基于PLC控制的水电站起重机变频调速系统应用研究
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摘要
随着我国巨型水电站的加速开发,水电工程建设和运行对特大型起重设备控制要求越来越高。对于水电站起重机,主要用于电站机组或闸门安装,在安装过程中如果出现故障,将对安装设备和安装工期造成很大的影响,可能造成重大设备损害事故和重大经济损失,所以对起重机工作可靠性要求很高。此外,吊车必须运行平稳、停车定位准确,速度变化范围宽,以满足各种工况下的起吊要求。还有水电站人员配置少,要求起重设备与主设备一样,具有较高的自动化水平和自我诊断功能。
以前水电站起重机拖动系统主要选用三相交流异步电动机,其主要调速方式为定子调压调速或转子串电阻调速,其特点是能量大量损耗、对机械冲击大、对操作人员技能要求高,工作效率低。控制方式采用继电器—接触器控制回路,故障率很高,维护量大,而且起重机运行时无法监测各种工作参数。总的来说,传统起重机电气控制系统无法满足上述对起重机高可靠性、灵活、智能化的要求。
随着微电子技术、电力电子技术和微处理器技术的发展,晶体管变频器和可编程控制器(PLC)应运而生。变频器不但克服了以往交流调速的许多缺点,而且矢量控制变频器的调速性能甚至可以和直流电动机的调速性能媲美。变频调速以其优异的起动、调速和制动性能,高效率、高功率因数和节能效果,广泛的应用范围等优点被国内外公认为最有发展前途的调速方式。在起重机领域,变频调速尤其显示它的优越性。PLC以可靠性高、使用灵活、维护工作量少等突出优点在工业领域得到了广泛的应用。
针对水电站大型起重机控制要求和特点,本文以三峡工程选用的桥门机为背景,研究现有的水电站起重机控制的特点,对现有技术方案分析比较,确定合适的起重机变频调速总体结构和控制方式;研究并设计起重机控制流程、绘制控制流程图,确定整机PLC配置方式和配置数目;研究起重机PLC控制网络结构和连接方式、人机界面硬件选择和程序设计。针对水电站起重机一些特殊功能的实现要求,提出控制思路,解决了一些关键技术,如:门式起重机抓梁水平自动纠偏问题,并进行相关的软硬件设计。
通过较长时间的实际运行,该控制系统完全满足要求,具有自动化水平高、功能完善、可靠性高等特点。
With the development of giant hydropower station in china, hydroelectric projects' construction and operation need the oversize crane equipments to have high performance control. The hydropower station's cranes are used in Power Station's set or Installation. If there is failure in the process of installation, It will be a great impact on the project, causing significant damage to equipment and economic losses, so the high reliability of crane is very important. In addition, the crane must be operated smoothly, parked positioning accuracy and has a wide speed range, in order to meet the demands of all conditions. Because there are few staff in the hydropower stations, it demands crane on the high level of automation and self-diagnosis function.
Three-phase AC asynchronous motor was selected for the drive system of Hydropower station crane. The method of Adjustable-speed including adjustable voltage speed control or adjustable series with resistance speed control, is characterized by large energy loss, mechanical shock, the high skill requirements for operators, low work efficiency. Control methods in which use Relay-contactor control loop, have high failure rate, and can't monitor various parameters. In a word, the electrical control system of traditional crane can't meet cranes' high reliability, flexible and intelligent demands.
With the development of microelectronic technology, power electronics and microprocessor technology, transistors converter and programmable logical controller (PLC) came into existing. Inverter not only overcomes many shortcomings of AC Drive, but also it uses vector control method that can compare with DC motor speed performance. Frequency Conversion Adjustable-speed has excellent startup, speed regulation, braking performance, high efficiency, high power factor and energy-saving effect. It was recognized as the most promising speed regulation method. Frequency Conversion Adjustable-speed shows its superiority especially in crane domain. With the high reliability, the use of flexible and low maintenance working, PLC is widely used in industrial areas.
For Hydropower giant cranes' control requirements and characteristics, this paper researches on the existing hydropower stations crane control characteristics, compares the existing technical programs, determines a suitable Frequency Conversion Adjustable-speed structure and control; designs the crane's control system processes, protracts control flow charts and determines the number of PLC units. And this paper focuses on crane's network structure, connection methods, human-machine interface and procedures design. For some special function of Hydropower cranes, this paper puts forward some control ideas which solve some key technologies, such as: automatically correcting deviation, and designs associated with software and hardware.
After longer actual operation, this control system fully meets the performance requirements, and has high level of automation, perfect function and high reliability characteristics.
以前水电站起重机拖动系统主要选用三相交流异步电动机,其主要调速方式为定子调压调速或转子串电阻调速,其特点是能量大量损耗、对机械冲击大、对操作人员技能要求高,工作效率低。控制方式采用继电器—接触器控制回路,故障率很高,维护量大,而且起重机运行时无法监测各种工作参数。总的来说,传统起重机电气控制系统无法满足上述对起重机高可靠性、灵活、智能化的要求。
随着微电子技术、电力电子技术和微处理器技术的发展,晶体管变频器和可编程控制器(PLC)应运而生。变频器不但克服了以往交流调速的许多缺点,而且矢量控制变频器的调速性能甚至可以和直流电动机的调速性能媲美。变频调速以其优异的起动、调速和制动性能,高效率、高功率因数和节能效果,广泛的应用范围等优点被国内外公认为最有发展前途的调速方式。在起重机领域,变频调速尤其显示它的优越性。PLC以可靠性高、使用灵活、维护工作量少等突出优点在工业领域得到了广泛的应用。
针对水电站大型起重机控制要求和特点,本文以三峡工程选用的桥门机为背景,研究现有的水电站起重机控制的特点,对现有技术方案分析比较,确定合适的起重机变频调速总体结构和控制方式;研究并设计起重机控制流程、绘制控制流程图,确定整机PLC配置方式和配置数目;研究起重机PLC控制网络结构和连接方式、人机界面硬件选择和程序设计。针对水电站起重机一些特殊功能的实现要求,提出控制思路,解决了一些关键技术,如:门式起重机抓梁水平自动纠偏问题,并进行相关的软硬件设计。
通过较长时间的实际运行,该控制系统完全满足要求,具有自动化水平高、功能完善、可靠性高等特点。
With the development of giant hydropower station in china, hydroelectric projects' construction and operation need the oversize crane equipments to have high performance control. The hydropower station's cranes are used in Power Station's set or Installation. If there is failure in the process of installation, It will be a great impact on the project, causing significant damage to equipment and economic losses, so the high reliability of crane is very important. In addition, the crane must be operated smoothly, parked positioning accuracy and has a wide speed range, in order to meet the demands of all conditions. Because there are few staff in the hydropower stations, it demands crane on the high level of automation and self-diagnosis function.
Three-phase AC asynchronous motor was selected for the drive system of Hydropower station crane. The method of Adjustable-speed including adjustable voltage speed control or adjustable series with resistance speed control, is characterized by large energy loss, mechanical shock, the high skill requirements for operators, low work efficiency. Control methods in which use Relay-contactor control loop, have high failure rate, and can't monitor various parameters. In a word, the electrical control system of traditional crane can't meet cranes' high reliability, flexible and intelligent demands.
With the development of microelectronic technology, power electronics and microprocessor technology, transistors converter and programmable logical controller (PLC) came into existing. Inverter not only overcomes many shortcomings of AC Drive, but also it uses vector control method that can compare with DC motor speed performance. Frequency Conversion Adjustable-speed has excellent startup, speed regulation, braking performance, high efficiency, high power factor and energy-saving effect. It was recognized as the most promising speed regulation method. Frequency Conversion Adjustable-speed shows its superiority especially in crane domain. With the high reliability, the use of flexible and low maintenance working, PLC is widely used in industrial areas.
For Hydropower giant cranes' control requirements and characteristics, this paper researches on the existing hydropower stations crane control characteristics, compares the existing technical programs, determines a suitable Frequency Conversion Adjustable-speed structure and control; designs the crane's control system processes, protracts control flow charts and determines the number of PLC units. And this paper focuses on crane's network structure, connection methods, human-machine interface and procedures design. For some special function of Hydropower cranes, this paper puts forward some control ideas which solve some key technologies, such as: automatically correcting deviation, and designs associated with software and hardware.
After longer actual operation, this control system fully meets the performance requirements, and has high level of automation, perfect function and high reliability characteristics.
引文
[1]王兆安、黄俊,电力电子技术北京:机械工业出版社,2000
[2]韩安荣,通川变频器及其应用 北京:机械工业出版社,2000
[3]郑晟、巩建平、张学,现代可编程控制器原理与应用 北京:科学出版社,1999
[4]SIEMENS.SIMOVERT MASTERDRIVES Compendium Vector Control,1998
[5]吴激扬,变频器-PLC在电站起重机中的应用,变频器世界,2004.4:105-108
[6]陆纪国、夏文彦,二峡尾水门式启闭机的控制技术,水力电力机械,Vol.25 No.1Feb.2003:16-18
[7]杜京义,基于PROFIBUS-DP网络的桥式起重机控制系统,起重运输机械,2003.7:31-32
[8]吴文昭,牛洪瑜,交流凋速技术展望,河丙学院学报,Vol.22 No.2(2006):37-39
[9]王向辉,门式启闭机抓梁电缆卷筒的改造.起重运输机械,2005.5:60-62
[10]刘焕江,变频凋速在1200t桥式起重机上的应用,起重运输机械,2004.6:28-29
[11]李汉强,刘玉娟,高承伟,起重机电动机矢量变频调速理论与实现,港口装卸 2002.4:4-6
[12]陆纪国、夏文彦,2x1250/250kN门式启闭机的控制系统,起重运输机械,2003.1:39-41
[13]徐立娟,华满香,PLC控制的变频调速在桥式起重机拖动系统中的应用,电气开关,2002.1:16-17
[14]魏全浩,变频调速技术在起重机起升机构上的应用,电工技术,2004.5:38-39
[15]郭俊如,PLC在工业控制中的地位,内蒙古石油化工 Vol.30,2004:49-50
[16]姜健,徐叶淮,张蓉,PLC在门座式起重机中的应用,测控技术 2003,Vol.22,No.2:51-53
[17]SIEMENS.SIEMENS ProTool V6.0 User Mannual.1998.
[18]王兰,李传信,赵厚鑫,人机界面在干式变压器PLC温控系统中的应用,仪表技术,2005.4:26-27
[19]朱镇达,2x200t桥式起重机电气控制系统的设计,机电工程,Vol.21 No.7 2004:25-28
[20]何志渔,王素玲,变频调速技术在港口及船舶起重机械中的应用,中国修船,2002.2:34-36
[21]谭振国,变频调速技术在起重机械上的可行性应用探讨,水电厂自动化,2006.10:181-183
[22]梁景成,李保健,变频调速系统在门式起重机中的应用,铁道货运,2004.4::38-42
[23]杨成惠,薛志勇,变频调速在桥式起重机上应用的理论研究,莱钢科技,2002.4:14-16
[24]刘晓星,苗根蝉,姚振南,王培红,变频调速在水电站门式起重机中的应用,电工技术杂志,2002.3:16-18
[25]三峡工程大坝及电站厂房研究,长江水利委员会 武汉:湖北科学技术出版社,1997.10
[26]SIEMENS.SIMOVERT MASTERDRIVES,Frequency Converter(AC-AC) Compact Type,1998
[27]SIEMENS.SIMATIC CP341 Point-to-point Communication Manual,1998
[28]王智唐、王玲,变频器在桥式起重机控制电路中的应用,电气时代,2006.3:88-92
[29]顾文溢,变频系统在起重机上的应用,港口装卸,1999.3:12-14
[30]周彩珍,基于PLC的起重机变频凋速系统,机电工程,Vol.24 No.2 Feb.2007:77-78
[31]向爱国、蔺伯文,交流变频调速系统在港口起重机上的应用研究,港口装卸,2001.2
[32]赵瑾,可编程控制器(PLC)在起重机控制系统改造中的应用,南京师大学报(工程技术版),Vol.1 No.4,2001:11-13
[33]马寅,起重机的变频调速,起重运输机械,2001.12:21-23
[34]宁秋艳,起重机的电气调速系统,重工科技 2006 No.2:44-45
[35]刘焕江,起重机交流调速特点,起重运输机械,2004.5:29-33
[36]邓肖粤,汗雄海,桥式起重机变频调速及PLC控制的设计,机电工程,Vol_23 No.9Sep.2006:25-27
[37]徐锋、杨彦青、金珍珍,桥式起重机提升机构电力拖动变频调速技术改造,电气开关2007.No.1:41-43
[38]罗乔民,我国变频凋速技术的发展概况,广东科技,2006.4:54-55
[39]周连毅,西门子PLC与其变频器间的现场总线通讯,科技情报开发与经济,Vol 15 No.172005:223-224
[40]刘晓星,西门子矢量型变频器在起重机中的应用,重丁科技2005 No.1:30-34
[41]SIEMENS.SIMATIC S7 System,Service & Programming course,2000
[42]Corriga G.,GiuaA.An Implicit Gain-scheduling Controller for Cranes[J].IEEE Transaction on Control systems Technology,1998(1).
[43]SIEMENS.Siemens Universal Serial Interface Protocol USS Protocol.User Mannual,1998
[44]SIEMENS.Step7 V5.1 User Mannual,2000
[45]John G,Kassakian.Principles of Power Electronics.Addis on Wesley publishing company,1991
[46]Rashid M H.Power Electronics.Prentice-Hall,Inc,1988
[47]Bose BK.A State-of-the-Art Tutorial on Power Electronics and Drives.University of Tennesses,1992
[48]SIEMENS.Voltage-Source DC Link Converters SIMVERT P for Variable-speed AC Drives.Catalog DA66.2,1993
[49]Nobuyoshi Mutoh,et al.Tdpless Control Method for General-purpose Inverters.IEEE Trans.Indnstry Applications,1992,28(5)
[50]Loenhard W.Power Electronics and Microelectronics,Tool for Future Electrical Energy Conversion.Proceedings IPEMC'97
[2]韩安荣,通川变频器及其应用 北京:机械工业出版社,2000
[3]郑晟、巩建平、张学,现代可编程控制器原理与应用 北京:科学出版社,1999
[4]SIEMENS.SIMOVERT MASTERDRIVES Compendium Vector Control,1998
[5]吴激扬,变频器-PLC在电站起重机中的应用,变频器世界,2004.4:105-108
[6]陆纪国、夏文彦,二峡尾水门式启闭机的控制技术,水力电力机械,Vol.25 No.1Feb.2003:16-18
[7]杜京义,基于PROFIBUS-DP网络的桥式起重机控制系统,起重运输机械,2003.7:31-32
[8]吴文昭,牛洪瑜,交流凋速技术展望,河丙学院学报,Vol.22 No.2(2006):37-39
[9]王向辉,门式启闭机抓梁电缆卷筒的改造.起重运输机械,2005.5:60-62
[10]刘焕江,变频凋速在1200t桥式起重机上的应用,起重运输机械,2004.6:28-29
[11]李汉强,刘玉娟,高承伟,起重机电动机矢量变频调速理论与实现,港口装卸 2002.4:4-6
[12]陆纪国、夏文彦,2x1250/250kN门式启闭机的控制系统,起重运输机械,2003.1:39-41
[13]徐立娟,华满香,PLC控制的变频调速在桥式起重机拖动系统中的应用,电气开关,2002.1:16-17
[14]魏全浩,变频调速技术在起重机起升机构上的应用,电工技术,2004.5:38-39
[15]郭俊如,PLC在工业控制中的地位,内蒙古石油化工 Vol.30,2004:49-50
[16]姜健,徐叶淮,张蓉,PLC在门座式起重机中的应用,测控技术 2003,Vol.22,No.2:51-53
[17]SIEMENS.SIEMENS ProTool V6.0 User Mannual.1998.
[18]王兰,李传信,赵厚鑫,人机界面在干式变压器PLC温控系统中的应用,仪表技术,2005.4:26-27
[19]朱镇达,2x200t桥式起重机电气控制系统的设计,机电工程,Vol.21 No.7 2004:25-28
[20]何志渔,王素玲,变频调速技术在港口及船舶起重机械中的应用,中国修船,2002.2:34-36
[21]谭振国,变频调速技术在起重机械上的可行性应用探讨,水电厂自动化,2006.10:181-183
[22]梁景成,李保健,变频调速系统在门式起重机中的应用,铁道货运,2004.4::38-42
[23]杨成惠,薛志勇,变频调速在桥式起重机上应用的理论研究,莱钢科技,2002.4:14-16
[24]刘晓星,苗根蝉,姚振南,王培红,变频调速在水电站门式起重机中的应用,电工技术杂志,2002.3:16-18
[25]三峡工程大坝及电站厂房研究,长江水利委员会 武汉:湖北科学技术出版社,1997.10
[26]SIEMENS.SIMOVERT MASTERDRIVES,Frequency Converter(AC-AC) Compact Type,1998
[27]SIEMENS.SIMATIC CP341 Point-to-point Communication Manual,1998
[28]王智唐、王玲,变频器在桥式起重机控制电路中的应用,电气时代,2006.3:88-92
[29]顾文溢,变频系统在起重机上的应用,港口装卸,1999.3:12-14
[30]周彩珍,基于PLC的起重机变频凋速系统,机电工程,Vol.24 No.2 Feb.2007:77-78
[31]向爱国、蔺伯文,交流变频调速系统在港口起重机上的应用研究,港口装卸,2001.2
[32]赵瑾,可编程控制器(PLC)在起重机控制系统改造中的应用,南京师大学报(工程技术版),Vol.1 No.4,2001:11-13
[33]马寅,起重机的变频调速,起重运输机械,2001.12:21-23
[34]宁秋艳,起重机的电气调速系统,重工科技 2006 No.2:44-45
[35]刘焕江,起重机交流调速特点,起重运输机械,2004.5:29-33
[36]邓肖粤,汗雄海,桥式起重机变频调速及PLC控制的设计,机电工程,Vol_23 No.9Sep.2006:25-27
[37]徐锋、杨彦青、金珍珍,桥式起重机提升机构电力拖动变频调速技术改造,电气开关2007.No.1:41-43
[38]罗乔民,我国变频凋速技术的发展概况,广东科技,2006.4:54-55
[39]周连毅,西门子PLC与其变频器间的现场总线通讯,科技情报开发与经济,Vol 15 No.172005:223-224
[40]刘晓星,西门子矢量型变频器在起重机中的应用,重丁科技2005 No.1:30-34
[41]SIEMENS.SIMATIC S7 System,Service & Programming course,2000
[42]Corriga G.,GiuaA.An Implicit Gain-scheduling Controller for Cranes[J].IEEE Transaction on Control systems Technology,1998(1).
[43]SIEMENS.Siemens Universal Serial Interface Protocol USS Protocol.User Mannual,1998
[44]SIEMENS.Step7 V5.1 User Mannual,2000
[45]John G,Kassakian.Principles of Power Electronics.Addis on Wesley publishing company,1991
[46]Rashid M H.Power Electronics.Prentice-Hall,Inc,1988
[47]Bose BK.A State-of-the-Art Tutorial on Power Electronics and Drives.University of Tennesses,1992
[48]SIEMENS.Voltage-Source DC Link Converters SIMVERT P for Variable-speed AC Drives.Catalog DA66.2,1993
[49]Nobuyoshi Mutoh,et al.Tdpless Control Method for General-purpose Inverters.IEEE Trans.Indnstry Applications,1992,28(5)
[50]Loenhard W.Power Electronics and Microelectronics,Tool for Future Electrical Energy Conversion.Proceedings IPEMC'97