CN100386700C - Bulk producing controlling method based on bulk producing controlling system - Google Patents
Bulk producing controlling method based on bulk producing controlling system Download PDFInfo
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- CN100386700C CN100386700C CNB2004100479243A CN200410047924A CN100386700C CN 100386700 C CN100386700 C CN 100386700C CN B2004100479243 A CNB2004100479243 A CN B2004100479243A CN 200410047924 A CN200410047924 A CN 200410047924A CN 100386700 C CN100386700 C CN 100386700C
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Abstract
The present invention discloses a batch productive controlling method based on a batch productive controlling system. The batch productive controlling system comprises a host computer and a lower computer which is connected to field devices, wherein the lower computer is provided with a batch controlling program which comprises: A. forced operative commands are set in the system; B. codes of the batch controlling program are executed for generating relevant controlling commands and sending the controlling commands to relevant devices for modifying the actual state of the devices; C. when the present invention receives the forced operative commands and forced operative target steps input by a user, virtual executing results can be obtained by the virtual execution for the starting steps of the batch controlling program to the target steps, and the virtual execution comprises the execution of codes in the batch controlling program, the generation of corresponding controlling commands, and the generation of the virtual state of the devices; D. the actual state of the devices is modified into the same state as the virtual state of the devices; E. the batch controlling program is continuously executed from the target steps for controlling the subsequent production.
Description
Technical field
The present invention relates to the automation control area in the industrial flow, relate in particular to a kind of control method of industrial batch process.
Background technology
Industrial processes are that the product that is continuous flows, discrete bulk article flows or the product of discrete number is divided into continuous flow procedure, batch production process and discrete production run by the product of its output.
Wherein, batch production process is made up of the operation of carrying out in certain sequence more than, finishes the final products that those operations just can be produced some.Produce the product of greater number if desired, then need repeat these operations step.
In batch production process, the value volume and range of product of field apparatus is a lot.With substance law PVC (Polyvinylchloride) production technology is example, and the equipment of employing is two formula opertaing devices mostly, and as solenoid valve, stop valve, motor, pump, its quantity is up to more than 700.And each equipment all needs it is carried out on/off operation, therefore, controls whole batch production process by producing control system in batches usually.
See also Fig. 1, Fig. 1 is a kind of theory structure synoptic diagram of producing control system control batch process in batches.Produce control system in batches, as DCS (collecting and distributing) control system or PLC (programmable logic controller (PLC)) control system, in order to control whole batch production process.It generally is made up of host computer 4 and slave computer 5.Wherein,
At present, producing control system in batches has two kinds of control models: automatic mode and manual mode, corresponding control is produced in batches just two kinds of control methods: autocontrol method and hand operated control method.Described automatic control is meant that under automatic mode computing machine is carried out the code of finishing in advance in the batch control program 6 automatically one by one, produces corresponding control command, and exports control command to corresponding device, and the virtual condition of change equipment is to control the work of this equipment; And hand operated control method is meant under manual mode, and the operator directly sends control command on host computer 4, export this control command to corresponding apparatus by slave computer 5, with the production of remote field equipment.In producing control system in batches, control batch process by selecting wherein a kind of pattern.
But, because the execution speed of hand operated control method is slow, efficient is low, thus adopt autocontrol method to carry out the code that batch control program 6 is finished in advance usually, and then progressively finish the various operational phases in the batch production process.
When the code that adopts autocontrol method control batch control program 6 in the batch production process is carried out, owing to existing unpredictable or artificial reason to cause batch control program 6 can't continue normal situation about carrying out, can enter manual mode, by the work of hand operated control method control corresponding apparatus.But in producing control system in batches, the kind of fault handling is more, and corresponding control command is also various.
With substance law PVC production technology is example, common faults handle as: equipment failure is handled (equipment break down information), step operation overtime and is handled (some special steps wait for that as reinforced the step operation surpasses official hour), control program and suspend and handle (because technological reason, operating personnel suspend production), reinforced error handling processing (needing blowing or reinforced again), batch operation cancellation (this batch produced cancellation, do not produce)
And corresponding control command of the processing of each fault type in the prior art, be that different fault handlings need be carried out different command, still be example with PVC production, which comprises at least to issue orders: (operation response person's pausing operation is used for the temporary transient interruption of program for " startup " (being used for the startup of batch control program), " time-out "; Perhaps the program automatic pause interrupts when equipment breaks down, wait for operator's treatment facility problem), (data that are used for after reinforced process is made mistakes are preserved " maintenance ", so that continue to finish reinforced process after recovering), " stepping " is (when because the on-site signal handling failure causes the step switch condition when not satisfying, control program is forced to enter next step), " retry " (startup once more that is used for behind the program halt is carried out), " continuation " (is used for having carried out when keeping order after reinforced the makeing mistakes, the startup once more of control program is carried out) and " cancellation " (cancel this batch production process, system returns to original state again) etc.
Because control command is various in the batch production process, therefore causes the establishment complexity of batch control program 6, and then increase the difficulty of operating personnel's debugged program.Also have, operating personnel need remember various control commands, and this not only wastes time and energy and various command is obscured easily, cause and use inconvenient even because the incorrect consequence that causes dangerous production of control command of use.
Also have, in batch production process, have some special producing, repeat a certain operational phase as needing in process of production, this just need repeat a certain section code in the batch control program 6; Also skip a certain operational phase such as needing in the production run, this just need skip batch control program 6 when controlling automatically a certain section code still, adopts existing autocontrol method, but can't satisfy the needs of those productions.
In addition, in the existing batch process control method, neither one close friend's equipment display interface makes operator (user) learn the duty (normal, fault, electricity etc.) of certain equipment, brings the inconvenience of using and monitoring to operations of operators.
Summary of the invention
The object of the present invention is to provide the control method in a kind of batch production process, automatically perform batch control program with the control batch production process to solve the available technology adopting automatic mode, under the situation that improper production occurs, user's intractability is big and influence the technical matters of production security.
For addressing the above problem, the invention provides a kind of control method based on the batch process of producing control system in batches, described batch process control system comprises host computer and the slave computer that is connected with field apparatus, one control program in batches is set on the described slave computer, comprises: A, the imperative operation order is set in described system; B, carry out described batch control program code, produce corresponding control command and send described control command to relevant device to revise described device physical status; C, when the target of described imperative operation order that receives user input and imperative operation during the step, go on foot from virtual execution of initial step to the described target of described batch control program, obtain virtual execution result, described virtual execution comprises the code of carrying out in the described batch control program, produces corresponding control command and generates described equipment virtual state; D, described device physical status is modified as identical with described equipment virtual state; E, continue to carry out described batch control program from the described target step, thereby control follow-up production.
Also comprise between B step and the C step: the manual mode that enters system.
Receiving the described imperative operation order of user's input and the target step of imperative operation further comprises: B1: when receiving described imperative operation order, the request user imports step number of forcing the target step; B2: the step number that receives the described pressure target step; B3: when described step number and the pressure target that sets in advance when the step in number tabulation is number all inequality step by step, the request user re-enters step number of forcing the target step.
Step C also comprises: before virtual execution, preserve step number of the current run time version of described batch control program.
Step D further comprises: D1: when equipment virtual state and device physical status are inequality, send and force inconsistent signal, the described device physical status of request user's modification; D2: receive and preserve amended device physical status.
Described batch process comprises bulk polymerizod polyvinyl chloride PVC production.
This method also comprises: an output interface is set on described host computer, all states of equipment are shown with different display modes.
Described display mode comprises different Show Colors.Compared with prior art, the present invention has the following advantages: the present invention is provided with the imperative operation order, when carrying out under automatic mode that batch control program breaks down or improper production (skipping a certain operational phase in a certain operational phase or the production run as repeating), the user directly imports the imperative operation order, just can be with batch control program from the virtual execution of initial step to forcing target step, obtain to carry out to forcing the equipment actual output state of target during the step, thereby make calling program continue to carry out from forcing the target step, eliminated the program implementation fault, and the improper production needs in the production run have also been satisfied, the most important thing is, exempted and remembered various control command, be user-friendly to.
Description of drawings
Fig. 1 is the theory structure synoptic diagram that a kind of control system control is produced in batches;
Fig. 2 is the principle flow chart of the control method of a kind of batch process based on above-mentioned batch process control system of the present invention;
Fig. 3 is the process flow diagram of a specific embodiment of the present invention;
Its operational phase of producing of Fig. 4 for the PVC polymerization in the batch control program in this batch process control system.
Embodiment
Below in conjunction with accompanying drawing, specify the present invention.
Also see also Fig. 1, produce control system in batches and comprise host computer 4 and the slave computer 5 that is connected with field apparatus, one control program 6 in batches is set on the slave computer 5, carry out batch control program 6 code, produce corresponding control command and send described control command to relevant device to revise device physical status.
See also Fig. 2, it is the principle flow chart of the control method of a kind of batch process based on above-mentioned batch process control system of the present invention.It comprises
S110: the imperative operation order is set in system;
S120: carry out batch control program 6, produce corresponding control command and send described control command to relevant device to revise described device physical status;
S130: when the target of described imperative operation order that receives user's input and imperative operation goes on foot, go on foot from virtual execution of initial step to the described target of batch control program 6, obtain virtual execution result, described virtual execution comprises the code of carrying out in the batch control program, produces corresponding control command and generates described equipment virtual state;
S140: device physical status is modified as identical with the equipment virtual state;
S150: carry out batch control program from the continuation of target step, thereby control follow-up production.
See also Fig. 3, be the process flow diagram of a specific embodiment of the present invention.The method that this control is produced in batches may further comprise the steps:
S210: in producing control system in batches, the imperative operation order is set;
S220: enter automatic mode, automatically perform code in the batch control program, produce corresponding control command and send this control command, to revise device physical status, the work of opertaing device to corresponding device by slave computer;
S230: in the batch control program implementation, program occurs and can't continue normal execution, need skip certain subprogram code and enter next section code or requirement when repeating improper production such as certain partial code, switch to the manual mode of system;
The user can send control command by host computer, and the subsequent operation in this operational phase is finished, and also can directly arrive on-site manual start and stop equipment;
Because imperative operation is improper production control procedures, in order to prevent misoperation of users, system generally switches to the manual mode of system earlier, and this also is the needs of production safety operation;
S240: when system receives the user when importing the imperative operation order, the inputting interface that output sets in advance, the request user imports step number in imperative operation target step, and this inputting interface can be an also choice box of dialog box;
S250: when system receives step in imperative operation target step of user input, judge the legitimacy in this step number; The present invention can preestablish the step number tabulation of forcing the target step, with the step that receives number and the step number comparison of forcing in number tabulation of target step one by one,, then carry out subsequent step if having identically, otherwise ask the user to import step number again, number legal until the step of input;
Host computer is preserved current operation step number of the batch control program of ordinary production, to improve the security of producing;
S260: after the step in target step is number legal, go on foot from virtual the execution to target of the initial step of batch control program, obtain virtual execution result, virtual execution comprises the code of carrying out in the batch control program, produce corresponding control command, generation equipment virtual state, but not to the corresponding device transmitting control commands and do not change device physical status;
S270:, switch to manual mode when system carries out to forcing target after the step;
S280: judge whether all devices virtual state is identical with this device physical status, if identical, carry out step S290, force inconsistent signal otherwise send, request user's modification device physical status is identical with the equipment virtual state until amended device physical status;
The user can also can also reach the purpose of revising device physical status to on-site manual start and stop equipment by remote control relevant device on host computer;
S290: system began to continue to carry out follow-up code from the target step, thereby controlled follow-up production run.
Below to produce with a simple substance law PVC polymerization be example, specify the present invention.
See also Fig. 4, the operational phase that it is produced for the PVC polymerization in the batch control program in this batch process control system.
The equipment that relates in this production has elementary vacuum system equipment (to mainly contain vacuum pump, terminal valves etc.), secondary vacuum system (mainly contains vacuum pump, terminal valve etc.), charging system (mainly contains charging valve, charge pumps etc.), the VCM condenser system (mainly contains compressor, terminal valve etc.) and dash, wash system's (mainly containing flushing pump, flushing valve etc.) etc.
Comprise in this program:
First section program code: its initial step number is 100, is mainly used in to finish valve inspection operation, promptly each field apparatus is checked, judges whether each equipment is in the equipment state of regulation;
Second section program code, its initial step number is 200, is mainly used in to finish the vacuum system operation,, equipment is vacuumized processing that is, vacuum-type is selected by the operator, when still operation back employing secondary vacuum is opened in execution, otherwise adopts vacuum one time:
The 3rd section program code, its initial step number is 300, be mainly used in and finish that for the first time VCM (vinyl chloride) is reinforced, the pressure testing checked operation, that is, and after vacuum is qualified, beginning adds a spot of VCM in polymeric kettle, time-delay checks whether the still pressure descends, and checks with this whether polymeric kettle descends, and checks the sealing situation of polymeric kettle and process pipe with this;
The 4th section program code, its initial step number is 400, is mainly used in to finish seed pan feeding, the reinforced operation of VCM for the second time, the reinforced operation of initiating agent, promptly, after pressure testing was qualified, the seed in the seed still added polymeric kettle, and the flushing VCM of seed still is joined polymeric kettle, after seed adds, add VCM once more to pre-customized,, add initiating agent then as 32 tons;
The 5th section program code, its initial step number is 500, is mainly used in and finishes heating, warming temperature, promptly heats, heats up, and pressure is stopped heating during to 0.9MPa;
The 6th section program code, its initial step number is 600, is mainly used in the polyreaction operation, and promptly controlling polymeric kettle pressure is 0.95MPa, and polymerization reaction time is about 5 hours;
The 7th section program code, its initial step number is 700, is mainly used in to finish once the degassing of the degassing/secondary, VCM reclaimer operation;
The 8th section program code, its initial step number is 800, is mainly used in to finish the stripping operation;
The 9th section program code, its initial step number is 900, is mainly used in and finishes discharging, blows, washes the still operation;
The tenth section program code, its initial step number is 926, is mainly used in into still operation, promptly drives still by the bath of operator's selected amount, if need the people to enter polymeric kettle then carry out into still locking, otherwise EOP (end of program) enters next batch production.
Suppose program is carried out stripping during the stage, and stripping partly has one or several valve to break down (as valve feedback states mistake), and batch control program will be suspended by bug monitor this moment, can't normally carry out down.The operator switches to manual state with program; In the pulpit,, finish the stripping operation by host computer remote control relevant device (or to on-site manual start and stop equipment); Operating personnel import the imperative operation order, the input imperative operation target step 900 (also can be legal step number that can imperative operation in Unit 800, concrete step number decide according to the actual operation of finishing of operating personnel); Systems inspection to 900 is step in legitimate targets step number; Enter imperative operation, program begins virtual 900 end (time is approximately 1 minute) of carrying out from beginning the step; After virtual operation finished, Automatic Program was set to manually, and program is checked all devices virtual condition simultaneously, when device physical status and this equipment virtual state are inequality, these equipment was produced inconsistent alarm; The operator manually exports and then revises device physical status according to the inconsistent prompting of equipment with it, after eliminating all inconsistent warnings, and the switchable automatic mode of system; This moment in the initial step next time of program changes 900 into, and program can continue to automatically perform from Unit 900.
The step of batch control program number in the process of implementation the operator can't revise, normally predefined when writing batch control program, this also considers from safety.
In addition, suppose that mistake is elected nitrogen stripping (program run is to 800 multisteps) as because operator's general idea should be selected steam stripping.At this moment, the operator can import imperative operation order and input to force the step in target step number be 800; What control program was virtual ran to for 800 steps from beginning the step; After virtual operation finished, Automatic Program was set to manually, and the operator will have the inconsistent apparatus modifications of pressure to the required state of auto-programming, and it is inconsistent to eliminate pressure; Switch to automatically, start-up routine, program re-executed since 800 steps, and the operator can reselect again.
It is a lot of that other can use the situation of imperative operation to also have, and no longer enumerates at this.
At present, the operator mainly obtains the state of field apparatus from host computer, whether get electric signal as motor, motor is in still halted state signal of operation, the valve switch signal or the like that puts in place, and inconsistent signal of the pressure of equipment and fault-signal generally are composite signals, but not actual signal from field apparatus, be in the simple signal, the operator can't judge be motor whether, motor is in still halted state number of operation, accurate information such as valve switch puts in place, based on this, the present invention is provided with an output interface on described host computer, all states of equipment are shown with different display modes.Described display mode comprises different Show Colors.
With a motor is example, gets electric and does not have fault as motor, and the motor sign of output interface is shown in green, has that motor is masked as yellow under the inconsistent situation of pressure, and motor is when operation, and motor is masked as black etc.
Claims (8)
1. control method based on the batch process of producing control system in batches, described batch process control system comprises host computer and the slave computer that is connected with field apparatus, and a batch control program is set on the described slave computer, it is characterized in that, comprising:
A, the imperative operation order is set in described system;
B, carry out described batch control program code, produce corresponding control command and send described control command to relevant device to revise described device physical status;
C, when the target of described imperative operation order that receives user input and imperative operation during the step, go on foot from virtual execution of initial step to the described target of described batch control program, obtain virtual execution result, described virtual execution comprises the code of carrying out in the described batch control program, produces corresponding control command and generates described equipment virtual state;
D, described device physical status is modified as identical with described equipment virtual state;
E, continue to carry out described batch control program from the described target step, thereby control follow-up production.
2. the control method based on the batch process of producing control system in batches as claimed in claim 1 is characterized in that, also comprises between B step and the C step: the manual mode that enters system.
3. the control method based on the batch process of producing control system in batches as claimed in claim 1 or 2 is characterized in that, the described imperative operation order of reception user input and the target step of imperative operation further comprise:
B1: when receiving described imperative operation order, the request user imports step number of forcing the target step;
B2: the step number that receives the described pressure target step;
B3: when described step number and the pressure target that sets in advance when the step in number tabulation is number all inequality step by step, the request user re-enters step number of forcing the target step.
4. the control method based on the batch process of producing control system in batches as claimed in claim 1 is characterized in that step C also comprises: before virtual execution, preserve step number of the current run time version of described batch control program.
5. as claim 1 or 3 described control methods, it is characterized in that step D further comprises based on the batch process of producing control system in batches:
D1: when equipment virtual state and device physical status are inequality, send and force inconsistent signal, the described device physical status of request user's modification;
D2: receive and preserve amended device physical status.
6. the control method based on the batch process of producing control system in batches as claimed in claim 1 is characterized in that described batch process comprises bulk polymerizod polyvinyl chloride PVC production.
7. as claim 1 or 6 described control methods, it is characterized in that, also comprise: an output interface is set on described host computer, all states of equipment are shown with different display modes based on the batch process of producing control system in batches.
8. the control method based on the batch process of producing control system in batches as claimed in claim 7 is characterized in that described display mode comprises different Show Colors.
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| CNB2004100479243A CN100386700C (en) | 2004-06-09 | 2004-06-09 | Bulk producing controlling method based on bulk producing controlling system |
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| CNB2004100479243A CN100386700C (en) | 2004-06-09 | 2004-06-09 | Bulk producing controlling method based on bulk producing controlling system |
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| CN100386700C true CN100386700C (en) | 2008-05-07 |
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Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101963807B (en) * | 2010-10-19 | 2012-12-05 | 浙江华章科技有限公司 | Group control system for multi-path start-stop control |
| CN102588258B (en) * | 2012-02-10 | 2015-04-22 | 云南大红山管道有限公司 | Remote monitoring device and monitoring method for feed pump |
| CN102537469B (en) * | 2012-02-10 | 2014-01-22 | 云南大红山管道有限公司 | Remote monitoring device of electric valve of iron ore concentrate pipeline and monitoring method of remote monitoring device |
| CN105606184A (en) * | 2016-01-14 | 2016-05-25 | 徐州徐工施维英机械有限公司 | Control method and control system of material production line |
| CN112232539B (en) * | 2019-07-26 | 2022-09-06 | 中冶南方工程技术有限公司 | Automatic bulk cargo yard automobile transportation material sampling batching method |
| CN111308968A (en) * | 2019-12-27 | 2020-06-19 | 黑龙江省科学院智能制造研究所 | Formula batching management system and management control method |
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| JPS62162103A (en) * | 1986-01-11 | 1987-07-18 | Omron Tateisi Electronics Co | Batch processing device for controlling apparatus |
| JPH0322003A (en) * | 1989-06-20 | 1991-01-30 | Fuji Electric Co Ltd | Sequence control system for batch process |
| JP2002297234A (en) * | 2001-04-03 | 2002-10-11 | Yamatake Sangyo Systems Co Ltd | Apparatus for operating and monitoring batch plant and recording medium and program |
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2004
- 2004-06-09 CN CNB2004100479243A patent/CN100386700C/en not_active Expired - Fee Related
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62162103A (en) * | 1986-01-11 | 1987-07-18 | Omron Tateisi Electronics Co | Batch processing device for controlling apparatus |
| JPH0322003A (en) * | 1989-06-20 | 1991-01-30 | Fuji Electric Co Ltd | Sequence control system for batch process |
| JP2002297234A (en) * | 2001-04-03 | 2002-10-11 | Yamatake Sangyo Systems Co Ltd | Apparatus for operating and monitoring batch plant and recording medium and program |
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Assignee: Ningbo Keyuan Plastic Co.,Ltd. Assignor: Zhongkong Technology Co., Ltd., Zhejiang Contract record no.: 2010990000405 Denomination of invention: Bulk producing controlling method based on bulk producing controlling system Granted publication date: 20080507 License type: Exclusive License Open date: 20050223 Record date: 20100622 |
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