加热炉计算机控制系统的设计与实现

工业大学硕士学位论文进行了大量文献检索工作，对前人的研究工作进行总结和分析。介绍了加热炉的工艺流程、结构和性能参数。第三章介绍了加热炉基础自动化系统，包括燃烧系统和顺控系统，并对交叉限幅串级温度控制系统进行了改进，提出了FUZZY-PID温度控制系统，开发了具有通用性的步进梁速度曲线控制模块，并对速度曲线进行了优化，取得了良好的使用效果第四章建立炉钢坯的传热过程的机理数学模型，并从工程角度进行简化，给出了一维的导热模型和总括热吸收率算法。以此为理论基础开发的钢温预报模型程序，预测的钢温和实测数据基本吻合，数据令人满意。同时结合智能控制理论，提出了基于炉区分段的BP神经网络钢坯温度预报模型，并进行了仿真研究。第六章阐述了西门子PLC控制系统的特点与其在大型轧钢步进梁式加热炉LEVEL1系统上的应用，并给出了基于平台的C#软件和ORACLE数据库平台开发的加热炉二级控制系统的实现。图2.1加热炉示意图[39]建立了用于钢坯温度预测的三维导热数学模型，其控制方程如式(4.10)[40]：式中，λ为导热系数，单位是W/(m2·℃)；Cp为比热，单位是J/(m3·℃)；t为板坯温度，单位是℃。三维导热数学模型总括热吸收率法[41,42]是计算炉膛传热过程的一种简化方法。为了解决加热炉复杂的热交换和复杂的机理模型，大幅度降低了描述边界条件的复杂程度。它将被加热物体的表面辐射热流密度描述为炉气（或热电偶）温度与被加热物体表面温度的黑体辐射之差乘以总括热吸收率的形式。这种方法计算量小且精度能够满足生产要求，其中计算总括热吸收率的准确性是决定软测量模型成败的关键。其边界条件可由下式给出[43]：式中：qs：表面辐射热流密度，W/m2；σ：Steafan-Boltzman常数；￠：炉膛总括热吸收率；Tf：板坯所在处的炉温，K；Ts：板坯的表面温度，K；也就是说，板坯的外部传热除了受到炉气温度的影响外，主要取决于总括热吸收率，而且在炉子的各种操作状态下，总括热吸收率在炉子的给定位置上基本保持不变。序号图/表号名称页码备注1图2.1加热炉示意图92图3.1双交叉限幅温度控制系统123图3.2基本模糊控制器的结构144图3.3典型步进梁速度曲线175图3.4优化的步进梁速度曲线186图4.1微元网格体热量传递示意图237图4.2BP神经网络结构278图4.3（a）图4.3（b）未分段BP网络上表面温度曲线未分段BP网络中心温度曲线289图4.4（a）图4.4（b）分段BP网络上表面温度曲线分段BP网络中心温度曲线2910图5.1LEVEL1级网络结构图3111图5.2LEVEL2级网络结构图3312图5.33513图5.43614图5.5SOCKET通讯结构图4015图6.1PCS7系统典型结构图4316图6.2SIMATICMANAGER主界面4317图6.3SIMATICMANAGER硬件组态界面4418图6.4SIMATICMANAGER网络组态界面4419图6.5顺控程序结构图4520图6.6仪控程序结构图4821图6.74922图6.85023图6.9WINCC软件开发主画面5224图6.10燃控系统主监控画面5325图6.11顺控系统主监控画面5326图6.12步进梁参数设置画面5427图6.13轧制计划管理画面5628图6.14入炉核对画面5729图6.15炉跟踪画面5830图6.16模型跟踪数据表画面5831图6.17模型数据柱状图59序号图/表号名称页码备注1表2.1加热炉烧嘴型式与能力配置102表3.1模糊控制查询表153表3.2194表4.1245表5.1LEVEL2级网络通讯方式326表5.2417表6.1488表6.249序号中心温度（℃）上表面（℃）下表面（℃）炉气温度（℃）143.069.740.5306.3244.674.442.1552.1350.387.247.5653.4456.997.352.6653.4564.7105.157.6652.3672.5112.262.7657.5780.6120.767.7639.3888.8124.372.8640.0997.4130.177.9680.010100.1135.283.0712.81198.6140.788.5704.812107.1146.293.9709.413121.2151.699.8724.114134.1158.3101.0777.815143.1166.1103.3780.516151.3172.8101.4772.517160.3177.9101.0768.718168.5182.6106.5792.119177.1189.6114.7799.820185.3196.2123.4806.721193.9203.3132.8806.022202.1208.7142.6813.723211.5215.0149.7821.924219.6222.4155.9824.625229.0229.0161.8822.226237.5234.8167.7825.827246.9240.7174.4835.928255.4248.0181.1839.729265.1255.8188.1833.230273.9262.4194.8833.931283.2268.9201.8843.332292.4275.9208.5853.833301.7284.4215.2856.634311.3291.7222.6860.135320.8299.0230.0882.136330.3307.4237.1928.737339.9320.1244.5929.138349.4329.6251.9920.439360.0337.6258.9910.140369.8345.6265.1949.941379.6358.5271.7962.742389.8370.6279.8959.943400.0381.6288.7959.944410.8391.7297.2963.145421.3401.1305.7967.946431.8410.9314.2973.647442.2420.6322.6976.848452.7430.0330.7980.449462.7439.3339.1985.350472.4448.6347.1986.551482.0458.3355.5989.052491.7466.8363.1989.053501.3475.7371.0987.754510.2484.3379.0993.855519.5493.2386.9995.056528.0501.3394.9997.557536.9510.3402.8996.358545.4518.4410.71000.359553.5526.5418.61004.060561.7534.7426.5997.961569.5542.1434.01005.262577.3549.5441.51011.763585.1558.0449.01017.064592.5566.5456.51017.065599.5575.4463.91007.766606.6582.9471.01015.067613.7590.7478.91022.368620.4598.5485.91026.069627.1607.7493.81026.070633.8615.6502.31029.371640.5623.4511.61028.972646.9630.8520.51054.373653.3640.2529.81056.474659.2649.5538.41061.375665.6657.8547.31058.976671.6665.3555.91058.577677.6672.8564.01070.878683.3681.1572.31073.779689.0689.7579.71074.280694.2697.3587.21072.181699.9704.1594.21077.982705.2710.9600.61104.583710.1718.8607.31110.084715.0726.4614.01111.385719.6734.0621.91114.686724.2740.5629.81111.787729.5747.8637.21112.588733.7754.3644.41111.789737.5761.2651.11115.190741.7767.3656.81113.091746.7773.8662.41116.892752.4780.4668.11115.193758.9786.9673.81111.494765.4793.1679.41116.495772.3799.3685.11116.496780.0804.7690.81127.897787.7811.7696.51128.798795.1817.9701.81135.899802.8824.9707.11143.0100810.6832.3713.21145.2101818.3839.3719.31149.4102826.9847.2725.01145.2103835.1854.6730.71147.4104843.3862.1735.71149.5105851.9869.5740.71155.9106859.7877.0745.71162.7107868.8885.3751.11156.3108878.2892.8755.31149.6109887.7899.2761.51149.2110897.2903.9767.61143.2111906.7909.1774.21141.2112916.7913.5780.41143.3113926.2918.3786.61145.0114935.4923.1792.81150.6115944.2928.6799.01151.4116952.6933.9805.21154.4117961.1939.5812.31156.6118968.8944.3818.91157.9119977.2950.3826.31164.7120984.9956.0833.81164.8121992.2961.6840.81166.5122999.6966.8847.91166.11231006.9971.7854.61168.31241013.4977.0861.71170.81251020.4982.2869.21170.91261027.4987.5876.01167.11271033.5991.6882.71165.41281039.3995.7889.51164.61291045.5999.8896.21163.81301050.91003.9902.21164.21311056.21008.0909.01175.01321061.61012.9915.41177.61331066.21018.2923.01187.01341070.41024.8929.91190.51351075.01030.5937.11200.11361079.21036.7944.41203.61371082.91043.7950.81209.31381086.71049.9957.71224.61391090.91057.4964.61231.21401094.71066.1972.41226.41411098.51072.3979.31226.51421102.81077.8987.01230.51431107.01084.1995.21235.41441110.81089.11001.31236.31451114.21093.71007.51237.21461118.11098.41014.51234.21471122.31103.41021.51239.51481126.61108.11026.91240.01491131.31111.91032.7124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