江西新(xin)鋼公司(si)硅鋼連續退火線使用(yong)了一套(tao)由西門子S7-315F為(wei)平臺設計的獨立急(ji)停(ting)(ting)系(xi)統(tong)，通過急(ji)停(ting)(ting)系(xi)統(tong)與主(zhu)控(kong)TDC系(xi)統(tong)的通訊協調來保證連退機(ji)組(zu)在(zai)事故時(shi)能(neng)快速停(ting)(ting)車(che)。但(dan)在(zai)實(shi)際(ji)生(sheng)產應(ying)用(yong)中(zhong)，當主(zhu)控(kong)TDC系(xi)統(tong)出(chu)現(xian)故障(不穩(wen)定)時(shi)，急(ji)停(ting)(ting)控(kong)制(zhi)系(xi)統(tong)失效(xiao)最(zui)終導致堆帶、斷帶等事故，為(wei)解決這一問題，新(xin)鋼公司(si)自(zi)(zi)動化部(bu)軋材(cai)自(zi)(zi)動化車(che)間硅鋼作業區對急(ji)停(ting)(ting)系(xi)統(tong)進(jin)(jin)行了有針對性(xing)的功能(neng)測試，并(bing)針對測試結果進(jin)(jin)行優化改造，取得了良好的效(xiao)果。

　　在(zai)生產中存(cun)在(zai)很多問題，當TDC控制器死機(ji)(ji)后(hou)，無(wu)(wu)(wu)法(fa)給傳動系統發(fa)出(chu)減速(su)(su)速(su)(su)度(du)指(zhi)令(ling)，導(dao)致電機(ji)(ji)只能按自身慣性減速(su)(su)運(yun)行(xing)并緩(huan)慢停車;無(wu)(wu)(wu)法(fa)給電機(ji)(ji)抱閘發(fa)出(chu)鎖緊(jin)信號，因(yin)此抱閘不(bu)動作;爐輥擺動出(chu)現無(wu)(wu)(wu)法(fa)停止的(de)(de)狀況，以原工藝(yi)段(duan)(duan)速(su)(su)度(du)繼(ji)續(xu)運(yun)行(xing)，測(ce)試時(shi)發(fa)現退(tui)火爐段(duan)(duan)的(de)(de)張(zhang)(zhang)(zhang)力(li)(li)釋(shi)放(fang)裝(zhuang)(zhuang)置在(zai)失電后(hou)沒有(you)縮回，導(dao)致停機(ji)(ji)狀態(tai)下，張(zhang)(zhang)(zhang)力(li)(li)釋(shi)放(fang)裝(zhuang)(zhuang)置失效(xiao)，無(wu)(wu)(wu)法(fa)將(jiang)張(zhang)(zhang)(zhang)力(li)(li)釋(shi)放(fang)，此時(shi)機(ji)(ji)組處于(yu)失控狀態(tai)，各(ge)段(duan)(duan)張(zhang)(zhang)(zhang)力(li)(li)、速(su)(su)度(du)無(wu)(wu)(wu)法(fa)協調控制，可能造成爐內斷帶、堆(dui)帶等(deng)情況;由于(yu)各(ge)段(duan)(duan)殘存(cun)張(zhang)(zhang)(zhang)力(li)(li)的(de)(de)影響，設備在(zai)停機(ji)(ji)后(hou)仍然會以很低的(de)(de)速(su)(su)度(du)運(yun)行(xing)，入口(kou)段(duan)(duan)、入口(kou)活(huo)套、清洗(xi)段(duan)(duan)、退(tui)火爐、干燥爐無(wu)(wu)(wu)明顯堆(dui)帶現象(xiang)，出(chu)口(kou)活(huo)套、卷取(qu)機(ji)(ji)有(you)明顯堆(dui)帶現象(xiang)。因(yin)此，如何避免(mian)大量堆(dui)帶是優化改造的(de)(de)重(zhong)點。

　　一是(shi)根據TDC系(xi)(xi)統(tong)(tong)死機過(guo)(guo)程(cheng)(cheng)中的(de)(de)(de)(de)數據監控(kong)(kong)(kong)(kong)，發(fa)現S120系(xi)(xi)統(tong)(tong)將(jiang)(jiang)發(fa)出故(gu)(gu)障代(dai)碼(ma)F07220(與主(zhu)控(kong)(kong)(kong)(kong)PLC通訊中斷(duan));在(zai)(zai)S120系(xi)(xi)統(tong)(tong)中參數P2100和P2101分別代(dai)表故(gu)(gu)障代(dai)碼(ma)以及(ji)該故(gu)(gu)障代(dai)碼(ma)的(de)(de)(de)(de)系(xi)(xi)統(tong)(tong)反應，因此我們將(jiang)(jiang)代(dai)碼(ma)進行了重新(xin)設(she)置(zhi)(zhi)。二是(shi)對自動(dong)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)系(xi)(xi)統(tong)(tong)優化，針對測試中出現的(de)(de)(de)(de)退(tui)火(huo)(huo)爐張(zhang)力急劇增(zeng)大(da)(da)而張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)失效的(de)(de)(de)(de)情況，對自動(dong)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)系(xi)(xi)統(tong)(tong)做出如下(xia)調整：三是(shi)將(jiang)(jiang)張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)的(de)(de)(de)(de)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)由TDC主(zhu)控(kong)(kong)(kong)(kong)系(xi)(xi)統(tong)(tong)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)改(gai)為急停系(xi)(xi)統(tong)(tong)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)，通過(guo)(guo)改(gai)造線(xian)路，將(jiang)(jiang)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)升降的(de)(de)(de)(de)氣閥直接連接到急停系(xi)(xi)統(tong)(tong)S7-315F的(de)(de)(de)(de)輸出點(dian)上。同(tong)時(shi)(shi)在(zai)(zai)急停程(cheng)(cheng)序(xu)中增(zeng)加(jia)張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)的(de)(de)(de)(de)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)程(cheng)(cheng)序(xu)塊;四(si)是(shi)將(jiang)(jiang)原有控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)信號和急停信號的(de)(de)(de)(de)輸入點(dian)新(xin)增(zeng)至張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)塊中，并增(zeng)加(jia)延遲(chi)動(dong)作時(shi)(shi)間防止因信號干擾(rao)而造成誤動(dong)作;五(wu)是(shi)通過(guo)(guo)將(jiang)(jiang)張(zhang)力釋(shi)放(fang)裝(zhuang)(zhuang)(zhuang)置(zhi)(zhi)功能(neng)轉移，使其在(zai)(zai)TDC系(xi)(xi)統(tong)(tong)失效的(de)(de)(de)(de)情況下(xia)仍能(neng)保證正常(chang)工作，及(ji)時(shi)(shi)釋(shi)放(fang)過(guo)(guo)大(da)(da)的(de)(de)(de)(de)張(zhang)力，防止退(tui)火(huo)(huo)爐段因張(zhang)力過(guo)(guo)大(da)(da)導致斷(duan)帶事故(gu)(gu)。

　　通過對(dui)急(ji)停(ting)系(xi)統(tong)(tong)性的(de)改造，雖TDC控制系(xi)統(tong)(tong)故障仍有發生，但急(ji)停(ting)系(xi)統(tong)(tong)很(hen)好的(de)保證了機組(zu)在異常狀況下的(de)及(ji)時、穩定可靠(kao)停(ting)車，未(wei)造成堆帶(dai)和斷帶(dai)事故，節約(yue)了故障時間(jian)，確保了生產(chan)的(de)順行。