基于现场总线网络的PCH-4KNA型打包机控制系统设计
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摘要
自动打包机是现代高速线材生产线特有的设备,它集机械、电气、液压控制为一体,动作准确,为现代化的线材生产线构筑了一道靓丽的风景线。
为了满足国内钢铁企业对提高产品包装质量,符合国际包装标准的需要,我们对现有的全自动高线打包机进行了升级改造,并取得了成功。
本文详细论述了一项基于PROFIBUS-DP网络的打包机自动控制系统设计。核心控制部分采用SIEMENS公司的S7-400系列PLC。本文首先论述了课题的背景及来源,国内外研究现状及发展前景,并在此基础上提出了自己的研究方向。综述了现场总线技术的概念、特点、系统组成、通讯协议。以及可编程控制器PLC的特点和优点,工作原理等。设计了控制系统的硬件和软件部分:核心控制部分采用的是SIEMENS公司的S7-400系列PLC,构建现场总线自动控制网络的基础是PROFIBUS-DP网络,由SIEMENS公司的S7-412DP作为现场控制总线主站,SIEMENS的分散式I/O的ET200M系列模块作为现场控制总线的从站。从而构建了一个基于PROFIBUS-DP网络的二级自动控制网络。软件开发系统是基于WINDOWS操作系统的SIEMENS公司的STEP7软件。
此外,在本设计中还详细说明了安装调试时所出现的问题,并根据实践经验对设备维护中可能出现的故障提出一些解决方法。
Automatic coil compactor is a unique equipment for modern high-speed wire rod production line which combines mechanical、electric、hydraulic pressure and its actions are accurate, which builds a beautiful scenery line for the modern wire rod production line .
In order to satisfy the domestic iron and steel enterprise to improve the product packing quality and conform to the international packing standard need,we have carried on the promotion transformation to the existing automatic coil compactor and have obtained the success.
This thesis describes clearly a design of compactor's automatic control system based on the PROFIBUS-DP network. The kernel of the design compactor's control system is the S7-400 series PLC of the SIEMENS Company. The paper elaborates firstly the topic's background and the origin, the domestic and foreign present researching situation and the prospects for development. According to this, research direction and the goal are put forward and the field bus technological concept, the characteristic, the system's composition and the communication agreement are summarized. As well as programmable controller PLC characteristic and merit, principle of work etc. The control system of hardware and the software have been designed: The core of control section uses SIEMENS corporation's S7-400 series PLC, the construction of field bus network control is on the basis of PROFIBUS-DP network, SIEMENS corporation's S7-412DP takes a scene control of the main bus station, the SIMENS dispersible type I/O ET200M series module takes the scene control bus from the station. Thus building a network based on PROFIBUS-DP control of the two networks. The development of software system is based on SIEMENS corporation's STEP7 software of WINDOWS operating system.
In addition, It describes the arisen problems in detail in the installation and debugging and proposes some solutions to possible failures in accordance with practice and experience in equipment's maintenance.
为了满足国内钢铁企业对提高产品包装质量,符合国际包装标准的需要,我们对现有的全自动高线打包机进行了升级改造,并取得了成功。
本文详细论述了一项基于PROFIBUS-DP网络的打包机自动控制系统设计。核心控制部分采用SIEMENS公司的S7-400系列PLC。本文首先论述了课题的背景及来源,国内外研究现状及发展前景,并在此基础上提出了自己的研究方向。综述了现场总线技术的概念、特点、系统组成、通讯协议。以及可编程控制器PLC的特点和优点,工作原理等。设计了控制系统的硬件和软件部分:核心控制部分采用的是SIEMENS公司的S7-400系列PLC,构建现场总线自动控制网络的基础是PROFIBUS-DP网络,由SIEMENS公司的S7-412DP作为现场控制总线主站,SIEMENS的分散式I/O的ET200M系列模块作为现场控制总线的从站。从而构建了一个基于PROFIBUS-DP网络的二级自动控制网络。软件开发系统是基于WINDOWS操作系统的SIEMENS公司的STEP7软件。
此外,在本设计中还详细说明了安装调试时所出现的问题,并根据实践经验对设备维护中可能出现的故障提出一些解决方法。
Automatic coil compactor is a unique equipment for modern high-speed wire rod production line which combines mechanical、electric、hydraulic pressure and its actions are accurate, which builds a beautiful scenery line for the modern wire rod production line .
In order to satisfy the domestic iron and steel enterprise to improve the product packing quality and conform to the international packing standard need,we have carried on the promotion transformation to the existing automatic coil compactor and have obtained the success.
This thesis describes clearly a design of compactor's automatic control system based on the PROFIBUS-DP network. The kernel of the design compactor's control system is the S7-400 series PLC of the SIEMENS Company. The paper elaborates firstly the topic's background and the origin, the domestic and foreign present researching situation and the prospects for development. According to this, research direction and the goal are put forward and the field bus technological concept, the characteristic, the system's composition and the communication agreement are summarized. As well as programmable controller PLC characteristic and merit, principle of work etc. The control system of hardware and the software have been designed: The core of control section uses SIEMENS corporation's S7-400 series PLC, the construction of field bus network control is on the basis of PROFIBUS-DP network, SIEMENS corporation's S7-412DP takes a scene control of the main bus station, the SIMENS dispersible type I/O ET200M series module takes the scene control bus from the station. Thus building a network based on PROFIBUS-DP control of the two networks. The development of software system is based on SIEMENS corporation's STEP7 software of WINDOWS operating system.
In addition, It describes the arisen problems in detail in the installation and debugging and proposes some solutions to possible failures in accordance with practice and experience in equipment's maintenance.
引文
[1] 高速轧机线材生产编写组.高速轧机线材生产[M].北京:冶金工业出版社,1995:42-69
[2] 胡任安.钢铁工业自动化的新技术(上)[J].冶金自动化.2001,1:1-4
[3] 陈彦.承钢高线自动打包机 PLC 控制系统[J].PLC 公控机与集散控制系统.2006,12:48-50
[4] 张学勤.新型棒材打捆机气动控制系统[J] .上海冶金设计.1992,4:22-25
[5] 胡任安.钢铁工业自动化的新技术(下)[J].冶金自动化.2001,2:6-11
[6] 沈鑫刚.全自动钢管打捆机的研究与开发.浙江大学硕士学位论文.浙江:浙江大学,2005.
[7] 邱惠.线材打包机的改造[J].柳钢科技.2001,4:64-65
[8] SUND BIRSTA COIL COMPACTOR INSTRUCTION MANUAL
[9] SUND—BIRSTA.PCH—4KNA User Reference Book.1997
[10] 王跃强,刘伟病等.高速线材厂打包机电器控制系统的改进[J].冶金自动化.2005,2:35-36
[11] Bruckner Company Siemens SIMATIC S5-135U Programmable Controller CPU928A Manual.1991
[12] 孙喜田.关于我国现场总线技术发展策略的思考[J]. 自动化与仪器仪表.2000,5:1-3
[13] 凌志浩.吴勤勤等.现场总线技术的现状与展望(一)[J] .电气时代.2004,7:76-79
[14] 夏继强,刑春香.现场总线工业控制网络技术[M].北京:北京航空航天大学出版社,2005:284-386
[15] 张州.现场总线技术及其应用研究[D].郑州大学硕士学位论文.郑州:郑州大学,2005.
[16] 潘晓宁,郝晓弘等. PROFIBUS-DP 工控网的通讯原理[J].1999,5:25-27
[17] Simens AG.Statment Lis(tSTL)for S7-300 and S7-400 Programming Reference Manual,2002:89-105
[18] SCHICKHUBER. Mccarthy Distributed Field bus and Control Network System[J].Computing&Control Engineering Journal.1997,1:53-55
[19] Joans Berge.Field bus Enables Innovation Measurements [J]. Advance in Instrumentation and Control.1996,1:11-14
[20] 吕景泉.可编程控制器及其应用[M].北京:机械工业出版社.2001:50-89
[21] 廖常初.S7-300/400 PLC 应用技术[M].北京:机械工业出版社.2005:220-341
[22] 骆德汉.可编程控制器与现场总线网络控制[M].科学出版社,2003:188-250
[23] SIEMENS AG , SIMATIC S5 ET 200M Distributed I/O Device Manual.2002
[24] 杨海等.西门子工业控制网络在棒材连轧生产线的应用[J].包钢科技.2002,5:32-35
[25] 扬晓东.现场总线技术在变电站综合自动化中的应用[J].广东电力.2002,4:45-46
[26] Configuring Hardware and Communication Connections STEP7 V5.0.Siemens AG,2006
[27] Siemens AG. Configuring Hardware and Communication Connections STEP7 V5.2 Manual,2002:145-169
[28] STEP7 User Manual.Siemens AG,1998
[29] SIENENS AG , SIMATIC S7 Programming With STEP7 V5.0 Manual.2000
[30] 邓燕妮,周大钧等.西门子 S7-300 PLC 在胎面联动线控制系统中的应用[J].山东轻工业学报(自然科学版).2004,3: 11-15
[31] 张学勤. 新型棒材打捆机气动控制系统[J].上海冶金设计,1992,4: 22-25
[32] 王洪 .高速线材打捆机液压系统分析[J].机床与液压. 2001,3: 135-137
[33] 李万钮.可编程控制器 PLC 在棒材打捆机中的应用[J].机械工程师.1998,6:31-32
[34] 朱雪彤,刘海宽.液压打包机的 PLC 控制[J].佳木斯大学学报.2001,4:411-414
[35] 路雨祥.液压气动技术手册[M].北京:机械工业出版社.2002
[36] 郭崇善,冯小兰等.液压打包机 PC 控制. [J].青海大学学报(自然科学版).1997,4:14-16
[37] 王锦标.现场总线控制系统[J]. 微计算机信息.1996,6:8-16
[38] 周明.现场总线控制[M].北京:中国电力出版社,2002:24-67
[39] Katz M. Biwer, G.Bender K. the profibus application layer, FZI University,Karlsruhe,1990.
[40] 阳宪惠.现场总线技术及其应用[M].北京:清华大学出版社,1999,6:145-262
[41] Manfred Popp. PROFIBUS-DP 快速入门. 北京: 中国机电一体化技术应用协会现场总线(PROFIBUS)专业委员会,1998.
[42] PROFIBUS Technical Description Version. April 1997
[43] 于印泉.现场总线技术应用及基于 Profibus 与 Intranet/Internet 的网络监控系统的研究[D].北方交通大学硕士学位论文.北方交通大学,2001.
[44] 唐济扬.现场总线与工厂底层自动化及信息集成技术[J].PROFIBUS 中国通讯.2003,5:9-12
[45] 郁佳敏.现场总线 PROFIBUS 智能化 DP 从站的设计[J].自动化与仪表.2001,1:37-39
[46] 周益明.PROFIBUS-DP 现场总线通信研究及智能从站设计[D].南京航空航天大学硕士学位论文.南京:南京航空航天大学,2005.
[47] ET200M Distributed I/O Device Manual.Siemens AG,1997
[48] Robert Lewis,Design of distributed control systems in the next millennium, Computing&Control Engineering Journal,Aug.1997.
[49] 钟秉林,黄仁.机械故障诊断学[M].北京:机械工业出版社.2002:24-41
[50] 顾勤林.汽车电控系统在线故障诊断方法的研究[D]. 合肥工业大学硕士学位论文.合肥:合肥工业大学,2005
[51] 周青龙.故障诊断与监控[M].北京:兵器工业出版设.1992:103-152
[52] 刘炳春. 基于模糊神经网络的故障诊断方法与应用研究[D]. 河北工业大学硕士学位论文.河北:河北工业大学,2005
[53] 沈庆根.郑水英.设备故障诊断[M].化学工业出版社.2001:141-220
[54] 王由华.工业控制系统神经网络故障诊断方法研究[D]. 北京化工大学硕士学位论文.北京:北京化工大学,2002
[2] 胡任安.钢铁工业自动化的新技术(上)[J].冶金自动化.2001,1:1-4
[3] 陈彦.承钢高线自动打包机 PLC 控制系统[J].PLC 公控机与集散控制系统.2006,12:48-50
[4] 张学勤.新型棒材打捆机气动控制系统[J] .上海冶金设计.1992,4:22-25
[5] 胡任安.钢铁工业自动化的新技术(下)[J].冶金自动化.2001,2:6-11
[6] 沈鑫刚.全自动钢管打捆机的研究与开发.浙江大学硕士学位论文.浙江:浙江大学,2005.
[7] 邱惠.线材打包机的改造[J].柳钢科技.2001,4:64-65
[8] SUND BIRSTA COIL COMPACTOR INSTRUCTION MANUAL
[9] SUND—BIRSTA.PCH—4KNA User Reference Book.1997
[10] 王跃强,刘伟病等.高速线材厂打包机电器控制系统的改进[J].冶金自动化.2005,2:35-36
[11] Bruckner Company Siemens SIMATIC S5-135U Programmable Controller CPU928A Manual.1991
[12] 孙喜田.关于我国现场总线技术发展策略的思考[J]. 自动化与仪器仪表.2000,5:1-3
[13] 凌志浩.吴勤勤等.现场总线技术的现状与展望(一)[J] .电气时代.2004,7:76-79
[14] 夏继强,刑春香.现场总线工业控制网络技术[M].北京:北京航空航天大学出版社,2005:284-386
[15] 张州.现场总线技术及其应用研究[D].郑州大学硕士学位论文.郑州:郑州大学,2005.
[16] 潘晓宁,郝晓弘等. PROFIBUS-DP 工控网的通讯原理[J].1999,5:25-27
[17] Simens AG.Statment Lis(tSTL)for S7-300 and S7-400 Programming Reference Manual,2002:89-105
[18] SCHICKHUBER. Mccarthy Distributed Field bus and Control Network System[J].Computing&Control Engineering Journal.1997,1:53-55
[19] Joans Berge.Field bus Enables Innovation Measurements [J]. Advance in Instrumentation and Control.1996,1:11-14
[20] 吕景泉.可编程控制器及其应用[M].北京:机械工业出版社.2001:50-89
[21] 廖常初.S7-300/400 PLC 应用技术[M].北京:机械工业出版社.2005:220-341
[22] 骆德汉.可编程控制器与现场总线网络控制[M].科学出版社,2003:188-250
[23] SIEMENS AG , SIMATIC S5 ET 200M Distributed I/O Device Manual.2002
[24] 杨海等.西门子工业控制网络在棒材连轧生产线的应用[J].包钢科技.2002,5:32-35
[25] 扬晓东.现场总线技术在变电站综合自动化中的应用[J].广东电力.2002,4:45-46
[26] Configuring Hardware and Communication Connections STEP7 V5.0.Siemens AG,2006
[27] Siemens AG. Configuring Hardware and Communication Connections STEP7 V5.2 Manual,2002:145-169
[28] STEP7 User Manual.Siemens AG,1998
[29] SIENENS AG , SIMATIC S7 Programming With STEP7 V5.0 Manual.2000
[30] 邓燕妮,周大钧等.西门子 S7-300 PLC 在胎面联动线控制系统中的应用[J].山东轻工业学报(自然科学版).2004,3: 11-15
[31] 张学勤. 新型棒材打捆机气动控制系统[J].上海冶金设计,1992,4: 22-25
[32] 王洪 .高速线材打捆机液压系统分析[J].机床与液压. 2001,3: 135-137
[33] 李万钮.可编程控制器 PLC 在棒材打捆机中的应用[J].机械工程师.1998,6:31-32
[34] 朱雪彤,刘海宽.液压打包机的 PLC 控制[J].佳木斯大学学报.2001,4:411-414
[35] 路雨祥.液压气动技术手册[M].北京:机械工业出版社.2002
[36] 郭崇善,冯小兰等.液压打包机 PC 控制. [J].青海大学学报(自然科学版).1997,4:14-16
[37] 王锦标.现场总线控制系统[J]. 微计算机信息.1996,6:8-16
[38] 周明.现场总线控制[M].北京:中国电力出版社,2002:24-67
[39] Katz M. Biwer, G.Bender K. the profibus application layer, FZI University,Karlsruhe,1990.
[40] 阳宪惠.现场总线技术及其应用[M].北京:清华大学出版社,1999,6:145-262
[41] Manfred Popp. PROFIBUS-DP 快速入门. 北京: 中国机电一体化技术应用协会现场总线(PROFIBUS)专业委员会,1998.
[42] PROFIBUS Technical Description Version. April 1997
[43] 于印泉.现场总线技术应用及基于 Profibus 与 Intranet/Internet 的网络监控系统的研究[D].北方交通大学硕士学位论文.北方交通大学,2001.
[44] 唐济扬.现场总线与工厂底层自动化及信息集成技术[J].PROFIBUS 中国通讯.2003,5:9-12
[45] 郁佳敏.现场总线 PROFIBUS 智能化 DP 从站的设计[J].自动化与仪表.2001,1:37-39
[46] 周益明.PROFIBUS-DP 现场总线通信研究及智能从站设计[D].南京航空航天大学硕士学位论文.南京:南京航空航天大学,2005.
[47] ET200M Distributed I/O Device Manual.Siemens AG,1997
[48] Robert Lewis,Design of distributed control systems in the next millennium, Computing&Control Engineering Journal,Aug.1997.
[49] 钟秉林,黄仁.机械故障诊断学[M].北京:机械工业出版社.2002:24-41
[50] 顾勤林.汽车电控系统在线故障诊断方法的研究[D]. 合肥工业大学硕士学位论文.合肥:合肥工业大学,2005
[51] 周青龙.故障诊断与监控[M].北京:兵器工业出版设.1992:103-152
[52] 刘炳春. 基于模糊神经网络的故障诊断方法与应用研究[D]. 河北工业大学硕士学位论文.河北:河北工业大学,2005
[53] 沈庆根.郑水英.设备故障诊断[M].化学工业出版社.2001:141-220
[54] 王由华.工业控制系统神经网络故障诊断方法研究[D]. 北京化工大学硕士学位论文.北京:北京化工大学,2002