基于PLC的分布式系统在锅炉监控中的应用研究
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摘要
锅炉是工业生产中能源动力供应的主要设备,也是我国北方大部分城市集中供热和建筑采暖的主要设备。伴随着计算机应用技术与信息技术的不断发展,以可编程逻辑控制器(PLC:Programmable Logic Controller)为核心的计算机监控系统在工业锅炉控制中的应用越来越引起人们的广泛关注。
锅炉作为将一次能源转化为二次能源的高耗能、高污染的设备,因自动化程度不高而长期工作在非经济工况状态下,结果导致了我国能源消耗的居高不下和环境污染。此外,我国目前的锅炉行业还存在着劳动力密集以及生产与管理脱节的情况。为了充分发挥能源效能、减轻工人劳动强度、提高企业信息化管理水平,设计一套安全、可靠、有效的系统来实现锅炉生产的自动监控势在必行。
本文以三台工业热水锅炉及其相关辅助控制设备为研究对象,采用Siemens S7-300 PLC为核心控制器,结合Profibus现场总线技术,利用变频调速技术、网络技术和冗余技术,将现场所有控制设备构建为分布式监控系统。通过对下位机与上位机的软件编程和软硬件组态,实现了三台热水锅炉的全部监控。
Profibus总线是工业自动化领域广泛使用的现场总线标准,ET200M是Siemens PLC用来实现分布式I/O的模块化从站,利用接口模块IM153-2可以方便地把ET200M从站接入到Profibus总线上,使S7-300 PLC分布式锅炉监控系统的实现成为可能。
变频器通讯控制是网络技术在变频器技术中的一项新的应用,该应用有效地节约了系统的硬件成本,通过Profibus总线上通讯报文的收发,使交流变频调速技术的实现更加简单、可靠。
软冗余技术是一种通过软件来实现的、低成本的冗余技术。结合支持软冗余的硬件设备,系统可以在主系统发生故障的情况下自动切入到备用系统中,极大地提高了系统的可靠性。
自动负荷调节是应工艺的要求通过软件编程的方式实现的对燃烧系统各风机进行的自动调节,该技术在保证了锅炉安全运行的前提下,减少了系统能量及能源的浪费,是节能环保的关键性技术。
此外,顺序控制及系统中的安全保护机制保证了系统的安全运行;信息丰富、人机交互友好的上位机画面,实时显示了系统运行时的全部数据和状态,方便了操作和信息管理。
The boiler is the main equipment which provides energy and power in industrial production and is widely used in the north of our country for central heating project and building supply heating. With the development of the computer and information technology, the application of computer supervisor and control system which is based on PLC arises more and more attention in industrial boiler automation.
Being a kind of equipment which transform the primary energy into secondary energy and having consumed much energy and caused serious pollution, the boilers cause high energy consumption and severe environmental pollution, because they were working under non-economical condition and low automation level for a long time. Furthermore, at present, there are concentration of labor force and the separation of manufacturing and administration in the boiler industry. In order to improve the efficiency of energy utilization sufficiently, reduce the labor intensity of workers, and improve the management level of information in the enterprise, a set of supervisor and control system with enough safety, liability and high efficiency which can guarantee the boiler's automation is very necessary.
The paper takes three industry hot water boilers and their related assistant control devices as object of study. Using Siemens S7-300 PLC as their core controller and making use of profibus field-bus protocol, speed regulation technology of frequency converter, network technology and redundant technology, the system construct all of control devices to be distributed supervisory and control system. Furthermore, the project realized supervisory and control of three hot water boilers by software programming and hardware building.
The profibus is the field-bus standard that is used widely the industrial automation field and ET200M is used as a slave unit to be used to realize distributed I/O station in Siemens PLC systems. ET200M unit can be insert into profibus field-bus conveniently by making use of interface module IM153-2, thus, S7-300 PLC distributed supervisory control system in boiler gets possibility to be realization.
Communication control for frequency converter is one new application that makes use of network technology in frequency converter technology. The technology can save much hardware costs effectively and realize speed regulation simply and reliably by the aid of frequency converter and transmit-receive of communication messages in profibus field-bus.
Software redundancy is one kind of low costs redundancy technology by use of programming. The technology can improve reliability of system greatly on the basis of hardware that supports redundancy realization. When master system's failure happened, the slave system can enter into working state voluntarily to take over working task.
Load adjusting automatically is used to adjust speed of all wind machines to suitable value by use of programming for the purpose of meeting requirement of system techniques. The technology reduces the energy consumption and resource waste under the guarantee of boiler burning safely. It is a key technology of energy conservation and environment protection.
Besides, sequential control and safety mechanism of system ensure that the system can work safely. HMI pictures that include rich information and friendly man-machine conversation show all system data and state real-timely and provide convenience of operation and information management greatly.
锅炉作为将一次能源转化为二次能源的高耗能、高污染的设备,因自动化程度不高而长期工作在非经济工况状态下,结果导致了我国能源消耗的居高不下和环境污染。此外,我国目前的锅炉行业还存在着劳动力密集以及生产与管理脱节的情况。为了充分发挥能源效能、减轻工人劳动强度、提高企业信息化管理水平,设计一套安全、可靠、有效的系统来实现锅炉生产的自动监控势在必行。
本文以三台工业热水锅炉及其相关辅助控制设备为研究对象,采用Siemens S7-300 PLC为核心控制器,结合Profibus现场总线技术,利用变频调速技术、网络技术和冗余技术,将现场所有控制设备构建为分布式监控系统。通过对下位机与上位机的软件编程和软硬件组态,实现了三台热水锅炉的全部监控。
Profibus总线是工业自动化领域广泛使用的现场总线标准,ET200M是Siemens PLC用来实现分布式I/O的模块化从站,利用接口模块IM153-2可以方便地把ET200M从站接入到Profibus总线上,使S7-300 PLC分布式锅炉监控系统的实现成为可能。
变频器通讯控制是网络技术在变频器技术中的一项新的应用,该应用有效地节约了系统的硬件成本,通过Profibus总线上通讯报文的收发,使交流变频调速技术的实现更加简单、可靠。
软冗余技术是一种通过软件来实现的、低成本的冗余技术。结合支持软冗余的硬件设备,系统可以在主系统发生故障的情况下自动切入到备用系统中,极大地提高了系统的可靠性。
自动负荷调节是应工艺的要求通过软件编程的方式实现的对燃烧系统各风机进行的自动调节,该技术在保证了锅炉安全运行的前提下,减少了系统能量及能源的浪费,是节能环保的关键性技术。
此外,顺序控制及系统中的安全保护机制保证了系统的安全运行;信息丰富、人机交互友好的上位机画面,实时显示了系统运行时的全部数据和状态,方便了操作和信息管理。
The boiler is the main equipment which provides energy and power in industrial production and is widely used in the north of our country for central heating project and building supply heating. With the development of the computer and information technology, the application of computer supervisor and control system which is based on PLC arises more and more attention in industrial boiler automation.
Being a kind of equipment which transform the primary energy into secondary energy and having consumed much energy and caused serious pollution, the boilers cause high energy consumption and severe environmental pollution, because they were working under non-economical condition and low automation level for a long time. Furthermore, at present, there are concentration of labor force and the separation of manufacturing and administration in the boiler industry. In order to improve the efficiency of energy utilization sufficiently, reduce the labor intensity of workers, and improve the management level of information in the enterprise, a set of supervisor and control system with enough safety, liability and high efficiency which can guarantee the boiler's automation is very necessary.
The paper takes three industry hot water boilers and their related assistant control devices as object of study. Using Siemens S7-300 PLC as their core controller and making use of profibus field-bus protocol, speed regulation technology of frequency converter, network technology and redundant technology, the system construct all of control devices to be distributed supervisory and control system. Furthermore, the project realized supervisory and control of three hot water boilers by software programming and hardware building.
The profibus is the field-bus standard that is used widely the industrial automation field and ET200M is used as a slave unit to be used to realize distributed I/O station in Siemens PLC systems. ET200M unit can be insert into profibus field-bus conveniently by making use of interface module IM153-2, thus, S7-300 PLC distributed supervisory control system in boiler gets possibility to be realization.
Communication control for frequency converter is one new application that makes use of network technology in frequency converter technology. The technology can save much hardware costs effectively and realize speed regulation simply and reliably by the aid of frequency converter and transmit-receive of communication messages in profibus field-bus.
Software redundancy is one kind of low costs redundancy technology by use of programming. The technology can improve reliability of system greatly on the basis of hardware that supports redundancy realization. When master system's failure happened, the slave system can enter into working state voluntarily to take over working task.
Load adjusting automatically is used to adjust speed of all wind machines to suitable value by use of programming for the purpose of meeting requirement of system techniques. The technology reduces the energy consumption and resource waste under the guarantee of boiler burning safely. It is a key technology of energy conservation and environment protection.
Besides, sequential control and safety mechanism of system ensure that the system can work safely. HMI pictures that include rich information and friendly man-machine conversation show all system data and state real-timely and provide convenience of operation and information management greatly.
引文
[1]唐永耀.锅炉控制及PLC应用[D].合肥:合肥工业大学,2006
[2]何群.基于广义预测控制的锅炉测控系统研究[D].秦皇岛:燕山大学,2005
[3]G.Ju,S.B.Chen.A study of the constrained model predictive control for the boiler superheated steam of a thermal power plant[J].Journal of Engineering for Thermal Energy and Power,2004,16(6):641-643
[4]于海生,潘松峰.微型计算机控制技术[M].北京:清华大学出版社,1999
[5]我国工业自动化市场现状分析报告[EB/OL].http://www.labbase.net/News/ShowNewsDetails-1-23-0A985E4ACC674200.html
[6]孙增圻.计算机控制理论及应用[M].北京:清华大学出版社,1989
[7]涂植英.过程控制系统[M].北京:机械工业出版社,1983
[8]徐传诏,赵岩.我国工业锅炉的现状、差距与展望[J].应用能源技术,2002,(4):42-43
[9]刘福仁.我国锅炉现状及存在的问题[J].北京市计划劳动管理干部学院学报,2005,13(3):42-45
[10]任毅,孙伟.我国流化床锅炉热工控制技术的发展与思考[J].煤矿机电,2004,(1):26-29
[11]赵钦新.燃油燃气锅炉[M].西安:西安交通大学出版社,2000
[12]王登贵.PLC模块化生产设备计算机监控系统设计与研究[D].西安:西北农林科技大学,2007
[13]冯雪飞.基于企业网的高炉电除尘计算机监控系统研究与开发[D].武汉:武汉理工大学,2003
[14]杨国良,林拥军.PLC在区域供冷自控系统中的应用及分析[J].电气传动自动化,2006,28(3):49-52
[15]L.F.Zhou,L.H.Ma.Study on satisfactory predictive control algorithm for complex systems[C].Fifth World Congress on Intelligent Control and Automation,2004,1:659-662
[16]汪志峰.可编程序控制器原理与应用[M].西安:西安电子科技大学出版社,2004
[17]邓星钟,周祖德,邓坚.机电传动控制[M].武汉:华中理工大学出版社,1998
[18]王常力,罗安.集散型控制系统选型与应用[M].北京:清华大学出版社,1995
[19]Kolokotsa D,Stavrakakis G.S.Genetic algorithms optimized fuzzy controller for the indoor environmental management in buildings implemented using PLC and local operating networks[J].Engineering Applications of Artificial Intelligence,2002,15(5):417-428
[20]藤福生.微机监控技术[J].计算机应用,1994
[21]白焰,吴鸿,杨国田.分散控制系统与现场总线控制系统.基础、评选、设计和应用[M].北京:中国电力出版社,2000
[22]G.Godena,M.Colnaric.Exception handling for PLC-based process control software[J].Microprocessors and Microsystems,2000,24:407-414
[23]王欢.基于PROFIBUS现场总线的PLC控制系统研究与设计[D].北京:北方工业大学,2007
[24]单林.PROFIBUS现场总线的技术和发展前景[J].淮阴工学院学报,2000,9(2):18-22
[25]任洪波.基于现场总线的热工控制系统研究及其组态程序开发[D].上海:同济大学,2006
[26]Ma'rio Alves,Eduardo Tovar.Real-time communications over wired/wireless Profibus networks supporting inter-cell mobility[J].Computer Networks,2007,51:2994-3012
[27]J.Silvestre,V.Sempere.An architecture for flexible scheduling in Profibus networks[J].Computer Standards & Interfaces,2007,29:546-560
[28]何忠蛟.锅炉水温的PID控制算法研究[J].锅炉制造,2005,(3):6-8
[29]潘祥亮,罗利文.模糊PID控制在工业锅炉控制系统中的应用[J].Industrial Furnace,2004,26(3):38-40
[30]D.Q.Mayne,J.B.Rawlings.Constrained model predictive control:Stability and optimality[J].Automatica,2000,38(12):2093-2102
[31]K.Nakano,T.Yamamoto.A Design of Robust Self-Tuning GPC-Based PID Controllers[C].IECON Proceedings,2003,1:285-290
[32]Xiang-Jie Liu,Felipe Lara-Rosano,C.W.Chan.Neurofuzzy networkmodelling and control of steam pressure in 300MW steam-boiler system[J].Engineering Applications of Artificial Intelligence,2003,16:431-440
[33]刘哲纬,嵇鹏,金文兵,颜建军.控制系统冗余技术初探[A].第八届工业仪表与自动化学术会议论文集[C],2007
[34]刘滨.SIEMENS SIMATIC S7-300 PLC在锅炉计算机监控系统中的应用[J].微计算机信息,2003,19(8):24-25
[35]S.A.Kalogirou.Artificial intelligence for the modeling and control of combustion progress[J].A Review Progress in Energy and Combustion Science,2003,29(6):515-566
[36]Richalet J,Rault A.Model Predictive Heuristic Control:Application to Industrial Process[J].Automatica,1978,14(5):413-428
[37]SIMATIC STEP7 V5.4编程使用手册[Z].北京:西门子(中国)有限公司自动化与驱动集团,2006
[38]西门子(中国)有限公司自动化与驱动集团.深入浅出西门子S7-300 PLC[Z].北京:北京航空航天大学出版社,2004
[39]SIMATIC ET200M分布式I/O站操作指导[Z].北京:西门子(中国)有限公司自动化与驱动集团,2005
[40]力控用户手册[Z].北京:北京三维力控科技有限公司,2005
[41]MicroMaster 430变频器使用手册[Z].北京:西门子(中国)有限公司,2006
[42]SIMATIC S7-200可编程控制器系统手册[Z].北京:西门子(中国)有限公司自动化与驱动集团,2004
[43]张锐,潘泽友.冗余技术在分布式控制系统中的应用研究[J].微计算机信息,2007,23(11):35-37
[2]何群.基于广义预测控制的锅炉测控系统研究[D].秦皇岛:燕山大学,2005
[3]G.Ju,S.B.Chen.A study of the constrained model predictive control for the boiler superheated steam of a thermal power plant[J].Journal of Engineering for Thermal Energy and Power,2004,16(6):641-643
[4]于海生,潘松峰.微型计算机控制技术[M].北京:清华大学出版社,1999
[5]我国工业自动化市场现状分析报告[EB/OL].http://www.labbase.net/News/ShowNewsDetails-1-23-0A985E4ACC674200.html
[6]孙增圻.计算机控制理论及应用[M].北京:清华大学出版社,1989
[7]涂植英.过程控制系统[M].北京:机械工业出版社,1983
[8]徐传诏,赵岩.我国工业锅炉的现状、差距与展望[J].应用能源技术,2002,(4):42-43
[9]刘福仁.我国锅炉现状及存在的问题[J].北京市计划劳动管理干部学院学报,2005,13(3):42-45
[10]任毅,孙伟.我国流化床锅炉热工控制技术的发展与思考[J].煤矿机电,2004,(1):26-29
[11]赵钦新.燃油燃气锅炉[M].西安:西安交通大学出版社,2000
[12]王登贵.PLC模块化生产设备计算机监控系统设计与研究[D].西安:西北农林科技大学,2007
[13]冯雪飞.基于企业网的高炉电除尘计算机监控系统研究与开发[D].武汉:武汉理工大学,2003
[14]杨国良,林拥军.PLC在区域供冷自控系统中的应用及分析[J].电气传动自动化,2006,28(3):49-52
[15]L.F.Zhou,L.H.Ma.Study on satisfactory predictive control algorithm for complex systems[C].Fifth World Congress on Intelligent Control and Automation,2004,1:659-662
[16]汪志峰.可编程序控制器原理与应用[M].西安:西安电子科技大学出版社,2004
[17]邓星钟,周祖德,邓坚.机电传动控制[M].武汉:华中理工大学出版社,1998
[18]王常力,罗安.集散型控制系统选型与应用[M].北京:清华大学出版社,1995
[19]Kolokotsa D,Stavrakakis G.S.Genetic algorithms optimized fuzzy controller for the indoor environmental management in buildings implemented using PLC and local operating networks[J].Engineering Applications of Artificial Intelligence,2002,15(5):417-428
[20]藤福生.微机监控技术[J].计算机应用,1994
[21]白焰,吴鸿,杨国田.分散控制系统与现场总线控制系统.基础、评选、设计和应用[M].北京:中国电力出版社,2000
[22]G.Godena,M.Colnaric.Exception handling for PLC-based process control software[J].Microprocessors and Microsystems,2000,24:407-414
[23]王欢.基于PROFIBUS现场总线的PLC控制系统研究与设计[D].北京:北方工业大学,2007
[24]单林.PROFIBUS现场总线的技术和发展前景[J].淮阴工学院学报,2000,9(2):18-22
[25]任洪波.基于现场总线的热工控制系统研究及其组态程序开发[D].上海:同济大学,2006
[26]Ma'rio Alves,Eduardo Tovar.Real-time communications over wired/wireless Profibus networks supporting inter-cell mobility[J].Computer Networks,2007,51:2994-3012
[27]J.Silvestre,V.Sempere.An architecture for flexible scheduling in Profibus networks[J].Computer Standards & Interfaces,2007,29:546-560
[28]何忠蛟.锅炉水温的PID控制算法研究[J].锅炉制造,2005,(3):6-8
[29]潘祥亮,罗利文.模糊PID控制在工业锅炉控制系统中的应用[J].Industrial Furnace,2004,26(3):38-40
[30]D.Q.Mayne,J.B.Rawlings.Constrained model predictive control:Stability and optimality[J].Automatica,2000,38(12):2093-2102
[31]K.Nakano,T.Yamamoto.A Design of Robust Self-Tuning GPC-Based PID Controllers[C].IECON Proceedings,2003,1:285-290
[32]Xiang-Jie Liu,Felipe Lara-Rosano,C.W.Chan.Neurofuzzy networkmodelling and control of steam pressure in 300MW steam-boiler system[J].Engineering Applications of Artificial Intelligence,2003,16:431-440
[33]刘哲纬,嵇鹏,金文兵,颜建军.控制系统冗余技术初探[A].第八届工业仪表与自动化学术会议论文集[C],2007
[34]刘滨.SIEMENS SIMATIC S7-300 PLC在锅炉计算机监控系统中的应用[J].微计算机信息,2003,19(8):24-25
[35]S.A.Kalogirou.Artificial intelligence for the modeling and control of combustion progress[J].A Review Progress in Energy and Combustion Science,2003,29(6):515-566
[36]Richalet J,Rault A.Model Predictive Heuristic Control:Application to Industrial Process[J].Automatica,1978,14(5):413-428
[37]SIMATIC STEP7 V5.4编程使用手册[Z].北京:西门子(中国)有限公司自动化与驱动集团,2006
[38]西门子(中国)有限公司自动化与驱动集团.深入浅出西门子S7-300 PLC[Z].北京:北京航空航天大学出版社,2004
[39]SIMATIC ET200M分布式I/O站操作指导[Z].北京:西门子(中国)有限公司自动化与驱动集团,2005
[40]力控用户手册[Z].北京:北京三维力控科技有限公司,2005
[41]MicroMaster 430变频器使用手册[Z].北京:西门子(中国)有限公司,2006
[42]SIMATIC S7-200可编程控制器系统手册[Z].北京:西门子(中国)有限公司自动化与驱动集团,2004
[43]张锐,潘泽友.冗余技术在分布式控制系统中的应用研究[J].微计算机信息,2007,23(11):35-37