基于Modbus的闸门卷扬启闭机智能集控系统设计与研究
摘要
闸门卷扬启闭机系统,广泛应用于水利工程中,有广阔的市场前景,但现有的传统闸门卷扬启闭机系统中一般无电机及系统的保护措施,或只是对电机进行一些简单的硬件保护,使得传统闸门卷扬启闭机系统在使用中常会发生电机烧毁、钢绳拉断或缠绕事故,或者由于保护装置的误动作使电机跳闸导致生产中止,无法保证生产的顺利进行与安全；此外,传统闸门卷扬启闭机系统中采用闸门开度仪和编码器来采集高度信息,给PLC发出控制信号,误差较大且所需的信号线较多,系统复杂,可靠性差,给施工、调试、生产和检修都带来不便,从而耗费大量的人力、物力、财力。
本文着眼于改造传统闸门卷扬启闭机控制系统,解决现存的工业生产问题,构建了一种可对起重设备进行集中精确测量、保护及操作的闸门卷扬启闭机智能集控系统。系统由PLC、电力检测仪表、旋转编码器、压力传感器、人机界面、接触器、中间继电器、电流互感器、电机、减速器、制动器、按钮、开关和指示灯等组成,将PLC应用于闸门卷扬启闭机系统作为智能控制核心,通过编码器检测闸门的高度位置及提升速度,以PLC软件编程实现对系统的实时监控,使用电力监测仪表检测系统工作时的三相电流、电压和有功功率,从PLC软件编程上优化程序,实现对电机及系统的保护,从而解决安全生产问题,实现实时准确的监控及保护于一体。
Modbus协议是一种国际通用的工业标准协议,为用户提供了一种开放、灵活和标准的通信技术,通过此协议,控制器相互之间、控制器经由网络和其它设备之间可以通信。本文研究了Modbus工业控制网络协议,提出一种基于Modbus协议的闸门卷扬启闭机通信与控制模型,在每个闸门卷扬启闭机智能控制系统内部,将包括电力检测仪表、人机界面和旋转编码器在内的各种检测及显示设备用Modbus网络连接至PLC,大大降低了系统的硬件复杂度；多个闸门卷扬启闭机智能控制系统也以Modbus网络连接至上位机,实现集中监控。实验表明,基于Modbus协议的通信与控制方式可以方便有效地将各种检测与控制设备联入系统,不仅降低了硬件成本,使采用统一的硬件系统来控制各种不同的闸门卷扬启闭机成为可能,还降低了开发和维护的成本,具有较高的通用性及经济价值。
在上位机部分,本文采用了国产组态王软件,研究以Modbus通信协议实现对多台下位机的监控,无需多串口卡,简化了系统,便于系统操作及维护,易于将来的功能扩展与综合自动化的实现。
本文所研究的基于Modbus的控制系统并不局限于闸门卷扬启闭机智能集控系统中,还可应用于其它工业控制系统中。
Cable hoist system of sluice is extensively applied in water conservancy project, and has wide market prospect. But generally there are not protection measures for motor or system, or only some simple protection of hardware for motor, in the existing traditional cable hoist systems of sluice. So when they were used there often happen some events that motors burn down and wire rope snapped or winded, or production stopped because of the protective device mistake action leading to motor tripping, and that can't guarantee normal production and safety in production. In addition, in the traditional cable hoist systems of sluice, one instrument for gate opening and one rotary coder were used for gathering information of gate opening, and then sent the control signal to the PLC, and big errors might occur, more signal wire were required. So the system is very complicated, poor reliability might occur, and it is bad for the construction, commissioning, production and maintenance, and should consume massive manpower, physical resource, and financial resource.
This paper is to focus on reforming traditional cable hoist control system of sluice, resolving existing industry production problems, and constructing one cable hoist intelligent integrated control system of sluice, which can achieve accurate measurement, protection and operation for the lifting equipment. The system is formed by PLC, electric power monitoring instrument, rotary encoder, pressure transducer, HMI, contactor, auxiliary relay, current transformer, motor, reducer, brake, buttons, switches and indicator lights, etc. The PLC is applied to the cable hoist system of sluice as the intelligent control core, from the software programming real-time monitoring system is achieved by detection gate opening and the speed through the encoder, and protections for motor and system are achieved by optimizing the PLC program using three-phase current, voltage and active power from electric power monitoring instrument. So the problem about safety in production should be resolved, and real-time accurate monitoring and protection for system are also achieved.
The Modbus protocol is an international industrial standard protocols, provides users with an open, flexible and standard communication technology. Through the protocol, controllers and controllers, or controllers and other devices through the network can be communication. The Modbus industrial control network protocol was studied in this paper, a communication and control model of gate hoist based on Modbus was presented. By the model in each intelligent control system of gate hoist, many detecting and display equipments including electric power monitoring instrument, rotary encoder and HMI, which is compatible with Modbus, can be connected to the PLC by Modbus network, and the system hardware complexity should be reduced; and many intelligent control systems of gate hoist can also be connected to PC by Modbus network, So integrated control and monitoring should be achieved. The experiment indicates that all the detecting and control equipments can be effectively connected to the system by the communication and control method based on Modbus, which reduces cost of hardware, and it is possible to use the same hardware system controlling different gates hoist, and also reduces development and maintenance cost, and has a high practicability and economic value.
In addition, PC with the software Kingview and Modbus communication protocol can monitor several PLC at the same time. It shouldn't need the serial board, and the system was simplified. So it is easier to operate and maintain the system, and realize future function development and integrated automation.
The control system based on Modbus in this paper is not only applied in the intelligent control system of gate hoist, but can also be extensively applied in various industrial control systems.
本文着眼于改造传统闸门卷扬启闭机控制系统,解决现存的工业生产问题,构建了一种可对起重设备进行集中精确测量、保护及操作的闸门卷扬启闭机智能集控系统。系统由PLC、电力检测仪表、旋转编码器、压力传感器、人机界面、接触器、中间继电器、电流互感器、电机、减速器、制动器、按钮、开关和指示灯等组成,将PLC应用于闸门卷扬启闭机系统作为智能控制核心,通过编码器检测闸门的高度位置及提升速度,以PLC软件编程实现对系统的实时监控,使用电力监测仪表检测系统工作时的三相电流、电压和有功功率,从PLC软件编程上优化程序,实现对电机及系统的保护,从而解决安全生产问题,实现实时准确的监控及保护于一体。
Modbus协议是一种国际通用的工业标准协议,为用户提供了一种开放、灵活和标准的通信技术,通过此协议,控制器相互之间、控制器经由网络和其它设备之间可以通信。本文研究了Modbus工业控制网络协议,提出一种基于Modbus协议的闸门卷扬启闭机通信与控制模型,在每个闸门卷扬启闭机智能控制系统内部,将包括电力检测仪表、人机界面和旋转编码器在内的各种检测及显示设备用Modbus网络连接至PLC,大大降低了系统的硬件复杂度；多个闸门卷扬启闭机智能控制系统也以Modbus网络连接至上位机,实现集中监控。实验表明,基于Modbus协议的通信与控制方式可以方便有效地将各种检测与控制设备联入系统,不仅降低了硬件成本,使采用统一的硬件系统来控制各种不同的闸门卷扬启闭机成为可能,还降低了开发和维护的成本,具有较高的通用性及经济价值。
在上位机部分,本文采用了国产组态王软件,研究以Modbus通信协议实现对多台下位机的监控,无需多串口卡,简化了系统,便于系统操作及维护,易于将来的功能扩展与综合自动化的实现。
本文所研究的基于Modbus的控制系统并不局限于闸门卷扬启闭机智能集控系统中,还可应用于其它工业控制系统中。
Cable hoist system of sluice is extensively applied in water conservancy project, and has wide market prospect. But generally there are not protection measures for motor or system, or only some simple protection of hardware for motor, in the existing traditional cable hoist systems of sluice. So when they were used there often happen some events that motors burn down and wire rope snapped or winded, or production stopped because of the protective device mistake action leading to motor tripping, and that can't guarantee normal production and safety in production. In addition, in the traditional cable hoist systems of sluice, one instrument for gate opening and one rotary coder were used for gathering information of gate opening, and then sent the control signal to the PLC, and big errors might occur, more signal wire were required. So the system is very complicated, poor reliability might occur, and it is bad for the construction, commissioning, production and maintenance, and should consume massive manpower, physical resource, and financial resource.
This paper is to focus on reforming traditional cable hoist control system of sluice, resolving existing industry production problems, and constructing one cable hoist intelligent integrated control system of sluice, which can achieve accurate measurement, protection and operation for the lifting equipment. The system is formed by PLC, electric power monitoring instrument, rotary encoder, pressure transducer, HMI, contactor, auxiliary relay, current transformer, motor, reducer, brake, buttons, switches and indicator lights, etc. The PLC is applied to the cable hoist system of sluice as the intelligent control core, from the software programming real-time monitoring system is achieved by detection gate opening and the speed through the encoder, and protections for motor and system are achieved by optimizing the PLC program using three-phase current, voltage and active power from electric power monitoring instrument. So the problem about safety in production should be resolved, and real-time accurate monitoring and protection for system are also achieved.
The Modbus protocol is an international industrial standard protocols, provides users with an open, flexible and standard communication technology. Through the protocol, controllers and controllers, or controllers and other devices through the network can be communication. The Modbus industrial control network protocol was studied in this paper, a communication and control model of gate hoist based on Modbus was presented. By the model in each intelligent control system of gate hoist, many detecting and display equipments including electric power monitoring instrument, rotary encoder and HMI, which is compatible with Modbus, can be connected to the PLC by Modbus network, and the system hardware complexity should be reduced; and many intelligent control systems of gate hoist can also be connected to PC by Modbus network, So integrated control and monitoring should be achieved. The experiment indicates that all the detecting and control equipments can be effectively connected to the system by the communication and control method based on Modbus, which reduces cost of hardware, and it is possible to use the same hardware system controlling different gates hoist, and also reduces development and maintenance cost, and has a high practicability and economic value.
In addition, PC with the software Kingview and Modbus communication protocol can monitor several PLC at the same time. It shouldn't need the serial board, and the system was simplified. So it is easier to operate and maintain the system, and realize future function development and integrated automation.
The control system based on Modbus in this paper is not only applied in the intelligent control system of gate hoist, but can also be extensively applied in various industrial control systems.
引文
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[3]什么是闸门启闭机.[EB/OL]. [2008-12-10] http://www.jyqbj.cn/Channel4/ShenMeShiZhaMenQiBiJi.html
[4]闸门的类型介绍.[EB/OL]. [2008-12-10] http://www.cnhydro.com/product/zmqbj/web/zswd-3.asp
[5]况群意.基于PROFIBUS现场总线控制的闸门监控系统的开发[D].武汉：武汉理工大学,2004：1-3
[6]徐小增,廖裕铮.建筑卷扬机的单片机控制系统设计[J].佛山科学技术学院学报,2001,19(4),27-30
[7]牛广文,边玉国等.PLC与组态软件在闸门监控系统中的应用[J].低压电器,2007(13),24-26
[8]叶晴炜.小水电综合自动化系统的研究与开发[D].中南大学.2007：1-5
[9]章少静.闸门启闭控制方式设计探讨[J].水利工程.2001,(2),24-25+28
[10]谢云敏.PLC在水电厂快速闸门控制中的应用[J].南昌水专学报,1999,18(2),54-59
[11]Modicon. Modbus通信协议.[EB/OL]. [2008-3-20] http://www.daxia.com/list_1678.shtml
[12]高润秋.启闭机电动机过载保护方案的改进[J].起重运输机械,1996,8,19-20
[13]孟扬,张伟等.编码器基础及应用[J].机电一体化专栏,2007,1,36-38
[14]上海建景自动化科技有限公司.增量型编码器与绝对型编码器的区分.[EB/OL]. [2008-9-28] http://www.gkong.com/learn/learn_detail.asp?learn_id=1295
[15]S7-200的60个常见问题解答.[EB/OL]. [2008-11-28] http://blog.gkong.com/more.asp?name=lightwhite&id=25103
[16]SIEMENS, S7-200可编程控制器系统手册[M].2005,8,Siemens AG 2004,361-368
[17]Jillzhang.浮点数在计算机中存储方式[EB/OL].(2007-6-26)[2008-3-20] http://www.chenjiliang.com/article/view.aspx?articleId=2650&typeid=80
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