Double pump duplex high precision filling apparatus and control method thereof
Technical field
The present invention relates to a kind of auxiliary equipment to petrochemical industry series products (like crude oil, finished product wet goods) or filling medicament use in pending water; Especially a kind of double pump duplex high precision filling apparatus, the controller of this device are set up with advanced PID-PWM filling pulse control method based on reliable double pump control method and are formed.
Background technology
In order to improve the performance of crude oil, finished product wet goods petrochemical industry series products; Need in oil plant, add all kinds of medicaments according to a series of conditions such as kind, season, temperature, humidity, reduce the power and the application life of polluting, improving motor so that fuel oil fully burns to reach as in fuel oil, adding cleaning agent; In order to improve water quality, need in pending water, add various medicaments, as: breaking milk and removing oil agent, flocculation medicament and Biocidal algae-killing agent etc.Sometimes even need multichannel to annotate simultaneously.
At present, the artificial filling of the many dependences of medicament filling, the filling precision fluctuates with employee's quality difference, and labour intensity is also bigger; Part adopts the measuring pump technology to add automatically, also exists with environment (like temperature) to change the shortcoming that the variation of measuring pump precision causes whole measuring accuracy to reduce more greatly; Part adopts converter technique, and a variable-frequency motor and a gear pump are adopted in each filling loop, realize following in proportion the main flow filling through the rotating speed of regulating certain road pump; For the multichannel filling, need the many complete equipments of buying, cost is very high; If multichannel filling common motor and gear pump, exist the loop of respectively annotating independent, disturb between mutually, can't realize that the multichannel medicament carries out the problem of independent filling simultaneously.
Summary of the invention
That the object of the invention the objective of the invention is is big to the labour intensity that adopts at present artificial filling medicament mode to exist, measuring accuracy is poor, adopt the measuring pump mode to annotate is prone to the lower and multichannel filling of measuring accuracy affected by environment and will buys many cover filing provisions, problem that cost performance is extremely low, designs a kind of double pump duplex high precision filling apparatus.
For realizing above technical purpose, the present invention will take following technical scheme:
A kind of double pump duplex high precision filling apparatus is connected between pharmacy jar and the multichannel main flow pipeline; Comprise controller and the double pump mechanism between pharmacy jar and multichannel main flow pipeline of being linked in sequence, multichannel filling mechanism, the corresponding one by one setting of each main flow pipeline of respectively annotate mechanism and the multichannel main flow pipeline of said multichannel filling mechanism; Content gauge is installed in the said pharmacy jar; Double pump mechanism comprises conventional dispenser pump branch road and the subsequent use dispenser pump branch road that is connected in parallel; Conventional dispenser pump branch road comprises conventional dispenser pump and the flap valve that is connected with conventional dispenser pump fluid issuing; Subsequent use dispenser pump branch road comprises subsequent use dispenser pump and the flap valve that is connected with subsequent use dispenser pump fluid issuing; Each bar main flow pipeline of multichannel main flow pipeline disposes a main flow pump and main flow meter respectively; Each filling mechanism of multichannel filling mechanism comprises filling flow meter, electromagnetic valve and the flap valve that is linked in sequence; Simultaneously, the fluid issuing of double pump mechanism is connected with pharmacy jar through backflow mechanism, in addition, and setting pressure sensor on the connecting line of the fluid issuing of double pump mechanism and multichannel filling mechanism; Said controller is the PLC controller, and this PLC controller comprises double pump control module and electromagnetic valve break-make control module; Electromagnetic valve break-make control module is through the filling flow meter and be installed in the main flow meter institute feedback data on the main flow branch conveyance conduit, the automatically break-make of control electromagnetic valve; The double pump control module is automatically controlled the action of conventional dispenser pump and subsequent use dispenser pump through content gauge, pressure sensor, main flow pump and main flow meter institute feedback data.
The fluid issuing of said pharmacy jar is connected with the fluid intake of double pump mechanism through strainer.
Said backflow mechanism comprises and connects pipeline and be installed in the safety valve that connects on the pipeline that the two ends that connect pipeline are connected with pharmacy jar with the fluid issuing of double pump mechanism respectively.
Said safety valve is a safety overflow valve.
Another technical purpose of the present invention provides a kind of above-mentioned control method of stating double pump duplex high precision filling apparatus, comprises filling double pump progress control method and PID-PWM filling pulse control method; Wherein:
Described filling double pump progress control method may further comprise the steps: (1) parameter preset---the minimum working pressure value F of preset double pump mechanism in the PLC controller
0x, maximum working pressure value F
0s, t start-up time of each dispenser pump in the double pump mechanism
0And normal working hours threshold values t
f(2) starting device---start arbitrary main flow pump, when the PLC controller receives the closure signal of contactor auxiliary contact feedbacks of this main flow pump, start arbitrary dispenser pump of double pump mechanism; (3) double pump control---the PLC controller starts duration t through received dispenser pump
0The starting pressure value F that the back is exported
o, at threshold values t normal working hours
fInterior actual working pressure value F
WAnd the continuous working period of this dispenser pump, control the operation conditions of two dispenser pumps in the double pump mechanism automatically; (4) closing device---close all main flow pumps, when the PLC controller receives the off state signal of contactor auxiliary contact feedbacks of all main flow pumps in the multichannel main flow pipeline, two dispenser pumps in the stop double pump mechanism; (5) starting device once more, when making the main flow pump work, start with step (4) in last in running order another relative dispenser pump;
Described PID-PWM filling pulse control method may further comprise the steps:
1) calculates actual filling ratio
,
; Wherein:
is actual measurement filling flow velocity;
is corresponding actual measurement principal flow velocity;
2) the PID-PWM controller carries out computing based on the deviation and the digital PID algorithm of filling ratio set-point and actual filling ratio, obtains the duty ratio of time
of control electromagnetic valve:
Where:
,
for a given proportion of the actual percentage deviation;
for the PID-PWM controller scaling parameter;
for the PID-PWM controller integral time parameter;
for the PID-PWM controller derivative time parameters;
for the PID-PWM controller cycle;
3) the electromagnetic valve unlatching time is
; Shut-in time is
; Wherein:
is the electromagnetic valve switch cycle;
; Wherein:
is for to avoid electromagnetism to send out the minimum switch periods of high frequency oscillation;
is electromagnetic valve switch cycle factor of proportionality,
for surveying principal flow velocity.
Then the expression formula of controller output is following:
;
4) the controller output valve is 1 o'clock, and it is effective to add the agent enable signal, and electromagnetic valve is opened; The controller output valve is 0 o'clock, and it is invalid to add the agent enable signal, closed electromagnetic valve.
According to above technical scheme, can realize following beneficial effect:
1, the invention solves that the labour intensity that existing manual filling medicament mode exists is big, measuring accuracy is poor, adopt the measuring pump mode to annotate and be prone to the lower and multichannel filling of measuring accuracy affected by environment and will buy many cover filing provisions, problem that cost performance is extremely low.
2, double pump duplex high precision filling apparatus of the present invention adopts reliable double pump control method, shared two gear pumps, and equally loaded, subsequent use each other, reliability is high;
3, double pump duplex high precision filling apparatus of the present invention; Adopt the PID-PWM charging method; The duty cycle conversion that will produce through PWM for the closed loop PID control of this analog quantity of filling ratio is the switch control of electromagnetic valve, replaces directly regulating the electric control valve valve position, and system's rapidity is good; Control accuracy is high, and hardware cost is low.
4, double pump duplex high precision filling apparatus of the present invention adopts the PID-PWM charging method, adjusts the electromagnetic valve switch cycle automatically according to principal flow velocity, can guarantee the time marquis that principal flow velocity is little, and the filling frequency is slack-off, prolongs the electromagnetic valve working life; In the time of guaranteeing that principal flow velocity is big again, the filling frequency is accelerated, and realizes in time annotating.Avoid magnetic valve high frequency concussion, good with the net synchronization capability of time (or main flow), can effectively avoid adding, leak and add.
5, the present invention realizes that through safety overflow valve the medicament filling refluxes, and can stablize multichannel filling mechanism fluid intake forward direction operating pressure simultaneously, need not to adopt converter technique, and cost performance is high.
6, the present invention can be widely used in to petrochemical industry series products (like crude oil, finished product wet goods) or in pending water, add medicament, especially is used in the medicament multichannel proportioning filling with certain viscosity.
Description of drawings
Fig. 1 is a structural representation of the present invention;
Fig. 2 is a filling double pump operation control flow chart of the present invention;
Fig. 3 is of the present invention based on PID-PWM filling pulse control closed loop block diagram;
Wherein, 1, controller; 2, control panel; 3, double pump mechanism; 4, safety valve; 5, pressure sensor; 6, filling flow meter; 7, electromagnetic valve; 8, strainer; 9, flap valve; 10, content gauge 10.
The specific embodiment
Below will combine accompanying drawing that technical scheme of the present invention at length is described.
As shown in Figure 1, double pump duplex high precision filling apparatus of the present invention is connected between pharmacy jar and the multichannel main flow pipeline; Comprise controller 1, control panel 2 and the double pump mechanism 3 between pharmacy jar and multichannel main flow pipeline of being linked in sequence, multichannel filling mechanism; Multichannel main flow pipeline is meant separate parallel main flow pipeline more than two.Multichannel filling mechanism is meant separate parallel filling mechanism more than two; The shared fluid intake of each mechanism that annotates; But have a fluid issuing separately; This fluid issuing is connected with corresponding main flow pipeline, the annotate corresponding one by one setting of each main flow pipeline of respectively annotate mechanism and multichannel main flow pipeline of mechanism of promptly said multichannel; Guidance panel is connected with controller 1, and controller 1 can adopt singlechip controller 1 or the Siemens S7-200 PLC controller 1 of 80C51; Control panel 2 can adopt Siemens OP270; Content gauge 10 is installed in the said pharmacy jar; Double pump mechanism 3 comprises conventional dispenser pump branch road and the subsequent use dispenser pump branch road that is connected in parallel; Conventional dispenser pump branch road comprises conventional dispenser pump and the flap valve 9 that is connected with conventional dispenser pump fluid issuing; Subsequent use dispenser pump branch road comprises subsequent use dispenser pump and the flap valve 9 that is connected with subsequent use dispenser pump fluid issuing; Wherein, conventional dispenser pump and subsequent use dispenser pump are pump A and the pump B in the accompanying drawing 1, and the fluid issuing of pharmacy jar is connected with the fluid intake of double pump mechanism 3 through strainer 8; Each bar main flow pipeline of multichannel main flow pipeline disposes a main flow pump and a main flow meter respectively; Each filling mechanism of multichannel filling mechanism comprises filling flow meter 6, electromagnetic valve 7 and the flap valve 9 that is linked in sequence; Simultaneously; The fluid issuing of double pump mechanism 3 is connected with pharmacy jar through backflow mechanism; Said backflow mechanism comprises and connects pipeline and be installed in the safety valve 4 that connects on the pipeline; These two ends that connect pipeline are connected with pharmacy jar with the fluid issuing of double pump mechanism 3 respectively, and said safety valve 4 is a safety overflow valve; In addition, setting pressure sensor 5 on the connecting line of the fluid issuing of double pump mechanism 3 and multichannel filling mechanism; Said controller 1 is a PLC controller 1, and this PLC controller 1 comprises double pump control module and electromagnetic valve 7 break-make control modules; Electromagnetic valve 7 break-make control modules are through filling flow meter 6 and be installed in the main flow meter institute feedback data on the main flow branch conveyance conduit, the automatically break-make of control electromagnetic valve 7; The double pump control module is automatically controlled the action of conventional dispenser pump and subsequent use dispenser pump through content gauge 10, pressure sensor 5, main flow pump and main flow meter institute feedback data.
Specifically, content gauge 10 according to the invention is installed in and detects the residual pharmacy amount on the pharmacy jar; A, B double pump are connected to the end that of strainer 8 through input channel; Strainer 8 is gone into end and is connected to the pharmacy jar bottom through pipeline, and A, B double pump are gone into end through two output channels with flap valve 9 respectively and linked to each other, and A, B double pump are two shared gear pumps; Can equally loaded, subsequent use each other; The safety valve 4 that goes out to be connected to of flap valve 9 is gone on the flow meter in end, pressure sensor 5 and multichannel filling loop; Safety valve 4 goes out end and is connected to the pharmacy jar top through pipeline; Safety valve 4 can be controlled the outlet pressure of double pump; After being adjusted to a certain force value, by when the filling passage opens that way is different to cause forward direction filling changes in flow rate, it can be regulated and reflux size and guarantee that pump discharge pressure is constant.Filling flow meter 6 goes out end and is connected the back with electromagnetic valve and links to each other with corresponding main flow pipeline through flap valve 9, the filling flow meter 6 test agents flow of annotating, and whether the electromagnetic valve execution annotates.Controller 1 links together through the RS485 bus with control panel 2; Controller 1 links together through cable and A, B double pump, pressure sensor 5, flow meter, electromagnetic valve and content gauge 10, and controller 1 is used to gather information such as pump discharge pressure, each road medicament filling flow, medicament liquid level; With modes such as 485 communication modes or level, pulse receive that the filling that main trafficdirector 1 sends enables, relevant information such as principal flow velocity or total amount pulse; Based on advanced control algorithm, pump A, pump B and multichannel electromagnetic valve are implemented effectively control, reach the while duplex high precision and annotate automatically.Control panel 2 is man-machine manipulation interfaces of double pump duplex high precision medicament filling control device; Support automatic, manual work mode; The manual control of A pump, B pump; Parameter modification is convenient.
Another technical purpose of the present invention provides a kind of control method of above-mentioned double pump duplex high precision filling apparatus, comprises filling double pump progress control method and PID-PWM filling pulse control method; Wherein:
Described filling double pump progress control method may further comprise the steps: the minimum working pressure value F of double pump mechanism 3 is preset in (1) in PLC controller 1
0x, maximum working pressure value F
0s, t start-up time of each dispenser pump in the double pump mechanism
0, normal working hours threshold values t
fWherein, minimum working pressure value F
0xCan be taken as 3 kg/cm
2And maximum working pressure value F
0sThen can be taken as 8.5 kg/cm
2Start-up time t
0Value be generally 10 seconds, normal working hours threshold values t
f=4~6 hours, t
fValue according to the decision of the viscosity of medicament in the pharmacy jar, viscosity is big more, t
fThe choosing value is big more; (2) start arbitrary main flow pump, when PLC controller 1 receives the closure signal of contactor auxiliary contact feedback of this main flow pump, start arbitrary dispenser pump of double pump mechanism; (3) measure dispenser pump and start duration t
0The starting pressure value F that the back is exported
o, and with starting pressure value F
oFeed back to PLC controller 1; (4) PLC controller 1 is with received starting pressure value F
oWith preset working low pressure limit value F
0x, maximum working pressure value F
0sCompare: if starting pressure value F
oAll the time be lower than low pressure limit value F0x, this dispenser pump of stop starts another dispenser pump simultaneously; If starting pressure value F
oBetween low pressure limit value F
0xAnd upper pressure limit value F
0sBetween, keep the normal operation of this dispenser pump; If starting pressure value F
oBe higher than upper pressure limit value F
0s, this dispenser pump of stop; (5) measure dispenser pump at threshold values t normal working hours
fInterior actual working pressure value F
W, and with actual working pressure value F
WFeed back to PLC controller 1; (6) PLC controller 1 is with received actual working pressure value F
WWith preset working low pressure limit value F
0x, maximum working pressure value F
0sCompare: if actual working pressure value F
WBe lower than low pressure limit value F
0x, this dispenser pump of stop starts another dispenser pump simultaneously; If starting pressure value F
oBetween low pressure limit value F
0xAnd upper pressure limit value F
0sBetween, keep the normal operation of this dispenser pump; If starting pressure value F
oBe higher than upper pressure limit value F
0s, this dispenser pump of stop; (7) PLC controller 1 detects the dispenser pump continuous working period and equals threshold values t normal working hours
fThe time, this dispenser pump of stop starts another dispenser pump; (8) close all main flow pumps, when PLC controller 1 receives the off state signal of contactor auxiliary contact feedbacks of all main flow pumps in the multichannel main flow pipeline, two dispenser pumps in the stop double pump mechanism; When (9) starting the main flow pump once more, be in that dispenser pump of stop state during startup main flow pump operation last time in the double pump mechanism at last.
Hence one can see that, and filling double pump progress control method of the present invention has following characteristics:
1) arbitrary main flow pump startup, dispenser pump (A or B) starts; All main flow pumps stop, and dispenser pump (A or B) stops.
2) under the normal condition, two dispenser pumps alternately start: this starts operation A pump, then starts operation B pump next time, and the A pump that then reruns reaches load balancing.
3) start certain dispenser pump after 10 seconds, the output pressure of this dispenser pump can't reach setting value (like 3 kg/cm
2), or after dispenser pump normally moves, but its output pressure is lower than setting value once more (like 3 kg/cm
2) can automatically switch to another dispenser pump.
4) certain pressure is high to be limit (like 8.5 kg/cm when pressure surpasses
2) the control pump trip, be convenient to equipment is overhauled.
Described PID-PWM filling pulse control method may further comprise the steps:
1) calculates actual filling ratio
,
; Wherein:
is actual measurement filling flow velocity;
is corresponding actual measurement principal flow velocity;
refers to the flow that this main flow pipeline passes through in the unit interval; Actual measurement filling flow velocity
; The pharmaceutical quantities that refers to filling in the unit interval; When flow meter is output as the pulse signal form; Actual measurement filling flow velocity
; Wherein
is the pharmaceutical quantities of unit pulse representative;
is the unit interval; General consistent with the cycle
of PID-PWM controller 1, the umber of pulse that
sends for unit interval
interior flow meter.
2) PID-PWM controller 1 carries out computing based on the deviation and the digital PID algorithm of filling ratio set-point and actual filling ratio, obtains the duty ratio of time
of control electromagnetic valve:
Where:
,
for a given proportion of the actual percentage deviation;
for the PID-PWM controller is a scaling parameter;
for the PID-PWM controller is an integral time parameter;
for the PID-PWM controller is a differential time parameter;
for the PID-PWM Controller 1 cycle; PID-PWM controller parameter tuning can be a classic ZN method using 4:1 attenuation ratio, select the final PID parameters:
,
,
,
;
3) the electromagnetic valve unlatching time is
; Shut-in time is
; Wherein:
is the electromagnetic valve switch cycle;
; Wherein:
is for avoiding the minimum switch periods of magnetic valve high frequency concussion;
is electromagnetic valve switch cycle factor of proportionality,
for surveying principal flow velocity;
Then the expression formula of controller 1 output is following:
;
4) controller 1 output valve is 1 o'clock, and it is effective to add the agent enable signal, and electromagnetic valve is opened; Controller 1 output valve is 0 o'clock, and it is invalid to add the agent enable signal, closed electromagnetic valve.