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此外，安全也是化工企業(yè)生產運營的重中之重。該企業(yè)要求新工廠采用的DCS系統(tǒng)在安全防爆、報事件管理和連鎖記錄等方面具有。為加快以數(shù)據(jù)為驅動的智能制造轉型，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，并可在移動終端實現(xiàn)對生產報表的瀏覽。
　　由于下屬工廠遍布各地，該企業(yè)對DCS系統(tǒng)的可復制性、擴展性和互聯(lián)能力也提出要求，希望系統(tǒng)在二期項目中可實現(xiàn)系統(tǒng)的輕松復制，并在未來具備多工廠間的互聯(lián)能力，實現(xiàn)MES系統(tǒng)的可持續(xù)擴展，滿足企業(yè)未來的發(fā)展需要。
解決方案
　　PlantPAx高度集成的標準控制面板和編程模塊，提供了完善和簡便的操作，多語言的自由切換，也高度引了客戶。基于標準工業(yè)以太網(wǎng)的網(wǎng)絡架構，PlantPAx使得互聯(lián)企業(yè)變成了可能，能夠滿足企業(yè)未來發(fā)展的需要。
　　系統(tǒng)集成商LSI(Logical Systems LLC)作為羅克韋爾自動化的解決方案合作伙伴負責此次項目的實施，LSI在化工生產工藝和控制方面具備專業(yè)知識和豐富的項目實施經(jīng)驗，這也是客戶在選擇合作伙伴時重點考察的方面。
　　為了幫助客戶限度地降低項目的實施風險，并在截止時間之前實現(xiàn)順利投產，項目實施團隊對客戶的實際生產工藝需求進行了的系統(tǒng)性分析，并制定了一個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的服務平臺上部署了3臺操作員站對9條生產線進行集中測與控制。先進的批次控制技術實現(xiàn)了靈活的工藝配方編輯管理與執(zhí)行功能。整個系統(tǒng)采用了3套Allen-Bradley? ControlLogix? 可編程自動化控制器分別對原料區(qū)、生產區(qū)、成品區(qū)及公用工程設備和生產工藝進行控制?？煽康腜owerFlex系列變頻器為整個系統(tǒng)的7×24小時穩(wěn)定運行提供了保障。系統(tǒng)中配置了一臺Historian服務器以實現(xiàn)長達10年以上的生產歷史記錄的追蹤。此外，系統(tǒng)采用全廠級的Ethernet/IP工業(yè)以太網(wǎng)既保證了當前所有設備的通信而可靠，又為未來的MES系統(tǒng)及ERP系統(tǒng)等功能擴展提供了可能。
　　在2017年底項目正式確定后，項目團隊便開始了系統(tǒng)設計工作。得益于PlantPAx提供的豐富預定義圖形和設備控制功能庫，以及強大的設備及批次控制仿真功能，團隊在一個月的時間里便已根據(jù)客戶的工藝要求完成了整個系統(tǒng)共9條生產線的組態(tài)及功能仿真測試，并得到了客戶的認可。2018年1月便將系統(tǒng)部署到客戶的實際工廠中進行I/O檢查并用水替代原料進行了一系列的功能驗證和優(yōu)化，均得到了令人滿意的結果。
效果
　　面對客戶有限的資料和復雜需求，為了確保項目成功實施且限度地縮短開發(fā)時間，項目實施團隊從項目啟動之初就根據(jù)客戶的工藝要求選擇的項目配置，并進行方案優(yōu)化、編程和調試，確保了交貨期，同時滿足了高標準低成本的需求。在整個項目的跟蹤、招投標和實施的過程中，羅克韋爾自動化的銷售團隊和技術支持團隊貫穿始終，為項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可。客戶的生產經(jīng)理評價說：“通過PlantPAx系統(tǒng)，新工廠的生產人員數(shù)量降低了50%，生產效率提高了35%。”
　　結合批次管理功能，PlantPAx系統(tǒng)幫助客戶快速、地實現(xiàn)產品切換?？蛻舻墓に囐|量經(jīng)理對此給予了高度評價：“在批次管理系統(tǒng)中，生成新的配方并下裝生產只需要短短的二十幾分鐘，大大地提高了生產效率，新產品的投產時間降低了80%?！?br /> 　　通過與全廠級自動化技術的緊密融合并采用開放式通信標準，PlantPAx可以為新工廠乃至整個企業(yè)的過程運營創(chuàng)造更大價值，幫助企業(yè)實現(xiàn)工廠間的互聯(lián)，打造互聯(lián)企業(yè)，達成集約節(jié)約、環(huán)保、綠色低碳和可持續(xù)的發(fā)展目標。


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