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5X00070G01 可靠性高、应用非常广泛的工业控制产品
PLC是现代工业的三大支柱之一，是可靠性高、应用非常广泛的工业控制产品。在中大型模块化的PLC产品中，CPU模块（*处理器）是PLC的中心。一些重大的工业生产线往往要求连续运行不能停顿，而可靠性再高的PLC也不能保证故障为零，因此，双CPU的冗余控制是一种满足连续生产要求、提高系统可用性的有效手段。下面以熔盐炉自控系统为实例详述双CPU冗余控制的实现方法。
一、熔盐炉自动系统综述
熔盐炉自控系统是一水硬铝管道化溶出生产线上的重要环节，控制熔盐的加热和循环，用熔盐的热量去循环加热铝矿石浆。铝矿石浆的加热至关重要，影响zui终产品—氧化铝的质量和产量，因此，熔盐的温度控制和循环控制非常重要。
由于熔盐炉系统在管道化工程中的重要性，同时考虑到熔盐是一种活跃的化学品，在不同的温度下有不同的形态，低温下凝固，高温下不稳定会发生化学反应，从而腐蚀管壁甚至于爆炸，所以安全、可靠、操作简便和自动化管理是系统设计的关键，因此考虑用一套双CPU冗余的PLC、两套工控机、高质量的传感器、变送器和执行机构来控制两台1200万大卡的熔盐炉、一台盐泵、一组盐阀、一个熔盐槽和其他相关设备，实现熔盐的加热和循环过程自动化、计算机操作、监控和管理的自动化控制。
控制器PLC、工控机(包括显示器)、通讯网络和电源及关键测试点等系统中的重要部件均采用冗余结构，两套工控机和大屏幕显示器组成的两套监控操作管理台并行运行；两条冗余的ControlNet高速通讯网络同时传送数据；两套直流电源同时向控制器PLC、变送器和开关量输入模块供电，关键测试点同时设置两个传感器测试数据。
冗余设计使系统关键部件的可靠性提高了一倍，而使系统的整体可靠性大大的提高。
5X00070G01 可靠性高、应用非常广泛的工业控制产品
PLC is one of the three pillars of modern industry and is a highly reliable and widely used industrial control product. In medium and large modular PLC products, the CPU module (* processor) is the center of the PLC. Some major industrial production lines often require continuous operation can not stop, and no matter how high the reliability of the PLC can not guarantee zero failure, therefore, dual CPU redundancy control is an effective means to meet the requirements of continuous production and improve the availability of the system. The following takes the automatic control system of molten salt furnace as an example to describe the implementation method of double CPU redundancy control.
I. Overview of automatic system of molten salt furnace
The automatic control system of molten salt furnace is an important link in the dissolution production line of duralumin pipe, which controls the heating and circulation of molten salt, and uses the heat of molten salt to heat the aluminum ore pulp. The heating of aluminum ore pulp is very important, which affects the quality and output of the final product – alumina, so the temperature control and circulation control of molten salt are very important.
Due to the importance of molten salt furnace system in pipeline engineering, and considering that molten salt is an active chemical with different forms at different temperatures, solidification at low temperatures, unstable chemical reactions will occur at high temperatures, thereby corroding pipe walls and even exploding, safety, reliability, easy operation and automated management are the keys to system design. Therefore, consider using a set of double CPU redundant PLC, two sets of industrial computers, high-quality sensors, transmitters and actuators to control two 12 million calories of molten salt furnace, a salt pump, a group of salt valves, a molten salt tank and other related equipment, to achieve the automatic control of molten salt heating and circulation process, computer operation, monitoring and management.
The important components in the system, such as controller PLC, industrial computer (including display), communication network, power supply and key test points, all adopt redundant structure, and two sets of monitoring and operation management stations composed of two sets of industrial computer and large screen display run in parallel; Two redundant ControlNet high-speed communication networks transmit data simultaneously; Two sets of DC power supplies simultaneously supply power to the controller PLC, transmitter and switch input module, and the key test point sets two sensor test data at the same time.
The redundancy design doubles the reliability of the key components of the system and greatly improves the overall reliability of the system.
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