加熱爐計(jì)算機(jī)控制系統(tǒng)的設(shè)計(jì)與實(shí)現(xiàn)

工業(yè)大學(xué)碩士學(xué)位論文進(jìn)行了大量文獻(xiàn)檢索工作，對(duì)前人的研究工作進(jìn)行總結(jié)和分析。介紹了加熱爐的工藝流程、結(jié)構(gòu)和性能參數(shù)。第三章介紹了加熱爐基礎(chǔ)自動(dòng)化系統(tǒng)，包括燃燒系統(tǒng)和順控系統(tǒng)，并對(duì)交叉限幅串級(jí)溫度控制系統(tǒng)進(jìn)行了改進(jìn)，提出了FUZZY-PID溫度控制系統(tǒng)，開(kāi)發(fā)了具有通用性的步進(jìn)梁速度曲線(xiàn)控制模塊，并對(duì)速度曲線(xiàn)進(jìn)行了優(yōu)化，取得了良好的使用效果第四章建立爐鋼坯的傳熱過(guò)程的機(jī)理數(shù)學(xué)模型，并從工程角度進(jìn)行簡(jiǎn)化，給出了一維的導(dǎo)熱模型和總括熱吸收率算法。以此為理論基礎(chǔ)開(kāi)發(fā)的鋼溫預(yù)報(bào)模型程序，預(yù)測(cè)的鋼溫和實(shí)測(cè)數(shù)據(jù)基本吻合，數(shù)據(jù)令人滿(mǎn)意。同時(shí)結(jié)合智能控制理論，提出了基于爐區(qū)分段的BP神經(jīng)網(wǎng)絡(luò)鋼坯溫度預(yù)報(bào)模型，并進(jìn)行了仿真研究。第六章闡述了西門(mén)子PLC控制系統(tǒng)的特點(diǎn)與其在大型軋鋼步進(jìn)梁式加熱爐LEVEL1系統(tǒng)上的應(yīng)用，并給出了基于平臺(tái)的C#軟件和ORACLE數(shù)據(jù)庫(kù)平臺(tái)開(kāi)發(fā)的加熱爐二級(jí)控制系統(tǒng)的實(shí)現(xiàn)。圖2.1加熱爐示意圖[39]建立了用于鋼坯溫度預(yù)測(cè)的三維導(dǎo)熱數(shù)學(xué)模型，其控制方程如式(4.10)[40]：式中，λ為導(dǎo)熱系數(shù)，單位是W/(m2·℃)；Cp為比熱，單位是J/(m3·℃)；t為板坯溫度，單位是℃。三維導(dǎo)熱數(shù)學(xué)模型總括熱吸收率法[41,42]是計(jì)算爐膛傳熱過(guò)程的一種簡(jiǎn)化方法。為了解決加熱爐復(fù)雜的熱交換和復(fù)雜的機(jī)理模型，大幅度降低了描述邊界條件的復(fù)雜程度。它將被加熱物體的表面輻射熱流密度描述為爐氣（或熱電偶）溫度與被加熱物體表面溫度的黑體輻射之差乘以總括熱吸收率的形式。這種方法計(jì)算量小且精度能夠滿(mǎn)足生產(chǎn)要求，其中計(jì)算總括熱吸收率的準(zhǔn)確性是決定軟測(cè)量模型成敗的關(guān)鍵。其邊界條件可由下式給出[43]：式中：qs：表面輻射熱流密度，W/m2；σ：Steafan-Boltzman常數(shù)；￠：爐膛總括熱吸收率；Tf：板坯所在處的爐溫，K；Ts：板坯的表面溫度，K；也就是說(shuō)，板坯的外部傳熱除了受到爐氣溫度的影響外，主要取決于總括熱吸收率，而且在爐子的各種操作狀態(tài)下，總括熱吸收率在爐子的給定位置上基本保持不變。序號(hào)圖/表號(hào)名稱(chēng)頁(yè)碼備注1圖2.1加熱爐示意圖92圖3.1雙交叉限幅溫度控制系統(tǒng)123圖3.2基本模糊控制器的結(jié)構(gòu)144圖3.3典型步進(jìn)梁速度曲線(xiàn)175圖3.4優(yōu)化的步進(jìn)梁速度曲線(xiàn)186圖4.1微元網(wǎng)格體熱量傳遞示意圖237圖4.2BP神經(jīng)網(wǎng)絡(luò)結(jié)構(gòu)278圖4.3（a）圖4.3（b）未分段BP網(wǎng)絡(luò)上表面溫度曲線(xiàn)未分段BP網(wǎng)絡(luò)中心溫度曲線(xiàn)289圖4.4（a）圖4.4（b）分段BP網(wǎng)絡(luò)上表面溫度曲線(xiàn)分段BP網(wǎng)絡(luò)中心溫度曲線(xiàn)2910圖5.1LEVEL1級(jí)網(wǎng)絡(luò)結(jié)構(gòu)圖3111圖5.2LEVEL2級(jí)網(wǎng)絡(luò)結(jié)構(gòu)圖3312圖5.33513圖5.43614圖5.5SOCKET通訊結(jié)構(gòu)圖4015圖6.1PCS7系統(tǒng)典型結(jié)構(gòu)圖4316圖6.2SIMATICMANAGER主界面4317圖6.3SIMATICMANAGER硬件組態(tài)界面4418圖6.4SIMATICMANAGER網(wǎng)絡(luò)組態(tài)界面4419圖6.5順控程序結(jié)構(gòu)圖4520圖6.6儀控程序結(jié)構(gòu)圖4821圖6.74922圖6.85023圖6.9WINCC軟件開(kāi)發(fā)主畫(huà)面5224圖6.10燃控系統(tǒng)主監(jiān)控畫(huà)面5325圖6.11順控系統(tǒng)主監(jiān)控畫(huà)面5326圖6.12步進(jìn)梁參數(shù)設(shè)置畫(huà)面5427圖6.13軋制計(jì)劃管理畫(huà)面5628圖6.14入爐核對(duì)畫(huà)面5729圖6.15爐跟蹤畫(huà)面5830圖6.16模型跟蹤數(shù)據(jù)表畫(huà)面5831圖6.17模型數(shù)據(jù)柱狀圖59序號(hào)圖/表號(hào)名稱(chēng)頁(yè)碼備注1表2.1加熱爐燒嘴型式與能力配置102表3.1模糊控制查詢(xún)表153表3.2194表4.1245表5.1LEVEL2級(jí)網(wǎng)絡(luò)通訊方式326表5.2417表6.1488表6.249序號(hào)中心溫度（℃）上表面（℃）下表面（℃）爐氣溫度（℃）143.069.740.5306.3244.674.442.1552.1350.387.247.5653.4456.997.352.6653.4564.7105.157.6652.3672.5112.262.7657.5780.6120.767.7639.3888.8124.372.8640.0997.4130.177.9680.010100.1135.283.0712.81198.6140.788.5704.812107.1146.293.9709.413121.2151.699.8724.114134.1158.3101.0777.815143.1166.1103.3780.516151.3172.8101.4772.517160.3177.9101.0768.718168.5182.6106.5792.119177.1189.6114.7799.820185.3196.2123.4806.721193.9203.3132.8806.022202.1208.7142.6813.723211.5215.0149.7821.924219.6222.4155.9824.625229.0229.0161.8822.226237.5234.8167.7825.827246.9240.7174.4835.928255.4248.0181.1839.729265.1255.8188.1833.230273.9262.4194.8833.931283.2268.9201.8843.332292.4275.9208.5853.833301.7284.4215.2856.634311.3291.7222.6860.135320.8299.0230.0882.136330.3307.4237.1928.737339.9320.1244.5929.138349.4329.6251.9920.439360.0337.6258.9910.140369.8345.6265.1949.941379.6358.5271.7962.742389.8370.6279.8959.943400.0381.6288.7959.944410.8391.7297.2963.145421.3401.1305.7967.946431.8410.9314.2973.647442.2420.6322.6976.848452.7430.0330.7980.449462.7439.3339.1985.350472.4448.6347.1986.551482.0458.3355.5989.052491.7466.8363.1989.053501.3475.7371.0987.754510.2484.3379.0993.855519.5493.2386.9995.056528.0501.3394.9997.557536.9510.3402.8996.358545.4518.4410.71000.359553.5526.5418.61004.060561.7534.7426.5997.961569.5542.1434.01005.262577.3549.5441.51011.763585.1558.0449.01017.064592.5566.5456.51017.065599.5575.4463.91007.766606.6582.9471.01015.067613.7590.7478.91022.368620.4598.5485.91026.069627.1607.7493.81026.070633.8615.6502.31029.371640.5623.4511.61028.972646.9630.8520.51054.373653.3640.2529.81056.474659.2649.5538.41061.375665.6657.8547.31058.976671.6665.3555.91058.577677.6672.8564.01070.878683.3681.1572.31073.779689.0689.7579.71074.280694.2697.3587.21072.181699.9704.1594.21077.982705.2710.9600.61104.583710.1718.8607.31110.084715.0726.4614.01111.385719.6734.0621.91114.686724.2740.5629.81111.787729.5747.8637.21112.588733.7754.3644.41111.789737.5761.2651.11115.190741.7767.3656.81113.091746.7773.8662.41116.892752.4780.4668.11115.193758.9786.9673.81111.494765.4793.1679.41116.495772.3799.3685.11116.496780.0804.7690.81127.897787.7811.7696.51128.798795.1817.9701.81135.899802.8824.9707.11143.0100810.6832.3713.21145.2101818.3839.3719.31149.4102826.9847.2725.01145.2103835.1854.6730.71147.4104843.3862.1735.71149.5105851.9869.5740.71155.9106859.7877.0745.71162.7107868.8885.3751.11156.3108878.2892.8755.31149.6109887.7899.2761.51149.2110897.2903.9767.61143.2111906.7909.1774.21141.2112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