With the continuous progress of papermaking production processes and equipment, the requirements for automatic control of papermaking production are getting higher and higher, and manufacturers are paying more and more attention to this aspect. How to better choose and fit the actual configuration automatically The control system has been prominently placed in front of the manufacturers. The automatic control of paper production has traditionally been focused on electric drives. Now the scope has been extended to beating control systems, dispensing control systems, sizing flow control systems, multi-zone ventilation control systems (heat pump control) and moisture quantification in the dryer section of paper machines. Testing and other aspects, commonly known as the DCS process control system and the QCS quality inspection system, are moving in the direction of centralized control of the entire plant.
First, the electrical drive transmission system In recent years, the general use of foreign power transmission control system, the transmission system speed accuracy, dynamic response and reliability have been greatly improved, especially the promotion of AC frequency control device, the production Manufacturers have obtained great benefits, which have caused fundamental changes in many problems that have plagued domestically-made analog control devices from manufacturers for a long time, and have improved production efficiency. At present, the drive system has moved from the initial analog settings to full digital network communications. The latter has higher resolution and more precise control. At the same time, as part of the centralized control system of the whole plant, it is easy to communicate with other relevant parts through the data network. For this reason, the market share of some controllers with weak communication functions or poor openness of communication protocols is gradually declining, and some well-known high-end controllers are increasingly being used. The company has long been engaged in the automation engineering project of the paper industry. Since the first 1760/300 paper machine all-digital electric drive system was put into operation in Guangning People Paper Mill in 1994, Siemens advanced technology has been used to successfully develop different controls. System, formed a more complete product line. In the production lines of paperboard and other thick paper grades, if the vehicle speed is below 150m/min, we usually use Siemens MDV type inverters, Siemens S7-200 PLCs, and USS data communication protocols. The biggest feature of this configuration is the simple structure, economical and practical. In the paper machine or tissue paper or specialty paper production line with a vehicle speed of 150m/min or more, we usually use Siemens 6SE70 engineering inverters, Siemens S7-200 or S7-300 PLCs, and USS data communication protocols. This configuration is characterized by a simple structure and high control accuracy. When larger machines or users have high requirements for the networking capacity and configuration level of the electric drive system, we use the Siemens 6SE70 inverter, Siemens 57-400 PLC representing the current advanced level, using PROFIBUS-DP. The data bus network is used for communication. The main features of this configuration are high communication speeds, up to 12MB/s. The system has large capacity and the field data bus can connect to 127 stations.
Second, the whole plant integrated control system With the rapid development of industrial automation process control theory and computer technology, people put forward higher requirements for the industrial automation process control system, the three major issues facing the system data between the various levels The exchange volume rapidly increases, the field bus technology in the system is integrated and improved, and the software is safe and reliable. PCS is a new generation of process control system developed in this situation. It is a process control system for the entire production process based on Siemens' TELEPER M series distribution system and S5, S7 series PLCs. The PCS7 control system introduced by Siemens uses SIMATIC PCS7 software and SIEMENS S7 series hardware to form a complete, unified factory automation system. It is a new generation of process control system based on the idea of ​​fully integrated automation.
1. Control structure and communication network: The whole plant integrated control system is generally divided into process control level, automation level and field level.
Process Control Level The process control level uses a high-performance PC that uses standard software and networks to implement process diagnostics, process monitoring, control, and plant-wide information management. With the standard display and operation window, the screens and diagrams of various production processes can be displayed. All operating parameters and equipment parameters are called for modification and adjustment. All data can be copied and archived at any time. The system is completely open.
The automation level automation level adopts the CPU with single processor or multiprocessor, and the communication between automation level and process control level is realized by SIMATIC NET INDUSTRIA ETHERNET industrial Ethernet. The network system can access 1024 sites at a rate of 10MB/S. Communication with the field level is implemented by the SIMATIC NET PROFIBUS-DP communication network. The speed can reach 12MB/S, and the system can connect 127 stations.
At the field level at the field level, there are mainly three types of standard system products connected to the field bus. On-site operation panel OP27, OP25, TP27 and so on. The operation panels OP27, OP25, TP27, etc. are suitable for distributed, device-related control and monitoring. Different drive and transmission groups can have standard graphic displays and the same operating procedures. AC frequency converters and other control devices. 6SE70, 6RA70 as the motor drive and control unit, with the same performance, a clear hardware structure, clear operation and fault diagnosis. Remote intelligent interface SIMMIC S7 ET200. The ET200MI/O series offers digital and analog I/O units of various voltage and protection levels that can be placed centrally or dispersedly in the field. Other sensors and actuators can be directly connected to this open bus structure.
The PROFIBUS fieldbus PROFIBUS is used for field control and detection of the data exchange of the acquisition unit. The PROFIBUS field bus is an open field bus based on the international standard EN50170. It adopts the token scheduling principle for data communication, mainly including the high-speed bus PROFIBUS-DP (H2) with the highest baud rate up to 12M and the intrinsically safe low speed for the process. Bus PROFIBUS PA (H1). The perfect combination of DP and PA makes the PROFIBUS fieldbus superior in structure and performance to other fieldbuses. PROFIBUS is suitable for both automatic system communication with on-site signal units and for direct connection of transmitters, actuators, actuators, and other field instruments and devices with interfaces for the acquisition and monitoring of on-site signals and for use with a pair of Twisted pair replaces the traditional large number of transmission cables. Significant savings in cable costs are achieved, which in turn saves construction commissioning and maintenance time and costs after the system is put into operation. It is worth noting that at present, in the paper machine electric drive system, it seems that foreign countries have used the PROFIBUS-DP field data bus network to communicate without exception. This will undoubtedly be the most widely used in the future because it is reliable. The site and real-time control network are relatively perfect in terms of both sex and safety, but due to factors such as price, the use of medium and small-sized paper machines is less.
2. Operating system and software SIMATIC fully integrated automation system can now provide a unified technical environment for all automation applications, mainly: unified data management, unified communication protocol, unified configuration and programming software. SIMATIC PCS uses WinCC as monitoring software of the upper computer. The operating system uses Windows NT4.0. The communication network adopts Industrial Ethernet and PROFIBUS field bus. Industrial Ethernet is used for data communication between system stations and PROFIBUS network is used for communication of I/O stations. SIMATIC PCS uses programming software and field device libraries that conform to IEC-1131-3 international standards, providing continuous control, sequence control and high-level programming languages. The field device library provides a large number of commonly used field device information and function blocks, which can greatly simplify the configuration work and shorten the project cycle. SIMATIC PCS7 has ODBC, OLE and other standard interfaces, and applies open networks such as Ethernet and PROFIBUS field bus, which has a strong openness. It can be easily connected to the upper computer management system and other manufacturers' control systems. On the server, the operating system uses Windows NT 4.0 control software using the SIMATIC WINCC control system. SIMATIC WINCC is an important part of SIMATIC Totally Integrated Automation. For us, we can connect the symbol table in the configuration process to the variables of WINCC, and can also directly reflect the control information of the controller in the WINCC system. . The features of the SIMATIC WINCC control system: In a relatively short period of time, SIMATIC WINCC has evolved into one of the most successful HMI/SCADA systems in the world. The Windows Control Center (Windows Control Center) is the first process monitoring system that uses 32-bit technology. Its preemptive multitasking features are suitable for rapid reaction to process events. The openness and extensibility of WINCC are its most prominent features, and openness is mainly reflected in software:
a. Integrated standard database interface, ODBC/SQL. When the manufacturer establishes the information data management system in the whole factory, the data of the production site can be connected to the whole plant information data management system through the database interface.
b. Provides a standard OPC, industrial ActiveX interface. Through the interface, other application programs can be integrated into the process screen and exchange relevant data with WINCC. The WINCC control system integrates the OPC interface for connecting with other controller drivers that conform to the OPC specification. Therefore, WINCC can theoretically All controllers are supported.
c. Provides standard API programming dates, program engineers can use other programming languages ​​to access WINCC through the API interface to exchange data. The basic function of WINCC:
Graphic system: Through the configuration, it can form a rich and dynamic parameter control screen.
Trend filing: Event and incident analysis and trends that occur during the production process can be recorded in WINCC.
Informational alarms: WINCC captures process information and local events, puts these contents in archives, and optionally extracts them when needed, or moves directly to the relevant process screen.
Production reports: WINCC provides a set of reporting systems that can easily produce black and white and color production reports;
Third, the company's application in the paper industry PCS system The company in recent years, Siemens PCS7 system developed on the basis of the whole plant integrated control system, according to the actual situation, the use of multiple CPU control structure, to better solve the rapidity of the system The problem of security and security has led to the localization of the integrated control system for the whole plant. It has not only achieved centralized management, but also dispersed and strengthened local control capabilities. It has achieved good results in the course of operation.
Take the dry paper machine at Pingping Paper Mill in Shandong as an example:
1. System control structure: This system adopts PCS7 system control structure. From top to bottom, it is a three-tier network structure: process control level, automation level, and field control level. The field control level has 9 field operation stations and 7 display terminals to display and control the process parameters of the local area respectively. According to the requirements of the complete machine control system, the system is divided into nine parts:
1) Main drive control system 2) Temperature control system 3) Pressure control system 4) Tension control system 5) Humidity control 6) Paper break detection 7) Adhesive spray control 8) Auxiliary transmission control system 9) Air circuit control system 2. Three functional level field control levels of the system:
1) This class is composed of 9 SIEMENS S7 PLCs, 7 display terminals and several inverter controllers, intelligent process controllers, tension sensors, humidity sensors, pressure sensors, photoelectric sensors and transmitters.
2) It is powerful and easy to use. PLCs, intelligent process controllers, etc., according to the layout of the equipment site, adopt a distributed layout to respond to production process events in real time on the spot, which greatly reduces the cable wiring from the site to the control room, making the production process control localized and modularized. Improve the performance of the system, reduce the risk factor, and it is conducive to the expansion and maintenance of the system.
3) The on-site operation and display terminal (PWS) displays production data in real time with dynamic graphics (XY graphics), and field operators can operate field devices through the touch screen.
4) The intelligent process controller etc. completes the automatic control of parameters such as pressure and temperature, respectively.
5) PLC and intelligent process controllers and transmitters control the PLC through on-site control network, connect the center, and exchange various real-time information.
Automation control level (central control level):
1) This level consists of SIEMENS large PLCS7-414.
2) Use the PROFIBUS communication protocol to form an advanced L
First, the electrical drive transmission system In recent years, the general use of foreign power transmission control system, the transmission system speed accuracy, dynamic response and reliability have been greatly improved, especially the promotion of AC frequency control device, the production Manufacturers have obtained great benefits, which have caused fundamental changes in many problems that have plagued domestically-made analog control devices from manufacturers for a long time, and have improved production efficiency. At present, the drive system has moved from the initial analog settings to full digital network communications. The latter has higher resolution and more precise control. At the same time, as part of the centralized control system of the whole plant, it is easy to communicate with other relevant parts through the data network. For this reason, the market share of some controllers with weak communication functions or poor openness of communication protocols is gradually declining, and some well-known high-end controllers are increasingly being used. The company has long been engaged in the automation engineering project of the paper industry. Since the first 1760/300 paper machine all-digital electric drive system was put into operation in Guangning People Paper Mill in 1994, Siemens advanced technology has been used to successfully develop different controls. System, formed a more complete product line. In the production lines of paperboard and other thick paper grades, if the vehicle speed is below 150m/min, we usually use Siemens MDV type inverters, Siemens S7-200 PLCs, and USS data communication protocols. The biggest feature of this configuration is the simple structure, economical and practical. In the paper machine or tissue paper or specialty paper production line with a vehicle speed of 150m/min or more, we usually use Siemens 6SE70 engineering inverters, Siemens S7-200 or S7-300 PLCs, and USS data communication protocols. This configuration is characterized by a simple structure and high control accuracy. When larger machines or users have high requirements for the networking capacity and configuration level of the electric drive system, we use the Siemens 6SE70 inverter, Siemens 57-400 PLC representing the current advanced level, using PROFIBUS-DP. The data bus network is used for communication. The main features of this configuration are high communication speeds, up to 12MB/s. The system has large capacity and the field data bus can connect to 127 stations.
Second, the whole plant integrated control system With the rapid development of industrial automation process control theory and computer technology, people put forward higher requirements for the industrial automation process control system, the three major issues facing the system data between the various levels The exchange volume rapidly increases, the field bus technology in the system is integrated and improved, and the software is safe and reliable. PCS is a new generation of process control system developed in this situation. It is a process control system for the entire production process based on Siemens' TELEPER M series distribution system and S5, S7 series PLCs. The PCS7 control system introduced by Siemens uses SIMATIC PCS7 software and SIEMENS S7 series hardware to form a complete, unified factory automation system. It is a new generation of process control system based on the idea of ​​fully integrated automation.
1. Control structure and communication network: The whole plant integrated control system is generally divided into process control level, automation level and field level.
Process Control Level The process control level uses a high-performance PC that uses standard software and networks to implement process diagnostics, process monitoring, control, and plant-wide information management. With the standard display and operation window, the screens and diagrams of various production processes can be displayed. All operating parameters and equipment parameters are called for modification and adjustment. All data can be copied and archived at any time. The system is completely open.
The automation level automation level adopts the CPU with single processor or multiprocessor, and the communication between automation level and process control level is realized by SIMATIC NET INDUSTRIA ETHERNET industrial Ethernet. The network system can access 1024 sites at a rate of 10MB/S. Communication with the field level is implemented by the SIMATIC NET PROFIBUS-DP communication network. The speed can reach 12MB/S, and the system can connect 127 stations.
At the field level at the field level, there are mainly three types of standard system products connected to the field bus. On-site operation panel OP27, OP25, TP27 and so on. The operation panels OP27, OP25, TP27, etc. are suitable for distributed, device-related control and monitoring. Different drive and transmission groups can have standard graphic displays and the same operating procedures. AC frequency converters and other control devices. 6SE70, 6RA70 as the motor drive and control unit, with the same performance, a clear hardware structure, clear operation and fault diagnosis. Remote intelligent interface SIMMIC S7 ET200. The ET200MI/O series offers digital and analog I/O units of various voltage and protection levels that can be placed centrally or dispersedly in the field. Other sensors and actuators can be directly connected to this open bus structure.
The PROFIBUS fieldbus PROFIBUS is used for field control and detection of the data exchange of the acquisition unit. The PROFIBUS field bus is an open field bus based on the international standard EN50170. It adopts the token scheduling principle for data communication, mainly including the high-speed bus PROFIBUS-DP (H2) with the highest baud rate up to 12M and the intrinsically safe low speed for the process. Bus PROFIBUS PA (H1). The perfect combination of DP and PA makes the PROFIBUS fieldbus superior in structure and performance to other fieldbuses. PROFIBUS is suitable for both automatic system communication with on-site signal units and for direct connection of transmitters, actuators, actuators, and other field instruments and devices with interfaces for the acquisition and monitoring of on-site signals and for use with a pair of Twisted pair replaces the traditional large number of transmission cables. Significant savings in cable costs are achieved, which in turn saves construction commissioning and maintenance time and costs after the system is put into operation. It is worth noting that at present, in the paper machine electric drive system, it seems that foreign countries have used the PROFIBUS-DP field data bus network to communicate without exception. This will undoubtedly be the most widely used in the future because it is reliable. The site and real-time control network are relatively perfect in terms of both sex and safety, but due to factors such as price, the use of medium and small-sized paper machines is less.
2. Operating system and software SIMATIC fully integrated automation system can now provide a unified technical environment for all automation applications, mainly: unified data management, unified communication protocol, unified configuration and programming software. SIMATIC PCS uses WinCC as monitoring software of the upper computer. The operating system uses Windows NT4.0. The communication network adopts Industrial Ethernet and PROFIBUS field bus. Industrial Ethernet is used for data communication between system stations and PROFIBUS network is used for communication of I/O stations. SIMATIC PCS uses programming software and field device libraries that conform to IEC-1131-3 international standards, providing continuous control, sequence control and high-level programming languages. The field device library provides a large number of commonly used field device information and function blocks, which can greatly simplify the configuration work and shorten the project cycle. SIMATIC PCS7 has ODBC, OLE and other standard interfaces, and applies open networks such as Ethernet and PROFIBUS field bus, which has a strong openness. It can be easily connected to the upper computer management system and other manufacturers' control systems. On the server, the operating system uses Windows NT 4.0 control software using the SIMATIC WINCC control system. SIMATIC WINCC is an important part of SIMATIC Totally Integrated Automation. For us, we can connect the symbol table in the configuration process to the variables of WINCC, and can also directly reflect the control information of the controller in the WINCC system. . The features of the SIMATIC WINCC control system: In a relatively short period of time, SIMATIC WINCC has evolved into one of the most successful HMI/SCADA systems in the world. The Windows Control Center (Windows Control Center) is the first process monitoring system that uses 32-bit technology. Its preemptive multitasking features are suitable for rapid reaction to process events. The openness and extensibility of WINCC are its most prominent features, and openness is mainly reflected in software:
a. Integrated standard database interface, ODBC/SQL. When the manufacturer establishes the information data management system in the whole factory, the data of the production site can be connected to the whole plant information data management system through the database interface.
b. Provides a standard OPC, industrial ActiveX interface. Through the interface, other application programs can be integrated into the process screen and exchange relevant data with WINCC. The WINCC control system integrates the OPC interface for connecting with other controller drivers that conform to the OPC specification. Therefore, WINCC can theoretically All controllers are supported.
c. Provides standard API programming dates, program engineers can use other programming languages ​​to access WINCC through the API interface to exchange data. The basic function of WINCC:
Graphic system: Through the configuration, it can form a rich and dynamic parameter control screen.
Trend filing: Event and incident analysis and trends that occur during the production process can be recorded in WINCC.
Informational alarms: WINCC captures process information and local events, puts these contents in archives, and optionally extracts them when needed, or moves directly to the relevant process screen.
Production reports: WINCC provides a set of reporting systems that can easily produce black and white and color production reports;
Third, the company's application in the paper industry PCS system The company in recent years, Siemens PCS7 system developed on the basis of the whole plant integrated control system, according to the actual situation, the use of multiple CPU control structure, to better solve the rapidity of the system The problem of security and security has led to the localization of the integrated control system for the whole plant. It has not only achieved centralized management, but also dispersed and strengthened local control capabilities. It has achieved good results in the course of operation.
Take the dry paper machine at Pingping Paper Mill in Shandong as an example:
1. System control structure: This system adopts PCS7 system control structure. From top to bottom, it is a three-tier network structure: process control level, automation level, and field control level. The field control level has 9 field operation stations and 7 display terminals to display and control the process parameters of the local area respectively. According to the requirements of the complete machine control system, the system is divided into nine parts:
1) Main drive control system 2) Temperature control system 3) Pressure control system 4) Tension control system 5) Humidity control 6) Paper break detection 7) Adhesive spray control 8) Auxiliary transmission control system 9) Air circuit control system 2. Three functional level field control levels of the system:
1) This class is composed of 9 SIEMENS S7 PLCs, 7 display terminals and several inverter controllers, intelligent process controllers, tension sensors, humidity sensors, pressure sensors, photoelectric sensors and transmitters.
2) It is powerful and easy to use. PLCs, intelligent process controllers, etc., according to the layout of the equipment site, adopt a distributed layout to respond to production process events in real time on the spot, which greatly reduces the cable wiring from the site to the control room, making the production process control localized and modularized. Improve the performance of the system, reduce the risk factor, and it is conducive to the expansion and maintenance of the system.
3) The on-site operation and display terminal (PWS) displays production data in real time with dynamic graphics (XY graphics), and field operators can operate field devices through the touch screen.
4) The intelligent process controller etc. completes the automatic control of parameters such as pressure and temperature, respectively.
5) PLC and intelligent process controllers and transmitters control the PLC through on-site control network, connect the center, and exchange various real-time information.
Automation control level (central control level):
1) This level consists of SIEMENS large PLCS7-414.
2) Use the PROFIBUS communication protocol to form an advanced L
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