Summary of the invention
The object of this invention is to provide a kind of intelligence accurately combustion control device, system and method, can effectively make combustion atmosphere more evenly, steadily, in technique adjustment or debugging, more there is operability, effectively overcome currently available technology above shortcomings.
The object of the invention is to be achieved through the following technical solutions:
According to an aspect of the present invention, provide a kind of intelligence accurately combustion control device, the former switch board of heating furnace matched with heating furnace comprising setting, actuating unit and checkout gear, described actuating unit is all connected with central control system by switching device shifter with the former switch board of heating furnace, described central control system comprises central controller, described central controller is connected with remote controllers and host computer by operation board, and described central controller controls is connected with combustion balance treating apparatus, handoff-security ensuring equipment and signal cross feedback device, described combustion balance treating apparatus is connected with described actuating unit by executing agency's drive unit.
Further, described checkout gear comprises temperature sensor, pressure sensor, oxygen voltage sensor and flow sensor.
According to a further aspect in the invention, provide a kind of intelligence accurately combustion control system, this intelligence is the combustion control system former switch board of heating furnace matched with heating furnace that comprises setting accurately, Executive Module and detection module, described Executive Module is all connected with central control system by handover module with the former switch board of heating furnace, described central control system comprises central control module, described central control module is connected with remote controllers and host computer by operation board, and described central control module control connection has combustion balance processing module, handoff-security assurance module and signal cross feedback module, described combustion balance processing module is connected with described Executive Module by executing agency's driver module, wherein,
Central control module, for sending corresponding control instruction according to the control of control information to the heating furnace pre-set pre-set, and the Detection Information of reception and the transmission of analytic signal cross feedback module and comparative result information, send according to described Detection Information and comparative result information and match and the control instruction pre-set with Detection Information and comparative result;
Operation board, for receiving and sending the command information that described central control module sends, and receives and sends the control information of the remote controllers that pre-set and/or host computer transmission;
Remote controllers and/or host computer, for receiving the command information of operation board, and feeding back the control information of the and instruction information match pre-set, sending described control information according to described command information;
Combustion balance processing module, for receiving the command information of central control module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information, and by executing agency's driver module, described operation instruction information is sent to handover module;
Handoff-security assurance module, for receiving the command information of central control module, and analyzes described command information, sends the operational order of the and instruction information match prestored according to described command information to handover module;
Handover module, for receiving the command information of executing agency's driver module and/or the transmission of handoff-security assurance module, and switches to the control system of the and instruction information match pre-set according to described command information;
The former switch board of heating furnace, for receiving the command information of handover module, and utilizes the control system pre-set to control heating furnace;
Executive Module, for receiving the command information of handover module, and performs the operation of the and instruction information match prestored according to described command information;
Detection module, for receiving the command information of handover module, and performs the operation detected heating furnace matched with described command information pre-set, and sends described Detection Information according to described command information;
Signal cross feedback module, for receiving and analyzing the Detection Information of described detection module, compares described Detection Information and the standard information pre-set, and by Detection Information and comparative result information feed back to central control module.
Further, described checkout gear comprises temperature sensor, pressure sensor, oxygen voltage sensor and flow sensor.
Further, also comprise:
Report generation module, for receiving Detection Information and the comparative result information of the transmission of described signal cross feedback module, generates the report matched according to comparative result information.
According to a further aspect in the invention, provide a kind of intelligence accurately method for controlling combustion, this intelligence is the method for controlling combustion former switch board of heating furnace matched with heating furnace that comprises setting accurately, Executive Module and detection module, described Executive Module is all connected with central control system by handover module with the former switch board of heating furnace, described central control system comprises central control module, described central control module is connected with remote controllers and host computer by operation board, and described central control module control connection has combustion balance processing module, handoff-security assurance module and signal cross feedback module, described combustion balance processing module is connected with described Executive Module by executing agency's driver module, wherein, comprise the following steps:
Central control module is utilized to send corresponding control instruction according to the control of control information to the heating furnace pre-set pre-set, and the Detection Information of reception and the transmission of analytic signal cross feedback module and comparative result information, send according to described Detection Information and comparative result information and match and the control instruction pre-set with Detection Information and comparative result;
Received by operation board and send the command information that described central control module sends, and receive and send the control information of the remote controllers that pre-set and/or host computer transmission;
Received the command information of operation board by remote controllers and/or host computer, and feed back the control information of the and instruction information match pre-set according to described command information, send described control information;
The command information of central control module is received by combustion balance processing module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information, and by executing agency's driver module, described operation instruction information is sent to handover module;
Received the command information of central control module by handoff-security assurance module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information to handover module;
Received the command information of executing agency's driver module and/or the transmission of handoff-security assurance module by handover module, and switch to the control system of the and instruction information match pre-set according to described command information;
Received the command information of handover module by the former switch board of heating furnace, and utilize the control system pre-set to control heating furnace;
Received the command information of handover module by Executive Module, and perform the operation of the and instruction information match prestored according to described command information;
Receive the command information of handover module by detection module, and perform the operation that heating furnace is detected matched with described command information pre-set according to described command information, and send described Detection Information;
Received by signal cross feedback module and analyze the Detection Information of described detection module, described Detection Information and the standard information that pre-sets are compared, and by Detection Information and comparative result information feed back to central control module.
Further, described checkout gear comprises temperature sensor, pressure sensor, oxygen voltage sensor and flow sensor.
Further, also comprise:
Received Detection Information and the comparative result information of the transmission of described signal cross feedback module by the report generation module pre-set, generate the report matched according to comparative result information.
Beneficial effect of the present invention is: native system can to the combustion atmosphere Real-Time Monitoring of regional in kiln, and automatically adjust combustion mode according to monitoring result, kiln is made to continue to burn under " optimal combustion state ", fundamentally stop the generation of " oxygen debt burning " and " oxygen-enriched combusting " two kinds of situations, thus effectively reduce oxidization burning loss and reduce gas consumption, also can significantly reduce pernicious gas NO simultaneously
xgeneration and discharge; The control ability of native system is enough to tackle changeable On-the-spot factor, " intelligent accurate system control " will replace " Artificial Control " completely, the randomness to kiln combustion control climate caused by human factor and uncertainty are effectively stopped, make combustion atmosphere more evenly, steadily, in technique adjustment or debugging, more there is operability, effectively raise the practicality of native system, be conducive to the propagation and employment in market.
Detailed description of the invention
Below in conjunction with the accompanying drawing in the embodiment of the present invention, be clearly and completely described the technical scheme in the embodiment of the present invention, obviously, described embodiment is only the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, the every other embodiment that those of ordinary skill in the art obtain, all belongs to the scope of protection of the invention.
As shown in Figure 1, according to the embodiment of the present invention according to an aspect of the present invention, provide a kind of intelligence accurately combustion control device, the former switch board 12 of heating furnace matched with heating furnace comprising setting, actuating unit 11 and checkout gear 13, described actuating unit 11 is all connected with central control system 1 by switching device shifter 10 with the former switch board 12 of heating furnace, described central control system 1 comprises central controller 2, described central controller 2 is connected with remote controllers 4 and/or host computer 5 by operation board 3, and described central controller 2 control connection has combustion balance treating apparatus 6, handoff-security ensuring equipment 9 and signal cross feedback device 8, described combustion balance treating apparatus 6 is connected with described actuating unit 11 by executing agency's drive unit 7.
According to a further aspect in the invention, provide a kind of intelligence accurately combustion control system, this intelligence is the combustion control system former switch board of heating furnace matched with heating furnace that comprises setting accurately, Executive Module and detection module, described Executive Module is all connected with central control system by handover module with the former switch board of heating furnace, described central control system comprises central control module, described central control module is connected with remote controllers and host computer by operation board, and described central control module control connection has combustion balance processing module, handoff-security assurance module and signal cross feedback module, described combustion balance processing module is connected with described Executive Module by executing agency's driver module, wherein,
Central control module, for sending corresponding control instruction according to the control of control information to the heating furnace pre-set pre-set, and the Detection Information of reception and the transmission of analytic signal cross feedback module and comparative result information, send according to described Detection Information and comparative result information and match and the control instruction pre-set with Detection Information and comparative result;
Operation board, for receiving and sending the command information that described central control module sends, and receives and sends the control information of the remote controllers that pre-set and/or host computer transmission;
Remote controllers and/or host computer, for receiving the command information of operation board, and feeding back the control information of the and instruction information match pre-set, sending described control information according to described command information;
Combustion balance processing module, for receiving the command information of central control module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information, and by executing agency's driver module, described operation instruction information is sent to handover module;
Handoff-security assurance module, for receiving the command information of central control module, and analyzes described command information, sends the operational order of the and instruction information match prestored according to described command information to handover module;
Handover module, for receiving the command information of executing agency's driver module and/or the transmission of handoff-security assurance module, and switches to the control system of the and instruction information match pre-set according to described command information;
The former switch board of heating furnace, for receiving the command information of handover module, and utilizes the control system pre-set to control heating furnace;
Executive Module, for receiving the command information of handover module, and performs the operation of the and instruction information match prestored according to described command information;
Detection module, for receiving the command information of handover module, and performs the operation detected heating furnace matched with described command information pre-set, and sends described Detection Information according to described command information;
Signal cross feedback module, for receiving and analyzing the Detection Information of described detection module, compares described Detection Information and the standard information pre-set, and by Detection Information and comparative result information feed back to central control module.
Also comprising report generation module, for receiving Detection Information and the comparative result information of the transmission of described signal cross feedback module, generating the report matched according to comparative result information.
As shown in Figure 2, according to a further aspect in the invention, provide a kind of intelligence accurately method for controlling combustion, this intelligence is the method for controlling combustion former switch board of heating furnace matched with heating furnace that comprises setting accurately, Executive Module and detection module, described Executive Module is all connected with central control system by handover module with the former switch board of heating furnace, described central control system comprises central control module, described central control module is connected with remote controllers and host computer by operation board, and described central control module control connection has combustion balance processing module, handoff-security assurance module and signal cross feedback module, described combustion balance processing module is connected with described Executive Module by executing agency's driver module, wherein, comprise the following steps:
Central control module is utilized to send corresponding control instruction according to the control of control information to the heating furnace pre-set pre-set, and the Detection Information of reception and the transmission of analytic signal cross feedback module and comparative result information, send according to described Detection Information and comparative result information and match and the control instruction pre-set with Detection Information and comparative result;
Received by operation board and send the command information that described central control module sends, and receive and send the control information of the remote controllers that pre-set and/or host computer transmission;
Received the command information of operation board by remote controllers and/or host computer, and feed back the control information of the and instruction information match pre-set according to described command information, send described control information;
The command information of central control module is received by combustion balance processing module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information, and by executing agency's driver module, described operation instruction information is sent to handover module;
Received the command information of central control module by handoff-security assurance module, and analyze described command information, send the operational order of the and instruction information match prestored according to described command information to handover module;
Received the command information of executing agency's driver module and/or the transmission of handoff-security assurance module by handover module, and switch to the control system of the and instruction information match pre-set according to described command information;
Received the command information of handover module by the former switch board of heating furnace, and utilize the control system pre-set to control heating furnace;
Received the command information of handover module by Executive Module, and perform the operation of the and instruction information match prestored according to described command information;
Receive the command information of handover module by detection module, and perform the operation that heating furnace is detected matched with described command information pre-set according to described command information, and send described Detection Information;
Received by signal cross feedback module and analyze the Detection Information of described detection module, described Detection Information and the standard information that pre-sets are compared, and by Detection Information and comparative result information feed back to central control module.
The report generation module also comprised by pre-setting receives Detection Information and the comparative result information of the transmission of described signal cross feedback module, generates the report matched according to comparative result information.
Wherein, described checkout gear 13 comprises temperature sensor 14, pressure sensor 15, oxygen voltage sensor 16 and flow sensor 17.
During embody rule, native system is applicable to recuperative heater and the non-recuperative heater of routine, and wherein, the heating furnace working of a furnace possesses following condition:
1, each bringing-up section all has electric flow control valve, and at present still can hand-guided;
2, each bringing-up section is equipped with flowmeter;
3, furnace pressure baffle plate is Electronic control.
In addition, native system is also the electrical automation system carrying out " intellectuality accurately controls " for the fired state of large-scale steel rolling heating kiln, this control system integrates " online measuring technique ", " basic combustion control technology ", " fuzzy control technology ", is specially for the upgrading Optimal Control System of original PLC control system.
This system utilizes the real-time atmosphere of multiple combustion zone in kiln to analyze data as control foundation, rely on " Combustion System model ", whole combustion system is changed into " closed loop " control model from original " open loop " control model, and by self-recision function, make the combustion atmosphere in whole kiln be in all the time " optimal combustion state ".
First, native system is built-in with accurate " Mathematical Modeling of oxygen gesture, carbon potential, temperature triadic relation " that pre-set, the arithmetic model of oxygen gesture, carbon potential, temperature triadic relation is the core technology setting up accurately burning, it is the basis to the fuzzy control of heating kiln system implementation, and system can realize controlling the matrixing of heating kiln each section of fired state.
In addition, native system additionally uses heating kiln " optimal combustion operating mode is detected " technology, and so-called " optimal combustion operating mode " refers under the prerequisite meeting basic heating process requirement, fired state when fuel consumption, remaining oxygen simultaneously can be made all to be in minimum; " optimal combustion operating mode is detected " technology utilizes control system and kiln interaction, the optimum posture should made when optimal combustion operating mode according to each combustion zone (valve) in interactive results verification kiln, finds out the valve interactive relationship that can form " optimal combustion operating mode " with this.Finally " intelligent accuracy-control system " is by using " the optimal combustion operating mode " that detect as control basis, realizes accurate Combustion System according to online feedback data and Controlling model.
Finally, technology that native system have employed " dual system redundancy backup ", effectively raise stability and the reliability of system cloud gray model, wherein, " dual system redundancy backup " technology refers to the mutual redundancy technique of original PLC combustion control system and intelligent accuracy-control system.This technology requires for the safety and stability of industrialized production and design, and can automatically switch because of fault or manually switch, to ensure the uninterrupted operation of production line between original PLC system and intelligent accurate system.
In addition, two kinds of modes of having plugged into of the input signal of native system:
One, field instrument collection: by all kinds of instrument signal access one-to-two signal isolated gates required in on-the-spot for original system I/O cabinet, wherein a road exports original system to, and an other road is connected to " IBCS intelligence accurately combustion system ".Can the work of well in advance circuit bridging in signal connection procedure, avoid signal interruption occurs, what this mode can be produced in safeguards system access procedure carries out as usual.
Two, network communication collection: read on-the-spot all kinds of instrument signal from original system, the mode of communication can be determined according to field network structure and remaining port form, mainly comprises MPI and Ethernet form etc.
All signal can be realized in two systems synchronous by any one in above-mentioned two kinds of modes.Wherein the second way is more convenient, avoids the maintenance in on-the-spot hard wired troublesome operation and use procedure, but which requires that user side provides certain technology to coordinate.
The output signal of native system is mainly switched by solid-state relay by Flux Valve Control signal.The common of relay is connected to situ flow adjustable valve, and normal-closed end is connected to original system control output end, and Chang Kaiduan is connected to native system output.Under the non-adapter state of native system, relay is in release conditions, and original system is regulated flow control valve by the normally-closed contact of relay, and the output signal of " IBCS intelligence accurately combustion system " is unsettled at the normally opened contact place of relay; After native system adapter, relay adhesive, " IBCS intelligence accurately combustion system " is regulated flow control valve by the normally opened contact of relay, and the output signal of original system is unsettled at relay normally open contact place.
Switching mode flexibility and reliability between two systems, can switch respectively to the upper and lower of single hop, namely six groups can be divided into switch for three sections of heating furnaces, switches gas valve and the air valve of this group during switching simultaneously.Can take over by single hop in debug process, facilitate the adjustment of parameter.All can take over by a key when automatically running, respectively organizing interval 20S during adapter and taking over respectively, avoid concentrating adapter to produce furnace pressure and impact.Produce impact to valve for avoiding during adapter, system is provided with level and smooth adapter, reads current valve aperture before adapter, and forced system exports currency simultaneously, can not produce and impact, taken over rear system and started steady adjustment again in guarantee adapter process to valve.
The switching of relay controls to carry out at the client actions interface of native system, provides external control contact simultaneously, conveniently switches the access of native system and exiting in original system.
In addition, when concrete engineering is applied, atmosphere analyzer can also be set up in native system, wherein, high-temperature atmosphere analyzer operation principle: in order to realize the tracking to oxygen voltage in high-temperature atmosphere, we set up one or more charged particle moving state detecting area in burner hearth, insert high-temperature atmosphere analyzer in search coverage, to the combustion atmosphere Real-Time Monitoring under hot environment, and charged particle rate travel is sent to central control system with the form of potential change amount.
The oxygen content of furnace atmosphere and the consistent relationship of output potential, but when temperature is also as variable, this electromotive force can not the reference potential of representatively remaining oxygen, according to the control experience of foreign iron and steel industry, by the experimental data of reality, the counterlogic of this electromotive force and temperature has been carried out secondary calculation process by " IBCS intelligence accurately combustion system ", make at any temperature, all can form corresponding relation by between the residual oxygen value of " truly " in stove and electromotive force, like this, this signal can with temperature signal, pressure signal carries out the foundation analyzed together as computer system, thus the enforcement supervision achieved furnace atmosphere situation and control.
Heating furnace atmosphere analyzer feature:
1, atmosphere change can be formed preliminary corresponding relation with electromotive force;
2, can in real time (online) send data;
3, adopt transition metal as medium, adapt to high temperature 600 DEG C-1700 DEG C;
4, long service life, is generally about 2 years, does not need frequent maintenance.
Concrete, the process control of native system is as follows:
This control system belongs to first class control system, and this system has Non-follow control and automatically controls two kinds of mode of operations.Non-follow control is based on original manual control mode basis, mutually switches, do not change original Non-follow control function, here no longer introduce between automatic, manual.
Automatic control system starts successfully in burning, after combustion chamber enters normal combustion state, namely sensor in multiplexed detection district enters real data acquisition state, and furnace atmosphere situation of change is converted into Δ U1-Δ U3 simultaneously, Δ T1-Δ T9, Δ P1-Δ P2, then be sent to data transformations system and carry out A/D conversion, according to preset algorithm routine, " IBCS intelligence accurately combustion system " carries out calculation process to the signal imported into, after D/A conversion, finally be loaded into driving arrangement (angular control apparatus, frequency conversion control device, step motion control equipment), realize the control to follower.After follow-up device response, the air-fuel ratio in stove is corrected thereupon, the result of correction, again being transferred back in control system and carry out analysis judgement, and for revising furnace atmosphere further, completing the full closed loop control of atmosphere.
In sum, according to above technical scheme, and native system and existing system are carried out contrast test confirmation, and the kiln under native system controls is fired steel billet with the accurate combustion system of remaining oxygen 1%-2% and is used original PLC control mode to fire steel billet, has following remarkable result:
1, reduce the oxidization burning loss of steel billet in sintering procedure, oxidization burning loss reduces 1.4 ‰ before comparatively applying--and 4.1 ‰, that is, often fire 1 kiloton steel and reduce scaling loss 1.4--4.1 ton (different kind oxidization burning loss is different);
2, the overall energy consumption of heating kiln is reduced.Total fuel consumption reduces by 3.7% before comparatively applying, if according to ton steel consumption gas 200m
3/ t calculates, and is roughly equal to ton steel consumption gas and reduces 7.4m
3/ t;
3, temperature fluctuation amplitude in stove is reduced.Temperature fluctuation amplitude in stove only at about ± 7 DEG C, comparatively before application ± fluctuating range of 20 DEG C improves significantly, and makes in-furnace temperature curve more steady, Temperature Distribution evenly;
4, decarburization is reduced.By carrying out micro test to the steel surface fired, result shows, the decarburization of steel is effectively improved before comparatively applying;
5, environmental protection is increased.Be only 2% owing to accurately controlling remaining oxygen in the rear furnace atmosphere formed, break NO
xthe primary condition generated, significantly will reduce NO
xdischarge;
Native system can to the combustion atmosphere Real-Time Monitoring of regional in kiln, and automatically adjust combustion mode according to monitoring result, kiln is made to continue to burn under " optimal combustion state ", fundamentally stop the generation of " oxygen debt burning " and " oxygen-enriched combusting " two kinds of situations, thus effectively reduce oxidization burning loss and reduce gas consumption, also can significantly reduce pernicious gas NO simultaneously
xgeneration and discharge; The control ability of native system is enough to tackle changeable On-the-spot factor, " intelligent accurate system control " will replace " Artificial Control " completely, the randomness to kiln combustion control climate caused by human factor and uncertainty are effectively stopped, make combustion atmosphere more evenly, steadily, in technique adjustment or debugging, more there is operability, effectively raise the practicality of native system, be conducive to the propagation and employment in market.
The foregoing is only preferred embodiment of the present invention, not in order to limit the present invention, within the spirit and principles in the present invention all, any amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.