Abstract: As China's cement industry and other process industries, the next decade will face the market and energy; clean production and environmental protection; efficient and standardized; responsible and coordinated challenges. Energy saving, environmental protection, safety, and efficiency are the topics that every cement group must face, and automation technology and these four major goals are closely linked. This article will provide a brief description of the latest development trends in the field of automation and the cement industry. In order to develop China's cement industry, we will build a broader platform for communication and communication.
First, information technology to promote automation Information technology to transform the cement industry, to promote the automation of information, automation and then promote the realization of energy, environmental protection, safety, and efficiency of the four major goals, has become the consensus of the industry. In today's automation field, the smooth flow of information can be basically achieved through the Ethernet from the field level of the process to the management of the factory (group). The so-called "modern integrated production process" is the information technology, network technology and modern new technology. Combine and apply it to all stages of an enterprise's product life cycle. Through the seamless integration of information, process optimization, and resource optimization, the integration of logistics, information flow, and value flow can be realized to shorten the development cycle (T) of new product development. Improve quality (Q), reduce costs (C), improve services (S), and improve the environment (E), thereby improving the company's market resilience and competitiveness, and want to adapt to develop a series of management software, such as ERP , MRP, MIS, PES, etc., and more and more show its huge economic benefits.
Some major cement groups in China are following this trend of informatization under the current pressure of increasing competition and advancing the development of automation. For example, in the past few years, a domestic cement group has been implementing the automatic control system configuration for a new cement production line. At the top of the field level and process control level (PCS), a manufacturing execution system (MES) layer has also been added, and ERP is under planning and operation, namely enterprise resource planning and management, which includes a production management system, a quality control system, Purchasing management system, warehouse management system, sales subsystem, equipment management system, financial management system, office automation management system and integrated management subsystem. In the cement market, where supply exceeds demand and competition is fierce, the Group has initially implemented the MES operation, the control and execution of the group management has been significantly improved, and the refined operation mode has brought the logistics costs and raw material costs under control. With a substantial increase in comprehensive benefits, net profit increased by 12.76% over the same period of last year. The author believes that the Group's MES operation is still in its initial stage, and it is necessary to further develop the unified production scheduling and the decision-making of the company's leaders into a true enterprise management level (ERP).
The combination of computer technology, network technology and advanced control technology now no longer stays at the theoretical and experimental stages such as model prediction, neurons and neural networks, fuzzy control, and multivariable control. Advanced control algorithms such as adaptive and self-optimizing have been put into practice and used in controllers such as DCS and PLC, and this trend is accelerating. In the cement industry, fuzzy control, multivariable control, and expert systems for kilns and mills were used as early as the last century, but these were mostly developed by cement equipment suppliers such as FLS, KHD, etc. They provided only independent The software has little to do with the system. And now the supplier of the control system has used advanced control algorithms in controllers such as DCS and PLC, such as the CEMAT integrated standard software developed by Siemens for the cement industry. It has function blocks for process control optimization in cement plants. Including kiln calcining and grinding load optimization control, this software package is integrated in Siemens' process control system PCS7; ABB's OptimizeIT optimization expert is integrated in IndustryIT, it integrates a large number of proven advanced control technologies and extensive Expert knowledge bases, such as fuzzy logic, control models, neurons and fuzzy control, are used to control the cement production process and implement optimized decision management.
Another hotspot of IT technology and automation is the penetration control system of public databases, local area networks, the Internet, and wireless technologies, which flatten the control system and realize cross-platform and cross-regional control. Siemens fully automated TIA automation concept, Schneider's "Collaborate Automation Collaborate Automation", "Transparent Ready Transparent", "Unity Automation Platform" new concept; and Rockwell proposed fully integrated EtherNet/IP, etc., these new automation The concept makes the automated control system more complete and perfect.
Second, the complementarity and penetration of automation technology DCS, PLC, IPC are the three pillars of the field of automatic control, the competition between them is fierce, but they draw on each other and penetrate with each other, thus forming a mixed PLC/DCS hybrid control strategy. System HCS, a consulting group called it PAC. The cement industry as a typical process industry has decided its leading position in the logic control of the switch. Simultaneously, the processing of the analog quantity is mostly simple display and given, and the control loop is basically a single loop control which is not complicated. These characteristics are suitable for HCS application. Currently, PLC-dominated Siemens, Schneider, Rockwell, and other companies have introduced mixed-control PLC/DCS hybrid systems such as Siemens' PCS7, ABB's AC800F, 800M, Schneider's Modicon Quantum, and Rockwell's ControlLogix. Has been promoted as a leading product in the cement industry and has achieved impressive results.
The main features of hybrid system HCS are: building a common, integrated development environment, providing a common development platform, shared tags, and a single database to meet the needs of multi-domain automation system design and integration;
At the same time, it uses a modular hardware architecture that can be freely combined to reduce the overhead of system upgrades. It supports fieldbus international standards such as IEC61158 to achieve a highly decentralized automation environment. It also supports de facto industrial Ethernet standards and can be easily integrated with higher-level ERP, MIS, and MES. Some cement plant control systems use Siemens' PCS7, and they feel that they have taken a big step forward than Siemens' original PLC and step7 systems. They mainly focus on the perfection of the development environment and facilitate the integration of the MIS and MES of the Group. Design institutes and system integrators who do system engineering are crucial.
Third, the automation system pays more attention to function and information security. Safer production is attracting more and more people's attention. Human life is above all else. It has become an important indicator for measuring modern industry. The significance of security accidents is more important in China. The main considerations for automation control systems are: electrical safety, explosion-proof safety, information security, and functional safety. Information security refers to the security of the system due to information leakage, hacker intrusion, etc. Functional safety refers to the possible danger caused by failure of the security function performed by the control system. The international standards that have been successively introduced include IEC61508—Functional Safety Standards for Electrical/Electronic/Programmable Electronic Safety-related Systems, and IEC61511—Functional Safety Standards for Safety Instrumented Systems in the Process Industry. Generally, the overall level of safety SIL is used to assess the degree of risk. There are four levels. The higher the safety level SIL, the lower the risk.
The cement industry has mostly adopted a new type of cement dry process, which is a highly continuous process, and has achieved the order and chain control of computer systems. The author believes that the new dry process has a higher safety level. To further improve the overall safety level must enhance the fault diagnosis link; man-machine interface to facilitate the monitoring of the fault; the production line with larger production scale, such as Nissan ten thousand tons of clinker production line system configuration to increase redundancy, and other information security Must pay close attention to, especially to enhance the safety level of explosion-proof coal mill workshop, for the establishment of low-temperature waste heat power generation enterprises, the overall safety level of SIL is higher than the average business.
In the field of automation, standard products such as fault-tolerant S7F/FH systems from Siemens and Gruard PLC from Rockwell have been introduced. Some companies configure special security modules and corresponding configuration software, and are maintained by passive devices. The development of diagnostics into preventive safety measures has also led to the introduction of many safety protocols, such as PROFIsafe and CIPsafety.
Fourth, control system from centralized to decentralized development of intelligent distributed I / O is a certain part of the I / O to form an autonomous node, which itself has a processor, to complete a certain part of the control. Since it is combined in a framework, it can be installed directly on the site, even where space is limited, but it can also be linked to a central computer, thereby simplifying the control system from a traditional three-tier structure to a two-tier structure. Many well-known PLC manufacturers have introduced distributed I/O, such as Siemens' ET200 series, Rockwell's FlexArmor I/O, Wago's WAGO-SPEEDWAY767 and other high-speed intelligent I/Os.
Intelligent distributed I/O will make the system configuration of the cement production line more flattened. Remote I/O applications such as mines and pre-dosing stations can be replaced with intelligent distributed I/O to save I/O. O The overall cost of installing cables and control systems.
Fifth, wireless communication technology further penetrates the control field Wireless communication technology as a complement to the wired control system is emerging in industrial automation systems, is also a new growth point of industrial automation products, running in the 2.4GHz1SM band frequency hopping spread spectrum (FHSS ) Wireless transmission technology has excellent anti-interference and high reliability. Wireless LAN and wireless mesh networks have expanded the coverage of wireless transmission. The data security of wireless communication is a concern of people, but a series of measures such as adding security passwords and encryption passwords can be used to ensure the secure transmission of data. It is reported that the HART Foundation will launch a new HART wireless communication protocol in the near future.
Wireless communication technology has many applications in the automotive, petrochemical, and water treatment industries. In the cement industry, some large-scale group auxiliary processes have also adopted wireless technologies. For example, Jidong Cement Group has adopted wireless control in circulating water pumping stations. Zhejiang Some cement plants use wirelessly controlled loading and unloading of bulk cement vessels. Considering that some cement plants occupy a large amount of physical space, some process measurement locations are difficult to install, and some process measurement point environments are very harsh. The cost of installing the devices with traditional hard wiring is very low. Too high, if you switch to wireless communication, you can save energy and reduce wiring and maintenance costs.
In the field of wireless communications, there are many suppliers, such as Siemens' SCALANCEW, which is a wireless LAN product series that can be used for communication between mobile devices and can also communicate between mobile devices and fixed networks; Phoenix Corporation (Phoenix) Products using wireless communication technology have Bluetooth, LAN and Trustedwireless (trusted wireless), there are many Chinese companies in the development of the corresponding products.
Sixth, human-machine interface is more humane Human-machine interface has been fully serialized, including handheld, panel, desktop and PC models. The future man-machine interface is not only limited to SCADA and programming, monitoring and diagnostics. In the field of industrial automation, man-machine interface can provide more and more information for operation and management personnel, powerful modular software and multiple customers. The machine/server architecture makes the human-machine interface a unified software platform for enterprise real-time production information and business vertical integration. It is also a medium for connecting to the outside world. Drive the various I/O modules through the driver or OPC, in short the human-machine interface has already evolved into a complete system. The operation of a cement group MES and the control of group management mainly rely on a variety of man-machine interfaces. Through OPC, the information exchange between cement production lines within the group is realized, and the interconnection between the main control system and each sub-control system is realized. , such as raw material quality control systems.
Seventh, the frequency changer performance further expands The frequency changer application field has expanded from the regular fan, the pump type and so on to the transportation, the feed machinery and so on, in the industry application face also is more and more widespread, therefore its function also further enhances and diversifies On the one hand, it is an all-digital, full-featured, self-adapting and tuning technology that can compensate for load changes, especially distributed high-end frequency converters with communication, networking, and integrated PLC. On the other hand, it is a simple or dedicated inverter and a mechatronic inverter. As far as control technology is concerned, DTC direct torque control and sensorless vector control are the development direction. The current speed response is about 2ms, and the current response can reach 0.1 to 0.5ms. The development trend of speed regulation is to improve the control accuracy of the speed. Generally, when the closed loop is used, it corresponds to the full range. When the speed ratio is 1:100 or higher, the speed control accuracy is as high as 0.05%. In addition, the performance of the inverter in low-speed overload, stable, four-quadrant operation capability and load balancing of one machine to drive multiple motors have also been enhanced.
In the cement industry for the implementation of energy saving, in the fan, pump, conveyor equipment, feeding machinery has been widely used, how to withstand a large overload torque at low speed, improve the cost performance of medium voltage converter is proposed to the manufacturer Subject. Siemens' introduction of Robinson's medium voltage drive as the preferred solution for medium voltage drives will help improve cost-effectiveness.
In addition to the above mentioned fields, special attention has been given to the automation industry, and the emergence of radio frequency identification (RFID) technology has promoted the rapid development of machine vision and its systems; and the vision system is integrated with a motion control system. Highly intelligent, this is extremely beneficial for manufacturing companies with hundreds of drives to increase production efficiency and reduce operating costs. Another hot spot is the breakthrough development of industrial Ethernet, which enables industrial-controlled three-tier networks to seamlessly connect and communicate with the IT world. The development of automation technology will enable us to realize the four goals of energy saving, environmental protection, safety and efficiency as soon as possible.
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