0 Preface This paper introduces the design experience of the Huangshan Xin'anjiang large-scale steel dam gate control system. The system has good reliability, stability and real-time performance, which is in line with the principle of risk dispersion of the control system. 1 System introduction Huangshan Xinanjiang Steel Dam Gate has 5 holes, each with a width of 46 m and a water blocking height of 4.8 m. The steel dam gate dumped to the downstream side and flooded after lying down. The maximum water height at the top of the door (when standing) is 40 cm to form a waterfall landscape effect. The design water depth above the gate during flooding is 7.78 m. The maximum rotation angle of the gate is not less than 90 °, and the gate can be locked at any set angle. The steel dam gate is driven by a hoist, and the hydraulic hoist is arranged on two sides, in which the hoist on the right bank controls the 2-hole gate and the hoist on the left bank controls the 3-hole gate. Under normal working conditions, the operating speed can reach 3 to 5 m / min, and the dam can be lifted and collapsed within 10 minutes, which can effectively ensure the timely discharge of floods during sudden floods. The schematic diagram is shown in Figure 1. The control system of the steel dam gate is designed according to the requirements of "less number of people on duty", and the three-layer topology structure of the control center, on-site control and equipment is composed on the principle of "layered management and centralized control". The system configuration and equipment selection make full use of the advanced technology in the computer field. Both the software and hardware adopt a fully open and distributed modular structure, which makes it have good scalability and is also convenient for the intelligent operation and management. As a subsystem of Xin'anjiang Water Control Project, the steel dam gate control system not only has a monitoring center (central control room), but also has two local control stations (PLC01 station and PLC02 station) on the left and right bank hydraulic hoisting machine rooms. Among them, the PLC01 station controls the 2-hole gate, and the PLC02 station controls the 3-hole gate. The most critical control object of the system is the stroke control of the hydraulic cylinder of the hydraulic hoist to prevent the hydraulic cylinder from being distorted or even damaged due to excessive hydraulic cylinder stroke deviation when the steel dam gate is opened and closed. 2 System structure The Xinanjiang steel dam gate control system has a three-layer topology. The first layer is the control center layer. Taking the network management switch of the hub control center as the core, the communication protocol is TCP / IP, and the data throughput rate of the communication network is 100 Mb / s. The operator station of the control center adopts the dual-machine redundant hot backup working mode. If any computer fails, it will not affect the normal operation of the system and ensure the high availability of the system. The engineer station can carry out upper and lower software programming and debugging. This layer completes the functions of system data analysis, monitoring, control, communication and management scheduling, and displays the process parameters, electrical parameters, equipment operating status (work / stop / fault) and gate opening during the work of the steel dam gate. The second layer is the local control layer. Taking the Schneider Unity platform as the control core, it mainly completes data acquisition, sequence control flow, logic control flow and data exchange with other devices in the system for field devices. The control layer network adopts a TCP / IP network and a ring topology, uses single-mode fiber as the communication medium, and forms an industrial Ethernet network with a bandwidth of 100 Mb / s through an Ethernet ring switch to achieve high-speed transmission of control signals. The network is a self-healing ring network. When a fiber breakpoint occurs in the ring network, the communication can still proceed normally. At the same time, as the control backbone network of the hub, the fiber optic ring network can add or delete any device online at any node, and it will not affect the operation and communication of other devices, fully considering the convenience of the management of the hub engineering system. The control system topology is shown in Figure 2. The third layer is the device layer. Use the MB communication interface on the Unity PLC to perform multi-point communication with the soft starter in the MCC cabinet and other intelligent instruments. This kind of communication method that directly uses bus cable connection without traditional I / O modules realizes the digital transmission of data between discrete devices and PLCs in the field, while reducing costs to a minimum. This low-cost, high-efficiency information integration model for low-level devices has gradually become the mainstream in the control field. 3 Control system design 3.1 Technical requirements The technical requirements for the control system are as follows: (1) Due to the high level of control required for steel dam gates, the load rate of the module must be less than 50%; (2) The balance of I / O points is 15%; (3) The internal memory occupancy capacity is less than or equal to 50%, and the external memory occupancy capacity is less than or equal to 40%; (4) Under the premise of meeting the control requirements of high stability, improve the performance-price ratio; (5) When the system fails, the maintenance personnel can quickly eliminate the failure according to the restored historical records. 3.2 The hardware composition of the control station PLC The system design uses Schneider's Unity series PLC. The power supply is redundantly configured. The Unity modules all support live hot-swap function. The module fault self-check function can make the module's fault instantly reflect on the host computer system, which greatly facilitates the steel dam gate. Control system operation, maintenance and maintenance personnel. Take the left bank PLC01 station as an example, the switch output 54 points, switch input 152 points, analog output 5 points, analog input 11 points, the right bank PLC02 station is the same. When the module is configured, there must be a 15% margin on the actual statistical points. PLC01 station hardware configuration is shown in Table 1. 3.3 Host monitoring system The upper monitoring system is responsible for the steel dam gate control, system management, PLC programming, upper configuration and debugging. The programming software uses Schneider Unity Pro software, the upper monitoring software uses Wonderware's Intouch 10.O, and the operating system is Window XP Professional. Unity Pro programming software completes the allocation of hardware configuration and sub-station addresses, and writes the control logic of the entire system program. The programming software uses the international standard IEC6113l-3 programming language, which is easy to understand, intuitive and simple, and a powerful programming environment can basically meet all industrial logic requirements. Intouch 10.0 monitoring software is a set of industrial automation configuration software, which provides a "process window" and real-time data for the system, and provides the operator with a powerful and convenient man-machine interface. Intouch realizes data collection, device control, recording, fault alarm and other functions through the local PLC, and performs real-time display, event recording, printing, etc. in the form of graphics or reports. 3.4 Control mode The operation and operation of the steel dam gate control system are equipped with three working modes: "remote automatic", "remote manual" and "local manual". "Remote automatic" mode is the normal main operation mode. According to the conditions for the automatic sequence operation of the steel dam gate, the entire work process is completed on the operator station. In the process of programming, pay attention to the automatic sequential execution. Any failure or interruption signal of the operating personnel can interrupt the running program and return to a safe state, so that the failure of the program or the instructions of the operating personnel will be displayed on the screen in real time. "Remote manual" mode is for the operator to operate the controlled object on the screen. In the remote manual mode, the system provides rich operation guidance and feedback information to guide the operation of the operator to prevent misoperation. The "local manual" mode is where the operating personnel operate the controlled object through the buttons on the local control cabinet. 4 Realization of main control functions The gate width of each hole of Xinanjiang Steel Dam Gate is 46 m, and the small stroke deviation of the hydraulic cylinders on both sides of the hydraulic hoist will produce a large torsion, causing the gate to deflect, jam, or even damage during the opening process. The stroke control of the hydraulic cylinder during operation is the key. In order to prevent the hydraulic cylinder stroke deviation from being too large during the opening and closing of the steel dam gate, each gate hoist is provided with a gate opening (travel) detection device. The local PLC can accept the gate sent by the absolute encoder in the detection device The opening data (resolution is 1/4 096), the control center can closely monitor the operation of each gate of the hole according to this data. Among them, the stroke detection device and the stroke switch are the key detection components, which require the selection of products with high reliability and advanced technology. The main control function of the steel dam gate can be successfully realized through the stroke detection device: (1) Synchronous control of hydraulic cylinder. In the gate opening and closing process, the stroke detection device continuously detects the stroke deviation of two hydraulic cylinders of the same hole gate throughout the process. When the deviation value is equal to 20 mm, the hydraulic system automatically adjusts the oil input and output of the corresponding hydraulic cylinder, so that Synchronize. When the stroke deviation of two hydraulic cylinders is greater than or equal to 40 mm, the hydraulic system automatically stops and issues an alarm signal. (2) Gate reset control. When the gate is opened to the predetermined working opening, the system can automatically monitor the actual opening of the gate. When the gate slides down to 150 mm from the open working position due to system leakage, the control system should automatically instruct the hydraulic pump motor unit to start and turn the gate Ascension and restoration. If the gate continues to slide to 200 mm, the control system should automatically command the standby hydraulic pump motor unit to start, lift the gate back to its original position, and send out an alarm signal at the same time. (3) Limit position control. Gate full-open position measurement: when the gate reaches the full-open position, a switch signal is given through the travel switch to stop the gate opening operation; gate full-closed position measurement: when the gate reaches the fully-closed position, a switch is given through the travel switch Signal to stop the gate closing operation. (4) Pressure measurement of the main circuit of the hydraulic system. The system can automatically measure the pressure of the oil source of the gate operation pressure, the pressure of the two chambers of the oil cylinder, and the pressure of the main valve and oil in the oil circuit. The control system detects and diagnoses the working state of the hydraulic system in order to take protective measures in time. (5) Measuring the running state of motor and oil pump. Check whether the motor input command is executed and the oil pump is running normally. 5 Conclusion Huangshan Xinanjiang Steel Dam Gate is the second largest steel dam currently under construction in China, and its control system requires advanced, reliable and safe. During the demonstration and implementation of the steel dam gate project, Schneider Un-ity PLC was used as the platform to fully utilize some advanced and mature technologies in the current industrial control field, so that the system has high reliability, high stability and flexible scalability The function provides good technical support for the less-duty management mode of the steel dam gate. Since the design of this system was started in January 2009, it has organized many water conservancy engineering experts to review the drawing design, and the participating experts were very satisfied with the design of the control system. The system is currently being commissioned, and it is expected to be officially put into operation by the end of the year. After the operation, it will play a huge role in the urban water conservancy construction in Huangshan City and obtain considerable economic benefits. Social benefits.
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