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附錄
離散型PLC 控制系統(tǒng)在紅外線干燥爐中的應用
一、前言
紅外線干燥爐在烘干方面與其他的烘干方法相比，越來越顯示出它的優(yōu)勢，例如：面積小，干燥循環(huán)短，節(jié)省能量和減輕污染等。為了提高烘干爐大面積加熱的準確性和迅速性，也為了操作方便和保養(yǎng)簡便, 可以使用采用了觸摸屏的PLC控制器, 下面對這一控制系統(tǒng)的組成，功能和特點進行分析。
帶鋼深加工過程中，采用加熱干燥的工藝生產(chǎn)線非常多，例如：噴漆，涂復合材料，印染等。使用紅外線烘干爐生產(chǎn)線生產(chǎn)，具有干燥速度快，涂層厚度均勻等優(yōu)點。這烘干方法最早應用可以追溯到， 30年代初，主要是使用在汽車噴漆實驗室，醫(yī)院等。直到70年代，因為新的射線材料的問世和高溫輻射技術的發(fā)展，紅外線的使噴漆能達到很薄的表面涂層（厚度一般在1 ? 4μm）。
二、系統(tǒng)的組成
這種干燥爐的生產(chǎn)線為雙重烘干涂層生產(chǎn)線（即安將裝有兩個紅外干燥爐） ，因為兩個干燥爐和主機之間的控制距離遠，控制的地方分散，如果使用同一地點控制，則現(xiàn)場布線復雜，維護不便。綜合考慮生產(chǎn)線的布局特點，我們使用了觸摸屏PLC的分布式控制系統(tǒng)，在屏幕上（人-機界面）的監(jiān)視器上操作，使現(xiàn)場布線，調(diào)試和維修非常方便，系統(tǒng)結構圖如下
圖一 干燥爐控制系統(tǒng)結構繪圖
在系統(tǒng)生產(chǎn)線的使用的PLC（ GE90 - 70系列）主機主要用于處理干燥爐控制系統(tǒng)提供生產(chǎn)線的工藝參數(shù)，如噴涂速度，厚度，寬度等， PLC控制系統(tǒng)按照這些參數(shù)進行相應的控制; 1 ＃ ， 2 ＃爐的監(jiān)測數(shù)據(jù)顯示在屏幕上;干燥爐PLC部分，主要是完成與顯示在屏幕上的數(shù)據(jù)交換，以及現(xiàn)場的實際參數(shù)的數(shù)據(jù)采集，處理后，控制主站及生產(chǎn)線的PLC主機通過GENIUS網(wǎng)絡與干燥爐的PLC進行數(shù)據(jù)交流（此外，在為了節(jié)省投資， PLC的變頻也起著噴涂機的相關設備的控制和數(shù)據(jù)收集） ;干燥爐PLC控制主機主要完成由1 ＃ ， 2 ＃ 完成干燥爐PLC的變頻傳輸?shù)闹噶睿瑫r分別完成根據(jù)現(xiàn)場搜集的相關數(shù)據(jù)，以及對干燥爐相關設備的控制，從而保證了干燥爐控制系統(tǒng)和整個帶鋼生產(chǎn)線工作的協(xié)調(diào)和升溫控制的準確和快捷性。
三、PLC控制系統(tǒng)控制功能
1、干燥爐PLC的變頻
該干燥爐PLC的變頻位于現(xiàn)場的1 ＃ ，在2 ＃爐控制服務器，最具代表性的是美國GE公司的90-30系列PLC ，主要完成了以下控制功能：
運行方面的管理，傳輸?shù)狡聊簧贤ㄟ^RS232連接，實現(xiàn)數(shù)據(jù)交換并進行處理，從現(xiàn)場傳感器收集數(shù)據(jù);
故障診斷分析報告的處理;操作權限的設制和密碼管理。
干燥爐的PLC與生產(chǎn)線的PLC主機通過GENIUS網(wǎng)絡進行對相關的信息交流。此外，PLC還完成了噴涂機電氣設備的控制和相關參數(shù)的數(shù)據(jù)采集。
2、干燥爐的PLC控制主機
干燥爐PLC控制主機設置的程序對兩個干燥爐分別控制，互不干擾，主要完成以下控制：
使干燥爐熱強度和生產(chǎn)線的速度曲線相適應; 干燥爐各個區(qū)域的溫升曲線的建立和修訂; 整個干燥爐電控設備互連邏輯控制;數(shù)據(jù)采集與處理;
干燥爐的PLC控制主機與生產(chǎn)線的PLC主機通過GENIUS網(wǎng)絡
進行相關信息的交流。
3、觸摸屏人-機界面系統(tǒng)
觸摸屏（如日本DIGTAL公司GP570 ）PLC，能適應惡劣工作環(huán)境，主機和輸入輸出設備等機構體積較小，高度有效的人-機界面，安裝在這個系統(tǒng)中對現(xiàn)場控制，主要用途為完成以下任務：
通過菜單上的管理功能，實現(xiàn)多屏幕演示;通過RS232完成與干燥爐的PLC的數(shù)據(jù)交換; 通過功能鍵，可控制干燥爐的所有電氣設備的功能（例如：工作的雙向選擇，設備啟動，停止等） ; 設置和改變干燥爐各個區(qū)域的加熱模式; 搜集各個區(qū)域的硅控整流器壓力調(diào)節(jié)器的主要技術參數(shù)（電壓，電流等）;顯示報警與診斷信息。
4、 系統(tǒng)通信和數(shù)據(jù)交換
離散控制系統(tǒng)的通信和數(shù)據(jù)交換主要是通過局域網(wǎng)。 這個局域網(wǎng)通信設備主要由主控制的PLC （GE90 - 70 ） GBC的總線控制單元和分控的PLC （ GE90 - 30 ） GCM模式通信模塊構成。
主線可靠的通信設計，用單屏蔽雙絞線，可避免電子噪聲干擾，數(shù)據(jù)主線153.6k高速傳輸，傳輸大于2000米。 主線最多可連接32個通訊設備，總控站建立在PLC的GBC設備的編號是31 ＃ ，在其他分控機的PLC控制采用循環(huán)模式。通信協(xié)議是一種點對點主線控制，由0 ＃設備經(jīng)過1 ＃設備（通過時，地址的設備消耗時間極短）進行“令牌”方式傳輸，如下圖表：
圖二 “令牌”傳輸方式
當一些設備獲得指令 ，從主線傳輸達到128字節(jié)的數(shù)據(jù)，這些全面的數(shù)據(jù)信息對應在PLC內(nèi)存中的％I（開關量輸入） ，％Q（下開關量輸出） ， ％AI（模擬量輸入） ， ％AQ （模擬量輸出） ，或%Q（下參數(shù)記錄）等相關資料。但每個設備可在任何時間接受關于這條主線必須具備全面的數(shù)據(jù)，其他設備傳輸（當然不是要限制是否取得指令 ） 。因此，通過主線，干燥爐主控制系統(tǒng)（ PLC ）的雙方才有可能收集控制變頻到現(xiàn)場干燥爐信息，傳輸這些信息后進行處理，以變頻控制進行對輸出控制，數(shù)據(jù)在觸摸屏上顯示。
因為主線通訊設備使用雙絞線串行連接，從而簡化了主機與各單元之間的電氣連接，提高了系統(tǒng)的穩(wěn)定性和可靠性，減少工作負荷，并在工作過程中電氣設備的安裝與維修也得到簡化。
觸摸屏（ GP570 ）與系統(tǒng)的通信，用的RS232通信電纜直接和干燥爐部分PLC的CPU模塊連接。通過這種連接，數(shù)送到屏幕上數(shù)據(jù)與干燥爐的PLC控制相互交流，通過前文提到的網(wǎng)絡該干燥爐主控站相互交流數(shù)據(jù)，從而實現(xiàn)了觸摸屏干燥爐相關設備的控制和每一種工藝參數(shù)上線的示范，以及信號的報警和故障診斷。
五、結語
由以上對涉及到人-機界面的干燥爐觸摸屏PLC控制系統(tǒng)的介紹，可以看出優(yōu)點主要表現(xiàn)在：
結構符合標準化，模塊化的使用，增強了整個系統(tǒng)的可靠性，且易于維護。各控制部分的數(shù)據(jù)傳輸使用了即時通信線路，提高了數(shù)據(jù)傳輸速率，從而保證了控制系統(tǒng)的控制精度;
高效的人-機界面系統(tǒng)（GP570觸摸屏）建立了有效的監(jiān)測系統(tǒng)，有利于故障的監(jiān)控警報和處理；
因為之間的控制部分使用了專用通信網(wǎng)絡，采用具有屏蔽能力的雙絞線，簡化了現(xiàn)場布線，也使整個電氣安裝，調(diào)試和維修更方便。
英語原文
Dispersible type PLC control system in infrared
drying stove application
One, foreword
The infrared drying stove compares in the drying aspect with other dry ways, more and more demonstrates its superiority, for example: The area small, the dry cycle is short, saves the energy and the reduction environmental pollution and so on. In order to enhance dries the stove to heat up the volume control the accuracy and the rapidity, as well as the operation convenience and the easy maintenance, to introduce PLC in the control system to control and to touch the screen person - machine connection, under emphatically discussed this In themcontrol system the composition, the function and the characteristic. strip deep processing process, needs to heat up the drying craft the production line to be very many, for example: Paints, compound, the dyeing, spreads models and so on. In order to suitable should the kind of production line production, the speed quick, the coating be continuously thin and so on the characteristic, mostly used has radiated the way primarily infrared stove to carry on drying. This heat transfer way most early may trace to the beginning of the 30's, mainly uses in automobile lacquer baking with the laboratory, the hospital and so on, to 70's, because the new radiation material is published and the high temperature directed radiation technology development, infrared causes to heat up dryly in the thin material specially is in the strip surface coating (thickness generally in 1 ~ 4μm)
Second, system composition
This stove locates the production line for double spreads double dries the coating production line (to be loaded with two infrared drying stoves), because two drying stoves and the host control between the cabinet the distance farther, controls the place dispersible, if uses the common control, then the scene wiring is complex, maintains inconveniently. The synthesis considered the production line the layout characteristic, we used had touch the PLC distributional control plan which the screen (person - machine connection) monitored, caused the scene wiring, the debugging and the maintenance extremely facilitates, system structure drawing as follows:
drying stove control system structure drawing
In system production line PLC (the GE90-70 series) the master control stands mainly for dries the stove control system to provide production line craft parameter and so on strip speed, thickness, width and active status, in order to drying stove PLC controls the master station to act according to these parameters to carry on the corresponding control; 1#, the 2# stove monitoring touches the screen mainly to use for to carry on the drying stove active status the control and the corresponding craft parameter establishment, as well as each kind of parameter and the information were demonstrating; The drying stove PLC substation mainly completes with touches the screen the data exchange as well as the scene actual parameter data acquisition, after processing controls the master station and the production line PLC master control station exchange information again through the GENIUS network with drying stove PLC (in addition, in order to save investment, this PLC substation also is shouldering coating machine correlation equipment control and field data gathering in production line); Drying stove PLC controls the master station mainly to complete the instruction which by 1#, 2# in the drying stove PLC substation transmits, simultaneously separately completes according to the scene gathering correlation data to 1#, the 2# drying stove correlation equipment control, thus had guaranteed the drying stove control system and the entire strip production line work coordination and heats up the control to be accurate and the rapidity.
Third, PLC system control function
1) dries the stove PLC substation
The drying stove PLC substation is located scene 1# and in the 2# stove control desk, used US to be general (GE) electrical company's 90-30 series PLC, mainly completed the following control function:
The operationn connection management, with touches the screen through the RS232 connection realization the data exchange;
And carry on processing from the scene ndetector set or the sensor gathering data;
The breakdown diagnoses andn reports to the police information processing;
Dries the stove anxiously to stop the control, the operator data revision rank limit and the password nmanagement.
Stands and drying stove PLC with the production line PLC master control controls the master station to carry on the related exchange of information through the GENIUS network.
In addition, this PLC has also completed to the coating machine electrical equipment control and the correlation parameter data acquisition, because has nothing to do with the drying stove control, no longer states in this.
2) dries stove PLC to control the master station
Drying stove PLC controls the master station to be located the host to control in the room, carries on to two drying stoves separately controls, mutually does not disturb, mainly completes the following control:
Causes to dry the stove to heat up the intensity and the production line velocity curve adapts;
Dries the stove various areas curve nthe establishment and the revision;
To entire drying stove electricallyn controlled equipment interconnection/succession logic control;
Controls in the room to the host the drying stove control device each kind of metering nequipment or the active status data acquisition and processing;
Standsn and a drying stove PLC minute control station with the production line PLC master control carries on the related exchange of information through the GENIUS network.
3) touches the screen person - machine connection system
Touches the screen (to use Japanese DIGTAL Corporation GP570) is specially is the small workstation which the PLC application designs, adapts the bad industry environment, the collection main engine, the input-output device to a body, the volume is smaller, may take between the operator and the control system contacts the highly effective person - machine connection, installs in this system on the scene control desk kneading board, mainly uses for to complete the following task:
Entrusts with the menu management function, the realization dividesn the page and the multi- screens demonstration;
Completes through the RS232 connection with the drying stove PLC minute control station data exchange; n
Through the function key, may control the drying stove all electricaln equipment the active status (for example: The work way choice, the equipment start, stops and so on);
The establishment and the revision drying stoven various areas heat up the pattern in the data area, facilitates the drying stove many kinds of working pattern the choice;
Demonstrates various areasn silicon-controlled rectifier pressure regulator main technology parameter (voltage, electric current and so on) and the drying stove active status and the on-line temperature and so on the important parameter;
Visual display alarmn with diagnosis information and corresponding explanation.
Fourth, system communication and data exchange
This disperser -like control system communication and the data exchange mainly are (the GENIUS main line) realizes through a local area network.
This local area network communication equipment mainly by master control PLC (GE90-70) GBC GENIUS bus control unit and minute control station PLC (GE90-30) GCM+ the enhancement GENIUS communication module composes.
The GENIUS main line is, it which the reliable communication designs for the industry environment in uses the list shielded twisted pair, may avoid the electronic noise the disturbance, the data passable main line 153.6K speed transmission, the transmission has been away from long amounts to 2,000 meters.
The GENIUS main line most may connect 32 communication equipment, master control stands in PLC the GBC equipment number to have to establish is 31#, in other minute control stations PLC GCM+ may carry on the free establishment according to the position, the GENIUS communication agreement is one kind point-to-point "makes the sign main line" the system, some one kind of electron "make the sign" (TOKEN) from 0# the equipment everywhere 1# equipment (through when address equipment which has not used consumes time to be very few) circulates the transmission, following chart.
When some equipment obtains "makes the sign", it may to the main line transmission reach 128 bytes overall situations data, these overall situation data information correspond to in PLC memory %I (switch quantity input), %Q (switch quantity output), %AI (simulation quantity input), %AQ (simulation quantity output), or %Q (parameter register) and so on the related information. But each equipment may at any time accepts on the main line to possess the overall situation data which other equipment transmits (certainly not to limit to whether obtains "makes sign"). Thus, through the GENIUS main line, dries the stove master control to stand (PLC) both to be possible to gather arrives controls in the substation to the scene drying stove the infed information, and may the again transmission for dry these information after processing the stove to control the substation to carry on the output control either is touching the screen to progress the good condition or the data display.
Because on the GENIUS main line communication equipment uses the twisted pair line serial connection, thus simplified the master control to stand with the minute control station between electrical connection, enhanced the system stability and the reliability, reduced the work load and in the movement process maintenance quantity which the electrical equipment installed.
This control system touches the screen (GP570) with the system communication, has used the RS232 communication electric cable direct and drying stove minute control station PLC CPU in the module RS232 connection is connected. Through this connection, touches the screen to be possible mutually to exchange the data with drying stove minute control station PLC, but should divide control station PLC to be possible to stand and the production line master control through the above-mentioned GENIUS local area network with the drying stove master control stands mutually exchanges the data, thus realized by has touched the screen to dry the stove correlation equipment the control and each kind of craft parameter on-line demonstration as well as breakdown information reporting to the police with the breakdown diagnosis.
Fifth, concluding remark
Introduces the PLC network in the drying stove control and touches the screen person - machine interface control system, the merit mainly displays in:
The structuren disposition conforms to the standardization, the simplification and the modular principle, thus enhanced the entire wrap system reliability and the easy maintenance;
Between various control stations the data transfer uses then real-time communication link, enhanced the data transfer rate, thus has guaranteed the control system control precision;
The powerful highlyn effective person - machine connection system (GP570 touches screen), has established the effective relation method between the operator and the drying stove, by carries on the monitoring to the scene equipment, from diagnosis and initialization establishment and so on;
The permission future enable then entire control system through the installment partial hardware and correlation software the function to obtain the expansion;
Because between variousn control stations has used the private network, only uses a list shielded twisted pair then to be possible respectively to divide the control station and the master control station relates, maximum limit simplified the scene wiring, also causes the entire electrical installment, the debugging and the maintenance is more convenient.