造纸法再造烟叶生产线自动控制与信息集成系统的设计与研究
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摘要
烟草薄片,是指通过利用烟梗、烟叶等原料,同时掺兑香料,而制造生成的一种“再造烟叶”；此方法能够人为地改变烟卷的理化特性,进而降低其中的焦油含量,从源头上减少吸烟产生的有害物质。造纸法再造烟叶是目前世界上生产烟草薄片最先进的方法之一,它可以通过浸泡、磨浆等工艺提取出烟梗、烟叶中的有效成分,同时按照厂家要求改善原料配比,以造纸法生产出具有不同香气的薄片产品,具有重大的经济与社会效益。
随着工业自动化生产的发展进步,烟草薄片产品市场需求量日益增长,需要对现有的薄片生产线进行技术探究与改造,以达到保障安全生产,节能减排,提高生产效率,满足市场需求的目的；本课题以实际项目为依托,根据“集中管理,分散控制”的原则,充分调研了解相关及类似行业的生产运行状况,综合运用工业控制领域中的许多先进技术,对造纸法再造烟叶生产线自动控制与信息集成系统进行了设计研究。
在对烟草薄片生产工艺原理充分分析与了解的前提下,本文提出以现场总线技术为基础构建SCADA系统的设计思路。PLC控制器选用美国罗克韦尔公司(AB)的Logix5000系列,以NetLinx开放式网络为基础,将分布式设备(变频器、软启动器、现场智能仪表、现场子站等)与控制器连接至DeviceNet网络完成控制命令与信息的传输,不同的控制器通过连接到ControlNet网络完成高效的信息传送,最后以Ethernet/IP的形式完成对整个系统的集成管理。利用专用的RSLogix5000编程软件编写完善的PLC控制程序与硬件配置；通过通信软件RSLinx完成PLC与上位机的通信；用网络配置软件RSNetWorx对网络系统作出规划与配置；上位机采用GE FUNUC公司的iFIX组态软件作为客户机与服务器,利用其脚本编辑和OPC功能,通过调用COM组件,绘制人性化的操作与监控界面,实现报表、报警等功能。
本文以烟草薄片自动化生产线为研究对象,研究了各个工艺环节的自动化控制策略,采用先进的网络通讯技术、现场总线技术、模糊控制技术、智能检测技术、视频监控技术、计算机技术,集可编程控制器、智能仪表、电机变频调速控制、上位监控组态于一体,实现了造纸法再造烟叶生产线自动控制与信息集成系统。
通过对原有的生产工艺流程自动化控制进行改进和完善,目前生产线能够平稳运行,整条生产线的运行速度得到了提高,产品质量满足工艺要求；不仅改善了工人的工作环境,提高了生产效率,而且降低了生产成本,提高了生产线的自动化水平,达到了节能减排的目的。本课题通过对烟草薄片生产线的自动控制与信息集成系统的研究,可以为再造烟叶生产企业的自动化生产提供理论依据和技术支持,也可以作为类似相关行业提高生产效率,改善生产环境的技术参考。
Tobacco sheet is a kind of reconstituted tobacco, which is made of many materials, such as tobacco stems leavies and spices. It can change the physical and chemical properties of cigarettes artificially, and reduce the contents of tar, thereby we can lessen the harmful substances effectively which come from smoking. Nowadays, one of the best methods to manufacture reconstituted tobacco is by papermaking. It can extract the active ingredients of tobacco stems and leaves, by means of soaking, grinding and so on. Cigarette products can also be produced with different aroma through changing the ratio of raw materials. It can bring great benefit to the economy and society.
With the high development of automatic producing industry, the demand for tobacco sheet production increases day by day. So it is necessery to inquiry and reconstruct the existing producing line to ensure the safety of production, save energy, reduce emissions, improve the efficiency of production. This subject is based on an actual project with the principle of "centralized management, decentralized control". This paper makes a comprehensive research on the related profession, and designs the automatic control and information integration system by combining many advanced techniques for industry contro.
Under the premise of full analysis and understanding of the principle of tobacco sheet production process, this paper presents building SCADA system design ideas based on field bus technology. Logix5000series of American rockwell (AB) was chosen as the PLC controller., and on the basis of NetLinx open network, distributed equipment (frequency converter, soft starter, field intelligent instrument, the Sub-station, etc.) and the controller were connected to the DeviceNet network to complete the control command and information transmission, different controllers were connected to the ControlNet network to complete efficient information transmission, integrated management of the entire system was achieved in the form of Ethernet/IP at last. Using a dedicated RSLogix5000programming software to write perfect PLC control program and the hardware configuration; through communication software RSLinx, completed the communication of the PLC with the host computer; using network configuration software of the RSNetWorxto plan and configurated the network system; the iFIX configuration software of GE FANUC company was chosen as the upper computer to work as the client and server, and using its Script editor and OPC function to draw humanized operation and monitoring interface, statements, alarm and other functions by calling the COM component.
This paper uses the tobacco sheet automatic production line as the research object, studied the automation control strategies of each step of the process, and adapted advanced network communication technology, fieldbus technology, fuzzy control technology, intelligent detection technology, video monitoring technology, computer technology, combing programmable controllers, intelligent instruments, electrical frequency control of motor speed control, upper monitor configuration as a whole, implemented automatic control of the paper-making reconstituted tobacco production line and information integration system.
Through improving and completing the automation control of the original production process, current production line can run smoothly, the whole production line operation speed is improved, the product quality can meet the process requirements. Not only the working environment of workers and production efficiency are improved but also reduce production costs, improve the level of automation of the production line to achieve the purpose of energy saving. Through researching the automatic control and information integration system of the tobacco sheet production line, this program can provide theoretical basis and technical support of automated production for the reengineering of tobacco leaf production enterprise, and also can be used as a technical reference to the similar or the related industry to improve the production efficiency and the production environment.
随着工业自动化生产的发展进步,烟草薄片产品市场需求量日益增长,需要对现有的薄片生产线进行技术探究与改造,以达到保障安全生产,节能减排,提高生产效率,满足市场需求的目的；本课题以实际项目为依托,根据“集中管理,分散控制”的原则,充分调研了解相关及类似行业的生产运行状况,综合运用工业控制领域中的许多先进技术,对造纸法再造烟叶生产线自动控制与信息集成系统进行了设计研究。
在对烟草薄片生产工艺原理充分分析与了解的前提下,本文提出以现场总线技术为基础构建SCADA系统的设计思路。PLC控制器选用美国罗克韦尔公司(AB)的Logix5000系列,以NetLinx开放式网络为基础,将分布式设备(变频器、软启动器、现场智能仪表、现场子站等)与控制器连接至DeviceNet网络完成控制命令与信息的传输,不同的控制器通过连接到ControlNet网络完成高效的信息传送,最后以Ethernet/IP的形式完成对整个系统的集成管理。利用专用的RSLogix5000编程软件编写完善的PLC控制程序与硬件配置；通过通信软件RSLinx完成PLC与上位机的通信；用网络配置软件RSNetWorx对网络系统作出规划与配置；上位机采用GE FUNUC公司的iFIX组态软件作为客户机与服务器,利用其脚本编辑和OPC功能,通过调用COM组件,绘制人性化的操作与监控界面,实现报表、报警等功能。
本文以烟草薄片自动化生产线为研究对象,研究了各个工艺环节的自动化控制策略,采用先进的网络通讯技术、现场总线技术、模糊控制技术、智能检测技术、视频监控技术、计算机技术,集可编程控制器、智能仪表、电机变频调速控制、上位监控组态于一体,实现了造纸法再造烟叶生产线自动控制与信息集成系统。
通过对原有的生产工艺流程自动化控制进行改进和完善,目前生产线能够平稳运行,整条生产线的运行速度得到了提高,产品质量满足工艺要求；不仅改善了工人的工作环境,提高了生产效率,而且降低了生产成本,提高了生产线的自动化水平,达到了节能减排的目的。本课题通过对烟草薄片生产线的自动控制与信息集成系统的研究,可以为再造烟叶生产企业的自动化生产提供理论依据和技术支持,也可以作为类似相关行业提高生产效率,改善生产环境的技术参考。
Tobacco sheet is a kind of reconstituted tobacco, which is made of many materials, such as tobacco stems leavies and spices. It can change the physical and chemical properties of cigarettes artificially, and reduce the contents of tar, thereby we can lessen the harmful substances effectively which come from smoking. Nowadays, one of the best methods to manufacture reconstituted tobacco is by papermaking. It can extract the active ingredients of tobacco stems and leaves, by means of soaking, grinding and so on. Cigarette products can also be produced with different aroma through changing the ratio of raw materials. It can bring great benefit to the economy and society.
With the high development of automatic producing industry, the demand for tobacco sheet production increases day by day. So it is necessery to inquiry and reconstruct the existing producing line to ensure the safety of production, save energy, reduce emissions, improve the efficiency of production. This subject is based on an actual project with the principle of "centralized management, decentralized control". This paper makes a comprehensive research on the related profession, and designs the automatic control and information integration system by combining many advanced techniques for industry contro.
Under the premise of full analysis and understanding of the principle of tobacco sheet production process, this paper presents building SCADA system design ideas based on field bus technology. Logix5000series of American rockwell (AB) was chosen as the PLC controller., and on the basis of NetLinx open network, distributed equipment (frequency converter, soft starter, field intelligent instrument, the Sub-station, etc.) and the controller were connected to the DeviceNet network to complete the control command and information transmission, different controllers were connected to the ControlNet network to complete efficient information transmission, integrated management of the entire system was achieved in the form of Ethernet/IP at last. Using a dedicated RSLogix5000programming software to write perfect PLC control program and the hardware configuration; through communication software RSLinx, completed the communication of the PLC with the host computer; using network configuration software of the RSNetWorxto plan and configurated the network system; the iFIX configuration software of GE FANUC company was chosen as the upper computer to work as the client and server, and using its Script editor and OPC function to draw humanized operation and monitoring interface, statements, alarm and other functions by calling the COM component.
This paper uses the tobacco sheet automatic production line as the research object, studied the automation control strategies of each step of the process, and adapted advanced network communication technology, fieldbus technology, fuzzy control technology, intelligent detection technology, video monitoring technology, computer technology, combing programmable controllers, intelligent instruments, electrical frequency control of motor speed control, upper monitor configuration as a whole, implemented automatic control of the paper-making reconstituted tobacco production line and information integration system.
Through improving and completing the automation control of the original production process, current production line can run smoothly, the whole production line operation speed is improved, the product quality can meet the process requirements. Not only the working environment of workers and production efficiency are improved but also reduce production costs, improve the level of automation of the production line to achieve the purpose of energy saving. Through researching the automatic control and information integration system of the tobacco sheet production line, this program can provide theoretical basis and technical support of automated production for the reengineering of tobacco leaf production enterprise, and also can be used as a technical reference to the similar or the related industry to improve the production efficiency and the production environment.
引文
[1]程永照.回顾与展望：烟草经济研究文集[C].北京：世界图书出版公司,2003.
[2]于建军.卷烟工艺学[M].北京：中国家业出版社,2009.
[3]唐兴平,陈学榕，戴达松,胡荣汤,包可翔.烟草废弃物造纸法制烟草薄片[J].福建农林大学学报(自然科学版),2007,36(2)：205-207.
[4]闫英俊.薄片生产线自动控制系统的开发与设计[D].济南：山东大学,2009.
[5]陈祖刚,蔡冰,王建新,叶明樵熊斌.国内外造纸法薄片工艺与品质比较[J].烟草科技,2002,175(2)：4-10.
[6]唐杰斌,赵传山,韩文佳.造纸法再造烟叶生产工艺的改进[J].烟草科技,2009,264(7)：15-17.
[7]刘领,王能如,黄义德,徐增汉李章海.烘烤技术对烧后烟叶香味品质影响的研究[J].安徽农业科学,2006,34(11)：2428-2430.
[8]张德江.计算机控制系统[M].北京：机械工业出版社,2007.
[9]王华忠.监控与数据采集(SCADA)系统及其应用[M].北京：电子工业出版社,2010.
[10]Pimenta A, Paravela Jr C, Prizon D, et al. Computer to fieldbus control system interface: U.S. Patent 6,304,934[P].2001-10-16.
[11]李正军.计算机测控系统设计与应用[M].北京：机械工业出版社,2004.
[12]凌志浩.DCS与现场总线控制系统[M].上海：华工理工大学出版社,2008.
[13]Rockwell Automation.NetLinx Selection Guide[DB/OL].2009,5.
[14]Biegacki S,VanGompel D. The application of DeviceNet in process control[J]. ISA transactions,1996,35(2):169-176.
[15]黄允凯,谈英姿.深入浅出NetLinx网络架构[M].北京：机械工业出版社,2009.
[16]Rockwell Automation.ControlLogix System User Manual[DB/OL].2010,11.
[17]Rockwell Automation.Point I/O Selection Guide[DB/OL].2010,9.
[18]Rockwell Automation.FlexLogix Controller System User Manual[DB/OL].2007.2.
[19]Biegacki S, VanGompel D. The application of DeviceNet in process control[J]. ISA transactions,1996,35(2):169-176.
[20]Bi-zhou LI U M M E I. The applications of ATV71 FREQUENCYCON VERTER and twido PLC (made by schneider electric) in the press machine of our factory [J][J]. Manufacturing Automation,2007,7:030.
[21]乔旭兴.造纸法再造烟叶智能控制系统的设计研究[D].济南：山东大学,2011.
[22]Xiaoyin D X W Z H. The Communication Interface Study between Matlab and RsLinx/Rs View in the ITS [J][J]. Microcomputer Applications,2005,7:017.
[23]Rockwell Automation. Getting Results with RSNetWorx for ControlNet/DeviceNet [DB/OL].2008,5.
[24]Lian F L, Moyne J R, Tilbury D M. Performance evaluation of control networks:Ethernet, ControlNet, and DeviceNet[J]. Control Systems, IEEE,2001,21(1):66-83.
[25]Schneider Electric.Altivar 71 DeviceNet card[DB/OL].2005,5.
[26]Rockwell Automation. Logix5000 Controllers Design Considerations [DB/OL].2010,9.
[27]CARR D, SHEARER J.Nonlinear Control and Decision Making Using Fuzzy Logic in Logix[J]. Rockwell Automation,2007.
[28]McGrew R W, Vaughn R B. Discovering vulnerabilities in control system human-machine interface software[J]. Journal of Systems and Software,2009,82(4):583-589.
[29]Intellution Inc.Educational Services 254 Student Guide[DB/OL].2000.
[30]David J.Kruglinshi.Visual C++技术内幕[M].北京：清华大学出版社,2009.
[31]黄海.Excel VBA语法与应用辞典[M].北京：中国青年出版社,2009.
[32]Balas, Mark. "Feedback control of flexible systems." Automatic Control, IEEE Transactions on 23.4 (1978):673-679.
[33]王红艳；吴彦锐；陈景文.造纸机速度链的设计与工作原理变频器世界[M],2006.
[34]Karolev, Nestor A., and Peter W. Gold. "Load distribution of timing belt drives transmitting variable torques." Mechanism and machine theory 30.4 (1995):553-567.
[35]董宁.自适应控制[M].北京：北京理工大学出版社,2009.
[36]张国良.模糊控制及其MATLAB应用[M].西安：西安交通大学出版社,2002.
[37]Xie, Shi-hong, Li-bo Jiang, and Guo-dong Liu. "Application of Fuzzy Adaptive PID Control Algorithm on Dryers Steam System of Paper Machine." Control and Instruments in Chemical Industry 34.1 (2007):33.
[38]曾光奇,胡均安,王东,刘春玲.模糊控制理论与工程应用.武汉：华中科技大学出版社,2006.
[39]刘金琨.先进PID控制MATLAB仿真.北京：电子工业出版社,2004.
[40]乔旭兴.造纸法再造烟叶智能控制系统的设计研究[D].济南：山东大学,2011.
[41]Chu Y, TAO Y Computer simulation of the self-adaptive fuzzy PID conrol system based on MATLAB[J]. JOURNAL-ANHUI UNIVERSITY OF TECHNOLOGY,2004,21(1): 49-52.
[2]于建军.卷烟工艺学[M].北京：中国家业出版社,2009.
[3]唐兴平,陈学榕，戴达松,胡荣汤,包可翔.烟草废弃物造纸法制烟草薄片[J].福建农林大学学报(自然科学版),2007,36(2)：205-207.
[4]闫英俊.薄片生产线自动控制系统的开发与设计[D].济南：山东大学,2009.
[5]陈祖刚,蔡冰,王建新,叶明樵熊斌.国内外造纸法薄片工艺与品质比较[J].烟草科技,2002,175(2)：4-10.
[6]唐杰斌,赵传山,韩文佳.造纸法再造烟叶生产工艺的改进[J].烟草科技,2009,264(7)：15-17.
[7]刘领,王能如,黄义德,徐增汉李章海.烘烤技术对烧后烟叶香味品质影响的研究[J].安徽农业科学,2006,34(11)：2428-2430.
[8]张德江.计算机控制系统[M].北京：机械工业出版社,2007.
[9]王华忠.监控与数据采集(SCADA)系统及其应用[M].北京：电子工业出版社,2010.
[10]Pimenta A, Paravela Jr C, Prizon D, et al. Computer to fieldbus control system interface: U.S. Patent 6,304,934[P].2001-10-16.
[11]李正军.计算机测控系统设计与应用[M].北京：机械工业出版社,2004.
[12]凌志浩.DCS与现场总线控制系统[M].上海：华工理工大学出版社,2008.
[13]Rockwell Automation.NetLinx Selection Guide[DB/OL].2009,5.
[14]Biegacki S,VanGompel D. The application of DeviceNet in process control[J]. ISA transactions,1996,35(2):169-176.
[15]黄允凯,谈英姿.深入浅出NetLinx网络架构[M].北京：机械工业出版社,2009.
[16]Rockwell Automation.ControlLogix System User Manual[DB/OL].2010,11.
[17]Rockwell Automation.Point I/O Selection Guide[DB/OL].2010,9.
[18]Rockwell Automation.FlexLogix Controller System User Manual[DB/OL].2007.2.
[19]Biegacki S, VanGompel D. The application of DeviceNet in process control[J]. ISA transactions,1996,35(2):169-176.
[20]Bi-zhou LI U M M E I. The applications of ATV71 FREQUENCYCON VERTER and twido PLC (made by schneider electric) in the press machine of our factory [J][J]. Manufacturing Automation,2007,7:030.
[21]乔旭兴.造纸法再造烟叶智能控制系统的设计研究[D].济南：山东大学,2011.
[22]Xiaoyin D X W Z H. The Communication Interface Study between Matlab and RsLinx/Rs View in the ITS [J][J]. Microcomputer Applications,2005,7:017.
[23]Rockwell Automation. Getting Results with RSNetWorx for ControlNet/DeviceNet [DB/OL].2008,5.
[24]Lian F L, Moyne J R, Tilbury D M. Performance evaluation of control networks:Ethernet, ControlNet, and DeviceNet[J]. Control Systems, IEEE,2001,21(1):66-83.
[25]Schneider Electric.Altivar 71 DeviceNet card[DB/OL].2005,5.
[26]Rockwell Automation. Logix5000 Controllers Design Considerations [DB/OL].2010,9.
[27]CARR D, SHEARER J.Nonlinear Control and Decision Making Using Fuzzy Logic in Logix[J]. Rockwell Automation,2007.
[28]McGrew R W, Vaughn R B. Discovering vulnerabilities in control system human-machine interface software[J]. Journal of Systems and Software,2009,82(4):583-589.
[29]Intellution Inc.Educational Services 254 Student Guide[DB/OL].2000.
[30]David J.Kruglinshi.Visual C++技术内幕[M].北京：清华大学出版社,2009.
[31]黄海.Excel VBA语法与应用辞典[M].北京：中国青年出版社,2009.
[32]Balas, Mark. "Feedback control of flexible systems." Automatic Control, IEEE Transactions on 23.4 (1978):673-679.
[33]王红艳；吴彦锐；陈景文.造纸机速度链的设计与工作原理变频器世界[M],2006.
[34]Karolev, Nestor A., and Peter W. Gold. "Load distribution of timing belt drives transmitting variable torques." Mechanism and machine theory 30.4 (1995):553-567.
[35]董宁.自适应控制[M].北京：北京理工大学出版社,2009.
[36]张国良.模糊控制及其MATLAB应用[M].西安：西安交通大学出版社,2002.
[37]Xie, Shi-hong, Li-bo Jiang, and Guo-dong Liu. "Application of Fuzzy Adaptive PID Control Algorithm on Dryers Steam System of Paper Machine." Control and Instruments in Chemical Industry 34.1 (2007):33.
[38]曾光奇,胡均安,王东,刘春玲.模糊控制理论与工程应用.武汉：华中科技大学出版社,2006.
[39]刘金琨.先进PID控制MATLAB仿真.北京：电子工业出版社,2004.
[40]乔旭兴.造纸法再造烟叶智能控制系统的设计研究[D].济南：山东大学,2011.
[41]Chu Y, TAO Y Computer simulation of the self-adaptive fuzzy PID conrol system based on MATLAB[J]. JOURNAL-ANHUI UNIVERSITY OF TECHNOLOGY,2004,21(1): 49-52.