基于PLC的锅炉燃烧控制系统设计外文文献原文.docx
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基于PLC的锅炉燃烧控制系统设计外文文献原文.docx
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基于PLC的锅炉燃烧控制系统设计外文文献原文
BoilerlevelcontrolsystembasedonControlLogix5550PLC
Abstract-ThispaperisaresearchdesignbasedonEFPTprocesscontroldevice.Inthedesign,actualindustryfieldhasbeensimulatedandcorrespondingmodelinghasbeencarriedonfortheboilerlevelsystem.ThentheappropriatePIDparameterhasbeensortedoutandControlLogia5550PLChasbeenusedtocontroltheentireboilerlevelsystem.
Atlast,acorrespondingcontrolinterfacehasbeenestablishedandtheboilerlevelhasbeenunderasafeandaccuratecontrol
Keywords:
EFPT,PID,Modeling,Boilerlevel;
1Introduction
Thetaskoftheindustrialboilerlevelcontrolistomaintainadynamicbalancebycontrollingthewaterflowandevaporation,sothatthedrumlevelcanbemaintainedinthetechnologicallevel,whichisanecessityforensuringsafeoperationandalsooneofthemainindicatorsoftheboiler'snormaloperation.Waterlevelwhichistoohighwillaffecttheeffectofthesteam-waterseparation,buttoolowitiswillbreakringcycleorevencauseboilerexplosion.Toensureasafeandefficientproduction,theboilerlevelmustbestrictlycontrolledinmaintainingconstantorchangingonlyaccordingtoacertainrule.
UsingLogix5550PLCwithanalogyI/Omodules,launchedbyRockwellAutomationCompanyascontrollers,andEFPTprocesscontrolexperimentaldeviceascontrolobject,thissystemhavebroughttheboilerwaterlevelunderanaccuratecontrolinaminiboilersystemwithsensorsandactuatorsthatusedinindustrialproduction.
Fig.1Boilerlevelsettingvalueadjustmentsystem
2SystemOverview
ThissystemiscomposedofanEFPTprocesscontroldevice,aninverter,aLogix5550PLCandacomputer.EFPTprocesscontroldeviceisasimulatedheatingandwatersupplyanddrainagesystemforamicro-smallboiler.Itrealizesprocesscontrolinaminiboilersystemwithsensorsandactuatorsusedinindustrialproduction.Theactuatorincludesnotonlymeasuringappliance,butalsoACinverter,heatingcontroller,heaterandsoon.Thesystemsimulatesindustryscenethroughamini-boilerheating,watersupplyanddrainagesystem,whichisreliableandvisual.
Inthedesign,boilerLevelwasselectedasthecontrolledvariable.Thecontrolledobjectiscomposedofthewatertrough,theforcepump,theboilerandthepipe-linevalve.MicroMaster6SE9214-ODA40inverteristakenastheactuatorandtheboilerleveliscontrolledbyLogix5550.ConfigurationsoftwareRSView32andtouchscreenPanelView1000arecombinedtorealizethereal-timemonitoring.Inthedesign,asimpledesignofsingle-loopboilerliquidlevelvalueadjustmentisselectedforthestudy.ThecompositionofthesystemisshowninFig.1.
Inthedesign,theinverterasanactuatordirectlyreceivesPLCanalogyI/Oportoutput,andconvertersintofrequencyofinvertersoastodrivethe3-phasemotorintheliftpump,changetheinlet,andadjusttheboilerleveltothedynamicbalanceatlast.Andtheconfigurationsoftwareisusedtodesignmonitoringpicturetorealizethecomputerandthetouchscreentotheboilerlevellong-distanceandthescenemonitoring.
3EstablishingMathematicsmodelforthechargedobject
Oneofthemaintasksofestablishingcontrolsystemmathematicalmodelistodeterminethemathematicalmodelofthecontrolledobject.Generally,therearetwokindsofbasicmethodsforestablishingprocesscontrolmathematicalmodel:
mechanismanalysisandexperimentalmethod.However,forcontrolledobjectwhosestructureandinternalprocessisverycomplex,itisverydifficulttodeterminetheobjectjustbyitsowninternalphysicalprocessandtosolveoutthedifferentialequationssystematically.Besides,consideringthenonlinearfactor,mechanismanalysisusedsomeapproximationandhypothesisformathematicaldeduction.Althoughtheseapproximationandassumptionshavepracticalbasis,butnotfullyreflectactualsituation,andevencauseincalculableeffects.
Therefore,inthisdesign,theexperimentalmethodischosentoestablishamathematicalmodelforcontrolledobject.Thiskindofmodelingisbasedontheinputandoutputintheactualproductionprocess,thatistosay,establishingmathematicalmodelforthecontrolledobjectthroughprocessidentificationandparameterestimation.Inthisdesign,stepresponsecurvemethodisusedtoidentifymathematicalmodelsoftheprocess.A20Hzstepdisturbanceinputsignalisappliedtothechargedobject,andtheresponsecurveoftheoutputthatchangeswithtimecanbemapped.Aftertheanalysis,thetransferfunctionofthecontrolledobjectcanbedefined.Intheprocessofexperiment,theobjectwasconductedseveraltests.UsingRSLogix5000trendmonitoringfunctioncurve,morethan10chargedobjectstepresponsecurvehavebeenrecorded.Toalltheparametersforaverage,steadytime:
ts≈821.525s,steadyvalue:
h(∞)=58.5,peaktime:
tp=394.4sovershoot:
a%}29%.Accordingtothetheoreticalanalysis,thecontrolledobjectisthemostlikelysecond-orderobject.
However,thedifferenceisveryapparentbetweentheidealsecond-ordercontrolledobjectstepresponsecurveandtheactualcurves.Sotheidealcurvecan'tresponsetoitsactualcharacteristics.Itisinferredthatthecontrolledobjectmaybethesecond-ordercontrolledobjectthatincludeszero.ThetryanderrormethodandMATLABsimulationtoolsareusedtogetacurvewhoseparametersareclosetotheaveragedynamicparametersofthecontrolledobject'sresponsecurve.ItisshowninFig.2.
Someadjustmentscanbemadeaccordingtothefollowingrules:
1)Whenthezeroisclosertotheimaginaryaxis,settlingtimewillbelongerandtheovershootwillbebiggerandpeaktimewillbesmaller.Withthezeroclosingtotheimaginaryaxis,theeffectismoreobvious.
2)Theeffectwhichtheclosedloopdominantapiceshaveondynamicperformanceisincreasingthepeaktime,reducingtheovershootandadjustingtime.Nonparametricmodelisusedtodescribethecontrolledobject.Inotherwords,stepresponsecurvewhichapproximatelydescribethecontrolledobjectisusedbecauseofthecontrolledobject'scomplexityanduncertainty.
4Theinstallationofcontrollerparameter
4.1Theselectionofcontrolalgorithm
Afterestablishingtheapproximatemathematicalmodelofthecontrolledobject,acompletefeedbackcontrolsystemcanbeformedtoimprovetheperformanceoftheopen-loopcontrolsystem.PIDisanidealcontrollawinthatintegralisintroducedbasingontheproportion,whichcaneliminatetheresidualerror,plusthederivativeaction,whichcanalsoimprovethestabilityofthesystem.Accordingtothecharacteristicsofthecontrolledobjectandlaboratoryconditions,asingle-loopfeedbackcontrolloopforthecontrolledobjectisestablished,andPIDalgorithmisusedtorealizeboilerlevelcontrol.TheschematicdiagramoflevelcontrolisshowninFig.3.
Opentheoutletvalvetoacertaindegree,andmakethehydraulicdischargeinvariable.Comparingtheprocessvariablesofthewaterlevelinfeedbackwiththegivenvolume,thedeviationcanbeobtained.PIDinstructiondoesPIDoperationonthedeviation,andtheresultsisacontrolvariable,sothefrequencyoftheinvertercanbechangedtocontroltherotatespeedofthepump.Iftheliquidlevelisonthehighside,theresultsmakethecontrolvariablesmaller,and
reducetherateofinflow,makeliquidlevellower;ifthelevelisonthelowside,theresultsmakethecontrolvariablelarger,andincreasetherateofinflow,makeliquidlevelhigher.
4.2TheParameterTuningofPID
Becausethetransferfunctionofthecontrolledobjectincludesazerosecond-orderlink,thecomputationworkloadisquitebigregardlessofusingtheroot-locusmethodorthefrequencycharacteristiclawamongtheorymethodswhentuningPIDparameter.Andtheprocessmathematicalmodelcanonlyreflectdynamicparameterapproximately,sothereliabilityoftheparametervaluewhichisobtainedbythetheoreticalcalculationisnotveryaccurateanditwillbeadjustedconstantlyinthescene.Therefore,engineeringparametertuningischosentoseekthePIDparameterinthedesign.Thecommonmethodofengineeringtuningaredynamiccharacteristicparameters,thestableboundarylaw,thedecaycurvelawandfieldexperiencesettingmethod,etc.IntheprocessofPIDparameters,the4:
1decaycurvelawis
adopted.Thestepsare:
1)Intheclosedsystem,regulator'sintegraltimeissetthelargest(Ti≈∞)anddifferentialtimeTdissetzero(Td=0).Theproportionistakenthegreatvaluetoperformthegivenvalueperturbationexperimentrepeatedly,andtheproportionisreducedgraduallyuntiltherecordcurvepresentsupto4:
1weaken.Thentheproportioniscalled4:
1weakenproportionss
andthedistancesbetweentwoneighboringwaveridge'sarecalled4:
1dampedcycleTs.Intheexperiment,thelevelquantitativetestissetforthe200mm,andthenthesystemresponsecurveisobtainedandreorganized4:
1decaycurve(thickredlineisshowninFig.4
'Thusmeasuring:
δs≈8,Ts≈2.2;
2)Accordingtothefollowingformula,eachparameteroftheregulatorsis
δ=0.8,δs≈6.4;
Ti=0.3,Ts≈6.6;
Td=0.1,Ts≈2.2
3)Accordingtotheseresults,regulatorparametersareset.Thenthedynamicprocessofsystemisobservedandtheparametersaremadeadjustmenttodeterminetheoptimumparameters.
5MonitoringDesign
RSView32softwareandPanelBuilder32softwareofRockwellAutomationCompanyarerespectivelyusedtodesignmonitorscreentocompletesuchfunctionasanimatingdisplay,parametersetting,reportoutput,thecurrentcurvedisplayandhistorycurvedisplayandsoon.Andmakethecomputerandtouchscreenachievetheremoteandon-sitecontroltot
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