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基礎(chǔ)自動化系統(tǒng)采用ABB公司的RMC200軋鋼控制系統(tǒng)，它是一個(gè)開放型集散控制系統(tǒng)，由一套MP200／1過程站和一套AS520操作員站組成。過程站由一個(gè)CPU機(jī)架帶一個(gè)I／O機(jī)架組成，CPU機(jī)架上安裝了CPU模板DSPC172、內(nèi)存模板DSMB176、16通道的DSAI130、8通道的DSAO120以及32通道的DI／DO模板，通過通訊模板DSCS140連接到MasterBus300總線上，與其它過程站進(jìn)行通訊，I／O機(jī)架由總線擴(kuò)展模塊DSBC172實(shí)現(xiàn)總線擴(kuò)展。
操作員站采用HP-UNIX工作站，并通過實(shí)時(shí)加速器板連接到MasterBus300的冗余接口，通過它操作人員可直接對現(xiàn)場水冷設(shè)備進(jìn)行監(jiān)控，主要功能有：（1）成組系統(tǒng)的自動/手動的啟停（2）棒材支數(shù)設(shè)定和實(shí)時(shí)監(jiān)控（3）事件與報(bào)警清單的顯示與打印等。成組系統(tǒng)的主要畫面有啟動畫面、設(shè)定畫面、維護(hù)畫面、事件畫面和報(bào)警畫面。
3軟件實(shí)現(xiàn)
包括系統(tǒng)軟件和應(yīng)用軟件。
（1）系統(tǒng)軟件：
ABB Master Piece200中央單元是一高性能32位微處理器。系統(tǒng)軟件存儲在EPROM模塊中，系統(tǒng)軟件包括一個(gè)實(shí)時(shí)操作系統(tǒng)和一個(gè)ABB Master Piece語言（AMPL）執(zhí)行器。
（2）應(yīng)用軟件
應(yīng)用軟件存儲在帶后備電池的RWM（讀/寫存儲器）中，用ABB Master Piece語言（AMPL）編制，實(shí)現(xiàn)了結(jié)構(gòu)化程序設(shè)計(jì)。工業(yè)控制程序往往功能繁多該語言根據(jù)工業(yè)控制要求，將編程元素設(shè)計(jì)成一個(gè)個(gè)圖形功能塊，稱為PC元素。PC元素內(nèi)有三種結(jié)構(gòu)類元素PCPGM、CONTRM和FUNCM，PCPGM是程序結(jié)構(gòu)的*高層，旨在完成一個(gè)完整的控制功能，一個(gè)PCPGM下允許一個(gè)或幾個(gè)CONTRM，而一個(gè)CONTRM下又可包含一個(gè)或幾個(gè)FUNCM，從而使整個(gè)程序結(jié)構(gòu)呈階梯狀，實(shí)現(xiàn)了結(jié)構(gòu)化設(shè)計(jì)。
另外，在CPU內(nèi)還有一個(gè)實(shí)時(shí)數(shù)據(jù)庫，它的作用是存儲數(shù)據(jù)和在程序間傳遞數(shù)據(jù)。數(shù)據(jù)庫內(nèi)的元素稱為DB元素，這些元素包括過程站所使用的的I／O模板和信號及程序中產(chǎn)生的其它數(shù)據(jù)信息。
4控制功能
4.1工藝設(shè)備
成組區(qū)主要接收來自冷床的棒材，通過磁性手將棒材擺放緊湊，成組并輸送到剪切輥道（ＣＣＬ）。
成組區(qū)包括以下設(shè)備：
拆疊裝置(DPAS)、對齊輥道(LIN)：100 個(gè)帶槽輥
成組設(shè)備：（１） 磁性成組小車(FT)；（２） 成組輸送鏈(FC)；（３） 磁性手指(MF)；（４） 支撐活板(SFL)
提取傳輸設(shè)備：成組移送小車(ET1，ET2，ET3,MET)
成組區(qū)工藝流程圖如圖：
4．2 對齊輥道 (LIN)
對齊輥道位于冷床的出口側(cè), 由100
個(gè)帶槽輥組成，每10個(gè)為一組,冷床尾端有一個(gè)固定緩沖機(jī)械擋板將鋼材頭部對齊。使用的輥道段由操作員或自動地根據(jù)軋制表設(shè)定.
由MCC控制正轉(zhuǎn)(反轉(zhuǎn)已取消)。運(yùn)行狀態(tài)有間歇或連續(xù)運(yùn)行。間歇周期允許輥道起動條件：冷床起動周期信號延時(shí)、延時(shí)停止（Ｔ２）。
4．3 成組和傳輸區(qū)
4．3.1 概述
在這個(gè)區(qū)域用相同的設(shè)備接收來自冷床的棒材，通過磁性手精確地將棒材擺放緊湊，成組并傳輸?shù)捷伒馈?br />
本區(qū)包括以下設(shè)備：
成組設(shè)備：
（１） 磁性成組小車(FT)；（２） 成組輸送鏈(FC)；（３） 磁性手指(MF)；（４） 支撐活板(SFL)
提取傳輸設(shè)備：
成組移送小車(ET1...ET10,MET)
4．3.2 功能描述
4．3．2.1 磁性成組小車
為保證連續(xù)成組，提供兩組同樣的小車（Ａ和Ｂ）。兩組小車輪流工作，一組總是停在收集區(qū)（上部位置：從冷床接收棒材），而另一組向提取小車上卸鋼材，或返回停放位置或一直停放(下部位置).
每個(gè)單元通過一齒輪箱由直流電機(jī)單獨(dú)驅(qū)動。并配備以下傳感器：兩個(gè)編碼器（速度和位置控制）、兩個(gè)接近開關(guān)（用于位置編碼器復(fù)位 DI5.4/FT_SG1_CHG_A、DI5.5/FT_SG2_CHG_B）、兩個(gè)接近開關(guān)用于冷床卸料(DI5.6/FT_SG3_DISCHG_A、DI5.7/FT_SG4_DISCHG_B)、四個(gè)限位開關(guān)(電機(jī)緊急停止：DI5.8/FT_SG5_CHG_MOV_A、DI5.9/FT_SG6_DISCHG_MOV_A、DI5.12/FT_SG9_CHG_MOV_B、DI5.13/FT_SG10_DISCHG_MOV_B）。
4．3．2.2成組輸送鏈
成組輸送鏈有三組，每組通過齒輪箱由交流電機(jī)驅(qū)動。為每部分配備下列傳感器：一個(gè)脈沖發(fā)生器和安裝在馬達(dá)上的過熱電偶。成組輸送鏈和磁性成組小車同步，這樣鋼材能夠按要求的距離放置。成組輸送鏈的檢測元件:兩個(gè)接近開關(guān)用于檢測鋼材在鏈子上（DI5.14/FC_SG1_LAYERDET、DI5.15/FC_SG2_LAYERDET）、計(jì)算機(jī)給出速度給定值到變頻柜（AO1.1/FC1_IN_SPREF、AO1.2/FC2_IN_SPREF、AO1.3/FC3_IN_SPREF）、同時(shí)監(jiān)視編碼器的工作電壓（AI1.2/FC1_TACHO_5V、AI1.3/FC2_TACHO_5V、AI1.4/FC3_TACHO_5V）。
收集期間傳送鏈與成組小車的運(yùn)動總是同步的, 當(dāng)成組完成后, 成組小車和傳送鏈在小于冷床周期時(shí)間的短時(shí)間內(nèi)移到提取區(qū)。成組小車輪流運(yùn)行。
每組棒材由N根組成(在OS設(shè)定)。
成組小車從停止位置上升以后, 小車移到適當(dāng)位置收集該組的根棒材， 在每個(gè)冷床周期，通過限位開關(guān)檢測到的固定橫梁*后一齒上的棒材被裝入成組小車上, 棒材計(jì)數(shù)器N1加一，棒材裝入小車以后(冷床周期開始后一恰當(dāng)時(shí)間)，如果N14．3．2.3 電磁手。電磁手用于在成組區(qū)抓起棒材且正確地放在成組小車上。提供兩套手指“Ａ”和“Ｂ”在小車定位時(shí)夾持鋼材。當(dāng)兩根棒材被同時(shí)卸下時(shí)，（雙齒槽周期）兩套手指同時(shí)使用，否則用一套。手指到冷床的距離可根據(jù)根據(jù)產(chǎn)品尺寸進(jìn)行機(jī)械調(diào)整。
4．3．2．4 支撐活板
活板和磁性指有相同的功能, 它們同時(shí)應(yīng)用. 它固定在冷床架上. 配備兩套活板(A,B), ,用于在小車定位期間抓起棒材，它們和磁性指一樣以相同的周期工作。
檢測元件有: 兩個(gè)接近開關(guān)分別檢測兩套活板的下部位置（DI5.1/MF_SG1_FLAP1_DWN、DI5.2/MF_SG2_FLAP2_DWN） ，操作員控制(CP3): 活板升/降控制。
4．3．2．5 棒材組傳輸設(shè)備
該設(shè)備分成四部分: 部分包括一個(gè)電磁提取小車; 其余部分為提取小車。提取順序和在輥道上的輸送
1 *后一組成組小車步進(jìn)信號和提取小車在停止位置(P1): 提取小車上升并磁化.
2 小車在收集位置: 成組小車去磁并下降.
3 成組小車在下部位置: 成組小車返回等待位置. 一個(gè)傳感器( 由安裝在冷床固定齒上的凸輪裝置驅(qū)動)檢測返回行程. 同時(shí), 小車上升到*高(*1)
4 提取小車在上部位置, 來自位置變送器和個(gè)提取小車傳感器的信號并加延時(shí)Ts(*2):提取小車向輥道方向前移
5 如果輥道正運(yùn)行或(和)檢測到上面有原料, 提取小車停在中間位置(P2)(*3).
如果輥道和夾送輥停止并且沒有檢測到輥道上有原料:提取小車前進(jìn)至卸料位置P3, P3在輥道中心位置(*4).
6 提取小車在位置P3(*3): 提取小車下降.
7 組提取小車去磁并降至*低位置,所有小車降低, 所有提取小車返回停止位置(P1)，輥道啟動。
ET1有上、中、下三個(gè)位置檢測;ET2包括ET2～ET5,只有下部位置檢測; ET3包括ET6～ET10,只有下部位置檢測。在水平方向上, 每組小車分別有左右超限檢測和上料位置檢測開關(guān). 在程序中, ET動作先后有如下七步，循環(huán)做矩型運(yùn)動.ET_LIFTPOSPICKUP；(2)ET_LIFTPOSUNLOAD；(3)ET_POSWAIT；(4)ET_POSCRT；
(5)ET_LIFTPOSCRTLVL；(6)ET_LIFTPOSDOWN； (7)ET_POSPARK
水平方向運(yùn)動時(shí)，將水平位置給定（0，300，1460）賦給ET_POSREF, *后通過COM_CV01元素的I4ORD1和I4ORD2端通訊到四個(gè)小車的傳動系統(tǒng),控制設(shè)備動作.
4．4 拆疊緩冷系統(tǒng)
該系統(tǒng)用于彈簧扁鋼. 對彈簧扁鋼來說, 只用到60m 的冷床, 扁鋼需要緩慢冷卻. 因此它們被組成疊狀送入冷床. 當(dāng)進(jìn)入卸貨區(qū)域以后，扁鋼被一個(gè)接一個(gè)卸下. 拆疊緩冷系統(tǒng)的主要設(shè)備：（1）拆疊設(shè)備(Unstacking)；（2）提升設(shè)備(lift)；（3）傾翻設(shè)備(tilt)；（4）升降擋板(stop)
5應(yīng)用效果
該系統(tǒng)自97年底投運(yùn)以來，運(yùn)行可靠、穩(wěn)定，大大提高了其工作效率，保證了軋鋼生產(chǎn)。
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DAYKIN 480V, 4.6A TRANSFORMER DISCONNECT LTFS-01 L
BRAD HARRISON 600V 8A 5P MALE/FEMALE 3' MINI-CHANGE CORDSET, 41319 *NEW*
DAYKIN DTFP-0807 WR TRANSFORMER DISCONNECT, 1500 VA 460/115 VAC 3.26|8.69/4.35 A
GOULD E20D1L1 CLASS E20 OVERLOAD RELAY KIT, NIB
MIDDEX-ELECTRON?IC TYPE WKL-22 180 RANGE 4-PIN SENSOR, D-78582 *NEW*
FUJI ELECTRIC 800V 60A POWER DIODE MODULE 2RI60E-080 *LOT OF 4*
UNIVERSAL LIGHTING 120V 60HZ MAGNETIC RAPID START BALLAST, 931-LH-TC-P *NEW*
THOMAS & BETTS STEEL CITY 1" 3-PIECE CONDUIT COUPLINGS, EK403 *NEW LOT OF 23*
PHILIPS ECG 100V 25A HIGH-SPEED SWITCHING PNP TRANSISTOR ECG393 *NEW, LOT OF 10*
DWYER INSTRUMENTS 125/480VAC 15A 10 PSI LOW DIFFERENTIAL PRESSURE SWITCH, 1823-2
MERLIN GERIN 2A SINGLE POLE CIRCUIT BREAKER C60N 24501 *LOT OF 17*
ISLATROL NORMAL-COMMON MODE 120VAC 7.5A 50/60Hz LINE FILTER IC+107
BRAND-REX TELETAPE UTC-25-P26-B CABLE, NIB
COOPER ARROW HART T1333 125 VOLTS 2 POLE 3 WIRE RECEPTACLE, LOT OF 8, NIB
ALLEN-BRADLEY 480V, COMBINATION STARTER 712-AJB242 SER. L
ATLAS COPCO 400V 30A AC POWER BOX 9040120201
RED LION CONTROLS IMP20162 APOLLO INTELLIGENT METER, NIB SEALED
MATRIX MS3476L18-8P CONNECTOR PLUG, NEW IN BAG SEALED
FAUVER LFG-2-300S 3000 PSI 1/4" NPT 2.5" S.S. CASE GLYCERIN FILLED GAUGE, NIB
ADVANCE 120/208/240/277?V 1-150W CORE & COIL BALLAST KIT, 71A8176-001D *NEW*
SQUARE D 175A 600V POWER DISTRIBUTION BLOCK 9080 LBC362104
RUSSELLSTOLL 20A, 125V, 2W, 3-PIN FEMALE, EVER-LOCK CONNECTOR 8683CTN *NEW*
APPLETON 2 1/2" SIZE CONDUIT LOCKNUT BL-250 *LOT OF 8 NEW*
SCHNEIDER TELMECANIQUE 25A 600V STARTER 16-25AMP OVERLOAD GV3-M25
MICRON VALU TRAN STEP DOWN CONTROL TRANSFORMER VF1K0BTZ13JK
SMC EZ STACK 10 100-240VAC, 1A 16 PORT ETHERNET HUB SMC3116T
PEPPERL & FUCHS 10-30VDC, 0.2A SAFETY SWICTH ASSEMBLY VFSP75-04-NBB20?L3MA2C3V1HR
MOELLER 230/400VAC 2 POLE CIRCUIT BREAKER FAZ C10 *LOT OF 5*
BRIDGEPORT 3/4" NPT EMT CONNECTORS, 231-DC2 *NEW LOT OF 25*
APC DB25 MALE/DB25 MALE RS232 STRAIGHT-THROUG?H CABLE 0035-6 *NEW LOT OF 3*
AMF POTTER & BRUMFIELD 24VDC, 1/4HP, 120VAC, 10A, RELAY KUP14D15 *NEW*
DAITO 125V, 7.5A, IR: 125VAC 10000A 125VDC 1000A, FUSES PL475L *LOT OF 5, NEW*
ALLEN BRADLEY 10A 250V GENERAL PURPOSE RELAY 700-HA33Z01 SER. D
RACINE 110-115VOLTS 50/60HZ COIL H-2496 *NEW*
RUSSELLSTOLL 125V 20A 2W 3P EVER LOK RECEPTACLE, 8013U-1 *NEW*
MERLIN GERIN MULTI-9 C60N 3A TYPE-C 480VAC CIRCUIT BREAKER 24461
GENERAL ELECTRIC DE361R FLEX-A-PLUG PLUG-IN DEVICE BUS PLUG, 30 Amp, Style 2
DIAMOND C-3470CL-08-P 1-1/4" COTTER STYLE CHAIN CONNECTOR linS, LOT OF 2, NNB
FANUC ROBOTICS 3-PHASE 75A LINE REACTOR A81L-0001-0123
EBM 220V 0.35A 75W COOLING FAN K2E220-AA40-05
TURCK RKG 4T-0.5-RSM 31/S600 300 VOLT 18 AWG 4-PIN STRAIGHT CORDSET, NEW SEALED
FUJI ELECTRIC 110-130V COIL 20A CONTACTOR 4NC0H0 SC-5-1(19) W/TR-5-1N/3 & SZ-A40
APPLIED ROBOTICS FEMALE REPLACEMENT PROB KIT 94502-P1054 *NEW* LOT OF 14
COSEL 5V 0.8A/12V 1.0A 100-120VAC AC/DC POWER SUPPLY, RMB15U-1 *NEW*
BUSSMANN 20A LOW PEAK DUAL ELEMENT TIME DELAY FUSE LPJ-20SP *LOT OF 6*
THOMAS & BETTS 250V/600VAC 60A EVER-LOK PLUG F27194
FONSAN 12VDC, 0.18A, 80x80x26mm DC BRUSHLESS FAN DFB0812H
SIEMENS I-T-E F353 ENCLOSED HEAVY DUTY SWITCH, 100 Amp 600 VAC ENCL 1
TOKIMEC 24VDC, 1/2" NPT, SOLENOID VALVE DG4VC-3-0C-M-PS?2-H-7-52
R-K ELECTRONICS 24VDC 0.05-5 MINUTE TIMER RELAY CDB-24D-2-5M *NEW*
BUSSMANN 200A, 600V 3-POLE FUSEHOLDER 1B0089
INTERlinBT RKM 57-TR2 5-PIN FEMALE MINIFAST TERMINATING RESISTOR, LOT OF 3, NNB
ALTECH 4-PIN TO 3-WIRE 2M CABLE 8000-5070 *NEW*
TRERICE 1/4" NPT 100 PSI PRESSURE GAUGE, 52-2199 *NEW*
COOPER BUSSMANN 600VAC 30A 2-POLE FUSIBLE SWITCH CCP-2-30CC
AMPHENOL ADVANTAGE LINE P27954 CABLE PLUG, LOT OF 6, NEW
DYNALCO CONTROLS 0-1000Hz SPEED SWITCH / TRANSMITTER SST2200A-1
SQUARE D 600V, 200A, 50/60Hz,SAFETY SWITCH H364
ATC SERIES 319 120V ON DELAY ADJUSTABLE TDR SECOND TIMER TDR SS 319B 001
SCIEMETRIC SigMETER ANALYSIS & TEST SYSTEM PANEL METER MODEL 1102 *NO CASE*
ROTANIUM 15A, 125V, SAF-T-CONECT RECEPTACLE KIT *NEW*
W.E. ANDERSON FLOTECT 125/250VAC 10A FLOAT SWITCH, L4SS *NEW*
ABB 1 N.O. 1N.C. AUXILIARY CONTACT CAL5-11 *LOT OF 6*
POTTER & BRUMFIELD R10-T1P2-115V RELAY, NEW IN BAG
AUTOMATIC VALVE 48/24VDC, 50/60HZ, 4.4W, 10BAR SOLENOID VALVE 409B43S39A-DB7
ALLEN BRADLEY 15A, 24VDC RELAY 700-HB33Z24 SER. E *NEW, LOT OF 2*
GENERAL ELECTRIC FVK361R BUSWAY SWITCH PLUG, STYLE 2, 30 Amp RUSTED
ALLEN BRADLEY 600VAC 60A 3-POLE TRAILER FUSE BLOCK 1494V-FSR666 SER. A
IFM EFECTOR INDUCTIVE SENSOR IFK3007-BPKG/M/?US-104-DPS SER A *LOT OF 7, NEW*
SQUARE D 30528-001-51 30528-001-50 ECS-1002 JOKAB SAFETY GATE BOX, NIB
LEVITON 125/250V 30A 3 POLE 3 WIRE LOCKING PLUG, 2661 *NEW*
ROSS 2-10 BAR, 115V/60HZ, 5P MALE, PILOT OPERATED SOLENOID VALVE 8076B4342 *NEW*
SQUARE D 12VDC COIL MINIATURE GENERAL PURPOSE RELAY RSD4V51 *NEW*
HUBBELL 250V 10A 3POLE 3WIRE TWIST-LOCK PLUG HBL7567C *NEW*
CUTLER-HAMMER 24V CORROSION RESISTANT PRESTEST LIGHT E34FPB24 *NEW*
OMRON A165E-S-03U 3-WIRE EMERGENCY STOP SWITCH, LOT OF 8, NNB
WEIDMULLER 30A 600V SINGLE POLE FUSEHOLDER WSI 25/1 CC *LOT OF 3*
GRAYHILL 3-30VDC 140VAC 6A SOLID STATE RELAY 70S2-04-B-06-N
ADVANCE RELB-2S40-SC 120 VOLTS RAPID START ELECTRONIC BALLAST, NEW
BRAD HARRISON 600V 8A 5P MALE 12" MINI-CHANGE RECEPTACLES, 41338 *NEW LOT OF 6*
TPC WIRE & CABLE SUPER-TREX 4P 1M MALE RECEPTACLE, 94437 *NEW*
PARKER PV22-FB2V-B16 300 PSI APPROX 1/2" SHAFT ROTARY ACTUATOR, NEW
BUSS 600V 30A 3-POLE CLASS J FUSEHOLDER J60030-3COR
SIEMENS 600V 10A CONTACT BLOCK W/ HOLDER, 3SB14 00-0B *NEW*
CUTLER-HAMMER 110/120V COIL 27A NEMA SIZE 1 REVERSING STARTER AN56DN0 SER. B1
CUTLER-HAMMER 110/120V COIL 27A NEMA SIZE 1 REVERSING STARTER AN56DN0 SER. A1
ADVANCE RC2S102TP MAGNETIC STD RPAID START BALLAST, NIB
TURCK 20-250VAC, 20-230VDC PROXIMITY SENSOR Bi2-PRS260-ADZ3?0X2-B1131/S34
ASCO MP-C-080 238210-032D 120 V 60 Hz | 100 V 50 Hz COIL, LOT OF 2, NNB
GENERAL ELECTRIC 240V POWER SUPPLY TRANSFORMER UNIT LAMP SOCKET CR104PXG23 *NEW*
BOSCH LINE FILTER D-64711 ERBACH 107 TYPE: NV 20/1F-D 1070078431-205
COOPER BUSSMANN 250V 6.3A IN-LINE FUSE HOLDER, HEX-JW-DRYC *NEW*
OHMITE 150K OHMS TYPE AB POTENTIOMETER, CMU1541 RV4NAYSD154A *NEW*
TURCK COMBI-PROX 20-250VAC PROXIMITY SWITCH Bi20NF-CP40-BZ3?X
EGS HEVI-DUTY HS5F7.5AS NON-VENTILATED AUTOMATION TRANSFORMER, 7.5 kVA
HUBBELL 347/600VAC 30A 4P 4W INSULGRIP TWIST-LOCK PLUG, HBL2771 *NEW*
MARSHALLTOWN 3-1/2" FIG. 71C-10# RETARD 1/4" BACK CONN. STEEL 0-30 GAUGE, NIB
TELEMECANIQUE 600V CONTACTOR CA3 DN31 *LOT OF 2*
PANDUIT PN10-10RX-L 10 STUD 14-10 WIRE PAN-TERM TERMINALS, LOT OF 45, NIB
MOELLER SINGLE POLE 230/400VAC 10A CIRCUIT BREAKER FAZ C10 *LOT OF 5*
HUBBELL 125VOLTS 15A 2P 3W SINGLE TWIST-LOCK RECEPTACLE HBL4710 *NEW*
ALLEN BRADLEY 600V 30A 3-POLE FUSEHOLDER SET 40023-415-02 W/ X-401978
SPECTRO WIRE AND CABLE FEMALE BULLET CONNECTOR 302435 *NEW* LOT OF 50
WOODHEAD 36473 CABLE STRAIN RELIEF 1.250-1.375 INCH, LOT OF 2, NNB
NAMCO 20-230V 0.5A 3000 PSI 2-WIRE 3-PIN CYLINDICATOR SNESOR, EE230-10420?
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