【作者】 刘志刚；

【导师】 罗小川；

【作者基本信息】 东北大学 ， 系统工程， 2014， 硕士

【摘要】 电熔镁砂是一种熔点高、抗氧化性和抗渣性强的高级耐火材料,被广泛应用于冶金、航空航天等行业。电熔镁砂的生产存在高耗能和产品品位低等问题,随着生产企业对能源利用效率和产品品位要求的提升,应用于电熔镁行业的控制算法越来越复杂,传统的PLC控制器难以满足复杂控制算法的应用要求,需要设计新的控制器以满足电熔镁炉生产过程控制的需要。本文在国家重点基础研究发展计划(973计划)项目“复杂生产制造过程一体化控制系统理论和技术基础研究”的支持下,针对PLC控制系统难以实现复杂控制算法的问题,结合电熔镁炉控制系统的现状,论证嵌入式技术应用于电熔镁行业的可行性,结合电熔镁炉控制算法的要求,首先提出了基于X86架构的电熔镁炉嵌入式控制系统硬件的总体架构设计,在此架构下完成嵌入式控制器的设计与开发,为电熔镁复杂控制算法提供支持平台,并在工业现场进行验证。本文主要工作归纳如下：(1)分析了以PLC为核心的电熔镁炉控制系统的现状和局限性,介绍了嵌入式控制系统的发展现状,介绍了电熔镁炉的结构、熔炼工艺,分析了电熔镁炉的控制难点和控制方法以及嵌入式技术应用于电熔镁行业的可行性。(2)完成了电熔镁炉嵌入式控制系统的需求分析,确定电熔镁炉嵌入式控制系统所具有的功能,完成电熔镁炉嵌入式控制系统硬件的总体架构设计。(3)完成了电熔镁炉嵌入式控制器的开发。根据电熔镁炉嵌入式控制系统硬件的总体设计,完成嵌入式控制器主控板和数据采集板的选型,并使用Matlab的Simulink模块完成数据采集板驱动程序的编写,针对嵌入式控制器处理的信号与现场信号不匹配和生产现场强电磁干扰的问题,设计开发信号调理板,实现对输入输出信号的转换和隔离功能,并且针对控制器散热和防尘问题,完成机械外观设计与实现,最终完成电熔镁炉嵌入式控制器的开发。(4)将开发完成的电熔镁炉嵌入式控制器在实验室进行了硬件在回路仿真和工业现场应用验证,并对实验结果进行分析和总结。更多还原

【Abstract】 Fused magnesia is an advanced refractory material with high melting point, strong oxidation and slag resistance which is widely used in metallurgy and aerospace industries. Problems are found in the production of fused magnesia, including high energy consumption and low grade. With requirements of higher efficiency of energy utilization and the product grade, the control algorithm in fused magnesia industry is increasingly complex. Since the traditional PLC controller is difficult to meet the requirements of the complex control algorithm, the design and development of embedded controller is necessary to solve the existing problems in fused magnesium furnace.Supported by national basic research program of China (973 Program, NO2009CB320601), this thesis considers the condition of current controller systems and demonstrates the feasibility of embedded controller in fused magnesia industry. In accordance with the requirements of the control algorithm, this thesis, based on the design of X86, presents the overall framework of hardware in embedded controller system for the first time. Under that framework, this thesis completed the design and development of the embedded controller, offered a platform to support the complex control algorithm and verified the results on industrial fields. The main works of this thesis are as follows:(1) This thesis analyzed the current situation and limitations of PLC control systems for fused magnesium furnace, introduced the trends of embedded industrial controllers, described the structure and smelting technology of fused magnesia, and analyzed the difficulties and methods in controlling, as well as the feasibility of embedded technology in fused magnesium industry.(2) Then, the thesis analyzed the needs of embedded controller in fused magnesium furnace, determined the functions of embedded controller and completed the overall framework’s design.(3) This thesis completed the development of embedded controller in fused magnesium furnace. According to the overall design, the thesis completed the selection of an embedded controller board and a data acquisition board. Matlab Simulink module is used to complete the programming of the data acquisition board drivers. The signal conditioning board is developed to solve the problems like the mismatching between signals in embedded controller and on the worksite, thus achieving transformation and isolation of signals’input and output. In addition, the mechanical design and implication is completed to solve thermal dissipation and dust prevention problems.(4) Finally, series of experiments are carried out to test the embedded controller in fused magnesium furnace, including fused magnesium furnace hardware-in-loop simulation system experiment and industrial worksites experiment. The results show that the controller is effective in the scene of the production process.更多还原