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Chuong1 TNU
Chuong1 TNU
Trang
Mc tiu ca mn hc
-
T chc ca mn hc
Sau phn gii thiu chung, mn hc s a ra phng php tip cn cc ni dung sau:
-
T ng ho v tm quan trng ca n
T ng ho l mt lnh vc rng ln c p dng v tt c cc lnh vc hot ng ca
con ngi, c bit l lnh vc sn xut. Ngy nay nh tha hng nhng thnh tu to ln ca
cng ngh in t, cng ngh my tnh c cng ngh thng tin, cng ngh t ng ho c
bc pht trin nhy vt.
T ng ho l bc pht trin tip theo sau c kh ho v in kh ho. T ng ho l
qu trnh s dng thit b thay th chc nng kim tra v iu khin ca con ngi trong mt
quy trnh sn xut. H thng t ng ho bt u xut hin vi vic s dng cc thit b o lng
kim tra cc thng s cng ngh v cht lng ca sn phm. Cc h thng ny thng bo kh
chnh xc cc thng tin v trng thi ca thit b, cc thng s quy trnh cng ngh,...Cc thng
tin ny trc y ch c nhng ngi dy dn kinh nghim mi chun on c, nhng cng ch
m bo mc chnh xc tng i. Cc thng tin ca h thng o phc v c lc cho qu
trnh hon thin quy trnh cng ngh.
Bc pht trin tip theo ca qu trnh t ng ho l s dng h thng iu chnh t
ng cc thng s cng ngh. y l bc pht trin kh mnh ca h thng t ng ho cng
Cc ng dng ca t ng ho
T ng ho c p dng vo tt c cc lnh vc hot ng ca con ngi.
Pht in:
S truyn dn:
in, kh t, du.
S phn phi:
in, nc.
Qu trnh:
Giy, thc n, thuc (dc), ch to v gia cng kim loi, gng knh, xi
mng, ho cht, nh my tinh ch (du, ng...), du v kh.
Ch to:
Xy dng:
Nh sn xut
a im
ABB
CH-SE
Alstom
FR
Ansaldo
IT
Emerson
US
General Electric
US
Hitachi
JP
Honeywell
US
Rockwell Automation
US
Shneider Electric
FR
Tlmecanique, Squre-D,..
Ivensys
UK
Siemens
DE
Yokogawa
JP
1.1.3.
-
Tm quan trng ca t ng ho
T ng ho cho php gim gi thnh v nng cao nng sut lao ng. Trong mi thi
i, cc qu trnh sn xut lun c iu khin theo cc quy lut kinh t. C th ni gi
thnh l mt trong nhng yu t quan trng xc nh nhu cu pht trin ca t ng ho.
Khng mt sn phm no c th cnh tranh c nu gi thnh ca n cao hn cc sn
phm cng loi, c tnh nng tng ng ca cc hng khc. Trong bi cnh nn kinh t
lun phi i ph vi cc hin tng nh lm pht, chi ph vt t, lao ng, qung co v
bn hng ngy cng tng, buc cng nghip ch to phi tm kim cc phng php sn
xut tt nht gim gi thnh sn phm. Mt khc nhu cu nng cao cht lng sn
phm s lm tng mc phc tp ca qu trnh gia cng. Khi lng cc cng vic n
gin cho php tr lng thp s gim nhiu. Chi ph cho o to cng nhn v i ng
phc v, gi thnh thit b cng tng theo. y l ng lc mnh kch thch s pht trin
ca t ng ho.
1.1.4.
-
Nhng mong i t ng ho
Cc yu cu v quy trnh
Tng an ton, m bo li ch
Kt ni vi qun l v k ton
Tr gip a ra quyt nh
Qun l ti sn
m bo v ch bo dng
Cc cng c ca nh sn xut
1.1.5.
-
100,000 n 10,000,000 im
S hp l ca t ng ha nh th no?
1.2.
-
Cc v d v cc qu trnh t ng ho
Cc phng tin giao thng:
+ t: Theo cch truyn thng: iu khin cc thit b ring bit (Cc ca,ch ngi,
radio,..), iu khin ng c (exhaust regulations).Mu US 2001 : 19% ca gi
thnh l cc thit b in t, khuynh hng: +10% trn nm.
+ Phng tin ng st: C hn 20 my tnh c ni vi nhau trong mt u my
iu khin cc b phn: lc ko, chun on, tn hiu, hin th, nng lng...
Cc li ch:
Cc cnh tay rbt: c ng dng nhiu trong nghip ch to lp rp. Gii hn dui
thng: 2-3 m (cc robot vn chuyn 10-20m), c c im l thng xuyn lp trnh li
cho nhng nhim v mi, trang b my tnh nhng n gin, phn cp iu khin...
Ngnh cng nghip dc phm: t ng ha trong nhiu khu kim k, qun l cng
thc, ng gi, th mu, gim st v theo di m bo sn xut tun theo cc lut ca
chnh ph,
Sn xut theo qu trnh (qu trnh cng ngh): c c im l nguyn liu c np lin
tc, thng 24 gi mt ngy. v d: xi mng, giy v bt giy.
Sn xut xi mng:
L quay l tri tim ca qu trnh sn xut xi mng: cc l nghin c nung v a sn
T ng ha trong xy dng: tham gia iu khin h thng cung cp cho nhng cng
trnh ln hoc cm dn c: cht t, kh hu, qun l nng lng, HVAC= Nhit, Thng
hi v Lm mt= iu ho khng kh.
ng dng trong cc sn bay: iu khin v kim sot h thng cc ca, khu vc an ninh,
vn chuyn hnh l, cc khu vc ct v h cnh, iu khin t ng t xa h thng cc ta
nh ln: t chy, s truy nhp an ton, nng lng, chiu sng, iu ho khng kh,
truyn thng, iu khin giao thng.
iu khin giao thng: kim sot cc hin tng la, xm nhp, nng lng, nc, h
thng thng hi, kim sot nhim, Camra quan st, iu khin nh sng, ngn nga tc
ng..
H thng x l nc: (nc thi v nc sch) nhim v qun l h thng bm, thng
cha, thnh phn ha hc, b lc, cc ng c, cht lng...
Thit b ph: My pht in Mtan
Cng ngh x l rc thi, cc l t rc: Cung cp nguyn liu th, qu trnh t chy,
lm sch khi, iu khin mi trng, qu trnh pht phi hp (hi nc, hi nng), phn
tch tro, x l tro.
S lng ln cc im (nh my in, my bin p, b ngt in, trm bin p) nm trn 2km
n2000 km mi phn.
1.3.
1.3.1.
Vng h - vng kn
Di quan im s cu trc, ta c th phn thnh 2 loi: iu khin vng h v iu
Hnh
1.3.2.
1.4.
Phn cp h thng t ng ho
Mc d c s ng dng rt rng ri, nhng gia cc h thng iu khin ch c mt phn
Cp 3
Computer network
Supervision
DCS, SCADA, HMI
Process control
H K TH QTCN
Local control
H KT
Individual control
Diu khin rieng
Cp 2
Cp 1
Cp 0
Computers
Terminals
Controllers
PID
PLC
Sensors measurement
actuators, motors,
relay, valves
QTCN- PROCESS
HnhHnh
1. 1.1 Cu trc phn cp ca h iu khin
Qu trnh cng ngh ( QTCN- Process) l i tng iu khin, c th l mt my sn
xut hay mt tp hp my sn xut nhm hon thnh mt nhim v sn xut nh trc.
Cp 0 (Individual Control) l cp tip xc gia h iu khin v QTCN. y c cc
cm bin, cc thit b o dng thu nhn cc tin tc t QTCN. cp ny cn c cc c cu
chp hnh, r le, ng c, van, kch .v.v dng nhn thng tin iu khin v chp hnh cc lnh
iu khin.
-
Trng: thu thp d liu (cm bin v thit b chp hnh), chuyn i d liu
khng x l ngoi tr vic hiu chnh php o v gn lin vi bo v.
mm do, c th dng vo cc cng ngh khc nhau do c th coi PLC l thit b iu khin
vn nng.
-
nhm (khu vc): iu khin mt phn d phn bit ca nh my (cc vng kn, ngoi tr
vic can thip ca ngi vn hnh)
+ phi hp cc nhm ring l
+ iu chnh cc im t v cc thng s
+ t lnh cho mt vi n v hoc tt c
Control). cp 2 c cc my tnh (MT) hoc mng my tnh. MT thu nhn cc thng tin v
QTCN (t cp 1 a ln) x l cc thng tin v trao i thng tin vi ngi iu khin
(NK). Thng qua MT, NK c th can thip vo QTCN, nh vy h iu khin y thuc h
ngi - my. cp ny thng c cc H iu khin phn tn ( Distributed Control System DCS), H kim tra v thu thp d liu ( Supervisory Control and Data Acquisition - SCADA )
-
hin th ha cc thit
Sn xut: qun l thc hin, ti nguyn, b tr cng vic, gim st cht lng,
lp chng trnh sn xut, bo dng, bo hnh.
Nhng nh ngha sau y gip chng ta phn bit gia cc h KT v cc h K TH
Hnh 1.
Hnh 1.
Hnh 1.
Cc cp cao hn
+ D liu th gim khi cp iu khin tng, khi kiu d liu cp cao hn c
to ra (vd: dng thng tin tm tt).
+ Qu trnh x l d liu v a ra quyt nh tr ln phc tp hn (i hi s dng
mu).
+ Cc yu cu v thi gian tnh ton c gim bt.
+ D liu c lu tr.
Cp SCADA
+ Cc d liu phc tp c trnh by cho ngi iu khin quan st,
+ tr gip a ra quyt nh (h thng chuyn gia) v tham kho.
Cc cp thp hn
+ Cc cp thp (gn nht vi thit b) th hu ht c i hi kht khe v thi gian p
ng.
+ S lng ca d liu th l rt ln.
+ Qu trnh x l n gin.
+ Cc cp ny ngy nay thng dng iu khin my tnh, ngoi tr trong cc tnh
hung khn cp, cho bo dng hoc kim tra.
Hnh 1.
Hnh 1.
1.5.
1.5.1.
Nguyn tc chung
+ H thng iu khin phi ph hp vi h thng thit b, khng phi ngc li
+ Cu trc h thng iu khin phn nh bn cht ca nh my
+ Mt cch l tng, mi n v ca h thng phi nn c b iu khin ring ca
n, c tng tc vi cc b iu khin khc ca cc n v lin quan, phn nh
mi quan h vt l ca chng.
Cu trc vo ra
Cng vic ni dy phc tp, chi ph cho cp dn cao: s lng ln cc cp ni, cu trc
phc tp, cng thit k, lp t ln.
Km tin cy: Phng php truyn dn tn hiu tng t gia cc thit b trng v thit b
iu khin d chu nh hng ca nhiu, gy ra sai s m khng c kh nng pht hin.
Nu c li truyn thng cng d dng pht hin nh cc bin php bo ton d liu ca h
bus.
Bus h thng:
+ Chc nng:
Bus trng
+ Chc nng:
Ghp ni trm iu khin vi cc trm vo/ra phn tn, ghp ni trm iu khin
trc tip vi cc thit b trng thng minh.
+ c im k thut:
Mng tc thp hoc va phi (< 10Mbit/s), yu cu tnh nng thi gian thc
cao, tin cy cao, c bit trong mi trng d chy n.
+ Cc loi bus thng c s dng:
Profibus-DP, Profibus-PA, Foundation Field busH1, Control net, Device Net,
mng c chng ca ring hng sn xut, s dng RS-485
1.5.2.4. Thit b thng v bus trng
1.5.3.
Cu trc iu khin
Cu trc c in nht
Thng c s dng cho cc h thng c qui m va v nh, c bit tiu biu trong
cc ngnh cng nghip ch to, lp rp (cc dy chuyn song song c lp vi nhau)
C th s dng kt hp cu trc vo/ra tp trung hoc vo/ra trc tip vi bus trng.
Hon ton khng c s phi hp gia chng cng chia s gii quyt cng mt
nhim v.
linh hot thp: M rng cng nh thay i mt phn trong h thng i hi phi
dng ton b h thng.
Hiu nng km: Ton b thng tin u phi a v trung tm, chm tr do thi gian
truyn dn v x l tp trung
Ch ph hp vi cc ng dng qui m nh
My tnh trung
tm
(Mainframe
Grou
Contro
Sensors,
Grou
Contro
Grou
Contro
PLC
plan
iu khin phi hp gia cc my tnh iu khin c th din ra trc tip hoc thng
qua cc my tnh gim st trung tm (MTGS).
Hnh 1.
1.6.
1.6.1.
1.6.2.
Cc cng c
1.7.
Cu trc h con
K hoch sn xut
Lao ng tin lng
Vt t thit b
.
.
.
.
.
.
Cc h con
chc nng
K hoch ti v
Hnh chnh
m bo
thng tin
m bo
ton hc
m bo
k thut
Cc h con m bo
Hnh 1-4: Cu trc h con ca h K TH QTCN
Cu trc phn cp
T
TG
T
Trung tm
iu khin
Trung tm
tnh ton
Terminal
T
TG
TG
Trm
trung gian
TTK
TTTT
TTK
Bus
1.8.
Nhiu
Hiu lc php l ca
cc d liu ban u
D kin v k
hoch sn xut
Qu trnh sn xut
Hiu lc php l
ca qu trnh
tnh ton
Kt qu
tnh ton
X l d liu bng
my tnh
1
Yu t so
sanh
C cu so
snh
0
1.8.3.
Cu trc m bo ton hc
m bo ton hc bao gm nhng thnh phn sau:
M hnh ton hc
Xy dng m hnh ton hc l mt trong nhng giai on quan trng nht ca vic xy
dng h thng iu khin. Thng thng cng vic ny phi do cc chuyn gia am hiu v qu
trnh cng ngh v nm vng v ton hc m nhim. i vi cc k s cng ngh, thng
khng kh nng t mnh xy dng m hnh ton hc, nhim v chnh l la chn cc m hnh
ton hc sn c sao cho ph hp vi qu trnh cng ngh m minh ang quan tm nghin cu.
Hin nay ngi ta thng dng cc loi m hnh ton hc sau y:
-
Thut ton
M hnh ton hc tuy rt quan trng nhng ch mi l cu trc hnh thc ca vic x l
thng tin ch cha phi l qu trnh x l theo khng gian v thi gian. Gii quyt vn ny l
nhim v ca m bo thut ton, c ngha l trn c s m hnh ton hc chn phi xy dng
cc th tc, cc phng php gii cho kt qu chnh xc thi gian tnh ton ngn, t tn b nh
.v.v. Thut ton l mt ngnh chuyn su v c tc dng rt ln trong vic gii cc bi ton iu
khin.
1.9.3.
Chng trnh tnh ton l mt tp chng trnh dng tnh trn my tnh. Chng trnh
ny th hin m hnh ton hc v thut ton chn. Chng trnh tnh ton ph thuc vo ngn
ng lp trnh v loi my tnh. Thng thng cn c cc cn b chuyn su v lp trnh m
nhim vic ny.
Cc ngn ng lp trnh hin nay thng gp l PASCAL, C++, Visual Basic v.v..
gim nh vic lp trnh ngy nay ngi ta xy dng cc loi ngn ng chuyn dng. V d nh
m phng c GPSS (The General Purpose Simulation System), SIMSCRIPT, SIM++, Matlab
Simulink, v.v. V thc cht cc ngn ng loi ny l tp hp ca nhiu chng trnh con di
dng cc lnh, ngi s dng ch cn khai bo nhng thng s cn thit v lp trnh trn tp lnh
c. Tu thuc c im cng ngh v yu cu ca bi ton t ra m ngi iu khin xy
dng nhng chng trnh tnh thch hp.
m bo thng tin v m bo ton hc c coi l phn mm ca h K TH QTCN.
1.10.
m bo k thut
1.10.1.
Cu trc m bo k thut
Terminal
Nhu cu truyn d liu trong h K TH QTCN rt ln, thng xuyn phi truyn cc
thng tin t di ln trung tm x l, v truyn cc thng tin x l (cc mnh lnh iu
khin) t trn xung cc terminal tc ng vo QTCN.
Mt h truyn d liu c cu trc nh Hnh 2-2
KLL
NT
MH
G
C
D
M
CH
Nhiu
Ngun tin (NT) bao gm cc tin tc nh mnh lnh, trng thi thit b (lm vic, ngh, s
c) thng s k thut (nhit , p sut, tc .v.v.). truyn tin i xa, cc tin tc ny phi
c m ho (MH) sau iu ch (C) thnh cc tn hiu (TH) c tham s (bin , tn s,
pha) thch hp vi truyn tin i xa. M ho l qu trnh bin i mt- mt gia tin tc v tn hiu.
Trong t m ngoi nhm tn hiu mang tin cn c cc tn hiu d dng chng nhiu. Tn hiu
ra khi thit b iu ch c a vo knh lin lc (dy dn, cp, radio). Thng thng trong
knh lin lc c cc loi nhiu (di dng xung in).Nhiu lm cho nhm tn hiu (t m) c
truyn i b sai lch, tn hiu 1 0 v ngc li tn hiu 01. cui ng dy lin lc ta thu
c tn hiu trong c c nhiu. Thit b gii iu ch ngc (GC) dng phc hi li tn
hiu b suy gim trong qu trnh truyn qua knh lin lc. Thit b dch m (DM) kim tra pht
hin v sa sai trong t m nhn c, sau dch ra tin tc ban u (TT) c truyn. Tin
tc c a vo c cu chp hnh (CH) tc ng ln i tng (T).
Vn quan trng ca h truyn tin l m bo chnh xc v tc truyn tin. i vi
nhng h iu khin trc tuyn (online) th vic truyn tin, x l tin phi c thc hin kp vi
qu trnh din bin cng ngh. Nhng h truyn tin nh vy gi l h lm vic trong thi gian
thc. Ngy nay ngi ta thng dng tc truyn tin t 4800 bit/s tr ln. Truyn tin nh vy l
rt nhanh, do vn chng nhiu, nng cao chnh xc truyn tin l mt trong nhng vn
quan trng nht ca h truyn tin.
H thng thit b tnh ton bao gm cc b phn sau y:
B x l trung tm
Thit b nh trong, nh ngoi
Thit b vo ra
ng truyn d liu
Thit b tnh ton l mt trong nhng thit b quan trng nht ca h K TH QTCN.
Ngy nay xut hin my tnh th h th t, cc my vi tnh gn nh, tc x l tin cao, b
nh ln, giao tip vo ra thun tin. Tt c nhng iu lm thay i mt cch c bn b
mt ca h K TH QTCN, to nn kh nng ng dng rng ri cc h K TH QTCN vo
nhiu lnh vc kinh t- x hi khc nhau.