PCS-C process control system experimental equipment

Ⅰ、Equipment Overview

This process control system experimental equipment is divided into four parts: upper control layer system, experimental object layer, detection sensor, transmission, execution equipment, and upper control software. System features: The whole system is placed on a movable test bench, which is compact and the test device occupies a small area.

1. Upper control layer system:

①, intelligent instrument control module; ②, DDC control system. ③、PLC control system;

2、Experimental object layer system:

Ⅱ、Experimental items of  this process control system experimental equipment

1. Single-capacity water tank characteristic experiment;

2. Double-capacity water tank characteristic experiment;

3. Electric valve flow characteristic experiment;

4. Single-loop control experiment;

5. Electric regulating valve branch single-capacity liquid level control experiment;

6. Upper water tank double-capacity liquid level control experiment;

7. Electric regulating valve branch flow control experiment;

8. Temperature control experiment;

9. Flow control experiment;

10. Pressure control experiment;

11. Upper water tank double-capacity cascade control experiment;

12. Cascade control system of lower water tank liquid level and electric regulating valve flow;

13. Frequency converter branch single-capacity liquid level control experiment;

14. Three-capacity liquid level control experiment;

15. Frequency converter branch flow control experiment

16. Boiler liner temperature control experiment

Ⅲ、Technical indicators

(1) Power supply

Three-phase AC power supply: 380VAC±10%, 50Hz±5%, 16A, the system must be well grounded.

(2) The input and output signals of the system instruments comply with IEC standards.

Transmitter current source signal: 4-20mADC.

Instrument sampling: 1-5V (250Ω) / 0.2-1V (50Ω).

(3) The system provides a DC linear regulated power supply (24VDC/1A).

(4) Host computer configuration software;

The experimental system is developed using MCGS (Monitor and Control Generated System) all-Chinese industrial control configuration software.

(5) Equipment size: 1620×700×1900mm

IV、System composition and description

(I) Control object: It consists of an aluminum profile installation frame, an external stainless steel water storage tank, a plexiglass three-tank series water tank, a jacketed stainless steel atmospheric pressure boiler container, stainless steel pipelines, objects, etc.

1. Standard aluminum profile installation frame: European standard 40*40 aluminum profile plexiglass three-tank series water tank, a jacketed stainless steel atmospheric pressure boiler container. The stainless steel tabletop can be installed on the bottom plate to install the detection sensor actuator, pipelines, etc.

2. Experimental table: The control object is placed on the experimental table;

3. External stainless steel water tank and water pump, the entire frame is installed on movable casters as a whole. The water pump outlet is equipped with a quick-connect connector, and the water pump can be connected to the control object pipeline system for experiment.

4. Organic glass three-tank series water tank:

① Organic glass two-tank series water tank: Made of imported organic glass, upper, middle and lower water tanks (length 200×width 200×height 400mm), middle water tank (length 200×width 200×height 400mm), lower water tank (length 200×width 200×height 400mm), upper, middle and lower water tanks are installed in series, each water tank is equipped with overflow pipe, lower drain pipe and valve, pressure level sensor interface

5. Stainless steel normal pressure heating boiler container with jacket:

Inner tank Φ100×500 (through dynamic heated water), with single-phase 1.8KW electric heating tube, jacket Φ150×400 (with insulation cotton), heating boiler container is made into a fully enclosed type (not only can be used for temperature experiment, but also for pressure experiment), Pt100 temperature sensor is installed in the inner tank.

System power: power-adjustable three-phase stainless steel circulating water pump: can be composed of a stainless steel pump + electric regulating valve + electromagnetic flowmeter power flow regulation system, or a stainless steel pump + frequency converter + electromagnetic flowmeter power flow regulation system.

The temperature control and voltage regulating module + radiator form the boiler heating power system: fully isolated single-phase AC thyristor voltage regulating module; control signal: 4-20mADC. Heating ring power: 1800W, 220VAC.

(II) Detection sensors and actuators:

1. Flow sensor: electromagnetic flowmeter + flow transmitter. Equipped with Cao Xin Instrument electromagnetic flow transmitter, rated flow 0.2-1.2m3/h, measurement accuracy ±1.0%, 4-20mA standard signal output;

2. Liquid level sensor: three diffused silicon liquid level sensors, respectively used to detect the liquid level of the upper, middle and lower water tanks. In addition, a diffused silicon pressure sensor is added to the heating boiler container to detect the container pressure during the constant pressure water supply experiment. Mainly equipped with Cao Xin instrument level transmitter, 4-20mA standard signal output, 0.5 level measurement accuracy, wide application range, high precision, high temperature qualitative, high reliability, exquisite structure, easy installation, small zero drift

3. Temperature sensor: 2 Pt100 thermal resistor sensors, 2 Pt100 thermal resistor temperature transmitters. Used to detect the inner tank temperature of stainless steel atmospheric pressure heating boiler with jacket.

4. Frequency converter: One Mitsubishi FR-D720S-0.4K-CH frequency converter. Used to adjust the water supply pressure and flow of the frequency conversion power branch.

5. Electric control valve: Configure one Wanxun electric control valve, rated flow of 0.28-0.30 cubic meters per hour, 4-20mA signal input. Used to adjust the water supply pressure and flow of the electric control valve power branch.

Ⅴ、PCS-C upper process control system

1. Structure of GLGK-2 upper control operation table:

GLGK-2 upper control operation/experimental table is manufactured and installed as a whole with the experimental object device. The upper control operation/experimental table is installed above the aluminum alloy experimental table.

2. PCS-C upper control operation experimental panel

Upper control operation experimental panel: steel spray-coated structure.

High-voltage control panel: equipped with leakage protection air switch and current leakage protector, fully considering personal safety protection; equipped with key-powered power start control circuit and multiple groups of fuses, and each group of high-voltage output has fuses for protection and control, ensuring equipment safety and convenient operation and control; equipped with phase-split voltmeter and indicator light, intuitive, high-voltage information at a glance; equipped with inverter and its control interface panel, convenient for inverter familiarization, operation and application.

Controller panel: frequency conversion controller panel, intelligent instrument control panel, data acquisition module control panel.

Signal interface panel: The instrument signals and electrical signals in the control object are transferred to the signal wiring board, providing AI, AO, DO and other sensor detection and actuator control signal interfaces, so that students can connect them to form different control systems. The experimenter uses safe plug-in wires to make different wiring between the experimental board and the signal board to complete various process control experiments.

VI、Introduction to the functions of GLGK-2 upper process control system:

1. S7-200PLC control system

With the development of science and technology, PLC, even Micro PLC, can be competent for a variety of control tasks. The PLC control system host provided by this product uses Siemens' S7200 series (CPU224XP), which mainly demonstrates the perfect performance of small (Micro) PLC in meeting small-scale control tasks, and provides more and stronger experimental platforms for cultivating engineering talents. Users can choose small PLCs from other manufacturers according to the actual situation of their school.

2. Intelligent instrument control system

The core of the instrument control system is various instruments with communication functions, mainly including AI708 and AI818 intelligent regulators. Various algorithms are integrated in the instruments. Various parameters of the instrument control algorithm are adjusted according to the on-site conditions to achieve control effects. At the same time, the instrument with communication function communicates with the software platform of the host computer. Various parameters and process values of the instrument enter the database of the software platform (generally industrial control configuration software), and the configuration process screen and operation interface can be used to easily adjust parameters on the host computer and record and analyze process values.

3. DDC control system

DDC control systems generally have two forms. One is in the form of an external data acquisition module, the core of which is a data acquisition module with RS485 communication and computer algorithm software; the other is a data acquisition board using an industrial computer and an ISA or PCI slot. The external data acquisition module is easy to install, and there is no signal attenuation when the data is sent to the computer by communication when it is installed on site. Therefore, this product adopts the first application method. It mainly includes Beijing Jizhida 8017 and 8024 analog input and output modules.

The data acquisition module is directly installed on the console, and the powerful algorithm configuration function in the industrial control software MCGS is used to conveniently build a DDC control system with a human-machine interface. In the DDC system, open algorithm software is provided for experimental and algorithm programming reference, which is convenient for experimental teaching and engineering talent training.

VII、Safety protection system

(I) Boiler heating program control protection system

1. The boiler heating tank is equipped with a water level protection device. If the water level does not reach a certain height, the control system cannot control the thyristor voltage regulator to work.

2. The electric heating tube power control switch uses a key switch. When not in the experiment, the teacher protects the key to avoid misoperation by unrelated personnel.

(II) Power protection measures

1. A current type leakage protector is added.

2. A fuse is added to the two-phase power supply to prevent circuit breakage.

(III) Power start and stop control method;

The start and stop button is used to control the contactor to control the start and stop of the power supply.

(IV) Leakage protection device and safety and safety commitment;

(V) Reliable protection function of various power supplies and various instruments

1. The strong current of various power supplies and various instruments is controlled by switches. Students do not connect the wires by themselves, and there is no problem of mixing strong and weak currents.

2. The experimental strong current wiring plug adopts a closed structure to prevent electric shock accidents.

Synchronous PC version:

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