高炉入炉料计量信息远程自动采集系统的设计与应用
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摘要
随着国际钢铁市场竞争的加剧，钢铁企业为了提升竞争力，着力推行ERP(企业资源计划)，依托信息化技术有效整合和充分利用企业的各类信息资源。基础数据及基础信息的完整、准确、及时是ERP正常运行的保证。为满足济钢ERP系统有效运行，要求炼铁高炉投入料计量信息要实现远程自动采集。
本论文来源于作者承担的实际技术工作，主要阐述了济钢炼铁厂入炉料计量信息远程自动采集系统的方案设计、论证与实施。通过对济钢炼铁厂高炉工控系统及槽下控制系统工艺现状的深入研究与分析，在以炼铁槽下电子配料秤量系统及槽下PLC控制的基础上，设计了1750m~3高炉和350m~3高炉数据采集系统的总体方案。硬件上，1750m~3高炉为确保工控系统的安全性，采取从二级服务器中采集基础数据，并通过物理隔离网闸，将计量数据上传ERP的计质量系统；350m~3高炉因要采集的槽下PLC之间距离较远，串口有效距离不够，每座高炉采用串口服务器构建PLC与主干网的信息通道，实现计量数据的远程采集，6座350m~3高炉基础数据都汇总到采集服务器，经过数据处理后，通过IPUSH消息中间件将计量数据上传计质量系统。软件上，采用三维力控组态软件编制采集软件、利用Delphi7软件工具编写高炉变料管理程序等应用程序，成功实现了济钢炼铁高炉入炉料按照高炉、按物料种类、按时间及时准确的传送到ERP的计质量系统，填补了济钢ERP系统炼铁投入料计量信息的空白，成功搭建了炼铁生产投入信息的共享平台，很好的满足了炼铁投入、产出成本分析的需要，为实现精细化炼铁奠定了基础。
本文的亮点在于硬件上成功应用先进的物理隔离网闸、IPUSH消息中间件等技术，物理隔离网闸实现了主干网与工控网的有效隔离，极大的增强了网络系统的安全性；应用IPUSH技术屏蔽网络硬件平台的差异性和操作系统与网络协议的异构性，大幅度提升了企业级的应用性能，满足关键业务的需求。软件上自主研发高炉变料管理程序及采集软件等，实现了入炉料以每座高炉为单元的实时采集及按物料种类的匹配、存储计算及自动上传。整个系统采集方式采用以太网传输，提高了系统网络传输的速度及可靠性。
As the development of competition in steel industry, many steel enterprises use ERP to improve competitiveness via integrating information of enterprise by information technology. An efficient ERP system needs integrative, accurate and in time basic data. This motivated us to implement the automatic remote data acquiring system of blast furnace charging.
This paper, which is based on a project undertaken by me, describes the detail design, analysis and practice of automatic remote data acquiring system of blast furnace charging system. I first detailedly studied the status of process control system under slot and all control system of the blast furnace in JiGang iron smelting plant. then I designed the integrative system of data acquiring in 1750m~3 and 350m~3 blast furnace.
In design of hardware structure, in order to make sure safety of the control system of 1750m~3 blast furnace, the system acquires basic data from the secondary server, and transmits them to metrology system of ERP via network gate with physical isolation. About the 350m~3 blast furnaces whose under slot PLCs separate too far each other to acquire data via series interface, I design a series interface server structure between PLCs and main network, so the data of 6 350m~3 blast furnace can be all collected together in series interface server, be pre-treated and transmit to metrology system of ERP via IPUSH middle-ware. In design of software, I use 3-D force control configure to program the sampling software, and program the charging control software on Delphi 7 programming platform.
My system successfully realizes that the charging data with information about every blast furnace, the kind of charges and charging time can be transferred to ERP metrology system in time. This system built the share platform of iron smelting charging information which was a blank field in Jigang ERP system. So my system well adapt to the needs of cost and yield analysis and becomes the bedrock to realize Lean Management in iron making process.
The high line of hardware design in this paper is the usage of the advanced technologies such as network gate with physical isolation and IPUSH message middle-ware. The former highly improved the safety of network by physically isolating main network and process control network; the later shield the differences of network hardware platform and the heterogeneity of operation systems and network protocols. So, my design can highly improved the performance of this industrial application system. About software design, I programmed the charging control and data sampling software. The network structure is based on Ethernet, which has high reliability and high transmitting speed.
本论文来源于作者承担的实际技术工作，主要阐述了济钢炼铁厂入炉料计量信息远程自动采集系统的方案设计、论证与实施。通过对济钢炼铁厂高炉工控系统及槽下控制系统工艺现状的深入研究与分析，在以炼铁槽下电子配料秤量系统及槽下PLC控制的基础上，设计了1750m~3高炉和350m~3高炉数据采集系统的总体方案。硬件上，1750m~3高炉为确保工控系统的安全性，采取从二级服务器中采集基础数据，并通过物理隔离网闸，将计量数据上传ERP的计质量系统；350m~3高炉因要采集的槽下PLC之间距离较远，串口有效距离不够，每座高炉采用串口服务器构建PLC与主干网的信息通道，实现计量数据的远程采集，6座350m~3高炉基础数据都汇总到采集服务器，经过数据处理后，通过IPUSH消息中间件将计量数据上传计质量系统。软件上，采用三维力控组态软件编制采集软件、利用Delphi7软件工具编写高炉变料管理程序等应用程序，成功实现了济钢炼铁高炉入炉料按照高炉、按物料种类、按时间及时准确的传送到ERP的计质量系统，填补了济钢ERP系统炼铁投入料计量信息的空白，成功搭建了炼铁生产投入信息的共享平台，很好的满足了炼铁投入、产出成本分析的需要，为实现精细化炼铁奠定了基础。
本文的亮点在于硬件上成功应用先进的物理隔离网闸、IPUSH消息中间件等技术，物理隔离网闸实现了主干网与工控网的有效隔离，极大的增强了网络系统的安全性；应用IPUSH技术屏蔽网络硬件平台的差异性和操作系统与网络协议的异构性，大幅度提升了企业级的应用性能，满足关键业务的需求。软件上自主研发高炉变料管理程序及采集软件等，实现了入炉料以每座高炉为单元的实时采集及按物料种类的匹配、存储计算及自动上传。整个系统采集方式采用以太网传输，提高了系统网络传输的速度及可靠性。
As the development of competition in steel industry, many steel enterprises use ERP to improve competitiveness via integrating information of enterprise by information technology. An efficient ERP system needs integrative, accurate and in time basic data. This motivated us to implement the automatic remote data acquiring system of blast furnace charging.
This paper, which is based on a project undertaken by me, describes the detail design, analysis and practice of automatic remote data acquiring system of blast furnace charging system. I first detailedly studied the status of process control system under slot and all control system of the blast furnace in JiGang iron smelting plant. then I designed the integrative system of data acquiring in 1750m~3 and 350m~3 blast furnace.
In design of hardware structure, in order to make sure safety of the control system of 1750m~3 blast furnace, the system acquires basic data from the secondary server, and transmits them to metrology system of ERP via network gate with physical isolation. About the 350m~3 blast furnaces whose under slot PLCs separate too far each other to acquire data via series interface, I design a series interface server structure between PLCs and main network, so the data of 6 350m~3 blast furnace can be all collected together in series interface server, be pre-treated and transmit to metrology system of ERP via IPUSH middle-ware. In design of software, I use 3-D force control configure to program the sampling software, and program the charging control software on Delphi 7 programming platform.
My system successfully realizes that the charging data with information about every blast furnace, the kind of charges and charging time can be transferred to ERP metrology system in time. This system built the share platform of iron smelting charging information which was a blank field in Jigang ERP system. So my system well adapt to the needs of cost and yield analysis and becomes the bedrock to realize Lean Management in iron making process.
The high line of hardware design in this paper is the usage of the advanced technologies such as network gate with physical isolation and IPUSH message middle-ware. The former highly improved the safety of network by physically isolating main network and process control network; the later shield the differences of network hardware platform and the heterogeneity of operation systems and network protocols. So, my design can highly improved the performance of this industrial application system. About software design, I programmed the charging control and data sampling software. The network structure is based on Ethernet, which has high reliability and high transmitting speed.
引文
1. Steve Barker Protecting deductive databases from unauthorized retrieval and update request[J]. Data&Knowledge Engineering, 2002, 43: 293-315
2. Jose S. [Draft] Recommendation T.126 Multipoint Still Image and Annotation Protocol, 1995
3. Boucher J, Heath M, Suffolk. Data protocols for multimedia conferencing draft recommendation T. 120, 1996
4. Bakken D E. MIDDLEWARE, Eneyelopedia of Distributed Computing. Kluwer Acedemic Press, 2001
5. Verissimo P, Rodrigues L. Distributed Systems for System Architects. Kluwer Academic Press, 2001
6. IBM. MQSeries system administration SC33-1873-01[DB/CD]
7. Postel J, Reynolds J. File transfer protocol RFC 959(1985)[S/OL]
8．金占明 企业管理学．北京：清华大学出版社，2002．8：220-226
9．周传华 企业ERP系统的实践过程解读 中国制造业信息化，2003．6：34-35
10．史群生 ERP系统成功实施的关键CAD／CAM与制造业信息化，2003．11：32-34
11．陈家祥 钢铁冶金学 北京：冶金工业出版社，1990．5：1-7
12．廉晓霞 配料秤系统精度探析．沈阳：衡器，2003．7：34-35
13．孙衍军 配料秤在LF-50钢包精炼炉中的应用．沈阳：衡器，1996．2：25-26
14．范军 无线通讯技术在远程数据采集中的应用．四川：四川冶金，2006．01
15．王枫 张晓娟 物理隔离技术的原理与实现 计算机安全，2006．12
16．许云明 李春胜物理隔离网闸的原理及应用 计算机安全，2005．12
17．魏勇 张权 中间件技术研究 电子技术应用，2004．11
18．李冰颖 舒远仲 叶申锐 中间件技术的研究与应用，南昌航空工业学院学报，2004．02
19．贾文峰 中间件技术及其应用 洛阳大学学报，2005．04
20．张进宇 李晓明 一种基于消息中间件的多服务器文件存储系统计算机工程与设计 2003．12：21-27
21．丁金明 曲兴华 宋丽梅 串口技术在工业现场多点数据测量中的应用 电子测量与仪器学报，2005．03
22．柯伯乐 池江 汤天浩 基于MOXA多串口卡的多串口通讯的实现 工业控制计算机，2004．01
23．宋捷 于敏 基于消息中间件的网络协同编辑环境框架．北京：华中科技大学学报，2003．10：360-361
24．杨新平 周咏梅 中间件的原理与应用．华南金融电脑，2003．2：53-55
25．李代平 章文Oracle9i数据库应用基础．北京：冶金工业出版社，2003．1：27-33
26．胡永华Oracle数据库的性能优化．云南：云南电力技术，2003．6：69-70
27．力控用户手册．北京：三维力控科技有限公司，1999：132．156
28．Andrew S．Tanenbaum计算机网络．北京：清华大学出版社，2004．8：31-68
29．张立科Delphi7组件编程参考手册．北京：人民邮电出版社，2003．11：8-306
30．李之明高玉琢Delphi7组件经典解析．北京：中国铁道出版社，2003．6：11-46
31．申曼Delphi高手突破．北京：清华大学出版社，2002：
32．周晓宁槽下秤校准办法．济钢：济钢计量管理处，2006．1
2. Jose S. [Draft] Recommendation T.126 Multipoint Still Image and Annotation Protocol, 1995
3. Boucher J, Heath M, Suffolk. Data protocols for multimedia conferencing draft recommendation T. 120, 1996
4. Bakken D E. MIDDLEWARE, Eneyelopedia of Distributed Computing. Kluwer Acedemic Press, 2001
5. Verissimo P, Rodrigues L. Distributed Systems for System Architects. Kluwer Academic Press, 2001
6. IBM. MQSeries system administration SC33-1873-01[DB/CD]
7. Postel J, Reynolds J. File transfer protocol RFC 959(1985)[S/OL]
8．金占明 企业管理学．北京：清华大学出版社，2002．8：220-226
9．周传华 企业ERP系统的实践过程解读 中国制造业信息化，2003．6：34-35
10．史群生 ERP系统成功实施的关键CAD／CAM与制造业信息化，2003．11：32-34
11．陈家祥 钢铁冶金学 北京：冶金工业出版社，1990．5：1-7
12．廉晓霞 配料秤系统精度探析．沈阳：衡器，2003．7：34-35
13．孙衍军 配料秤在LF-50钢包精炼炉中的应用．沈阳：衡器，1996．2：25-26
14．范军 无线通讯技术在远程数据采集中的应用．四川：四川冶金，2006．01
15．王枫 张晓娟 物理隔离技术的原理与实现 计算机安全，2006．12
16．许云明 李春胜物理隔离网闸的原理及应用 计算机安全，2005．12
17．魏勇 张权 中间件技术研究 电子技术应用，2004．11
18．李冰颖 舒远仲 叶申锐 中间件技术的研究与应用，南昌航空工业学院学报，2004．02
19．贾文峰 中间件技术及其应用 洛阳大学学报，2005．04
20．张进宇 李晓明 一种基于消息中间件的多服务器文件存储系统计算机工程与设计 2003．12：21-27
21．丁金明 曲兴华 宋丽梅 串口技术在工业现场多点数据测量中的应用 电子测量与仪器学报，2005．03
22．柯伯乐 池江 汤天浩 基于MOXA多串口卡的多串口通讯的实现 工业控制计算机，2004．01
23．宋捷 于敏 基于消息中间件的网络协同编辑环境框架．北京：华中科技大学学报，2003．10：360-361
24．杨新平 周咏梅 中间件的原理与应用．华南金融电脑，2003．2：53-55
25．李代平 章文Oracle9i数据库应用基础．北京：冶金工业出版社，2003．1：27-33
26．胡永华Oracle数据库的性能优化．云南：云南电力技术，2003．6：69-70
27．力控用户手册．北京：三维力控科技有限公司，1999：132．156
28．Andrew S．Tanenbaum计算机网络．北京：清华大学出版社，2004．8：31-68
29．张立科Delphi7组件编程参考手册．北京：人民邮电出版社，2003．11：8-306
30．李之明高玉琢Delphi7组件经典解析．北京：中国铁道出版社，2003．6：11-46
31．申曼Delphi高手突破．北京：清华大学出版社，2002：
32．周晓宁槽下秤校准办法．济钢：济钢计量管理处，2006．1