隧道窑控制及管理系统设计
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摘要
作为砖瓦工业中一种非常重要的烧成设备，隧道窑在卫生陶瓷、耐火材料等砖瓦产品的生产过程中已经得到了越来越广泛的应用。隧道窑的测控系统也从早期的仪表控制发展到现代控制技术的应用，如PLC的应用，DCS系统的普及以及模糊控制技术的应用等。然而，总体上我国隧道窑生产过程自动化程度相对较低，既严重限制了砖瓦产品质量水平的提高，又造成了较大的能源消耗。因此，通过PLC的应用，系统管理利用DCS系统，提高我国隧道窑生产过程的自动化水平，降低能源消耗，具有重要的理论及现实意义。
本文针对某企业156米高温隧道窑，在深入分析隧道窑生产工艺要求以及国内外隧道窑自动控制系统发展状况之后，设计了一套包括现场控制层、显示操作层和信息管理层的集成自动化控制系统。该控制系统采用稳定性、可靠性高的PLC(可编程逻辑控制器)作为现场控制层的控制器，编程控制采用智能化改进型积分分离PID控制器控制压力和流量，利用先进的网络技术构建了一个生产管理平台，实现隧道窑生产信息管理系统稳定可靠地运行。它既着眼于窑炉设备的安全、经济运行，又着眼于整个企业的生产管理。通过管理促进控制，管控结合，有效地提高了窑炉系统的生产效率。该系统采用全集成自动化工程的思想进行设计，整个系统应用共同的组态和编程，共同的数据管理与通信，实现了各层之间的高度集成。系统采用模块化的设计结构，并具有完全的开放性，使系统具备良好的可扩充性。
在实际生产过程中良好的运行状况表明，本文开发的隧道窑计算机控制与管理系统设计合理，功能先进。降低了工人的劳动强度，降低了能源的消耗，在一定程度上为隧道窑生产过程自动控制技术的发展进行了实践探索和理论储备。
As one of the most important burnt equipments in the tile industry, tunnel kiln already obtained more and more widespread application in sanitary ceramics, refractory material and other tile production process. The measuring and control system of tunnel kiln already developed from early instrument control to modern control system, such as PLC application, DCS system and fuzzy control technology application. However, the tunnel kiln process automation is relatively low compare to other countries. That restricts the improvement of the tile products quality, and result in huge energy consumption. Therefore, it will have an important theory and practical significance to improve our tunnel kiln process automation through PLC application while system management through DCS system.
This article aims at one enterprise's tunnel kiln system with 156 meters long high-temperature tunnel kiln.After analyzing tunnel kiln process requirements and its automatic control system development status in domestic and abroad, designed a set of integrated automatic control system consists of on-site operating floor, display operating floor and information management. This control system adopts the stable and reliable PLC as controller; it formed a plant supervision platform through advanced network technology. It considered the tunnel kiln equipments safety, economic operation, also for the whole enterprise production control. To accelerate control through management, we combined control and management together; therefore, the production efficiency of the tunnel kiln was improved effectively. This control system designed according to fully integrated automatic engineering theory, the whole system applied the same configuration and program, the same data management and communication system to realize high integration among all levels. This system adopts modularized configuration, possess wholly openness in order to keep the system well expendability.
The practical process performance indicates the tunnel kiln control system and the management system that we exploit is reasonable and with sufficient functions, that decreased human workload and energy consumption,and theory preparation for tunnel kiln process automatic control technology development in a certain extent.
本文针对某企业156米高温隧道窑，在深入分析隧道窑生产工艺要求以及国内外隧道窑自动控制系统发展状况之后，设计了一套包括现场控制层、显示操作层和信息管理层的集成自动化控制系统。该控制系统采用稳定性、可靠性高的PLC(可编程逻辑控制器)作为现场控制层的控制器，编程控制采用智能化改进型积分分离PID控制器控制压力和流量，利用先进的网络技术构建了一个生产管理平台，实现隧道窑生产信息管理系统稳定可靠地运行。它既着眼于窑炉设备的安全、经济运行，又着眼于整个企业的生产管理。通过管理促进控制，管控结合，有效地提高了窑炉系统的生产效率。该系统采用全集成自动化工程的思想进行设计，整个系统应用共同的组态和编程，共同的数据管理与通信，实现了各层之间的高度集成。系统采用模块化的设计结构，并具有完全的开放性，使系统具备良好的可扩充性。
在实际生产过程中良好的运行状况表明，本文开发的隧道窑计算机控制与管理系统设计合理，功能先进。降低了工人的劳动强度，降低了能源的消耗，在一定程度上为隧道窑生产过程自动控制技术的发展进行了实践探索和理论储备。
As one of the most important burnt equipments in the tile industry, tunnel kiln already obtained more and more widespread application in sanitary ceramics, refractory material and other tile production process. The measuring and control system of tunnel kiln already developed from early instrument control to modern control system, such as PLC application, DCS system and fuzzy control technology application. However, the tunnel kiln process automation is relatively low compare to other countries. That restricts the improvement of the tile products quality, and result in huge energy consumption. Therefore, it will have an important theory and practical significance to improve our tunnel kiln process automation through PLC application while system management through DCS system.
This article aims at one enterprise's tunnel kiln system with 156 meters long high-temperature tunnel kiln.After analyzing tunnel kiln process requirements and its automatic control system development status in domestic and abroad, designed a set of integrated automatic control system consists of on-site operating floor, display operating floor and information management. This control system adopts the stable and reliable PLC as controller; it formed a plant supervision platform through advanced network technology. It considered the tunnel kiln equipments safety, economic operation, also for the whole enterprise production control. To accelerate control through management, we combined control and management together; therefore, the production efficiency of the tunnel kiln was improved effectively. This control system designed according to fully integrated automatic engineering theory, the whole system applied the same configuration and program, the same data management and communication system to realize high integration among all levels. This system adopts modularized configuration, possess wholly openness in order to keep the system well expendability.
The practical process performance indicates the tunnel kiln control system and the management system that we exploit is reasonable and with sufficient functions, that decreased human workload and energy consumption,and theory preparation for tunnel kiln process automatic control technology development in a certain extent.
引文
[1] 曹明月．浅谈陶瓷生产企业的计算机应用[J]．河北陶瓷，1996
[2] 李西利．砖瓦工业的隧道窑[J]．砖瓦，1998，5．
[3] 姜金宁．耐火材料工业热工过程及设备[M]．北京：冶金工业出版社，1997，10．
[4] 刘志国．我国陶瓷窑炉技术水平现状与发展思路[J]．四川建材，2002，1．
[5] 高平良．陶瓷工业及陶瓷窑炉自动控制系统发展的展望[J]．陶瓷，1995，6．
[6] 雷涛，曾学军．现代隧道窑的计算机控制与管理系统[J]．佛山陶瓷，2002，12(12)：30-31．
[7] 万全应．引进西德卫生陶瓷隧道窑的消化与吸收[J]．陶瓷研究，1994，6．
[8] 徐胜昔．卫生陶瓷烧成用窑炉发展之我见[J]．中国陶瓷工业，2004．4，11(2)：47-49．
[9] 第一座凯乐钢外壳隧道窑在西班牙投入使用[J]，砖瓦，1994，3．
[10] 贺燮炎．谈现代轻型隧道窑[J]．陶瓷科学与艺术，2004．5．
[11] 边冰．基于PLC硬件系统的隧道窑温度模糊控制方案[J]．佛山陶瓷，2004．8，(92)：24-25．
[12] Zhang Huaguang, Yang Yingxu, Chai Tianyou. The present status and future developments of multivariable fuzzy control(Ⅱ) [J]. Control and Decision, 1995, 10(4): 289-295.
[13] 陈理君，宋镜明，沈丽．隧道窑模糊控制中模糊控制解析式及隶属函数的研究[J]．中国建材科技．2000，5
[14] 田军，李成利，王文韬．DRNN神经网络的电加热炉解耦控制[J]，青岛科技大学学报，2005．8，26(4)：359-361．
[15] 舒怀林，郭秀才，舒杰磊．注塑机料筒多段温度PID神经网络解耦控制系统[J]．计算技术与自动化，2004，23(4)：55-57．
[16] Gilman, G. F. Jerry. Boiler control systems engineering. Portland: Scitech Book News, Sep 2005.
[17] 王锦标．计算机控制系统[M]．北京：清华大学出版社，2004．
[18] 孙增圻．计算机控制理论及应用．北京：清华大学出版社，1989．
[19] 何衍庆．集散控制系统原理及应用(修订版)，化学工业出版社，1999．5
[20] Broomhead D S, LoweD. Multivariable functionalin terpolation and adaptiven etworks[J]. Complex Systems, 1988,2:321-355.
[21] Boiler control system reducers NOx emissions without burners. New York: Chemical Engineering. Jul 1994.
[22] 西门子中国有限公司自动化与驱动集团自动化系统部．深入浅出西门子S7-300PLC．北京：北京航空航天大学出版社，2004．
[23] 王树青．先进控制技术及应用．化学工业出版社，1999．
[24] 王为兵．PLC系统通信扩展于网络互连技术．机械工业出版社，2005，1．
[25] Chai T Y. Multivariable Intelligent decoupling control and its application[C]. Hefei: Proceedings of the 3th World Congresson Intelligent Control and Automation, 2000.
[26] 陶永华主编．新型PID控制及其应用[M]．北京：机械工业出版社．2002
[27] 翁维勤，孙洪程．过程控制系统及工程 第二版．北京：化学工业出版社，2002，7．
[28] Siemens AGStatement List (STL) for S7-300 and S7-000 Programming Reference[M], 2002.
[29] 王锦标．计算机控制系统．北京：清华大学出版社，2004．
[30] 常斗南．可编程控制器原理、应用、实验．机械工业出版社，2002．
[31] 杨玉飞．高温隧道窑[J]．有色冶金节能，1997，(4)：68
[32] Gilman, G. F. Jerry. Boiler control systems engineering. Portland: Scitech Book News, Sep 2005.
[33] Jim Cahilh Potlatch uses "mini-DCS" to upgrade boiler control at its Lewiston, Idaho, mill. San Francisco: Pulp & Paper. Apr 1997.
[34] Karppanen, Erkki, Tech. D., Advanced control of an industrial circulating fluidized bed boiler using fuzzy logic. Finland: Oulun Yliopisto, 2000,
[35] 西门子中国有限公司自动化与驱动集团．SIEMENS SIMATIC S7-300 PLC硬件和安装手册．北京：西门子公司，2003．
[2] 李西利．砖瓦工业的隧道窑[J]．砖瓦，1998，5．
[3] 姜金宁．耐火材料工业热工过程及设备[M]．北京：冶金工业出版社，1997，10．
[4] 刘志国．我国陶瓷窑炉技术水平现状与发展思路[J]．四川建材，2002，1．
[5] 高平良．陶瓷工业及陶瓷窑炉自动控制系统发展的展望[J]．陶瓷，1995，6．
[6] 雷涛，曾学军．现代隧道窑的计算机控制与管理系统[J]．佛山陶瓷，2002，12(12)：30-31．
[7] 万全应．引进西德卫生陶瓷隧道窑的消化与吸收[J]．陶瓷研究，1994，6．
[8] 徐胜昔．卫生陶瓷烧成用窑炉发展之我见[J]．中国陶瓷工业，2004．4，11(2)：47-49．
[9] 第一座凯乐钢外壳隧道窑在西班牙投入使用[J]，砖瓦，1994，3．
[10] 贺燮炎．谈现代轻型隧道窑[J]．陶瓷科学与艺术，2004．5．
[11] 边冰．基于PLC硬件系统的隧道窑温度模糊控制方案[J]．佛山陶瓷，2004．8，(92)：24-25．
[12] Zhang Huaguang, Yang Yingxu, Chai Tianyou. The present status and future developments of multivariable fuzzy control(Ⅱ) [J]. Control and Decision, 1995, 10(4): 289-295.
[13] 陈理君，宋镜明，沈丽．隧道窑模糊控制中模糊控制解析式及隶属函数的研究[J]．中国建材科技．2000，5
[14] 田军，李成利，王文韬．DRNN神经网络的电加热炉解耦控制[J]，青岛科技大学学报，2005．8，26(4)：359-361．
[15] 舒怀林，郭秀才，舒杰磊．注塑机料筒多段温度PID神经网络解耦控制系统[J]．计算技术与自动化，2004，23(4)：55-57．
[16] Gilman, G. F. Jerry. Boiler control systems engineering. Portland: Scitech Book News, Sep 2005.
[17] 王锦标．计算机控制系统[M]．北京：清华大学出版社，2004．
[18] 孙增圻．计算机控制理论及应用．北京：清华大学出版社，1989．
[19] 何衍庆．集散控制系统原理及应用(修订版)，化学工业出版社，1999．5
[20] Broomhead D S, LoweD. Multivariable functionalin terpolation and adaptiven etworks[J]. Complex Systems, 1988,2:321-355.
[21] Boiler control system reducers NOx emissions without burners. New York: Chemical Engineering. Jul 1994.
[22] 西门子中国有限公司自动化与驱动集团自动化系统部．深入浅出西门子S7-300PLC．北京：北京航空航天大学出版社，2004．
[23] 王树青．先进控制技术及应用．化学工业出版社，1999．
[24] 王为兵．PLC系统通信扩展于网络互连技术．机械工业出版社，2005，1．
[25] Chai T Y. Multivariable Intelligent decoupling control and its application[C]. Hefei: Proceedings of the 3th World Congresson Intelligent Control and Automation, 2000.
[26] 陶永华主编．新型PID控制及其应用[M]．北京：机械工业出版社．2002
[27] 翁维勤，孙洪程．过程控制系统及工程 第二版．北京：化学工业出版社，2002，7．
[28] Siemens AGStatement List (STL) for S7-300 and S7-000 Programming Reference[M], 2002.
[29] 王锦标．计算机控制系统．北京：清华大学出版社，2004．
[30] 常斗南．可编程控制器原理、应用、实验．机械工业出版社，2002．
[31] 杨玉飞．高温隧道窑[J]．有色冶金节能，1997，(4)：68
[32] Gilman, G. F. Jerry. Boiler control systems engineering. Portland: Scitech Book News, Sep 2005.
[33] Jim Cahilh Potlatch uses "mini-DCS" to upgrade boiler control at its Lewiston, Idaho, mill. San Francisco: Pulp & Paper. Apr 1997.
[34] Karppanen, Erkki, Tech. D., Advanced control of an industrial circulating fluidized bed boiler using fuzzy logic. Finland: Oulun Yliopisto, 2000,
[35] 西门子中国有限公司自动化与驱动集团．SIEMENS SIMATIC S7-300 PLC硬件和安装手册．北京：西门子公司，2003．