extrusion cavity's temperature and the extrusion wheel's rotate velocity is completely depended on the workers' experience, which result in the big errors and low precision. In order to further increase the efficiency and to enhance the grade of the automatic control system , the CONFORM production line's computer supervisory control system is developed.
In this paper, an integrate method of supervising and controlling the CONFORM production line which uses PLC and IPC is introduced. This system is the improvement of it's original control system, which uses IPC as the upper computer and uses the configuration software as the users' customization operation flat in which the line's real-time control and the state display is performed. As the reliability and stability of the PLC, it is used to acquire data, execute the upper computer's commands, perform the logic control and the real-time control of the extrusion cavity's temperature etc.
After reform, the control functions are executed only by the PLC itself and independent of the upper computer. As far as the control method is concerned, the fuzzy control is chosened to simulate the manual work, because the temperature has the non-linear, inertia and hysteresis characters, which lead to the difficulty of establishing an accurate math model.
The results of system simulation and debugging show that the computer supervision system runs steadily and reliably, also, the performance of the temperature fuzzy control system is excellent, which has a better robust capability. The whole computer supervisory control system has met the anticipative requirements.
引文
[1]周德泽．袁南儿．应英．计算机智能监测控制系统的设计及应用．第一版．清华大学出版社．2002
[2]谢克明，夏路易．可编程控制器原理与程序设计．第一版．电子工业出版社，2002
[3]钟约先，林亨．机械系统计算机控制．第一版．清华大学出版社．2001
[4]杨武．陈旭．计算机与可编程控制器PLC对生产线进行控制的一种方法．包装工程．2000．6：35～37
[5]皮壮行，宫振鸣．李雪华．可编程控制器的系统设计与应用实例．第一版．机械工业出版社，2002
[6]马国华．监控组态软件及其应用．第一版．清华大学出版社，2001
[7]组态王6.0使用手册．2001
[8]杨如柏．张胜华等译．CONFORM连续挤压译文集．第一版．中南工业大学出版社，1989．9
[9]黄惟一，胡生清．控制技术与系统．第一版．机械工业出版社，2002
[10]杨德礼．微型计算机在过程控制中的应用．科学技术文献出版社，1988
[11]国处集散系统资料汇编．《仪器仪表与分析监测》编辑部，1986
[12]Phelps. H.S. Computer Integrated Manufacturing (CIM) in the Process Control Industry. 12th Advanced Control Conference. Purdue, 1986
[13]Fadum, O. Computer Integrated Manufacturing in Pulp. Pulp and Paper Journal: 18～23, July 1986
[14]Williams, T.J. A Description from the Viwepoint of Industrial Automation. Reference Model for CIM, IFAC 11th World Congress, vol.1, 1990
[15]诸静．控制理论十年回顾与展望．浙江大学学报．1993．27：1～7
[16]金以慧．过程控制．第一版．清华大学出版社，1993
[17]吕勇哉．工业过程模型化及计算机控制．化学工业出版社，1986
[18]顾兴源．计算机控制系统．冶金工业出版社，1985
[19]Zadeh.L.A. Fuzzy Sets. Informat Control. 1965, 8:338～353
[20]Zadeh.L.A. Fuzz Algoritlun. Infonnat Control. 1968
[21]Mamdani. E. H. Applications of Fuzzy Alvorithms for Simple Dynamic Plaint. Proc. IEEE. 1974
[22]Witold Pedrycz. Fuzzy Control and Fuzzy Systems. Research Studies Press LTD. 1989
[23]H.J.Zimmermann. Fuzzy Set Theory and Its Applications kluwer-Nijhoff Publishing. 1995
[24]Ronald R. Yager Lotfi A Zadeh. AnIntroduction to Fuzzy Logic Applications in Intelligence Systems. Kluwer Academic Publishers, 1992
[25]汪培庄．模糊集合论及其应用．上海科学技术出版社．1983
[26]李士勇．模糊控制和智能控制理论与应用．哈尔滨工业大学出版社，1990
[27]诸静．模糊控制原理与应用及其现状．电工技术杂志．1993(3)：18～22
[28]诸静．模糊控制原理与应用．第一版．机械工业出版社，1995
[29]胡淑礼．模糊数学及其应用．四川大学出版社 1994
[30]李洪兴．工程模糊数学方法及应用．天津科学技术出版社．1993
[31]何新贵．模糊知识处理的理论与技术．国防工业出版社．1994
[32]窦振中．模糊逻辑控制及其应用．北京航空航天大学出版社，1990
[33]杨和雄．李崇文．模糊数学和它的应用．天津科学技术出版社．1993
[34]戎月莉．计算机模糊控制原理及应用．北京航空航天大学出版社．1995
[35]张化光．复杂系统的模糊辨识与模糊自适应控制．东北大学出版社．1993
[36]贺剑锋．模糊控制的新近发展控制理论与应用．1994．11(2)
[37]鲍新福．自调整比例因子的模糊控制器．自动化学报．1987，13(2)
[38]王全章．模糊调节器参数的存线自整定．控制与决策．1989，4
[39]Frank. J. Bartos. Fuzzy Logic Widens Its Appeal to Industrial Controls. Control Engineering. 1993.6
[40]Nick Infelise. A Clear Vision of Fuzzy Logic. Control Engineering. 1991.7
[41]Payman Arabshahi. Fuzzy Control of Back-Propagation. IEEE'92
[42]T. J. Procyk, E. H. Mamdani. A Linguistic Self-Organizing Process Controller. Automatica. 1979.15～30
[43]Michio Sugeno. An Introductory Survey of Fuzzy Control. Information Sciences. 1985
[44]King.P.J, Mamdani.E.H._The Application of Fuzzy Control systems to Industrial Process. 6th IFAC World Congr. 1975
[45][日]水本雅晴．模糊工学的现状与展望．模糊系统与数学．1993，7(1)
[46]刘国荣．模型参考模糊自适应控制．控制理论与应用．1996，13(1)
[47]李士勇．Fuzzy-PID复合控制的数字仿真．计算机仿真．1988，(1)
[48]李士勇．一种新型的模糊智能控制器．哈尔滨工业大学学报．1988(4)
[49]邓聚龙．李士勇．Fuzzy控制的稳定性问题．模糊数学．1983(3)
[50]张曾科．模糊数学在自动化技术中的应用．第一版．清华大学出版社．1997，7
[51]李士勇．模糊控制·神经控制和智能控制论．第二版．哈尔滨工业大学出版社．1998，9
[52]王志凯，郭宗仁，李琰．用PLC实现模糊控制的两种程序设计方法．工业控制计算机．2002．2
[53]张东波，黄辉先，朱建林．基于Matlab仿真的模糊温度集控器．工业控制计算机．2002，2
[54]吕纯洁．道岔尖轨淬火温度自动控制系统的研制．大连铁道学院工学硕士论文．2001
[55]陈怀深．吴大正．高西全．MATLAB及在电子信息课程中的应用．第一版．电子工业出版社．2002
[56]黄忠霖．控制系统MATLAB计算及仿真．第一版．国防工业出版社，2001．11
[57]王红卫．建模与仿真．第一版．科学出版社，2002，3
[2]谢克明，夏路易．可编程控制器原理与程序设计．第一版．电子工业出版社，2002
[3]钟约先，林亨．机械系统计算机控制．第一版．清华大学出版社．2001
[4]杨武．陈旭．计算机与可编程控制器PLC对生产线进行控制的一种方法．包装工程．2000．6：35～37
[5]皮壮行，宫振鸣．李雪华．可编程控制器的系统设计与应用实例．第一版．机械工业出版社，2002
[6]马国华．监控组态软件及其应用．第一版．清华大学出版社，2001
[7]组态王6.0使用手册．2001
[8]杨如柏．张胜华等译．CONFORM连续挤压译文集．第一版．中南工业大学出版社，1989．9
[9]黄惟一，胡生清．控制技术与系统．第一版．机械工业出版社，2002
[10]杨德礼．微型计算机在过程控制中的应用．科学技术文献出版社，1988
[11]国处集散系统资料汇编．《仪器仪表与分析监测》编辑部，1986
[12]Phelps. H.S. Computer Integrated Manufacturing (CIM) in the Process Control Industry. 12th Advanced Control Conference. Purdue, 1986
[13]Fadum, O. Computer Integrated Manufacturing in Pulp. Pulp and Paper Journal: 18～23, July 1986
[14]Williams, T.J. A Description from the Viwepoint of Industrial Automation. Reference Model for CIM, IFAC 11th World Congress, vol.1, 1990
[15]诸静．控制理论十年回顾与展望．浙江大学学报．1993．27：1～7
[16]金以慧．过程控制．第一版．清华大学出版社，1993
[17]吕勇哉．工业过程模型化及计算机控制．化学工业出版社，1986
[18]顾兴源．计算机控制系统．冶金工业出版社，1985
[19]Zadeh.L.A. Fuzzy Sets. Informat Control. 1965, 8:338～353
[20]Zadeh.L.A. Fuzz Algoritlun. Infonnat Control. 1968
[21]Mamdani. E. H. Applications of Fuzzy Alvorithms for Simple Dynamic Plaint. Proc. IEEE. 1974
[22]Witold Pedrycz. Fuzzy Control and Fuzzy Systems. Research Studies Press LTD. 1989
[23]H.J.Zimmermann. Fuzzy Set Theory and Its Applications kluwer-Nijhoff Publishing. 1995
[24]Ronald R. Yager Lotfi A Zadeh. AnIntroduction to Fuzzy Logic Applications in Intelligence Systems. Kluwer Academic Publishers, 1992
[25]汪培庄．模糊集合论及其应用．上海科学技术出版社．1983
[26]李士勇．模糊控制和智能控制理论与应用．哈尔滨工业大学出版社，1990
[27]诸静．模糊控制原理与应用及其现状．电工技术杂志．1993(3)：18～22
[28]诸静．模糊控制原理与应用．第一版．机械工业出版社，1995
[29]胡淑礼．模糊数学及其应用．四川大学出版社 1994
[30]李洪兴．工程模糊数学方法及应用．天津科学技术出版社．1993
[31]何新贵．模糊知识处理的理论与技术．国防工业出版社．1994
[32]窦振中．模糊逻辑控制及其应用．北京航空航天大学出版社，1990
[33]杨和雄．李崇文．模糊数学和它的应用．天津科学技术出版社．1993
[34]戎月莉．计算机模糊控制原理及应用．北京航空航天大学出版社．1995
[35]张化光．复杂系统的模糊辨识与模糊自适应控制．东北大学出版社．1993
[36]贺剑锋．模糊控制的新近发展控制理论与应用．1994．11(2)
[37]鲍新福．自调整比例因子的模糊控制器．自动化学报．1987，13(2)
[38]王全章．模糊调节器参数的存线自整定．控制与决策．1989，4
[39]Frank. J. Bartos. Fuzzy Logic Widens Its Appeal to Industrial Controls. Control Engineering. 1993.6
[40]Nick Infelise. A Clear Vision of Fuzzy Logic. Control Engineering. 1991.7
[41]Payman Arabshahi. Fuzzy Control of Back-Propagation. IEEE'92
[42]T. J. Procyk, E. H. Mamdani. A Linguistic Self-Organizing Process Controller. Automatica. 1979.15～30
[43]Michio Sugeno. An Introductory Survey of Fuzzy Control. Information Sciences. 1985
[44]King.P.J, Mamdani.E.H._The Application of Fuzzy Control systems to Industrial Process. 6th IFAC World Congr. 1975
[45][日]水本雅晴．模糊工学的现状与展望．模糊系统与数学．1993，7(1)
[46]刘国荣．模型参考模糊自适应控制．控制理论与应用．1996，13(1)
[47]李士勇．Fuzzy-PID复合控制的数字仿真．计算机仿真．1988，(1)
[48]李士勇．一种新型的模糊智能控制器．哈尔滨工业大学学报．1988(4)
[49]邓聚龙．李士勇．Fuzzy控制的稳定性问题．模糊数学．1983(3)
[50]张曾科．模糊数学在自动化技术中的应用．第一版．清华大学出版社．1997，7
[51]李士勇．模糊控制·神经控制和智能控制论．第二版．哈尔滨工业大学出版社．1998，9
[52]王志凯，郭宗仁，李琰．用PLC实现模糊控制的两种程序设计方法．工业控制计算机．2002．2
[53]张东波，黄辉先，朱建林．基于Matlab仿真的模糊温度集控器．工业控制计算机．2002，2
[54]吕纯洁．道岔尖轨淬火温度自动控制系统的研制．大连铁道学院工学硕士论文．2001
[55]陈怀深．吴大正．高西全．MATLAB及在电子信息课程中的应用．第一版．电子工业出版社．2002
[56]黄忠霖．控制系统MATLAB计算及仿真．第一版．国防工业出版社，2001．11
[57]王红卫．建模与仿真．第一版．科学出版社，2002，3