步进式加热炉控制系统设计.docx

步进式加热炉控制系统设计

目 录
第一部分：步进式加热炉
1. 步进式加热炉简介………………………………………………………………………3. 步进式加热炉结构………………………………………………………………………4
3. 步进式加热炉工艺流程…………………………………………………………………5
第二部分：DCS系统的选型
⒈ DCS选型注意事项………………………………………………………………………7
⒉ 本设计DCS选型…………………………………………………………………………7
⒊ DCS系统硬件选型………………………………………………………………………8
⒋ 组态设计…………………………………………………………………………………8
⒌ 设备安装…………………………………………………………………………………9
⒍ 调试………………………………………………………………………………………9
第三部分：步进式加热炉控制系统设计方案
⒈ 步进式加热炉的主要性能参数…………………………………………………………9
⒉ 步进式加热炉具体控制方案设计………………………………………………………9
第四部分：DCS组态图
⒈ JX-300组态………………………………………………………………………………13
⒉ 加热炉控制系统演示工程………………………………………………………………14
⒊ 温度报警显示……………………………………………………………………………15
⒋ 温度和炉膛压力监控……………………………………………………………………16
第五部分：心得体会
第六部分：参考资料

一、步进式加热炉工艺流程
⒈步进式加热炉简介
⑴步进式加热炉
步进式加热炉是一种靠炉底或水冷金属梁的上升、前进、下降、后退的动作把料坯一步一步地移送前进的连续加热炉。
炉子有固定炉底和步进炉底，或者有固定梁和步进梁。前者叫做步进底式炉，后者叫做步进梁式炉。轧钢用加热炉的步进梁通常由水冷管组成。步进梁式炉可对料坯实现上下双面加热。

⑵步进式加热炉特点　

⒉步进式加热炉的结构
图（1）
⑴步进式加热炉结构图

图(2) 步进式加热炉炉底结构

⒊步进式加热炉工艺流程
一般情况下，加热炉沿炉膛长度方向分为预热段、加热段和均热段。进料端为预热段，炉气温度较低，其作用在于充分利用炉气热量，给进炉板坯预热到一定温度，以提高炉子的热效率。加热段为主要供热段，炉气温度较高，以利于实现板坯的快速加热，保证板坯加热到要求的目标温度。均热段位于出料端，炉气温度与金属料温度差别很小，保证出炉料坯的断面温度均匀。一般用于加热小断面料坯的炉子只有预热段和加热段。

钢坯加热是热轧生产工艺过程中的重要工序。其生产过程如下：对于步进式加热炉，钢坯的移动是通过固定梁和移动梁的周期运动来实现的。钢坯位于固定梁上，移动梁反复地进行上升、前进、下降、后退的矩形运动，移动梁的每一个循环运动带动钢坯在炉前进一步，而且保证钢坯没有任何滑动。传动机构的上下运动和前后运动分别是由独立的机构完成的。步进梁的进后运动多采用油压传动方式，上下运动可以采用油压传动也可以采用电动方式。钢坯被送到加热炉外的上料辊道上，经过测长后，从装料炉门进入炉内，然后在炉内悬臂辊道上进行对中定位，通过移动梁步进机械的周期运动，一步步地前进。当钢坯被输送到出炉位置，且已达到所要求的出炉温度，当接到允许出钢信号时，钢坯加热结束，由出料悬臂辊道从出料炉门送出，送往轧机进行轧制。
固定梁水平面
3
2
1
4
下
降
上
升
固定梁
移动梁
图（3）步进结构
步进行程如图（3）

连铸出坯焜道
装料焜道
装料机口
炉内固定梁
预热段
加热段
均热段
出料焜道
图(4)
工艺过程如图（4）

二、 DCS系统选型
⒈DCS选型注意事项
⒈ DCS可以用于不同的工艺过程，它是通用的控制设备。
⒉ 经济性，应该从DCS本身价格和预计所创效益角度考虑。　
⒊ 承包方的技术力量，也就是承包方对哪一工艺过程和DCS本身比较熟悉。　
⒋ 售后服务问题，国外厂商通常情况下存在配品、备件供应价格高，且不能及时供应问题。国内的DCS厂家配品、备件供应比较及时，售后服务方面做的也比较好。也可选用。
⒌ DCS的技术先进性，指系统采用了经过验证的最新技术，并有发展前途和生命力。　　　
选型不但要考虑项目规模和投资预算，还要考虑到一系列其它的因素，选型是否恰当往往从一开始就决定了该系统今后的命运，应慎重考虑。

⒉本设计DCS的选型
一般的工程项目，需要进行可行性研究和项目的基础设计，以确定工艺基本要求、系统的规模、测点的数目及特性（如量程、单位、阀特性、触点的常开和常闭等）、控制要求（如联锁、常规控制、特殊控制等）、需监控的流程画面（如带测点的工艺流程图样式、操作界面的样式）、报表样式及要求、控制室的布置设计等等。明确这些要求，为下一步的选型、组态、安装、调试等工作做了准备。选择浙大中控JX-300X组态系统。

JX-300X系统硬件结构

⒊DCS系统硬件选型
根据系统实际测点和控制情况，选择系统需要的硬件设备（机柜、机笼、卡件、操作站等），使硬件配置可以满足设计中的数据监控、画面浏览等要求，并为将来的系统扩展升级留有一定的余量。

加热炉I/O点数
检测区域
AI点数
AO点数
DI点数
DO点数

热电偶
热电阻
4~20mA
4~20mA

预热段上
11

3
3
42
26
预热段下
11

3
3
58
42
一加上
13

3
3
52
32
一加下
13

3
3
72
52
二加上
13

3
3
52
32
二加下
13

3
3
72
52
均热上
2

2
2
2
2
均热中
2

2
2
2
2
均热下
11

3
3
58
40
公共部分
7
17
12
6
42
20
汽化冷却部分

28
4
25
10

⒋组态设计
根据前期设计和硬件选型的结论，用 JX-300X 系统组态软件包中的相关软件实现控制站、操作站等硬件设备在软件中的配置，操作画面设计，流程图绘制、控制方案编写，报表制作等等。
一般的，组态设计按照以下的步骤进行：
①以系统整体构架为基础，进行总体信息的组态
②I/O 组态（I/O 设备、信号参数的设置）
③控制组态（控制方案的实现）
④操作组态（监控画面，如流程图等）
对于一个项目的组态设计，主要是指利用 JX-300X DCS 系统组态软件包，在工程师站上完成的设计、配置工作，这样的组态设计基本上是按照下面的步骤进行的：
1. 整理硬件及 I/O 信息，分配测点
2. 建立组态文件
3. 主机设置
4. 控制站 I/O 组态
5. 控制方案组态
6. 操作站组态
7. 编译、修正

⒌设备安装
设备安装之前，需要确定的是指控制室的环境布置是否符合 DCS 工作要求，是否具备供电条件，接地系统是否完成，机柜、操作台等是否就位，电缆的铺设是否符合标准，现场仪表的就位是否正常。
确认安装的准备工作就绪以后，可以进行设备接线、卡件安装等工作。
⒍调试
在设备就位的基础上，可以进行组态的下载以及控制系统的调试和联调。这些工作的进行测试了系统的各设备的通讯是否畅通，硬件工作是否正常，现场设备能否按照配置正确的工作，控制方案是否满足控制要求。

三、 步进式加热炉控制方案设计

⒉控制系统具体方案设计
采用具有快速补偿响应及抗积分饱和功能的双交叉限幅燃烧控制方法.
加热炉各段炉温控制采用PID控制，过程值来自于选定的热电偶的测量值。2根热电偶检测的温度偏差回路实时监视偏差值，温度偏差高时将报警提示操作工。炉温控制器有自动、手动两种控制方式。当煤气/空气调节阀输出达到60%以上而煤气/空气的流量过程值低于20%时，煤气/空气显示故障并停段。
在燃烧负荷发生急剧变化的情况下，由于空气流动管道与煤气流动管道特性间的差异，各阀门的响应速度和系统的响应速度不同，会带来缺氧燃烧现象和过氧燃烧现象的发生。当负荷增加时，燃料系统所需的煤气流量和空气流量理论上同时上升，但由于空气流量通常滞后，燃烧空气过少，此时燃料不能得到充分燃烧，致使热效率降低，同时造成烟囱冒黑烟，污染环境。相反负荷减少时，燃烧空气过多，多余的空气被加热后随废气一同带走，造成热效率降低，因此在燃烧控制中采用双交叉限幅控制。其结构是以出炉温度为一个主控回路，煤气流量和空气流量构成两个并联串级控制系统。其中，温度控制器是主控制器，实现温度的粗调，煤气流量控制器和空气流量控制器是平行的副控制器，完成精确控制。通过双交叉限幅，副回路控制器会在主回路的输出以及防止燃烧系统出现过氧和缺氧燃烧的上下限中选择一个合适的值给副回路控制器作为设定值，这样，煤气流量和空气流量会严格地按照一个合理的比值交替地上升，使实际的空燃比保持在合理的范围之内，从而克服了传统的串级控制系统存在的不足。
具有快速补偿响应功能的交叉限幅控制方法,双交叉限幅燃烧控制的响应速度受燃料流量控制和空气流量控制,响应速度的制约取决于其应较慢一方,通常是空气流量.控制的响应速度在炉温设定值动态优化设定的燃烧系统中,这一问题显得尤为突出通常的解决方法,是当炉温设定值的变化率较大时,取消双交叉限幅功能代之以串级并行控制.本文采用的方法是在现有的双交叉限幅燃烧控制的基础上增加一快速响应功能,以改善空气流量控制系统的响应速度.
这种控制方法主要思想是在正常状态下采用双交叉限幅燃烧控制方法,当负荷大幅度升降其变化超过响应速度,较快的燃料系统限制的能力时,燃料系统限制环节的输入输出之差,经动特性补偿方向性增益补偿和补偿量限制环节后,与空气系统限制环节的输出相加,此信号作为空气流量控制系统的设定值.实行强制性前馈作用以此来加快空气系统的响应速度,迅速解除对燃料系统的限制作用。

图中A 为炉温调节器的输出,B和 D分别为根据空气流量测量值求得的黑烟界限和空气过剩界限，C 和 E分别为根据燃料流量测量求得的黑烟界限和空气过剩界限，K1-K4 为偏置数 ,β为量程修正系数 ,μ为空气过剩率设定。

⑵煤气/空气流量控制

当空气和煤气管道压力过小的时候会造成回火事故，使加热炉既不能正常工作。为了保证不发生这样的事故，煤气管道压力不能太小，因此需要在煤气和空气管道压力持续减小，而温度调节系统无法发挥作用的时候需要完全切断煤气供应，对燃烧系统进行保护，以防止回火，造成不必要的损失。
煤气空气管道压力控制系统框图如图(5)所示：

气体管道
压力控制器
电动调节阀
压力检测变送
图（5）管道压力控制框图图
压力设定

PT
PC
流量
压力给定
压力
图（6）管道压力控制流程图

⑶炉膛压力控制
炉膛压力是实现加热炉自动控制的一个重要参数。当炉膛压力过高时，火烟就会从入(出)料口处大量冒出。这不仅使大量有效热量散失，增加炉子的燃料消耗，而且也容易烧坏炉子的钢结构和炉墙钢板，降低炉子的使用寿命。同时，炉压过大引起的冒火还会导致劳动环境的恶化。当炉膛压力过低时，会吸入大量的冷风，不但增加炉子的热耗还会增加钢坯的氧化烧损，甚至引起烧钢。因此，必须对炉膛压力进行有效控制。在加热炉最佳燃烧控制系统的基础上，炉膛压力控制可以通过控制烟道闸门的开启度或引风机调速来实现。
压力控制器
烟道闸门
炉膛
压力检测变送
烟道管道
压力设定
图（7）炉内压力控制框图
炉膛压力

图（8）炉内压力控制流程图

四、 DCS组态图
⒈JX-300组态图

⒉加热炉控制系统演示工程

⒊温度报警显示

⒋温度和炉膛压力监控

五、 心得体会
通过这次的过程控制课程设计，我学到了很多，不仅仅是知识方面。
刚接触到这个题目，感觉非常棘手，对各种只是都不了解，因而，就开始了搜索资料的过程。但是网上的资料也并不是很全面，很多东西还是很模糊，也去图书馆查阅了一些资料，再结合这自己所学的知识，慢慢的摸索出了一些门道。课程设计是一个综合性的题目，它包括的不只是过程控制的知识，还有像DCS，自动控制原理等等的知识的结合，是融会贯通的。这就让我将自己大学几年里学的知识综合到了一起，对自己所学的知识体系有了更进一步的理解。
老师也进行了课程设计的答疑，让一些同学分享了自己做课程设计的经验，再加上老师的讲解，我对这次课程设计的思路、知识有了更加深刻的认识，也给我做课程设计时有了一定的指导方向。通过我们小组成员的共同努力，我们成功的将这次过程控制课程设计完成了。
这次课程设计，让我学到了不少实际工程运用的知识，加深了我对课本知识的理解。同时，也锻炼了我对于问题分析，进而进行搜索、汇集、整理资料的能力。不仅如此，他还增强了我的团队意识，学习了团队的精神。总之，这是课程设计不只是一次知识的领悟，而且是对我人生发展的综合考验。我也能不断督促自己做的更好，不断的进步。
4.《组态软件应用指南:组态王Kingview和西门子WinCC》 王善斌主编北京:化学工业出版社,2011
5.《分布式控制系统(DCS)设计与应用实例》/王常力, 罗安主编北京:电子工业出版社,2004
6.电子文献：中国优秀硕士学位论文（加热炉控制）

（英文版 ）
easily blame, to prevent the broken window effect. Supervise the leading cadres to play an exemplary role, take the lead in the strict implementation of the < code > and < rule >, lead to safeguard the solemnity and authority of the party discipline, ensure that the party discipline and the laws and regulations for implementation in place. Throughout the discipline in the daily supervision and management
, strengthen supervision and inspection, from the thorough investigation of violations of discipline behavior. Strengthen to key areas, key departments and key projects as well as the masses reflect the concentration of the units and departments for supervision. - strengthening supervision, discipline inspection and supervision of cadres to set an example for compliance with the < code > and < rule > is a man must be hexyl, blacksmith needs its own hardware. Discipline inspection organs as the executor of the party discipline, and supervisor of the defenders, for its supervision must be more strictly, discipline inspection and supervision of cadres to firmly establish the awareness of Party Constitution, sense of discipline and rules consciousness, politics loyalty, sense obey. Action speak Ji Ordinance to set an example of the regulations of the rule of law, strengthen supervision and accept the supervision of the firmness and consciousness, do comply with < > and < >. To firmly establish the discipline must first be disciplined, the supervisor will be subject to the supervision of "concept, and consciously safeguard and implement party compasses party, take the lead in practicing" three strict real strict, so loyal, clean, play. To be good at learning, the Constitution and the < code > as morality, politics and brought to fruition; to implement < >, do not want to, dare not, not with disciplinary ruler to supervision; to discipline a ruler, often the control inspection, and consciously in the ideological red line to draw the row Ming Good accumulation is indeed the bottom line, so that the heart has fear, said to have quit, the line has ended. Attached: indifferent to heart, calmly to the table in our life, there are many unpredictable things will happen, some good, some bad things, we cannot control is powerless to stop, but with time, you will find in life sometimes turns out to be not good, some bad things finally turned out to be a good thing, but then we muddy however did not know, this is the life teach us things. 1, life can be complex, can also be simple. Want simple life of precipitation, to have enough time to reflect, to make Become more perfect. Life is the most important thing is not to win, but the struggle; not to have conquered, but to have fought well. 2, the plain is the background of life. Live a plain life, give up on themselves is not a coward, but the wise answers; not disillusioned after the heart, such as ashes, but experience the storm after the enlightenment; not unrewarding perfunctorily, but calm attitude of life of unrestrained self-confidence. Plain living, there is no noise noisy, no earthly troubles, more did not fill in the discontent of desire, some just a calm, a calm. 3, memory of heart will not good things to erase the, life is a When no movie, pain is a beginning, the struggle is a kind of process, death is a kind of ending. Give up this giving up is the helpless, do not give up the abandoned, do not give up this giving up is ignorance, do not give up should not give up is persistent. 4, a thing figured is heaven, think impassability is hell. Since the living, to live better. Sometimes we because of too narrow-minded, too care around the chores and penny wise and pound foolish, not worth the candle. Some things to attract trouble and worry, completely depends on how we look at and deal with it. Don't always take everything back to things, and don't get into a blind alley, don't want to face, don't be narrow-minded. Poke to care, is a kind of open-minded, a free and easy. 5, I am not afraid of others behind me a knife, I afraid to look back and see stab me, is my intention to treat people; I am not afraid of the truth to tell the best friend, I'm afraid he turned to it as a joke to tell don't 6, when we are in a positive frame of mind, you will find many good things; and when we are in a negative state of mind, you will find many depressed things; life happy and worry, all is you of life attitude, optimistic, good luck; loss of sink, Eritrea company. When you are in adversity, may wish to change a point of view to think everything over to the good Think, because good mentality decided the fate of the! 7, people are tired, rest; heart tired, calm. Grow up, mature, this society read. Tired and sad, squat down, to their a hug. Because the world no one can sympathize with you, have mercy on you. You cry, tears is your own; you pain, no one can understand. Then you only tears to smile. 8, each people have youth,
Each youth are a story, the life of the world never gets easier, I want what, wish the world all know, as has been the same; now want anything, for fear that others know, or like to lose the same. 9, the heart move, everything in the world is followed by birth, Rangrang, important thing is often the most difficult to open one's mouth, because words will reduce its importance; to let strangers people care about your life in the good things, the original is not easy 10, do not blame, do not laugh at who, also don't envy who. Like a person is a kind of feeling, not like a person is true. The truth is easy to explain, I feel Is unspeakable. The best travel life is that you in a strange place found a long lost touched. 11, happy life not in the bustling in, and in the peace of mind; no matter how many grievances, how uncomfortable, and ultimately to heal themselves or their own, others may got you to comfort, but never know your heart is how wanjianchuanxin. 12, ma'am, like a movie, learn to appreciate, learn to be grateful, learn tolerance, and goodness, helping others. Instead of accusing the society, as into one; and an exception is better to give than to what 13, don't envy him A sum of, don't lose your life and the life, respectively is: the former is a we experienced cannot escape in a day finally will last minute, while the latter is our persistent, we want to cherish the memory of those people and things. 14, learn to smile, learn to strong, the world you know so many people, so many people and you are, you cannot change also can't let everyone like you, so also do not want to do. Life is too short to go crazy to love to go to waste, to chase the dream to regret. 15, when temper, a blessing to go. A wounding elegant people, the key is to control their own emotions. With the mouth is the most stupid behavior. A control negative emotions than a can take a city more powerful water flow slow, language is expensive. People spent two years of time to learn to speak, but to spend a few years time to shut up. That is a kind of ability, that is a kind of wisdom. 16, life is not perfect, sometimes, growth is not a cry, not an eyeful of tears, there is no trace of emotion, there is no gleam of hope, no desire, no action, no static, there is only one kind of downward sinking feeling, sink A murky? 6? 7? 6? 7 sink? 6? 7? 6? 7 toward the bottom of the sink. 17, in some way, do not go, you will not know the other side scenery is beautiful. To you is not good, you do not mind too much, no one has an obligation to you; you learn knowledge, is you have weapons, you can start from scratch, but not unarmed; how do you treat people, does not represent how others treat you, if cannot see through this point, only inviting worry. 18, time is like a sponge in the water, as long as you are willing to squeeze, the total water is still there. Every life, after the ups and downs The best test of live, to life, survival and continuation, do not stop the struggle in the joys and sorrows of life on the road, so that different soul to bear life beat, acceptance of suffering. 19, indifferent to heart, calmly in table, elegant and comfortable life, do not take what is so important. The pursuit will be disappointed; to be alive, you will have trouble. Life is the most afraid of what all want to care about, but also what all grasp is not firm, without scenery, separated populations, such as not to desire, all docked in the fate of the end. Why is too rigid, the natural, to go stay not to live, let go of obsession, revel is 20, if the fate of the broken Hopes of sailing, please don't despair, the coast is still, if the fate of the withered petals of the beautiful, please do not sink, the spring is still, life will always be endless trouble, please don't helpless, because they are still alive, is still a