基于现场总线技术的线缆生产设备控制系统研究与设计
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摘要
电线电缆是我国经济建设中的一项重要产业，它与国民经济各行各业发展密切相关。有关其设备制造技术的研究与开发对于提升我国电线电缆行业的竞争力有着重要的意义。
本文通过对电线电缆行业国内外发展现状的仔细分析，找出和国外先进设备制造水平之间存在差距的重要原因——先进的自动化技术在工业控制系统中应用的滞后是我国设备制造最大的弱点。论文结合一个工程实际项目，对基于现场总线技术的电线电缆生产设备控制系统设计方法进行了研究，并在此基础上设计了某汽车用低压电线的生产设备控制系统。论文首先对聚合物挤出生产工艺进行了详细分析，基于流体力学理论推导出适合于塑料聚合物流体的其流率和挤出机螺杆转速之间的关系式。接着对线径控制方法进行了讨论，并针对设备的结构特点提出一种冷／热外径控制方法，即以热端外径作为控制反馈量，而根据冷端外径测量值和设定值之差对热端外径设定值进行修正，在此基础上设计了基于模糊自调整PID控制算法的控制器，以此来实现对线径的精确控制。仿真和设备运行结果表明采用模糊自调整PID控制器的控制效果优于PID控制器，也验证了本文所设计线径控制方法和控制算法的有效性。论文在详细分析汽车用低压电线生产工艺的基础上，设计了一个基于PROFIBUS现场总线技术的两层单主站总线网络结构的系统，并对总线网络的设计及组态方法、网络通信方法、网络设备故障诊断方法做了详细分析与实现，对系统软件的结构、设计及实现技术如程序设计的分层技术、错误处理编码技术、代码实现技术等给出详细分析和实现。
论文设计方案经过设备现场运行检验，其结果验证了本文设计方案的可行性和实用价值，并已在多条生产线设备上运行。
The trade of wire and cable is an important industry in the economic construction of our country, it is closely related to every walk of life of national economy and even world economic development. The research and development of its equipment making technology is important to improve our industry of wire and cable.
The current situation of the trade of wire and cable is analyzed both at home and abroad at first, and find out the reason why the gap of manufacturing technology of equipment between our country and of foreign countries. The greatest shortage of the industry of equipment manufacturing is the lag of advanced automatic technology's practical implementation in industry control systems. Combine a actual project , the thesis introduce a control system of equipment based on the PROFIBUS field bus technology, and design the control system of the low-voltage wire and cable of automobile. At the first , the technology of polymer extrusion has been analyzed in detail. The equation about the relation between flow rate and rev of extrusion machine has been deduced based on the theory of fluid mechanics. Then the diameter control method is discussed. In this thesis the method of controlling the cold and hot diameter has been designed, the hot diameter is acted as feedback, and the set point of hot diameter is updated according to the difference between cold measuring diameter and set value. And the PID controller based on the fuzzy self adjust of the controller's parameters has been adopted. The effect has been proved in production, the structure of two single layer network is designed based on the PROFIBUS field bus technology. The design and configuration method of the field bus network has been analyzed in detail, and the design method has been introduced, the procedure design methods have also been analyzed in detail, such as the technology of multilayer programming, the technology of the codes of dealt with the mistake and the codes implementation technique, etc.
The performance of network and system running result that come into being in experiment indicate the effectivity and practicality of the method. The hardware and software have been implemented in many production lines.
本文通过对电线电缆行业国内外发展现状的仔细分析，找出和国外先进设备制造水平之间存在差距的重要原因——先进的自动化技术在工业控制系统中应用的滞后是我国设备制造最大的弱点。论文结合一个工程实际项目，对基于现场总线技术的电线电缆生产设备控制系统设计方法进行了研究，并在此基础上设计了某汽车用低压电线的生产设备控制系统。论文首先对聚合物挤出生产工艺进行了详细分析，基于流体力学理论推导出适合于塑料聚合物流体的其流率和挤出机螺杆转速之间的关系式。接着对线径控制方法进行了讨论，并针对设备的结构特点提出一种冷／热外径控制方法，即以热端外径作为控制反馈量，而根据冷端外径测量值和设定值之差对热端外径设定值进行修正，在此基础上设计了基于模糊自调整PID控制算法的控制器，以此来实现对线径的精确控制。仿真和设备运行结果表明采用模糊自调整PID控制器的控制效果优于PID控制器，也验证了本文所设计线径控制方法和控制算法的有效性。论文在详细分析汽车用低压电线生产工艺的基础上，设计了一个基于PROFIBUS现场总线技术的两层单主站总线网络结构的系统，并对总线网络的设计及组态方法、网络通信方法、网络设备故障诊断方法做了详细分析与实现，对系统软件的结构、设计及实现技术如程序设计的分层技术、错误处理编码技术、代码实现技术等给出详细分析和实现。
论文设计方案经过设备现场运行检验，其结果验证了本文设计方案的可行性和实用价值，并已在多条生产线设备上运行。
The trade of wire and cable is an important industry in the economic construction of our country, it is closely related to every walk of life of national economy and even world economic development. The research and development of its equipment making technology is important to improve our industry of wire and cable.
The current situation of the trade of wire and cable is analyzed both at home and abroad at first, and find out the reason why the gap of manufacturing technology of equipment between our country and of foreign countries. The greatest shortage of the industry of equipment manufacturing is the lag of advanced automatic technology's practical implementation in industry control systems. Combine a actual project , the thesis introduce a control system of equipment based on the PROFIBUS field bus technology, and design the control system of the low-voltage wire and cable of automobile. At the first , the technology of polymer extrusion has been analyzed in detail. The equation about the relation between flow rate and rev of extrusion machine has been deduced based on the theory of fluid mechanics. Then the diameter control method is discussed. In this thesis the method of controlling the cold and hot diameter has been designed, the hot diameter is acted as feedback, and the set point of hot diameter is updated according to the difference between cold measuring diameter and set value. And the PID controller based on the fuzzy self adjust of the controller's parameters has been adopted. The effect has been proved in production, the structure of two single layer network is designed based on the PROFIBUS field bus technology. The design and configuration method of the field bus network has been analyzed in detail, and the design method has been introduced, the procedure design methods have also been analyzed in detail, such as the technology of multilayer programming, the technology of the codes of dealt with the mistake and the codes implementation technique, etc.
The performance of network and system running result that come into being in experiment indicate the effectivity and practicality of the method. The hardware and software have been implemented in many production lines.
引文
[1] 王迅．中国电缆工业对铝导体材料需求强劲．http://www.sata.org.cn, 2003
[2] 行业研究报告．2002年中国电线电缆行业研究报告．http://www.mei.net.cn, 2003
[3] 王春江等．电线电缆手册第一册(2版)．北京：机械工业出版社，2001，1～5
[4] 行业动态．电线电缆专用设备“十五”发展方向．http://www.jicheng.net.cn, 2002
[5] Pierre-Yves Bonvin. Extrusion Line for Fine Wires with Highly Expanded Insulation. Wire and Cable Asia, November 2003, 21-27
[6] Maschinenfabrik Niehoff GmbH & Co. KG. Superfine Wire and Multiwire Drawing Machines: New Development to Compliance with Ecological, Economic and Ergonomic Criteria. Wire and Cable Asia, July 2002, 10-16
[7] Cortinovis SpA. Innovative Stranding and Cabling Equipment for Power Cables. Euro Wire, July 2003, 15-23
[8] Sikora AG. Digital High-Speed FFT Analysis in the Production of High Bandwidth Cable and Other Extrusion Processes. Wire and Cable Asia, May 2003, 11-17
[9] Pierre-Yves Bonvin. Innovations in FEP Foam Production Leads to New C/D Control. Euro Wire, January 2003, 8-12
[10] 北京化工学院，华南工学院．塑料机械设计．北京：轻工业出版社，1983，52～68
[11] 陶永华．新型PID控制及其应用．北京：机械工业出版社，2002，117-148
[12] 诸静等．模糊控制原理与应用．北京：机械工业出版社，1995，337-352
[13] 闻新等．MATLAB模糊逻辑工具箱的分析与应用．北京：科学出版社，2001，118-140
[14] 刘金馄．先进PID控制及其MATLAB仿真．北京：电子工业出版社，2003，67-70
[15] 阳宪惠．现场总线技术及其应用．北京：清华大学出版社，1999，1-15
[16] 谭克勤，朱守云．现场总线与工业以太网络应用技术手册．上海：上海科学技术出版社，2002，1-25，86-228
[17] 周悦，王智等．几种现场总线的通信介质访问控制方式．工业仪表与自动化装置，2001，3：61-64
[18] 吕岗，谭得健等．现场总线的特点与发展．工矿自动化，2003，2：12-14
[19] 柴郁，李斌．现场总线技术的发展及应用展望．仪表技术，2001，2：21-26
[20] 赵天洪．现场总线与控制系统．电力系统自动化，2000，24：62-65
[21] 魏彬彬．现场总线控制系统的现状与未来．交通与计算机，2001，19：33-36
[22] Hans Jkel and Ernst Altmann. Extrusion Equipment for Automotive Applications. Wire and Cable Asia, May 2003, 12-18
[23] 陈仲民，程振杰．电线电缆偏心度的在线测量技术．南京邮电学院学报，1995，15：16-20
[24] John Grant. Non-Lead and Heavy-Metal-Free Trends in Wire and Cable. Euro Wire, March 2002, 22-28
[25] 丁军，盛守国等．复合无卤阻燃剂及其在电缆料中的应用研究．化学与粘合，1997，2：21-26
[26] 黄俊．PROFIBUS现场总线技术及其应用．制造业自动化，2003，25：41-44
[27] 郝晓弘，马向华．现场总线控制系统—新一代过程控制系统．工业控制计算机，2001，14：25-30
[28] 何国西．现场总线在PLC和工控机控制系统中应用方案比较．工业控制计算机，2003，16：31-36
[29] 刘辉．集散控制系统与现场总线技术．自动化与仪器仪表，2001，5：10-15
[30] 郝晓弘，马向华．论现场总线控制系统．自动化与仪表，2001，16：1-6
[31] 郁佳敏，万曼影等．现场总线PROFIBUS智能化DP从站的设计．自动化与仪表，2001，16：15-20
[32] 王锦标，刘宇．现场总线控制系统的集成技术．冶金自．动化，2002，3：16-20
[33] 朱荣，徐平川．现场总线与工业控制系统．昆明理工大学学报，2001，26：23-29
[34] 袁晓红，张连永．现场总线在过程控制中的应用．首都师范大学学报(自然科学版)，2003，24：35-41
[35] Eduardo Tovar, Francisco Vasques. Real-Time Fieldbus Communications Using Profibus Networks. IEEE Transactions on Industrial Electronics, December 1999, 46:1241-1251
[36] Eduardo Tovar, Francisco Vasques. Cycle Time Properties of the PROFIBUS Timed Token Protocol. Computer Communications, September 1999, 22: 1206-1216
[37] Hodson W R. Fieldbus to change DCS role, but death reports greatly exaggerated. [J] In Tech.1997, 11: 36-39.
[38] Ochsner M, Schrjer M. To fieldbus or not to fieldbus. [J] In Tech. 1997, 10:44-48
[39] C.M.Krishna, Kang G.Shin.Real-time Systems.北京:清华大学出版社, 2001, 12～23
[40] 朱二元等．软件工程技术概论．北京：科学出版社，2002，8～26
[41] 汤惟．软件工程基础．西安：西安交通大学出版社，2000，4～11
[42] Jef Raskin.The Human Interface(New Directions for Designing Interactive Systems).北京:机械工业出版社, 2002, 1-6
[43] 罗仕鉴等．人机界面设计．北京：机械工业出版社，2000，142～174
[44] [美] Tyson Gill著．段来盛，宋黎松等译．Visual Basic 6高级编程策略与范例．北京：电子工业出版社，2000，136-201
[45] 范逸之．Visual Basic与分布式监控系统——RS-232／485串行通信．北京：清华大学出版社，2002，36～46
[2] 行业研究报告．2002年中国电线电缆行业研究报告．http://www.mei.net.cn, 2003
[3] 王春江等．电线电缆手册第一册(2版)．北京：机械工业出版社，2001，1～5
[4] 行业动态．电线电缆专用设备“十五”发展方向．http://www.jicheng.net.cn, 2002
[5] Pierre-Yves Bonvin. Extrusion Line for Fine Wires with Highly Expanded Insulation. Wire and Cable Asia, November 2003, 21-27
[6] Maschinenfabrik Niehoff GmbH & Co. KG. Superfine Wire and Multiwire Drawing Machines: New Development to Compliance with Ecological, Economic and Ergonomic Criteria. Wire and Cable Asia, July 2002, 10-16
[7] Cortinovis SpA. Innovative Stranding and Cabling Equipment for Power Cables. Euro Wire, July 2003, 15-23
[8] Sikora AG. Digital High-Speed FFT Analysis in the Production of High Bandwidth Cable and Other Extrusion Processes. Wire and Cable Asia, May 2003, 11-17
[9] Pierre-Yves Bonvin. Innovations in FEP Foam Production Leads to New C/D Control. Euro Wire, January 2003, 8-12
[10] 北京化工学院，华南工学院．塑料机械设计．北京：轻工业出版社，1983，52～68
[11] 陶永华．新型PID控制及其应用．北京：机械工业出版社，2002，117-148
[12] 诸静等．模糊控制原理与应用．北京：机械工业出版社，1995，337-352
[13] 闻新等．MATLAB模糊逻辑工具箱的分析与应用．北京：科学出版社，2001，118-140
[14] 刘金馄．先进PID控制及其MATLAB仿真．北京：电子工业出版社，2003，67-70
[15] 阳宪惠．现场总线技术及其应用．北京：清华大学出版社，1999，1-15
[16] 谭克勤，朱守云．现场总线与工业以太网络应用技术手册．上海：上海科学技术出版社，2002，1-25，86-228
[17] 周悦，王智等．几种现场总线的通信介质访问控制方式．工业仪表与自动化装置，2001，3：61-64
[18] 吕岗，谭得健等．现场总线的特点与发展．工矿自动化，2003，2：12-14
[19] 柴郁，李斌．现场总线技术的发展及应用展望．仪表技术，2001，2：21-26
[20] 赵天洪．现场总线与控制系统．电力系统自动化，2000，24：62-65
[21] 魏彬彬．现场总线控制系统的现状与未来．交通与计算机，2001，19：33-36
[22] Hans Jkel and Ernst Altmann. Extrusion Equipment for Automotive Applications. Wire and Cable Asia, May 2003, 12-18
[23] 陈仲民，程振杰．电线电缆偏心度的在线测量技术．南京邮电学院学报，1995，15：16-20
[24] John Grant. Non-Lead and Heavy-Metal-Free Trends in Wire and Cable. Euro Wire, March 2002, 22-28
[25] 丁军，盛守国等．复合无卤阻燃剂及其在电缆料中的应用研究．化学与粘合，1997，2：21-26
[26] 黄俊．PROFIBUS现场总线技术及其应用．制造业自动化，2003，25：41-44
[27] 郝晓弘，马向华．现场总线控制系统—新一代过程控制系统．工业控制计算机，2001，14：25-30
[28] 何国西．现场总线在PLC和工控机控制系统中应用方案比较．工业控制计算机，2003，16：31-36
[29] 刘辉．集散控制系统与现场总线技术．自动化与仪器仪表，2001，5：10-15
[30] 郝晓弘，马向华．论现场总线控制系统．自动化与仪表，2001，16：1-6
[31] 郁佳敏，万曼影等．现场总线PROFIBUS智能化DP从站的设计．自动化与仪表，2001，16：15-20
[32] 王锦标，刘宇．现场总线控制系统的集成技术．冶金自．动化，2002，3：16-20
[33] 朱荣，徐平川．现场总线与工业控制系统．昆明理工大学学报，2001，26：23-29
[34] 袁晓红，张连永．现场总线在过程控制中的应用．首都师范大学学报(自然科学版)，2003，24：35-41
[35] Eduardo Tovar, Francisco Vasques. Real-Time Fieldbus Communications Using Profibus Networks. IEEE Transactions on Industrial Electronics, December 1999, 46:1241-1251
[36] Eduardo Tovar, Francisco Vasques. Cycle Time Properties of the PROFIBUS Timed Token Protocol. Computer Communications, September 1999, 22: 1206-1216
[37] Hodson W R. Fieldbus to change DCS role, but death reports greatly exaggerated. [J] In Tech.1997, 11: 36-39.
[38] Ochsner M, Schrjer M. To fieldbus or not to fieldbus. [J] In Tech. 1997, 10:44-48
[39] C.M.Krishna, Kang G.Shin.Real-time Systems.北京:清华大学出版社, 2001, 12～23
[40] 朱二元等．软件工程技术概论．北京：科学出版社，2002，8～26
[41] 汤惟．软件工程基础．西安：西安交通大学出版社，2000，4～11
[42] Jef Raskin.The Human Interface(New Directions for Designing Interactive Systems).北京:机械工业出版社, 2002, 1-6
[43] 罗仕鉴等．人机界面设计．北京：机械工业出版社，2000，142～174
[44] [美] Tyson Gill著．段来盛，宋黎松等译．Visual Basic 6高级编程策略与范例．北京：电子工业出版社，2000，136-201
[45] 范逸之．Visual Basic与分布式监控系统——RS-232／485串行通信．北京：清华大学出版社，2002，36～46