本钢炼钢厂1#AHF及RH实时数据通信系统的研究与开发
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摘要
随着计算机技术及网络通信技术的迅猛发展,国内外各钢铁企业为了提高生产效率,增强企业在市场中的竞争实力,对企业的自动化、信息化建设提出了更高的要求,希望能够利用计算机的强大功能来更好地实现企业生产管理的自动化、信息化,最终达到管控一体化的目标。在企业的自动化信息化建设进程中,有很多企业都不希望完全更换原有的基础自动化设备,一方面是由于这些设备运转良好,仍能满足生产需求;另一方面是如果彻底替换掉这些设备,不但投资大、开发周期长,而且还会严重影响企业的正常生产。因此大多数企业都希望能够找到一种解决此类问题的方法,即能够在保留原有自动化设备的基础上对其自动化系统进行改造和升级,实现企业自动化控制系统与信息管理系统的整合。
本文针对以上问题,提出了开发实时数据通信系统的解决方案,并以本钢炼钢厂1#AHF及RH炉外精炼设备为背景,分析了1#AHF及RH自动化系统中所存在的一级与二级自动化系统无法通信的问题,在保留一级自动化系统中原有的西门子公司S5-155U型PLC的基础上,对其自动化系统进行改造,设计并丌发了实时数据通信系统,实现了1#AHF及RH一级与二级自动化系统的实时通信。该系统通过工业以太网将一级自动化系统中的S5-155U型PLC与二级自动化系统中的计算机组网,采用组态软件WinCC将一级自动化系统S5-155U中的生产过程数据实时地采集到过程控制计算机,并采用OPC技术,通过实时数据通信软件取出这些数据,进行相应的处理,最后实时地发送到二级自动化系统的Oracle数据库服务器,完成了炼钢厂1#AHF及RH—级与二级自动化系统的实时通信。
目前,整个系统已在模拟环境中测试通过,其运转稳定、功能完整、性能可靠,达到了炼钢厂的生产实际需求,得到了工厂的认可。
With the rapid development of technologies of computer, network and communication, the national and international steel enterprises put forward the higher request to their automation and informatization construction in order to increase efficiency and enhance competitive ability. They want to construct the automation and informatization of enterprise by making use of the powerful functions of computer and achieve the aim of the integration of management and control finally. In the process of the automation and informatization construction of enterprise, a good deal of enterprises don't want their old basic automation devices to be replaced entirely. One side, these devices are still running normally, and can be satisfied with the requirement of production very well. On the other hand, if these old devices are replaced entirely, it will spend lots of money and extend the period of development. Even, it will break the daily production of enterprise seriously. So most of enterprises want to find a good method to solve this problem. They hope this method can improve and upgrade automation system on the foundation of reserving the old basic automation devices. And achieve the integration between the automation control system and management information system of enterprise.In view of the above-mentioned problem, this thesis introduces the solution which can solve the problem commendably by developing a real-time data communication system between level 1 and level 2 automation system of enterprise. Using the steel-making plant at Benxi Iron and Steel (Group) Co., LTD. as the background, it analyzes the problem which is about the information of production can't be transmitted from level 1 to level 2 automation system of 1# AHF & RH in steel-making plant. The automation system is improved on the foundation of reserving the old PLC devices of SIMENS S5-155U. It designs and develops the real-time data communication system, and achieves real-time communication between level 1 and level 2 automation system of 1# AHF & RH finally. This system connects S5-155U of the level 1 automation system with the process control computer of the level 2 automation system by technology of industrial Ethernet. The process control computer of the level 2 automation system collects the data of production from S5-155U of the level 1 automation system by the configuration software. The real-time data communication software is programmed by using the technology of OPC, which can collect the data form
configuration software and send the data to the server of Oracle database which is in the level 2 automation system immediately. Through this process, the real-time data communication system achieves the aim of real-time communication between level 1 and level 2 automation system of 1# AHF & RH in steel-making plant.At present, the test for real-time data communication system has been past in the simulative condition. In the testing process, the system is running stability, and its function is integrated, capability is credible. It is satisfied with the need of the steel-making plant, and be approbated by the enterprise.
本文针对以上问题,提出了开发实时数据通信系统的解决方案,并以本钢炼钢厂1#AHF及RH炉外精炼设备为背景,分析了1#AHF及RH自动化系统中所存在的一级与二级自动化系统无法通信的问题,在保留一级自动化系统中原有的西门子公司S5-155U型PLC的基础上,对其自动化系统进行改造,设计并丌发了实时数据通信系统,实现了1#AHF及RH一级与二级自动化系统的实时通信。该系统通过工业以太网将一级自动化系统中的S5-155U型PLC与二级自动化系统中的计算机组网,采用组态软件WinCC将一级自动化系统S5-155U中的生产过程数据实时地采集到过程控制计算机,并采用OPC技术,通过实时数据通信软件取出这些数据,进行相应的处理,最后实时地发送到二级自动化系统的Oracle数据库服务器,完成了炼钢厂1#AHF及RH—级与二级自动化系统的实时通信。
目前,整个系统已在模拟环境中测试通过,其运转稳定、功能完整、性能可靠,达到了炼钢厂的生产实际需求,得到了工厂的认可。
With the rapid development of technologies of computer, network and communication, the national and international steel enterprises put forward the higher request to their automation and informatization construction in order to increase efficiency and enhance competitive ability. They want to construct the automation and informatization of enterprise by making use of the powerful functions of computer and achieve the aim of the integration of management and control finally. In the process of the automation and informatization construction of enterprise, a good deal of enterprises don't want their old basic automation devices to be replaced entirely. One side, these devices are still running normally, and can be satisfied with the requirement of production very well. On the other hand, if these old devices are replaced entirely, it will spend lots of money and extend the period of development. Even, it will break the daily production of enterprise seriously. So most of enterprises want to find a good method to solve this problem. They hope this method can improve and upgrade automation system on the foundation of reserving the old basic automation devices. And achieve the integration between the automation control system and management information system of enterprise.In view of the above-mentioned problem, this thesis introduces the solution which can solve the problem commendably by developing a real-time data communication system between level 1 and level 2 automation system of enterprise. Using the steel-making plant at Benxi Iron and Steel (Group) Co., LTD. as the background, it analyzes the problem which is about the information of production can't be transmitted from level 1 to level 2 automation system of 1# AHF & RH in steel-making plant. The automation system is improved on the foundation of reserving the old PLC devices of SIMENS S5-155U. It designs and develops the real-time data communication system, and achieves real-time communication between level 1 and level 2 automation system of 1# AHF & RH finally. This system connects S5-155U of the level 1 automation system with the process control computer of the level 2 automation system by technology of industrial Ethernet. The process control computer of the level 2 automation system collects the data of production from S5-155U of the level 1 automation system by the configuration software. The real-time data communication software is programmed by using the technology of OPC, which can collect the data form
configuration software and send the data to the server of Oracle database which is in the level 2 automation system immediately. Through this process, the real-time data communication system achieves the aim of real-time communication between level 1 and level 2 automation system of 1# AHF & RH in steel-making plant.At present, the test for real-time data communication system has been past in the simulative condition. In the testing process, the system is running stability, and its function is integrated, capability is credible. It is satisfied with the need of the steel-making plant, and be approbated by the enterprise.
引文
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[9] 唐建军,李长荣,洪新.钢铁企业信息化和CIMS/ERP系统建设.上海金属.2003,25(3):24-27.
[10] 谢国庆.济钢三炼钢MES系统的研究与实现:(硕士学位论文).北京:北京航空航天大学,2004.
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[20] 宋真君.基于工业以太网的分布式控制系统的通信研究.厦门大学学报.2001,40(1):24-28.
[21] 周晓兵.以太网在工业自动化领域的应用现状和发展前景.自动化仪表.2001,22(10):55-58.
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[23] 袁秀英.组态控制技术.北京:电子工业出版社,2003.
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[30] 扬路明,雷亚军.组态软件WinCC在自动监控系统中的应用.计算技术与自动化.2003,22(4):21-24.
[31] 陈冠玲.工控组态软件与其它软件数据交换的三种方式.计算机测量与控制.2002,10(11):754-756.
[32] 施晓红,佘龙华,龙志强.PC与PLC的动态数据交换(DDE)研究.电气传动.2005,35(4):45-47.
[33] 徐波,熊萍.ODBC数据库互操作技术综述.计算机应用.1998,18(3):1-4.
[34] 王双庆,邢建春.OPC——现代工业控制软件互操作标准.测控技术.2000,19(3):43-45.
[35] 邢建春,王平,仲未央等.工业控制软件互操作标准OPC综述.工业控制计算机.2003,13(1):29-33.
[36] 薛福珍,林盛荣,唐瑛.基于OPC数据访问规范的客户端软件研究与开发.计算机工程.2002,28(4):229-231.
[37] 王鲲,袁中凡.OPC接口技术在工业自动化系统中的应用.中国测试技术.2005,31(1):95-97.
[38] 蔡翔云.OPC规范及其开发应用.昆明理工大学学报.2002,27(3):1-7.
[39] 王汉新.Visual Basic程序设计.北京:科学出版社,2002.
[40] McLaughlin, R.T. Control networks: The impact on industry. Sensor Review. 1997,17(3):192-193.
[41] Bowers, Alicia. Automation. PPI Pulp and Paper International. 2003, 5(2):37-39.
[42] Anon. Understanding PLC networks. Electrical Construction and Maintenance. 1996,95(1):3.
[43] Phillips, Kirt. PLCs over the net. Industrial Computing. 1998, 17(8):32-33.
[44] Farsi, M. Application of a PLC as a cell controller using a communication network. IEE Colloquium (Digest). 1995, 11(2):31-34.
[45] NilssonJ. real-time control systems with time delays. Sweden: Lund Institute of Technology, 1998.
[46] Bhullar, Romel. S. Strategies for implementing advanced process controls in a distributed control system (DCS). ISA Transactions. 1993, 32(2):147-158.
[47] Aacck, W. sky. How to guarantee factory communication with switched Ethernet: survey of its emerging technology. IEEE. 2000, 2525-2530.
[48] Manuele, Bertoluzzo, Ethernet Networks for Factory Automatoion. IEEE, 2002, 175-180.
[49] Mintchell, Gary A. OPC integrates the factory floor. Control Engineering. 2001,48(1):39-44.
[50] Holley, Don. OPC unites industrial automation systems. ISA TECH/EXPO Technology Update Conference Proceedings. 1997, 1(3):11-17.
[51] Vaca, Rod. OPC the universal connectivity tool. ISA TECH/EXPO Technology Update Conference Proceedings. 2000, 40(2):113-118.
[52] Tinham, Brian. OLE/OPC and systems for process control. Control and Instrumentation. 1997. 29(4):24.
[53] Chisholm, Al. Technical overview of the OPC data access interfaces. ISA TECH/EXPO Technology Update Conference Proceedings. 1998, 2(1):63-72.
[54] 赵伟.精炼工序钢水温度控制研究:(硕士学位论文).沈阳:东北大学,2003.
[55] 岳铁莹,于华财,谭明祥.150tAHF炉外精炼工艺参数优化.钢铁.2005,40(4):28-31.
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[2] 林行辛,王东涛.钢铁工业自动化的进展与展望.河北冶金.1998,(2):25-29.
[3] 王晨,李波.钢铁生产过程自动化的发展和展望.河南冶金.2005,13(1):22-24.
[4] 袁宇峰.我国钢铁工业自动化的现状和发展.钢铁研究.2004,(3):49-51.
[5] 马竹梧.钢铁工业自动化进展及今后任务.工程设计CAD与智能建筑.1995,(4):7-12.
[6] 罗竑.我国中小企业信息化建设研究:(硕士学位论文).北京:北京交通大学,2004.
[7] 王少军.包钢信息化建设的研究:(硕士学位论文).北京:北京科技大学,2004.
[8] 王成立.广钢股份公司信息化方案研究:(硕士学位论文).北京:北京科技大学,2004.
[9] 唐建军,李长荣,洪新.钢铁企业信息化和CIMS/ERP系统建设.上海金属.2003,25(3):24-27.
[10] 谢国庆.济钢三炼钢MES系统的研究与实现:(硕士学位论文).北京:北京航空航天大学,2004.
[11] 刘向辉.炼铁企业控制网与信息网互联及生产现场信息实时管理:(硕士学位论文).北京:北京科技大学,2004.
[12] 黄明琪,冯济缨,王福平.可编程序控制器.重庆:重庆大学出版社.2003.
[13] 弭洪涛,王忠礼.PLC实用技术.北京:科学出版社,2004.
[14] ISA. Fieldbus Standard for Use in Industrial Control Systems. Texas: ISA, 1997.
[15] 唐济扬.现场总线技术(Profibus)应用指南.北京:中国现场总线专业委员会,1998.
[16] 阳宪惠.现场总线技术及其应用.北京:清华大学出版社,1999.
[17] Tommesse J P. A review of fieldbus. Annual review in control, 1998, (2): 35-45.
[18] Tovar, Eduardo. Real-time fieldbus communications using Profibusnet works. IEEET ransactionon Industrial Electronics. 1999, 46(6):1241.
[19] 陈积明.工业以太网的研究现状及展望.化工自动化仪表.2001,28(6):35-38.
[20] 宋真君.基于工业以太网的分布式控制系统的通信研究.厦门大学学报.2001,40(1):24-28.
[21] 周晓兵.以太网在工业自动化领域的应用现状和发展前景.自动化仪表.2001,22(10):55-58.
[22] L. Lo, Bello. Performances Analysis of Ethernet Networks in the Process Control. IEEE. 2000, 655-660.
[23] 袁秀英.组态控制技术.北京:电子工业出版社,2003.
[24] 高淑敏,费玉华.PLC和Pc实时通信方法的研究.自动化博览.2003,(6):62-64.
[25] 谢军.工控组态软件的功能分析和应用.交通与计算机.2000,18(3):46-48.
[26] 李志刚.工控组态软件及其在工业控制中的应用.微计算机信息.1998,14(3):43-46.
[27] 易异勋.工控系统组态软件体系结构的研究.基础自动化.2000,7(4):62-64.
[28] 马国华.监控组态软件及其应用.北京:清华大学出版社,2001.8
[29] 西门子(中国)有限公司.SIMATIC HMI WinCC系统描述.北京:西门子(中国)有限公司,2002.
[30] 扬路明,雷亚军.组态软件WinCC在自动监控系统中的应用.计算技术与自动化.2003,22(4):21-24.
[31] 陈冠玲.工控组态软件与其它软件数据交换的三种方式.计算机测量与控制.2002,10(11):754-756.
[32] 施晓红,佘龙华,龙志强.PC与PLC的动态数据交换(DDE)研究.电气传动.2005,35(4):45-47.
[33] 徐波,熊萍.ODBC数据库互操作技术综述.计算机应用.1998,18(3):1-4.
[34] 王双庆,邢建春.OPC——现代工业控制软件互操作标准.测控技术.2000,19(3):43-45.
[35] 邢建春,王平,仲未央等.工业控制软件互操作标准OPC综述.工业控制计算机.2003,13(1):29-33.
[36] 薛福珍,林盛荣,唐瑛.基于OPC数据访问规范的客户端软件研究与开发.计算机工程.2002,28(4):229-231.
[37] 王鲲,袁中凡.OPC接口技术在工业自动化系统中的应用.中国测试技术.2005,31(1):95-97.
[38] 蔡翔云.OPC规范及其开发应用.昆明理工大学学报.2002,27(3):1-7.
[39] 王汉新.Visual Basic程序设计.北京:科学出版社,2002.
[40] McLaughlin, R.T. Control networks: The impact on industry. Sensor Review. 1997,17(3):192-193.
[41] Bowers, Alicia. Automation. PPI Pulp and Paper International. 2003, 5(2):37-39.
[42] Anon. Understanding PLC networks. Electrical Construction and Maintenance. 1996,95(1):3.
[43] Phillips, Kirt. PLCs over the net. Industrial Computing. 1998, 17(8):32-33.
[44] Farsi, M. Application of a PLC as a cell controller using a communication network. IEE Colloquium (Digest). 1995, 11(2):31-34.
[45] NilssonJ. real-time control systems with time delays. Sweden: Lund Institute of Technology, 1998.
[46] Bhullar, Romel. S. Strategies for implementing advanced process controls in a distributed control system (DCS). ISA Transactions. 1993, 32(2):147-158.
[47] Aacck, W. sky. How to guarantee factory communication with switched Ethernet: survey of its emerging technology. IEEE. 2000, 2525-2530.
[48] Manuele, Bertoluzzo, Ethernet Networks for Factory Automatoion. IEEE, 2002, 175-180.
[49] Mintchell, Gary A. OPC integrates the factory floor. Control Engineering. 2001,48(1):39-44.
[50] Holley, Don. OPC unites industrial automation systems. ISA TECH/EXPO Technology Update Conference Proceedings. 1997, 1(3):11-17.
[51] Vaca, Rod. OPC the universal connectivity tool. ISA TECH/EXPO Technology Update Conference Proceedings. 2000, 40(2):113-118.
[52] Tinham, Brian. OLE/OPC and systems for process control. Control and Instrumentation. 1997. 29(4):24.
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