CN104020800A - Online dyeing feedback control system and method - Google Patents
Online dyeing feedback control system and method Download PDFInfo
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- CN104020800A CN104020800A CN201410240694.6A CN201410240694A CN104020800A CN 104020800 A CN104020800 A CN 104020800A CN 201410240694 A CN201410240694 A CN 201410240694A CN 104020800 A CN104020800 A CN 104020800A
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Abstract
An online dyeing feedback control system comprises a temperature sensor, a multi-factor dye-uptake module, an online monitoring controller and a temperature regulating controller. The temperature sensor is used for detecting the working temperature in a reaction kettle. The multi-factor dye-uptake module is used measuring and calculating the dye-uptake according to the working temperature, the salinity and the bath ratio. The online monitoring controller is used for comparing dye-uptakes obtained in real time with a set dye-uptake to obtain errors and error variable quantity and obtaining a temperature change value according to the errors and the error variable quantity. The temperature regulating controller is used for comparing the temperature change value and a current working temperature to obtain a temperature regulating value and controlling a heating system of the reaction kettle to work according to the temperature regulating value. The invention further provides an online dyeing feedback control method. The online dyeing feedback control system and method realize online feedback control and is high in control precision and working efficiency.
Description
Technical field
The invention belongs to the automation field of dyeing, relate to a kind of dyeing online feedback control system and method thereof.
Background technology
At present, as the textile printing and dyeing industry of China's traditional industries, obtain fast development, although its output increases year by year, benefit is unsatisfactory.Its basic reason is that the fast development of dyeing is accompanied by high energy consumption, high pollution discharge and high water consumption.Therefore be necessary the hi-techs such as automatic technology and modern electronic technology to be applied to dyeing, and active research dyeing new technology and new technology, change the growth pattern of traditional dyeing and finishing industry, reach the object that reduces energy consumption and reduce pollutant emission, the profitability and the level of profitability that improve enterprise, be improved the quality and benefits of economic growth.
Summary of the invention
Cannot online feedback control in order to overcome existing dyeing apparatus, control accuracy is lower, work efficiency is lower deficiency, the invention provides a kind of real-time online FEEDBACK CONTROL, control accuracy is higher, work efficiency is higher dyeing online feedback control system and method thereof.
The technical solution adopted for the present invention to solve the technical problems is:
A dyeing online feedback control system, described control system comprises:
For detection of the temperature sensor of working temperature in reactor,
For calculate the multifactor dye-uptake model of dye-uptake according to working temperature, salinity and bath raio,
For relatively obtaining error and error change amount according to the dye-uptake that obtains in real time and the dye-uptake of setting, and according to error and error change, measure the On-line monitor controller of temperature change value;
And, for relatively obtaining temperature regulated value according to temperature change value and current operating temperature, and according to the temperature regulation controller of the heating system work of temperature regulated value control reactor;
Described temperature sensor is positioned at reactor, be connected with the data input pin of multifactor dye-uptake model, the output terminal of described multifactor dye-uptake model is connected with the output terminal of monitoring controller, the output terminal of described temperature sensor, monitoring controller is connected with the input end of described temperature regulator respectively, and the output terminal of described temperature regulator is connected with the control end of the heating system of reactor.
Further, described temperature sensor comprises K type thermopair and temperature collect module, and described K type thermopair one end is connected with temperature collect module, and the other end is inserted in the middle part temperature acquisition mouth of reactor.
Further, described multifactor dye-uptake model is based on multifactorial BP neural network model.
Further, described control system also comprises: for the influence degree size to dye-uptake according to influence factors such as batch (-type) dyeing course temperature, salinity and bath raioes, for control system selects temperature as the off-line monitoring controller of master control object.
Described off-line monitoring controller adopts field mouth method.
Further again, in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
A dyeing online feedback control method, described control method comprises the following steps:
1) gather the real time temperature of reactor, by dyeing, required to determine salinity and bath raio, through multifactor dye-uptake model, draw real-time dye-uptake;
2) On-line monitor controller using real-time dye-uptake and set error between dye-uptake and error rate as input, carry out fuzzy operation and set up question blank, the fuzzy quantity that inquiry draws can draw and need the temperature change value that regulates through reverse gelatinization; This temperature change value and real time temperature value relatively obtain temperature regulated value, and this temperature regulated value is as the input of temperature regulation controller;
3) in temperature regulation controller, control the power on/off time of the heating system of reactor according to temperature regulated value, the temperature of control course of reaction to assigned temperature value, realizes the accurate control to dyeing course dye-uptake according to the slope of appointment.
Further, described control method comprises the following steps: described control method also comprises: 4), as real time temperature surpasses default safety value, report to the police.
Further, described multifactor dye-uptake model is based on multifactorial BP neural network model.
Further, described off-line monitoring controller adopts field mouth method, and the influence degree size according to influence factors such as temperature, salinity and bath raioes in batch (-type) dyeing course to dye-uptake, for control system selects temperature as master control object.
Further again, described step 2) in, in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
Beneficial effect of the present invention is mainly manifested in: by On-line monitor controller, dye liquor state is carried out to real-time online detection and prediction, temperature regulation controller utilization advanced person's Robust Control Algorithm decides appropriate control behavior, make Color farthest approach target effect, realizing online feedback controls, thereby stablized the quality of dyeing product, dyeing one-time success rate is improved.For the even more important meaning of dyeing and finishing industry, be that it is to change dyeing according to dye liquor state that the online feedback of dyeing course is controlled, and reaches and shortens dyeing time, reduction energy consumption and discharge of wastewater.
Dyeing online feedback control system of the present invention and method thereof, can realize the production of dyeing on medium-scale dye vat production line, can use the method for " soft measurement " to realize the dye-uptake that detects online dyestuff, recycling monitoring controller, temperature regulation controller are controlled temperature, realize the real-time dye-uptake of dye vat and follow the tracks of the dye-uptake curve of setting, be beneficial to improve the even dyeing effect of textile dyeing.Whole system is simple in structure, easy to operate, " soft measurement " precision is high, work efficiency high.
Accompanying drawing explanation
Fig. 1 is the schematic diagram of overflow dyeing machine, wherein, and 1-variable valve, 2-PT100 thermopair, 3-liquid level gauge, 4-motor, 5-heating rod, 6-filling spout, 7-test tank (dyestuff), 8-test tank (auxiliary agent), 9-circulation pipe, 10-sieve plate, 11-test tank (ph liquid), 12-outlet valve, 13-reductor.
Fig. 2 is the block diagram of control system.
Fig. 3 is the schematic diagram of control system
Embodiment
Below in conjunction with accompanying drawing, the invention will be further described.
With reference to Fig. 1～Fig. 3, a kind of dyeing online feedback control system, described control system comprises:
For detection of the temperature sensor of working temperature in reactor,
For calculate the multifactor dye-uptake model of dye-uptake according to working temperature, salinity and bath raio,
For relatively obtaining error and error change amount according to the dye-uptake that obtains in real time and the dye-uptake of setting, and according to error and error change, measure the On-line monitor controller of temperature change value;
And, for relatively obtaining temperature regulated value according to temperature change value and current operating temperature, and according to the temperature regulation controller of the heating system work of temperature regulated value control reactor;
Described temperature sensor is positioned at reactor, be connected with the data input pin of multifactor dye-uptake model, the output terminal of described multifactor dye-uptake model is connected with the output terminal of monitoring controller, the output terminal of described temperature sensor, monitoring controller is connected with the input end of described temperature regulator respectively, and the output terminal of described temperature regulator is connected with the control end of the heating system of reactor.
Further, described temperature sensor comprises K type thermopair and temperature collect module, and described K type thermopair one end is connected with temperature collect module, and the other end is inserted in the middle part temperature acquisition mouth of reactor.
Further, described multifactor dye-uptake model is based on multifactorial BP neural network model.
Further, described control system also comprises: for the influence degree size to dye-uptake according to influence factors such as batch (-type) dyeing course temperature, salinity and bath raioes, for control system selects temperature as the off-line monitoring controller of master control object.
Described off-line monitoring controller adopts field mouth method.
Further again, in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
In the present embodiment, reactor structure comprises reductor and stirring vane; Electrical control cabinet is realized the startup of whole control system and the anxious function such as stop, and comprises solid-state relay, auxiliary reclay, contactor, electrothermal relay; PLC control system comprises ADAM5510 type PLC, K type thermopair, multifactor dye-uptake model, monitoring controller, temperature regulation controller.
Described reactor, adopts inside and outside two-layer physical construction, has three heating rods.
Described K type thermopair is connected with temperature collect module.
Described auxiliary reclay, solid-state relay are connected with digital output module.
Described multifactor dye-uptake model, based on single factor dye-uptake gray model, does not carry out repeated subtraction, and in conjunction with the multifactor dye-uptake model of neural network, for calculating real-time dye-uptake, precision is high.
Described monitoring controller, can divide On-line monitor controller and off-line monitoring controller by state.
Described temperature regulation controller, utilizes the strong robustness of algorithm to control the heat time of experiment porch heating rod, reaches temperature is carried out to the object of precisely controlling, and effectively solves the time lag shortcoming of temperature variation.
A dyeing online feedback control method, described control method comprises the following steps:
1) gather the real time temperature of reactor, by dyeing, required to determine salinity and bath raio, through multifactor dye-uptake model, draw real-time dye-uptake;
2) On-line monitor controller using real-time dye-uptake and set error between dye-uptake and error rate as input, carry out fuzzy operation and set up question blank, the fuzzy quantity that inquiry draws can draw and need the temperature change value that regulates through reverse gelatinization; This temperature change value and real time temperature value relatively obtain temperature regulated value, and this temperature regulated value is as the input of temperature regulation controller;
3) in temperature regulation controller, control the power on/off time of the heating system of reactor according to temperature regulated value, the temperature of control course of reaction to assigned temperature value, realizes the accurate control to dyeing course dye-uptake according to the slope of appointment.
Further, described control method comprises the following steps: described control method also comprises: 4), as real time temperature surpasses default safety value, report to the police.
Further, described multifactor dye-uptake model is based on multifactorial BP neural network model.
Further, described off-line monitoring controller adopts field mouth method: the influence degree size according to influence factors such as temperature, salinity and bath raioes in batch (-type) dyeing course to dye-uptake, and for control system selects temperature as master control object.
Further again, described step 2) in, in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
In the present embodiment, detect online the real-time dye-uptake of dyestuff, feed back to the input end of control system, realize the method that dyestuff dye-uptake is accurately controlled, comprise the steps:
1) off-line monitoring controller employing field mouth method is that control system is selected suitable control parameter, show that temperature is the factor to the influence degree maximum of dye-uptake in batch (-type) dyeing course, using temperature as control system master control object;
2) gather the real time temperature of dye vat, through multifactor dye-uptake model, draw corresponding dye-uptake;
3) On-line monitor controller using the real-time dye-uptake of soft-sensing model " collection " and set error between dye-uptake and error rate as input, with expert controlled experience, carry out fuzzy operation, set up question blank, the fuzzy quantity that inquiry draws can draw through reverse gelatinization the temperature value that needs adjusting, as the input of temperature regulation controller;
4) the power on/off time of temperature regulation controller output experiment porch heating rod, the temperature of controlling course of reaction rises (or fall) to assigned temperature value (Current Temperatures and required adjusting temperature value sum) according to the slope of appointment (scholar by dyeing and finishing industry provides), realizes the accurate control to dyeing course dye-uptake;
5) control procedure 2)-4) step circulates until holding stage finishes, and as temperature over-range, PLC reports to the police.
As shown in Figure 2, online feedback control system comprises PLC control system and reactor dyeing apparatus.Native system adopts the working method that PLC controls, PC monitors.Operating personnel, without very strong knowwhy, only need motion action according to the rules can complete whole dyeing flow.
The implementation process of described field mouth method is as follows:
1) selected quality characteristic: select dyestuff dye-uptake as quality characteristic.
2) judge the function of quality characteristic: hope large-scale quality characteristic, slip-stick artist wishes that dye-uptake is more high better, so dye-uptake is large as far as possible.
3) list all factors that affect dye-uptake:
Temperature, salinity, pH value, bath raio, temperature retention time, fixation time, the preparation water quality of dye liquor are, the size of cloth, cloth form (combing or general comb) and loom rotating speed.
4) make the level of controlling elements
5) make the level of interference factor
6) set up suitable orthogonal table, formulate complete test plan, carry out and test and record, analyze experimental data.
7) analyze experiment and draw these three parameters that parameter has the greatest impact to dye-uptake of temperature, salinity and bath raio.
Before starting this device, need to conscientiously check that whether the connection line in electrical control cabinet is normal, whether the cross spider between PC and PLC connects normally, guarantees that pipe joint place does not exist leakage situation, whether the hydraulic pressure oil mass in temperature tube meets the demands, and the course of work of system is as follows:
(1) in the oil filler injection liquid force feed (60L) of reactor, also injection liquid force feed (3/5 pipe) in temperature tube.And K type thermopair is inserted in temperature tube.Notice that the oil mass in pipe can not be too many, otherwise can overflow after heating.
(2) take off the motor 4 on reactor, reductor 13, upper cover, upper sieve plate, prepares dye liquor (according to given salinity, bath raio preparation), and cloth is stacked between two-layer sieve plate, fixes upper sieve plate, loads onto motor and speed reducer.
(3) check that whether wiring is correct and guarantee that reactor relieving device is unimpeded.
(4) press the start button on electrical control cabinet panel, the isolating switch first closing in electrical control cabinet, whole control system is started working.
(5) in dyeing course, temperature collect module is responsible for gathering the temperature data of K type thermopair, data calculate real-time dye-uptake and relatively draw error and error rate with system dye-uptake setting value through dye-uptake model, using this input as On-line monitor controller; On-line monitor controller response input, output needs the temperature value of adjusting, and the input using it as temperature regulation controller; Temperature regulation controller is made response to this, by adjusting the heating rod power on/off time, the temperature of controlling course of reaction rises (or fall) to assigned temperature value according to the slope of appointment (scholar by dyeing and finishing industry provides), realizes dyeing course dye-uptake is accurately controlled.In sum, temperature data acquisition, processing etc. all have relevant control program to complete, without operating personnel's too much manual operation, operating personnel only need to notice that temperature can not transfinite (transfinite and have alarm lamp flicker), need to press scram button once transfinite at any time.
(6) on PC interface, show when dye vat temperature is more than or equal to 90oC, press stop button.
(7) according to the similar step of step 2, take off cloth and emit dye liquor, cleaning dye vat.
(8) cloth needs through washing after taking out, then dries.
(9) end of operation.
The foregoing is only preferred embodiment of the present invention, not in order to limit the present invention, all any modifications of doing within the spirit and principles in the present invention, be equal to and replace and improvement etc., within being all included in protection scope of the present invention.
Claims (10)
1. a dyeing online feedback control system, is characterized in that: described control system comprises:
For detection of the temperature sensor of working temperature in reactor,
For calculate the multifactor dye-uptake model of dye-uptake according to working temperature, salinity and bath raio,
For relatively obtaining error and error change amount according to the dye-uptake that obtains in real time and the dye-uptake of setting, and according to error and error change, measure the On-line monitor controller of temperature change value;
And, for relatively obtaining temperature regulated value according to temperature change value and current operating temperature, and according to the temperature regulation controller of the heating system work of temperature regulated value control reactor;
Described temperature sensor is positioned at reactor, the data input pin of multifactor dye-uptake model connects, the output terminal of described multifactor dye-uptake model is connected with the output terminal of monitoring controller, the output terminal of described temperature sensor, monitoring controller is connected with the input end of described temperature regulator respectively, and the output terminal of described temperature regulator is connected with the control end of the heating system of reactor.
2. a kind of dyeing online feedback control system as claimed in claim 1, it is characterized in that: described temperature sensor comprises K type thermopair and temperature collect module, described K type thermopair one end is connected with temperature collect module, and the other end is inserted in the middle part temperature acquisition mouth of reactor.
3. a kind of dyeing online feedback control system as claimed in claim 1 or 2, is characterized in that: described multifactor dye-uptake model is based on multifactorial BP neural network model.
4. a kind of dyeing online feedback control system as claimed in claim 1 or 2, it is characterized in that: described control system also comprises: for the influence degree size to dye-uptake according to influence factors such as batch (-type) dyeing course temperature, salinity and bath raioes, for control system selects temperature as the off-line monitoring controller of master control object.
5. a kind of dyeing online feedback control system as claimed in claim 4, is characterized in that: described off-line monitoring controller adopts field mouth method.
6. a kind of dyeing online feedback control system as claimed in claim 1 or 2, is characterized in that: in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
7. the control method that dyeing online feedback control system as claimed in claim 1 realizes, is characterized in that: described control method comprises the following steps:
1) gather the real time temperature of reactor, by dyeing, required to determine salinity and bath raio, through multifactor dye-uptake model, draw real-time dye-uptake;
2) On-line monitor controller using real-time dye-uptake and set error between dye-uptake and error rate as input, carry out fuzzy operation and set up question blank, the fuzzy quantity that inquiry draws can draw and need the temperature change value that regulates through reverse gelatinization; This temperature change value and real time temperature value relatively obtain temperature regulated value, and this temperature regulated value is as the input of temperature regulation controller;
3) in temperature regulation controller, control the power on/off time of the heating system of reactor according to temperature regulated value, the temperature of control course of reaction to assigned temperature value, realizes the accurate control to dyeing course dye-uptake according to the slope of appointment.
8. control method as claimed in claim 7, is characterized in that: described control method comprises the following steps: described control method also comprises: 4), as real time temperature surpasses default safety value, report to the police.
9. control method as claimed in claim 7 or 8, is characterized in that: described multifactor dye-uptake model is for based on multifactorial BP neural network model.
10. control method as claimed in claim 7 or 8, is characterized in that: described step 2), in described On-line monitor controller, error and error change amount obtain temperature change value by fuzzy control method.
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| CN105088595A (en) * | 2015-09-11 | 2015-11-25 | 河海大学常州校区 | Printing and dyeing on-line color matching equipment and method based on neural network model |
| CN106436116A (en) * | 2016-11-22 | 2017-02-22 | 常州市宏大电气有限公司 | Online detection apparatus for intermittent dyeing machine process liquid parameters |
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| CN109914120A (en) * | 2019-02-01 | 2019-06-21 | 东华大学 | A kind of design method of dye formulation |
| CN109946245A (en) * | 2019-02-01 | 2019-06-28 | 东华大学 | A kind of computer for colouring method of dyestuff |
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| CN109811493A (en) * | 2019-02-01 | 2019-05-28 | 东华大学 | A kind of multi-component dyes dyeing course gives liquid method automatically |
| CN110471382A (en) * | 2019-08-19 | 2019-11-19 | 绍兴数纺科技有限公司 | Remote production real-time monitoring system |
| CN112198801A (en) * | 2020-11-18 | 2021-01-08 | 兰州理工大学 | Mine filling slurry concentration robust control method |
| CN112198801B (en) * | 2020-11-18 | 2021-07-23 | 兰州理工大学 | Mine filling slurry concentration robust control method |
| CN112987672A (en) * | 2021-03-05 | 2021-06-18 | 广东道氏技术股份有限公司 | Gain scheduling method and device for ceramic pattern-permeating ink mixed line production |
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