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The characteristics and trends of PLC, DCS and industrial PC
PLC、工業(yè)PC與DCS的特點與趨勢
At present, widely used in industrial automation systems of the three large industrial PC, DCS and PLC. Here, for their economic and technological standards and development trends described.
目前，廣泛應用于工業(yè)自動化系統(tǒng)的3大件是工業(yè)PC、DCS和PLC。在此，對于他們的經(jīng)濟技術水平和發(fā)展趨勢進行敘述。
First, the characteristics and Application of PLC
一、可編程序控制器的特點及應用
1.PLC Application
1. PLC的應用
Early PLC (Programmable Logic Controller, PLC), mainly to replace relay logic control to achieve. With computer technology, communications technology and the rapid development of automatic control technology, the PLC will be the traditional relay control technology and the emerging computer technology and communications technology integration, with high reliability, strong function and flexible, Programming simple, easy to use and a series of advantages, as well as good performance of the industrial environment and control targets of performance in industrial production in a wide range of applications.
早期的可編程序控制器(Programmable Logic Controller，PLC)，主要用來代替繼電器實現(xiàn)邏輯控制。隨著計算機技術、通信技術和自動控制技術的迅速發(fā)展，可編程序控制器將傳統(tǒng)的繼電器控制技術與新興的計算機技術和通信技術融為一體，具有可靠性高、功能強、應用靈活、編程簡單、使用方便等一系列優(yōu)點，以及良好的工業(yè)環(huán)境工作性能和自動控制目標實現(xiàn)性能，在工業(yè)生產(chǎn)中得到了廣泛的應用。
1969, the United States Digital Equipment Corporation (DEC) developed the world's first programmable controller. Early separation from the programmable controller components and small and medium-sized integrated circuit component, the main function previously performed by the relay is completed sequence control, such as timing. The early 1970s, small size, strong function and cheaper microprocessors used PLC, makes the PLC function has been enhanced significantly. In terms of hardware, in addition to maintaining its original switch modules, has also increased the simulation module, remote I / O modules and special function modules all. In terms of software, easy to use PLC Electric staff in the ladder diagram programming language, in addition to maintaining the original logic functions, has also increased the arithmetic operations, data processing and transmission, communications and self-diagnostic capabilities. In the 1980's, the late, as ultra-large-scale integrated circuit technology is developing rapidly, microprocessor market a sharp price drop, the PLC makes the microprocessors used by the general improvement in grades. Furthermore, in order to further improve the processing speed of PLC, the manufacturer has developed a dedicated logic chip, greatly improving the PLC hardware and software functions.
1969年，美國數(shù)字設備公司(DEC)研制出世界上第一臺可編程控制器。早期的可編程控制器由分離元件和中小規(guī)模集成電路組成，主要功能是執(zhí)行原先由繼電器完成的順序控制、定時等。70年代初期，體積小、功能強和價格便宜的微處理器被用于PLC，使得PLC的功能大大增強。在硬件方面，除了保持其原有的開關模塊以外，還增加了模擬量模塊、遠程I/O模塊和各種特殊功能模塊。在軟件方面，PLC采用極易為電氣人員掌握的梯形圖編程語言，除了保持原有的邏輯運算等功能以外，還增加了算術運算、數(shù)據(jù)處理和傳送、通訊、自診斷等功能。進入80年代中、后期，由于超大規(guī)模集成電路技術的迅速發(fā)展，微處理器的市場價格大幅度下跌，使得PLC所采用的微處理器的檔次普遍提高。而且，為了進一步提高PLC的處理速度，各制造廠商還研制開發(fā)了專用邏輯處理芯片，大大提高了PLC軟、硬件功能。
2.Characteristics PLC
2. PLC的特點
In the developed industrial countries, PLC has been widely used in all industrial sectors. According to "The United States market information" World PLC and software market report, in 1995 the global software PLC and its economies of scale of about 5 billion US dollars [5]. As electronic technology and the development of computer technology, the PLC functions are greatly enhanced, with the following characteristics:
在發(fā)達工業(yè)國家，PLC已經(jīng)廣泛的應用在所有的工業(yè)部門。據(jù)“美國市場信息”的世界PLC以及軟件市場報告稱，1995年全球PLC及其軟件的市場經(jīng)濟規(guī)模約50億美元[5]。隨著電子技術和計算機技術的發(fā)展，PLC的功能得到大大的增強，具有以下特點：
(1) high reliability. PLC benefited from the high-reliability hardware and software on a series of anti-jamming measures and the cycle of its special scanning methods of work.
(1)可靠性高。PLC的高可靠性得益于軟、硬件上一系列的抗干擾措施和它特殊的周期循環(huán)掃描工作方式。
(2) with rich I / O interface module. PLC for different industrial field signal and the corresponding I / O modules and industrial devices or equipment at the scene of a direct connection. In addition to improving performance, it also has a variety of man-machine dialogue interface modules to the industrial composition of local area networks, it also multiple communications network interface module.
(2)具有豐富的I/O接口模塊。PLC針對不同的工業(yè)現(xiàn)場信號，有相應的I/O模塊與工業(yè)現(xiàn)場的器件或設備直接連接。另外為了提高操作性能，它還有多種人機對話的接口模塊；為了組成工業(yè)局部網(wǎng)絡，它還有多種通訊聯(lián)網(wǎng)的接口模塊。
(3) modular structure. To meet the needs of various industrial control, in addition to a small PLC unit, the vast majority of PLC are modular structure. PLC various components, including the CPU, power supply, I / O, etc. is modular in design from the rack and cables will connect each module, the system's size and function in accordance with the needs of users of its own portfolio.
(3)采用模塊化結構。為了適應各種工業(yè)控制需要，除了單元式的小型PLC以外，絕大多數(shù)PLC均采用模塊化結構。PLC的各個部件，包括CPU、電源、I/O等均采用模塊化設計，由機架及電纜將各模塊連接起來，系統(tǒng)的規(guī)模和功能可根據(jù)用戶的需要自行組合。
(4) easy to learn programming. Most of the PLC programming relay control circuit similar to the ladder diagram form, the user, do not have computer expertise, it is easy to general engineering and technical personnel understand and master.
(4)編程簡單易學。PLC的編程大多采用類似于繼電器控制線路的梯形圖形式，對使用者來說，不需要具備計算機的專門知識，因此很容易被一般工程技術人員所理解和掌握。
(5) Installation is simple and easy maintenance. PLC does not require specialized equipment room in a variety of industrial environments can be directly run. Various modules are run and fault indication devices, user-friendly understanding of the operation and find fault. The modular structure, so any failure of a module, users can replace the module, allowing the system to rapidly resume operation.
(5)安裝簡單，維修方便。PLC不需要專門的機房，可以在各種工業(yè)環(huán)境下直接運行。各種模塊上均有運行和故障指示裝置，便于用戶了解運行情況和查找故障。由于采用模塊化結構，因此一旦某模塊發(fā)生故障，用戶可以通過更換模塊的方法，使系統(tǒng)迅速恢復運行。
Second, the characteristics and Application of industrial PC
二、工業(yè)PC
1.Industrial PC industrial control applications
1. 工業(yè)PC的工業(yè)控制應用
Industrial PC hardware and software support of a broad, diverse varieties can take full advantage of excellent graphical user interface capabilities, the industrial users an enormously attractive. Early PC but not suitable for industrial process control automation applications, such as increasing modified by strengthening the protection of the case, such as cooling damping taken measures to meet the industrial environment is the application of some of the requirements of the characteristics of its early development. In recent years, with the further integration of chips increase, the increase in functionality, system board technology, packaging components and surface mount technology improvements, and standard industrial bus, a standard operating system and graphical user interface software development, the Industrial PC development and application to enter its peak period, the complete machine reliability improved hardware, system software has continually improved, greatly enriched applications, in-depth industrial automation and control industries in various fields. According to incomplete statistics, in the industrial automation industrial PC usage in the total industrial control computer 65%, and an annual growth rate of 21 per cent continued to expand. PC manufacturing industry by buying rate of the PC market as a whole accounted for about 10 percent. In the industrial automation process control systems used in industrial management industry accounted for 44.1%, applied to the console operator of 36.4%, applied to the management of the quality of 18.8%, applied to monitor and control, engineers console, Data Acquisition System respectively of the total 18.2%, 12.6% and 11.1%.
工業(yè)PC具有廣泛軟硬件支持特性，品種豐富多樣，能充分利用優(yōu)良圖形用戶界面功能，對工業(yè)用戶有巨大吸引力。但早期PC不適合工業(yè)自動化過程控制應用，通過加固改裝如增加保護機殼、采取減振降溫等措施，滿足工業(yè)環(huán)境應用的一些要求是其初期發(fā)展的特點。近年來，隨著芯片集成度的進一步提高，功能增加，制板工藝、元器件封裝和表面安裝技術的改進，及標準工業(yè)總線、標準操作系統(tǒng)和圖形用戶界面軟件的發(fā)展，工業(yè)PC的發(fā)展和應用進入鼎盛時期，整機硬件可靠性提高，系統(tǒng)軟件不斷完善，應用軟件極大豐富，深入工業(yè)自動化控制行業(yè)各個領域。據(jù)不完全統(tǒng)計，工業(yè)PC在工業(yè)自動化中的使用率占全部工業(yè)控制計算機的65%，且每年以21%的增長速度繼續(xù)擴大。制造業(yè)購買的工業(yè)PC按金額計算占整個PC市場10%左右。在工業(yè)自動化過程控制系統(tǒng)行業(yè)應用于工業(yè)管理的占44.1%，應用于操作員控制臺的占36.4%，應用于質量管理的占18.8%，應用于監(jiān)視和控制、工程師控制臺、數(shù)據(jù)采集系統(tǒng)的分別占總數(shù)的18.2%、12.6%和11.1%。
Industrial PC A notable feature is independent of configuration, but also with the DCS, PLC, CNC and other computer connected network. At present, almost all DCS, PLC manufacturers use industrial PC control system preparation procedures, more and more companies use industrial control system operator interface PC as a workstation. Formed by the industrial PC computer control system in the field of industrial automation process control play a very important role, has been outstanding for factory and workshop level process control, data acquisition, batch processing, quality control, automation and machine optimization and experts control, and other tasks.
工業(yè)PC的一個顯著特點是可獨立組態(tài)，也可與DCS、PLC、CNC和其他計算機連成網(wǎng)絡。目前，幾乎所有DCS、PLC生產(chǎn)制造商都采用工業(yè)PC編制控制系統(tǒng)程序，越來越多控制系統(tǒng)公司采用工業(yè)PC作為操作員界面工作站。由工業(yè)PC所組成的計算機控制系統(tǒng)在工業(yè)自動化過程控制領域發(fā)揮了十分重要的作用，已出色地用于工廠和車間級過程控制、數(shù)據(jù)采集、批量處理、質量管理、機床自動化以及優(yōu)化和專家控制等任務。
2. Main features of the PC industry
2. 工業(yè)PC的主要特點
(1)an industry-standard application
(1)工業(yè)標準的應用
In order to enable different computer manufacturers can be linked to one another, as well as take full advantage of the market varied PC components and the functions provided by the module, industrial PC with standard interface, which not only required by the IEEE, DIN and ISO standards, to adopt AT (ISA), EISA and STD, VME, Multibus Ⅱ, and other bus standards. Industrial PC now has been widely adopted PCI, PCMCIA bus standard, the two industry-standard bus for improved performance and speed of a PC great role.
為了使不同廠家生產(chǎn)的計算機能相互連接，也為充分利用市場上多種多樣PC元件和模塊所提供的功能，工業(yè)PC采用了標準接口，它不僅需采用IEEE、DIN和ISO等標準，還需采用AT(ISA)、EISA及STD、VME、MultibusⅡ等總線標準?，F(xiàn)在工業(yè)PC已廣泛采用了PCI、PCMCIA總線標準，這兩種標準總線對于提高工業(yè)PC性能和速度有極大推動作用。
(2)to take the necessary protection measures
(2)采取必要的保護措施
Applications must be based on the control of environmental conditions on the PC industry adopt various protective measures, adapted from a project management departments to the scene operational control applications. Industrial PC must be able tolerance of the harsh conditions at the production environment, we must have good heat dissipation, ventilation, waterproof, dustproof, anti-jamming and anti-corrosion and anti-shock, anti-vibration and a series of protective features.
必須根據(jù)控制應用的環(huán)境條件對工業(yè)PC采取各種保護性措施，使之適合于從工程管理部門到現(xiàn)場操作控制的應用。工業(yè)PC必須要能耐受條件惡劣的現(xiàn)場生產(chǎn)環(huán)境，必須具備良好的散熱、通風、防水、防塵、抗干擾、抗腐蝕、防沖擊、抗振動等一系列保護性特點。
(3)industrial operating system
(3)采用工業(yè)操作系統(tǒng)
MS-DOS because of lack of memory, unable to support multi-task, the lack of real-time features networking capacity and poor, has been basically not used. Along with the main computer chip, the rapid development of higher speed and better performance of industrial PC endless. In addition, almost all software development companies have shifted the focus will be open to the OS / 2, Windows and Unix, and other operating systems. Especially suitable for industrial process control automation real-time multi-tasking operating system application of Windows NT/2000 PC industry has generally become the mainstream operating system.
MS-DOS因內存不足，無法支持多任務，缺乏實時性功能，連網(wǎng)能力差等缺點，目前已基本不采用了。隨著計算機主芯片的飛速發(fā)展，更高性能和更高速度的工業(yè)PC層出不窮。另外，現(xiàn)在幾乎所有軟件開發(fā)公司都已將開放重點轉移到OS/2、Windows和Unix等操作系統(tǒng)上。尤其是適合于工業(yè)自動化過程控制系統(tǒng)實時多任務操作應用的Windows NT/2000已經(jīng)普遍成為工業(yè)PC的主流操作系統(tǒng)。
(4)and automation equipment and communications systems
(4)與自動化設備和系統(tǒng)的通信
Industrial PC should be able to with a variety of automated equipment and systems for effective communication, such as PLC, DCS, data acquisition systems, as well as on a management computer communication. With the continuous development of new technologies, due to open systems and system integration technology for the development needs of the PC industry these communications will be increasingly important role in the show.
工業(yè)PC須能與各種自動化設備和系統(tǒng)進行有效通信，如與PLC、DCS、數(shù)據(jù)采集系統(tǒng)以及上一級管理計算機的通信。隨著新技術的不斷發(fā)展，由于系統(tǒng)開放和系統(tǒng)集成技術的發(fā)展需要，工業(yè)PC的這些通信功能將會越來越顯示出其重要作用。
Standard communications network to the development of the industrial PC applications more open, and will enable its small computer pose a greater threat. MAP agreement to Ethernet-based communication networks to allow various computer systems communicate with each other directly. Different levels of automation in the mutual communication network systems, require separate handling of the communication channel. Industrial PC required monitoring level from the lower level data acquisition system and transmitted to a computer on.
標準通信網(wǎng)絡的發(fā)展使工業(yè)PC的應用更開放，并能使它對小型計算機構成更大威脅。以MAP協(xié)議為基礎的Ethernet通信網(wǎng)絡允許各種計算機系統(tǒng)間直接相互通信。在不同級別自動化網(wǎng)絡系統(tǒng)間相互通信時，則需單獨處理各通信信道。監(jiān)控級工業(yè)PC則需從下級系統(tǒng)采集數(shù)據(jù)信息，并傳送到上一級計算機。
(5)the safe operation of
(5)安全操作特性
In addition to the PC industry adopt various protective measures, the need for the operation of state industrial PC monitor, monitor the operation of computer systems and software, scheduled inspection procedures specified in the implementation of the cycle. Computer should be able to monitor the power supply, and failure or excessive deviation warning signal was issued.
除了對工業(yè)PC采取各種保護性措施以外，還需要對工業(yè)PC的操作狀態(tài)進行監(jiān)視，監(jiān)視計算機的運行及其軟件系統(tǒng)，檢查具體程序在預定周期內的執(zhí)行情況。計算機應能監(jiān)視電源電壓，并在故障或偏差過大時發(fā)出報警信號。
3.Industrial PC the status quo and development trend
3. 工業(yè)PC的現(xiàn)狀及發(fā)展趨勢
Industrial PC now have a wide range of performance and functionality, low-grade industrial PC with a CRT terminal operators, high-grade industrial workstation with a PC. Thus, high-grade and low-grade industrial PC workstation performance and the price of overlap, the difference is disappearing, industrial PC and workstations increasingly blurred the boundaries between.
工業(yè)PC現(xiàn)在具有各種各樣的性能和功能，低檔工業(yè)PC與CRT操作終端相當，高檔工業(yè)PC可與工作站相當。因此，高檔工業(yè)PC與低檔工作站的價格和性能重疊，差別正在消失，工業(yè)PC與工作站之間的界限越來越模糊。
Industrial PC workstation is the industrial automation process control system applications excellent choice, standard communication networks and the use of graphical operating system makes industrial PC and other equipment to effectively communicate. With 32-bit and 64-bit computer chips and the emergence of use, will be further enhanced industrial PC workstation functionality and performance, but also to a higher future direction.
工業(yè)PC工作站是工業(yè)自動化過程控制系統(tǒng)應用的優(yōu)良選擇，標準通信網(wǎng)絡和圖形化操作系統(tǒng)的采用使得工業(yè)PC與其他設備能有效地進行通信。隨著32位和64位計算機芯片的出現(xiàn)和使用，將會進一步提高工業(yè)PC工作站的功能和性能，今后還會向更高方向發(fā)展。
Industrial PC software is in the process of industrial automation control system of a key application. Hardware performance and the improvement of the drop in prices, as well as standardization and greater efficiency, better graphics and the use of the operating system to promote industrial PC software is an important factor in development. At present, the rapid development of industrial PC software on the market has thousands of independent software development company can supply in the industrial PC running on industrial process control configuration software package to meet the rapid growth of the industrial user needs. Industrial PC application of industrial process control software packages are running on the configuration of OS / 2, Windows, and UNIX operating system standard. Industrial process control applications have emerged in large quantities, software development companies can provide a large number of industrial PC on the run for the PLC, DCS, such as industrial automation and control system configuration tools and graphical user interface software. Many PLC, DCS manufacturers development of the software configuration tool for automatic control system has become an important component. They used to replace dedicated industrial PC workstations, for the creation of real-time database, the control loop, graphic footage showed police records, real-time and historical trend data recording and process control, simulation, and other tasks. Now, for the process of surveillance and control, unit control, factory data collection, process optimization control, process control, simulation, statistical quality-control (SQC), the Statistical Process Control (SPC) and expert system for the control of industrial automation and control package has been tremendous developments. DAE applications such as IBM's software platform and the emergence of applications, the application provides a unified software development tool. Application Platform features from the PC-industry data exchange within the factory to the coordination of multiple systems, the standard data interface allows computer control equipment and exchange of data and information networks, for integrated information management and control system provides great convenience.
軟件是工業(yè)PC在工業(yè)自動化過程控制系統(tǒng)中應用的關鍵。硬件性能的提高和價格的下降，以及標準化和功效更強、更好圖形化操作系統(tǒng)的采用是促進工業(yè)PC軟件發(fā)展的重要因素。當前，工業(yè)PC軟件發(fā)展迅速，市場上已有數(shù)千家獨立軟件開發(fā)公司能供應在工業(yè)PC上運行的工業(yè)過程控制組態(tài)軟件包，以滿足急速增長的工業(yè)用戶需要。工業(yè)PC上應用的工業(yè)過程控制組態(tài)軟件包大多運行在OS/2、Windows和UNIX等標準操作系統(tǒng)上。工業(yè)過程控制應用軟件大批量涌現(xiàn)，軟件開發(fā)公司提供了大量可在工業(yè)PC之上運行，用于PLC、DCS等工業(yè)自動化控制系統(tǒng)的組態(tài)工具和圖形化人機界面軟件。許多PLC、DCS生產(chǎn)制造商開發(fā)的組態(tài)工具軟件已成為其自動化控制系統(tǒng)的重要組成部分。他們采用工業(yè)PC代替專用工作站，用于建立實時數(shù)據(jù)庫、控制回路、圖形畫面顯示、報警記錄、實時和歷史數(shù)據(jù)趨勢記錄以及過程控制仿真等任務?，F(xiàn)在，各種用于過程監(jiān)視與控制、單元控制、工廠數(shù)據(jù)采集、過程優(yōu)化控制、過程控制仿真、統(tǒng)計式質量控制(SQC)、統(tǒng)計式過程控制(SPC)以及專家系統(tǒng)控制的專用工業(yè)自動化控制軟件包都有了巨大發(fā)展。IBM公司DAE等應用平臺軟件的出現(xiàn)和應用，為應用軟件開發(fā)提供了統(tǒng)一工具。應用平臺功能可從工業(yè)PC機間的數(shù)據(jù)交換到工廠范圍內多個系統(tǒng)的協(xié)調，其標準數(shù)據(jù)接口允許計算機、控制設備和網(wǎng)絡間互換數(shù)據(jù)信息，這些為集成信息管理與控制系統(tǒng)提供了極大方便。
Along with the standard graphical operating system continuously improve and develop, process control and industrial automation package greatly enriched, the industrial PC applications will increasingly strong.
隨著標準圖形化操作系統(tǒng)的不斷完善和發(fā)展，以及工業(yè)自動化過程控制軟件包的極大豐富，工業(yè)PC的應用必將日益旺盛。
Three, the characteristics and Application of DCS
三、 DCS
DCS since its birth, after decades of continuous improvement, development and modernization has been very mature. Compared with the early, the scale of their systems, control functions, and other areas have been tremendous developments in changes in the reliability, flexibility, adaptability, scalability, cost-effective integrated technical indicators have seen increased and improved. Has been widely used in petrochemical, pharmaceutical, energy, chemicals, paper, oil refining, metallurgy and food and beverage, and other industries, and has made very significant economic and social benefits. According to statistics, production facilities from analog instruments to DCS control the economic benefits can be achieved by the overall efficiency of 60%. DCS average payback period for 12, after the introduction of advanced control strategies can reduce the payback period of 0.5 to 1 year. DCS is today into various kinds of advanced control technology and equipment, and to the comprehensive integrated information management and automated process control systems, that is, CIMS direction.
DCS自誕生以來，經(jīng)過幾十年的不斷改進、發(fā)展和更新?lián)Q代，已相當成熟。與初期相比，其系統(tǒng)規(guī)模、控制功能等各方面都有了巨大發(fā)展變化，在可靠性、靈活性、適應性、擴展性、性價比等綜合技術指標方面都有了很大提高和改善。目前已廣泛應用于石化、制藥、能源、化工、造紙、煉油、冶金及食品飲料等工業(yè)，并已取得極為顯著的經(jīng)濟和社會效益。據(jù)統(tǒng)計，生產(chǎn)裝置由模擬控制儀表改為DCS所取得的經(jīng)濟效益可占整體效益的60%。DCS投資回收期平均為一兩年，采用高級控制策略后可使投資回收期縮短0.5～1年。當今DCS正在融入各種先進控制技術與設備，并全面向集成化信息管理與自動化過程控制系統(tǒng)，即CIMS方向發(fā)展。
1.Development process
1.發(fā)展歷程
From 1975, the DCS roughly experienced the 1975 ~ 1980, the first generation, from 1980 to 1985 the second generation, and after 1985 the third generation of three stages of development. Many manufacturers take DCS phased development strategy, adopted in the early systems continue to develop and improve, then launched with a variety of new features of the new system, the new system compatible with the original equipment homogeneous.
從1975年以來，DCS大致經(jīng)歷了1975～1980年的第一代，1980～1985年的第二代，以及1985年以后的第三代3個發(fā)展階段。許多生產(chǎn)廠家的DCS采取階段性發(fā)展策略，通過對早期系統(tǒng)不斷發(fā)展和改進，進而推出具有各種新特點的新系統(tǒng)，新系統(tǒng)與原設備均相兼容。
Early DCS storage capacity small, relatively simple function. System modules include process control, process interface modules, CRT operator station, control computer and data Highway, Part 5. Its characteristics are using microprocessors to achieve decentralized control, CRT operator station and the process control unit separation operation carried out on display and remote control configuration. Honeywell company TDC-2000 is the first generation of the representation of DCS products.
早期DCS存儲容量小，功能較簡單。系統(tǒng)主要包括過程控制單元、過程接口單元、CRT操作站、監(jiān)控計算機和數(shù)據(jù)公路等5部分。其特點是采用微處理器實現(xiàn)分散控制，CRT操作站與過程控制單元分離，進行集中顯示操作和遠程控制組態(tài)。Honeywell公司TDC-2000是第一代DCS的代表性產(chǎn)品。
DCS mainly by second-generation local area networks, multi-function controllers, the computers, enhanced operator station, multif