工业现场总线技术是近年来自动化行业最为关注的技术之一,给自动化控制技术带来了很大的进步。传统的现场级控制系统系统不开放、可集成性差、而且可靠性不易保证。现场总线控制系统(Fieldbus Control System,FCS)使用一条通信电缆将现场设备(智能化、带有通信接口)连接,用数字化通信代替4-20mA/24VDC信号,完成现场设备控制、监测、远程参数化等功能。它具有很多优点,在工业自动化领域有明显的优势,如集成性高、组态简单、设计安装方便、易于维护和扩展、可以节约软硬件投资等,使先进的现场设备管理功能得以实现。现场总线已广泛应用于各个领域,如电力监控、能源管理等。
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武钢炼铁厂从2003年六号高炉新建工程开始尝试使用现场总线,这也是全国首例在高炉系统中采用总线。在六号高炉刚投产之初,一场意外导致主控楼失火,将炉顶布料和热风炉系统几乎所有电气线路烧坏,按照传统的现场级控制方式起码要半个月的恢复时间,但因为使用了现场总线,电缆数量很少,我们仅用了三天时间就恢复了生产,使高炉提前十几天恢复生产,突出显示了高炉现场总线控制系统在维护和抢修方面相对于传统的现场控制方式的强大优势。现场总线技术在武钢炼铁厂的应用,使得高炉的电气设备在控制和稳定性上得到了很大提高,目前已经在其它各高炉得到推广,在炼铁厂取得了良好的效果。
二 传统的高炉自动化控制系统的现状及不足
高炉系统主要由炉顶上料系统、槽上和槽下供料系统、卷扬系统、喷煤系统、热风炉系统、炉前出铁场系统和INBA渣处理系统等构成,生产工艺复杂,分散点多,环境条件特殊,对电气设备的要求非常高,这就造成了电气自动化系统非常庞杂,故障率高,维护量大。
目前我国高炉所采用的控制基本上是传统的现场控制方式。传统的现场级与车间级自动化监控及信息集成系统(包括:基于PC、PLC、DCS产品的分布式控制系统),其主要特点之一是,现场层设备与控制器之间的连接是一对一(一个I/O点对设备的一个测控点)所谓I/O接线方式,信号传递4-20mA(传送模拟量信息)或24VDC(传送开关量信息)信号。如图1所示:
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