铝箔退火炉监控系统研究与设计
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摘要
本文详细分析了采用PLC控制技术结合工业计算机进行退火炉自动化过程设计的基本原理及方法。
论文在分析退火炉特性及工作原理的基础上,分别给出了采用PLC控制技术进行工业过程设计的硬件配置过程和软件设计方法。其中控制器的硬件采用Rockwell/Allen-Bradley(AB)公司的SLC5/03,软件设计分为上位机监控部分和下位PLC程序设计部分,分别由AB公司提供的组态软件RSView32和程序设计软件RSLogix500实现。监控部分由多个组态界面构成,可以将退火炉当前的所有状态信息集中显示到上位机,便于操作人员了解系统全貌和各点的工作状况,并可实时调整系统参数,优化系统输出,大大提高了控制过程的自动化程度,改善操作人员的劳动强度,降低故障率。系统的PLC程序设计利用编程软件RSLogix500,采用梯形图的编程方式,直观清晰,易于修改和调试。在控制算法方面,本论文考虑到退火炉各炉段所具有的耦合性、非线性、大惯性等特征,在传统PID控制基础上,利用PLC的软件编程环境,根据现场工程技术人员的实际经验知识,进一步开发设计了模糊控制器,该模糊控制器能够根据现场不同情况,实现PID参数的自整定,取得了良好的控制效果。
经实践运行表明整个控制系统具有良好的可靠性、自适应性和鲁棒性,可以很好的满足铝箔退火炉的生产工艺要求,退火过程中系统运行稳定可靠,操作系统易学易用,在冶金行业具有广阔的应用前景。
This paper analyses the basic theory and method in detail about how to apply the PLC and computer to design the automatic control process for the annealing furnace.
After analyzing the furnace's characteristics and working theory, the paper gives the design procedure for both hardware and software about the system. The hardware of controller is made up of the SLC5/03 that made by RockwellAllen-Bradley. For the software design, it includes two parts: supervising software and programming part. They are separately designed by the software RSView32 and RSLogix500 provided by AB Company. Meanwhile, the supervising software is composed of several screens. All the current information comes from the furnace can be centralized to the supervising screens. In this way, the operators can know well about the whole furnace state, modifying the system parameters in time, improving the automation process and deducing the faults. To the programming Software, the paper brings forth the ladder program mode. This method is visual and clear. It. is also convenient to debug. Concerning to the control algorithm, the paper designs the fuzzy controller according to the engineers' practical experience. This mainly because the traditional PID algorithm can't solve the coupling、nonlinear、inertial problems of the furnace very well. Therefore, aiming at the heating and temperature-holding process, the paper designs the fuzzy system. As the result, the PID Parameters can be adjusted and the control output can be optimized.
The system has high reliability and stability for running, operation system can study and use easily .It has wide application prospect in the metallurgical industry.
论文在分析退火炉特性及工作原理的基础上,分别给出了采用PLC控制技术进行工业过程设计的硬件配置过程和软件设计方法。其中控制器的硬件采用Rockwell/Allen-Bradley(AB)公司的SLC5/03,软件设计分为上位机监控部分和下位PLC程序设计部分,分别由AB公司提供的组态软件RSView32和程序设计软件RSLogix500实现。监控部分由多个组态界面构成,可以将退火炉当前的所有状态信息集中显示到上位机,便于操作人员了解系统全貌和各点的工作状况,并可实时调整系统参数,优化系统输出,大大提高了控制过程的自动化程度,改善操作人员的劳动强度,降低故障率。系统的PLC程序设计利用编程软件RSLogix500,采用梯形图的编程方式,直观清晰,易于修改和调试。在控制算法方面,本论文考虑到退火炉各炉段所具有的耦合性、非线性、大惯性等特征,在传统PID控制基础上,利用PLC的软件编程环境,根据现场工程技术人员的实际经验知识,进一步开发设计了模糊控制器,该模糊控制器能够根据现场不同情况,实现PID参数的自整定,取得了良好的控制效果。
经实践运行表明整个控制系统具有良好的可靠性、自适应性和鲁棒性,可以很好的满足铝箔退火炉的生产工艺要求,退火过程中系统运行稳定可靠,操作系统易学易用,在冶金行业具有广阔的应用前景。
This paper analyses the basic theory and method in detail about how to apply the PLC and computer to design the automatic control process for the annealing furnace.
After analyzing the furnace's characteristics and working theory, the paper gives the design procedure for both hardware and software about the system. The hardware of controller is made up of the SLC5/03 that made by RockwellAllen-Bradley. For the software design, it includes two parts: supervising software and programming part. They are separately designed by the software RSView32 and RSLogix500 provided by AB Company. Meanwhile, the supervising software is composed of several screens. All the current information comes from the furnace can be centralized to the supervising screens. In this way, the operators can know well about the whole furnace state, modifying the system parameters in time, improving the automation process and deducing the faults. To the programming Software, the paper brings forth the ladder program mode. This method is visual and clear. It. is also convenient to debug. Concerning to the control algorithm, the paper designs the fuzzy controller according to the engineers' practical experience. This mainly because the traditional PID algorithm can't solve the coupling、nonlinear、inertial problems of the furnace very well. Therefore, aiming at the heating and temperature-holding process, the paper designs the fuzzy system. As the result, the PID Parameters can be adjusted and the control output can be optimized.
The system has high reliability and stability for running, operation system can study and use easily .It has wide application prospect in the metallurgical industry.
引文
[1]王祝堂.具有国际竞争力的中国铝箔业[J].金属世界,2005(4):5
[2]王祝堂,郑祥健,海鹏.最优化铝箔厂--建设新铝箔厂的最佳选择[J].轻合金加工技术,1999,27(8):1-4
[3]国际冶金机电手册(VOL.3).北京:冶金工业出版社,1992:487-521
[4]戎宗义.国内外加热炉和热处理炉的现状和节能技术.特殊钢,1999,20(5):35-39
[5]王翠梅,焦兴贵,喻文春.铝箔退火炉的设计与应用.轻金属,2003,(12):47-50
[6]王宗众.耐火纤维及其增强涂料在加热退火炉上的应用与节能[J].现代节能,1995(5):10
[7]孟祥和等.新型高效退火炉[J],工业炉,1996,(4):17-20
[8]宫淑贞,王冬青.可编程控制器原理及应用.北京:人民邮电出版社,2002
[9]Silva C W.A criterion for knowledge base decoupling in fuzzy-logic control systems[J].IEEE Transaction on System,Man&Cybernetics,1994,2 4:1549-1552
[10]Tong R.M.A Retrospective View of Fuzzy Control System.Fuzzy Sets and system[J],1989.14(3)
[11]Sugeno M,Nishida M.Fuzzy control of model car.Fuzzy Sets and System [J],1985.16:103-113
[12]邵本述.国外工业炉及热工文摘.工业炉,2004,26(5):51-53
[13]赵春隆.铝箔退火炉电控设备的改造[J].有色设备,2006(6):35-36
[14]宋湛苹,史京.工业炉的现状与发展趋势.Industrial Furnace,2004,26(6):13-18
[15]戎宗义.国内外加热炉和热处理炉的现状和节能技术.特殊钢,1999,20(5):40-47
[16]李朝迅.5t铝箔退火炉炉温均匀性的改进[J].轻合金加工技术,1997,25(2):42-43
[17]J.Dauer.Improved combustion control enhances furnace performance.Industrial Heating,2004,(4):39-42
[18]黄桂银.20t退火炉温度控制设计.铝镁通讯,2002(3):46-48
[19]王刚.基于RSView32的铝箔退火炉监控系统开发.工业控制计算机,2007(7):41
[20]可编程序控制器系统.浙江大学出版社,2000.3
[21]陆建国.微机控制的可控硅交流调功器.江苏电器,2005(6)
[22]辛琦.智能晶闸管调功器在电加热温度控制中的应用.工业加热,1999(6):30-31
[23]钱晓龙.DH-485工业局域网络及应用.基础自动化,2001(8):44-45
[24]SLC 500安装和操作手册.1998,Rockwell公司
[25]http://www.Rockwellautomation.com.cn
[26]RSLogix500编程手册.Rockwell公司
[27]Rsview32用户指南.Rockwell公司
[28]诸静等.模糊控制原理与应用[M],北京机械工业出版社,1995.7
[29]余永权.单片机模糊逻辑控制[M],北京:北京航天航空大学出版社,1995
[30]Ying H,SilerW,Buckley J J,Fuzzy control theory:A nonlinear case[J],Automatica,1990,26:513-520
[31]汪培庄.模糊集合论及其应用[M],上海:上海科学技术出版社,1983
[32]张恩勤,施颂椒,翁正新.一类基于PfD控制的新型模糊控制方法[J],上海交通大学学报,2000,34(56):30-34
[33]刘国荣,阳宪惠.模糊自适应PID控制器[J],控制与决策,1995,10(6):558-562
[34]Joongseon Joh,Ye-Haw Chen,RezaL angari.On the stability isseus of linear,Takagi-Sugeno fuzzy models[J],IEEE Trans,Fuzzy Syst,1998.3.16:402-410
[35]李士勇等.模糊控制和智能控制理论与应用[M],哈尔滨:哈尔滨工业大学出版社1990
[36]黄峰,汪岳峰.模糊参数自整定PID控制器的设计与仿真研究.光学精密工程,2004,12(2):235-239
[37]Hung T.Nguyen,Nadiuram R.Prasad,Fuzzy modeling and control,CRC Pr,Boca Raton,1999
[38]KingPJ,Mamdani EH.The Application of Fuzzy Control Systems to Industial Process.Automatic,1997,3:235-242
[39]Yang Yu,Wang Wen G e,Yu De Jie,Ding Ge.A fuzzy parameters adaptive PID controller design of digital positional servo system.Proceedings of 2002International Conference on machine Learning and Cybernetics,2002,(3):10-14.
[40]陈理君.微机模糊控制[M].武汉:武汉工业大学出版社,1994,112-120
[41]Ton.A.Control Engineering Review of Fuzzy Systems.Automatic,1997,(13):559-569
[2]王祝堂,郑祥健,海鹏.最优化铝箔厂--建设新铝箔厂的最佳选择[J].轻合金加工技术,1999,27(8):1-4
[3]国际冶金机电手册(VOL.3).北京:冶金工业出版社,1992:487-521
[4]戎宗义.国内外加热炉和热处理炉的现状和节能技术.特殊钢,1999,20(5):35-39
[5]王翠梅,焦兴贵,喻文春.铝箔退火炉的设计与应用.轻金属,2003,(12):47-50
[6]王宗众.耐火纤维及其增强涂料在加热退火炉上的应用与节能[J].现代节能,1995(5):10
[7]孟祥和等.新型高效退火炉[J],工业炉,1996,(4):17-20
[8]宫淑贞,王冬青.可编程控制器原理及应用.北京:人民邮电出版社,2002
[9]Silva C W.A criterion for knowledge base decoupling in fuzzy-logic control systems[J].IEEE Transaction on System,Man&Cybernetics,1994,2 4:1549-1552
[10]Tong R.M.A Retrospective View of Fuzzy Control System.Fuzzy Sets and system[J],1989.14(3)
[11]Sugeno M,Nishida M.Fuzzy control of model car.Fuzzy Sets and System [J],1985.16:103-113
[12]邵本述.国外工业炉及热工文摘.工业炉,2004,26(5):51-53
[13]赵春隆.铝箔退火炉电控设备的改造[J].有色设备,2006(6):35-36
[14]宋湛苹,史京.工业炉的现状与发展趋势.Industrial Furnace,2004,26(6):13-18
[15]戎宗义.国内外加热炉和热处理炉的现状和节能技术.特殊钢,1999,20(5):40-47
[16]李朝迅.5t铝箔退火炉炉温均匀性的改进[J].轻合金加工技术,1997,25(2):42-43
[17]J.Dauer.Improved combustion control enhances furnace performance.Industrial Heating,2004,(4):39-42
[18]黄桂银.20t退火炉温度控制设计.铝镁通讯,2002(3):46-48
[19]王刚.基于RSView32的铝箔退火炉监控系统开发.工业控制计算机,2007(7):41
[20]可编程序控制器系统.浙江大学出版社,2000.3
[21]陆建国.微机控制的可控硅交流调功器.江苏电器,2005(6)
[22]辛琦.智能晶闸管调功器在电加热温度控制中的应用.工业加热,1999(6):30-31
[23]钱晓龙.DH-485工业局域网络及应用.基础自动化,2001(8):44-45
[24]SLC 500安装和操作手册.1998,Rockwell公司
[25]http://www.Rockwellautomation.com.cn
[26]RSLogix500编程手册.Rockwell公司
[27]Rsview32用户指南.Rockwell公司
[28]诸静等.模糊控制原理与应用[M],北京机械工业出版社,1995.7
[29]余永权.单片机模糊逻辑控制[M],北京:北京航天航空大学出版社,1995
[30]Ying H,SilerW,Buckley J J,Fuzzy control theory:A nonlinear case[J],Automatica,1990,26:513-520
[31]汪培庄.模糊集合论及其应用[M],上海:上海科学技术出版社,1983
[32]张恩勤,施颂椒,翁正新.一类基于PfD控制的新型模糊控制方法[J],上海交通大学学报,2000,34(56):30-34
[33]刘国荣,阳宪惠.模糊自适应PID控制器[J],控制与决策,1995,10(6):558-562
[34]Joongseon Joh,Ye-Haw Chen,RezaL angari.On the stability isseus of linear,Takagi-Sugeno fuzzy models[J],IEEE Trans,Fuzzy Syst,1998.3.16:402-410
[35]李士勇等.模糊控制和智能控制理论与应用[M],哈尔滨:哈尔滨工业大学出版社1990
[36]黄峰,汪岳峰.模糊参数自整定PID控制器的设计与仿真研究.光学精密工程,2004,12(2):235-239
[37]Hung T.Nguyen,Nadiuram R.Prasad,Fuzzy modeling and control,CRC Pr,Boca Raton,1999
[38]KingPJ,Mamdani EH.The Application of Fuzzy Control Systems to Industial Process.Automatic,1997,3:235-242
[39]Yang Yu,Wang Wen G e,Yu De Jie,Ding Ge.A fuzzy parameters adaptive PID controller design of digital positional servo system.Proceedings of 2002International Conference on machine Learning and Cybernetics,2002,(3):10-14.
[40]陈理君.微机模糊控制[M].武汉:武汉工业大学出版社,1994,112-120
[41]Ton.A.Control Engineering Review of Fuzzy Systems.Automatic,1997,(13):559-569