M18单圆盘铜浇铸机控制系统研究与设计
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摘要
铜由于其良好的导电性、传热性、延展性、耐腐性,己广泛应用于机械、电子、化工等各个行业。铜圆盘浇铸机是铜冶炼环节的重要机组之一,我国少部分冶炼企业引进的是国外设备,引进价格是同类国产设备价格的三倍以上,致使固定资产占用大。因此,研究与开发定量铜圆盘浇铸机对我国铜冶炼企业具有重要意义。
本文在金昌冶炼厂旧M18铜圆盘浇铸工艺机理分析的基础上,研究并设计适合该厂的M18单圆盘铜浇铸机控制系统。在铜圆盘浇铸中,为实现铜阳极板浇铸质量的有效控制,采用双模模糊控制技术控制浇铸称重,利用浇铸包的重量差作为输入量,伺服位置传感器信号为反馈信号,浇铸包的倾倒速度为输出量,当重量偏差大于某一个阈值时,采用比例控制,提高系统响应速度；当偏差减小到阈值以下时,采用模糊控制,以提高系统的阻尼性能,减小超调。
该控制系统硬件主要由工控机(IPC)、可编程控制器(PLC)与变频器组成,利用PLC控制浇注计量,圆盘运行、阳极板提升与平移,以及系统各部分协调工作。采用变频调速驱动圆盘电机、平移电机,实现速度的良好控制,改善了系统运行特性；软件实现包括上位机系统监控软件和下位机PLC控制程序的编制。根据工艺设备控制要求,采用STEP7V5.4软件,运用“结构化编程”方式,编制PLC程序,用WINCC组态软件,设计出监控程序,对系统进行监控和管理；借助PROFIBUS-DP现场总线和工业以太网搭建系统的通讯网络,实现信息相互交换。
运行结果表明,该系统能有效减少浇铸过程阳极板的重量误差,提高圆盘运行的平稳性,满足实际铜浇铸生产的需求。
Copper has been widely used in such industries as mechanism, electronics and chemistry for its conductivity, diathermancy, ductility and rot-proof-ness. Copper casting wheel is an important part of copper smelting. In china, some metallurgical enterprises use foreign equipment, whose prices are more than three times as much as the domestically produced equipment, taking up a large fixed assets. Therefore, the research and development of the quantitative copper casting wheel system disk have great significance for copper smelting enterprises.
Based on the technological transformation of Jinchang Smelter——old M18 casting equipment, we learn from similar imported equipment and update it to design a new set of control system. In order to effectively control the exact casting quantity of the anode plate, the weight of casting uses the approach of dual-mode fuzzy control, using the different weights of the casting packages as input, the servo position sensor signal as the feedback signal, and the dumping speed of casting packages as output to form a dual-mode fuzzy control:when the weight of a deviation is greater than a threshold, we can make use of proportional control to improve the system response; when the bias is reduced below the threshold, we can use the fuzzy control to improve the system's damping performance to reduce the overshoot.
The control system mainly consists of IPC (IPC), programmable logic controller (PLC), the drive components with PLC control system as its core and the control measure casting, disc operation, the anode plate enhance and translation as coordination. Disk drive motor and pan motor use frequency control to achieve good control of speed and improve the operating characteristics of the system. The software of the system includes PC system monitoring software and slave PLC control program. According to the process of the equipment, the system uses STEP 7 V5.4 software and "structured programming" approach to complete PLC program. Besides, the system uses WINCC configuration software to design a monitoring program for monitor and management. The control system uses PROFIBUS-DP Field-bus and Industrial Ethernet, setting up the communication technology within the system and realizing the exchange of information.
As it is reported, this new system can effectively overcome the quantity error of the anode plate and enhance the stability of the disc in order to satisfy the demand of real operation.
本文在金昌冶炼厂旧M18铜圆盘浇铸工艺机理分析的基础上,研究并设计适合该厂的M18单圆盘铜浇铸机控制系统。在铜圆盘浇铸中,为实现铜阳极板浇铸质量的有效控制,采用双模模糊控制技术控制浇铸称重,利用浇铸包的重量差作为输入量,伺服位置传感器信号为反馈信号,浇铸包的倾倒速度为输出量,当重量偏差大于某一个阈值时,采用比例控制,提高系统响应速度；当偏差减小到阈值以下时,采用模糊控制,以提高系统的阻尼性能,减小超调。
该控制系统硬件主要由工控机(IPC)、可编程控制器(PLC)与变频器组成,利用PLC控制浇注计量,圆盘运行、阳极板提升与平移,以及系统各部分协调工作。采用变频调速驱动圆盘电机、平移电机,实现速度的良好控制,改善了系统运行特性；软件实现包括上位机系统监控软件和下位机PLC控制程序的编制。根据工艺设备控制要求,采用STEP7V5.4软件,运用“结构化编程”方式,编制PLC程序,用WINCC组态软件,设计出监控程序,对系统进行监控和管理；借助PROFIBUS-DP现场总线和工业以太网搭建系统的通讯网络,实现信息相互交换。
运行结果表明,该系统能有效减少浇铸过程阳极板的重量误差,提高圆盘运行的平稳性,满足实际铜浇铸生产的需求。
Copper has been widely used in such industries as mechanism, electronics and chemistry for its conductivity, diathermancy, ductility and rot-proof-ness. Copper casting wheel is an important part of copper smelting. In china, some metallurgical enterprises use foreign equipment, whose prices are more than three times as much as the domestically produced equipment, taking up a large fixed assets. Therefore, the research and development of the quantitative copper casting wheel system disk have great significance for copper smelting enterprises.
Based on the technological transformation of Jinchang Smelter——old M18 casting equipment, we learn from similar imported equipment and update it to design a new set of control system. In order to effectively control the exact casting quantity of the anode plate, the weight of casting uses the approach of dual-mode fuzzy control, using the different weights of the casting packages as input, the servo position sensor signal as the feedback signal, and the dumping speed of casting packages as output to form a dual-mode fuzzy control:when the weight of a deviation is greater than a threshold, we can make use of proportional control to improve the system response; when the bias is reduced below the threshold, we can use the fuzzy control to improve the system's damping performance to reduce the overshoot.
The control system mainly consists of IPC (IPC), programmable logic controller (PLC), the drive components with PLC control system as its core and the control measure casting, disc operation, the anode plate enhance and translation as coordination. Disk drive motor and pan motor use frequency control to achieve good control of speed and improve the operating characteristics of the system. The software of the system includes PC system monitoring software and slave PLC control program. According to the process of the equipment, the system uses STEP 7 V5.4 software and "structured programming" approach to complete PLC program. Besides, the system uses WINCC configuration software to design a monitoring program for monitor and management. The control system uses PROFIBUS-DP Field-bus and Industrial Ethernet, setting up the communication technology within the system and realizing the exchange of information.
As it is reported, this new system can effectively overcome the quantity error of the anode plate and enhance the stability of the disc in order to satisfy the demand of real operation.
引文
[1]北京君略产业研究院2010年中国铜行业研究报告
[2]杨小琴.阳极浇铸设备在铜火法精炼中的应用.有色冶炼.2003,6(14)
[3]http://www.outotec.com
[4]施贤蛟.自动定量浇铸技术国产化的研究与应用.有色冶金.2000,1
[5]刑兵锁.[硕士论文]：江西理工大学；2008
[6]Zhongbao Chen, Lih-Sheng Tumg. A review of current developments in process and quality controfor injection molding.Advances in Polymer Technology.2005, 24(3):165-182
[7]黄奇志.提高圆盘浇铸机阳极铜板质量的探讨[J]有色冶炼,2002,(4)42-44
[8]李刚,袁春峰,刘军.有色冶金设计与研究2010,(4)31卷第2期
[9]方勇.圆盘浇铸机的设计特点及其维护；中国科学院上海冶金研究所；材料物理与化学(专业)博士论文2000年度
[10]廖常初.S7-300/400PLC应用技术.机械工业出版社,2005
[11]骆德汉.可编程控制器与现场总线网络控制.北京：科学出版社,2005
[12]SIEMENS SIMATIC S7-300程序控制硬件与安装.西门子(中国)有限公司.北京,1996
[13]曹承志.微型计算机控制新技术.北京：机械工业出版社,2001,3
[14]许益民.电液比例控制系统分析与设计.机械工业出版社,2005
[15]王永华.现代电气及可编程控制技术.北京航空航天大学出版社,2002
[16]张进秋,陈永利,张中民.可编程控制器的系统设计与应用实例.机械工业出版,2000
[17]韩安荣.通用变频器及其应用.机械工业出版社,2002,9
[18]SIEMENS工业通讯网络及现场总线部件.西门子(中国)有限公司.北京,2001
[19]http://www.ad.siemens.com.cn
[20]诸静.模糊控制理论与系统原理.北京：机械工业出版社,2005：381
[21]郭庆祝,孟维明,宋扬.模糊控制技术发展现状及研究热点.自动化博览,2005(4)：68-70
[22]李鑫,李众.模糊自适应在线调整PID参数控制器.仪器仪表用户,2004
[23]SehenkerB, Agarwal M.Predictive control of a beneh — scale chemical reactor based on neurai-network models.IEEE Trans Control Syst Tech,1998,6(3):388 —400.
[24]Tsen A Y D, Jang S S,Wong D, Joseph B.Rule-base strueture identifieation in an adaptive—network—based fuzzy inference system.IEEE Trans.on Fuzzy System,1996,42(2):455—465.
[25]张吉礼.模糊—神经网络控制原理与工程运用.哈尔滨工业大学出版社,2004,6：1-3
[26]Dong D, McAvoy T J.Multi—Stage Batch Process Monitoring.Control Conference Seattle WA,1995:21—23.
[27]Mauer,G.F.A fuzzy logic controller for an ABS braking system. Fuzzy Systems. IEEE Transactions on,Volume:3 Issue:4, Nov 1995
[28]汤兵勇,路林吉.模糊控制理论与应用技术.北京：清华大学出版社,2002.
[29]诸静等.模糊控制原理及应用.机械工业出版社,2005.
[30]K.K.Tan,S.N.Huang,X Jiang.Adaptive Control of Ram Velocity for the Injection Moulding Machinem.IEEE Transactions on Control Systems Technology, Vol.9,No.4,2001,663-671.
[31]S Huang,K.K.Tan,T H Lee.Predictive control of ram velocity in injection molding. Polymer-Plastic Tech,Eng(S 1525-6111),1999,38(2):285-303.
[32]K.K.Tan,J C Tang.Learning-enhanced PI Control of Ram Velocity in Injection Molding Machines[J].Engineering Applications of Artificial Intelligence (S0952-1976),2002,15(1):65-72.
[33]曾岳南,陈伯时.异步电动机无速度传感器的矢量控制.电气传动自动化
[34]冯垛生,曾岳南.无速度传感器矢量控制原理与实践.北京：机械工业出版社,1997
[35]S N Huang,K.K.Tan,T H Lee.Neural-Network-Based Predictive Learning Control of Ram Velocity in Injection Molding[J].IEEE Trans.on Systems,Man and Cybernetics (S1097-6977),2004,34(3):363-368.
[36]陶永华.新型PID控制及应用(第2版).北京：机械工业出版社,2003
[37]曹健,李尚义,赵克定.电液伺服系统的二自由度PID控制[J].机床与液压,2001(6)：54-55
[38]张贤明.MATLAB语言及应用案例ISBN:978-7-5641-2424-3东南大学出版社
[39]周元芳.结构化及面向对象的程序设计方法在PLC编程中的应用.浙江工业大学学报,2003,31(3)：264-267
[40]刘建昌,于洪磊等。S7-300\400PLC工业网络通信技术指南
[41]刘错,周海.深入浅出西门子S7-300 PLC.北京：北京航空航天大学出版社,2004：37-39
[42]SIMATIC WinCC V6.0使用手册.北京：西门子(中国)公司,2004
[43]SIEMENS SIMATIC Step 7 V5.4编程手册.
[44]高鸿斌,孔美静,赫孟合.西门子PLC与工业控制网络应用.北京：电子工业出版社,2006
[45]崔坚,李佳.西门子工业网络通信指南.北京：机械工业出版社,2005
[46]SIMATIC S7-300 Programmable Controller. Germany:Siemens Automation and DrivesGroup,2002
[47]SIMATIC NET PROFIBUS Networks. SIEMENS AG.1997
[48]Siemens AG. Working with STEP7 V5.4 Getting Started[M].Germany:Siemens Automation and Drives Group 2003:101108
[49]李练兵、岳大为、申莉莉编.变频器应用实践.化学工业出版,2009,9
[50]罗志军,尹斌.基于Profibus-DP的PLC与PC现场总线控制系统.微计算机信息,2004(11)
[51]SIEMENS SIMATIC S7-300和S7-400梯形逻辑编程参考手册.2001.7
[52]宋伯生.PLC编程理论,算法及技巧.北京：机械工业出版社,2005,6：21-629
[53]任建芳,孙涛WinCC Global Script在数据存储中的应用.控制工程,2003(9)：45-48.
[54]Siemens A G. SIMATIC WinCC system desription. Germany Siemens 2000.
[55]SIEMENS SIMATIC CP34I Getting Started Guide
[56]张春.西门子STEP7编程语言与使用技巧.机械工业出版社,2011,4
[57]李泽光,杨建学,郝莉.PROFIBUS-DP及与变频器的通信.机电工程技术
[58]西门子(中国)有限公司自动化与驱动集团编.深入浅出西门子WinCC V6.北京航空航天大学出版社.2005.9
[59]陈章平,杨泽,沈国宇,戴金.西门子S7-300/400 PLC控制系统设计与应用.清华大学出版社
[60]何有世刘秋生.管理信息系统.东南大学出版社,2009,1
[2]杨小琴.阳极浇铸设备在铜火法精炼中的应用.有色冶炼.2003,6(14)
[3]http://www.outotec.com
[4]施贤蛟.自动定量浇铸技术国产化的研究与应用.有色冶金.2000,1
[5]刑兵锁.[硕士论文]：江西理工大学；2008
[6]Zhongbao Chen, Lih-Sheng Tumg. A review of current developments in process and quality controfor injection molding.Advances in Polymer Technology.2005, 24(3):165-182
[7]黄奇志.提高圆盘浇铸机阳极铜板质量的探讨[J]有色冶炼,2002,(4)42-44
[8]李刚,袁春峰,刘军.有色冶金设计与研究2010,(4)31卷第2期
[9]方勇.圆盘浇铸机的设计特点及其维护；中国科学院上海冶金研究所；材料物理与化学(专业)博士论文2000年度
[10]廖常初.S7-300/400PLC应用技术.机械工业出版社,2005
[11]骆德汉.可编程控制器与现场总线网络控制.北京：科学出版社,2005
[12]SIEMENS SIMATIC S7-300程序控制硬件与安装.西门子(中国)有限公司.北京,1996
[13]曹承志.微型计算机控制新技术.北京：机械工业出版社,2001,3
[14]许益民.电液比例控制系统分析与设计.机械工业出版社,2005
[15]王永华.现代电气及可编程控制技术.北京航空航天大学出版社,2002
[16]张进秋,陈永利,张中民.可编程控制器的系统设计与应用实例.机械工业出版,2000
[17]韩安荣.通用变频器及其应用.机械工业出版社,2002,9
[18]SIEMENS工业通讯网络及现场总线部件.西门子(中国)有限公司.北京,2001
[19]http://www.ad.siemens.com.cn
[20]诸静.模糊控制理论与系统原理.北京：机械工业出版社,2005：381
[21]郭庆祝,孟维明,宋扬.模糊控制技术发展现状及研究热点.自动化博览,2005(4)：68-70
[22]李鑫,李众.模糊自适应在线调整PID参数控制器.仪器仪表用户,2004
[23]SehenkerB, Agarwal M.Predictive control of a beneh — scale chemical reactor based on neurai-network models.IEEE Trans Control Syst Tech,1998,6(3):388 —400.
[24]Tsen A Y D, Jang S S,Wong D, Joseph B.Rule-base strueture identifieation in an adaptive—network—based fuzzy inference system.IEEE Trans.on Fuzzy System,1996,42(2):455—465.
[25]张吉礼.模糊—神经网络控制原理与工程运用.哈尔滨工业大学出版社,2004,6：1-3
[26]Dong D, McAvoy T J.Multi—Stage Batch Process Monitoring.Control Conference Seattle WA,1995:21—23.
[27]Mauer,G.F.A fuzzy logic controller for an ABS braking system. Fuzzy Systems. IEEE Transactions on,Volume:3 Issue:4, Nov 1995
[28]汤兵勇,路林吉.模糊控制理论与应用技术.北京：清华大学出版社,2002.
[29]诸静等.模糊控制原理及应用.机械工业出版社,2005.
[30]K.K.Tan,S.N.Huang,X Jiang.Adaptive Control of Ram Velocity for the Injection Moulding Machinem.IEEE Transactions on Control Systems Technology, Vol.9,No.4,2001,663-671.
[31]S Huang,K.K.Tan,T H Lee.Predictive control of ram velocity in injection molding. Polymer-Plastic Tech,Eng(S 1525-6111),1999,38(2):285-303.
[32]K.K.Tan,J C Tang.Learning-enhanced PI Control of Ram Velocity in Injection Molding Machines[J].Engineering Applications of Artificial Intelligence (S0952-1976),2002,15(1):65-72.
[33]曾岳南,陈伯时.异步电动机无速度传感器的矢量控制.电气传动自动化
[34]冯垛生,曾岳南.无速度传感器矢量控制原理与实践.北京：机械工业出版社,1997
[35]S N Huang,K.K.Tan,T H Lee.Neural-Network-Based Predictive Learning Control of Ram Velocity in Injection Molding[J].IEEE Trans.on Systems,Man and Cybernetics (S1097-6977),2004,34(3):363-368.
[36]陶永华.新型PID控制及应用(第2版).北京：机械工业出版社,2003
[37]曹健,李尚义,赵克定.电液伺服系统的二自由度PID控制[J].机床与液压,2001(6)：54-55
[38]张贤明.MATLAB语言及应用案例ISBN:978-7-5641-2424-3东南大学出版社
[39]周元芳.结构化及面向对象的程序设计方法在PLC编程中的应用.浙江工业大学学报,2003,31(3)：264-267
[40]刘建昌,于洪磊等。S7-300\400PLC工业网络通信技术指南
[41]刘错,周海.深入浅出西门子S7-300 PLC.北京：北京航空航天大学出版社,2004：37-39
[42]SIMATIC WinCC V6.0使用手册.北京：西门子(中国)公司,2004
[43]SIEMENS SIMATIC Step 7 V5.4编程手册.
[44]高鸿斌,孔美静,赫孟合.西门子PLC与工业控制网络应用.北京：电子工业出版社,2006
[45]崔坚,李佳.西门子工业网络通信指南.北京：机械工业出版社,2005
[46]SIMATIC S7-300 Programmable Controller. Germany:Siemens Automation and DrivesGroup,2002
[47]SIMATIC NET PROFIBUS Networks. SIEMENS AG.1997
[48]Siemens AG. Working with STEP7 V5.4 Getting Started[M].Germany:Siemens Automation and Drives Group 2003:101108
[49]李练兵、岳大为、申莉莉编.变频器应用实践.化学工业出版,2009,9
[50]罗志军,尹斌.基于Profibus-DP的PLC与PC现场总线控制系统.微计算机信息,2004(11)
[51]SIEMENS SIMATIC S7-300和S7-400梯形逻辑编程参考手册.2001.7
[52]宋伯生.PLC编程理论,算法及技巧.北京：机械工业出版社,2005,6：21-629
[53]任建芳,孙涛WinCC Global Script在数据存储中的应用.控制工程,2003(9)：45-48.
[54]Siemens A G. SIMATIC WinCC system desription. Germany Siemens 2000.
[55]SIEMENS SIMATIC CP34I Getting Started Guide
[56]张春.西门子STEP7编程语言与使用技巧.机械工业出版社,2011,4
[57]李泽光,杨建学,郝莉.PROFIBUS-DP及与变频器的通信.机电工程技术
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