结晶器激振系统的PLC控制与在线监测的研究
|
摘要
控制结晶器按给定振动方式运动是连铸工艺的关键技术。传统的结晶器振动方式是按正弦方式运动的。随着现代工业的发展，高效连铸技术的提出，原来由偏心轮驱动四连杆机构的机械振动装置已经无法满足生产节奏和工艺的要求。液压伺服驱动的振动装置不仅可以实现非正弦振动，提高了铸坯质量，而且还加快了生产进程，因此在当今各工业国家钢铁行业得到了普遍采用。
然而，对于国内各钢铁企业来说，结晶器伺服激振系统毕竟是一项新技术，在使用过程当中仍存在许多问题，需要我们不断地消化和吸收。因此，本文以连铸机结晶器伺服激振控制系统为对象进行了研究。
本文对生产过程的计算机控制系统进行了综述，分析比较了PLC控制系统与继电器控制系统、通用计算机控制系统以及集散控制系统的各自特点，并提出了混合控制系统的概念。连铸机激振系统的振动波形由PLC产生，本文对其控制原理进行了阐述，并结合SIMATIC Step 7编程软件，分析了其需要采集的输入／输出数字、模拟量，进而对PLC程序设计的整个组织结构进行了分析。同时，本文利用西门子Prodave软件包，采用CP5611通讯卡，基于VC++编程软件，实现了下位PLC和上位工控机之间的网络通讯。此外，对PLC站点之间的通信，本文也作了论述。
根据监测方案的基本思想以及连铸机监测系统的基本功能要求，作者在分析比较了几种数据采集方案的基础上，提出了结晶器监测系统的硬件总体设计，并给出了状态监测仪表和传感器布点图。对VB和WinCC作为监控开发软件做了分析比较，结合现场实际，选择PROFIBUS作为网络通信技术方案，决定利用WinCC开发上位机监控系统。
本文对国外四大著名组态软件做了分析比较，阐明了选择WinCC组态软件作为本监控系统的原因。利用PLC从现场采集得到的数据，基于WinCC组态软件，对结晶器激振系统重要的状态参数分别以趋势和数值的方式进行了实时状态监测，为故障诊断提供了依据。利用WinCC内嵌的C函数，实现了报表的打印日期选择以及管理员权限登陆的管理等功能。对WinCC的sybase数据库，分别利用MS Excel／MS Query、C动作和Visual Basic实现了对其进行操作。此外，探讨了利用OPC实现现场总线信号与系统监控软件之间的通讯，并就WinCC与PLC的过程通讯做了阐述，给出了它们通讯的具体实现步骤。
本文还对电液系统的监测理论进行了详细分析。提出了状态变化特性及相应的敏感因子，对引起液压系统失效的根源性工况原因作了分析，并描述了其特征参数的选取。作者就根源性工况监测策略提出了结晶器激振系统的观察点图，并选取了其相应的观察参数。同时，对液压系统性能失效监测策略、参数的选取以及其性能失效评判作了探讨。在此基础上，对连铸机激振液压系统的故障机理进行了深入分析。首先就系统中的重要液压元件泵、电液伺服阀、油缸、溢流阀做了故障机理研究；此外，针对结晶器激振系统故障现象和原因的错综复杂性，从整体的角度对该液压系统所有可能存在的故障进行了根源性研究。
It's a vital technology to control the mold oscillator according to a specified style of oscillating. The traditional mould oscillates with a sine wave. With the development of modern industry, the speed of casting and the quality of slab are demanded higher and higher. Thus, the mechanical oscillating instrument driven by the eccentric wheel is no longer satisfied with the rhythm of production and the technology. However, the mould oscillation movement performed by hydraulic cylinders not only can oscillates in nosine wave but also improves the mass of slab and quickens the speed of production. Therefore, it is widely used in the iron and steel factories all over the world.
However, the oscillating instrument driven by servo-valve is new to all the domestic factories. There are many problems when using it, so it needs to be absorbed by users. In the following, the control system of the hydraulic oscillating instrument will be discussed.
In this paper, the PLC control system is compared with the Relay Control System? the general computer Control System and the Distributed Control System, and the integrated system is also given. The wave of mold oscillation is generated by PLC, and in this paper the controlling principle is expounded. Then the organization of PLC programme is researhed according to SIMATIC Step 7.At the same time, the network communication between the upper computer and the lower PLC is achieved with Prodave software based on VC++ workstation. Besides, the communication between PLCs is also discussed.
According to the basic idea of monitoring scheme and the basic function requirement of mold monitoring system, the hardware total design of mold monitoring system is put forward and the distributed scheme of instruments and sensors are also given by the author on the basis of comparing several data-collection scheme. Moreover, the development software between VB and configuration software is compared. Finally, configuration software is chosen to develop the upper monitoring system, whose network communication is based on PROFIBUS.
In this paper, the four famous configuration software is compared, and the reason of choosing WinCC is interpreted. The vital data of the hydraulic oscillating instrument are collected by PLC and disposed by WinCC, and the critical realtime state parameters are displayed in HMI. Using the C function within WinCC, the choosing time function of report and the login function of administrators are achieved. Also, how to access the WinCC database is discussed in detail. At the same time, the communication between field bus and configuration software is discussed by using OPC technology. The process communication between WinCC and PLC is expatiated, then the detail connecting steps are given in this paper.
In this paper, the electro-hydraulic system's monitoring theory is analyzed in detail. The state changing characteristic and corresponding sensitivity gene are indicated, and the primary reason leading to hydraulic system invalidation is analyzed and the characteristic parameter is described.
The observed drawing of mold oscillation system is given by the author according to the monitoring strategy, and the corresponding observing parameters are chosen. Moreover, the monitoring strategy of hydraulic system performance, the choosing of corresponding parameter and the evaluation of performance invalidation are discussed. Finally, the fault mechanism of hydraulic components is analyzed in detail, which are pump, electro-hydraulic servo valve, cylinder and relief valve. Also, the fault mechanism of hydraulic system is studied from a point of the whole, which gives a hand to develop the fault diagnosis software of mold oscillator.
然而，对于国内各钢铁企业来说，结晶器伺服激振系统毕竟是一项新技术，在使用过程当中仍存在许多问题，需要我们不断地消化和吸收。因此，本文以连铸机结晶器伺服激振控制系统为对象进行了研究。
本文对生产过程的计算机控制系统进行了综述，分析比较了PLC控制系统与继电器控制系统、通用计算机控制系统以及集散控制系统的各自特点，并提出了混合控制系统的概念。连铸机激振系统的振动波形由PLC产生，本文对其控制原理进行了阐述，并结合SIMATIC Step 7编程软件，分析了其需要采集的输入／输出数字、模拟量，进而对PLC程序设计的整个组织结构进行了分析。同时，本文利用西门子Prodave软件包，采用CP5611通讯卡，基于VC++编程软件，实现了下位PLC和上位工控机之间的网络通讯。此外，对PLC站点之间的通信，本文也作了论述。
根据监测方案的基本思想以及连铸机监测系统的基本功能要求，作者在分析比较了几种数据采集方案的基础上，提出了结晶器监测系统的硬件总体设计，并给出了状态监测仪表和传感器布点图。对VB和WinCC作为监控开发软件做了分析比较，结合现场实际，选择PROFIBUS作为网络通信技术方案，决定利用WinCC开发上位机监控系统。
本文对国外四大著名组态软件做了分析比较，阐明了选择WinCC组态软件作为本监控系统的原因。利用PLC从现场采集得到的数据，基于WinCC组态软件，对结晶器激振系统重要的状态参数分别以趋势和数值的方式进行了实时状态监测，为故障诊断提供了依据。利用WinCC内嵌的C函数，实现了报表的打印日期选择以及管理员权限登陆的管理等功能。对WinCC的sybase数据库，分别利用MS Excel／MS Query、C动作和Visual Basic实现了对其进行操作。此外，探讨了利用OPC实现现场总线信号与系统监控软件之间的通讯，并就WinCC与PLC的过程通讯做了阐述，给出了它们通讯的具体实现步骤。
本文还对电液系统的监测理论进行了详细分析。提出了状态变化特性及相应的敏感因子，对引起液压系统失效的根源性工况原因作了分析，并描述了其特征参数的选取。作者就根源性工况监测策略提出了结晶器激振系统的观察点图，并选取了其相应的观察参数。同时，对液压系统性能失效监测策略、参数的选取以及其性能失效评判作了探讨。在此基础上，对连铸机激振液压系统的故障机理进行了深入分析。首先就系统中的重要液压元件泵、电液伺服阀、油缸、溢流阀做了故障机理研究；此外，针对结晶器激振系统故障现象和原因的错综复杂性，从整体的角度对该液压系统所有可能存在的故障进行了根源性研究。
It's a vital technology to control the mold oscillator according to a specified style of oscillating. The traditional mould oscillates with a sine wave. With the development of modern industry, the speed of casting and the quality of slab are demanded higher and higher. Thus, the mechanical oscillating instrument driven by the eccentric wheel is no longer satisfied with the rhythm of production and the technology. However, the mould oscillation movement performed by hydraulic cylinders not only can oscillates in nosine wave but also improves the mass of slab and quickens the speed of production. Therefore, it is widely used in the iron and steel factories all over the world.
However, the oscillating instrument driven by servo-valve is new to all the domestic factories. There are many problems when using it, so it needs to be absorbed by users. In the following, the control system of the hydraulic oscillating instrument will be discussed.
In this paper, the PLC control system is compared with the Relay Control System? the general computer Control System and the Distributed Control System, and the integrated system is also given. The wave of mold oscillation is generated by PLC, and in this paper the controlling principle is expounded. Then the organization of PLC programme is researhed according to SIMATIC Step 7.At the same time, the network communication between the upper computer and the lower PLC is achieved with Prodave software based on VC++ workstation. Besides, the communication between PLCs is also discussed.
According to the basic idea of monitoring scheme and the basic function requirement of mold monitoring system, the hardware total design of mold monitoring system is put forward and the distributed scheme of instruments and sensors are also given by the author on the basis of comparing several data-collection scheme. Moreover, the development software between VB and configuration software is compared. Finally, configuration software is chosen to develop the upper monitoring system, whose network communication is based on PROFIBUS.
In this paper, the four famous configuration software is compared, and the reason of choosing WinCC is interpreted. The vital data of the hydraulic oscillating instrument are collected by PLC and disposed by WinCC, and the critical realtime state parameters are displayed in HMI. Using the C function within WinCC, the choosing time function of report and the login function of administrators are achieved. Also, how to access the WinCC database is discussed in detail. At the same time, the communication between field bus and configuration software is discussed by using OPC technology. The process communication between WinCC and PLC is expatiated, then the detail connecting steps are given in this paper.
In this paper, the electro-hydraulic system's monitoring theory is analyzed in detail. The state changing characteristic and corresponding sensitivity gene are indicated, and the primary reason leading to hydraulic system invalidation is analyzed and the characteristic parameter is described.
The observed drawing of mold oscillation system is given by the author according to the monitoring strategy, and the corresponding observing parameters are chosen. Moreover, the monitoring strategy of hydraulic system performance, the choosing of corresponding parameter and the evaluation of performance invalidation are discussed. Finally, the fault mechanism of hydraulic components is analyzed in detail, which are pump, electro-hydraulic servo valve, cylinder and relief valve. Also, the fault mechanism of hydraulic system is studied from a point of the whole, which gives a hand to develop the fault diagnosis software of mold oscillator.
引文
[1] 刘明延，李平等．板坯连铸机设计与计算(上、下册)．机械工业出版社1990．2
[2] 史宸兴，实用连铸冶金技术．冶金工业出版社．1998．6
[3] 许万凌，肖志权等．高速连铸机液压伺服振动系统．冶金设备．1999．12
[4] 李运华，王占林等．基于电液伺服控制实现的连铸机结晶器振动装置．机械工程学报．1999．2
[5] 吴晓明，韩晓娟，王益群，李宪奎．结晶器非正弦高频振动电液伺服控制系统的研究．中国机械工程．2001．10
[6] 李运华，王占林等．连铸机结晶器振动装置及其计算机控制系统．液压与气动．1999．1
[7] 方一鸣，焦晓红，李宪奎等．液压伺服驱动连铸结晶器振动控制系统的设计．冶金自动化．2000．1
[8] 张伟．连铸结晶器电液伺服系统的研究．液压与气动．2003．5
[9] 曹承志．微型计算机控制新技术．机械工业出版社．2001．6
[10] 郑晟，巩建平等．现代可编程序控制器原理与应用．科学出版社．2002．5
[11] 王永华等．现代电气及可编程控制技术．北京航空航天大学出版社．2002．9
[12] 周恩涛．可编程控制器原理及其在液压系统中的应用．机械工业出版社．2003．2
[13] 郭宗仁，吴亦锋，郭永．可编程序控制器应用系统设计及通信网络技术．人民邮电出版社．2002．9
[14] 李枫．Profibus现场总线技术的应用．计算机工程．2003．3
[15] 林威汉，高春光，张海涛．国内组态软件的现状与未来．电气时代．2002．6
[16] 胡友明．杜润生，杨叔子．液压系统运行状态监测．液压与气动．2002．8
[17] 湛从昌．液压可靠性与故障诊断．冶金工业出版社．1995．1
[18] 李士勇编著．模糊控制·神经控制和智能控制论．哈尔滨工业大学出版社1996．10
[19] 袁洪芳．基于Internet的FMS远程监测与故障诊断技术研究．制造业自动化．2000．5
[20] 黎洪生等．远程在线监测与故障诊断系统的设计与实现．武汉理工大学学报．2001．7
[21] 黄志坚等．珠钢轧机液压在线监测系统．南方钢铁．2000．6
[22] 张健成等．大型液压系统的在线监测和故障诊断．液压与气动．1999．7
[23] SIMATIC STEP 7 V5.2编程．西门子(中国)有限公司自动化与驱动集团．2003．2
[24] http://www.ad.siemens.com.cn/
[25] Gerhard Bocher, Uwe Gohler. Operational experience with a resonance mould for continuous casting of slabs[C] .2nd European Conference on Continuous Casting,Florence/Italy.sept, 1991,141-147
[26] Yarnashita T. Development in mould oscillation.Proc.con-cast workshop on slab casting. 1987.Kashima;59-61
[27] LAD for s7 300/400 programming.SIEMENS AG.1998
[28] Kane,les A.Fieldbus Getting More Confusing.Hydrocarbon Processing,2000(4)
[29] Richard H C.Fieldbus Application.ISA Transactin, 1989:28
[30] Siemens AG.SIMATIC S7-300 Components for Totally Integrated Automation Germany:Siemens ACt 1997
[31] 朱浩波．PLC在机电设备故障诊断中的应用．哈尔滨理工大学学报．2001．8
[32] 张琳．PLC及组态软件在高炉槽下配料控制系统中的应用研．合肥工业大学．2002．6
[33] 何国西．现场总线在PLC和工控机控制系统中应用方案比较．工业控制计算机．2003．2
[34] 梁首发．S7—300可编程序控制器及工控组态软件WinCC应用．中国仪器仪表．2001．3
[35] 黎洪生，李超，周登科等．基于PLC和组态软件的分布式监控系统设计．武汉理工大学学报．2002．3
[36] 桂在吾，沈俊杰，陈久康．VB在组态软件中的应用．电气自动化．2002．10
[37] 卢建华．使用WinCC实现过程监控．武汉科技大学学报．2000．3
[38] 姚良挺，黄志坚．板坯连铸机液压振动台故障的诊断．液压与气动．2002．10
[39] 陈奎生．液压阀与液压控制系统[M]．武汉工业大学出版社出版．1997
[40] J Michael Kiss, Mustafa Ozgu, Mark C Bublitz, et al.tri-Axial mold oscillation monitoring system[A]. Steel making Conference Proceedings[C], 1993,76:383～394
[41] B Mairy, D Ramelot, G Habay, et al, Mould oscillation monitoring for casting optimization [A]Proceeding from the 2nd Continuous Casting Conference[C], 1985:59.1～59.8
[42] M Yao, D C Fang. On line measuring method for mould friction in continuous casting[J].Iron making and Steel making, 1996,23(6):522～527
[43] Florkowski M. Partial discharge analyzer supported by neural network as a tool for monitoring and diagnosis. Proc of the 8th ISH, Vol2,Yokohama.Japan, 1993
[44] Herbert L, Gilles ,Bruce R Forman. Measurement and analysis of slab caster mold movement[A].Steel making Conference Proceeding[C], 1991,74:219～232
[45] 陈志新等．板坯结晶器振动状态在线监测系统设计与实现．系统与装置．2001．2
[46] 姜苍华等．宝钢2号板坯连铸机结晶器拉坯阻力在线监测系统的设计与应用．系统与装置．2001．6
[47] 李运华等．连铸机结晶器电液伺服振动波形系统的开发研制[J]．机床与液压，1998．3
[48] 何存兴．液压元件[M]．机械工业出版社．1989
[49] 董选明等．机电控制系统故障诊断的回顾与展望．中国机械工程．1998．10
[50] 王益群等．液压传动及控制系统故障诊断技术的新进展．燕山大学报．1998．1
[51] SIMATIC HMI WinCC系统描述．西门子(中国)有限公司自动化与驱动集团．2002．1
[52] SIMATIC HMI WinCC 5.0 USER'S MANUAL.SIEMENS AG.2002.1
[2] 史宸兴，实用连铸冶金技术．冶金工业出版社．1998．6
[3] 许万凌，肖志权等．高速连铸机液压伺服振动系统．冶金设备．1999．12
[4] 李运华，王占林等．基于电液伺服控制实现的连铸机结晶器振动装置．机械工程学报．1999．2
[5] 吴晓明，韩晓娟，王益群，李宪奎．结晶器非正弦高频振动电液伺服控制系统的研究．中国机械工程．2001．10
[6] 李运华，王占林等．连铸机结晶器振动装置及其计算机控制系统．液压与气动．1999．1
[7] 方一鸣，焦晓红，李宪奎等．液压伺服驱动连铸结晶器振动控制系统的设计．冶金自动化．2000．1
[8] 张伟．连铸结晶器电液伺服系统的研究．液压与气动．2003．5
[9] 曹承志．微型计算机控制新技术．机械工业出版社．2001．6
[10] 郑晟，巩建平等．现代可编程序控制器原理与应用．科学出版社．2002．5
[11] 王永华等．现代电气及可编程控制技术．北京航空航天大学出版社．2002．9
[12] 周恩涛．可编程控制器原理及其在液压系统中的应用．机械工业出版社．2003．2
[13] 郭宗仁，吴亦锋，郭永．可编程序控制器应用系统设计及通信网络技术．人民邮电出版社．2002．9
[14] 李枫．Profibus现场总线技术的应用．计算机工程．2003．3
[15] 林威汉，高春光，张海涛．国内组态软件的现状与未来．电气时代．2002．6
[16] 胡友明．杜润生，杨叔子．液压系统运行状态监测．液压与气动．2002．8
[17] 湛从昌．液压可靠性与故障诊断．冶金工业出版社．1995．1
[18] 李士勇编著．模糊控制·神经控制和智能控制论．哈尔滨工业大学出版社1996．10
[19] 袁洪芳．基于Internet的FMS远程监测与故障诊断技术研究．制造业自动化．2000．5
[20] 黎洪生等．远程在线监测与故障诊断系统的设计与实现．武汉理工大学学报．2001．7
[21] 黄志坚等．珠钢轧机液压在线监测系统．南方钢铁．2000．6
[22] 张健成等．大型液压系统的在线监测和故障诊断．液压与气动．1999．7
[23] SIMATIC STEP 7 V5.2编程．西门子(中国)有限公司自动化与驱动集团．2003．2
[24] http://www.ad.siemens.com.cn/
[25] Gerhard Bocher, Uwe Gohler. Operational experience with a resonance mould for continuous casting of slabs[C] .2nd European Conference on Continuous Casting,Florence/Italy.sept, 1991,141-147
[26] Yarnashita T. Development in mould oscillation.Proc.con-cast workshop on slab casting. 1987.Kashima;59-61
[27] LAD for s7 300/400 programming.SIEMENS AG.1998
[28] Kane,les A.Fieldbus Getting More Confusing.Hydrocarbon Processing,2000(4)
[29] Richard H C.Fieldbus Application.ISA Transactin, 1989:28
[30] Siemens AG.SIMATIC S7-300 Components for Totally Integrated Automation Germany:Siemens ACt 1997
[31] 朱浩波．PLC在机电设备故障诊断中的应用．哈尔滨理工大学学报．2001．8
[32] 张琳．PLC及组态软件在高炉槽下配料控制系统中的应用研．合肥工业大学．2002．6
[33] 何国西．现场总线在PLC和工控机控制系统中应用方案比较．工业控制计算机．2003．2
[34] 梁首发．S7—300可编程序控制器及工控组态软件WinCC应用．中国仪器仪表．2001．3
[35] 黎洪生，李超，周登科等．基于PLC和组态软件的分布式监控系统设计．武汉理工大学学报．2002．3
[36] 桂在吾，沈俊杰，陈久康．VB在组态软件中的应用．电气自动化．2002．10
[37] 卢建华．使用WinCC实现过程监控．武汉科技大学学报．2000．3
[38] 姚良挺，黄志坚．板坯连铸机液压振动台故障的诊断．液压与气动．2002．10
[39] 陈奎生．液压阀与液压控制系统[M]．武汉工业大学出版社出版．1997
[40] J Michael Kiss, Mustafa Ozgu, Mark C Bublitz, et al.tri-Axial mold oscillation monitoring system[A]. Steel making Conference Proceedings[C], 1993,76:383～394
[41] B Mairy, D Ramelot, G Habay, et al, Mould oscillation monitoring for casting optimization [A]Proceeding from the 2nd Continuous Casting Conference[C], 1985:59.1～59.8
[42] M Yao, D C Fang. On line measuring method for mould friction in continuous casting[J].Iron making and Steel making, 1996,23(6):522～527
[43] Florkowski M. Partial discharge analyzer supported by neural network as a tool for monitoring and diagnosis. Proc of the 8th ISH, Vol2,Yokohama.Japan, 1993
[44] Herbert L, Gilles ,Bruce R Forman. Measurement and analysis of slab caster mold movement[A].Steel making Conference Proceeding[C], 1991,74:219～232
[45] 陈志新等．板坯结晶器振动状态在线监测系统设计与实现．系统与装置．2001．2
[46] 姜苍华等．宝钢2号板坯连铸机结晶器拉坯阻力在线监测系统的设计与应用．系统与装置．2001．6
[47] 李运华等．连铸机结晶器电液伺服振动波形系统的开发研制[J]．机床与液压，1998．3
[48] 何存兴．液压元件[M]．机械工业出版社．1989
[49] 董选明等．机电控制系统故障诊断的回顾与展望．中国机械工程．1998．10
[50] 王益群等．液压传动及控制系统故障诊断技术的新进展．燕山大学报．1998．1
[51] SIMATIC HMI WinCC系统描述．西门子(中国)有限公司自动化与驱动集团．2002．1
[52] SIMATIC HMI WinCC 5.0 USER'S MANUAL.SIEMENS AG.2002.1