CN105223917B - A kind of complex control system and method based on different type compressed air unit - Google Patents
A kind of complex control system and method based on different type compressed air unit Download PDFInfo
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The present invention relates to a kind of complex control system and method based on different type compressed air unit.The system includes main control unit, intermediate controlling unit, Terminal Control Element, air compressor unit.Main control unit, intermediate controlling unit and Terminal Control Element carry out data exchange by communication module.Intermediate controlling unit, Terminal Control Element are connected with CAN, and Terminal Control Element is connected with controlled air compressor unit respectively.Real-time change of the invention according to controlled quentity controlled variables such as the pressure of compressed air unit, flow and frequencies, using the Controlling model of different type compressed air unit, the Comprehensive Control to the double-screw type air compressor in current industrial general equipment, centrifugal air compressor and piston type air compressor is realized, has reached the purpose of energy-conservation.Experiment shows that control system of the present invention is stable, and energy-saving effect reaches more than 30%.
Description
Technical Field
The invention belongs to the field of air compressors, and relates to a comprehensive control system and a comprehensive control method for multi-machine type and multi-brand different types of air compression equipment.
Background
With the rapid development of modern production, compressed air has become an indispensable energy source, namely an air source, in human production and life, the compressed air is applied to production and life more and more widely, and the proportion of energy consumed by the compressed air is larger and larger.
An important goal of air compression control is to save system energy consumption. The energy saving of the air compression system is mainly realized by saving the energy consumption of an air source generating device, namely an air compressor, and for the whole air compressor set system, the energy consumption of the air compressor set is saved, so that the equipment can do useful work to the maximum extent.
A typical air compression system has many brands and types of features, and often a network of air compression systems includes more than two types of equipment with different manufacturing capabilities, equipment with different brands and characteristics, and equipment with different compression principles. At present, various manufacturers at home and abroad release products with various characteristics, and the products can be mainly divided into two categories: factory products and products developed by third party enterprises. Due to self-protection awareness of manufacturers and non-professionality of third parties, the control system has more problems, and the problems are mainly reflected in the following two aspects: one is that the function of the control system can only be used for monitoring. Most control systems only realize a monitoring function and can only provide functions of running states of equipment, alarming and the like. Secondly, the control system has higher requirements on operators. At present, the intellectualization degree of an air compression system is not high, the air compression system can only be called as semi-automatic equipment, and once the system has a sudden situation, the system can not be processed in time. Thus, the system can only operate properly with constant adjustments, which requires the operator to be reasonably familiar with the overall system.
The Chinese invention patent with the publication number of CN101526080A and the name of 'energy-saving control system and method for air compressor unit' discloses a variable-frequency energy-saving control method for a compressor unit, which has the function of automatically diagnosing the pressure change trend and can quickly respond to the pressure change, thereby saving energy. The method is suitable for the condition that users always use fluctuating gas, but if the method is used for maintaining the machine, part of machine users can be used as standby machines to operate twice a week, and particularly the effect is poor when the method is used for uniformly controlling various brands and different types of equipment.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a comprehensive control system and a comprehensive control method based on different types of air compression equipment, which are used for carrying out centralized control on a double-screw air compressor, a centrifugal air compressor and a piston type air compressor in the conventional industrial general equipment, so that coordinated air supply of multiple brands, types, specifications and the like is realized, and the aim of saving energy is fulfilled.
In order to achieve the purpose, the invention adopts the following technical scheme.
An integrated control system based on different types of air compression equipment, comprising: the air compressor control system comprises a main control unit, an intermediate control unit, terminal control units 1-n and controlled air compressor units 1-n, wherein the main control unit, the intermediate control unit and the terminal control units exchange data through communication modules, the intermediate control unit and the terminal control units 1-n are connected with a CAN bus, and the terminal control units 1-n are respectively connected with the controlled air compressor units 1-n. And n is the number of the air compressor sets.
Furthermore, the intermediate control unit is used for pipe network pressure control and alarm emergency treatment of the air compressor unit. The intermediate control unit comprises a communication module, a logic control module and a data storage module. The communication module is used for communication between the intermediate control unit and the main control unit and between the intermediate control unit and the terminal control unit. And the logic control module is used for implementing control according to a logic control mode when the communication of the main control unit fails.
Furthermore, the main control unit comprises a processor module, a communication module and a human-computer interaction module. The processor module is respectively connected with the communication module and the human-computer interaction module. The processor module is a data processing and control center. The communication module is used for transmitting a control instruction to realize communication among the main control unit, the intermediate control unit and the terminal control unit.
Further, the terminal control unit acquires a control quantity signal from the air compressor unit and controls the air compressor unit according to an instruction of the main control unit or the intermediate control unit. The terminal control unit comprises a signal processing module, a communication module, a control quantity sensor module and an alarm module. The communication module is used for communication among the terminal control unit, the intermediate control unit and the main control unit. The control quantity sensor module is installed on the air compressor set. The alarm module is used for sending out an alarm signal when the air compressor unit breaks down.
Further, the control quantity sensor module comprises a pressure sensor and a flow sensor. The pressure sensor is arranged at a position convenient for data acquisition in a pipe network of the air compressor unit, and the flow sensor is placed in the main pipeline.
Further, the air compressor units 1 to n include twin-screw type air compressors, centrifugal type air compressors, and piston type air compressors.
A method for carrying out comprehensive control by using the system comprises the following steps:
step 1, a terminal control unit obtains a control quantity signal from an air compressor set in real time, processes the signal and converts an analog signal into a digital signal.
And 2, the terminal control unit sends a control quantity signal to the intermediate control unit through a CAN bus or a communication module.
And 3, preprocessing the control quantity signal in the intermediate control unit and then sending the control quantity signal to the main control unit. The preprocessing comprises anti-interference filtering and data classification processing.
And 4, judging the working state of the air compressor unit by the main control unit according to the variable quantity of the control quantity signal and the corresponding response time and the control model of the air compressor unit.
And 5, the main control unit sends a control instruction to the middle control unit according to the working state of the air compressor unit, and the control instruction is sent to the terminal control unit after being sorted according to importance, so that the control of the air compressor unit is realized.
Further, the control quantity signal includes a pressure signal, a flow signal and a frequency signal. The pressure signal and the flow signal are respectively obtained by a pressure sensor and a flow sensor, and the frequency signal is obtained by a frequency converter of the air compressor unit.
Further, the control models include a global control model and an individual control model. Wherein,
an overall control model: and evaluating the air conditioning allowance according to the corresponding relation among the pressure, the flow and the lacked flow of the air compressor unit. Determining the number of the air compressor sets needing to be started according to the air conditioner allowance and the required flow, then calculating the time for starting the air compressor sets, and starting the air compressor sets when the time node is reached.
Individual control model: for the centrifugal air compressor unit, performing multivariate calculation according to the starting response time, the response time of the hot standby unit and the change of the flow after the centrifugal air compressor unit is converged into a pipeline, and summarizing and counting; for the screw type air compressor unit, performing multivariate calculation according to the starting response time, the variable-frequency response time and the flow change of an incoming pipeline, and performing summary and statistics; and for other types of air compressor units, a self-learning optimization method is adopted, and the similar models are corrected according to actual changes.
Further, when the main control unit goes wrong or fails or is powered off, the intermediate control unit cannot communicate with the main control unit, the main control unit automatically hands over the control right to the intermediate control unit, and under the control of the intermediate control unit, the air compressor unit is started at the lowest pressure and unloaded and stopped timely at the highest pressure. When the intermediate control unit fails, the terminal control unit cannot receive the instruction of the intermediate control unit, and the air compressor unit performs pressure maintaining operation in a loading and unloading mode under the control of the terminal control unit. When the main control unit and the middle control unit have problems, the terminal control unit performs control to ensure that the air compressor unit performs pressure maintaining operation in a loading and unloading mode.
Compared with the prior art, the invention has the following beneficial effects:
according to the invention, the control models of different types of air compression equipment are applied according to the real-time change of the control quantities such as the pressure, the flow, the frequency and the like of the air compression equipment, so that the comprehensive control of a double-screw air compressor, a centrifugal air compressor and a piston air compressor in the current industrial general equipment is realized, and the purpose of energy conservation is achieved. Experiments show that the control system provided by the invention is stable in operation, and the energy-saving effect reaches more than 30%.
Drawings
Fig. 1 is a block diagram of the air compression integrated control system according to the present invention.
Detailed Description
The invention is further illustrated with reference to the following figures and examples.
The invention provides a comprehensive control system and a comprehensive control method based on different types of air compression equipment, which are used for establishing different control models aiming at the different types of air compression equipment and realizing multi-brand, multi-type and multi-specification coordinated air supply control. Fig. 1 is a block diagram of an intelligent Compressed air system (IMS or ICMS), which includes: the system comprises a main control unit, a middle control unit, terminal control units 1-n and air compressor sets 1-n. The main control unit is located in the monitoring room, the middle control unit is located in the station room, and the terminal control unit is located near or inside the air compressor unit. The main control unit, the intermediate control unit and the terminal control unit exchange data through the communication module. The middle control unit and the terminal control units 1-n are connected with a CAN bus, and the terminal control units 1-n are respectively connected with the controlled air compressor units 1-n. And n is the number of the air compressor sets.
The terminal control units 1-n obtain control quantity signals from the air compressor units 1-n in real time and send the control quantity signals to the intermediate control unit, the control quantity signals are sent to the main control unit after being preprocessed by the intermediate control unit, and the main control unit sends control instructions according to the change conditions of the control quantity signals and sends the control instructions to the terminal control units 1-n through the intermediate control unit to control the air compressor units 1-n.
The intermediate control unit is used for basic pipe network pressure control and alarm emergency treatment. The intermediate control unit comprises a communication module, a logic control module and a data storage module. The communication module is used for communication between the intermediate control unit and the main control unit and between the intermediate control unit and the terminal control unit. The logic control module adopts a processor chip and has the main function of controlling each unit in a logic control mode when the communication of the main control unit fails; and when the main control unit is in normal communication, preprocessing the data and controlling according to instructions. The preprocessing comprises anti-interference filtering and data classification processing. And the data storage module is used for storing the control quantity data of the operation of the air compressor, which is acquired by the terminal control unit, in real time.
The main control unit comprises a processor module, a communication module and a man-machine interaction module. The processor module is respectively connected with the communication module and the human-computer interaction module. The processor module is a data processing and control center, and an optimization control program is put in according to the requirements of customers to realize optimization control. The communication module is used for communication among the main control unit, the intermediate control unit and the terminal control unit. The human-computer interaction module is a matching processor facing to an interface by a user and used for setting control parameters for debugging and matching with a field operation environment. The control parameters set are as follows: working pressure range (lowest working pressure, highest working pressure), main technical parameters (starting time, loading time, communication mode and the like) of each device, and system response time (which can be adjusted to avoid system overshoot).
And the terminal control unit is used for acquiring a control quantity signal of the air compressor unit and controlling the air compressor unit according to an instruction of the main control unit or the middle control unit. The terminal control unit comprises a signal processing module, a communication module, a control quantity sensor module and an alarm module. The signal processing module is used for processing the control quantity signals acquired from the air compressor set and converting the analog signals into digital signals. The communication module is used for communication between the terminal control unit and the intermediate control unit as well as the main control unit. The control quantity sensor module is used for acquiring control quantity signals of the air compressor unit and comprises a pressure sensor, a flow sensor and a frequency sensor. The pressure sensor is arranged at a position suitable for data acquisition in the pipe network; the flow sensor is installed on the main pipeline. The alarm module is used for sending out alarm signals when the air compressor set and the main control unit are in failure and the control logic data are in error.
The air compressor units 1-n are air compressors of different brands and different types. Industrial general air conditioning equipment is divided into a centrifugal air compressor (dynamic type), a screw air compressor (positive displacement type) and a piston air compressor (positive displacement type) according to the working principle; the method is divided into the following steps according to the adjusting mode: loading and unloading control air compressor, adjustable valve control air compressor and variable frequency control air compressor. Different types of equipment have different operation characteristics, and the influence fed back to the whole system pipe network is different.
A method for carrying out comprehensive control by using the system comprises the following steps:
step 1, a terminal control unit obtains a control quantity signal from an air compressor set in real time, processes the signal and converts an analog signal into a digital signal.
And 2, the terminal control unit sends a control quantity signal to the intermediate control unit through a CAN bus or a communication module.
And 3, preprocessing the control quantity signal in the intermediate control unit and then sending the control quantity signal to the main control unit. The preprocessing comprises anti-interference filtering and data classification processing.
And 4, judging the working state of the air compressor unit by the main control unit according to the variable quantity of the control quantity signal and the corresponding response time and the control model of the air compressor unit.
And 5, the main control unit sends a control instruction to the intermediate control unit according to the working state of the air compressor unit, the control instruction is sent to the terminal control unit after being sorted according to importance, for example, advanced alarm needs to be processed immediately, frequency adjustment needs to be adjusted according to response, and the like, so that the control of the air compressor unit is realized.
The control models include a global control model and an individual control model. The overall control model is used to control all air compressor groups and the individual control models are used to control individual compressor groups. Wherein,
an overall control model: and evaluating the air conditioning allowance according to the corresponding relation among the pressure, the flow and the lacked flow of the air compressor unit. Determining the number of the air compressor sets needing to be started according to the air conditioner allowance and the required flow, then calculating the time for starting the air compressor sets, and starting the air compressor sets when the time node is reached.
The main control unit stores a product database of a mainstream brand, and corrects the control model according to the running condition in actual running. The optimal operating scheme can be selected by combining according to the database.
Individual control model: different types of air compressor sets correspond to different models, which are described below.
Centrifugal air compressor set: and performing multivariate calculation according to the starting response time, the response time of the hot standby machine and the change of the flow after the flow is converged into the pipeline, and performing summarization and statistics.
Screw type air compressor unit: and performing multivariate calculation according to the starting response time, the variable-frequency response time and the flow change of the incoming pipeline, and performing summarization and statistics.
Other types of air compressor sets: and correcting the similar model by adopting a self-learning optimization method according to actual change. For example, theoretically, a screw air compressor should be linear frequency conversion, but a certain air quantity attenuation is caused by the production process of each manufacturer brand, so that self-learning correction is needed in actual operation, and accurate control can be performed by considering the air quantity change of the system. Meanwhile, the system attenuation which needs to be considered by the centrifugal air compressor is different from that of the volumetric air compressor, and the system attenuation is inconsistent with that of pipe network systems of multiple brands, and the system attenuation and the volumetric air compressor need to be adjusted according to the actual conditions.
When the main control unit goes wrong or fails or is powered down, the intermediate control unit cannot communicate with the main control unit, the main control unit automatically hands over the control right to the intermediate control unit, the air compressor unit is started at the lowest pressure under the control of the intermediate control unit, and the air compressor unit is unloaded and stopped timely at the highest pressure. When the intermediate control unit fails, the terminal control unit cannot receive the instruction of the intermediate control unit, and the air compressor unit performs pressure maintaining operation in a loading and unloading mode under the control of the terminal control unit.
The main control unit, the intermediate control unit and the terminal control unit are mutually matched to realize redundant control, namely when some control units are in failure, the control of the air compressor unit can still be realized. The following are 4 common control methods:
the first method is as follows: the main control unit, the intermediate control unit and the terminal control unit are all normal, and control is realized through communication (transmitting control quantity signals, receiving control instructions and the like) among the three units. The controlled object may be all or a part of the air compressor group.
The second method comprises the following steps: when the main control unit has a problem or a fault or is powered down, the intermediate control unit cannot communicate with the main control unit, and the main control unit automatically hands over the control right to the intermediate control unit. The terminal control unit obtains a control quantity signal from the air compressor set and sends the control quantity signal to the intermediate control unit through the communication module. The middle control unit is controlled according to logic, so that the air compressor set is started at the lowest pressure and unloaded and stopped timely at the highest pressure.
The third method comprises the following steps: when the intermediate control unit fails, the terminal control module communicates with the main control unit through the communication module (transmits a control quantity signal, receives a control instruction and the like), and performs energy-saving optimization control according to a control method set by the main control unit.
The method is as follows: when the main control unit and the middle control unit have problems, the terminal control unit performs control independently, so that the air compressor unit performs pressure maintaining operation in a loading and unloading mode.
The present invention is not limited to the above-described embodiments, and any obvious modifications or alterations to the above-described embodiments may be made by those skilled in the art without departing from the spirit of the present invention and the scope of the appended claims.
Claims (9)
1. An integrated control system based on different types of air compression equipment, comprising: the system comprises a main control unit, an intermediate control unit, terminal control units 1-n and controlled air compressor units 1-n, wherein the main control unit, the intermediate control unit and the terminal control units exchange data through communication modules, the intermediate control unit and the terminal control units 1-n are connected with a CAN bus, and the terminal control units 1-n are respectively connected with the controlled air compressor units 1-n; n is the number of the air compressor units;
the terminal control unit is used for acquiring a control quantity signal from the air compressor set in real time, processing the signal and converting an analog signal into a digital signal;
the terminal control unit is also used for sending a control quantity signal to the intermediate control unit through a CAN bus or a communication module;
the intermediate control unit is used for preprocessing the control quantity signal and then sending the preprocessed control quantity signal to the main control unit; the preprocessing comprises anti-interference filtering and data classification processing;
the main control unit is used for judging the working state of the air compressor unit according to the variable quantity of the control quantity signal and the corresponding response time and the control model of the air compressor unit;
the main control unit is also used for sending a control instruction to the middle control unit according to the working state of the air compressor unit, and sending the control instruction to the terminal control unit after sequencing according to importance so as to realize the control of the air compressor unit;
the control models comprise a general control model and an individual control model; wherein,
an overall control model: evaluating the air conditioner allowance according to the corresponding relation of the pressure, the flow and the lacked flow of the air compressor unit; determining the number of air compressor sets needing to be started according to the air conditioner allowance and the required flow, then calculating the time for starting the air compressor sets, and starting the air compressor sets when the time node is reached;
individual control model: for the centrifugal air compressor unit, performing multivariate calculation according to the starting response time, the response time of the hot standby unit and the change of the flow after the centrifugal air compressor unit is converged into a pipeline, and summarizing and counting; for the screw type air compressor unit, performing multivariate calculation according to the starting response time, the variable-frequency response time and the flow change of an incoming pipeline, and performing summary and statistics; and for other types of air compressor units, a self-learning optimization method is adopted, and the similar models are corrected according to actual changes.
2. The integrated control system based on different types of air compression equipment as claimed in claim 1, wherein the intermediate control unit is used for pipe network pressure control and alarm emergency treatment of the air compressor unit; the intermediate control unit comprises a communication module, a logic control module and a data storage module; the communication module is used for communication between the intermediate control unit and the main control unit and between the intermediate control unit and the terminal control unit; and the logic control module is used for implementing control according to a logic control mode when the communication of the main control unit fails.
3. The integrated control system based on different types of air compression equipment as claimed in claim 1, wherein the main control unit comprises a processor module, a communication module and a human-computer interaction module; the processor module is respectively connected with the communication module and the human-computer interaction module; the processor module is a data processing and control center; the communication module is used for transmitting a control instruction to realize communication among the main control unit, the intermediate control unit and the terminal control unit.
4. The integrated control system based on different types of air compression equipment as claimed in claim 1, wherein the terminal control unit acquires a control quantity signal from the air compressor unit and controls the air compressor unit according to an instruction of the main control unit or the intermediate control unit; the terminal control unit comprises a signal processing module, a communication module, a control quantity sensor module and an alarm module; the communication module is used for communication among the terminal control unit, the intermediate control unit and the main control unit; the control quantity sensor module is installed on the air compressor unit; the alarm module is used for sending out an alarm signal when the air compressor unit breaks down.
5. The integrated control system based on different types of air compression equipment according to claim 4, wherein the control quantity sensor module comprises a pressure sensor, a flow sensor; the pressure sensor is arranged at a position convenient for data acquisition in a pipe network of the air compressor unit, and the flow sensor is placed in the main pipeline.
6. An integrated control system based on different types of air compression equipment according to claim 1, characterized in that the air compressor group comprises a twin screw air compressor, a centrifugal air compressor and a piston air compressor.
7. A method for controlling by using the system of any one of claims 1 to 6, comprising the steps of:
step 1, a terminal control unit acquires a control quantity signal from an air compressor unit in real time, processes the signal and converts an analog signal into a digital signal;
step 2, the terminal control unit sends a control quantity signal to an intermediate control unit through a CAN bus or a communication module;
step 3, the control quantity signal is sent to a main control unit after being preprocessed in the intermediate control unit; the preprocessing comprises anti-interference filtering and data classification processing;
step 4, the main control unit judges the working state of the air compressor unit according to the variable quantity of the control quantity signal and the corresponding response time and the control model of the air compressor unit;
step 5, the main control unit sends a control instruction to the middle control unit according to the working state of the air compressor unit, and the control instruction is sent to the terminal control unit after being sorted according to importance, so that the control of the air compressor unit is realized;
step 4, the control models comprise a general control model and an individual control model; wherein,
an overall control model: evaluating the air conditioner allowance according to the corresponding relation of the pressure, the flow and the lacked flow of the air compressor unit; determining the number of air compressor sets needing to be started according to the air conditioner allowance and the required flow, then calculating the time for starting the air compressor sets, and starting the air compressor sets when the time node is reached;
individual control model: for the centrifugal air compressor unit, performing multivariate calculation according to the starting response time, the response time of the hot standby unit and the change of the flow after the centrifugal air compressor unit is converged into a pipeline, and summarizing and counting; for the screw type air compressor unit, performing multivariate calculation according to the starting response time, the variable-frequency response time and the flow change of an incoming pipeline, and performing summary and statistics; and for other types of air compressor units, a self-learning optimization method is adopted, and the similar models are corrected according to actual changes.
8. The method of claim 7, wherein the control quantity signal comprises a pressure signal, a flow signal, and a frequency signal; the pressure signal and the flow signal are respectively obtained by a pressure sensor and a flow sensor, and the frequency signal is obtained by a frequency converter of the air compressor unit.
9. The method of claim 7, wherein when the master control unit fails or malfunctions or loses power, the intermediate control unit is unable to communicate with the master control unit, the master control unit automatically hands over control to the intermediate control unit, the air compressor train is started at the lowest pressure and unloaded and shut down at the right time at the highest pressure under the control of the intermediate control unit; when the intermediate control unit fails, the terminal control unit cannot receive an instruction of the intermediate control unit, and the air compressor unit performs pressure maintaining operation in a loading and unloading mode under the control of the terminal control unit; when the main control unit and the middle control unit have problems, the terminal control unit performs control to ensure that the air compressor unit performs pressure maintaining operation in a loading and unloading mode.
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| CN108361186B (en) * | 2018-02-27 | 2019-11-29 | 首钢京唐钢铁联合有限责任公司 | Optimization method for air compressor system of steel plant |
| CN111623593A (en) * | 2020-06-09 | 2020-09-04 | 山东冰轮海卓氢能技术研究院有限公司 | Intelligent unit system for freezing, refrigerating and refrigerating system and control method thereof |
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| CN204140299U (en) * | 2014-08-03 | 2015-02-04 | 北京恒企新能源科技有限公司 | The air compression system that vertical wind machine drives |
| CN104317260A (en) * | 2014-09-25 | 2015-01-28 | 安徽国源节能技术研究院有限公司 | Intelligent three-stage energy saving management and control system based on embedded public building energy saving |
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