温室大棚测控系统设计毕业设计


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    温室棚测控系统设计
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    智红外温度传感器
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    智红外温度传感器
    断发展工艺技术工艺工程师说重挑战加保持目前迅速变化监测控制方法程求项务已变相迫切然红外温度传感器制造商正户提供需工具应付挑战:新计算机相关硬件软件通信设备先进数字电路中工具新代红外温度计智传感器
    天新智红外传感器代表两迅速发展结合红外测温通常计算机联系起高速数字技术科学联盟文书称智传感器微处理器作编程双收发器传感器间串行通信生产车间计算机控制室电路体积传感器更简化紧张尴尬区安装智传感器集成新现程控制系统新先进水温度监测控制方面程控制方面工程师提供直接处

    1集成智传感器程线
    时广泛推行智红外传感器新红外测温已成功应程监测控制十年果工艺工程师需改变传感器设置关闭者删线传感器尝试手动重置位然导致路线延误某情况十分危险升级传感器通常需购买新单位校准进程生产线停滞时候安装例某传感器镀锌铁丝厂安装桶熔融铅锌盐酸毫费力狭窄道流出安全利益考虑生产线关闭少降温24时前改变升级传感器
    天工艺工程师远程配置监测处理升级维护红外温度传感器带双RS 485接口RS 232通信功智模型简化融入程控制系统程旦传感器安装生产线工程师根参数适应断变化条件切控制室中电脑举例说果环境温度波动程序身历类型厚度温度改变程工程师需做定制恢复保存计算机终端设置果智传感器高温度环境电缆断裂者未组成部分失败障进行动修复该传感器激活触发报警停机防止损坏产品机械果烤炉冷器失败音响LO警报信号指出里问题关闭生产线

    11 延长传感器寿命
    智传感器符合数千种类型进程必须完全定义智传感器包含读(擦编程读存储器)户重新编程满足具体程序求现场标定诊断传感器制造商实软件
    拥智传感器处固件芯片嵌入式软件通通讯联系升级修订成利生产线移走传感器固件升级延长传感器工作寿命真正智传感器智化
    Raytek公司马拉松系列全系列1 2色红外温度计达32智传感器联网现模式包括综合单位光纤传感器电子盒套确保高温环境安装
    点击传感器窗口显示特定传感器配置设置 Windows图形界面直观易配置屏幕工艺工程师够监测电流传感器设置调整满足需重置传感器回工厂默认值显示信息RS 485接口RS 232串口连接传感器
    头两栏户输入第三第时间监测传感器参数某参数通屏幕定制程序PC传感器命令更改参数户通方面改变输入:
    •继电器触点设定NO (常开)数控(通常关闭)
    •中继功设定警报设定点
    •温度单位改变摄氏度华氏度反然
    •显示器模拟输出模式改变智传感器加两色容量
    •激光(传感器配激光瞄准)开启关闭
    •毫安输出设置范围作动进程触发警报
    •发射率(1色)斜率(两色)热值设定发射率斜率值般金属非金属材料说明确定发射斜坡通常包含传感器中
    •信号处理定义温度参数返回均返回象均气温段时间峰值举行返回象高温度段时间外部触发
    •音响报警劳报警设定警告温度变化程线引发破产品障加热器冷器容
    •衰减表明报警关闭设置双色智传感器例子中果镜头95%遮蔽报警警告说温度结果失准确性(称肮脏窗口报警)95%默默闻触发动关机进程

    12 智红外传感器应
    智型红外传感器生产程温度关重高品质产品中
    红外温度传感器监控产品种热工前干燥前温度智传感器配置高速点网络(定义见文)远程监控计算机独立寻址传感器测量温度调查数单独季度绘制成图表便监测温度数程存档远程处理功设置点报警器发射率信号处理信息载传感器结果更严格程控制

    13 远程线寻址
    持续图2相似程智传感器连接显示器图表记录器控制器分单独网络该传感器安排点点点配置者简单独立
    点配置传感器(达32某情况)联结网络型电缆传感器拥址允许分设定操作参数智传感器RS 485接口FSK信号(频移键控)通信控制室电脑设置相距离达1200米( 4000英尺)RS 485接口3000米(点零零零万英尺)FSK信号程序RS 232接口通信电缆长度限制100英尺
    点点安装智传感器连接图表记录程控制器显示器控制计算机种类型安装数字通信结合毫安电流回路作完整全方位进程通信软件包
    时专门程序需专门软件壁纸制造商需系列传感器编程检查休息眼泪着整新闻界涂层运行区环境表温度果发现表面正常现象传感器必须触发警报例满足客户商具体求工程师出版协议数编写程序定义程序远程飞虫身安装传感器关闭生产线

    2刻度标定传感器升级
    点点点单传感器网络工艺工程师需适软件工具计算机校准配置监控升级传感器简单易数采集配置实程序通常智传感器套件购买时部分定义软件
    外校准软件相智传感器校准新参数直接载传感器电路传感器前参数保存存储计算机数文件确保完整记录校准参数变化保留套校准技术包括单点偏移两三点变温度:
    •单点抵消 果单温度特定程中传感器读数需重置符合已知温度单点偏移校准应偏移适温度整温度范围工作例果已知温度浮动玻璃生产线1800°F智传感器系列传感器校准温度
    •两点 果传感器读数必须符合两特定温度两点校准图3示应选择种技术校准温度计算增益偏移适整温度范围温度
    •三点变温度 果进程具广泛温度范围传感器读数必须符合三具体温度选择3点变温度校准种技术校准温度计算两收益两偏移第增益偏移适低中点温度第二盘中点温度三点校准单双点相太常见偶尔制造商需执行技术满足特定标准
    现场校准软件允许常规诊断方法包括运行智传感器电源电压中继试验结果工艺工程师知道传感器效果佳做出必障排更加容易

    3结尾
    新代智红外温度传感器求工艺工程师必须新生产技术产量增加带变化现配置传感器满足特殊控制程需延长传感器寿命远远超出先前聪明设计生产速度提高设备停机时间必须减少通监测设备微调温度变量需关闭进程工程师保持高效率程提供高质量产品智红外传感器数字化处理组件通讯力提供定程度现没实现灵活性安全性易性
    红外线( IR )辐射电磁波谱中包括线电波微波见光紫外线伽马射线X射线IR见部分频谱线电波间红外波长通常微米表示光谱范围071000微米0714微米波段红外测温
      采先进光学系统探测器非接触式红外温度计专注部分0714微米波段部分象(黑体)排放量佳红外量某特定点线红外波段程需独特传感器模型具体光学探测器类型例传感器狭窄集中343微米频谱范围适合测量表面温度聚乙烯相关材料传感器设5微米衡量玻璃表面 光传感器金属金属箔片更广泛光谱范围衡量温度较低表面纸纸板聚铝箔复合材料
      象通温度体现排放红外量增加减少发出量目标发射率测量表明物体温度
    发射率术语量化源发光特性材料表面红外传感器具调发射率设定通常0110准确测量表面类型温度
    发出量象通光学系统达红外传感器重点源光敏探测器然探测器红外量转换成电信号转换成温度值基传感器校准方程目标发射率温度值显示传感器种智传感器转换成数字输出显示计算机终端

    Smart Infrared Temperature Sensors

    Keeping up with continuously evolving process technologies is a major challenge for process engineers Add to that the demands of staying current with rapidly evolving methods of monitoring and controlling those processes and the assignment can become quite intimidating However infrared (IR) temperature sensor manufacturers are giving users the tools they need to meet these challenges the latest computerrelated hardware software and communications equipment as well as leadingedge digital circuitry Chief among these tools though is the next generation of IR thermometers—the smart sensor
    Today’s new smart IR sensors represent a union of two rapidly evolving sciences that combine IR temperature measurement with highspeed digital technologies usually associated with the computer These instruments are called smart sensors because they incorporate microprocessors programmed to act as transceivers for bidirectional serial communications between sensors on the manufacturing floor and computers in the control room (see Photo 1) And because the circuitry is smaller the sensors are smaller simplifying installation in tight or awkward areas Integrating smart sensors into new or existing process control systems offers an immediate advantage to process control engineers in terms of providing a new level of sophistication in temperature monitoring and control
    Integrating Smart Sensors into Process Lines
    While the widespread implementation of smart IR sensors is new IR temperature measurement has been successfully used in process monitoring and control for decades (see the sidebar How Infrared Temperature Sensors Work below) In the past if process engineers needed to change a sensor’s settings they would have to either shut down the line to remove the sensor or try to manually reset it in place Either course could cause delays in the line and in some cases be very dangerous Upgrading a sensor usually required buying a new unit calibrating it to the process and installing it while the process line lay inactive For example some of the sensors in a wire galvanizing plant used to be mounted over vats of molten lead zinc andor muriatic acid and accessible only by reaching out over the vats from a catwalk In the interests of safety the process line would have to be shut down for at least 24 hours to cool before changing and upgrading a sensor
    Today process engineers can remotely configure monitor address upgrade and maintain their IR temperature sensors Smart models with bidirectional RS485 or RS232 communications capabilities simplify integration into process control systems Once a sensor is installed on a process line engineers can tailor all its parameters to fit changing conditions—all from a PC in the control room If for example the ambient temperature fluctuates or the process itself undergoes changes in type thickness or temperature all a process engineer needs to do is customize or restore saved settings at a computer terminal If a smart sensor fails due to high ambient temperature conditions a cut cable or failed components its failsafe conditions engage automatically The sensor activates an alarm to trigger a shutdown preventing damage to product and machinery If ovens or coolers fail HI and LO alarms can also signal that there is a problem andor shut down the line
    Extending a Sensor’s Useful Life
    For smart sensors to be compatible with thousands of different types of processes they must be fully customizable Because smart sensors contain EPROMs (erasable programmable read only memory) users can reprogram them to meet their specific process requirements using field calibration diagnostics andor utility software from the sensor manufacturer
    Another benefit of owning a smart sensor is that its firmware the software embedded in its chips can be upgraded via the communications link to revisions as they become available—without removing the sensor from the process line Firmware upgrades extend the working life of a sensor and can actually make a smart sensor smarter
    The Raytek Marathon Series is a full line of 1 and 2color ratio IR thermometers that can be networked with up to 32 smart sensors Available models include both integrated units and fiberoptic sensors with electronic enclosures that can be mounted away from high ambient temperatures
    (see Photo 1) Clicking on a sensor window displays the configuration settings for that particular sensor The Windows graphical interface is intuitive and easy to use In the configuration screen process engineers can monitor current sensor settings adjust them to meet their needs or reset the sensor back to the factory defaults All the displayed information comes from the sensor by way of the RS485 or RS232 serial connection
    The first two columns are for user input The third monitors the sensor’s parameters in real time Some parameters can be changed through other screens custom programming and direct PCtosensor commands Parameters that can be changed by user input include the following
    · Relay contact can be set to NO (normally open) or NC (normally closed)
    · Relay function can be set to alarm or setpoint
    · Temperature units can be changed from degrees Celsius to degrees Fahrenheit or vice versa
    · Display and analog output mode can be changed for smart sensors that have combined one and twocolor capabilities
    · Laser (if the sensor is equipped with laser aiming) can be turned on or off
    · Milliamp output settings and range can be used as automatic process triggers or alarms
    · Emissivity (for onecolor) or slope (for twocolor) ratio thermometers values can be set Emissivity and slope values for common metal and nonmetal materials and instructions on how to determine emissivity and slope are usually included with sensors
    · Signal processing defines the temperature parameters returned Average returns an object’s average temperature over a period of time peakhold returns an object’s peak temperature either over a period of time or by an external trigger
    · HI alarmLO alarm can be set to warn of improper changes in temperature On some process lines this could be triggered by a break in a product or by malfunctioning heater or cooler elements
    · Attenuation indicates alarm and shut down settings for twocolor ratio smart sensors In this example if the lens is 95 obscured an alarm warns that the temperature results might be losing accuracy (known as a dirty window alarm) More than 95 obscurity can trigger an automatic shutdown of the process
    Using Smart Sensors
    Smart IR sensors can be used in any manufacturing process in which temperatures are crucial to highquality product
    Six IR temperature sensors can be seen monitoring product temperatures before and after the various thermal processes and before and after drying The smart sensors are configured on a highspeed multidrop network (defined below) and are individually addressable from the remote supervisory computer Measured temperatures at all sensor locations can be polled individually or sequentially the data can be graphed for easy monitoring or archived to document process temperature data Using remote addressing features set points alarms emissivity and signal processing information can be downloaded to each sensor The result is tighter process control
    Remote Online Addressability
    In a continuous process similar to that in Figure 2 smart sensors can be connected to one another or to other displays chart recorders and controllers on a single network The sensors may be arranged in multidrop or pointtopoint configurations or simply stand alone
    In a multidrop configuration multiple sensors (up to 32 in some cases) can be combined on a networktype cable Each can have its own address allowing it to be configured separately with different operating parameters Because smart sensors use RS485 or FSK (frequency shift keyed) communications they can be located at considerable distances from the control room computer—up to 1200 m (4000 ft) for RS485 or 3000 m (10000 ft) for FSK Some processes use RS232 communications but cable length is limited to <100 ft
    In a pointtopoint installation smart sensors can be connected to chart recorders process controllers and displays as well as to the controlling computer In this type of installation digital communications can be combined with milliamp current loops for a complete allaround process communications package
    Sometimes however specialized processes require specialized software A wallpaper manufacturer might need a series of sensors programmed to check for breaks and tears along the entire press and coating run but each area has different ambient and surface temperatures and each sensor must trigger an alarm if it notices irregularities in the surface For customized processes such as this engineers can write their own programs using published protocol data These custom programs can remotely reconfigure sensors on the fly—without shutting down the process line
    Field Calibration and Sensor Upgrades
    Whether using multidrop pointtopoint or single sensor networks process engineers need the proper software tools on their personal computers to calibrate configure monitor and upgrade those sensors Simple easytouse data acquisition configuration and utility programs are usually part of the smart sensor package when purchased or custom software can be used
    With field calibration software smart sensors can be calibrated new parameters downloaded directly to the sensor’s circuitry and the sensor’s current parameters saved and stored as computer data files to ensure that a complete record of calibration andor parameter changes is kept One set of calibration techniques can include onepoint offset and two and threepoint with variable temperatures
    • Onepoint offset If a single temperature is used in a particular process and the sensor reading needs to be offset to make it match a known temperature onepoint offset calibration should be used This offset will be applied to all temperatures throughout the entire temperature range For example if the known temperature along a float glass line is exactly 1800°F the smart sensor or series of sensors can be calibrated to that temperature
    • Twopoint If sensor readings must match at two specific temperatures the twopoint calibration shown in Figure 3 should be selected This technique uses the calibration temperatures to calculate a gain and an offset that are applied to all temperatures throughout the entire range
    • Threepoint with variable temperature If the process has a wide range of temperatures and sensor readings need to match at three specific temperatures the best choice is threepoint variable temperature calibration (see Figure 4) This technique uses the calibration temperatures to calculate two gains and two offsets The first gain and offset are applied to all temperatures below a midpoint temperature and the second set to all temperatures above the midpoint Threepoint calibration is less common than one and twopoint but occasionally manufacturers need to perform this technique to meet specific standards
    Field calibration software also allows routine diagnostics including power supply voltage and relay tests to be run on smart sensors The results let process engineers know if the sensors are performing at their optimum and make any necessary troubleshooting easier
    Conclusion
    The new generation of smart IR temperature sensors allows process engineers to keep up with changes brought on by newer manufacturing techniques and increases in production They now can configure as many sensors as necessary for their specific process control needs and extend the life of those sensors far beyond that of earlier nonsmart designs As production rates increase equipment downtime must decrease By being able to monitor equipment and finetune temperature variables without shutting down a process engineers can keep the process efficient and the product quality high A smart IR sensor’s digital processing components and communications capabilities provide a level of flexibility safety and ease of use not achieved until now
    How Infrared Temperature Sensors Work
    Infrared (IR) radiation is part of the electromagnetic spectrum which includes radio waves microwaves visible light and ultraviolet light as well as gamma rays and Xrays The IRrange falls between the visible portion of the spectrum and radio waves IR wavelengths are usually expressed in microns with the IR spectrum extending from 07 to 1000 microns Only the 0714 micron band is used for IR temperature measurement
    Using advanced optic systems and detectors noncontact IR thermometers can focus on nearly any portion or portions of the 0714 micron band Because every object (with the exception of a blackbody) emits an optimum amount of IR energy at a specific point along the IR band each process may require unique sensor models with specific optics and detector types For example a sensor with a narrow spectral range centered at 343 microns is optimized for measuring the surface temperature of polyethylene and related materials A sensor set up for 5 microns is used to measure glass surfaces A 1 micron sensor is used for metals and foils The broader spectral ranges are used to measure lower temperature surfaces such as paper board poly and foil composites
    The intensity of an object's emitted IR energy increases or decreases in proportion to its temperature It is the emitted energy measured as the target's emissivity that indicates an object's temperature
    Emissivity is a term used to quantify the energyemitting characteristics of different materials and surfaces IR sensors have adjustable emissivity settings usually from 01 to 10 which allow accurate temperature measurements of several surface types
    The emitted energy comes from an object and reaches the IR sensor through its optical system which focuses the energy onto one or more photosensitive detectors The detector then converts the IR energy into an electrical signal which is in turn converted into a temperature value based on the sensor's calibration equation and the target's emissivity This temperature value can be displayed on the sensor or in the case of the smart sensor converted to a digital output and displayed on a computer terminal
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