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此外，安全也是化工企業(yè)生產(chǎn)運(yùn)營(yíng)的重中之重。該企業(yè)要求新工廠采用的DCS系統(tǒng)在安全防爆、報(bào)事件管理和連鎖記錄等方面具有。為加快以數(shù)據(jù)為驅(qū)動(dòng)的智能制造轉(zhuǎn)型，企業(yè)還希望通過DCS系統(tǒng)提高數(shù)據(jù)管理和使用水平，使歷史數(shù)據(jù)具有可追溯性，并可在移動(dòng)終端實(shí)現(xiàn)對(duì)生產(chǎn)報(bào)表的瀏覽。
　　由于下屬工廠遍布各地，該企業(yè)對(duì)DCS系統(tǒng)的可復(fù)制性、擴(kuò)展性和互聯(lián)能力也提出要求，希望系統(tǒng)在二期項(xiàng)目中可實(shí)現(xiàn)系統(tǒng)的輕松復(fù)制，并在未來(lái)具備多工廠間的互聯(lián)能力，實(shí)現(xiàn)MES系統(tǒng)的可持續(xù)擴(kuò)展，滿足企業(yè)未來(lái)的發(fā)展需要。
解決方案
　　PlantPAx高度集成的標(biāo)準(zhǔn)控制面板和編程模塊，提供了完善和簡(jiǎn)便的操作，多語(yǔ)言的自由切換，也高度引了客戶?；跇?biāo)準(zhǔn)工業(yè)以太網(wǎng)的網(wǎng)絡(luò)架構(gòu)，PlantPAx使得互聯(lián)企業(yè)變成了可能，能夠滿足企業(yè)未來(lái)發(fā)展的需要。
　　系統(tǒng)集成商LSI(Logical Systems LLC)作為羅克韋爾自動(dòng)化的解決方案合作伙伴負(fù)責(zé)此次項(xiàng)目的實(shí)施，LSI在化工生產(chǎn)工藝和控制方面具備專業(yè)知識(shí)和豐富的項(xiàng)目實(shí)施經(jīng)驗(yàn)，這也是客戶在選擇合作伙伴時(shí)重點(diǎn)考察的方面。
　　為了幫助客戶限度地降低項(xiàng)目的實(shí)施風(fēng)險(xiǎn)，并在截止時(shí)間之前實(shí)現(xiàn)順利投產(chǎn)，項(xiàng)目實(shí)施團(tuán)隊(duì)對(duì)客戶的實(shí)際生產(chǎn)工藝需求進(jìn)行了的系統(tǒng)性分析，并制定了一個(gè)高可行性的解決方案。該解決方案以PlantPAx系統(tǒng)為中心，在FactoryTalk View SE的服務(wù)平臺(tái)上部署了3臺(tái)操作員站對(duì)9條生產(chǎn)線進(jìn)行集中測(cè)與控制。先進(jìn)的批次控制技術(shù)實(shí)現(xiàn)了靈活的工藝配方編輯管理與執(zhí)行功能。整個(gè)系統(tǒng)采用了3套Allen-Bradley? ControlLogix? 可編程自動(dòng)化控制器分別對(duì)原料區(qū)、生產(chǎn)區(qū)、成品區(qū)及公用工程設(shè)備和生產(chǎn)工藝進(jìn)行控制?？煽康腜owerFlex系列變頻器為整個(gè)系統(tǒng)的7×24小時(shí)穩(wěn)定運(yùn)行提供了保障。系統(tǒng)中配置了一臺(tái)Historian服務(wù)器以實(shí)現(xiàn)長(zhǎng)達(dá)10年以上的生產(chǎn)歷史記錄的追蹤。此外，系統(tǒng)采用全廠級(jí)的Ethernet/IP工業(yè)以太網(wǎng)既保證了當(dāng)前所有設(shè)備的通信而可靠，又為未來(lái)的MES系統(tǒng)及ERP系統(tǒng)等功能擴(kuò)展提供了可能。
　　在2017年底項(xiàng)目正式確定后，項(xiàng)目團(tuán)隊(duì)便開始了系統(tǒng)設(shè)計(jì)工作。得益于PlantPAx提供的豐富預(yù)定義圖形和設(shè)備控制功能庫(kù)，以及強(qiáng)大的設(shè)備及批次控制仿真功能，團(tuán)隊(duì)在一個(gè)月的時(shí)間里便已根據(jù)客戶的工藝要求完成了整個(gè)系統(tǒng)共9條生產(chǎn)線的組態(tài)及功能仿真測(cè)試，并得到了客戶的認(rèn)可。2018年1月便將系統(tǒng)部署到客戶的實(shí)際工廠中進(jìn)行I/O檢查并用水替代原料進(jìn)行了一系列的功能驗(yàn)證和優(yōu)化，均得到了令人滿意的結(jié)果。
效果
　　面對(duì)客戶有限的資料和復(fù)雜需求，為了確保項(xiàng)目成功實(shí)施且限度地縮短開發(fā)時(shí)間，項(xiàng)目實(shí)施團(tuán)隊(duì)從項(xiàng)目啟動(dòng)之初就根據(jù)客戶的工藝要求選擇的項(xiàng)目配置，并進(jìn)行方案優(yōu)化、編程和調(diào)試，確保了交貨期，同時(shí)滿足了高標(biāo)準(zhǔn)低成本的需求。在整個(gè)項(xiàng)目的跟蹤、招投標(biāo)和實(shí)施的過程中，羅克韋爾自動(dòng)化的銷售團(tuán)隊(duì)和技術(shù)支持團(tuán)隊(duì)貫穿始終，為項(xiàng)目的成功提供了有力保障。
　PlantPAx系統(tǒng)在新工廠的表現(xiàn)得到了客戶的一致認(rèn)可?？蛻舻纳a(chǎn)經(jīng)理評(píng)價(jià)說：“通過PlantPAx系統(tǒng)，新工廠的生產(chǎn)人員數(shù)量降低了50%，生產(chǎn)效率提高了35%?！?br /> 　　結(jié)合批次管理功能，PlantPAx系統(tǒng)幫助客戶快速、地實(shí)現(xiàn)產(chǎn)品切換?？蛻舻墓に囐|(zhì)量經(jīng)理對(duì)此給予了高度評(píng)價(jià)：“在批次管理系統(tǒng)中，生成新的配方并下裝生產(chǎn)只需要短短的二十幾分鐘，大大地提高了生產(chǎn)效率，新產(chǎn)品的投產(chǎn)時(shí)間降低了80%?！?br /> 　　通過與全廠級(jí)自動(dòng)化技術(shù)的緊密融合并采用開放式通信標(biāo)準(zhǔn)，PlantPAx可以為新工廠乃至整個(gè)企業(yè)的過程運(yùn)營(yíng)創(chuàng)造更大價(jià)值，幫助企業(yè)實(shí)現(xiàn)工廠間的互聯(lián)，打造互聯(lián)企業(yè)，達(dá)成集約節(jié)約、環(huán)保、綠色低碳和可持續(xù)的發(fā)展目標(biāo)。


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