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SR-507,
SR-507
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我国城市地铁使用的大型PLC控制系统一直被西门子、施耐德、罗克韦尔三个品牌垄断着,直到和利时的大型PLC产品研发成功,才实现了该领域的自主可控。然而,国产PLC控制系统的产业化推广之路却并不平坦。
在每个地铁车站里,照明灯点亮或是熄灭、电扶梯上行或是下行、每扇屏蔽门打开或是关上、通风和给排水设备开启或是关闭……这些看似平平常常毫不起眼的设施,背后是怎么管理的,来去匆匆的乘客很少有人会注意到。其实,对地铁车站中的供电设备、机电设备的控制,对车站防灾系统的管理,对车站每个末端开关的控制,都要依靠后台的“城市轨道交通用大规模网络化高可靠PLC控制系统”来操作和完成。
PLC全称可编程逻辑控制器(Programmable Logic Controller),实质是一种专用于自动化控制的工业计算机系统。城市轨道交通是一个庞大而复杂的系统,以PLC、SCADA为代表的轨道交通自动化系统是保障运营安全、提高运输效率的核心技术装备。
三选一的固定模式
地铁车站内的PLC主要应用于轨道交通的综合监控系统、车站环境监控系统、牵引供电系统、低压配电系统、照明系统、应急电源系统、变电所综合自动化系统、屏蔽门系统、电扶梯系统、给排水系统……这样的应用场景对大型PLC产品的安全性和可靠性的要求非常高。在深深的地下,如果照明控制失灵导致漆黑一片,如果电扶梯的上行下行出现混乱,都可能会引发事故甚至造成人身伤亡。所以,站在地铁管理者的角度,他们更愿意选用国际上知名品牌的比较成熟的大型PLC产品。
多年来,地铁选购的城市轨道交通用大型PLC控制系统基本都是西门子、施耐德、罗克韦尔这三个品牌的产品,甚至发展到在项目招标时,招标文件里就赤裸裸指明说大型PLC系统必须在这三个品牌中3选1。
为什么在大型PLC领域,我国的企业鲜有涉足呢?因为产品研发投入大,研发周期长,中小企业根本无法完成。即使是小型PLC控制系统,虽然国内很多厂家都在研发生产,但也只能做硬件开发和系统集成,核心的组态软件和实时控制引擎则直接购买德国的产品拿来用。这种软硬件适配的方式却不能应用在大型PLC控制系统的研发中,因为双机冗余同步很难做到,也难以通过各类安全认证。
PLC控制系统是工业实现自动化、智能化的基础,也就是相当于计算机系统中的“芯片”,即所谓“工业芯”。在中国,工业系统中的大型PLC基本都是采用进口厂商的产品,也就是在用国外的“工业芯”,如果国外不再给中国提供产品,那我国的工业发展就会出现障碍。
为解决地铁站里的“卡脖子”问题,2014年,和利时集团承接了工业强基专项“城市轨道交通用大规模网络化高可靠智能PLC控制系统项目”,该项目计划总投资8745.32万元,项目实际完成总投资8756.22万元,投资完成率100.12%。
在强基专项的支持下,和利时基于二十余年的工业控制技术积累,与北京地铁紧密合作,以西门子的S7-400和罗克韦尔1756系列等高端大型PLC为参考目标产品,自主研发了城市轨道交通用大规模网络化高可靠PLC控制系统。经过2年的努力,共研发了20余种PLC模块产品和软件。项目研发的PLC系统的性能和功能均达到西门子S7-400和罗克韦尔1756系列等国际同类产品先进水平,并通过了CE、UL、阿基里斯等电气安全和信息安全国际认证。
终于,在我们自己的地铁车站里,可以用上我们自主研发的大型PLC控制系统了。
研发与应用
项目伊始其实并不被看好,计划总投资8745.32万元,如此大的开发投入,作为一家民营企业,和利时必须考虑项目的投入产出比。和利时集团技术总监朱毅明给记者算了一笔账:“大型PLC产品一年大致能够销售3000万-4000万元,可整个的研发费用大概也需要三四千万。市场的销售毛利约20%-30%,纯利润的百分比也就是个位数了,从财务层面分析,这个项目一点意义都没有。投入产出比如此糟糕,使得当年的经营决策做得非常困难。”
虽然该项目产生的经济效益将很不理想,但大规模PLC是保证城市轨道交通安全高效运营的核心基础装备,开发具有自主知识产权的大规模PLC控制系统并实现产业化,可以促进和拉动高端制造业的发展,对国家战略安全具有实际意义。因此,和利时集团坚持项目开发,努力承担起企业的社会责任。也是因为这份担当,很多项目开发骨干面对华为、阿里、腾讯高薪酬的诱惑,面对互联网行业的风光前程,却能坚守在基础工业领域,全身心地投入到大型PLC系统的研发中。
在产品研发阶段,和利时引入新的管理方法,建立基于IPD的研发管理体系,打通各部门之间的壁垒,实现项目部、开发部、工艺部、生产部、测试部的协同工作,使项目按计划和目标稳步推进,研发的成本和质量都得到了比较好的控制。面临人员紧张、技术难点多等困难,项目经理采用扁平化的管理思路,增进与项目各小组成员的沟通,联合外部专家,集中攻克了一批关键技术难题。
大型PLC项目的核心研发团队主要设在西安,共30多人,团队中每个人压力都很大。轨道交通用大型PLC控制系统对安全性和可靠性要求极高,使用时只有一次机会,一旦出现问题,或者在一个地铁站里运转不利,那就不会再有其他地铁选择使用了,诸多努力都将付之东流。所以,研发团队任务繁重,日以继夜地连轴转。
规模网络化PLC是一项综合性技术,需要长期持之以恒地研发投入和多种行业的大量应用实践。因此在本项目执行期间,与国内多家科研、用户单位有着广泛而深入的合作,实践证明这种合作成效非常显著。例如,与机械工业仪器仪表综合技术经济研究所合作形成“大规模PLC技术评估体系和方法”;与北京轨道交通建设管理有限公司深度合作,将产品开发与应用结合在一起,设计符合用户实际需要的产品;与北京地铁紧密合作,将成果成功应用于北京地铁14号线……
城市轨道用大规模PLC的研制开发是一项复杂的系统性工程,该PLC涉及多项关键技术,需要不同专业的研发人员协同开发。和利时基于多年的PLC开发实践经验,对PLC软硬件开发中的共性技术进行模块化封装,沉淀到统一的技术平台,每个模块预留标准接口,实现不同职种开发人员的搭积木式的快速协同开发。虽然项目面向城市轨道交通应用场景,但新的共性技术也能进一步丰富技术平台,为其他应用场景的PLC产品开发奠定基础。
本项目PLC支持新型的实时工业以太网。在产品开发时,和利时积极与网络产品厂商沟通,并与网络产品厂商成立专项组,为PLC系统的应用,开发配套的网络产品,为用户提供一站式解决方案。同时,针对地铁综合监控系统的互联互通要求,PLC产品集成丰富的开放协议,保证地铁设备系统的无缝集成。
和利时作为国内领先的地铁综合监控系统集成商,对PLC产品的应用需求有着深刻的认识,为PLC产品的开发提供了很多重要的输入。此外,和利时产品部又充分调研了国内其他系统集成商的PLC需求,在产品定义时吸收众多用户的基础需求,提炼用户的创新需求,融合用户的前沿需求,保证了产品未来十几年可持续发展的竞争优势。
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20AB054A3AYNANC0 PowerFlex 70 AC Drive 54 A at 20 Hp 20A
GA647IFPLRNUNLMT GCA iFIX Plus SCADA Unlmt Run
GP647IFCLNTSRO100 GCP iFIX iClientTS Read Only 100 PK
IC600BF830RR Advanced I/O Receiver Module
IC647HSTCC75KM Calculation Collector for Historian - Standard Server 75000 Points (M4 Key)
IC647TDV915 CIMPLICITY HMI Server 1500 I/O Development & Runtime System
IC693MDL940LT Relay Output, 2 Amp (16 Points) (LT)
IC756LDV001K-912 DV Development - Intel/Linux RedHat Addt'l User, Korean, Version 9.12
Pico Controllers 1760-STARTL12AWA PICO AC STARTER PAK
PLC-5/1771 System 1771-OR ISOLATED OUTPUT MODULE, 6 OUTPUTS, 220V AC
Distributed I/O 1791-8BC BLOCK I/O 24V DC, 16 POINT MODULE
Communications 1786-FS10 200 MICRON CABLE ASSEMBLY 10 METERS (32.8 FT)
Operator Interface 9399-2SE32GRFR RSVIEW32 GETTING RESULTS GUIDE (FRENCH)
Support 9356-PRO2100R SUPT REINSTATEMENT CONTRACT FOR 9356PRO2100
Support 9324-RL0300FRS SUPT RENEWAL CONTRACT FOR 9324RL0300FR
EtherNet/IP Products 1771-DMC4 CONTROL COPROCESSOR - MAIN MODULE
RSI Software Products 9301-2SE3500ESE RSVIEW32 RUNTIME 100K (SPANISH)
RSI Software Products 9356-PRO2450U7R UPGRADE: OUT-SUPT: RSSQL PROF.1500 TO 32000 TAGS
Motion Control N-2302-1-F04AA SERV MTR,0.2NM,6000RPM,1000 LN ENCDR,BRK
44A730109-001R02 90-70 Carrying Case
IC200ALG320 ANALOG OUTPUT 12 BIT CURRENT 4CH
IC693MDL754 12/24VDC Output (0.75 amps per point) Module 32 point. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block).
Silver Series 2711E-T14C15 PANELVIEW 1400E TOUCHSCREEN TERMINAL 14" COLOR CRT
VMEM-SF VisualMEM ShopFloor Seat w/Automatic Data Collection.
20BD022A3AYNANC0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B
20G11FC8P7JA0NNNNN PowerFlex 755 AC Packaged Drive
22C-D060A103 PowerFlex 400- 30 kW (40 HP) AC Drive
ASMBII003 Quantum DROP CBL 50FT
285-BRC25-M8D Source Brake Patchcord Cable, 8M, M25
E6A2-CS5C 12-24VDC,集电极开路输出30VDC 30Ma,1相,100P/R,200P/R
1747-SN 远程I/O扫描模块
PXI-8431/4
EICON EiconCard C21 800-282-01 198-24257 030-157-10
MIC-3369
GW-2U600
PIO-32/32L(PCI)
SHB110
1492-MUA3-A10-A13 1773 - 1756 Conversion Mounting Assembly
通讯处理器CP 6ES7 340-1BH02-0AE0 CP340,标准串行通讯模块,20mA /TTY 接口,最高 19.2kbit/s,15 针 D 型接口
2094-BC07-M05-M Kinetix 6200/6500 Integrated Module
DEMOCD00008 Web Server DEMO CD
GFK-0730 OnTOP for Series 90-70 Online Troubleshooting and Operator Program User's Manual
IC210BDD012 24V DC Power Source, (6) 24VDC in/(4) out (Transistor) , (2) analog inputs, Expandable, without LCD/Keypad
IC647ARC050 PA Reporting Client 50 Pak
IC647PPSEWC Proficy Process Systems Engineering Workstation with CIMPLICITY
IC693CMM321CA Conformal Coated Ethernet Interface module. 10Mbits, supports SRTP and Modbus TCP Client/Server. The CMM321 no longer supports the AAUI/AUI interface. If the AAUI/AUI is required, please contact GE Global Customer Care.
IC754VBI12CTD View Interm 12 inch Color TFT Touch DC Blank
MSI-COA/COC-43 Automated COA Application-43
SLC/1746 System 1746-R10 REPLACEMENT COVERS & LABELS FOR CTLG # 1746-P1
Distributed I/O 1734-OB4E 24V DC 4 CHANNEL SOURCE OUTPUT MODULE
Application-specific products 1803-EEM20 EEM,32 PULSES, 24V DC
Operator Interface 2711-T10G9 PV1000 GRAYSCALE TOUCH, RS232(DH485) & RS232 PRINT
Support 9302-APOR SUPT REINSTATEMENT CONTRACT FOR 9302APO
Support 9381-PP2500ENS SUPT RENEWAL CONTRACT FOR 9381PP2500EN
DeviceNet Products 1791D-16V0 DNET 24 VDC COMPACTBLOCK I/O, 16 IN SOURCE, BASE
RSI Software Products 9301-2SE3350ESE RSVIEW32 RUNTIME 5K (SPANISH)