Air compressor automatic control system based on Siemens S7-200
In many large-scale processes such as metallurgical chemical power pharmacy, air compressor is an important auxiliary equipment, which can supply air separately or in combination. In order to ensure the supply of compressed air and save energy, prevent the compressor from malfunctioning and affect production. Several air compressors are often designed to operate in a coordinated manner.
In order to ensure a qualified gas supply quality, the basic tasks of stable pressure station automation are met. With the automation level effective automatic control system is a development trend.
1 Air compressor work flow Air compressor is to put atmospheric pressure. The atmospheric pressure of the air is output as the gas required by the user through energy conversion. It is an important power source. The work flow is mainly through the stage gas pressurization stage gas discharge gas condensation stage gas pressurization stage gas discharge pressure and condensing work process, finally Enter the gas storage tank. Its main process is 1.
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Your editor, Du Nenggang, He An 3 College, Department of Electrical Education. Suddenly, the party, for the information and work 2 technology 6, 64 software guide 2, 78 months by the workers throughout the day, the usual start and stop work required to be scheduled according to production needs. The air compressor unit is turned on by first turning on the water pump input cooling water and then opening the exhaust valve. Turn on the main motor, open the intake valve, and start the empty load. After running for about 5 minutes, close the exhaust valve. Enter the load to run. The parking process is to close the intake valve and then open the exhaust valve. Then turn off the main motor and water pump, and finally close the exhaust valve. During operation, the on-duty personnel are required to frequently check the condition of the unit, and should stop in an emergency when the rated current and voltage of the temperature and pressure motor exceed the allowable value. This process is now used for fully automatic control and monitoring and alarming devices are set up in the remote operating room. To achieve on-site unattended and remote monitoring alarms.
Air compressor control requires remote monitoring and operation of automatic start and stop parameters abnormal automatic stop function. To this end, the air compressor control system needs to take time to pick the following system parameters. The cylinder gas pressure level cylinder gas pressure and the gas tank gas pressure have a total of three pressure collection points.
Gas Intake Temperature Class Cylinder Gas Exhaust Temperature Oil Temperature Crankshaft Bearing 2 Point Temperature Motor Bearing 2 Point Temperature and Cooling Water Outlet Temperature A total of 9 temperature collection points... 3 motor current 1 point and total power supply 3 phase voltage total 3 Current and voltage collection points.
After the above system parameters are collected. Firstly, it is judged whether the relevant system parameters are abnormal. If it is abnormal, it is necessary to promptly enter the remote alarm and automatic parking, and perform real-time tour display. The equipment network is divided into 2 layers, the upper layer is 104 industrial control computer as the core, the cadaver layer is 87200 small, 0 controlled 2 level network, which can spread the danger and improve the network validity and reliability.
3 system overall design plan According to the specific requirements of the relevant air compressor system control, the design of the 07104 industrial computer as the core for logical sequence control, its framework 2.
The 01040 module system constitutes a high-performance data acquisition system, which is characterized by 816 single-ended analog inputs, the Asahi Division's morphing rate is 2 digits, and the modulo 1 is 241 5 or 1 0 converters are used ± outside. ±1 or 0440 analog input range, etc. Can meet the requirements of multi-parameter acquisition.
The temperature acquisition has two ranges of temperature signals for the system meter set, the second stage cylinder exhaust temperature is above 200.0, the measurement range is 1300, the digital temperature sensor, 81820, the measuring range is 550750, and the signal is single line connected. .
The pressure collection pressure signals are the first-stage cylinder pressure 彡 23-stage cylinder pressure of two sets of air compressors. 801 and 1; gas, 1; force 0.803.1 cylinders use 2 24 type pressure sensors, the range is, the mouth-class cylinder and the gas tank use 4 24, type pressure sensor, the range is 0250 ratio The working power supply is 012 full; the process output is about, and the current and voltage acquisition uses two current sensors to measure the current of two main motors. The range is 0,100, and a voltage sensor measures the total level of the 3-level switch to detect the presence or absence of cooling water. Designed for the cooling capacity input 415 415 puff system design Siemens 8 Ding 10 is a small programmable controller, can be used to replace the simple field control of the relay, can also be used for complex automation control systems, with strong communication Features.
The 87200 is highly reliable. It can be programmed with ladder statements and function modules. Its instructions are powerful and easy to grasp and operate. There is a high-speed counter high-speed output 10 controller ruler 8485 communication programming interface PPI communication protocol MPI communication protocol and free-mode communication protocol, 10 terminal strip can be easily disassembled. The maximum expandable to 248 digital points 10 or 35 analog 10, up to 26 spit and data storage space.
The process and control requirements of the air compressor, it is planned to use Siemens 87200 to control the air compressor automatically. From the above allocation of 10 ports. Air compressor control system requires at least 8 input ports and 16 output ports. Considering the scalability of this, the 87200 system with port 24 input and output 16 is used. The system uses the master-slave controller serial port of the upper and lower machines as the serial port. , 1 communication mode or free port communication mode. 104 industrial computer provides a 485 serial door, 485 string has D and 02 data lines, no hardware handshake signal line, therefore, only the software handshake communication mode 872000 serial port initialization can be set by chatting special flag 830 to fulfill. Sending data by sending an instruction, 41 directly sends 18720, bribes the command to receive data, only provides a receiving interrupt, each receiving data generates a secondary interrupt, and the received data is taken away from SMB2.
5 software design 07104 industrial computer software, 80 language programming. It is mainly composed of the sampling module and the alarm module.
Controller main program box 3.
The sampling filter module will be converted by the converter and filtered. This average filtering method works in the inverse subsampled value. Remove the maximum and minimum values. Then the remaining 2 sample values ​​are arithmetically averaged. As a filter value, the inverse of the program is taken as 1 acquisition display and alarm module. Each time the unit status parameter is detected, then the scale conversion and display are performed, and finally the system status parameters are normal. If it is normal, the next state parameter is detected, otherwise the main function that can be realized by the alarm shutdown and the corresponding software can be started and stopped by the software development and application field remote control air compressor unit. Detect all the system status parameters of all air compressor units and enable real-time display. When abnormal air compressor unit status parameters are detected, it can alarm and stop in time, and can display corresponding fault points, record each air compressor unit and, 1 Communication between the air compressor controls the start and stop states of the air compressor.
6 Ning press's energy-saving improvement air compressor is a complex and complex general-purpose equipment with long running time. The power of the motor is large, so the power consumption of the air compressor needs to be reduced. In order to meet the requirements of the change of gas consumption, the gas in the gas storage tank must maintain a constant pressure. At present, most air compressors use the adjustment method of cutting off the intake air to change the amount of gas discharged to the gas storage tank. Generally, two kinds of methods are used for the unloading operation of the air compressor, and no compressed gas is generated, and the motor is operated at no load. The other way to use the full load of 3060 is to stop the operation, which will lead to frequent start of the motor. The no-load starting current of the air compressor is about 5,7 times of the rated current. For the power grid and other purposes. Electrical equipment has a large impact and will shorten the service life of the air compressor.
The frequency conversion speed control can ensure that the air compressor runs at the minimum pressure required for production, the input power of the motor is greatly reduced, and the pressure closed-loop control is supplemented to realize the dynamic matching of the air supply pressure and speed of the air compressor, reducing the motor's The actual input power has achieved energy saving goals. The gas supply pressure is stable, the pressure is stable and reliable, and it can be adjusted at any time. The gas valve piece in the cylinder is no longer repeatedly opened and closed, and the valve seat spring and other working strips are greatly improved. The rapid flow and impact of high temperature and high pressure gas are avoided, and the maintenance workload is reduced.
7 Conclusion The air compressor automatic control system itself is a complete system, so pay attention to its systemicity when designing the system to analyze faults. The optimization of a certain part alone does not improve the overall performance of the system. If the accuracy of a single component or link is excessively pursued without considering the actual needs and the matching equipment associated with it, the system cost will be increased in vain. In the routine maintenance, there are also phenomena that make the system more complicated and complex. For example, the use of complicated control methods and equipment to realize the control that can be realized with a simple device violates the principle of simple and practical economy, and may increase the failure rate.
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Responsible Editor Liu Jun 66 Software Guide 2007 August issue
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