Background technology：
Various control technology applications are very extensive, lived from space flight, high ferro train, power plant, petrochemical industry, life ubiquitous,Having a kind of control field, we are often referred to as process control, its be mainly characterized by controlled device has mass exchange, carry out quality andThe transfer of energy, such as pharmaceutical factory, the reactor of petrochemical plant, it at work, its it is internal may existing physical change have chemistry againChange, the parameter such as temperature, pressure, liquid level in reactor is ceaselessly changing；For another example the power generation process of conventional thermoelectric factory is by steamingBoiler furnace produces steam, steam output pushing turbine band electrical power generators, and the steam after doing work is condensed into water, then byBoiler is heated into steam pushing turbine again, forms the physical state of material toward complex transformation, the transfer cycle of material；Pass throughThe chemical energy of fuel is transformed into electric energy by WATER AS FLOW MEDIUM, realizes the carrying of energy.Physically or chemically process automatically controls for these,Habitually it is referred to as industrial stokehold by people.
As the Process Control System for realizing industrial stokehold, usually by console, control rack, the sensing at sceneThe hardware devices such as device, transmitter, regulating valve and its actuator form, 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, realizes industryThe 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 holdThe direct drive control of row device, the aperture size of valve are controlled by the director demon in Process Control System, 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 to be installed on scene to be 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, and software control logic is correct, symbolClose expected design.After confirmation Process Control System is tested under static state and had no problem, it is also desirable to can test in some wayUnder room environmental, the dynamic characteristic of 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 confirmation control program whether reasonable.In fact, typically now newThe Process Control System ground, all it is after first set system processes, carries out simple static debugging in laboratory or manufactory, soAfter be directly installed on site of deployment, then carry out scene static debugging, then directly act at the scene controlled device enter 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 increasedAdd project cost, and certain technical risk be present
At present, for the monitoring software of important Process Control System that newly grinds before practical application, engineering monitoring partyOften propose to carry out " third-party software test " requirement to Engineering Project Implementation side, surveyed by the enterprise with software authentication qualificationTry qualified rear and can be used for real system.But the running software feature due to Process Control System and the software system on ordinary meaningThe operation of system is very different, and whom has seldom seen in practice and has carried out third-party testing to such monitoring software, has existedSupervision blind area.Concrete reason is：As the software systems on ordinary meaning, such as database software system, a calculating is usually constitutedMachine network environment achieves that the test of the function and performance of whole software systems.And the fortune of the monitoring software of Process Control SystemRow depends critically upon the actual motion of the hardware environment for forming control system and controlled device procedures system, in order to realize " softwareThis behavior of third-party testing ", always it is 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 length, the technical risk of project increases, upper management office or engineering monitoring party pairCan project reliably be completed to suspect on schedule.
Even across using the Process Control System shaped, the same Process Control System of a set of coming of new, dispatch from the factoryWhen should also carry out exfactory inspection.When carrying out exfactory inspection, such as test detection means is enriched 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 adjustedTrying the time can be longer.
Utility model content：
In order to realize the monitoring software for the Process Control System newly developed and its hardware before practical application, can closeManage under cost control, comprehensively and effectively test-based examination is carried out to its function and performance, pinpoints the problems and eliminates defect, especially can be rightIts monitoring software is carried out effective " third-party software test "；And the Process Control System for the production that can be shaped to enterprise is completeEquipment carries out effective exfactory inspection.Have to the software and hardware quality state of the Process Control System for manufacture of newly grinding or shapeThe inspection and evaluation of effect, the present invention propose " Process Control System test device " this product concept, and the device can not only be staticThe software and hardware of ground test process control system, moreover it is possible to the dynamically software of test process control system so that fruitfully open" the third-party software test " of exhibition Process Control System is possibly realized.
The technical solution adopted in the utility model is：A kind of test device of industrial process control system, mainly by adjustingValve actuator enhancement type analog device and simulation computer are formed, on the one hand regulation valve actuator enhancement type analog device uses circuit mouldIntend the action process of regulation valve actuator, accordingly dynamic changes and remembered the valve place value of a virtual regulating valve, also usesThe signal transmitting device of parameter monitoring, the signal intensity of sensor in breadboardin Process Control System；Simulation computer is used forThe control object of simulation process control system（That is industrial equipment or process apparatus）Operation process, according to the work number of equipmentIts course of work of model emulation, the state parameter of simulated equipment can constantly change on computers.Simulation computer is with adjustingSave valve actuator enhancement type analog device to network work by bus network or Ethernet, in a network based on simulation computerStand, regulation valve actuator enhancement type analog device is slave station.Simulation computer receives mould from regulation valve actuator enhancement type analog deviceThe valve position signal of plan, the new operating condition of simulated equipment is gone out according to the change of valve position signal and other associated information calculations,And its new state parameter is passed back to regulation valve actuator enhancement type analog device, transmitter/sensing as its change simulationThe foundation of device output signal size.
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, in receive process control systemValve opening, pass valve and the switching valve position control mode that the actuator control electric current signal or console that controller is sent are sent are openedMeasure the malfunction of signal, while the actuator working condition that simulator is simulated, mainly virtual valve place value and simulation in passSignal 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 " turning down valve position " On-off signal signal, 1 " control of valve position size " analog input signal, 1 " valve position is bigSmall feedback " analog quantity output signals, 1 valve position " controlling/use analog signalses control selections with on-off model " 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 its inputValve position Analog control signal size, on the other hand again can real-time display simulation valve seat opening actual at that 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, does not send fault-signal during on or off.
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, becomes analog signalses with circuit, feeds 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.
Method of testing is used by a kind of test device of industrial process control system：Tested Process Control SystemAdjustment control is exported into (i.e. control of valve position signal) in the form of on-off model or current signal according to its normal working methodRegulation valve actuator enhancement type analog device is sent to, after simulator receives control of valve position signal, current controling signal in this way, firstIt is consistent with reception value to change the size of the control of valve position signal shown on liquid crystal or LED display modules on simulator, opens in this waySignal is measured in pass, is indicated with corresponding light emitting diode on simulator, then opens big according to default valve or turns down 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 the output valve of resistance and temperature interface signal, 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 the velocity amplitude that every simulator in system sets virtual regulation valve events in simulator, and the value is stored in mould after settingIntend in the nonvolatile storage in device.
The beneficial effects of the utility model：This test device be able to can not only be realized important under effective cost controlThe effective exact p-value for the model machine equipment software and hardware that industrial process control system is newly developed, especially can effectively carry out program controlSystem " third-party testing of control software " work processed；The Process Control System that can be used for subsequently manufacturing is actual equip it is effectiveExfactory inspection.
Embodiment：
Reference picture 1, dotted line left part are the equipment that control room end is usually placed in in general Process Control System,Mainly console and control rack, console inside and display and operation panel are arranged manipulation instruction computer, display, set againStandby running LED, alarm window, the manipulation element such as button and binding post；Control rack arrange again controller and itsThe elements such as I/O modules, signal conversion element and binding post；Manipulation instruction computer in console and the control in control rackDevice processed is usually to be attached with the Ethernet of internal system, realizes data exchange；It is and other between console and control rackThe connection of signal is usually to be attached with controlling cable；Controller running-course control application software in rack, and controlManipulation instruction computer operation man-machine interface application software is used to be manipulated and be indicated on platform.The above equipment assembly is in additionThe application software of operation thereon just constitutes the semi-finished product of Process Control System, because its also not connected and monitored process fillsPut or the element such as transmitter, sensor and executing agency that equipment is arranged together, form process control system trulySystem.The semi-finished product of this Process Control System need to firmly believe in factory's manufacture, debugging and test in advance it is out of question after the assay was approved,Just installation is carried out in site of deployment and actual debugging is applied.For less Process Control System, control rack may not be set, andIt is also to realize the function of control rack in console.
Reference picture 1, dotted line right side are used for the test device of test process control system for the present invention, and it is held by regulating valveRow device enhancement type analog device and simulation calculation are formed.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 the signal transmitting device of parameter monitoring, the signal intensity of sensor 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 constantly change on computers.
The regulation valve actuator interface function and signal transmitting device, 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, sensing of industrial process-fieldThe interface function of device, then the real-world operation with 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, 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 and regulation valve actuator enhancement type analog device are networked work by bus network or Ethernet,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, to realize that the work-based logic of these element functions emulates, 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 adds the computer chip mode of other patterns, in 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 manipulate.A meanwhile regulationValve actuator enhancement type analog device several roads of circuit analog simulation are used for signal transmitting device/sensor that process variable monitorsExternal 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, is controlled in receive process control systemThe 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 sentThe fault status signal of signal, while the actuator working condition that simulator is simulated, mainly virtual valve place value and 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 " switchMeasure input signal, 1 " turning down valve position " On-off signal signal, 1 " control of valve position size " analog input signal, 1 " valvePosition size feedback " analog quantity output signals, 1 valve position " controlling/use analog signalses control selections with on-off model " switchMeasure input signal, 1 " malfunction " switching value output signal, 1 24V dc sources output.
Regulation valve actuator enhancement type analog device is furnished with two groups of liquid crystal or LED display modules, and one group is used to show its inputValve position Analog control signal size, another group be used for real-time display simulation valve seat opening actual at that time；Also can only 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 of the valve position Analog control signal of input and the valve seat opening actual at that time of simulation 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 when switch is on or offWhen represent actuator be in normal operating conditions, do not send fault-signal, while also give 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 valve actuator enhancement type analog device and pass through the signal transmitting device of itself, Sensor Analog Relay System output interface and controlCorresponding input terminal is connected in control rack or console or control cabinet in system, will come from simulation computer and emulateIndustrial 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 are provided with two-wire system 4mA~20mA signal output interfaces, are 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, -23 DEG C~322 DEG C of equipment operating temperature range can be simulated；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, the new operating condition of simulated equipment is gone out according to the change of valve position signal and other associated information calculations, and its is newState parameter be passed back to regulation valve actuator enhancement type analog device, as its change simulation transmitter/sensor export 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, for illustrating the method for testing of 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 the control of realityIn order to realize that the regulation of drum drum pressure and boiler drum water level need to configure two regulating valves in system processed, every regulating valve by with itsIntegral actuator direct drive and control are installed on, needs to configure drum drum pressure monitoring transducer, drum drum water in additionPosition pressure difference monitoring transducer and superheat steam temperature monitoring thermocouple sensor.
The boiler implosion part of Process Control System mainly by boiler implosion rack, boiler console and its be arranged in platform orInside cabinet or the element such as the controller on surface and its I/O modules, manipulation instruction computer, button switch, binding post is formed.
In order to verify that the design of hardware and software of the monitoring boiler function of 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 forms design of hardware and software realization of the test device to monitoring boiler function and tested.Wherein simulator withSimulation computer forms 485 bus network and cooperated together, and wherein simulation computer is main website, and two simulatorsFor slave station.The action process of wherein simulator analog simulation fuel flow regulation 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 of device analog simulation drum steam water-level regulation 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, and boiler console is powered with control rack, makes the control being installed on itApplication software operation in device and manipulation instruction computer, the related software and hardware function of test observation run whether correct, performanceWhether satisfaction requires.
Reference picture 3, it is by boiler implosion to valve opening, pass valve, the control of valve position mode selection signal for adjusting valve actuatorWhat 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 equalIt is connected on the binding post of boiler implosion rack.
When the boiler operatiopn state of simulation computer emulation, which reaches energy, to be balanced with mass input output, 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 opened by the control mode selection on consolePass 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, virtual valve place value increase or the control reduced are realized according to corresponding control signal,Worked during two kinds of control of valve position signal differences.
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, newest virtual valve place value is fetched when it adjusts valve actuator enhancement type analog device from fuel flow, first to voidThe valve place value of plan shown, and according to the valve place value of 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 vapourThe last look of bag pressure and superheat steam temperature parameter is 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.
After controller in boiler implosion rack receives the signal of drum steam water-level reduction, 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 dynamically to go round and begin 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 the velocity amplitude that every simulator in system sets virtual regulation 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.