BMEH584040 為了實現智能化和可視化，采用數據吞吐率高的ATmega128單片機作為系統的主控制芯片，用北京亞控公司的可視化高的組態王軟件作整個陶瓷性能檢測流程的監控系統。結合二者的優勢，設計一個便于操作，檢測精度高的陶瓷檢測系統。
檢測原理如下：室溫下，檢測在壓力差為1 mm水柱時1 h內以層流狀態通過厚度為1 cm、面積為1 m2的多孔陶瓷制品的氣體立方數。
1 系統結構及組成
基于AVR ATmega128單片機和北京亞控公司的組態軟件的陶瓷檢測系統，主要由上層控制系統和下層節點控制單元構成，結構圖如圖1所示。上層控制系統由上位機控制軟件、通信總線接口組成。下層控制單元由壓力采集變送板、控制CPU、總線接口、壓力傳感器、壓力反饋通信接口、液位傳感器等部分組成的。系統采用了總線結構、模塊化的設計方法，各部分組建方式靈活，并具有良好的可擴展性。控制系統還可外接通信模塊，與上位機通信，將數據信息上傳。AVR嵌入式控制器對執行機構發出控制指令，對電機的轉速進行控制，從而實現對壓力的檢測與控制。
上位機控制部分：主要由總線接口和上位機兩部分構成。其中總線接口一端和總線相連完成和總線的通信；另一端和上位機連接完成和上位機的通信。它的主要功能是將上位機的操作信號和控制參數傳送給的下位機節點。同時，將節點的數據傳輸給上位機做進一步處理。它和上位機之間的通信是通過RS 232串行口和上位機交換數據。
現場控制部分：現場控制層為系統的底層，它首先由信號采集調理模塊通過RS 232總線和上位機通信。然后由帶有總線接口的變送器和執行器來實現具體操作，它們之間通過RS 485總線進行通信，完成全部的控制工作。
2 系統硬件設計
從功能上來劃分，整個系統分為液位檢測模塊、PWM控制電機模塊、恒壓控制模塊、信號采集調理模塊、人機界面五部分。
主控模塊采用Atmel公司的高性能、低功耗的8位AVR微處理器。由于其先進的指令集以及單時鐘周期指令執行時間，ATmega128的數據吞吐率高達128 MIPS／MHz，從而可以減緩系統在功耗和處理速度之間的矛盾。JTAG接口通過JTAG接口實現對Flash、E2PROM、熔絲位和鎖定位的編程。片內集成了數據采集和控制系統中常用的模擬、數字外設及其他功能部件：內置FLASH程序存儲器、內部RAM，大部分器件內部還有位于外部數據存儲器空間的RAM。高速、流水線結構的內核，真正10位、100KSPS的8通道ADC，512 KB的E2PROM，擦寫壽命為100 000次。可工作于主機／從機模式的SPI串行接口具有獨立片內振蕩器的可編程看門狗定時器。
2．1 壓力傳感器調理電路設計
信號采集調理模塊中壓力傳感器部分采用DG通用系列標準型全不銹鋼焊接結構壓力變送器，精確度可達0．1％FS，具有小體積、高性能、高性價比、高穩定性、高靈敏度等特點。差壓傳感器電壓信號經濾波及正向跟隨后接分壓電阻。ATmega128內部A／D直接從分壓電阻上采樣得到10位A／D值。設計的壓力傳感器信號處理電路如圖2所示。
2．2 紅外液位檢測電路設計
為了自動檢測單位體積的檢測液的流動速度，在玻璃容器的輸入、輸出口分別安裝了紅外檢測系統。這里設計的紅外光源驅動電路如圖3所示。其中+12 V電壓通過兩個100 kΩ電阻加在放大器的兩端形成同相比例，放大電路放大倍數為Vi0=（1+RF／R1）V來驅動三極管的導通與截止，驅動發光二極管。
BMEH584040 ABB光纖通訊適配器RDCO-02C
ABB光纖通訊適配器RDCO-02C
ABB光纖通訊適配器RDCO-02C
ABB電路板 APOW-01C
ABB電路板 SMIO-01C
ABB電路板 NINP-61C
ABB電路板 NTNT-43C
ABB電路板 NPOW-42C
ABB電路板 NDCO-03C
ABB電路板 NAMC-11C
ABB電路板 NIOC-02C
ABB電路板 NXPP-01
ABB電路板 NGDR-02C
ABB電路板 NINP-61C
ABB電路板 RPBA-01
ABB電路板 RTAC-01
ABB電路板 NPOW-42C
ABB電路板 NDCO-03C
ABB電路板 NIOC-02C
ABB電路板 NGDR-02C
ABB電路板 NXPP-01
ABB電路板 AINT-02C
ABB電路板 RINT5311C
ABB電路板 RINT5411C
ABB電路板 RINT5514C
ABB電路板 RINT5611C
ABB電路板 RMIO-01C
ABB電路板 RDCU-02C
ABB電路板 RVARU5311
ABB電路板 RVAR5411
ABB電路板 RVAR5512
ABB電路板 RVAR5612
ABB電路板 RRFC5513+E202
ABB電路板 RRFC5622+E202
ABB電路板 AIBP-51
ABB電路板 AINP-01C
ABB電路板 APOW-01C
ABB電路板 AGDR-61C
ABB電路板 ADPI-01
ABB電路板 RDCO-02C
ABB電路板 RDCO-03
ABB電路板 ABRC-01C
ABB電路板 GINT5611C SP KIT
ABB電路板 SINT4610C REVG
ABB電路板 OINT5611 REV E
ABB電路板 SCIB-01C REV：D
ABB電路板 NPBA-12
ABB電路板 FS225R12KE3/AGDR-71C
ABB電路板 AINT-01C
ABB電路板 RMBA-01
ABB電路板 NINT-43C
ABB電路板 AGPS-21C
ABB電路板 RDC0-02C
ABB充電電阻 CBH165CH4145RO
ABB充電電阻 VHPR80HX 3R3K
ABB電路板 FMBA-01
ABB電路板 NDBU-95C
ABB電源板 SDCS-POW-4
電源板 SDCS-FEX-2A-0016 塊 2
電源板 SDCS-PIN-51 1
電源板 SDCS-POW-1-COA 2
電源板 SDCS-PIN-205B
電源板 SDCS-PIN-48
ABB備件 RBSU-02
ABB 變頻器風扇 RB2C-225/088 K093 EMC
光纖通訊卡 RDCO-03C
DCS備件 SDCS-PIN-205A
DCS備件 SDCS-PIN-205B
DCS備件 SDCS-PIN-51
光纖通訊適配器 RDCO-01C
光纖通訊適配器 RDCO-02C
ABB電流互感器 LF 505-S/SP13
BMEH584040 ALLEN BRADLEY INTERLOCK MECHANICAL 19-MCA1
RAMSEY LOAD CELL 10 31H 100KG C3 1031H100KGC3
METTLER TOLEDO LOAD CELL C11103500A 200 LB C3
PARKER HYDRAULIC VALVE F1200S/1A865 3000 PSI 110 V
BYRON JACKSON BW/IP 7002086 U-CUP FOLLOWER DVSS CF8
ELLIS/KUHNKE PNEUMATIC TIMER PANELMOUNT PT45 SZ B
2 KOBOLD FLOWMETER KDF-3225OR8 KDF-32250R8 1/4" NPT
FALK COVER & GRID ASSEMBLY 1050T-20
FLOUROWARE/GALTEK SOLENOID VALVE 203-3414-215-01
PROXIMITY ROTARY POSITION INDICATING SWITCH 12AD0
3 ROSS LOCK OUT EXHAUST VALVES 1523 C 4002 1" THD
WARNER PHOTOELECTRIC SCANNER 7125-448-002 MCS-625
UNITED ELECTRIC PRESSURE SWITCH J120-358 15-200 PSI
DODGE TORQUE TAMER 096022 SIZE 50 BORE 1 1/2" KEYED
WESTINGHOUSE CIRCUIT BREAKER HMCP050K2C 50 AMP 3 P
PULLOUT OMRON IN OUT MODULE CPM1A-20EDT 24 VDC
OMRON PROGRAMMABLE CONTROLLER CPM1A-40CDT-D-V1
2 HIRATA ROBOTIC CONTROL MODULES MICE-SD115
LAMBDA POWER SUPPLY JWS100-24/A
JAMESBURY 316 SS BALL VALVE 1 1/2" SW STAINLESS
2 OMRON PROXIMITY SWITCH TL-YS15MY11-US 100 TO 240
NSK BEARING NU2311ET7 604
4 GE REGAL BELOIT CAPACITOR 27L570 5UF 370 VAC
TCI SWING CHECK VALVE 316 SS 2" SOCKET WELD WP 200
3 O-Z/GEDNEY ALUMINUM CONDUIT BODY 1 1/2" LR-150A
CANON PRISM LENS TYPE A MG0-0200
ASHCROFT 4.5" DURAGAUGE GAUGE 45 1279SS 04L 3000#
AEG THYRO-A THYRISTOR POWER CONTROLLER 1A 400-100
AEG THYRO-A THYRISTOR POWER CONTROLLER 1A 500-40
MSA SOFTFEEL HYCAR RESPIRATOR MASK MED BLK 808074
MIDLAND LMR BATTERY CHARGER 70-C66
DWYER TRANSDUCER 601-3 0.20 IN W.C.
7 ASP 304/304L STAINLESS 3/4" SOCKET WELD COUPLING
11 CAMCO 304L STAINLESS 2" SOCKET WELD COUPLING
6 CAMCO/ASP 304L STAINLESS 1" 3/4" TEE SOCKET WELD
CLEVELAND MACHINE CONTROLS DRIVE W057N 2 HP 230V
CUTLER HAMMER REVERSING CONTACTOR CN55GN3AB SZ 2 3P
QUANDRANT 316 STAINLESS GATE VALVE 3/4" 6000 WOG SW
SQUARE D 15 AMP CIRCUIT BREAKER FAL32015
WHITE DRIVE ROLLER STATOR 200100A110AAAAA
PARKER HYDRAULIC VALVE TYPE SW 13MM 1/2" 400 WP
ASHCROFT DURAGAUGE GAUGE 35 1009 SW 02L 15# 3 1/2"
ASHCROFT 35 1009 SW 02L 15# DURAGAUGE GAUGE
SIEMENS DIGITAL INPUT MODULE 6ES5430-7LA12
OMRON LIMIT SWITCH 4VBQ3-4N
ALLEN BRADLEY TYPE PK CONTROL RELAY 700-PK800A1
ALLEN BRADLEY TYPE P CONTROL RELAY 700-P800A1
Honeywell Micro Switch PROXIMITY CONTROL FM FMH1
LOT OF 2 NEW POWELL BRASS GATE VALVE 2714 1 1/4" THREAD
AMETEK/USG THERMOMETER 9" BT-31 150-750o F 1/2" NPT
ASHCROFT VALVE CONTROL B461V 400 PSI 15A 125/250VAC
WARNER SENTEC PHOTOSCANNER MCS626-2 7105-448-007
ALLEN BRADLEY TYPE P CONTROL RELAY 700-P600A1 SER B
TEXAS INSTRUMENTS TERMINAL COMPUTER 5TI-3102
BW I.S. PLSS-50-3 SO2 PPM SENSOR MODULE ISPR2-DS3
RONAN X51-115-60SM-DAPFM
SIEMENS ITE CIRCUIT BREAKER ED63A030 30 AMP 3 POLE
SIEMENS HOUSING FOR SELECTOR SWITCH 3VU9133...A00
MOELLER CONTACTOR DILMC9-10 X-START 52W06
2 HUBBELL INSULGRIP TWIST-LOCK PLUG HBL2341 20A 2P
CUTLER HAMMER SIZE 0 STARTER B10BNO B10BN0 18 AMP
SQUARE D SWITCH 2601BW1
WATTS FLUIDAIR FS02-12WJR/M4 F602-12WJR REGULATOR
ITT FABRI-VALVE AIR ACTUATOR FOR GATE VALVE SIZE 6
4 IN PACK MAGNECRAFT RELAY W389ACX-9
ITT FABRI-VALVE GATE VALVE AIR ACTUATOR ONLY 316 SS
AGASTAT TIMING RELAY SSC22AGA 120 VAC/DC 10-300 SEC
2 EATON CIRCUIT BREAKER 15 AMP CF1-G3-U-0015-01A
VEEDER ROOT ZV-83S 110/120 VAC
DET DETECTOR CURRENT SUPPLY MODEL 0131 115 VAC
CUTLER HAMMER LIMIT SWITCH 10316H700 & E50KL202
BROWNING PILLOW BLOCK BEARING VPS-223 1-7/16"
FOXBORO ASSY MODULE B0139EY HIGH RNG 4-20 MA
SHARP CPU 120 PT INPUT OUTPUT MODULE ZV-120CU I/O
WESTINGHOUSE CIRCUIT BREAKER HMCP030H1C 30 AMP 600V
HONEYWELL SERVO MOTOR 362479-1 120 V
TIMKEN CUP BEARING JM36110
JOHN CRANE SEAL ASSY SYM 1.125 IN POLISH B93075
ASCO SOLENOID VALVE EF8342C22M 3/8" PIPE BRASS
MASONEILAN/DRES?SER TRANSDUCER 8006A EXPL PROOF
WESTINGHOUSE CIRCUIT BREAKER HMCP015E0C 15 AMP 600V
WESTINGHOUSE CIRCUIT BREAKER EHD3015 15 AMP 240/480
TELEDYNE FARRIS SAFETY RELIEF VALVE 1890 3/4" X 1"
DYNAMCO HEAVY DUTY LIMIT SWITCH HDL30
PARKER/BELLOWS SOLENOID VALVE L665392153 K1759035
VICKERS HYDRAULIC VALVE CVC500D5B2910
ANTENNA SPECIALIST TRANSIT ANTENNA 87845
2 BANNER SM2A31RQD PHOTOELECTRIC RECEIVER
2 BANNER PHOTOELECTRIC MINIBEAM SENSOR SM2A312LVQD
UNITED ELECTRIC PRESSURE SWITCH H400-550
KITZ GATE VALVE 1" CF8M 316 SS 150UMAM-GRF CL 150
KITZ BALL VALVE 2" 150UTBZM-FS(C) CF8M 316 SS CL150
WILLIAMS GATE VALVE 1" CF8M 316 SS CL150 S15F6-316G
SIEMENS PROXIMITY SWITCH SENSOR 3RG4013-0KA00
19 CUTLER HAMMER OVERLOAD HEATERS H2012B
2 CROUSE HINDS RECEPTACLE BOX FS12 1/2" ALUMINUM
24 PIPE FITTINGS NIPPLES 1/2" X 1 1/4" STAINLESS
10 PIPE FITTINGS 90 DEGREE ELBOW 3/8" THD STAINLESS
9 PIPE FITTINGS TEE 1/2" SOCKET WELD 304 STAINLESS
11 FITTINGS TEE COUPLING 1/2" SOCKET 304 STAINLESS
5 CAMCO 2" COUPLING SOCKET WELD 304L STAINLESS
WARREN CHECK VALVE 3/4" THREADED 316 STAINLESS 223
POWELL COMP DISC ANGLE VALVE 1" BRASS THD 151 CL150
ACME TRANSFORMER 45 KVA T-1A-53313-3S G 480V 3 PH
UNITED ELECTRIC TEMPERATURE CONTROLLER B105-120
UNITED ELECTRIC TEMPERATURE CONTROLLER B105-120
2 ALLEN BRADLEY PUSHBUTTON SWITCH 800T-QBH24RAR RED
UNITED ELECTRIC DIFF PRESSURE SWITCH J110K-140
UNITED ELECTRIC PRESSURE SWITCH H122-450
UNITED ELECTRIC PRESSURE SWITCH J120-551
PULLOUT ALLEN BRADLEY HIGH SPEED ENCODER 1746-HSCE
OMRON SYSMAC C200HG CPU43 MD215 C200HW-COM05-EV1
SJE RHOMBUS SENSOR FLOAT 1002161 20' CABLE WT N.O.
8 SIEMENS CERAMIC BOTTLE FUSE 16A FSB261 500V
23 BUSS ONE-TIME FUSE NON-5 5 AMP 250 V
ITE SIEMENS CIRCUIT BREAKER 40 AMP ED63A040 3 POLE
TERASAKI CIRCUIT BREAKER TEMBREAK XS60NS 60 AMP 3P
4 PARKER HYDRAULIC CHECK VALVE C800S 5000 PSI 15GPM
VICKERS HYDRAULIC CARTRIDGE VALVE CVI-50-D20-2-M-10
STEARNS SPRING SET DISC BRAKE 1-055-521-00-QF
JOHNSON DIFFERENTIAL PRESSURE CONTROL P74DA-18 P74
PENN DIFFERENTIAL PRESSURE CONTROL P74HA-12 P74
ASCO SOLENOID VALVE 8342G1 1/4" PIPE 4-WAY
ENDRESS HAUSER TRANSMITTER PMP731-053U6M11?X1
6 FIKE RUPTURE DISK 3" HOV BT 77.33 PSIG 316 SS
ALLEN BRADLEY INPUT MODULE 1771IAD 1771-IAD C PLC5
TRANSMATION ALARM 310A 310A-65 TYPE K
ALLEN BRADLEY RELAY 700-P1200A1 SER B 600 VAC 10 A
ALLEN BRADLEY AC DRIVE 1336S-BRF50-AE-DE5 5 HP E
TRANSMATION ALARM 530DC 1-5 VDC SPDT
ASHCROFT DURAGAUGE SOLID FRONT 1379AS 04L 0-30 PSI
SICK OPTIC DISTANCE MEASURING SENSOR DME2000-000S01
FISHER CONTROL VALVE 92S 300 PSIG 1 1/2" THREADED
ALLEN BRADLEY MANUAL RESET RELAY 592-J0V16 592-JOV16 B
FOXBORO SENSOR MODULE D0135SN 316L SILICONE
SQUARE D MODICON XBTH021010 OPERATOR INTERFACE
SQUARE D SIZE 3 MOTOR STARTER 8536SE01S 8536 SE01
FURNAS SIZE 3 MOTOR STARTER 14HB32AA11
PARKER/CONVUM VACUUM AIR GENERATOR CV-30AHSN
4 SIEMENS CIRCUIT BREAKER RAIL MOUNT 5SX2104-7 4 A
AMETEK ARC-LOC GAUGE 1981 4 1/2" 1500 PSI
NIP LEAR SIEGLER PCB ALARM BOARD RM41 80030024-1
MOORE RBT TRANSMITTER RBT/3W10-20/4-2?0ma/24VDC/-EZ9
5 TRICO #2 OPTOMATIC OILER W/ GUARD 40391 2 1/2 OZ
FOXBORO PH/ORP HOLDER SENSOR 222T-1X01 STY A
CUTLER HAMMER TRANSFORMER W/ FUSE BLOCK C340CG .105
PULLOUT OMRON REMOTE TERMINAL DRT1-ID16 24 VDC
PULLOUT ORIENTAL INDUCTION MOTOR 3IK15GN-AUL
PULLOUT ORIENTAL MOTOR CONTROL PACK SS21-UL 115 V
IN BOX PARKER HYDRAULIC VALVE D1VW001CNYCF 5000 PSI
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