Design of Coordinated Control SystemBased On Frequency ConversionZHOU YEFEIThesis submitted to the Faculty ofShanghai Jiao Tong UniversityIn partial fulfillment of the requirements for the degree ofMaster of ScienceinControl Theory and Control EngineeringSupervisor:Yang Yupu（Prof.）January 1，2007Shanghai，P.R.C
上海交通大学学位论文原创性声明本人郑重声明：所呈交的学位论文，是本人在导师的指导下，独立进行研究工作所取得的成果。除文中已经注明引用的内容外，本论文不包含任何其他个人或集体已经发表或撰写过的作品成果。对本文的研究做出重要贡献的个人和集体，均已在文中以明确方式标明。本人完全意识到本声明的法律结果由本人承担。学位论文作者签名：周烨斐日期：2007年1月25日
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变频调速协调控制系统设计摘要新型粗纱机在机械结构、系统传动以及电气控制方面都有较大的改变，它除去了传统粗纱机中的上、下锥轮，差速器，龙筋升降传动部件和成型机构，机械结构变得大为简化。新型粗纱机采用PLC控制四台变频器，分别独立驱动锭翼、罗拉、筒管和龙筋的电机来实现高效高质纺纱。机械结构的简化虽然可以在很多方面提高粗纱机的性能和稳定性，但是罗拉、锭翼、筒管、龙筋四个电机的同步控制成了整个控制系统设计的难点，从而粗纱的张力控制也成了最需要解决的问题。如何设计一个全新的控制系统来代替原先机械传动部分，实现和超越其功能是新型四电机粗纱机设计的关键和核心部分。张力控制的好坏决定着新型粗纱机能够开发成功。针对以上的关键和难点，本文从硬件和软件系统两方面来阐述解决方案，并且着重对张力控制系统的设计进行详细的分析。在硬件系统的设计方面，本文首先对整个控制系统的机械结构做了个简要说明；在电气系统方案方面，我们选择了由工控机、PLC、矢量
变频基础传动、光电传感器组成的系统，其中，工控机为综合监控系统，人机界面采用WINCC来设置纺织工艺参数，监控整车的运行和故障状态，它通过MPI网络协议和PLC进行通讯；PLC是实时控制的核心，获取粗纱位置光电传感器的检测值，并通过PROFIBUS-DP总线和四台矢量变频器进行通信，读取矢量变频器中各电机的速度，计算出各个电机的理论速度，然后向矢量变频器发送指令，设置各变频电机的速度，从而控制电机的运转。由于变频器对整个系统的重要性，本文又对变频器的选择以及其与PLC的通讯作了一个详细的描述。在硬件结构搭建完毕的基础上，本文在对控制对象分析后提出了张力控制方案。张力控制方案主要包括两方面：一、张力软测量模型。该模型的主要作用就是取代原先机械锥轮，根据实时的径向线密度调整卷绕直径，从而调整四电机的速度，改善其同步性。并且该模型具有自学的功能，使得该模型能够适应多种不同的机型，从而超越了机械锥轮的功能，有着更加广泛的应用。二、张力控制算法。该算法建立在软测量模型的基础上，通过优化过的闭环控制算法，不断地调整径向线密度，并且使其趋于稳定。这两方面相辅相成，从而使张力控制达到最优化。最后本文对整个软件系统作了分析，对软件的主要模块分开剖析，概述了模块与模块之间的关系，并且对最为复杂的几个模块进行仔细阐述，使得本系统的设计思路跃然纸上。通过合理的硬件系统，周详的软件系统和创新的张力控制方案，新
型四电机粗纱机在测试阶段运行良好，为其研发成功奠定了基础。关键词：同步控制，张力控制，变频器，软测量模型
Design of Coordinated Control SystemBased On Frequency ConversionAbstractThe new type of roving machine has undergone a great change in mechanical structure，systematictransmission and electrical control.It eliminated the up and down cone drums，differential device，railsdrive assembly and forming device，which simplified the mechanical architecture a lot.Inthis design，PLC controlled four frequency converters to separately drive four motors tomake flyer，roller，bobbin and rails run in a synchronized way.Thus，the roving machinecould product roving of high quality efficiently.Although simplification of mechanical architecture could enhance the performanceand the stability of the roving machine in many fields，it became difficult to execute asynchronized control over the four motors of roller，flyer，bobbin and rails in the wholedesign，which also made the tension control of rove become the key problem to be solved.The core of the design of the new type of machine is how to invent a brand-new controlsystem to substitute the traditional mechanical parts and to realize or even surpass theoriginal functions.Whether this new type of machine can be developed or not just dependson the performance of the tension control.According to the key problems and the most difficulties，this thesis expatiates on the solutionsfrom two aspects，hardware and software.Moreover，it emphasizes on the control system of the tensioncontrol in details.In the design of hardware，the thesis gives an overall view on its mechanical design.Then，in the
electrical design，we choose industrial computer，PLC，frequency converters，photo-electricitysensors.The industrial computer works HMI，it communicated with PLC via MPI;thePLC is the center of real-time control，it get the signal of roving height fromphoto-electricity sensors，communicates with frequency converter via PROFIBUS-DP，read the speed of four motors from frequency converter，compute the preset speed of fourmotors，then send commands to frequency to control the speed of motors.Due to theimportance of frequency converters in the whole system，the thesis gives a detailedpresentation on how to choose the frequency converters and its communication with PLC.On the basis of hardware system and the analysis of the control objects，the thesisputs forward the scenario of tension control，which consists of two programs.Firstly，it&’sthe tension measuring model.The major function of this model is to substitute thetraditional mechanical cone drums to adjust the winding diameter in terms of the real-timeradial density and then accordingly to adjust the speed of the four motors to improve thesynchronization.Besides，this model has the self-teaching ability to adapt to various kindsof machines.It surpassed the mechanical cone drums and therefore has a more extensiveapplication.Secondly，it&’s the algorithm of tension control.The algorithm is based on themeasuring model to adjust the radial density to a stable value through the optimizedclosed-loop methods.These two programs supplement each other to achieve theoptimization of the tension control.In the end，the thesis analyzes the whole software system，anatomizes the majorblocks and gives a profile of the relations among the blocks.In addition，it expatiates onthe most complicated blocks carefully to present a clear picture of the design.By our building a reasonable hardware system and a comprehensive software systemand inventing the tension control scenario，this new type of four-motor roving machineoperated well in the testing phases，which has placed a solid foundation of its successfuldevelopment.
KEY WORDS:Synchronization Control，Tension Control，Frequency Converter，Measuring Model
目录第一章绪论........................................................................................................................11.1研究背景................................................................................................................11.2传统粗纱机概况....................................................................................................41.3新型粗纱机介绍....................................................................................................61.4本章小节...............................................................................................................9第二章硬件系统结构......................................................................................................102.1系统机械结构......................................................................................................102.2电气系统方案....................................................................