Background technology：
Various control technology applications widely, are lived ubiquitous from space flight, high ferro train, power plant, petrochemical industry, life, there is onePlanting control field, we are often referred to as process control, and it, which is mainly characterized by controlled device, has mass exchange, carries out quality and energyTransfer, such as pharmaceutical factory, petrochemical plant reactor, it operationally, its it is internal may existing physical change have chemical change again,The parameters such as temperature, pressure, liquid level in reactor are ceaselessly changing；For another example the power generation process of conventional thermoelectric factory is by steam boilerSteam, steam output pushing turbine band electrical power generators are produced, and the steam after doing work is condensed into water, then added by boilerHeat forms the physical state of material toward complex transformation, the transfer cycle of material into steam pushing turbine again；Pass through WATER AS FLOW MEDIUMThe chemical energy of fuel is transformed into electric energy, the carrying of energy is realized.These physically or chemically process automatically control, by peopleHabitually it is referred to as industrial stokehold.
It is usually by console, control rack, the sensing at scene as the Process Control System for realizing industrial stokeholdThe hardware devices such as device, transmitter, regulating valve and its actuator are constituted, and its core is controller, is typically located at control machineIn cabinet or console, while whole control system has the operation that a set of monitoring software coordinates whole control system, industry is realizedThe technological process operating of process as expected.
The control object of process control often be made up of a series of pressure container tank body equipment, by various pipelines by itOrganically, according to work relationship connect, various regulating valves are configured on pipeline；Regulating valve by it is electronic, pneumatically or hydraulically holdRow device direct drive control, the aperture size of valve is finally, by the director demon control in Process Control System, to make to be controlledObject Process system order processed it is anticipated that requirement carry out the transfer of material and energy.
And Process Control System is in itself from being monolithically fabricated, it is mainly made up of two parts equipment group, and a part is putsThe equipment being placed between control room or control device, such as console, control rack, the nucleus equipment controller of Process Control System is justBe placed in control rack or console, control deck plate on can arrange display instrument, for indicate manipulation purpose computer andManipulation or the indicator elments such as control button switch.Another part is that the scene that is installed on is in same place with controlled device equipmentThe field apparatus such as sensor, transmitter and regulation valve actuator, these equipment are typically the specific controlled device for being arranged on correlationOn the body of equipment or on subsidiary pipeline.In this kind of Process Control System, the use accounting of regulating valve and its actuator equipmentIt is very big.
, should first in a static condition, to control system certainly after a set of new Process Control System prototype design comes outThe software and hardware of body is debugged, and confirms that the hardware signal relation transmission of control system itself is correct, software control logic is correct, symbolClose expected design.Confirming Process Control System after test has no problem under static state, it is also desirable to can be in some way in experimentUnder room environmental, the dynamic characteristic to Process Control System is debugged and tested, to reduce Process Control System in first ApplicationRisk that may be present is controlled in actual industrial process, while the debug time at practical application scene can be shortened, drop can be reachedThe purpose of low project cost.
Only by dynamic test, just can detect confirm control program whether reasonable.In fact, typically now newThe Process Control System ground, is all after first set system is processed, to carry out simple static debugging in laboratory or manufactory, soAfter be directly installed on site of deployment, then the scene of carrying out static debugging, controlled device is then directly acted at the scene and enters actionState is debugged, and is often debugged when groping the working law of controlled device, certainly will so be increased the field adjustable time of project, is increasedPlus project cost, and there is certain technical risk
At present, for the monitoring software of important Process Control System that newly grinds before practical application, engineering monitoring party is oftenPropose to carry out " third-party software test " requirement to Engineering Project Implementation side, tested and closed by the enterprise with software authentication qualificationLattice rear can be used for real system.But the running software feature due to Process Control System and the software systems on ordinary meaningOperation is very different, and whom has seldom seen in practice and has carried out third-party testing to such monitoring software, prison is there isPipe blind area.Concrete reason is：As the software systems on ordinary meaning, such as database software system usually constitutes a computer networkNetwork environment achieves that the test of the function and performance of whole software systems.And the operation of the monitoring software of Process Control System is tightAgain dependent on the hardware environment and the actual motion of controlled device procedures system for constituting control system, in order to realize " software the 3rdThis behavior of side's test ", is always unlikely to make the procedures system of a set of energy real work operation.
The process monitoring system software newly ground is before practical application, it is understood that there may be such or such potential problems, andDesigner can not be, it is realized that so as to go to eliminate；It can only go to find in practical application and solve, caused consequence is exactly：ProjectLater stage debugging work load is excessive, debugging cycle is long, the technical risk of project is increased, upper management office or engineering monitoring party pairCan reliably the completing on schedule of project suspect.
Even across using the Process Control System shaped, the same Process Control System of a set of coming of new is dispatched from the factoryWhen should also carry out exfactory inspection.When carrying out exfactory inspection, such as test detection means enriches complete, and test point gos deep into coverage rateExtensively, the problem of being left to scene will be lacked；Conversely, test detection means is limited single, being left to site problems may be more, and scene is adjustedThe examination time can be longer.
The content of the invention：
In order to be able to realize the monitoring software and its hardware of the Process Control System newly developed before practical application, can rationally intoUnder this control, comprehensively and effectively test-based examination is carried out to its function and performance, elimination defect of pinpointing the problems can especially be supervised to itSoftware is controlled to carry out effective " third-party software test "；And the complete set of equipments of the Process Control System for the production that enterprise can be shapedCarry out effective exfactory inspection.The software and hardware quality state of the Process Control System for manufacture of newly grinding or shape is carried out effectivelyInspection and evaluation, the present invention proposes " Process Control System test device " this product concept, and the device can not only be surveyed staticallyTry the software and hardware of Process Control System, moreover it is possible to the dynamically software of test process control system so that fruitfully carried out" the third-party software test " of process control system is possibly realized.
The technical solution adopted by the present invention is：A kind of test device of industrial process control system, is mainly held by regulating valveRow device enhancement type analog device and simulation computer are constituted, and on the one hand regulation valve actuator enhancement type analog device is adjusted with breadboardinThe action process of valve actuator is saved, accordingly dynamic changes and remembered the valve place value of a virtual regulating valve, also uses circuitThe signal transmitting device of parameter monitoring, the signal intensity of sensor in simulation process control system；Simulation computer is used to emulateThe control object of Process Control System（That is industrial equipment or process apparatus）Operation process, according to the work mathematical modulo of equipmentType emulates its course of work, and the state parameter of simulated equipment can be continually changing on computers.Simulation computer and regulating valveActuator enhancement type analog device is main website by bus network or Ethernet networking work, in a network simulation computer, is adjustedIt is slave station to save valve actuator enhancement type analog device.Simulation computer receives the valve of simulation from regulation valve actuator enhancement type analog devicePosition signal, change and other associated information calculations according to valve position signal go out the new operating condition of simulated equipment, and by itsNew state parameter is passed back to regulation valve actuator enhancement type analog device, is exported as the transmitter/sensor of its change simulationThe foundation of signal magnitude.
In regulation valve actuator interface and control system that the regulation valve actuator enhancement type analog device passes through itselfCorresponding actuator input and output terminal is connected in control rack or console or control cabinet, receives in Process Control SystemValve opening that the actuator control electric current signal or console that controller is sent are sent, close opening for valve and switching valve position control modeSignal is measured in pass, while the actuator working condition that simulator is simulated, mainly virtual valve place value and the malfunction of simulationSignal feeds back to controller.
The actuator interface of the regulation valve actuator enhancement type analog device specifically has 1 " opening big valve position " switching value defeatedEnter signal, 1 " turn down valve position " On-off signal signal, 1 " the size control of valve position " analog input signal, 1 " valve position is bigSmall feedback " analog quantity output signals, 1 valve position " with on-off model control/use analog signalses control selections " switching value are defeatedEnter signal, 1 " malfunction " switching value output signal, 1 24V dc sources output.
The regulation valve actuator enhancement type analog device is furnished with liquid crystal or LED display modules, on the one hand can show that it is inputtedValve position Analog control signal size, on the other hand again can show the valve seat opening actual at that time of simulation in real time；SimulatorShell is provided with a switch, and when switch is in off and on, simulator sends the faulty signal of actuator, and when switch is inRepresent that actuator is in normal operating conditions when opening or closing, do not send fault-signal.
It is described regulation valve actuator enhancement type analog device by itself signal transmitting device, Sensor Analog Relay System output interface withCorresponding input terminal is connected in control rack or console or control cabinet in control system, will come from simulation computerThe digitlization dynamic parameter of the industrial equipment operation process of emulation, analog signalses are become with circuit, feed back to process control systemController in system.
The regulation valve actuator enhancement type analog device is provided with two-wire system 4mA~20mA signal output interfaces, for simulatingSignal transmitting device output signal（Such as pressure, pressure difference, temperature, flow parameter）；It is used for direct mould provided with mV signal output interfacesIntend Thermocouple Temperature Signal；It is used to directly simulate resistance and temperature signal provided with variable resistor output interface；Provided with frequency signalOutput interface is used to simulate tach signal；One enhanced actuator simulator can be provided with multiple signal source output interface,A kind of signal source output interface can be provided only with.
The method of testing that a kind of test device of industrial process control system is used for：Tested Process Control SystemControl output (i.e. control of valve position signal) will be adjusted with on-off model or current signal form according to its normal working methodRegulation valve actuator enhancement type analog device is sent to, simulator is received after control of valve position signal, in this way current controling signal, firstThe size for changing the control of valve position signal shown on liquid crystal or LED display modules on simulator is consistent with reception value, opens in this waySignal is measured in pass, is indicated with corresponding light emitting diode on simulator, and that then opens greatly or turn down according to default valve is dynamicMake speed, increased or decrease virtual valve place value, and it is consistent with virtual valve place value to change valve position feedback output signal, Ji JiangxinThe tested control system of virtual valve place value loopback；Simulation computer at certain intervals by network interface access adjusted by the cycleValve actuator enhancement type analog device is saved, operational factor such as pressure, temperature, the rotating speed of the process apparatus that its simulation calculation is gone out are mostNew value gives simulator, and fetches newest virtual valve place value.
The regulation valve actuator enhancement type analog device receives the newest simulation run of process apparatus from simulation computerAfter parameter value, correspondingly change the output valve for the transmitter interface signal that scope is 4~20mA according to the classification of its parameter, orThe output valve of electric thermo-couple temperature interface signal, or resistance and temperature interface signal output valve, or speed-frequency interface letterNumber output valve, make the last look of their simulation run parameters with being received from simulation computer consistent.
Configuration adjustment valve actuator enhancement type analog device sets program on simulation computer, is connect with the program by networkMouth is that every simulator in system sets the virtual velocity amplitude for adjusting valve events in simulator, and the value is stored in mould after settingIntend in the nonvolatile storage in device.
Beneficial effects of the present invention：This test device can not only realize important industry under effective cost controlThe model machine that Process Control System is newly developed equips effective exact p-value of software and hardware, especially can effectively carry out process control systemSystem " third-party testing of control software " work；It can be used for effective the dispatching from the factory of the actual equipment of Process Control System subsequently manufacturedExamine.
Embodiment：
Reference picture 1, dotted line left part is to be usually placed in the equipment at control room end in general Process Control System, mainlyIt is to arrange manipulation instruction computer, display, equipment fortune inside console and control rack, console again with display and operation panelRow status indicator lamp, alarm window, the manipulation element such as button and binding post；Control rack arranges controller and its I/O againThe elements such as module, signal conversion element and binding post；Manipulation in console indicates computer and the control in control rackDevice is usually to be attached with the Ethernet of internal system, realizes data exchange；And other letters between console and control rackNumber connection be usually be attached with controlling cable；Controller running-course control application software in rack, and consoleUpper manipulation indicates that computer operation man-machine interface application software is used to be manipulated and be indicated.The above equipment assembly is transported in additionThe application software of row thereon just constitutes the semi-finished product of Process Control System, because it is also not connected with and monitored process apparatusOr the element such as the equipment transmitter, sensor and the executing agency that are arranged together, form Process Control System truly.The semi-finished product of this Process Control System need in factory's manufacture, debugging and to test in advance, firmly believe it is out of question after the assay was approved, just existSite of deployment install and actual debugging application.For less Process Control System, control rack may not be set, but willThe function of control rack is also realized in console.
It is used for the test device of test process control system on the right side of reference picture 1, dotted line for the present invention, it is held by regulating valveRow device enhancement type analog device and simulation calculation are constituted.On the one hand regulation valve actuator enhancement type analog device uses circuit analog regulationThe valve place value of the action process of valve actuator, accordingly one virtual regulating valve of dynamic change and memory, also uses circuit mouldIntend signal transmitting device, the signal intensity of sensor of parameter monitoring in Process Control System；Simulation computer is used to emulateThe control object of process control system（That is industrial equipment or process apparatus）Operation process, according to the work mathematical modeling of equipmentIts course of work is emulated, the state parameter of simulated equipment can be continually changing on computers.
Regulation valve actuator interface function and signal transmitting device, the biography having with regulation valve actuator enhancement type analog utensilSensor interface function replaces being arranged in the real regulation valve actuator and real signal transmitting device of industrial process-field, sensingThe interface function of device, then with the real-world operation of simulation computer simulation industry process device, to the process manufactured in factoryThe software and hardware function and performance of the semi-finished product of control system are tested and debugged before its application.
When carrying out actual test to a certain Process Control System, it can be controlled back according to the Process Control System practical adjustmentsThe quantity of how much configuration adjustment valve actuator enhancement type analog devices on road.
Simulation computer with regulation valve actuator enhancement type analog device by bus network or Ethernet networking work,Simulation computer is main website in network, and regulation valve actuator enhancement type analog device is slave station.
Fig. 2 show the interface schema of a regulation valve actuator enhancement type analog device, and it should have existing regulating valve to performInterface function and signal transmitting device, the interface function of sensor of device, are emulated with the work-based logic for realizing these element functions, withJust the test of Process Control System can be used for.The external interface function according to real one regulation valve actuator is first had to, is usedCircuit adds single-chip microcomputer or added in the computer chip mode of other patterns, analog regulation valve actuator and control system between controllerInteraction signaling interface, when it, which is connected to, is worked in Process Control System on the terminal of rack or console, controlCan be sensuously that a real regulation valve actuator is working when the control software at end or personnel's manipulation.Meanwhile, a regulationValve actuator enhancement type analog device is used for signal transmitting device/sensor that process variable is monitored with several roads of circuit analog simulationExternal interface.
Adjust valve actuator enhancement type analog device and pass through the regulation valve actuator interface of itself and the control in control systemCorresponding actuator input and output terminal is connected in rack or console or control cabinet, receives in Process Control System and controlsThe switching value of valve opening, pass valve and switching valve position control mode that the actuator control electric current signal or console that device is sent are sentSignal, while the actuator working condition that simulator is simulated, mainly virtual valve place value and the fault status signal of simulationFeed back to the controller of Process Control System.
Referring to Fig. 2, the actuator interface of regulation valve actuator enhancement type analog device has 1 " opening big valve position " switchAmount input signal, 1 " turning down valve position " On-off signal signal, 1 " the size control of valve position " analog input signal, 1 " valvePosition size feedback " analog quantity output signals, 1 valve position " with on-off model control/use analog signalses control selections " are switchedMeasure input signal, 1 " malfunction " switching value output signal, 1 24V dc sources output.
Adjust valve actuator enhancement type analog device and be furnished with two groups of liquid crystal or LED display modules, one group is used to show that it is inputtedValve position Analog control signal size, another group be used in real time show simulation valve seat opening actual at that time；Also can only it match somebody with somebodyOne group of liquid crystal or LED display modules are put, a switching switch is reconfigured at, with switch switching mode, divides on one group of display moduleThe size and the valve seat opening actual at that time of simulation of the valve position Analog control signal of input are not shown；Simulator shell is provided withOne double-pole switch, when switch is in off and on, simulator sends the faulty signal of actuator, and is opened or closed when switch is inWhen represent actuator be in normal operating conditions, fault-signal is not sent, while also giving the signal condition in simulatorCPU.3 light emitting diode lamps are set on simulator, instruction simulation device is respectively used to and receives valve opening, closes valve signal and work asPreceding control of valve position way choice state.
Adjust signal transmitting device, Sensor Analog Relay System output interface and control of the valve actuator enhancement type analog device by itselfCorresponding input terminal is connected in control rack or console or control cabinet in system, will be from simulation computer emulationIndustrial equipment operation process digitlization dynamic parameter, become analog signalses with circuit, feed back in Process Control SystemController.
Reference picture 2, regulation valve actuator enhancement type analog device is provided with two-wire system 4mA~20mA signal output interfaces, is used forAnalog signal transmitter output signal（Such as pressure, pressure difference, temperature, flow parameter）；It is used for provided with mV signal output interfaces straightConnect simulation Thermocouple Temperature Signal；It is used to directly simulate resistance and temperature signal provided with variable resistor output interface；Provided with frequencySignal output interface is used to simulate tach signal, is exported with square wave or sine wave；One enhanced actuator simulator canProvided with multiple signal source output interface, can also be provided only with a kind of signal source output interface.
Reference picture 2, in the present embodiment, the mV numbers scope of Thermocouple Temperature Signal output interface is 0~50mV, can be simulated0 DEG C~1100 DEG C of equipment operating temperature range；The resistance value scope of resistance and temperature signal output interface is 91 Ω~220Ω, can simulate -23 DEG C~322 DEG C of equipment operating temperature range；The frequency range of frequency signal output interface is 0~24kHz,If in real process system, the number of teeth for the fluted disc being installed on magnetoelectric tachometric transducer auxiliary work on equipment rotating shaft is120, then the frequency range can simulate 0~12000rpm equipment operating rotational speed range.
As shown in Fig. 2 in the present embodiment, regulation valve actuator enhancement type analog device configure 485 EBIs with it is upperSimulation computer carries out communications exchange data.Simulation computer receives the valve position of simulation from regulation valve actuator enhancement type analog deviceSignal, change and other associated information calculations according to valve position signal go out the new operating condition of simulated equipment, and its is newState parameter be passed back to regulation valve actuator enhancement type analog device, be used as its change simulation transmitter/sensor output letterThe foundation of number size.
Reference picture 3, depicts a part for a certain Process Control System, that is, realize monitoring boiler operatiopn state part andThe composition for the test device tested it, the method for testing for illustrating test device of the present invention.
The principal states parameter of boiler running process has drum drum pressure P, superheat steam temperature T and drum steam water-levelH, correspondingly Process Control System is at least provided with two regulating loops of drum drum pressure and drum steam water-level, in actual controlRegulation in system processed in order to realize drum drum pressure and boiler drum water level need to configure two regulating valves, every regulating valve by with itsIntegral actuator direct drive and control is installed on, configuration drum drum pressure monitoring transducer, drum drum water are needed in additionPosition pressure difference monitoring transducer and superheat steam temperature monitoring thermocouple sensor.
The boiler implosion part of Process Control System it is main by boiler implosion rack, boiler console and its be arranged in platform orCabinet inside or the controller on surface and its I/O modules, manipulation indicate that the elements such as computer, button switch, binding post are constituted.
In order to which the design of hardware and software for the monitoring boiler function of verifying the Process Control System designed and manufactured is correct, meetIt is actually needed, it is necessary to be tested it and debugged, for this from two regulation valve actuator enhancement type analog devices, then plus oneSimulation computer one test device of composition is realized to the design of hardware and software of monitoring boiler function tests.Wherein simulator withSimulation computer constitutes 485 bus network and cooperated together, and wherein simulation computer is main website, and two simulatorsFor slave station.Wherein one simulator analog simulation fuel flow adjusts the action process of valve actuator, and with its interface circuit mouldIntend the output signal of emulation drum drum pressure monitoring transducer and the output signal of superheat steam temperature thermocouple, another mouldIntend the action process that device analog simulation drum steam water-level adjusts valve actuator, and drum steam water-level is emulated with its interface circuitThe output signal of monitoring transducer.
Reference picture 3, two regulation valve actuator enhancement type analog devices of test, probable regulation valve actuator and changeSend device, sensor the same, its input/output interface signal terminal corresponding with boiler console, control rack is actual to be connectedConnect, simulation computer emulates the actual moving process of boiler, boiler console is powered with control rack, makes the control being installed on itDevice and manipulation indicate the application software operation in computer, and the related software and hardware function of test observation runs whether correct, performanceWhether satisfaction is required.
Reference picture 3, is by boiler implosion to adjusting the valve opening of valve actuator, closing valve, control of valve position mode selection signalWhat the shift knob on platform was sent, boiler console also receives the direct current 24V power supplys for carrying out self-regulating valve actuator, the dc sourcePower supply excitation is provided for 3 above-mentioned on-off models；Other regulating valve actuator signals and transmitter, sensor signal are equalOn the binding post for being connected to boiler implosion rack.
When the boiler operatiopn state that simulation computer is emulated reaches that energy exports balance with mass input, operational factor meetingMaintain a stable working condition.Now when needing to improve drum drum operating pressure, tested process control systemSystem will be sent the analog quantity control of valve position current signal being increased by the controller in control rack and give fuel flow regulating valveActuator enhancement type analog device, or by the button on console from manually adjusting the enhanced mould of valve actuator to fuel flowIntend device and send out big valve switch amount signal, two kinds of control of valve position way choices are that the control mode selection on console is openedPass switches over realization, by being manually dealt into simulator from console by switching value level signal during switching.Simulator according to work asPreceding control of valve position way choice state, the control that virtual valve place value increases or reduced is realized according to corresponding control signal,Two kinds of control of valve position signals work when different.
When fuel flow regulation valve actuator enhancement type analog device receives out big valve signal or specific control valve positionDuring value, big responsiveness can be held according to default valve, be stepped up the valve place value of virtual fuel flow regulating valve, and changeChange fuel flow control valve position feedback loop output signal is consistent with virtual valve place value, and virtual valve place value loopback that will be newly is testedThe Process Control System of examination；The cycle is enhanced by 485 bus access regulation valve actuator at certain intervals for simulation computerSimulator, fetches newest virtual valve place value, first to void when it adjusts valve actuator enhancement type analog device from fuel flowThe valve place value of plan shown, and valve place value according to newest fuel flow regulating valve and other to have related parameter to calculate newestDrum drum pressure, drum steam water-level and superheat steam temperature parameter value, now drum drum pressure, superheat steam temperatureParameter value should increase, and drum steam water-level should reduce, and replicating machine can be in next access cycle to simulator, by drum vapourBag pressure and the last look of superheat steam temperature parameter are passed back to fuel flow regulation valve actuator enhancement type analog device, by drumThe last look of steam water-level parameter is passed back to boiler drum water level regulation valve actuator enhancement type analog device.
Accordingly, fuel flow regulation valve actuator enhancement type analog device can be according to the drum drum pressure received from replicating machineThe last look of force parameter changes the output valve of 4~20mA transmitter interface signal, can be steamed according to the overheat received from replicating machineThe last look of vapour parameter changes the output valve of electric thermo-couple temperature interface signal；Boiler drum water level adjusts valve actuator enhancement type analog deviceThe output of 4~20mA transmitter interface signal can be changed according to the last look of the drum steam water-level parameter received from replicating machineValue.
Controller in boiler implosion rack is received after the signal of drum steam water-level reduction, and its control software should be to drumWater level regulation valve actuator enhancement type analog device sends the control signal of increase level control valve valve position.It will thus realizeOne control that dynamically goes round and begins again and the controlled process that moves in circles.
Program is set using the regulation valve actuator enhancement type analog device configured on simulation computer, passes through 485 busesInterface is that every simulator in system sets the virtual velocity amplitude for adjusting valve events in simulator, and the value is stored in after settingIn nonvolatile storage in simulator, it is configured according to the actual act velocity amplitude for the regulating valve for being modeled emulation.
Static debugging function can be also set in the simulated program of replicating machine, that is, be arranged on the human-computer interaction interface of replicating machineOn the operational factor of emulation is carried out it is strong put value function, and this value is also sent to regulation valve actuator enhancement type analog device, simulationDevice correspondingly changes the signal transmitting device of its emulation or the output valve of sensor interface again, reaches static test or debugging process controlThe purpose of system processed.
In summary, it is achieved that by this way to boiler implosion part software and hardware function and property in Process Control SystemThe test of energy.