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附件1：外文资料翻译译文

基于西门子PCS7的热风炉控制系统的设计

漳龙张.重庆的技术和商业大学，重庆，400067，中国（zhoupei@https://www.sodocs.net/doc/fe11145754.html,）输变电设备及系统安全与新技术国家重点实验室

technologychongqing大学，重庆，中国

本文介绍的方法利用西门子过程控制系统PCS7 V6.0控制加热炉。描述了两者的配置控制系统软件和硬件，功能通过该系统，随着困难解决方案。加热炉控制系统的配置双CPU冗余。采用工业以太网，欧洲流行的PROFIBUS DP现场总线和分布式I / O减反射膜结构。它采用ET200M I/O站的冗余。带PROFIBUS-DP通信接口和节点具有双控制器的通信协议（CPU）。

一、介绍

在生产过程中的热轧带钢，要求对来料板坯温度比较高；一般来说，应当是1 350℃左右。的加热炉的加热程序的设备，如能满足连续可靠的要求生产只有在控制的温度和输出量有很好的协调。加热炉采用可移动的步进梁移动冷板坯的出口侧的输入时，炉侧；钢板坯是移动的，它将被加热的喷嘴喷射炉气联合焦炭炉。当板坯入炉炉体的末端，它首先会被加热到850℃左右在预热段，然后约1300℃在加热段；最后将进入热浸泡部分使板坯加热均匀滚动。上述控制过程通常通过不断的PID （比例，积分和差分）。S分别对各控制截面的顶部或侧壁分别收集实际温度在每节该炉和再采样值将被发送到PLC（可编程逻辑控制器）实现连续比例，积分和微分（PID控制）通过测量值之间的差异空气和煤气流量设定值；然后开度每段的喷枪将调整控制气体的流量，温度控制，然而，因为它不是关于气体的燃烧清楚，如果这采用的方法是，热利用效率介质的极低、能耗非常大。在这里，一种改进的双交叉振幅限制全自动燃烧控制进行了介绍和其基本原理是进行控制燃烧的上部和下部各节在正常工作时间；如有必要，温度将上部调整信号可被视为套双交叉限幅控制和在下部前温度检测值可用于炉状态监测。这一原则主从控制模式可以更好地协调在上燃烧和供热平衡段和下部的燃烧上、下段均匀；同时，它认为天然气的燃烧，起到了很好的作用节能。在这个项目中，PCS7 V6.0由西门子将用于实现上述控制

功能。

二、简要介绍了PCS7系统

PCS7过程控制系统是一种先进的定位系列可编程逻辑控制器和TELEPERM通过西门子结合最系列机器人系统先进的计算机软件和硬件技术，采用可更换的操作站，强关系过程控制站与大容量和冗余分布式I/O总线的过程控制系统现场总线技术。PCS7已被应用在越来越多的行业

控制区作为一种面向过程的软件开发平台。它提出了一种完全集成的自动化解决方案，可以提供所有种类的一个统一的自动化应用技术环境。以下项目包括它：统一的数据管理，通信，配置和编程软件。基于环境以上，各种技术可以集成在一个在相同的全球数据库系统整体界面与用户。工程师或技术人员可以配置和在同一平台上的各种应用程序。复杂的工程是通过使用一个简单的组态平台。PCS7使PLC 纳入DCS系统更容易，体现真正的特征的计算机自动控制。

三、简要介绍热风炉控制系统

在复杂的工业过程系统，我们总是遇到这样的问题：多个约束条件的多变量系统：强耦合的非线性系统：大；时间延迟；多目标控制；等等。自定义控件技术无法解决上述问题。但先进控制技术可以很好的解决上述问题。怎么用在工业过程中应用先进控制技术产生的实用性是一个迫切需要解决的问题工业自动化研究领域。根据计算机技术的奔腾，硬件技术，网络技术，先进控制技术的产业化技术是可以实现的。本文提出了有用的容易实现可靠的控制方式实现步进式加热炉自动控制系统，对的基础上，包括过程控制理论，DCS和PLC技术，通信，现场总线，在步进式加热的特点炉，采用电气、仪表控制设备与技术实用、可靠和指标先进。我们可以实现仪表控制系统利用DCS和PLC电气控制系统。控制加热炉系统分为加热炉区PLC控制系统，PLC控制系统和加热辊炉DCS控制系统。仪表控制器电气连接的操作员站服务器IEEE以太网，采用DCS和PLC技术，网络和现场总线技术相结合的过程控制系统和过程计算机，智能仪器，实现仪器的驱动系统在一个系统的电气控制。

四、热风炉控制系统的组成

1.控制系统配置

在本文中，基于步进式加热炉控制过程中，控制系统是一个复杂的传热和字符的过程中，有许多特点如干扰，强耦合，大纯滞后等我们讨论的基础上的专用控制装置的设计步进式加热炉在细节包括的特点，相关的软件和硬件信息实现的控制。PID控制是综合控制规律仪表控制系统，因为它的成熟，熟悉在技术员和操作工，效果好，广泛的应用计算机数据控制设备，特别是复杂的控制系统，实践证明它适应各种工业过程控制。加热炉的关键设备：装载机机，卸船机，行走系统，系列转换辊，燃烧和跟踪板控制系统。的蓄热式加热炉的控制系统采用双CPU冗余，冗余环工业以太网，Profibus DP总线和分布式I / O减反射膜结构，显示的详细配置图1。利用该系统，可以进行传输测量和加权函数，跟踪检测，加载和卸载板，我们可以燃烧和彼此间交换数据来控制过程在所有产品线的轨道板和管理过程。加热炉的生产工艺如高目标产量，低消耗和污染，自动操作模式的实现。

2.硬件配置

如图1所示，在整个DCS控制系统加热炉有两个显著的特点：的第一个是基础自动化级采用冗余环结构，从而提高可靠性和系统的稳定性；第二，信息层采用标准的以太网结构使整个系统的大容量数据通信能力和方便的可扩展性。针对上述特点以下模式通过硬件的选择：

（1）选择过程控制器中cpu414-h由西门子S7-400系列的核心的加热炉控制系统共同构成了冗余系统的控制站与分布I/O ET200M；

（2）监控系统采用研华工业控制计算机和菲利普22“纯平彩色显示器工程师站和操作员站。操作该系统的站在形式的在线工作协调和他们是全透明、全容错，实现彼此的更换。这种模式使得本系统有利于可靠操作，数据分布合理，操作快捷速度，人机界面友好，使用方便等。

（3）三层网络体系结构的组成

标准的以太网（IEEE以太网802。×），西门子SIMATIC NET工业以太网和现场总线过程现场总线（EN50170）保证了高可靠性，无堵塞和高速度（10M ~ 100米）的数据尤其是在系统，通信，它采用双环容错光纤网络，更有效地保证现场抗干扰能力和的网络的数据传输可靠性高系统。

它采用Windows2000作为微软（英文）操作系统软件和PCS7工具集V6.3由西门子将组态在工程师站作为软件控制计算机和下位监控上位计算机。此外，它是具有工业以太网s7-redconnect

通信软件和冗余系统软件。操作员站设置上的位置计算机监控软件pcs7wincc，这是通过西门子和微软合作开发。此外，可以通过共同实现的功能监控软件，pcs7wincc可以加入各种控制和C脚本程序，VB程序实现更复杂的功能。B.功能的控制系统的实现为了使操作人员掌握操作在计算机控制系统的总体状况时间，准确的控制系统的稳定运行操作方便，本系统建立了系统工艺流程装配图，汽包工艺流程图，加热段和一个过程的流程图热节。

随着工业控制参数的画面，生动地反映该系统的生产过程的状态和提供对检测点的测量值的显示系统。此外，该系统还建立了环显示图片和集中控制各回路可在环图实现。单击“详细信息包括设定值，过程值，输出值，自动和手动开关，上下限报警过程变量对PID控制面板。模拟数量显示值和累积流量的模拟在形式的集中量。温度计显示系统的主要参数。解释根据控制系统功能装载自动运行程序流程。图2。

对加热炉的燃料混合气高炉、焦炉，热值不稳定，在以上的温度控制难度。在这项目，加热炉的控制方法温度和煤气流量和空气流量级联双交叉限幅方法控制设定值稳定在10℃±。具体思路如下：以温度该加热炉的主回路，煤气流和空气流作为辅助回路，输出的加热炉的温度控制回路将转化为煤气流的初始设定值空气流量。在煤气流量的控制将在高和低的选择根据空气流量将受到限幅根据高、低限的煤气流量等确定煤气流回路最终设定值。的在空气流量控制将受到高和低根据煤气流量的选择，将受到对限幅根据较高和较低的空气流动的限制，确定最终的设定值空气流动回路。。对加热温度的控制原理炉，煤气流量和空气流量串级双交叉限幅图3所示：

五、应用中的体会

目前现有的高速发展科学和技术，以提高自动化水平和减少劳动工人的强度，应用计算机和过程控制和监测的一些庞大而复杂的过程控制工业系统软件已经发展的一个必然趋势。在编程的过程中，强PCS7控制流程图的作用（CFC）使程序员可以方便、快速。唯一的不足是有模块的参数太多的选项，在的情况下，一个恰到好处的PID模块，可以满足需要控制可以开发，规划将更便捷、完善的。WinCC喇叭进行语音报警功能配置更容易和更快。这仅仅是必要的记录*。wav文件的语音报警和连接在喇叭功能的语音报警和报警事件。在WinCC和Step7股票组合的上位机

监控和一些职责收集现场数据合理，发挥各自的不同的设施优势，而应该是计算机的设计特点和前景控制系统。在系统调试过程和放投入运行，硬件设备的诊断功能PCS7是强大的，他们可以帮助现场调试工程师解决问题快。控制面板的信息内容全面。在PID参数的整定过程，可以观察在PV值和OP值和现场操作者改变可以操作的循环相关参数，节省开发人员的时间的量大。

参考文献：

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2.西门子公司配置硬件和通信。连接PCS7 V6.0手册，2002

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4.荷兰足球的发展和计算机在线控制性能在一个三区加热炉[J]，钢铁工程师1982,59（1），44-52.

5.弗莱德shenvar内陆。在步进梁式加热炉监控80热连轧机[J]，钢铁工程师，1987,64（3），23日至24日]

6.图瓦E，瓦斯奎斯f.real-time现场总线通信中的应用PROFIBUS网络。

7.B.波特，A.琼斯遗传调谐数字PID控制器。电子信件，1992，vol.28:843-844

8.j.l.tong，j.p鲍勃。数字PID控制器的设计模型工业电子，控制，仪器仪表和自动化，1992国际会议的程序，1992，第3卷：1157-1162

9.Y. Huang，s.yasunbu。一般的PID实用设计方法从传统的PID控制。第九届IEEE 国际会议上，2000，vol.2:969-972

10.保罗哈蒙。等。专家系统工具和应用程序，约翰威利和sons.inc，世界图书出版公司，1990

11.等k J，低t.pid控制器：理论，设计与调整。纽约：ISA，1995

12.Mann G K I G，轮毂，高斯林R G.分析直接作用模糊PID控制器结构。IEEE交易对系统，人，与控制，1999，29b：371-388

13.西门子ag.simatic微机用户手册[Z]。2000。

14.过程控制系统PCS7图书馆siemensag，2003。

15.PCS7过程contro1system操作员站。siemensag，2003

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17.软件冗余或SIMATIC S7-300和S7-400。siemensag，2003

18.波尔图理工学院，报告hurray-tr-98031998,4a特m L。现场总线控制系统。ISA. 附件2：外文原文（复印件）

The Reheating Furnace Control System Design Based On

SIEMENS PCS7

1Pei Zhou, 2Wei He, 2Zhanglong Zhang

1. Chongqing Techology and Business University, Chongqing, 400067,

China( zhoupei@https://www.sodocs.net/doc/fe11145754.html,)

2. State Key Laboratory of Power Transmission Equipment & System Security

and New TechnologyChongqing University,Chongqing,China

Abstract—This paper introduces that the method of using Siemens process control system PCS7 V6.0 to control the reheating furnace. It describes the configuration of both software and hardware of control system, function accomplished by the system and the difficulties along with solution. The reheating furnace control system is configurated with double CPU redundancy. It adopts industrial Ethernet , Europe popular PROFIBUS DP field bus and distributed I/O ET200M structure. It adopts ET200M I/O station redundancy communication interface and node with PROFIBUS DP protocol to communicate with double controller(CPU).

I INTRODUCTION

In the production process of hot mill strip, the requirement on the temperature of incoming slab billet is relatively high; generally speaking, it shall be 1 350℃ or so. The reheating furnace, as the equipment for reheating procedure, can meet the requirements on continuous reliable production only when the control over the temperature and the output quantity are well coordinated. The reheating furnace adopts moveable walking beam to move the cold slab billet to the exit side from the furnace enter side; whenthe slab billet is moving, it will be heated by the combination gas of burner nozzle injection furnace and coke furnace. When the slab billet enters the furnace from the tail end of the furnace body, firstly it will be heated to 850℃ or so in the preheating section and then to about 1300℃ in the reheating section; finally it will enter the heat soak section to make

the slab billet be heated evenly for rolling.

The above-mentioned control process is commonly accomplished by DCS (digital control system) of the instruments and the routine control strategy is to realize it through continuous PID (proportion, integral and differential). Several thermocouples are arranged respectively on the top or side wall of each control section to respectively gather the actual temperature in each section of the furnace and then the sampling values will be sent to PLC (programmable logic controller) so as to realize the continuous proportion, integral and differential control (PID control) via the difference between the measured values and the set value of gas and air flow; then the opening degree of the burner gun in each section will be adjusted to control the flow of gas so as to control the temperature, however, since it is not clear about the combustion of the gas, if this method is adopted, the utilization efficiency of heat medium is very low and the energy consumption is very large.

Here one kind of improved dual-crossing amplitude limiting full-auto combustion control will be introduced and its basic principle is to carry out the control over combustion at the upper part and lower part of each section in normal working time; if necessary, the temperature adjustment signal of the upper part can be regarded as the set control of the dual-crossing amplitude limiting loop and the former temperature detection value of the lower part can be used for monitoring the furnace condition. This principal and subordinate control mode can better coordinate the balance of combustion and heat supply between the upper section and lower section to make the combustion of the upper and lower section even; at the same time, it considers the combustion of gas, playing a good role in energy-saving. In this project, PCS7 V6.0 developed by Siemens will be used to realize the above-mentioned control function.

II BRIEF INTRODUCTION TO PCS7 SYSTEM

PCS7 is an advanced process control system orientated to all process control applications based on S5, S6 and S7 series programmable logic controller and TELEPERM series cyborg system by Siemens combining with the most advanced computer software and hardware technology, which adopts replaceable operation station,

strong relational distributed database support platform, highly-reliable process control station with large capacity redundancy and distributed I/O control sub-system of PROFIBUS process field bus technology. PCS7 has been applied in more and more industry control areas as a kind of procedure-oriented software development platform. It has advanced a sort of completely-integrated automatic solution and can provide Authorized licensed use limited to: UNIVERSIDAD ROSARIO. Downloaded on May 18,2010 at 20:00:01 UTC from IEEE Xplore. Restrictions apply. all kinds of automation applications with a uniform technical circumstance. The following items are included in it: unified data management, communication, configuration and programming software. Based on the circumstance above, all kinds of technologies can be integrated in a overall system with a global database on the same interface with users. Engineers or technicians can configurate and program in the same platform for all kinds of applications. The complicated engineering becomes simpler by using a configuration platform. The PCS7 makes the PLC incorporated in the DCS system more easily, embodying the genuine characteristics of the computerized automatic control.

III BRIEF INTRODUCTION TO CONTROL SYSTEM OF REHEATING

FURNACE

In the complex industrial process system，we always meet such problems :multiple constraint conditions: multi variable system: strong coupling; nonlinear system: large time delay; multi control target; and so on. Custom control technique can not solve above problems. But advanced control technique can deal well with those problems. How to use advanced control technique in industrial process and generate practical utility is a urgent problem in the industrial automate research realm. According as the galloping of computer technique，hardware technique, network technique，industrialization of advanced control technique is realizable. This article put forward the useful and easily-realizable and reliable control way to realize the automatic control system of walking reheating furnace，on the basis of including the theory of process control，technology of DCS and PLC，communication，field bus，and in term of the characteristic of the walking reheating furnace, also by using the electrical and instrument control

equipment with the practical and reliable technology and advanced quota. We can realize the instrument control system and electric control system by using DCS and PLC. The control system of reheating furnace is divided into furnace area PLC control system，roll PLC control system and reheating furnace DCS control system. The controller of instrument and electric connect to the server of the operater station by the IEEE Ethernet，by using DCS and PLC，the technology of network and field bus technology to combine the process control system and process computer ，intelligent instruments，drive system to realize the instrument and electric control in one system.

IV COMPOSITION OF CONTROL SYSTEM OF

REHEATING FURNACE

A. Configuration Of Control System

In this article，based on walking reheating furnace controlling process，control system is a complicated transmit heat and character process，has many peculiarity such as disturb，strong coupling，great pure lag etc. We discuss the design of dedicated control equipment of basis walking reheating furnace in detai1 including characteristic，correlative soft and hardware information and realization of control. PID control is are comprehensive controlling rule in meter controlling system，because of its mature, familiarity in technician and operator, well effect，broad appliance in computer DDC data controlling equipment and especially complicated controlling system，practice proved it adapt various industrial controlling process. The key equipment of the reheating furnace: loader machine，unloader machine，walking system，series transfer roll，control system of burning and tracking of slab. The whole control system of the reheating furnace is configurated with double CPU redundancy, redundancy ring industrial Ethernet, PROFIBUS DP bus and distributed I/O ET200M structure, with the detailed configuration shown inFig 1.

Make use of the system，we can carry out the function of transferring measuring and weighting ，detecting，loading and unloading tracking the slab，we can control process of burning and exchange data each other to track slab and manage the process over all of product line.Goals of reheating furnace’s producing process such as high yield，low

consuming and pollution，automatic operating mode are achieved.

A.1 Hardware configuration

Shown as Fig. 1, the whole DCS control system of the reheating furnace has two remarkable characteristics: the first one is that the basic automation level adopts redundancy ring structure so as to improve the reliability and stability of the system; the second one is that the information level adopts standard Ethernet structure to make the whole system large capacity data communication ability and convenient extensibility. Aiming at the above-mentioned characteristics the following modes will be adopted to select the hardware:

(1)Selecting the process controller CPU414-H in S7-400 series made by Siemens as the core of the whole control system of the reheating furnace to jointly form the redundancy system control station together with distributed I/O ET200M;

(2)The monitoring system adopts YANHUA industrial control computer and Philip 22” pure-flat color display as the engineer station and operator station. The operation stations of the system are working in form of online and coordination and they are full-transparent and full fault-tolerant, realizing the replacement with each other. This mode makes this system advantageous in reliable operation, reasonable data distribution, quick operation speed, friendly man-machine interface and convenient use and so on.

(3)The three-level network system structure composing of standard Ethernet (IEEE Ethernet 802.X), SIEMENS SIMATIC NET industrial Ethernet network and PROFIBUS Authorized licensed use limited to: UNIVERSIDAD ROSARIO. Downloaded on May 18,2010 at 20:00:01 UTC from IEEE Xplore. Restrictions apply. process field bus (EN50170) guarantees the high reliability, no blockage and high speed (10M~100M) of the data communication of the system, especially, it adopts double-ring fault-tolerant optical fiber network, more effectively guarantee the field anti-interference ability and high reliability of the data transmission of the network system.

A.2 Software configuration

It adopts Microsoft WINDOWS2000 (English) as the operating system software and PCS7 TOOL SET V6.3 made by Siemens will be configurated on engineer station as the

software to control the lower-position computer and monitor the upper-position computer. In addition, it is provided with Industry Ethernet S7-REDCONNECT communication software and redundancy H system software.

The operator station is provided with upper-position computer monitoring software PCS7WinCC, which is cooperatively developed by Siemens and Microsoft. Besides the functions that can be realized by the common monitoring software, PCS7WinCC can be added with various controls and C script program, VB program to accomplish more complicated functions.

B. Functions accomplished by control system

In order to make the operators master the operation condition of the whole control system of the computer in time, accurately control the stable operation of the system and convenient in operation, this system establishes system process flow assembly drawing, steam drum process flow chart, process flow chart of reheating section and the one of heat section. The process flow chart is the process flow display picture with industrial control parameters, vividly reflecting the production process state of this system and providing the display of the measured values of the detection points of the system. In addition, this system also establishes the loop display picture and the centralized control over each loop can be realized in the loop picture. Click the detailed information including set value, process value, output value, manual and auto switch and upper and lower limit alarm of the process variables on the PID control panel. The analog quantity displays value and flow accumulation of the analog quantity in form of centralization. The thermometer displays the main temperature parameters of the system. Functions of control system is explained according to program flow of loading automatic running. Fig.2

C. Difficulties and realization

The fuel for the reheating furnace is the mixed gas of blast furnace and coke oven, with unstable heat value, resulting in difficulty in control over the temperature. In this project, the control method of reheating the furnace Authorized licensed use limited to:

UNIVERSIDAD ROSARIO. Downloaded on May 18,2010 at 20:00:01 UTC from IEEE Xplore. Restrictions apply. temperature and coal gas flow as well as the air flow cascade dual-crossing amplitude limiting is adopted to stabilize the control set value within ±10℃. The detailed idea is as follows: taking the temperature of the reheating furnace as the main loop, the coal gas flow and air flow as the auxiliary loop, the output of the temperature loop of the reheating furnace will be transformed into the initial set value of the coal gas flow and air flow. The control over the coal gas flow will be subject to high and low selection according to the air flow and will be subject to the amplitude limiting according to the higher and lower limit of the coal gas flow so as to determine the final set value of the coal gas flow loop. The control over air flow will be subject to the high and low selection according to the coal gas flow and will be subject to the amplitude limiting according to the higher and lower limit of the air flow so as to determine the final set value of the air flow loop. 。The control principle of the temperature of reheating furnace, coal gas flow and air flow cascade dual-crossing amplitude limiting is shown in Fig. 3: Where, μ is the air surplus coefficient, β is the complementary coefficient of the flow measurement range, the ratio of air to gas=μ×β and K1, K2, K3 and K4 are the difference coefficient.

V EXPERIENCE IN APPLICATION

Nowadays there existing high-speed developments in science and technology, to enhance automation level and reduce laboring intensity of the workers, the applications of computers and the process controls and monitors to some huge and complex industrial systems with process control software have come to an inexorable tendency. During the process of programming, the strong function of control flow chart of PCS7 (CFC) enables the programmers be convenient and rapid. The only shortage is that there are too many options of the module parameters, in case that one just right PID block that can satisfy the need of control can be developed, the programming will be more convenient and perfect. HORN function of WinCC makes the voice alarm configuration easier and quicker. It is only necessary to record the *.wav file of voice for alarm and connect the voice alarm and alarm event in HORN function. The combination of the WinCC and

STEP7 shares some duties of the upper-position machine to monitor and collect data on the spot reasonably, exerts respective advantages of different facilities, and is supposed to be a characteristic and promising design of the computerized control system.In the process of system commissioning and being put into operation, the diagnostic functions of the hardware of PCS7 are strong and they can help the onsite commissioning engineer settle the problems quickly. The contents of information of PID panel are all-round. In the process of setting PID parameters, it can observe the change in PV value and OP value and the onsite operator can operate the related parameters of the loop conveniently, saving the a large quantity of time of the developers.

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