混凝土砌块成型自动化生产线控制系统开发
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摘要
随着我国墙改政策力度的加大,混凝土砌块必将打破房屋建筑材料中粘土砖的主导地位,为我国建筑业的健康发展和环境保护作出巨大贡献。由于目前大多数国产混凝土砌块成型设备自动化程度不高、生产效率较低,而进口混凝土砌块成型设备又价格昂贵,因此并不能满足国内混凝土砌块生产的需求。中国市场上急需一种符合中国国情、自动化程度高的混凝土砌块成型自动化生产设备。
本文以QT10-15混凝土砌块成型生产线为研究对象,在分析混凝土砌块成型生产工艺流程及控制需求基础上,运用可编程控制器、变频调速及工业组态软件等硬软件平台,研究设计开发了混凝土砌块成型生产线的集散式控制系统。为实现混凝土成型自动化生产线信息集成及可靠运行,本文着重研究了台达系列工控产品的通讯机制、主机液压系统流量PID控制、子母窑车精确定位、码垛控制、升降板机控制等关键技术。完成了基于WPLsoft、ScreenEditor及VB开发平台的混凝土砌块成型自动化生产线PLC控制程序及上位监控程序的设计、开发与调试,实现了控制系统过程控制、信息集成、工艺参数设定,历史数据管理及智能故障报警等功能。
现场调试运行表明:本文设计的混凝土砌块成型自动化生产线控制系统达到了预期的功能要求,具有较好的可靠性和实用性,满足现场生产的要求。
As China's effort to increase the wall materials innovation policy, the dominant position of clay brick in the housing construction materials will be broken by concrete segmen, which will advance the development of China's construction industry and make a significant contribution to environmental protection. Since the majority of China-made Block Forming Machine is not high degree of automation, low production efficiency, and import of Block Forming Machine is expensive. An economical and good degree of the automation block machine production line is urgent need in Chinese market.
QT10-15 Block Production line was chosed for the object of study in this dissertation. Distributed Control System was developed based on PLC, Frequency Control, Configuration Software, other industrial hardware and software platform after analyzed the production process and control requirements. For achieved information's integration and ensuring the system reliabler running, the Control Products of Detal's communication technology, the Block Machine hydraulic PID control, precise positioning Finger Cars, stack control, the control plate movements of key technologies were put emphasis on research. The PLC control procedures and monitoring procedures for the PC and HMI were developed based on the completion of the WPLsoft, ScreenEdit and VB development tool, which realized process control, information integration, process parameters setting, historical data management and intelligent fault alarm, and other functions.
Debugging at the scene indicated that: The design of the Block production line control system achieve the expected functional requirements, has good reliability and availability to meet the requirements of production at the scene.
本文以QT10-15混凝土砌块成型生产线为研究对象,在分析混凝土砌块成型生产工艺流程及控制需求基础上,运用可编程控制器、变频调速及工业组态软件等硬软件平台,研究设计开发了混凝土砌块成型生产线的集散式控制系统。为实现混凝土成型自动化生产线信息集成及可靠运行,本文着重研究了台达系列工控产品的通讯机制、主机液压系统流量PID控制、子母窑车精确定位、码垛控制、升降板机控制等关键技术。完成了基于WPLsoft、ScreenEditor及VB开发平台的混凝土砌块成型自动化生产线PLC控制程序及上位监控程序的设计、开发与调试,实现了控制系统过程控制、信息集成、工艺参数设定,历史数据管理及智能故障报警等功能。
现场调试运行表明:本文设计的混凝土砌块成型自动化生产线控制系统达到了预期的功能要求,具有较好的可靠性和实用性,满足现场生产的要求。
As China's effort to increase the wall materials innovation policy, the dominant position of clay brick in the housing construction materials will be broken by concrete segmen, which will advance the development of China's construction industry and make a significant contribution to environmental protection. Since the majority of China-made Block Forming Machine is not high degree of automation, low production efficiency, and import of Block Forming Machine is expensive. An economical and good degree of the automation block machine production line is urgent need in Chinese market.
QT10-15 Block Production line was chosed for the object of study in this dissertation. Distributed Control System was developed based on PLC, Frequency Control, Configuration Software, other industrial hardware and software platform after analyzed the production process and control requirements. For achieved information's integration and ensuring the system reliabler running, the Control Products of Detal's communication technology, the Block Machine hydraulic PID control, precise positioning Finger Cars, stack control, the control plate movements of key technologies were put emphasis on research. The PLC control procedures and monitoring procedures for the PC and HMI were developed based on the completion of the WPLsoft, ScreenEdit and VB development tool, which realized process control, information integration, process parameters setting, historical data management and intelligent fault alarm, and other functions.
Debugging at the scene indicated that: The design of the Block production line control system achieve the expected functional requirements, has good reliability and availability to meet the requirements of production at the scene.
引文
[1]迟政权,佟万泉.混凝土砌块的发展现状和趋势[J].辽宁建材,2005(1):25-26.
[2]付留根.我国砌块成型机械的机遇与发展趋势[J].建筑机械化,2003(4):17-19.
[3]师全忠.国外混凝土砌块成型设备技术性能[J].山东建材,1995(1):41-42.
[4]苑金生.国外混凝土砌块生产设备及发展趋势[J].中国建材装备,1996(6):41-42.
[5]吴志远,等.先进适用的QM5-16型全自动砌块生产线(成套设备)[J].混凝土,2001(12):58-60.
[6]李坦平,曾利群.混凝土砌块的发展现状与展望[J].砖瓦,2001(5):13-14.
[7]吴学松.建筑砌块成型机械发展及砌块生产线建设[J].建筑机械化,2001(1):12-14.
[8]郭爱荣.U型砌块成型机设计及其自动控制系统的研究[D].西北农林科技大学,2003.
[9]付留根,张明莉.砌块成型的振动特点[J].设计制造,2004(4):82-83.
[10]张明莉.振动技术在砌块成型机中的运用[J].建筑机械,2005(1):102-103.
[11]金建交,杨世春,等.砌块成型机的振动对砌块密实度的影响[J].机械工程与自动化,2006(1):50-52.
[12]作者不明.我国砌块设备整体技术水平提高[J].广东建材,2004(2):50.
[13]蒋翔俊,李峰飞,皱爱成.砌块成型机的PLC一触摸屏控制[J].建筑机械化,2006(2):39-40.
[14]韦庆杰,陈丽贤.QT3-35砌块成型机的研制[J].建筑砌块与砌块建筑,2001(4):32-34.
[15]王黎,于心俊,臧海河.免烧砌块成型机的设计[J].新型墙体材,2005(5):41-42.
[16]韩迎红.论砌块成型系统的改进方案和PLC[-J].点击新型墙材,2005(3):31-33.
[17]刘一凡,陈立定,等.砌块机生产线自动控制系统[J].建筑机械,2003(8):29-32.
[18]陈慧芳,等.砌块自动化生产线控制系统的开发[J].机械与电子,1999(6):56-57.
[19]许立梓,程良伦.工业控制机及其网络控制系统[M].北京:机械工业出版社.2005.
[20]唐瑛.现代工业过程控制系统的技术分析[J].机械与电子,2007(17):592-592.
[21]Masao Ogawa,Yutaka Henmi.Recent Developments on PC+PLC based Control Systems for Beer Brewery Process Automation Applications[C].SICE-ICASE International Joint Conference,Oct.18-21,2006 in Bexco,Busan,Korea:1053-1056.
[22]刘鑫.工业控制计算机技术的最新发展[J].PLC&FA,2005(6):36-39.
[23]La Fauci,Joseph.PLC or DCS:selection and trends[J].ISA Transactions,1997(1).
[24]张雪申,叶西宁.集散控制系统及其运用[M].北京:机械工业出版社,2006.
[25]GrayA.Mintchell.Distributed control Gose Discrete[J].Control Engineering,2000(10).
[26]Sheng qiang,Gao X.Z.,Xianyi Zhuang.PLC-based control systems for industrial production of fuel alcohol[J].IEEE International Conference on Industrial Technology,2002,2(11-14):827-832.
[27]魏克斯,赵钢.嵌入式微控制器、PLC、变频器、触摸屏、工控机、组态软件的综合应用[M].北京:机械工业出版社,2007.
[28]广州亿控自动化设备有限公司.台达DVP系列可编程控制器使用说明书[Z].2003(11).
[29]台达电子工业股份有限公司.HMI_catalogue_tc.pdf[Z].2008.
[30]刘凡馨.Visual Basical程序设计教程[M].北京:清华大学出版社,2007.
[31]Modbus通信协议[J].2003.
[32]Lin Chuangyi,Tang Lindai,Du Junyan.PRODUCT SPECIFICATION DVP Series PLC Communication Protocol V1.1a[J].PLC engineering document,2007.
[33]台达电子工业股份有限公司.VFD-B使用说明书[Z].2006.
[34]台达电子工业股份有限公司.DVP-PLC应用技术手册程序篇[M].2007.
[35]台达电子工业股份有限公司.DOP-HMI_SC Manual[M].2005.
[36]舒怀林.PID神经元网络及其控制系统[M].北京:国防工业出版社,2006.
[37]M H Moradi.New techniques for PID Controller Design[C].IEEE,2003:903-908.
[38]Kiam Heong Ang,Gregory Chong,Yun Li.PID Control System Analysis,Design,and Technology[C].IEEE,2005,13(4):559-576.
[39]Wu Qingming,Zhang Qiang,Zong Chi.Vibration control of block forming machine based on an artificial neural network[J].Lecture Notes in Computer Science.v 4491LNCS-I,n PART 1,Advances in Neural Networks-ISNN 2007-4th International Symposium on Neural Networks,ISNN 2007,Proceedings,2007:231-240.Quality Concretem,v 2,n 1-2,1996:9-12.
[40]刘颖明.型钢码垛机自动控制的位置检测与变频器控制[J].沈阳师范大学学报(自然科学版),2004:190-192.
[41]De Gloria.A,Faraboschi.P.Block placement with a Boltzmann machine[C].IEEE Trans Comput Aided Des Integr Circuits Syst.v3,n6,1994:694-701.
[42]Muller,Karlheinz.Schlosser machines for latest Fritz Herrmann block plant[J].
[43]鲁远栋,冼进.PLC机电系统应用设计技术[M].北京:电子工业出版社,2006.
[44]台达电子工业股份有限公司.DVP台达可程序控制器宣传手册[Z].
[45]台达电子工业股份有限公司.DVP-PLC应用技术手册[特殊模块篇]上册[J].2007.
[46]欧姆龙中国有限公司.TL-N□ME□产品说明书[Z].1999.
[47][德]H.K.屯肖夫.[日]I.稻崎.制造业传感器[M].北京:化学工业出版社,2005.
[48]欧姆龙中国有限公司.E3JK系列光电开关说明书[Z].1999.
[49]岳庆来,周锋,吴启红,胡洪.变频器、可编程序控制器及触摸屏综合应用技术[M].北京:机械工业出版社,2006.
[50]周志敏,周纪海,纪爱华.变频器工程应用[M].北京:电子工业出版社,2005.
[51]台达电子工业股份有限公司.VFD-B_catalouge_tr.PDF文档[Z].2003.
[52]台达电子工业股份有限公司.DVP/TP台达电子人机界面系列产品手册[Z].
[53]陈明,张京妹.控制系统可靠性设计[M].西安:西北工业大学出版社,2006.
[54]王德杰.变频器干扰产生的原因及防范措施[J].重型机械科技,2005:31-33.
[55]陈军.变频器干扰问题及其对策[J].中国西部科技,2006:16-17.
[56]金彦平.PLC控制系统可靠性技术[J].机床电器,2005(5):28-30.
[57]葛文峰.PLC控制系统的硬件抗干扰措施[J].2004(11):57-59.
[58]Martin Bergert,Christian Diedrich,Jens Kiefer,Thomas Bar.Automated PLC Software Generation Based on Standardized Digital Process Information[C].IEEE,2007,352-356.
[59]陈立定,吴玉香,苏开才.电气控制与可编程控制器[M].广州:华南理工大学出版社,2001.
[60]Halid Hrasnica,Ralf Lehnert.Performance comparison of reservation MAC protocols for PLC access networks under specific traffic conditions.Proceedings of SPIE[J].2003,5244:94-105.
[2]付留根.我国砌块成型机械的机遇与发展趋势[J].建筑机械化,2003(4):17-19.
[3]师全忠.国外混凝土砌块成型设备技术性能[J].山东建材,1995(1):41-42.
[4]苑金生.国外混凝土砌块生产设备及发展趋势[J].中国建材装备,1996(6):41-42.
[5]吴志远,等.先进适用的QM5-16型全自动砌块生产线(成套设备)[J].混凝土,2001(12):58-60.
[6]李坦平,曾利群.混凝土砌块的发展现状与展望[J].砖瓦,2001(5):13-14.
[7]吴学松.建筑砌块成型机械发展及砌块生产线建设[J].建筑机械化,2001(1):12-14.
[8]郭爱荣.U型砌块成型机设计及其自动控制系统的研究[D].西北农林科技大学,2003.
[9]付留根,张明莉.砌块成型的振动特点[J].设计制造,2004(4):82-83.
[10]张明莉.振动技术在砌块成型机中的运用[J].建筑机械,2005(1):102-103.
[11]金建交,杨世春,等.砌块成型机的振动对砌块密实度的影响[J].机械工程与自动化,2006(1):50-52.
[12]作者不明.我国砌块设备整体技术水平提高[J].广东建材,2004(2):50.
[13]蒋翔俊,李峰飞,皱爱成.砌块成型机的PLC一触摸屏控制[J].建筑机械化,2006(2):39-40.
[14]韦庆杰,陈丽贤.QT3-35砌块成型机的研制[J].建筑砌块与砌块建筑,2001(4):32-34.
[15]王黎,于心俊,臧海河.免烧砌块成型机的设计[J].新型墙体材,2005(5):41-42.
[16]韩迎红.论砌块成型系统的改进方案和PLC[-J].点击新型墙材,2005(3):31-33.
[17]刘一凡,陈立定,等.砌块机生产线自动控制系统[J].建筑机械,2003(8):29-32.
[18]陈慧芳,等.砌块自动化生产线控制系统的开发[J].机械与电子,1999(6):56-57.
[19]许立梓,程良伦.工业控制机及其网络控制系统[M].北京:机械工业出版社.2005.
[20]唐瑛.现代工业过程控制系统的技术分析[J].机械与电子,2007(17):592-592.
[21]Masao Ogawa,Yutaka Henmi.Recent Developments on PC+PLC based Control Systems for Beer Brewery Process Automation Applications[C].SICE-ICASE International Joint Conference,Oct.18-21,2006 in Bexco,Busan,Korea:1053-1056.
[22]刘鑫.工业控制计算机技术的最新发展[J].PLC&FA,2005(6):36-39.
[23]La Fauci,Joseph.PLC or DCS:selection and trends[J].ISA Transactions,1997(1).
[24]张雪申,叶西宁.集散控制系统及其运用[M].北京:机械工业出版社,2006.
[25]GrayA.Mintchell.Distributed control Gose Discrete[J].Control Engineering,2000(10).
[26]Sheng qiang,Gao X.Z.,Xianyi Zhuang.PLC-based control systems for industrial production of fuel alcohol[J].IEEE International Conference on Industrial Technology,2002,2(11-14):827-832.
[27]魏克斯,赵钢.嵌入式微控制器、PLC、变频器、触摸屏、工控机、组态软件的综合应用[M].北京:机械工业出版社,2007.
[28]广州亿控自动化设备有限公司.台达DVP系列可编程控制器使用说明书[Z].2003(11).
[29]台达电子工业股份有限公司.HMI_catalogue_tc.pdf[Z].2008.
[30]刘凡馨.Visual Basical程序设计教程[M].北京:清华大学出版社,2007.
[31]Modbus通信协议[J].2003.
[32]Lin Chuangyi,Tang Lindai,Du Junyan.PRODUCT SPECIFICATION DVP Series PLC Communication Protocol V1.1a[J].PLC engineering document,2007.
[33]台达电子工业股份有限公司.VFD-B使用说明书[Z].2006.
[34]台达电子工业股份有限公司.DVP-PLC应用技术手册程序篇[M].2007.
[35]台达电子工业股份有限公司.DOP-HMI_SC Manual[M].2005.
[36]舒怀林.PID神经元网络及其控制系统[M].北京:国防工业出版社,2006.
[37]M H Moradi.New techniques for PID Controller Design[C].IEEE,2003:903-908.
[38]Kiam Heong Ang,Gregory Chong,Yun Li.PID Control System Analysis,Design,and Technology[C].IEEE,2005,13(4):559-576.
[39]Wu Qingming,Zhang Qiang,Zong Chi.Vibration control of block forming machine based on an artificial neural network[J].Lecture Notes in Computer Science.v 4491LNCS-I,n PART 1,Advances in Neural Networks-ISNN 2007-4th International Symposium on Neural Networks,ISNN 2007,Proceedings,2007:231-240.Quality Concretem,v 2,n 1-2,1996:9-12.
[40]刘颖明.型钢码垛机自动控制的位置检测与变频器控制[J].沈阳师范大学学报(自然科学版),2004:190-192.
[41]De Gloria.A,Faraboschi.P.Block placement with a Boltzmann machine[C].IEEE Trans Comput Aided Des Integr Circuits Syst.v3,n6,1994:694-701.
[42]Muller,Karlheinz.Schlosser machines for latest Fritz Herrmann block plant[J].
[43]鲁远栋,冼进.PLC机电系统应用设计技术[M].北京:电子工业出版社,2006.
[44]台达电子工业股份有限公司.DVP台达可程序控制器宣传手册[Z].
[45]台达电子工业股份有限公司.DVP-PLC应用技术手册[特殊模块篇]上册[J].2007.
[46]欧姆龙中国有限公司.TL-N□ME□产品说明书[Z].1999.
[47][德]H.K.屯肖夫.[日]I.稻崎.制造业传感器[M].北京:化学工业出版社,2005.
[48]欧姆龙中国有限公司.E3JK系列光电开关说明书[Z].1999.
[49]岳庆来,周锋,吴启红,胡洪.变频器、可编程序控制器及触摸屏综合应用技术[M].北京:机械工业出版社,2006.
[50]周志敏,周纪海,纪爱华.变频器工程应用[M].北京:电子工业出版社,2005.
[51]台达电子工业股份有限公司.VFD-B_catalouge_tr.PDF文档[Z].2003.
[52]台达电子工业股份有限公司.DVP/TP台达电子人机界面系列产品手册[Z].
[53]陈明,张京妹.控制系统可靠性设计[M].西安:西北工业大学出版社,2006.
[54]王德杰.变频器干扰产生的原因及防范措施[J].重型机械科技,2005:31-33.
[55]陈军.变频器干扰问题及其对策[J].中国西部科技,2006:16-17.
[56]金彦平.PLC控制系统可靠性技术[J].机床电器,2005(5):28-30.
[57]葛文峰.PLC控制系统的硬件抗干扰措施[J].2004(11):57-59.
[58]Martin Bergert,Christian Diedrich,Jens Kiefer,Thomas Bar.Automated PLC Software Generation Based on Standardized Digital Process Information[C].IEEE,2007,352-356.
[59]陈立定,吴玉香,苏开才.电气控制与可编程控制器[M].广州:华南理工大学出版社,2001.
[60]Halid Hrasnica,Ralf Lehnert.Performance comparison of reservation MAC protocols for PLC access networks under specific traffic conditions.Proceedings of SPIE[J].2003,5244:94-105.
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