CN104020800B - Online dyeing feedback control system and method - Google Patents
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- CN104020800B CN104020800B CN201410240694.6A CN201410240694A CN104020800B CN 104020800 B CN104020800 B CN 104020800B CN 201410240694 A CN201410240694 A CN 201410240694A CN 104020800 B CN104020800 B CN 104020800B
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- 238000012544 monitoring process Methods 0.000 claims abstract description 20
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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, it is related to a kind of dyeing online feedback control system and its side
Method.
Background technology
At present, the textile printing and dyeing industry as China's traditional industries obtains fast development, although its yield increases year by year,
Benefit is unsatisfactory.Its basic reason is that the fast development of dyeing is discharged and high consumption along with high energy consumption, high pollution
Water.It is therefore desirable to by high-tech applications such as automatic technology and modern electronic technologies in dyeing, and actively research printing and dyeing
Industry new technology and new technology, change the growth pattern of traditional dyeing and finishing industry, reduce energy consumption and reduce pollutant emission
Purpose, improves profitability and the level of profitability of enterprise, so that the quality and benefits of economic growth is improved.
Content of the invention
In order to overcome the shortcomings of that existing dyeing apparatus cannot online feedback control, control accuracy be relatively low, operating efficiency is relatively low,
The invention provides a kind of real-time online feedback control, control accuracy is higher, operating efficiency is higher dyeing online feedback control
System and method.
The technical solution adopted for the present invention to solve the technical problems is:
A kind of dyeing online feedback control system, described control system includes:
For detecting the temperature sensor of operating temperature in reactor,
For calculating the multifactor dye-uptake model of dye-uptake according to operating temperature, salinity and bath raio,
Obtain error and error change amount for comparing with the dye-uptake setting according to the dye-uptake obtaining in real time, and according to
Error and error change measure the On-line monitor controller of temperature change value；
And, obtain temperature adjustment value for comparing with current operating temperature according to temperature change value, and adjusted according to temperature
Section value controls the temperature regulation controller of the heating system work of reactor；
Described temperature sensor be located at reactor in be connected with the data input pin of multifactor dye-uptake model, described many because
The plain output end of dye-uptake model is connected with the input of monitoring controller, described temperature sensor, the output of monitoring controller
End is connected with the input of described temperature regulation controller respectively, and the output end of described temperature regulation controller is added with reactor
The control end of hot systems connects.
Further, described temperature sensor includes K-type thermocouple and temperature collect module, described K-type thermocouple one end with
Temperature collect module is connected, and the other end is inserted in the middle portion temperature acquisition port of reactor.
Further, described multifactor dye-uptake model is based on multifactorial bp neural network model.
Further, described control system also includes: for according to temperature, salinity and bath raio in batch (-type) dyeing course
Etc. the influence degree size to dye-uptake for the influence factor, it is that control system selects temperature as the offline Supervised Control of master control object
Device.
Described offline monitoring controller adopts Taguchi's method.
Further, in described On-line monitor controller, error and error change amount obtain temperature by fuzzy control method
Degree changing value.
A kind of dyeing online feedback control method, described control method comprises the following steps:
1) gather the real time temperature of reactor, require to determine salinity and bath raio by dyeing, through multifactor dye-uptake
Model draws real-time dye-uptake；
2) On-line monitor controller using real-time dye-uptake and sets error between dye-uptake and error rate as defeated
Enter, carry out fuzzy operation and set up inquiry table, inquiring about the fuzzy quantity drawing and can drawing through anti fuzzy method needs the temperature adjusting to become
Change value；This temperature change value and real-time temperature values relatively obtain temperature adjustment value, and this temperature adjustment value is as temperature adjustment control
The input of device；
3) in temperature regulation controller, control the power on/off time of the heating system of reactor, control according to temperature adjustment value
The temperature of course of reaction processed, according to specified slope to assigned temperature value, realizes the precise control to dyeing course dye-uptake.
Further, described control method is further comprising the steps of: 4) as real time temperature exceedes preset security value, is reported
Alert.
Further, described multifactor dye-uptake model is based on multifactorial bp neural network model.
Further, described offline monitoring controller adopts Taguchi's method, according to temperature, salt in batch (-type) dyeing course
The influence degree size to dye-uptake for the influence factor such as concentration and bath raio, is that control system selects temperature as master control object.
Further, described step 2) in, in described On-line monitor controller, error and error change amount pass through Fuzzy Control
Method processed obtains temperature change value.
Beneficial effects of the present invention are mainly manifested in: carry out real-time online inspection by On-line monitor controller to dye liquor state
Survey and predict, temperature regulation controller determines appropriate controlling behavior using advanced Robust Control Algorithm, makes Color
Farthest close to target effect, realize online feedback control, thus stabilizing the quality of dyeing product, dyeing once success
Rate is improved.It is according to dye liquor state that the online feedback being dyeing course for the even more important meaning of dyeing and finishing industry controls
To change dyeing, to reach shortening dyeing time, reducing energy consumption and discharge of wastewater.
The dyeing online feedback control system of the present invention and its method, may be implemented in and carry out on medium-scale dye vat production line
Dyeing produces, and can realize, with the method for " hard measurement ", the dye-uptake that on-line checking goes out dyestuff, recycle monitoring controller, temperature
Degree adjusts controller and controls temperature, realizes the real-time dye-uptake of dye vat and follows the tracks of the dye-uptake curve setting, and is beneficial to and improves fabric dye
The even dyeing effect of color.Whole system structure is simple and convenient to operate, " hard measurement " high precision, high working efficiency the features such as.
Brief description
Fig. 1 is the schematic diagram of overflow dyeing machine, wherein, 1 regulating valve, 2 pt100 thermocouples, 3 liquid level gauges, 4 motors,
5 heating rods, 6 oil filling pipes, 7 measuring tanks (dyestuff), 8 measuring tanks (auxiliary agent), 9 circulation pipes, 10 sieve plates, 11 meters
Measuring tank (ph liquid), 12 outlet valves, 13 reductors.
Fig. 2 is the block diagram of control system.
Fig. 3 is the schematic diagram of control system
Specific embodiment
The invention will be further described below in conjunction with the accompanying drawings.
With reference to Fig. 1～Fig. 3, a kind of dyeing online feedback control system, described control system includes:
For detecting the temperature sensor of operating temperature in reactor,
For calculating the multifactor dye-uptake model of dye-uptake according to operating temperature, salinity and bath raio,
Obtain error and error change amount for comparing with the dye-uptake setting according to the dye-uptake obtaining in real time, and according to
Error and error change measure the On-line monitor controller of temperature change value；
And, obtain temperature adjustment value for comparing with current operating temperature according to temperature change value, and adjusted according to temperature
Section value controls the temperature regulation controller of the heating system work of reactor；
Described temperature sensor be located at reactor in be connected with the data input pin of multifactor dye-uptake model, described many because
The plain output end of dye-uptake model is connected with the input of monitoring controller, described temperature sensor, the output of monitoring controller
End is connected with the input of described temperature regulation controller respectively, and the output end of described temperature regulation controller is added with reactor
The control end of hot systems connects.
Further, described temperature sensor includes K-type thermocouple and temperature collect module, described K-type thermocouple one end with
Temperature collect module is connected, and the other end is inserted in the middle portion temperature acquisition port of reactor.
Further, described multifactor dye-uptake model is based on multifactorial bp neural network model.
Further, described control system also includes: for according to temperature, salinity and bath raio in batch (-type) dyeing course
Etc. the influence degree size to dye-uptake for the influence factor, it is that control system selects temperature as the offline Supervised Control of master control object
Device.
Described offline monitoring controller adopts Taguchi's method.
Further, in described On-line monitor controller, error and error change amount obtain temperature by fuzzy control method
Degree changing value.
In the present embodiment, reactor structure includes reductor and stirring vane；Electrical control cabinet is realized controlling system to whole
The function such as the startup of system and jerk, including solid-state relay, auxiliary reclay, contactor, electrothermal relay；Plc control system bag
Include adam5510 type plc, K-type thermocouple, multifactor dye-uptake model, monitoring controller, temperature regulation controller.
Described reactor, using inside and outside two-layer frame for movement, has three heating rods.
Described K-type thermocouple 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 test dye-uptake gray model, does not carry out repeated subtraction, in conjunction with god
Set up multifactor dye-uptake model through network, for calculating real-time dye-uptake, high precision.
Described monitoring controller, can divide On-line monitor controller and offline monitoring controller by state.
Described temperature regulation controller, using the heat time of the strong robustness Control release platform heating rod of algorithm,
Reach the purpose that temperature is precisely controlled, the time lag shortcoming of effectively solving temperature change.
A kind of dyeing online feedback control method, described control method comprises the following steps:
1) gather the real time temperature of reactor, require to determine salinity and bath raio by dyeing, through multifactor dye-uptake
Model draws real-time dye-uptake；
2) On-line monitor controller using real-time dye-uptake and sets error between dye-uptake and error rate as defeated
Enter, carry out fuzzy operation and set up inquiry table, inquiring about the fuzzy quantity drawing and can drawing through anti fuzzy method needs the temperature adjusting to become
Change value；This temperature change value and real-time temperature values relatively obtain temperature adjustment value, and this temperature adjustment value is as temperature adjustment control
The input of device；
3) in temperature regulation controller, control the power on/off time of the heating system of reactor, control according to temperature adjustment value
The temperature of course of reaction processed, according to specified slope to assigned temperature value, realizes the precise control to dyeing course dye-uptake.
Further, described control method is further comprising the steps of: 4) as real time temperature exceedes preset security value, is reported
Alert.
Further, described multifactor dye-uptake model is based on multifactorial bp neural network model.
Further, described offline monitoring controller adopts Taguchi's method: according to temperature, salt in batch (-type) dyeing course
The influence degree size to dye-uptake for the influence factor such as concentration and bath raio, is that control system selects temperature as master control object.
Further, described step 2) in, in described On-line monitor controller, error and error change amount pass through Fuzzy Control
Method processed obtains temperature change value.
In the present embodiment, the real-time dye-uptake of on-line checking dyestuff, feed back to the input of control system, realize on dyestuff
The method of dye rate precise control, comprises the steps:
1) offline monitoring controller adopts Taguchi's method to select suitable control parameter for control system, between showing that temperature is
The factor maximum to the influence degree of dye-uptake in formula of having a rest dyeing course, using temperature as control system master control object；
2) gather the real time temperature of dye vat, draw corresponding dye-uptake through multifactor dye-uptake model；
3) On-line monitor controller by the real-time dye-uptake of soft-sensing model " collection " and sets the error between dye-uptake
With error rate as input, fuzzy operation is carried out with expert controlled experience, set up inquiry table, inquire about the fuzzy quantity warp drawing
Anti fuzzy method can draw the temperature value needing to adjust, as the input of temperature regulation controller；
4) temperature regulation controller export experiment porch heating rod the power on/off time, control course of reaction temperature according to
The slope (being provided by the scholar of dyeing and finishing industry) specified rises (or fall) to assigned temperature value (Current Temperatures and required regulation
Temperature value sum), realize the precise control to dyeing course dye-uptake；
5) control process 2) -4) step circulation terminates until holding stage, such as temperature over-range, and plc is reported to the police.
As shown in Fig. 2 online feedback control system includes plc control system and reactor dyeing apparatus.The system adopts
Plc controls, the working method of pc monitoring.Operating personnel need not be very strong knowwhy it is only necessary to according to regulation motion action
Whole dyeing flow can be completed.
The implementation process of described Taguchi's method is as follows:
1) select quality characteristic: select dyestuff dye-uptake as quality characteristic.
2) judge the function of quality characteristic: hope large-scale quality characteristic, engineer is intended to dye-uptake, and the higher the better, more than institute
Dye rate is as big as possible.
3) list the factor of had an impact dye-uptake:
Temperature, salinity, ph value, bath raio, temperature retention time, fixation time, the water quality preparing dye liquor, 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, execution is tested and records, analyzes experimental data.
7) analysis experiment draws these three parameters of temperature, salinity and bath raio parameter maximum on dye-uptake impact.
Before starting this device, need conscientiously to check whether the connection line in electrical control cabinet is normal, pc machine and plc
Between cross spider whether connect normal it is ensured that there is not leakage situation at pipe joint, the The hydraulic oil in temperature tube whether
Meet and require, the course of work of system is as follows:
(1) in oil filler injection hydraulic oil (60l) of reactor, in temperature tube, it is also injected into hydraulic oil (3/5 pipe).And by k
In type thermocouple insertion temperature tube.Notice that the oil mass in pipe can not be too many, can overflow after otherwise heating.
(2) take off the motor 4 on reactor, reductor 13, upper lid, upper sieve plate, prepare dye liquor (according to given salt
Degree, bath raio are prepared), cloth is stacked between two-layer sieve plate, fixes upper sieve plate, load onto motor and speed reducer.
(3) check whether wiring is correct and guarantees that reactor relieving device is unimpeded.
(4) press the start button on electrical control cabinet panel, the breaker first closing in electrical control cabinet, whole control
System starts.
(5), in dyeing course, temperature collect module is responsible for gathering the temperature data of K-type thermocouple, and data is through dye-uptake mould
Type is calculated real-time dye-uptake and is compared with system dye-uptake setting value and draw error and error rate, in this, as online
The input of monitoring controller；The response input of On-line monitor controller, output needs the temperature value of adjustment, and adjusts as temperature
The input of section controller；Temperature regulation controller responds to this, by adjusting the heating rod power on/off time, controls and reacted
The temperature of journey rises (or fall) to assigned temperature value according to specified slope (being provided by the scholar of dyeing and finishing industry), realizes to dye
Color process dye-uptake carries out precise control.In sum, temperature data acquisition, process etc. all have associated control procedures to complete, no
Need that operating personnel's is excessively manually operated, operating personnel only need to note at any time that temperature can not transfinite (transfinites and have alarm lamp and dodge
Bright), once transfinite to need to press scram button.
(6) when showing on pc machine interface that dye vat temperature is more than or equal to 90 DEG C, press stop button.
(7) take off cloth and release dye liquor according to the similar step of step 2, in cleaning dye vat.
(8) cloth needs through washing after taking out, then dries.
(9) end of operation.
The foregoing is only presently preferred embodiments of the present invention, not in order to limit the present invention, all spirit in the present invention and
Any modification, equivalent and improvement of being made within principle etc., are all contained within protection scope of the present invention.
Claims (10)
1. a kind of dyeing online feedback control system it is characterised in that: described control system includes:
For detecting the temperature sensor of operating temperature in reactor,
For calculating the multifactor dye-uptake model of dye-uptake according to operating temperature, salinity and bath raio,
Obtain error and error rate for comparing with the dye-uptake setting according to the dye-uptake obtaining in real time, and according to error
Obtain the On-line monitor controller of temperature change value with error rate；
And, obtain temperature adjustment value for comparing with current operating temperature according to temperature change value, and according to temperature adjustment value
Control the temperature regulation controller of the heating system work of reactor；
Described temperature sensor be located at reactor in be connected with the data input pin of multifactor dye-uptake model, described multifactor on
The output end of dye rate model is connected with the input of monitoring controller, and described temperature sensor, the output end of monitoring controller are divided
It is not connected with the input of described temperature regulation controller, the heating system of the output end of described temperature regulation controller and reactor
The control end of system connects.
2. a kind of dyeing online feedback control system as claimed in claim 1 it is characterised in that: described temperature sensor includes
K-type thermocouple and temperature collect module, described K-type thermocouple one end is connected with temperature collect module, and the other end is inserted in reaction
The middle portion temperature acquisition port of kettle.
3. a kind of dyeing online feedback control system as claimed in claim 1 or 2 it is characterised in that: described multifactor upper dye
Rate 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 characterised in that: described control system is also
Including: for according to temperature, the salinity and bath raio influence factor influence degree size to dye-uptake in batch (-type) dyeing course,
Select temperature for control system as the offline monitoring controller of master control object.
5. a kind of dyeing online feedback control system as claimed in claim 4 it is characterised in that: described offline Supervised Control
Device adopts Taguchi's method.
6. a kind of dyeing online feedback control system as claimed in claim 1 or 2 it is characterised in that: described On-line monitor control
In device processed, error and error rate obtain temperature change value by fuzzy control method.
7. a kind of as claimed in claim 1 dyeing online feedback control system realize control method it is characterised in that: described
Control method comprises the following steps:
1) gather the real time temperature of reactor, require to determine salinity and bath raio by dyeing, through multifactor dye-uptake model
Draw real-time dye-uptake；
2) On-line monitor controller, using the error between real-time dye-uptake and setting dye-uptake and error rate as input, enters
Row fuzzy operation sets up inquiry table, inquires about the fuzzy quantity drawing and can draw the temperature change value needing to adjust through anti fuzzy method；
This temperature change value and real-time temperature values relatively obtain temperature adjustment value, and this temperature adjustment value is defeated as temperature regulation controller
Enter；
3) in temperature regulation controller, control the power on/off time of the heating system of reactor according to temperature adjustment value, control anti-
The temperature answering process, according to specified slope to assigned temperature value, realizes the precise control to dyeing course dye-uptake.
8. control method as claimed in claim 7 it is characterised in that: described control method is further comprising the steps of: 4) strictly according to the facts
Shi Wendu exceedes preset security value, is reported to the police.
9. control method as claimed in claim 7 or 8 it is characterised in that: described multifactor dye-uptake model be based on many because
The bp neural network model of element.
10. control method as claimed in claim 7 or 8 it is characterised in that: described step 2) in, described On-line monitor controls
In device, error and error rate obtain temperature change value by fuzzy control method.
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