基于WinCC的深孔镀铬监控系统设计与应用研究
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摘要
为了提高企业的综合实力和生产效率,企业自动化和信息化成为必然。在此基础上,本文研究了监控系统在电镀行业内的具体应用。
某集团深孔电镀车间由于种种原因,系统自动控制方式已彻底失效,现场的控制主要是人工操作,极大地限制了产品的合格率的提高,严重阻碍了生产的发展。
针对原控制系统存在的弊端以及对改造后控制系统的需求,在保留原手动控制方式下,本文提出了利用西门子组态软件WinCC和S7-300系列PLC以及原系统中的一些自动化设备组成DCS系统,实现整个电镀生产过程的自动化,同时增加了系统远程监视的功能,对生产过程实时监控,确保整个生产过程顺利的进行。
本文研究了利用上位机组态软件完成数据采集、历史数据库管理、生产工艺参数设置、生产现场模拟显示、报警、报表和打印功能。同时根据用户要求,利用脚本语言对WinCC二次开发,设计了深孔镀铬数据管理系统,利用自制数据库实现了字符型变量的存储和搜索显示,同时通过中间数据库翻译将WinCC以时间进行数据查询的方式扩展到以任意字符进行数据查询,在很大程度上提高了查询效率且操作简便。
为了实现对镀铬过程中工艺参数准确控制,针对深孔镀铬的工艺特点,本文提出并设计了将双工艺推广到多工艺的步趋控制方案,基于激励分析的变负载硅整流电源自动控制的方法以及利用上位机和原系统中的温控仪表组网的多点温度控制方案。考虑到控制系统的复杂性及对多线程的需求,由上位机编制控制策略,下位机PLC执行现场控制。
系统调试完后进行了试运行实验,采集的实验数据,验证了监控方案的可行性。
In order to win in fierce marketing competition, the enterprises have to improve the competitive power with the enterprise automation and information. For this, this thesis researches the application of the monitoring system in electroplating line.
Auto-control mode of the deep-hole electroplating system in a workshop of some cooperation has failed to work because of various reasons. The sport control has to be done by manpower, which restricts the increase of product qualification rate and hinders the productivity.
To overcome shortcomings of the original control system and to meet the demand of a renewed control system, a wholly automatic electroplating produce process is proposed based on a DCS system which consists of Siemens configuration software WinCC, S7-300 PLC and some original automation equipment. A system long-distance surveillance is also included to do real time observation to ensure a smooth produce process.
This thesis studies how to use configuration software of upper monitor to do the task of data collection, historical database management, setting up of produce process parameters, simulate display of produce scene, giving alarms, making report forms and printing. Moreover, to meet users’demand, a deep-hole chrome plating data management system has been developed by means of redevelopment of WinCC on the basis of script language, and saving and inquiry of character variables are realized by self-directed database. With the help of middle database translation, WinCC can change the data inquiry mode from time to any character, which largely increases inquiry efficiency and maneuverability.
To realize an accurate control of parameters in the chrome plating process, in the light characteristics of deep-hole chrome plating, this thesis works on a step-more control plan which extends from dual process to multi-process, varying load rectifier equipment control method based on incentive-analysis and multi-point temperature control scheme making use of upper monitor and the temperature-control instruments in the original system. To take into account the complexity of control system and the demand on multi-threading, upper monitors compile control strategy and lower monitors carry out spot control
A trial run has been done after the system debugging and the collected experimental data prove the feasibility of monitoring scheme.
某集团深孔电镀车间由于种种原因,系统自动控制方式已彻底失效,现场的控制主要是人工操作,极大地限制了产品的合格率的提高,严重阻碍了生产的发展。
针对原控制系统存在的弊端以及对改造后控制系统的需求,在保留原手动控制方式下,本文提出了利用西门子组态软件WinCC和S7-300系列PLC以及原系统中的一些自动化设备组成DCS系统,实现整个电镀生产过程的自动化,同时增加了系统远程监视的功能,对生产过程实时监控,确保整个生产过程顺利的进行。
本文研究了利用上位机组态软件完成数据采集、历史数据库管理、生产工艺参数设置、生产现场模拟显示、报警、报表和打印功能。同时根据用户要求,利用脚本语言对WinCC二次开发,设计了深孔镀铬数据管理系统,利用自制数据库实现了字符型变量的存储和搜索显示,同时通过中间数据库翻译将WinCC以时间进行数据查询的方式扩展到以任意字符进行数据查询,在很大程度上提高了查询效率且操作简便。
为了实现对镀铬过程中工艺参数准确控制,针对深孔镀铬的工艺特点,本文提出并设计了将双工艺推广到多工艺的步趋控制方案,基于激励分析的变负载硅整流电源自动控制的方法以及利用上位机和原系统中的温控仪表组网的多点温度控制方案。考虑到控制系统的复杂性及对多线程的需求,由上位机编制控制策略,下位机PLC执行现场控制。
系统调试完后进行了试运行实验,采集的实验数据,验证了监控方案的可行性。
In order to win in fierce marketing competition, the enterprises have to improve the competitive power with the enterprise automation and information. For this, this thesis researches the application of the monitoring system in electroplating line.
Auto-control mode of the deep-hole electroplating system in a workshop of some cooperation has failed to work because of various reasons. The sport control has to be done by manpower, which restricts the increase of product qualification rate and hinders the productivity.
To overcome shortcomings of the original control system and to meet the demand of a renewed control system, a wholly automatic electroplating produce process is proposed based on a DCS system which consists of Siemens configuration software WinCC, S7-300 PLC and some original automation equipment. A system long-distance surveillance is also included to do real time observation to ensure a smooth produce process.
This thesis studies how to use configuration software of upper monitor to do the task of data collection, historical database management, setting up of produce process parameters, simulate display of produce scene, giving alarms, making report forms and printing. Moreover, to meet users’demand, a deep-hole chrome plating data management system has been developed by means of redevelopment of WinCC on the basis of script language, and saving and inquiry of character variables are realized by self-directed database. With the help of middle database translation, WinCC can change the data inquiry mode from time to any character, which largely increases inquiry efficiency and maneuverability.
To realize an accurate control of parameters in the chrome plating process, in the light characteristics of deep-hole chrome plating, this thesis works on a step-more control plan which extends from dual process to multi-process, varying load rectifier equipment control method based on incentive-analysis and multi-point temperature control scheme making use of upper monitor and the temperature-control instruments in the original system. To take into account the complexity of control system and the demand on multi-threading, upper monitors compile control strategy and lower monitors carry out spot control
A trial run has been done after the system debugging and the collected experimental data prove the feasibility of monitoring scheme.
引文
[1] 于维新,程军梅.电镀工艺及其发展方向.航天工艺,1995(2):54-56.
[2] 史先焘,周靖,陈拓霖.电镀生产中的微机控制系统.电镀与涂饰,2005,24(3):54-57.
[3] 杜贵平,姜立新.电镀电源的现状及展望.新技术新工艺,2005(6):68-70.
[4] 易灿南,蔡康旭,胡鸿.某电镀车间 MLS 危险性评价.中国安全生产科学技术,2006.6,2(3):88-90.
[5] 张文辉.电镀车间环境改善的探讨.电镀与涂饰,1997.6,16(2):55-57.
[6] 张俊.建国后促进上海电镀工业发展的一些事.电镀与涂饰,1996.3,15(2):54-56.
[7] 宋新建.高频直流电镀电源技术.孔化与电镀,2002(7):33-35.
[8] 暨调和.国内外电镀技术发展趋势.电镀与涂饰,1995.9,14(3):50-55.
[9] 王常力,廖道文.集散控制系统设计与应用.北京:清华大学出版社,1999.
[10] Whether,S.M. The design and Implementation of a Framework for Configurable Software. Configurable Distributed System. 1996. Proceedings, Third International Conference on, 6-8 May 1996:136-143.
[11]Kruse G, Bramham J. You choose [product configuration software]. Manufacting Engineer,2003,82(4):34-37.
[12] Nigamanth Sridhar,Jason O.Hallstrom. Generating configurable containers for component-based software. Washington:IEEE Computer Society Press, 2003.61-66.
[13] 展在宏.西门子 S7-300 及工控组态软件 WinCC 的应用.包钢科技,2002.2,28(1):43-45.
[14] Siemens AG.. Overview of SINATIC WinCC 2004.
[15] Siemens AG.. SINATIC WinCC system description. Germany Siemens 2000.
[16] 毛联杰. S7-300 系列 PLC 与组态软件 WinCC 实现通信的方法.电气时代,2006(9):105-107.
[17] Harald Schumny,Norbert Zisky.A standard interface for site electronicsbased on modern fieldbus technlolgy.Computer Standards & Interfaces, 19(6):305-312.
[18] 高德欣,张文武,杨清.基于C/S模型的OPC客户端实现WinCC数据转储.化工自动化及仪表,2005,32(5):33-36.
[19] 苏昆哲.深入浅出西门子 WinCCV6.北京:北京航空航天大学出版社,2004.
[20] Siemens HMI, WinCC handbook for version 6.0,2004.
[21] 朱勇,叶 华,刘成良.使用 WinCC 在机电一体化系统中实现过程监控.仪表技术与传感器,2004(6):20-25.
[22] 任建芳,孙涛,胡卫华.WinCC Global Script 在数据存储中的应用.控制工程,2004,11(3):251-253.
[23] 贾智平,吴修国,裴红.基于 C/S 与 B/S 结合模式的企业 MIS 结构探讨.微机发展,2001(3):35-38.
[24] 朱扬勇,凌力.客户/服务器数据库应用开发.上海:复旦大学出版社,1997.
[25] 马小平,张宇飞.基于 C/S 模式下选煤厂网络监测系统的设计宇实现.煤矿自动化,2001(5):6-8.
[26] Sutart M. Wheater and Mark C. Little. The Design and Implementation of a Framework for Configurable Software.0-8186-7395-8/96, 1996 IEEE.
[27] C.Hofmeister,et al. Surgeon:a packager for dynamically reconfiguring distributed applications. Software Engineering Journal, 1993(2):95-101.
[28] M.Zimmermann and O.Drobnik Specification and Implementation of Reconfigurable Distributed Applications. Proceedings of the Second International Workshop on Configurable Distributed Systems, 1994(3): 23-24.
[29] 刘雄.基于 WinCC 的港口集散管理系统.武汉理工大学硕士学位论文.保存地点:武汉理工大学,2005.
[30] Gang Li, Jing Ying. A configuration software system for industrial monitoring and controlling. Information Acquisition. 2004. Proceedings International Conference on.June 21-25,2004:466-470.
[31] 杨金凤,马思乐.基于C Script实现WinCC 过程数据归档及报表查询功能.工业控制计算机,2007,20(2):3-5.
[32] R F M Aranha, V ganti, S Narayanan, C R Muthukrishnan, S T S Prasad, K Ramamritham. Implementation of a Real-Time Database System. Information System.1996.3, 21(2):80-83.
[33] Chenais A, Gelenbe E, Mitrani I. On the modeling of parallel access to share data Commun. ACM,1983,26:196-202.
[34] Rajesh Kmuar,Sridharan,Srinivasan. The design and development of a Web-based data acquisition system. IEEE Insturetion and Measurement.2002,51(3):427-432.
[35] 甄 立 东 , 巍瑾 , 牛 文 勇 .WinCC V6 归档 数据 处 理 . 微 计 算 机 信息 ,2005 ,21(10-1):54-57.
[36] 赵山林,高媛.C 程序设计.北京:人民邮电出版社,2004.
[37] 刘云生.实时数据库系统.计算机科学,1994(11):42-46.
[38] 周婼娜,琴现生,顾学民.并行产品开发模式下任务调度方法研究.计算机应用,2007(12):39-41.
[39] 官荷卿,张文博,魏峻等.一种应用敏感的 Web 服务请求调度策略.计算机学报,2006,29(7):1190-1194.
[40] Menasce D.A.. QoS-aware software components. IEEE Internet Computing, 2004, 8(2):91-93.
[41] Zeng Liang-Zhao, Benatallah Boualem. QoS-aware middleware for Web service composition. IEEE Transactions on Software Engineering,2004, 30(5): 311-327.
[42] 陈英革,王小英,赵海等.任务调度过程中就绪队列的优化研究.系统仿真学报,2006,18(4):877-882.
[43] Laone Hannah Thebe. An Overview of the Grid Application-level Scheduling. JOURNAL OF WUT(NFORMATION & MANAGEMENT ENGNEER NG),2005, 27(5):127-131.
[44] 廖春蓝.基于多线程的实时测控系统研究.机电工程技术,2006,35(3):25-27.
[45] 王淑红.感应电动机的脉宽调制技术及其策略实现.电气开关,2007(1):1-3.
[46] 张莉,王旭,刘宗富.电流型脉宽调制在异步电动机转速控制中的应用.控制与决策,2005,20(3):249-252.
[47] 黄伟,邓辉文.气动执行系统的线性化脉宽调制控制策略研究.西南师范大学学报(自然科学版),2006,31(4):112-115.
[48] Przyqara A,Kusch R,Naunin D.Real-time operating systems on small embedded devices for industrial control and communication . The 29 th Annual Conference of the IEEE Industrial Electronics Society. Virginia.2003. Virginia.2003 . Piscataway : Institute of Electrical and Electronics Engineers.Inc,2003:2047-2052.
[49] 金英,潘在平.脉宽调制控制方法研究.科技通报,2005,21(1):31-33.
[50] 李宏,徐德明,焦振宏.永磁无刷直流电动机不同 PWM 调节方式比较.微电机,2006,39(8):67-69.
[51] 曹琦.关于 PWM 技术.变频器世界,2004,9:61-62.
[52] 王传江,孙秀娟.用 I 2C 总线实现 AD7416 的多点温度控制系统.新器件新技术,2002(1):51-54.
[53] 王东涛,谭小晖.基于 WinCC 的培烧罐温度控制系统.冶金信息导刊,2006,(3):21-23.
[54] 杨军,答嘉曦,余调琴等.基于 PLC 和 WinCC 的温度控制系统设计.计算机与数字工程,2006,34(6):135-137.
[55] 马焉,陈露萍.如何在 WinCC 中使用 OLE 控件实现串行通讯.工业控制计算机,2005,14(12):25-27.
[56] 林英芸,杨熠普.在 WinCC 中实现串行通讯的两种方法.电子测量技术,2006.4,29(2):115-117.
[2] 史先焘,周靖,陈拓霖.电镀生产中的微机控制系统.电镀与涂饰,2005,24(3):54-57.
[3] 杜贵平,姜立新.电镀电源的现状及展望.新技术新工艺,2005(6):68-70.
[4] 易灿南,蔡康旭,胡鸿.某电镀车间 MLS 危险性评价.中国安全生产科学技术,2006.6,2(3):88-90.
[5] 张文辉.电镀车间环境改善的探讨.电镀与涂饰,1997.6,16(2):55-57.
[6] 张俊.建国后促进上海电镀工业发展的一些事.电镀与涂饰,1996.3,15(2):54-56.
[7] 宋新建.高频直流电镀电源技术.孔化与电镀,2002(7):33-35.
[8] 暨调和.国内外电镀技术发展趋势.电镀与涂饰,1995.9,14(3):50-55.
[9] 王常力,廖道文.集散控制系统设计与应用.北京:清华大学出版社,1999.
[10] Whether,S.M. The design and Implementation of a Framework for Configurable Software. Configurable Distributed System. 1996. Proceedings, Third International Conference on, 6-8 May 1996:136-143.
[11]Kruse G, Bramham J. You choose [product configuration software]. Manufacting Engineer,2003,82(4):34-37.
[12] Nigamanth Sridhar,Jason O.Hallstrom. Generating configurable containers for component-based software. Washington:IEEE Computer Society Press, 2003.61-66.
[13] 展在宏.西门子 S7-300 及工控组态软件 WinCC 的应用.包钢科技,2002.2,28(1):43-45.
[14] Siemens AG.. Overview of SINATIC WinCC 2004.
[15] Siemens AG.. SINATIC WinCC system description. Germany Siemens 2000.
[16] 毛联杰. S7-300 系列 PLC 与组态软件 WinCC 实现通信的方法.电气时代,2006(9):105-107.
[17] Harald Schumny,Norbert Zisky.A standard interface for site electronicsbased on modern fieldbus technlolgy.Computer Standards & Interfaces, 19(6):305-312.
[18] 高德欣,张文武,杨清.基于C/S模型的OPC客户端实现WinCC数据转储.化工自动化及仪表,2005,32(5):33-36.
[19] 苏昆哲.深入浅出西门子 WinCCV6.北京:北京航空航天大学出版社,2004.
[20] Siemens HMI, WinCC handbook for version 6.0,2004.
[21] 朱勇,叶 华,刘成良.使用 WinCC 在机电一体化系统中实现过程监控.仪表技术与传感器,2004(6):20-25.
[22] 任建芳,孙涛,胡卫华.WinCC Global Script 在数据存储中的应用.控制工程,2004,11(3):251-253.
[23] 贾智平,吴修国,裴红.基于 C/S 与 B/S 结合模式的企业 MIS 结构探讨.微机发展,2001(3):35-38.
[24] 朱扬勇,凌力.客户/服务器数据库应用开发.上海:复旦大学出版社,1997.
[25] 马小平,张宇飞.基于 C/S 模式下选煤厂网络监测系统的设计宇实现.煤矿自动化,2001(5):6-8.
[26] Sutart M. Wheater and Mark C. Little. The Design and Implementation of a Framework for Configurable Software.0-8186-7395-8/96, 1996 IEEE.
[27] C.Hofmeister,et al. Surgeon:a packager for dynamically reconfiguring distributed applications. Software Engineering Journal, 1993(2):95-101.
[28] M.Zimmermann and O.Drobnik Specification and Implementation of Reconfigurable Distributed Applications. Proceedings of the Second International Workshop on Configurable Distributed Systems, 1994(3): 23-24.
[29] 刘雄.基于 WinCC 的港口集散管理系统.武汉理工大学硕士学位论文.保存地点:武汉理工大学,2005.
[30] Gang Li, Jing Ying. A configuration software system for industrial monitoring and controlling. Information Acquisition. 2004. Proceedings International Conference on.June 21-25,2004:466-470.
[31] 杨金凤,马思乐.基于C Script实现WinCC 过程数据归档及报表查询功能.工业控制计算机,2007,20(2):3-5.
[32] R F M Aranha, V ganti, S Narayanan, C R Muthukrishnan, S T S Prasad, K Ramamritham. Implementation of a Real-Time Database System. Information System.1996.3, 21(2):80-83.
[33] Chenais A, Gelenbe E, Mitrani I. On the modeling of parallel access to share data Commun. ACM,1983,26:196-202.
[34] Rajesh Kmuar,Sridharan,Srinivasan. The design and development of a Web-based data acquisition system. IEEE Insturetion and Measurement.2002,51(3):427-432.
[35] 甄 立 东 , 巍瑾 , 牛 文 勇 .WinCC V6 归档 数据 处 理 . 微 计 算 机 信息 ,2005 ,21(10-1):54-57.
[36] 赵山林,高媛.C 程序设计.北京:人民邮电出版社,2004.
[37] 刘云生.实时数据库系统.计算机科学,1994(11):42-46.
[38] 周婼娜,琴现生,顾学民.并行产品开发模式下任务调度方法研究.计算机应用,2007(12):39-41.
[39] 官荷卿,张文博,魏峻等.一种应用敏感的 Web 服务请求调度策略.计算机学报,2006,29(7):1190-1194.
[40] Menasce D.A.. QoS-aware software components. IEEE Internet Computing, 2004, 8(2):91-93.
[41] Zeng Liang-Zhao, Benatallah Boualem. QoS-aware middleware for Web service composition. IEEE Transactions on Software Engineering,2004, 30(5): 311-327.
[42] 陈英革,王小英,赵海等.任务调度过程中就绪队列的优化研究.系统仿真学报,2006,18(4):877-882.
[43] Laone Hannah Thebe. An Overview of the Grid Application-level Scheduling. JOURNAL OF WUT(NFORMATION & MANAGEMENT ENGNEER NG),2005, 27(5):127-131.
[44] 廖春蓝.基于多线程的实时测控系统研究.机电工程技术,2006,35(3):25-27.
[45] 王淑红.感应电动机的脉宽调制技术及其策略实现.电气开关,2007(1):1-3.
[46] 张莉,王旭,刘宗富.电流型脉宽调制在异步电动机转速控制中的应用.控制与决策,2005,20(3):249-252.
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