基于PLC的数字式智能稳流系统开发及应用
摘要
电解铝属于国家产业政策控制的高耗能行业,因此降低电耗成了关乎行业生死的重要课题。随着技术的进步,降低电耗的方法也是多种多样,如采用先进的槽型、降低槽温、提高直流电流的平稳度等等,其中采用先进的稳流技术来提高电流的平稳度是投资少、见效快的措施之一,也是很多企业正在进行的工作。
本文以数字式自动稳流控制技术的开发为背景,针对电解铝企业的实际生产需要,提出了基于PLC的数字式自动稳流控制技术,阐明了PLC数字式自动稳流控制系统的控制原理和实现方法；分析了系统控制的难点、控制方法和控制算法的优化；建立了基于PID调节的,构成系列总电流大闭环、单机组电流小闭环嵌套的双闭环控制系统的总体技术方案。
随着计算机网络技术、电力电子技术、PLC自动控制技术的快速发展,铝电解供电整流系统的控制技术也得到了快速地发展,其控制技术向智能化、网络化和模块化方向发展；稳流控制的关键在于对饱和电抗器控制电流的控制,在本系统中饱和电抗器的电流控制采用PWM直流斩波控制技术,调节功率器件IGBT的占空比以改变电抗器的控制电流。本控制系统为全数字智能稳流控制系统,即稳流系统的控制、调节、触发、信号处理等各个控制环节全部采用PLC或其他智能控制装置通过软件程序控制实现,整个控制系统不需要硬件调整,稳流系统信息交换包括给定控制、稳流控制方式改变、稳流系统状态监视等实现了网络智能化控制,本系统已在中国铝业贵州分公司顺利投入运行,本技术在国内处于领先水平。
Electrolytic aluminum smelter is one of the high energy consuming industries under the control of national industrial policy. Thus how to reduce the power consumption is an important subject concerning the survival of the industry. With the development of technology, there are various methods to reduce the power consumption, such as adopting advanced types of pots, reducing the pot temperature and increasing the stability of the direct current etc... Among them, to increase the stability of the current by using advanced current regulation technology is one of the measures that cost less but effect faster. And many enterprises are working on it.
With the background of the development of the digital auto-current regulation technology, this paper aims at the actual production requirements for the smelter enterprises, presents the digital auto-current regulation technology, elaborates the control principle and ways of implementation for the PLC digital auto-current regulation system; and analyzes the difficulties in systematic control, control methods and optimization of the control calculation method; establishes a general technical scheme based on PID adjustment for a double closed-loop control system which is composed of a big closed-loop of series total current and a small closed-loop of single unit current.
With the fast development of the web technology, electrical and electronic technology as well as the PLC auto-control technology, the control technology for the rectification system in the power supply station of the smelter is also developing quickly and in the direction of intelligent, web control and modularization. The key part of the current regulation control lies in the control for the transductor. PWM DC chopper control technology is adopted to control the transductor current in this system, adjusting the space ratio of the power element IGBT in order to change the control current of the transductor. This control system is a complete digital intelligent current regulation system, i.e. each control link, such as the control of the current regulation system, adjustment, ignition, signal process etc. are all controlled by PLC or other intelligent control devices through software programme. There is no need to adjust them through hardware in the control system. The information exchange in the current regulation system includes preset control, shift of the current regulation control mode and state monitoring of the current regulation system. It realizes the intelligent web control. This system has been put into operation successfully in CHALCO, Guizhou Branch. It is an advanced technology in china.
本文以数字式自动稳流控制技术的开发为背景,针对电解铝企业的实际生产需要,提出了基于PLC的数字式自动稳流控制技术,阐明了PLC数字式自动稳流控制系统的控制原理和实现方法；分析了系统控制的难点、控制方法和控制算法的优化；建立了基于PID调节的,构成系列总电流大闭环、单机组电流小闭环嵌套的双闭环控制系统的总体技术方案。
随着计算机网络技术、电力电子技术、PLC自动控制技术的快速发展,铝电解供电整流系统的控制技术也得到了快速地发展,其控制技术向智能化、网络化和模块化方向发展；稳流控制的关键在于对饱和电抗器控制电流的控制,在本系统中饱和电抗器的电流控制采用PWM直流斩波控制技术,调节功率器件IGBT的占空比以改变电抗器的控制电流。本控制系统为全数字智能稳流控制系统,即稳流系统的控制、调节、触发、信号处理等各个控制环节全部采用PLC或其他智能控制装置通过软件程序控制实现,整个控制系统不需要硬件调整,稳流系统信息交换包括给定控制、稳流控制方式改变、稳流系统状态监视等实现了网络智能化控制,本系统已在中国铝业贵州分公司顺利投入运行,本技术在国内处于领先水平。
Electrolytic aluminum smelter is one of the high energy consuming industries under the control of national industrial policy. Thus how to reduce the power consumption is an important subject concerning the survival of the industry. With the development of technology, there are various methods to reduce the power consumption, such as adopting advanced types of pots, reducing the pot temperature and increasing the stability of the direct current etc... Among them, to increase the stability of the current by using advanced current regulation technology is one of the measures that cost less but effect faster. And many enterprises are working on it.
With the background of the development of the digital auto-current regulation technology, this paper aims at the actual production requirements for the smelter enterprises, presents the digital auto-current regulation technology, elaborates the control principle and ways of implementation for the PLC digital auto-current regulation system; and analyzes the difficulties in systematic control, control methods and optimization of the control calculation method; establishes a general technical scheme based on PID adjustment for a double closed-loop control system which is composed of a big closed-loop of series total current and a small closed-loop of single unit current.
With the fast development of the web technology, electrical and electronic technology as well as the PLC auto-control technology, the control technology for the rectification system in the power supply station of the smelter is also developing quickly and in the direction of intelligent, web control and modularization. The key part of the current regulation control lies in the control for the transductor. PWM DC chopper control technology is adopted to control the transductor current in this system, adjusting the space ratio of the power element IGBT in order to change the control current of the transductor. This control system is a complete digital intelligent current regulation system, i.e. each control link, such as the control of the current regulation system, adjustment, ignition, signal process etc. are all controlled by PLC or other intelligent control devices through software programme. There is no need to adjust them through hardware in the control system. The information exchange in the current regulation system includes preset control, shift of the current regulation control mode and state monitoring of the current regulation system. It realizes the intelligent web control. This system has been put into operation successfully in CHALCO, Guizhou Branch. It is an advanced technology in china.
引文
1.孙海维.SIMATIC可编程序控制器及应用,机械工业出版社,30-228,2005.1
2.王保荣.饱和电抗器稳流系统的应用,桂林电子科技大学创新在线,2007.1
3.聂立新.铝电解生产与自动稳流技术,有色金属(冶炼部分),2000
4.李莉、胡兴龙.铝电解直流大电流稳流系统的数字式改造,有色设备,2005.2
5.柳洪义.现代机械工程自动控制,东北大学,2002.3
6. 黄明琪、冯齐缨.微电脑可编程序控制器实用原理及程序设计,贵州科技出版社,1992.5
7.邹斌.富士晶闸管整流电源在铝电解工业中的应用,中国有色金属论文集,35-38,2000
8.西门子公司.西门子S7-200系统手册
9.西门子公司.西门子S7-300系统手册
10.高富国.电解铝厂变电站自动化系统,中国有色金属论文集,35-38,贵阳,2001
11.宋伯生.PLC编程理论、算法及技巧.北京：机械工业出版社,2005
12.廖常初.S7-300/400PLC应用技术.北京：机械工业出版社,2005
13.阳宪惠.工业数据通信与控制网络.北京：清华大学出版社,2003
14.廖常初.PLC编程及应用.北京：机械工业出版社,2002
15.廖常初.PLC基础及应用.北京：机械工业出版社,2003
16. Siemens AG.用于自动控制系统的工业通讯网络,2001
17. Siemens AG.STEP 7 V5.1编程使用手册,1998
18. Siemens AG.S7-300/400的系统软件和标准功能参考手册,2002
19. Siemens AGS7-300和M7-300可编程序控制器模板规范参考手册,2003
20.黄净.电器及PLC控制技术.北京：机械工业出版社,2002
21.徐昌荣.对国产PLC产业化的几点思考.自动化博览,2005(3)：18～20
22.吴坚.计算机控制系统[M],武汉：武汉理工大学出版社,2002.8
23.孙志毅.控制工程基础[M],北京：机械工业出版社,2002.8
24.陶永华.新型PID控制及其应用[M],北京：机械工业出版社,2002.9
25.丁炜、魏孔平.可编程序控制器在工业控制中的应用,化学工业出版社,16-24,2004.7
26.陈柏超.新型饱和电抗器理论及应用,武汉水利电力大学出版社,1999
27.陈义怀、胡卫华、王彦.IGBT的保护,电源技术应用,2004.11
28.周志敏、周纪海、纪爱华.IGBT和IPM及其应用电路,人民邮电出版社,2006.3
29.彭智刚、金新民.IGBT驱动电路,北京交通大学电气工程学院,2007
30.王建渊、钟彦儒、张晓滨.基于数字信号处理器的IGBT驱动电路可靠性分析与设计,西安理工大学电气自动化学院,2006.11
31.机电系统计算机控制技术,东北大学机械工程与自动化学院,2004.7
32.王花兰.电解系列电流的波动及自动稳流装置的应用,山西冶金,2001
33.王益考.220kV整流机组稳流控制系统,电气时代,2004.2
34.付新民、李建勇、郭莉莉.数字式稳流控制在铝电解整流系统中的应用,有色设备,2004.5
35.黄俊.半导体变流技术,西安交通大学,机械工业出版社,1986.11
36.姜国民.铜电解用整流器数字电源控制系统介绍,铜业工程,2005.4
37.庞伟民.整流电源的发展与动态,采矿技术,2002.4
38.付青、罗安、吴良柱、陈瑞若.基于自适应神经网络的大功率电解整流电源,电力电子技术,2004.6
39.魏婧.单神经元自适应PID控制在大功率整流电源中的应用,电气传动自动化,2005.5
40.陈忠华.可编程序控制器与工业自动化系统,机械工业出版社,2006
41. Gilles Michel. Programmable Logic Controllers Architecture and Application. John Wiley & Sons Ltd.,1990
42. Siemens AG.Standard PID Control Manual,2003
43. Siemens AG.S7-PLCSIM V5.2 User Manual,2002
44. Siemens AG.Prodave Operating Instructions,2004
45. Siemens AG.Working with STEP 7 V5.2 Getting Started,2002
46. Siemens AG.Programming with STEP 7 V5.2 Manual,2003
47. Siemens AG.SIMATIC S7-200 Programmable Controller System Manual,2004
48. Jim Childers.3.3 Volt Microprocessorsin Automotive Environment[Z], Application Note, TI,2001
49. TMS320 LF2407A DSP Conyrollers[Z], Texas Instruments Incorporated,1999
50. Manfred Popp. The rapid way to PROFIBUS-DP,1997
51. Stenerson, Jon. Fundamentals of Programmable Logic Controller,sensors,and communication.,2004
2.王保荣.饱和电抗器稳流系统的应用,桂林电子科技大学创新在线,2007.1
3.聂立新.铝电解生产与自动稳流技术,有色金属(冶炼部分),2000
4.李莉、胡兴龙.铝电解直流大电流稳流系统的数字式改造,有色设备,2005.2
5.柳洪义.现代机械工程自动控制,东北大学,2002.3
6. 黄明琪、冯齐缨.微电脑可编程序控制器实用原理及程序设计,贵州科技出版社,1992.5
7.邹斌.富士晶闸管整流电源在铝电解工业中的应用,中国有色金属论文集,35-38,2000
8.西门子公司.西门子S7-200系统手册
9.西门子公司.西门子S7-300系统手册
10.高富国.电解铝厂变电站自动化系统,中国有色金属论文集,35-38,贵阳,2001
11.宋伯生.PLC编程理论、算法及技巧.北京：机械工业出版社,2005
12.廖常初.S7-300/400PLC应用技术.北京：机械工业出版社,2005
13.阳宪惠.工业数据通信与控制网络.北京：清华大学出版社,2003
14.廖常初.PLC编程及应用.北京：机械工业出版社,2002
15.廖常初.PLC基础及应用.北京：机械工业出版社,2003
16. Siemens AG.用于自动控制系统的工业通讯网络,2001
17. Siemens AG.STEP 7 V5.1编程使用手册,1998
18. Siemens AG.S7-300/400的系统软件和标准功能参考手册,2002
19. Siemens AGS7-300和M7-300可编程序控制器模板规范参考手册,2003
20.黄净.电器及PLC控制技术.北京：机械工业出版社,2002
21.徐昌荣.对国产PLC产业化的几点思考.自动化博览,2005(3)：18～20
22.吴坚.计算机控制系统[M],武汉：武汉理工大学出版社,2002.8
23.孙志毅.控制工程基础[M],北京：机械工业出版社,2002.8
24.陶永华.新型PID控制及其应用[M],北京：机械工业出版社,2002.9
25.丁炜、魏孔平.可编程序控制器在工业控制中的应用,化学工业出版社,16-24,2004.7
26.陈柏超.新型饱和电抗器理论及应用,武汉水利电力大学出版社,1999
27.陈义怀、胡卫华、王彦.IGBT的保护,电源技术应用,2004.11
28.周志敏、周纪海、纪爱华.IGBT和IPM及其应用电路,人民邮电出版社,2006.3
29.彭智刚、金新民.IGBT驱动电路,北京交通大学电气工程学院,2007
30.王建渊、钟彦儒、张晓滨.基于数字信号处理器的IGBT驱动电路可靠性分析与设计,西安理工大学电气自动化学院,2006.11
31.机电系统计算机控制技术,东北大学机械工程与自动化学院,2004.7
32.王花兰.电解系列电流的波动及自动稳流装置的应用,山西冶金,2001
33.王益考.220kV整流机组稳流控制系统,电气时代,2004.2
34.付新民、李建勇、郭莉莉.数字式稳流控制在铝电解整流系统中的应用,有色设备,2004.5
35.黄俊.半导体变流技术,西安交通大学,机械工业出版社,1986.11
36.姜国民.铜电解用整流器数字电源控制系统介绍,铜业工程,2005.4
37.庞伟民.整流电源的发展与动态,采矿技术,2002.4
38.付青、罗安、吴良柱、陈瑞若.基于自适应神经网络的大功率电解整流电源,电力电子技术,2004.6
39.魏婧.单神经元自适应PID控制在大功率整流电源中的应用,电气传动自动化,2005.5
40.陈忠华.可编程序控制器与工业自动化系统,机械工业出版社,2006
41. Gilles Michel. Programmable Logic Controllers Architecture and Application. John Wiley & Sons Ltd.,1990
42. Siemens AG.Standard PID Control Manual,2003
43. Siemens AG.S7-PLCSIM V5.2 User Manual,2002
44. Siemens AG.Prodave Operating Instructions,2004
45. Siemens AG.Working with STEP 7 V5.2 Getting Started,2002
46. Siemens AG.Programming with STEP 7 V5.2 Manual,2003
47. Siemens AG.SIMATIC S7-200 Programmable Controller System Manual,2004
48. Jim Childers.3.3 Volt Microprocessorsin Automotive Environment[Z], Application Note, TI,2001
49. TMS320 LF2407A DSP Conyrollers[Z], Texas Instruments Incorporated,1999
50. Manfred Popp. The rapid way to PROFIBUS-DP,1997
51. Stenerson, Jon. Fundamentals of Programmable Logic Controller,sensors,and communication.,2004
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