300m~2烧结机控制系统的研究与开发
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摘要
该论文在国内外烧结机控制系统的现状及发展的基础上,详细论述了烧结生产过程的原理以及工艺特点,根据国内烧结过程控制系统的情况,应用西门子S7-400系列PLC和PROFIBUS现场总线设计了300m~2烧结机自动控制系统,并且分析了所设计的控制系统的实时性问题。
根据300m~2烧结机控制系统的需求分析,选用了西门子公司的S7-400/300系列PLC作为主控制器对生产过程进行过程自动控制,以及使用高性能商用计算机作为监控操作站,构建了一个300m~2烧结机两级计算机控制系统。根据烧结机控制系统I/O的统计和传感器的选型,对控制系统硬件进行了配置和选型,并采用STEP 7 V5.3软件进行了硬件组态。利用CPU416-2DP和CPU315-2DP作为Profibus-DP总线的主站,用ET200M作为总线的从站等,完成对现场总线各硬件的组态和通讯处理。
研究了PROFIBUS现场总线的协议组成、技术特点,着重介绍了PROFIBUS-DP协议标准的特点、主要功能以及通信类型。详细分析了PLC的循环扫描机制和PROFIBUS总线的数据链路层数据传输服务和MAC子层协议等关键技术。在此基础上给出了系统正常运行时,主从站间数据交换的测控周期,并进一步分析得出主站与分布式I/O从站通信的响应时间。
最后针对300m~2烧结机控制系统系统,考虑了PLC的I/O响应滞后和网络通信的时延特性,分析了该系统的实时性能。经分析研究证明,本论文所设计的自动控制系统实时性能完全可以得到保障,而且此分析研究有很大的工程应用价值。
Based on the current situation and development of controlling system of sintering machine at home and abroad,this paper analyse detailedly on the process principle and craft characteristic of the sintering production. According to the situation of the sintering controlling system in domestic, the automation controlling system of 300m~2 sintering machine based on SIEMENS S7-400 series PLC and PROFIBUS filedbus is designed, and analyse the real-time problem of controlling system.
According to control system demands of 300m~2 sintering machine, the thesis selected PLC of S7-300/400 series of Siemens as main controller to autocontrol produce process, and the commercial computer which is high performance as the monitor computer, which composed plural computer control system of 300m~2 sintering machine. According to the types select of sensor and transducer and the satistic mount of I/O of the control system of sintering machine, the thesis configured and select the types of control system hardwares and configured the hardwares of control system using Step7 V5.3 software. Then chose the CPU416-2DP and CPU315-2DP as the master of Profibus-DP and several ET200Ms as the slavers, and accomplish the communication.
This thesis introduced the concept, property, typical protocols of PROFIBUS technology, and the consist of protocols, properties of PROFIBUS were researched. The paper mainly introduced the property, the function and the communication of PROFIBUS. Based on deep analyses on several key technologies, such as the cyclic scanning mechanism of PLC、data transmission services and MAC protocol of PROFIBUS, message transaction cycle time formulae are given for data exchanges between master and slave in normal run state. Furthermore, the response time between master and I/O slave, is analyzed respectively.
Finally, for a control system of 300m~2 sintering machine, considered I/O response lag of PLC and the time delay properties of network, real-time property of the control system is analyzed. The application in the project shows that the real-time of the control system can completely obtain guarantee and the analytical method is of great value in practice.
根据300m~2烧结机控制系统的需求分析,选用了西门子公司的S7-400/300系列PLC作为主控制器对生产过程进行过程自动控制,以及使用高性能商用计算机作为监控操作站,构建了一个300m~2烧结机两级计算机控制系统。根据烧结机控制系统I/O的统计和传感器的选型,对控制系统硬件进行了配置和选型,并采用STEP 7 V5.3软件进行了硬件组态。利用CPU416-2DP和CPU315-2DP作为Profibus-DP总线的主站,用ET200M作为总线的从站等,完成对现场总线各硬件的组态和通讯处理。
研究了PROFIBUS现场总线的协议组成、技术特点,着重介绍了PROFIBUS-DP协议标准的特点、主要功能以及通信类型。详细分析了PLC的循环扫描机制和PROFIBUS总线的数据链路层数据传输服务和MAC子层协议等关键技术。在此基础上给出了系统正常运行时,主从站间数据交换的测控周期,并进一步分析得出主站与分布式I/O从站通信的响应时间。
最后针对300m~2烧结机控制系统系统,考虑了PLC的I/O响应滞后和网络通信的时延特性,分析了该系统的实时性能。经分析研究证明,本论文所设计的自动控制系统实时性能完全可以得到保障,而且此分析研究有很大的工程应用价值。
Based on the current situation and development of controlling system of sintering machine at home and abroad,this paper analyse detailedly on the process principle and craft characteristic of the sintering production. According to the situation of the sintering controlling system in domestic, the automation controlling system of 300m~2 sintering machine based on SIEMENS S7-400 series PLC and PROFIBUS filedbus is designed, and analyse the real-time problem of controlling system.
According to control system demands of 300m~2 sintering machine, the thesis selected PLC of S7-300/400 series of Siemens as main controller to autocontrol produce process, and the commercial computer which is high performance as the monitor computer, which composed plural computer control system of 300m~2 sintering machine. According to the types select of sensor and transducer and the satistic mount of I/O of the control system of sintering machine, the thesis configured and select the types of control system hardwares and configured the hardwares of control system using Step7 V5.3 software. Then chose the CPU416-2DP and CPU315-2DP as the master of Profibus-DP and several ET200Ms as the slavers, and accomplish the communication.
This thesis introduced the concept, property, typical protocols of PROFIBUS technology, and the consist of protocols, properties of PROFIBUS were researched. The paper mainly introduced the property, the function and the communication of PROFIBUS. Based on deep analyses on several key technologies, such as the cyclic scanning mechanism of PLC、data transmission services and MAC protocol of PROFIBUS, message transaction cycle time formulae are given for data exchanges between master and slave in normal run state. Furthermore, the response time between master and I/O slave, is analyzed respectively.
Finally, for a control system of 300m~2 sintering machine, considered I/O response lag of PLC and the time delay properties of network, real-time property of the control system is analyzed. The application in the project shows that the real-time of the control system can completely obtain guarantee and the analytical method is of great value in practice.
引文
[1]马竹梧.冶金原燃料生产自动化技术[M]. 2005
[2]叶匡吾.烧结过程、球团过程的能量流和优化选择[J].烧结球团,2010,35(1):1-6
[3]欧佩红. 217m2烧结机烧结终点优化控制系统设计及实现[D].中南大学,2008
[4]张晓龙,吴敏,向齐良等.基于预报的烧结终点模糊控制[J].计算机测量与控制,2005,13(10):1059-1060+1093
[5]陈许玲.烧结过程状态集成优化控制制导系统的研究[D].长沙:中南大学,2005:15-20
[6]汪吉鹏.工业控制技术的应用现状和发展方向[J].潍坊学院学报,2002,2(2):47-53
[7]纪文刚,魏永禄,张吉月.基于Profibus-DP的烧结过程控制系统的设计与实现[J].微计算机信息,2005,21(5):51-53
[8] T. Harakawa and T. Kawaguehi,Digital Control in Iron and Steel making Process[J],Automatica,1993,20(3):1185- 1202
[9]范晓慧,王海东,黄天正等.烧结过程控制专家系统的设计与开发[J].钢铁,2001,36(11):1-4
[10]李之甫.日本福山厂号烧结机实行无人操作[J].烧结球团,1997,22(3):49
[11]马竹梧.国外钢铁工业自动化的进展及展望(下)[J].冶金自动化,1997,(2):1-4
[12]毛晓明,薛平.宝钢烧结自动控制的发展[J].烧结球团,2004,29(5):23-26
[13]顿长勇,李香玲,郝继旺等.唐钢烧结自动控制系统的发展[J].天津冶金,2005,131(6):49-52
[14]纪文刚,魏永禄,张吉月.基于Profibus-DP的烧结过程控制系统的设计与实现[J].微计算机信息,2005,21(5):51-52
[15]吴伟宾.基于Profibus-DP的烧结燃料破碎控制系统[J].电子设计工程,2010,18(1):47-48
[16]韩晓东,刘艳辉.鞍钢炼铁总厂360m2烧结机的节能降耗实践[J].烧结球团,2010,35(1):56-58
[17]向齐良,吴敏,向婕.韶钢105 m2烧结机过程控制系统的设计与应用[J].冶金自动化,2005,(5):38-42
[18] Simatic PCS7 Software Instruction. Siemens issued [ EB/ OL ] .http :/ / epsaproc. bjx. com. cn/ dl/ news/ 67889. html , 2003,5-13.
[19] Kameoka K,Shi C. Advanced Weighing Technology, China Metrology Publishing House, 2000
[20]孙乐,金伟.神经网络在烧结混合料水分控制中的应用[J].大连轻工业学院学报,2003,22(3)
[21] Balajee S R, Wilson G S. Continuous infrared moisture measurements of sinter plant mix, core breeze, and blast furnace flue dust for moisture and fuel control[J].Iron Making Conference Proceedings, 1984, 43:59-71
[22]杨河清,程冰,叶正文等.多种物料水分在线自动检测技术的开发[J].烧结球团,2009,34(3):41-44
[23]吴晓峰,匡式文,张佳华等.烧结混合料加水控制策略分析与应用[J].山东冶金,2009,31(3):49-51
[24]公维娥,张新宁,田美. 265m2烧结机自动控制系统的三电一体化设计[J].国内外机电一体化,2008,11(1):7-9
[25]周洪,邓其军,孟红霞等.网络控制技术及应用[M].北京:中国电力出版社,2007
[26]冯冬芹,黄文君等.工业通信网络与系统集成[M].北京:科学出版社,2005
[27]杨家龙.基于网络环境的舰船机舱动力装置监控系统技术研究(博士学位论文)[D].哈尔滨:哈尔滨工程大学,2006
[28]陈卓. PLC与上位计算机通讯监控系统的研究与应用[D].重庆:重庆大学,2004
[29]吴中俊,黄永红.可编程序控制器原理及应用(第2版)[M].北京:机械工业出版社,2004,4
[30]田海,崔桂梅,王晓红等.西门子PLC控制网络的配置策略与应用[J].电气传动,2010,40(1):76-80
[31]寥常初. S7-300/400 PLC应用技术(第2版)[M],北京:机械工业出版社,2008,5
[32]雷霖.现场总线控制网络技术[M],北京:电子工业出版社,2004,4
[33]王智,王天然,Ye-qiong SONG等.工业实时通讯网络(现场总线)的基础理论研究与现状(上)[J].信息与控制, 2002, 31(2): 146-152
[34]孙鹤旭,梁涛,云利军. Profibus现场总线控制系统的设计与开发[M].北京:国防工业出版社,2007,4
[35] Profibus Specification Normative Parts of Profibus-FMS/DP/PA,Ed.l.0.Profibus User Organization,1998
[36] Josef Weigmann,Gerhard Kilian著,闫志强等译.西门子PROFIBUS工业通信指南(第2版)[M].北京:人民邮电出版社,2007,4
[37]侯维岩,费敏锐. PROFIBUS协议分析和系统应用[M].北京:清华大学出版社,2006,12
[38]任清珍,张军,黄天戍等.现场总线控制系统的进步性及其实时性研究[J].测控技术, 2004, 23(4): 37-4
[39]周悦,于海斌,王天然,等. Profibus和FF现场总线的性能分析与评价[J].吉林大学学报(信息科学版), 2004, 22(4): 434-437
[40]朱光磊,和敬涵. Profibus中的循环服务[J].电气传动, 2005,35(11): 52-55
[41]胡立坤,王庆超.浅析Profibus网络的FDL[J].化工自动化及仪表,2005,32(2): 29-34
[42] Kyung C L, Hyun H K. Development of performance model for calculation of communica- tion delay in Profibus token passing protocol[J]. Computer Standards and Interfaces,2003,25(2): 539-522
[43] E.Tovar, F.Vasques. Evaluating Worst Case Response Time in Mono and Mliti-master Profibus-DP[J].IEEE International workshop on factory communication systems,2002,233-240
[44] E.Tovar, F.Vasques. Guaranteeing Real-Time Message Deadline in PROFIBUS Networks. IEEE Proceedings of the 10th Euromicro Workshop on Real-Time Systems, 1998
[45]候维岩,费敏锐.令牌目的循环时间TTR对现场总线PROFIBUS测控周期的影响[J].仪器仪表学报,2005,26(4):399-402
[46]茹锋,贾立新,薛钧义. PROFIBUS协议的实时性能参数分析[J].小型微型计算机系统,2003, 24(5): 933-936
[47]王永华,A. Verwer(英)编著,唐济扬主审.现场总线技术及应用教程——从PROFIBUS到AS-i.北京:机械工业出版社,2006.12
[48]刘素英.基于PROFIBUS总线的单主站PLC控制系统实时性能研究[D].西安电子科技大学,2009,1
[2]叶匡吾.烧结过程、球团过程的能量流和优化选择[J].烧结球团,2010,35(1):1-6
[3]欧佩红. 217m2烧结机烧结终点优化控制系统设计及实现[D].中南大学,2008
[4]张晓龙,吴敏,向齐良等.基于预报的烧结终点模糊控制[J].计算机测量与控制,2005,13(10):1059-1060+1093
[5]陈许玲.烧结过程状态集成优化控制制导系统的研究[D].长沙:中南大学,2005:15-20
[6]汪吉鹏.工业控制技术的应用现状和发展方向[J].潍坊学院学报,2002,2(2):47-53
[7]纪文刚,魏永禄,张吉月.基于Profibus-DP的烧结过程控制系统的设计与实现[J].微计算机信息,2005,21(5):51-53
[8] T. Harakawa and T. Kawaguehi,Digital Control in Iron and Steel making Process[J],Automatica,1993,20(3):1185- 1202
[9]范晓慧,王海东,黄天正等.烧结过程控制专家系统的设计与开发[J].钢铁,2001,36(11):1-4
[10]李之甫.日本福山厂号烧结机实行无人操作[J].烧结球团,1997,22(3):49
[11]马竹梧.国外钢铁工业自动化的进展及展望(下)[J].冶金自动化,1997,(2):1-4
[12]毛晓明,薛平.宝钢烧结自动控制的发展[J].烧结球团,2004,29(5):23-26
[13]顿长勇,李香玲,郝继旺等.唐钢烧结自动控制系统的发展[J].天津冶金,2005,131(6):49-52
[14]纪文刚,魏永禄,张吉月.基于Profibus-DP的烧结过程控制系统的设计与实现[J].微计算机信息,2005,21(5):51-52
[15]吴伟宾.基于Profibus-DP的烧结燃料破碎控制系统[J].电子设计工程,2010,18(1):47-48
[16]韩晓东,刘艳辉.鞍钢炼铁总厂360m2烧结机的节能降耗实践[J].烧结球团,2010,35(1):56-58
[17]向齐良,吴敏,向婕.韶钢105 m2烧结机过程控制系统的设计与应用[J].冶金自动化,2005,(5):38-42
[18] Simatic PCS7 Software Instruction. Siemens issued [ EB/ OL ] .http :/ / epsaproc. bjx. com. cn/ dl/ news/ 67889. html , 2003,5-13.
[19] Kameoka K,Shi C. Advanced Weighing Technology, China Metrology Publishing House, 2000
[20]孙乐,金伟.神经网络在烧结混合料水分控制中的应用[J].大连轻工业学院学报,2003,22(3)
[21] Balajee S R, Wilson G S. Continuous infrared moisture measurements of sinter plant mix, core breeze, and blast furnace flue dust for moisture and fuel control[J].Iron Making Conference Proceedings, 1984, 43:59-71
[22]杨河清,程冰,叶正文等.多种物料水分在线自动检测技术的开发[J].烧结球团,2009,34(3):41-44
[23]吴晓峰,匡式文,张佳华等.烧结混合料加水控制策略分析与应用[J].山东冶金,2009,31(3):49-51
[24]公维娥,张新宁,田美. 265m2烧结机自动控制系统的三电一体化设计[J].国内外机电一体化,2008,11(1):7-9
[25]周洪,邓其军,孟红霞等.网络控制技术及应用[M].北京:中国电力出版社,2007
[26]冯冬芹,黄文君等.工业通信网络与系统集成[M].北京:科学出版社,2005
[27]杨家龙.基于网络环境的舰船机舱动力装置监控系统技术研究(博士学位论文)[D].哈尔滨:哈尔滨工程大学,2006
[28]陈卓. PLC与上位计算机通讯监控系统的研究与应用[D].重庆:重庆大学,2004
[29]吴中俊,黄永红.可编程序控制器原理及应用(第2版)[M].北京:机械工业出版社,2004,4
[30]田海,崔桂梅,王晓红等.西门子PLC控制网络的配置策略与应用[J].电气传动,2010,40(1):76-80
[31]寥常初. S7-300/400 PLC应用技术(第2版)[M],北京:机械工业出版社,2008,5
[32]雷霖.现场总线控制网络技术[M],北京:电子工业出版社,2004,4
[33]王智,王天然,Ye-qiong SONG等.工业实时通讯网络(现场总线)的基础理论研究与现状(上)[J].信息与控制, 2002, 31(2): 146-152
[34]孙鹤旭,梁涛,云利军. Profibus现场总线控制系统的设计与开发[M].北京:国防工业出版社,2007,4
[35] Profibus Specification Normative Parts of Profibus-FMS/DP/PA,Ed.l.0.Profibus User Organization,1998
[36] Josef Weigmann,Gerhard Kilian著,闫志强等译.西门子PROFIBUS工业通信指南(第2版)[M].北京:人民邮电出版社,2007,4
[37]侯维岩,费敏锐. PROFIBUS协议分析和系统应用[M].北京:清华大学出版社,2006,12
[38]任清珍,张军,黄天戍等.现场总线控制系统的进步性及其实时性研究[J].测控技术, 2004, 23(4): 37-4
[39]周悦,于海斌,王天然,等. Profibus和FF现场总线的性能分析与评价[J].吉林大学学报(信息科学版), 2004, 22(4): 434-437
[40]朱光磊,和敬涵. Profibus中的循环服务[J].电气传动, 2005,35(11): 52-55
[41]胡立坤,王庆超.浅析Profibus网络的FDL[J].化工自动化及仪表,2005,32(2): 29-34
[42] Kyung C L, Hyun H K. Development of performance model for calculation of communica- tion delay in Profibus token passing protocol[J]. Computer Standards and Interfaces,2003,25(2): 539-522
[43] E.Tovar, F.Vasques. Evaluating Worst Case Response Time in Mono and Mliti-master Profibus-DP[J].IEEE International workshop on factory communication systems,2002,233-240
[44] E.Tovar, F.Vasques. Guaranteeing Real-Time Message Deadline in PROFIBUS Networks. IEEE Proceedings of the 10th Euromicro Workshop on Real-Time Systems, 1998
[45]候维岩,费敏锐.令牌目的循环时间TTR对现场总线PROFIBUS测控周期的影响[J].仪器仪表学报,2005,26(4):399-402
[46]茹锋,贾立新,薛钧义. PROFIBUS协议的实时性能参数分析[J].小型微型计算机系统,2003, 24(5): 933-936
[47]王永华,A. Verwer(英)编著,唐济扬主审.现场总线技术及应用教程——从PROFIBUS到AS-i.北京:机械工业出版社,2006.12
[48]刘素英.基于PROFIBUS总线的单主站PLC控制系统实时性能研究[D].西安电子科技大学,2009,1