【SGM-01U3B2L】
文章對(duì)PLC自動(dòng)控制系統(tǒng)可靠性問(wèn)題進(jìn)行了較深入研究，提出了
提高系統(tǒng)可靠性運(yùn)行的方法。實(shí)踐證明這些方法的采用對(duì)提高
系統(tǒng)的可靠性是行之有效的。
關(guān)鍵詞：可靠性 PLC 自動(dòng)控制系統(tǒng)
1、引言
可編程控制器由于抗干擾能力強(qiáng)，可靠性高，編程簡(jiǎn)單，
性能價(jià)格比高，在工業(yè)控制領(lǐng)域得到越來(lái)越廣泛應(yīng)用。
工業(yè)年月機(jī)作為中央控制單元，配有組態(tài)軟件，選用大屏
幕實(shí)時(shí)監(jiān)視界面，實(shí)現(xiàn)各控制點(diǎn)的動(dòng)態(tài)顯示、數(shù)據(jù)修改、故障
診斷、自動(dòng)報(bào)警，還可顯示查詢歷史事件記錄，系統(tǒng)各主要部
件累計(jì)運(yùn)行時(shí)間，各裝置工藝流程圖，各裝置結(jié)構(gòu)圖等。中央
控制單元和下位機(jī)PLC之間采用串行通訊方式進(jìn)行數(shù)據(jù)交換，通
常距離在1000m以內(nèi)選用485雙絞線通訊方式，較常距離可選用光
纖通訊，更長(zhǎng)距離也可選用無(wú)線通訊方式。下位機(jī)選用PLC控制，
根據(jù)控制對(duì)象的多少，控制對(duì)象的范圍，可選用一臺(tái)或多臺(tái)PLC
進(jìn)行控制，PLC之間數(shù)據(jù)交換是利用內(nèi)部鏈接寄存器，實(shí)現(xiàn)數(shù)據(jù)
交換和共享。由于PLC對(duì)現(xiàn)場(chǎng)進(jìn)實(shí)時(shí)監(jiān)控具有很高的可靠性，且
編程簡(jiǎn)單、靈活，因此越來(lái)越受到人們重視。
2、控制系統(tǒng)可靠性降低的主要原因
雖然工業(yè)控制機(jī)和可編程控制器本身都具有很高的可靠性，
但如果輸入給PLC的開(kāi)關(guān)量信號(hào)出現(xiàn)錯(cuò)誤，模擬量信號(hào)出現(xiàn)較大
偏差，PLC輸出口控制的執(zhí)行機(jī)構(gòu)沒(méi)有按要求動(dòng)作，這些都可能
使控制過(guò)程出錯(cuò)，造成無(wú)法挽回的經(jīng)濟(jì)損失。
影響現(xiàn)場(chǎng)輸入給PLC信號(hào)出錯(cuò)的主要原因有：
1)造成傳輸信號(hào)線短路或斷路（由于機(jī)械拉扯，線路自身
老化，特別是鼠害），當(dāng)傳輸信號(hào)線出故障時(shí)，現(xiàn)場(chǎng)信號(hào)無(wú)法
傳送給PLC，造成控制出錯(cuò)；
2)機(jī)械觸點(diǎn)抖動(dòng)，現(xiàn)場(chǎng)觸點(diǎn)雖然只閉合一次，PLC卻認(rèn)為閉
合了多次，雖然硬件加了濾波電路，軟件增加微分指令，但由
于PLC掃描周期太短，仍可能在計(jì)數(shù)、累加、移位等指令中出錯(cuò)，
出現(xiàn)錯(cuò)誤控制結(jié)果；
3)現(xiàn)場(chǎng)變送器，機(jī)械開(kāi)關(guān)自身出故障，如觸點(diǎn)接觸不良，
變送器反映現(xiàn)場(chǎng)非電量偏差較大或不能正常工作等，這些故障
同樣會(huì)使控制系統(tǒng)不能正常工作。
影響執(zhí)行機(jī)構(gòu)出錯(cuò)的主要原因有：
1)控制負(fù)載的接觸不能可靠動(dòng)作，雖然PLC發(fā)出了動(dòng)作指
但執(zhí)行機(jī)構(gòu)并沒(méi)按要求動(dòng)作；
2)控制變頻器起動(dòng)，由于變頻器自身故障，變頻器所帶電
機(jī)并沒(méi)按要求工作；
3)各種電動(dòng)閥、電磁閥該開(kāi)的沒(méi)能打開(kāi)，該關(guān)的沒(méi)能關(guān)到
位，由于執(zhí)行機(jī)構(gòu)沒(méi)能按PLC的控制要求動(dòng)作，使系統(tǒng)無(wú)法正常
工作，降低了系統(tǒng)可靠性。要提高整個(gè)控制系統(tǒng)的可靠性，必
須提高輸入信號(hào)的可靠性和執(zhí)行機(jī)構(gòu)動(dòng)作的準(zhǔn)確性，否則PLC
應(yīng)能及時(shí)發(fā)現(xiàn)問(wèn)題，用聲光等報(bào)警辦法提示給操作人員，盡快
排除故障，讓系統(tǒng)安全、可靠、正確地工作。
3、設(shè)計(jì)完善的故障報(bào)警系統(tǒng)
在自動(dòng)控制系統(tǒng)的設(shè)計(jì)中我們?cè)O(shè)計(jì)了3級(jí)故障顯示報(bào)警系
統(tǒng)，1級(jí)設(shè)置在控制現(xiàn)場(chǎng)各控制柜面板，用指示燈指示設(shè)備正
常運(yùn)行和故障情況，當(dāng)設(shè)備正常運(yùn)行時(shí)對(duì)應(yīng)指示燈亮，當(dāng)該設(shè)
備運(yùn)行有故障時(shí)指示燈以1Hz的頻率閃爍。為防止指示燈燈泡
損壞不能正確反映設(shè)備工作情況，專門(mén)設(shè)置了故障復(fù)位/燈
試按鈕，系統(tǒng)運(yùn)行任何時(shí)間持續(xù)按該按鈕3s，所有指示燈應(yīng)全
部點(diǎn)亮，如果這時(shí)有指示等不亮說(shuō)明該指示燈已壞，應(yīng)立即更
換，改按鈕復(fù)位后指示燈仍按原工作狀態(tài)顯示設(shè)備工作狀態(tài)。
2級(jí)故障顯示設(shè)置在中心控制室大屏幕監(jiān)視器上，當(dāng)設(shè)備出
故障時(shí)，有文字顯示故障類型，工藝流程圖上對(duì)應(yīng)的設(shè)備閃爍，
歷史事件表中將記錄該故障。3級(jí)故障顯示設(shè)置在中心控制
信號(hào)箱內(nèi)，當(dāng)設(shè)備出現(xiàn)故障時(shí)，信號(hào)箱將用聲、光報(bào)警方式提
示工作人員，及時(shí)處理故障。在處理故障時(shí)，又將故障進(jìn)行分
類，有些故障是要求系統(tǒng)停止運(yùn)行的，但有些故障對(duì)系統(tǒng)工作
影響不大，系統(tǒng)可帶故障運(yùn)行，故障可在運(yùn)行中排除，這樣就
大大減少整個(gè)系統(tǒng)停止運(yùn)行時(shí)間，提高系統(tǒng)可靠性運(yùn)行水平。
4、輸入信號(hào)可靠性研究
要提高現(xiàn)場(chǎng)輸入給PLC信號(hào)的可靠性，首先要選擇可靠性
較高的變送器和各種開(kāi)關(guān)，防止各種原因引起傳送信號(hào)線短
路、斷路或接觸不良。其次在程序設(shè)計(jì)時(shí)增加數(shù)字濾波程序，
增加輸入信號(hào)的可信性。
在現(xiàn)場(chǎng)輸入觸點(diǎn)后加一定時(shí)器，定時(shí)時(shí)間根據(jù)觸點(diǎn)抖動(dòng)
情況和系統(tǒng)要的響應(yīng)速度確定，一般在幾十ms，這樣可保證
觸點(diǎn)確實(shí)穩(wěn)定閉合后，才有其它響應(yīng)。模擬信號(hào)濾波可采用
圖2b 程序設(shè)計(jì)方法，對(duì)現(xiàn)場(chǎng)模擬信號(hào)連續(xù)采樣3次，采樣間
隔由A/D轉(zhuǎn)換速度和該模擬信號(hào)變化速率決定。3次采樣數(shù)據(jù)
分別存放在數(shù)據(jù)寄存器DT10、DT11、DT12中，當(dāng)最后1次采樣
結(jié)束后利用數(shù)據(jù)比較、數(shù)據(jù)交換指令、數(shù)據(jù)段比較指令去掉
最大和最小值，保留中間值作為本次采樣結(jié)果存放在數(shù)據(jù)寄存
器DT0中。
提高讀入PLC現(xiàn)場(chǎng)信號(hào)的可靠性還可利用控制系統(tǒng)自身特
點(diǎn)，利用信號(hào)之間關(guān)系來(lái)判斷信號(hào)的可信程度。如進(jìn)行液位
控制，由于儲(chǔ)罐的尺寸是已知的，進(jìn)液或出液的閥門(mén)開(kāi)度和
壓力是已知的，在一定時(shí)間里罐內(nèi)液體變化高度大約在什
范圍是知道的，如果這時(shí)液位計(jì)送給PLC的數(shù)據(jù)和估算液位
高度相差較大，判斷可能是液位計(jì)故障，通過(guò)故障報(bào)警系統(tǒng)
通知操作人員檢查該液位計(jì)。又如各儲(chǔ)罐有上下液位極限保
護(hù)，當(dāng)開(kāi)關(guān)動(dòng)作時(shí)發(fā)出信號(hào)給PLC，這個(gè)信號(hào)是否真實(shí)可靠，
在程序設(shè)計(jì)時(shí)我們將這信號(hào)和該罐液位計(jì)信號(hào)對(duì)比，如果液
位計(jì)讀數(shù)也在極限位置，說(shuō)明該信號(hào)是真實(shí)的；如果液位
讀數(shù)不在
限位置，判斷可能是液位極限開(kāi)關(guān)故障或傳送信號(hào)線路故障，
同樣通過(guò)報(bào)警系統(tǒng)通知操作人員處理該故障。由于在程序
計(jì)時(shí)采用了上述方法，大大提高了輸入信號(hào)的可靠。
5、執(zhí)行機(jī)構(gòu)可靠性研究
當(dāng)現(xiàn)場(chǎng)的信號(hào)準(zhǔn)確地輸入給PLC后，PLC執(zhí)行程序，將結(jié)
果通過(guò)執(zhí)行機(jī)構(gòu)對(duì)現(xiàn)場(chǎng)裝置進(jìn)行調(diào)節(jié)、控制。怎樣保證執(zhí)行機(jī)
構(gòu)按控制要求工作，當(dāng)執(zhí)行機(jī)構(gòu)沒(méi)有按要求工作，怎樣發(fā)現(xiàn)故
障？我們采取以下措施：當(dāng)負(fù)載由接觸器控制時(shí)，啟動(dòng)或停止這
類負(fù)載轉(zhuǎn)為對(duì)接觸器線圈控制，啟動(dòng)時(shí)接觸器是否可靠吸合，
停止時(shí)接觸器是否可靠釋放，這是我們關(guān)心的。
X0為接觸器動(dòng)作條件，Y0為控制線圈輸出，X1為引回到PLC
輸入端的接觸器輔助常開(kāi)觸點(diǎn)，定時(shí)器定時(shí)時(shí)間大于接觸器動(dòng)
作時(shí)間。R0為設(shè)定的故障位，R0為ON表示有故障，做報(bào)警處理；
R0為OFF表示無(wú)故障。故障具有記憶功能，由故障復(fù)位按鈕清除。
當(dāng)開(kāi)啟或關(guān)閉電動(dòng)閥門(mén)時(shí)，根據(jù)閥門(mén)開(kāi)啟、關(guān)閉時(shí)間不同，
設(shè)置延時(shí)時(shí)間，經(jīng)過(guò)延時(shí)檢測(cè)開(kāi)到位或關(guān)到位信號(hào)，如果這些
信號(hào)不能按時(shí)準(zhǔn)確返回給PLC，說(shuō)明閥可能有故障，做閥故障報(bào)
警處理。程序設(shè)計(jì)如圖3b 所示。X2為閥門(mén)開(kāi)啟條件，Y1為控制
閥動(dòng)作輸出，定時(shí)器定時(shí)時(shí)間大于閥開(kāi)啟到位時(shí)間，X3為閥到
位返回信號(hào)，R1為閥故障位。
6、結(jié)論
我們?cè)趧倮吞飫倮捎蛷S勝砣注聚站自動(dòng)控制系統(tǒng)設(shè)計(jì)
采用了以上方法，經(jīng)過(guò)近2年的運(yùn)行證明這些方法的采用對(duì)提高
系統(tǒng)可靠性運(yùn)行是行之有效的。
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TRERICE Temperature Pressure Control TA901 CL I, II, III
Rebuilt Rosemount Temperature Transmitter 3051L2AB6BD21AA?M5 285PSIG 10.5-55VDC
United Electric Temperature Control B5 & B27A
Pyles Temperature Board 23600-201 Rev. A
ServiceFirst CNT00016 Temp Tempurature Control A19AGA-7 A19AGA7
Stork Tronic Temperature Controller 146951 ST48-WHDVM.0FP D-70569
Cleanstream Temperature Control System 550/H1500 10-12143-12-0-0?8
Honeywell Temperature Controller DC3005-0-000-1-?FM-W111 DC300500001FMW1?11
LHA SLG-5T Temperature Controller 45-220 deg F 0-100 deg C
Athena 6075-T0-E2 6075T0E2 Temperature Control 120/240 VAC Range 0-2000F
Marposs Temperature Probe Head 6740001900
Eurotherm Digital Temp Cont 849/VPR/R1/0/IA?A02/0/(AE163)/(?4 20mA=80 400)/AF137//
United Electric Controls UE Series 400 Temperature Controller F402-8BS 25S
Bently Nevada 3300 6 Channel Temperature Monitor 3300/35-XX-XX-0?0-00-00 81672-01
Athena 6075-T-E2 6075TE2 Temp Tempurature Control 120/240 VAC 0-2000F
Reliance Electric PCB Current Voltage Transductor 0-51831-6 Type CVTG
Rebuilt DRC Metric Transducer Encoder SST-10-M2-07A-S?607 DRC3952 1080141
Honeywell 3040A Transducer Accelerometer
TRANS TEK 0605 USPP 0605S2102020101 ROTARY POSITION TRANSDUCER
Millipore Pressure Transducer PPT 305 TR0002352672 100PSIG 0-5V TEFLON PFA
Dynamics Metric Transducer SST-10-M2-07C-S?533 CH98932A 00048285
WESCHLER YOKOGAWA Transducer WTD020J/CALIBRA?TED 246953-540-AHD-?0-0
BHL Electronics Load Transducer LDT 468836 Capacity of 50,000 lbs.
Phoenix Contact Mini MCR-SL-PT100-UI Pt100 Transducer No.:28, 64, 43, 5
GE 531X187VCTADG1 PC Board Transducer F31X187VCTAOG1 F31X187VCTACG1
Bellofram 961-158-076 961158076 Pressure Transducer Ratio 1:1 400 PSIG
LEM HEME LEM Current Transducer Module LC 1000-S/SP7 LC1000SSP7
DOVER FLEXO SUPB3-2500-0-DT?-XR-Z 2500LB. TENSION TRANSDUCER LOADCELL
Revere Transducer RLC-D3-28T-10MP?1 Output: 2.0mV/V Capacity: 28T 453848-02
Setra Pressure Transducer 225 2251Z05PCD411B1 -14.7-2985.3 PSIG 24VDC 4-20mA
WESCHLER INSTRUMENTS YE/WTD020J A12461 TRANSDUCER 4-20MADC 0-833WATTS
Giken Kogyo Nutrunner ANC-3500D AC Servo Motor TS 4203 Torque Transducer
OMAT OptiMil-XL Controller, A/Numeric LCD 0MLXL213
Yokogawa Yewmag Magnetic Flow Transducer YM315G-AA1-LSA*?A/SCT 150mm 6in 0.7A
Siemens I-P I/P Transducer 77-16f 77-16 Electro-Pneumat?ic 4-20mA 3-15PSIG
Federal Pacific SE2N.750F SE2N750F Isolation Transformer 120/240 Volts
ALLEN-BRADLEY BULLETIN 1497 CONTROL CIRCUIT TRANSFORMER 1497-N37 A 1000 VA
*Take Off* Yaskawa Single Phase 4KVA Transformer USN-B 0GT005-001 10% ED
GE Core & Coil Transformer 9T58B0052G09 6P296 9T58B52G9 1KVA 1PH TYPE IP
Siemens EN 61558-2-3 6155823 Ignition Transformer ZM 20/12 115V 50Hz
GE Transformer 9T23B3878 KVA 300 Type QL 3PH 300.0kVA Encl Type 2
GE 36B605538AEG02 Transformer CPT ASM 460V
Allen Bradley 80025-158-11 8002515811 Current Transformer 200-4 Ratio 60Hz
Furnas D52073 Current Transformer 50-60 Cycles Ampere Ratio 300-5
Square D Sorgel Transformer 37S5H 37.5 KVA Type 2
SOLA 23-23-125-8 Constant Voltage Transformer Harmonic Neutralized Type CVS
Allen Bradley Transformer 1497-H-BASX-0-N
Allen Bradley MCC Combination Starter 2112B BDB-5RG-6P Size 1 Bucket
Square D Pilot Light Transformer Type 9001 KP-1 9001KP1 110-120V 50-60Hz
Allen-Bradley Transformer Module 800E-3T5 Series A 800E3T5 110V 50Hz
Allen Bradley Control Circuit Transformer X-231644 CTLX53-5 5 KVA 240-480/120-24
GS General Signal Hevi-Duty General Purpose Power Transformer DT661H11S 3PH
Dow Hi-Tech Engineering CS-150 - 4000/4000 High Pressure Polyurethane Syst.
Jacke GmbH Power Supply 24 V Transformer Type Dang
GE Transformer Type QMS3 9T21J9703 CLASS AA 3Ph 7.50KVA 483V 60HZ
Modification Kit for Current Transformer Mounting Bracket 501219
Square D Transformer 9070 EO-10 S 30021-930-50 3 KVA 220-240 / 110-120 V
GE Illuminated Pushbutton Transformer Type CR104PBT91G1S2 Green Lens 120V
Eaton Cutler Hammer 10250T6087 Illuminated Selector Switch Series A4
Allen-Bradley 1497-N11P Sr A Bulletin 1497 Control Circuit Transformer 350V
SMC Tool Correction System Pressure Transformer Regulator AR2000-01BG-1R
Holec Current Transformer CT 741F0027 2000/5A 50-60Hz 9418 F 00786
Daniel Woodhead 1675-12/1678-12 Transformer 117V 50/60 Hz
A.O, Smith AC Motor C723 Transformer Cooling HF3J040N 1/3HP 1140/960RPM 1PH
Utility Relay Co. CT Current Transformer CT-10472B 600/300 TO 1A
Holzma Block Autotransformer 4-008-26-0389 0-240-45-7780 29.5 KVA transformer
RIY Programmable Isolated RTD Transmitter RIY/R0-50-140F/?4-20MA/12-42DC
Moore Industries SPT/TPRG/PRG/U Site-Programmab?le, Isolated Temperature Trans
Rosemount Pressure Transmitter 3051CD2A22A1AL4 3626PSI/250 BAR 10.5-55 VDC
PMC V-HA Electronic Pressure Transmitter Range 0-240# 24VDC
Rosemount Pressure Transmitter CD2A02A1AH2B1E5?L 3626PSI/250BAR 10.5-55 VDC
Endress Hauser Flowtec FTO1650 Flow Meter Transmitter
PMC Electronic Pressure Transmitter Model V-HA VHA Range 0-60# 24VDC
Acromag, Inc. Transmitter 150T-RBP-M052-X?-20-C Serial # TJ1410
Johnson Controls T-5210-1113 T52101113 Temperature Transmitter
Johnson Controls Temperature Transmitter T-5210-1002 17435 00120512
RBLT Rosemount 8712CR12N0B6 8712C/U Magnetic Flowmeter Transmitter
Magnetrol Guided Wave Radar Transmitter 705-510A-210 705-510A210 24VDC
Foxboro IDP10-I10C2IF-M?I IDP10I10C2IFMI Pressure Transmitter 12.5-42.0 VDC
Endress+Hauser Liquisys-M Transmitter CLM223F-IF8105 CLM223FIF8105
MAGNETROL TRANSMITTER 910-P1A0-001 120VAC
Micro Motion RFT97121PNU Flow Transmitter Remote 115VAC
Rebuilt Rosemount Temperature Transmitter 3051L2AB6BD21AA?M5 285PSIG 10.5-55VDC
Moore Industries ACT AC Current Transmitter ACT/0-150VAC/4-?20MA/117AC
Micro Motion Remote Flow Transmitter RFT9712 1PNU RFT97121PNU 940908
Endress + Hauser PMP731-053L9M11?F2 Cerabar Pressure Transmitter 5ZY0087
Rosemount Smart Family Magnetic Flow Transmitter R12M4N5 8712C
PMC Electronic Pressure Transmitter N-HC Range 0-100# 24VDC 4-20mA
Rosemount Magnetic Flow Transmitter 871CR12M4N5 115VAC 50/60HZ 1A 20W
Rosemount 3051CG5A02A1AH2?B1E5L4 Pressure Transmitter 2000PSIG 10.5-55VDC
Rosemount 1151DP4E22S2B1 Pressure Transmitter 2000 PSI
Foxboro IDP10-I10C2IF-M?I Pressure Transmitter w/ Mounting Hardware
Moore TIY Programmable Transmitter TIY/J1-50-140F/?4-20MA/12-42DC
Rosemount Magnetic Flow Transmitter 8712CP12N0M4 115VAC 1PH 1A 20W 4-20MA
Endress+Hauser Promass 80 Transmitter 80F08-AAASAAACB?BA8 20-55VAC 16-62VDC
Rebuilt Rosemount Pressure Transmitter 3051CG5A22A1JB4?M6E5 2000 PSIG 10.5-55 VDC
FOXBORO Electronic Transmitter 823DP-I3K1NL2-S SER A 12.5-65VDC 3000PSI
Omega Ricochet Ultrasonic Level Transmitter LVU-2001 Alphasonic
RiS SC-1372 Isolated RTD Transmitter 3Wire 32-650 deg F 200-450 4-20ma
Rosemount Pressure Transmitter 3051CG4A02A1AH2?B3 GIP XMTR 4-20mA
Rosemount Pressure Transmitter 3051CD2A02A1AS5 3626PSI/250BAR 10.5-55VDC
Celesco Transmitter Position PT8420-0015-821?-1141 1.0664mA/Inch Output4-20mA
Micro Motion Flow Transmitter 1FT97031C6D3U 85-250 VAC
EXAC Series 8300 Mass Flow Transmitter 8300EX 115VAC 50/60HZ 40VA
Bailey BC2421511 Pressure Transmitter 3600PSI
Foxboro I/A Series Magnetic Flow Transmitter IMT20-SA10CGZ-G STAB 120VAC
Rosemount Pressure Transmitter 3051CG5M22A1AB4?E5T1C2 2000PSI/138BAR 6-12VDC
Yokogawa PH Transmitter PH400-P-U-1-E*A 120 V AC 60HZ 8.5W
Rosemount Magnetic Flow Transmitter 8712CR12N5M4B6 115VAC 1PH 1A 20W 4-20MA
Rosemount Magnetic Flow Transmitter 8712C P03N5M4 8712CP03N5M4 3A 20W
Rosemount Pressure Transmitter 3051CD2A02A1AH2?B1N5E5L4 3626PSIG 10.5-55VDC
Rebuilt Rosemount Transmitter 3051CD2A02A1AS5 SMART Diff Pressure 4-20mA
Rosemount 3051CG4A22A1AB4 Gage Pressure Transmitter 300 PSI 10.5-55 VDC
Rosemount Flow Meter Transmitter APEXBC1A1SC4N04?A101M1
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