CN106919127A - A kind of level of filler material detection method based on software virtual technique - Google Patents
A kind of level of filler material detection method based on software virtual technique Download PDFInfo
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- CN106919127A CN106919127A CN201710060072.9A CN201710060072A CN106919127A CN 106919127 A CN106919127 A CN 106919127A CN 201710060072 A CN201710060072 A CN 201710060072A CN 106919127 A CN106919127 A CN 106919127A
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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
- G05B19/00—Programme-control systems
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Abstract
The present invention relates to a kind of level of filler material detection method based on software virtual technique, step is：Information collecting platform is set up, the input, output situation to material are counted, record the work information of measurand；Feeding model is set up, material is modeled respectively by species, the stream data gathered according to early stage are input into feeding model after being integrated treatment；Cutting-stock model is set up, blanking aggregate-value is counted；Material virtual detection model is set up, in this module, the virtual material position value that virtual material position shows is made up of feeding module with the difference of cutting module output in real time；Virtual level-sensing device automatic Calibration module is formulated, error is analyzed, adjusting parameter realizes closed-loop control.The present invention can significantly save hardware investment expense, treat that material situation is substantially improved, and prevent the feelings that feeding excessively causes windrow, and material supply is more smooth；The dust work time of labourer is greatly decreased, and occupational health situation is improved, and fully meets production needs.
Description
Technical field
The present invention relates to a kind of level of filler material detection method, specifically a kind of material material based on software virtual technique
Position detecting method.
Background technology
At present in the enterprises such as chemical metallurgy, material supply operation generally carries out material-level measure, thing using physics level-sensing device
Reason level-sensing device includes being following several according to purposes and structure type：Blocking rotary type level-sensing device, capacitance level meter, magneto material position
Meter, ultrasonic material level meter, guided wave radar material level gauge, laser level meter, radio frequency admittance level-sensing device, Plumb-bob Material Level Meter, ray type
Level-sensing device and weighing level indicator etc., above-mentioned all kinds of physics level-sensing devices respectively have advantage and disadvantage, and such as blocking rotary type level-sensing device detection is relatively leaned on,
But it is not durable；Conversely, capacitance level meter is although durable, but reliability is poor；Magneto level-sensing device is reliable, sensitive, durable, but
Exact vertical is required during installation, it is necessary to often correction；Ultrasonic material level meter and laser level meter be it is contactless, due to being pollinated
The influence of dirt, male and fomale(M＆F) and noise, the accuracy of measurement is poor；Guided wave radar material level gauge pin and radio frequency admittance level-sensing device are to certain
The measurement of point, the dielectric constant to measured medium has higher requirements, its accuracy easily by bridging, pulling force or when drift, the shadow of temperature drift
Ring；Ray type material position is calculated as contactless, there is pollution to environment, and price is high；Weight type charge level score two kinds of cable formula and belt, break
Hammer into shape, bury hammer and the phenomenon such as disorder cable happens occasionally；Weighing level indicator can measure mass/volume, but poor seismic behavior, influence
The accuracy of measurement.
Further shorten physics material position due to test point bad environments, situations such as dust, electromagnetism, common ground system interference
Meter service life.Physics level-sensing device cannot meet production needs.Physics level-sensing device installation amount is big, and maintenance workload is big, enterprise
It is difficult to automate feeding, mainly manually carries out feeding operation.Feeding workman is daily under the hazardous environments such as dust high-altitude,
Range estimation material position carries out feeding.Loading efficiency and accuracy cannot ensure.The occupational health of labourer is difficult to ensure that, artificial loading
The material deviation brought cannot overcome.Simultaneously because systematic parameter is more, error pattern is also different, manually carries out parameter adjustment work
Work amount is big, cumbersome.
The sectional drawing that current material information is shown on man-machine picture is as shown in figure 3, material position display range (unit：
Ton), the percentage of manual conversion's residue material position is needed, not intuitively, and blanking system picture part level-sensing device has been damaged.
The content of the invention
The physics level-sensing device used for the supply of material in the prior art has that service life is short, installation amount big, be difficult to reality
The existing automation deficiency such as feeding, the technical problem to be solved in the present invention be to provide one kind can substitute original physics level-sensing device,
The level of filler material detection method based on software virtual technique shown on man-machine picture.
In order to solve the above technical problems, the technical solution adopted by the present invention is：
A kind of level of filler material detection method based on software virtual technique of the present invention, comprises the following steps：
Information collecting platform is set up, the input, output situation to material are counted, record the operating mode letter of measurand
Breath；
Feeding model is set up, material is modeled respectively by species, treatment is integrated according to the stream data that early stage is gathered
Feeding model is input into afterwards；
Cutting-stock model is set up, blanking aggregate-value is counted；
Set up material virtual detection model, in this module, the virtual material position value that virtual material position shows by feeding module with
The difference of cutting module output in real time is constituted；
Virtual level-sensing device automatic Calibration module is formulated, error is analyzed, adjusting parameter realizes closed-loop control.
The loss that actually enters of feeding model is input into using average weighted mode, and reserved manual weights modification interface with
The change of adaptive temperature or operating mode.
Feeding mode input total amount is filled by feeding electricity conduction time of shaking with the product or belt scale metering of material kind of feeding stream
Put decision.
Cutting-stock model subtracts each other to count blanking by the numerical value of weighing silo after the numerical value of weighing silo before blanking and blanking
Aggregate-value；Virtual material position value is subtracted blanking aggregate-value by blanking after finishing, and updates the surplus value of current feed bin.
Increase first-order lag filtering link in cutting-stock model, eliminate feeding electricity shake after stopping still having to come less clout slow with
Machine adds the error brought.
Virtual material position shows that percentage is the range of feed bin divided by virtual material position value in the form of percentage.
Upper doses is not more than the 85% of feed bin volume, the occurrence of to prevent windrow；When virtual material position is less than 15%
Alarmed, reminded timely feeding.
The increase of virtual material position value is disposably added by the feeding cumulative amount that feeding module is exported, the reduction of virtual material position value
Difference before and after being weighed by cutting module is determined, to realize that feeding, blanking while carry out, are independent of each other.
Virtual level-sensing device automatic Calibration module is periodically manually demarcated, and weekly manually by field observation, is input into feed bin
Material position.
Also there is system exception treatment and self-diagnostic program, enumerate various abnormal conditions and captured, it is soft by setting
Part trap, responds to the abnormal interruption for causing, and DTC is exported automatically, to facilitate the judgement and treatment of failure.
The invention has the advantages that and advantage：
1. the virtual level-sensing device of the present invention fully meets production needs, using virtually by the way of artificial periodic calibrating is combined
Can full substitutes reason level-sensing device, it is more in material detection node, under the larger working condition of installation amount, can significantly save hardware
Investment cost, spare part expense, equipment maintenance cost；Physics level-sensing device hardware investment 2 can be saved using individual node after this technology
Ten thousand yuan or so, with reference to the average life span of on-site actual situations and physics level-sensing device, parts replacement, plant maintenance can be saved within every 3 years
Expense amounts to 30,000 yuan or so；In addition using after virtual material detection technique, treat that material situation is substantially improved, feeding excessively causes heap
Material situation has prevented, and material supply is more smooth.
2., using after the inventive method, feeding personnel's efficiency is greatly improved, and can more intuitively observe the residue of material
Situation and addition situation, to realize that automation refining operation provides important prerequisite condition；The dust work time of labourer is big
Width is reduced, and occupational health situation is greatly improved.
3., using after the inventive method, feeding process uses full-automatic operation, post normalizing operation to specification, and
And rule of thumb judged without feeding personnel, estimated, the accuracy of feeding is greatly improved, and is can be controlled within 1 ton, completely
Meet production needs.
4. compared with physics level-sensing device, the present invention is capable of achieving in the same time to carry out feeding and blanking operation simultaneously, overcomes
Physics level-sensing device carries out the blanking indeterminable shortcoming of inspection that blanking brings simultaneously during feeding.
Brief description of the drawings
Fig. 1 is the inventive method flow chart；
Fig. 2 is present system structure principle chart；
Fig. 3 is the feed bin situation display interface that operating personnel use in the prior art；
Fig. 4 is the feed bin situation display interface that operating personnel of the present invention use.
Specific embodiment
Under normal circumstances, before material-level detection system is transformed, to be carried out for original material-level detection system feasible
Property assessment, i.e., the detecting element of higher level, subordinate's operation to measurand carries out feasibility analysis, the survey to the detection of virtual material
Accuracy of measurement is estimated, and subordinate's operation of measurand must possess physical detection link, and operation and precision are relatively reliable.On
The material detection of level operation can be detected by physical component or calculated by charging equipment run time.Using several in evaluation process
Individual typical feed bin is tested.Loss and error are subtracted by the upper doses of primary Calculation higher level's operation, with subordinate material
Consumption is compared.If deviation is, less than or equal to 80%, the feasible knot of transformation then to be drawn in the range of craft precision permission
By implementing following method afterwards.
As shown in figure 1, a kind of level of filler material detection method based on software virtual technique of the present invention, comprises the following steps：
Information collecting platform is set up, the input, output situation to material are counted, record the operating mode letter of measurand
Breath；
Feeding model is set up, material is modeled respectively by species, treatment is integrated according to the stream data that early stage is gathered
Feeding model is input into afterwards；
Cutting-stock model is set up, blanking aggregate-value is counted；
Material virtual detection model is set up, in this module, the value that virtual material position shows is by feeding module and cutting module
The difference of output is constituted in real time；
Virtual level-sensing device automatic Calibration module is formulated, error is analyzed, adjusting parameter realizes closed-loop control.
Virtual material-level measure technology is a kind of non-physical detection technique, and the principle according to quality of material conservation is calculated in real time
Go out a kind of flexible measurement method of material surplus.The method can be realized metering suitable for the higher level of operation and subordinate's material
Between process links, by the superior and the subordinate's operation measurement means according to loss deviation can extrapolate level of filler material information.With physics
Level-sensing device is compared, and the virtual level-sensing device for producing can equally show that level of filler material is believed on the premise of hardware investment is not carried out
Breath.
To realize level of filler material detection function, the inventive method first has to set up necessary virtual module, as shown in Fig. 2
Set up material virtual detection model, feeding model, cutting-stock model and automatic Calibration module, with material virtual detection model as
The primary module of virtual material-level measure, after original physics level-sensing device damage or failure, material is carried out using virtual material-level measure technology
Level gauging, substitutes the physics level-sensing device of original damage, and the input of material, output are carried out by feeding model, cutting-stock model
Metering, increases the feedback element that automatic Calibration module realizes system, to improve closed-loop control precision, and by material information man-machine
Shown on picture.
In the present embodiment, work information is included under material variety, feeding form, the quantity of feed bin, the range of feed bin, feed bin
Detection, the stream of feeding and blanking, the material leakage situation of level operation, the parameter such as error species and loading and unloading cycle.
Feeding model is set up, material is modeled respectively by species.Treatment is integrated according to the stream data that early stage is gathered
Feeding model is input into afterwards.The loss that actually enters of feeding system uses average weighted mode input model, and reserved power manually
Value modification interface is with the change of adaptive temperature or operating mode.Feeding mode input total amount is shaken conduction time and a material kind feeding by feeding electricity
The metering devices such as the product or belt conveyer scale of stream are determined.
Set up cutting-stock model.The major function of cutting-stock model is to measure weighed after numerical value and the blanking of weighing silo before blanking
The numerical value of feed bin subtracts each other, and blanking aggregate-value is counted with this.Virtual material position value is subtracted blanking aggregate-value by blanking after finishing, and is updated
The surplus value of current feed bin.Shaken in view of feeding electricity in this module after stopping, still having and carry out clout less and slowly add at random, therefore set
Meter first-order lag filtering link, eliminates this error.
Set up material virtual detection model.In this module, the value (unit that virtual material position shows：Ton), by feeding module
Constituted with the difference that cutting module is exported in real time.The percentage that virtual material position shows is the range (unit of feed bin：Ton) divided by void
Intend material position value.In the form of percentage more intuitively reaction mass residue situation.In view of safety factor, upper doses will not
More than the 85% of feed bin volume, the occurrence of to prevent windrow, putty.Alarmed when virtual material position is less than 15%, carried
Awake timely feeding.The increase of virtual material position value is disposably added by the feeding cumulative amount that feeding module is exported, virtual material position value
The difference before and after being weighed by cutting module is reduced to determine.Be capable of achieving feeding, blanking is carried out simultaneously, is independent of each other.
Formulate virtual level-sensing device automatic Calibration module.The automatic Calibration module error occurs with traditional instrument carries out demarcation class
Seemingly, when system output value is larger with actual physics value deviation, in order to improve certainty of measurement, need to periodically be demarcated, manually will be true
It is real-valued to be revised as system output value, it is corrected.Difference is that virtual material-level measure technology can be by the big of deviation
Small and Changing Pattern automatically analyzes error Producing reason, and changes systematic parameter, and the error of nearest 10 times is counted into array, from
It is dynamic to calculate mean error.When newest deviation accumulation value more than mean error 10%, to the physical detection of subordinate's operation
Element carries out temperature drift and crosses zero shift inspection.As subordinate's detecting element is working properly, then in the feelings that system output value is higher
The condition lower gain 1% for improving material leakage coefficient 2%, reducing first-order lag filtering system automatically.In the case that system output is relatively low certainly
It is dynamic to reduce material leakage coefficient 2%, improve the gain 1% of first-order lag filtering system.Such as subordinate's detecting element operation irregularity, then in time
Repaired, controller parameter does not adjust.
In order to ensure certainty of measurement, virtual material-level measure needs periodically manually to be demarcated.Because systematic parameter is more, by mistake
Difference type is also different, manually carries out parameter adjustment workload greatly, cumbersome.Automatic Calibration module can be automatically performed parameter tuning
Work, only needs weekly manually by field observation, is input into bin-level.The introducing of this module increased the anti-of control system
Feedback link, realizes that closed-loop control further improves precision.
System exception treatment and self-diagnostic program.Software trap is set, response treatment is carried out to the abnormal interruption for causing.Row
Lift various abnormal conditions and captured.Automatic output DTC, to facilitate the judgement and treatment of failure.
Carry out the system integration, software test.After the completion of each submodule design, the input and output that monomer module is carried out first are imitated
True test, system combination linkage trial run is carried out after being completed.In production run test Programmable Logic Controller operation result with
Man-machine interface shows situation.Mistake in test is corrected and constantly improve one by one.Correction model parameter, iterates, until
Adjust virtual material accuracy of detection and reach production requirement.
In the inventive method, the virtual level-sensing device of blast furnace (LF ladle refinings) uses the corresponding weighing silo reality of high hopper
Value accumulative mode of successively decreasing is calculated.An initial alignment is carried out when sky feed bin is shaken, program is damaged according to material leakage, experience
Situations such as consumption coefficient, calculates loaded value and is shown in man-machine interface automatically, while the range according to feed bin calculates remaining hundred
Divide ratio, and shown in man-machine interface, when material surplus value is alarmed less than 15%, remind producers to expect in time.
In order to ensure that virtual material position truely and accurately reacts feed bin situation, refining plant carries out weekly once artificial demarcation, essence after demarcation
Exactness is significantly improved.To ensure to weigh accurately, error correction module also is introduced in program link, to subordinate's operation detecting element temperature
Degree drift, null offset carries out automatic compensation peeling.To electricity shake stop after material increase lag compensation.
Virtual level-sensing device also provides virtual function of weighing in addition to showing material position percent value, and operating personnel require no
Remaining percent value is converted, and a kilogram number for remaining material is directly displayed, and the numerical value of each high hopper is added after transforming in addition
History data set, operating personnel can be analyzed inquiry by historical trending analysis module.
Such as this technology is in certain number stove applicable cases as shown in figure 4, the newly-increased material residue kilogram number of blanking picture, recovers thing
The remaining percentage of material.Because feeding is completed by raw material workshop, without feeding weighing information in feeding process, accuracy is lower slightly, control
In the range of 1T, other station accuracy alleviate the not enough adverse effect caused to production of spare part expense significantly up to 0.6T.
In practice, transform virtual level-sensing device and amount to 26, save spare part and declare 1,040,000 yuan of expense.
Claims (10)
1. a kind of level of filler material detection method based on software virtual technique, it is characterised in that comprise the following steps：
Information collecting platform is set up, the input, output situation to material are counted, record the work information of measurand；
Feeding model is set up, material is modeled respectively by species, the stream data gathered according to early stage are integrated defeated after processing
Enter feeding model；
Cutting-stock model is set up, blanking aggregate-value is counted；
Material virtual detection model is set up, in this module, the virtual material position value that virtual material position shows is by feeding module and blanking
The difference of module output in real time is constituted；
Virtual level-sensing device automatic Calibration module is formulated, error is analyzed, adjusting parameter realizes closed-loop control.
2. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Feeding model
The loss that actually enters be input into using average weighted mode, and reserved manual weights modification interface is with adaptive temperature or operating mode
Change.
3. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Feeding model
Input total amount by feeding electricity shake conduction time with material kind feeding stream product or belt scale metering device determine.
4. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Cutting-stock model
Subtract each other to count blanking aggregate-value by the numerical value of weighing silo after the numerical value of weighing silo before blanking and blanking；After blanking is finished
Virtual material position value is subtracted into blanking aggregate-value, the surplus value of current feed bin is updated.
5. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：In blanking die
Increase first-order lag filtering link in type, eliminating feeding electricity and shaking after stopping still having to carry out clout less and slowly add the mistake brought at random
Difference.
6. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Virtual material position
Shown in the form of percentage, percentage is the range of feed bin divided by virtual material position value.
7. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Upper doses is not
More than the 85% of feed bin volume, the occurrence of to prevent windrow；Alarmed when virtual material position is less than 15%, reminded timely
Feeding.
8. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Virtual material position
The increase of value is disposably added by the feeding cumulative amount that feeding module is exported, before the reduction of virtual material position value is weighed by cutting module
Rear difference determines, to realize that feeding, blanking while carry out, are independent of each other.
9. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Virtual material position
Meter automatic Calibration module is periodically manually demarcated, and weekly manually by field observation, is input into bin-level.
10. the level of filler material detection method based on software virtual technique as described in claim 1, it is characterised in that：Also have
System exception treatment and self-diagnostic program, enumerate various abnormal conditions and are captured, and by setting software trap, draw to abnormal
The interruption for rising is responded, and DTC is exported automatically, to facilitate the judgement and treatment of failure.
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| CN108363353A (en) * | 2018-03-12 | 2018-08-03 | 唐山曹妃甸实业港务有限公司 | The operation quality guarantee of more reclaimer proportioning operating systems and operation quality detection method |
| CN110108333A (en) * | 2019-04-08 | 2019-08-09 | 中联重科股份有限公司 | Material level detection method and device for stirring container |
| CN115418475A (en) * | 2022-09-09 | 2022-12-02 | 苏州新凌电炉有限公司 | Intelligent monitoring management method and device for mesh belt furnace |
| CN115824352A (en) * | 2022-10-31 | 2023-03-21 | 淮阴工学院 | Self-adaptive digital radio frequency admittance level meter |
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| CN108363353A (en) * | 2018-03-12 | 2018-08-03 | 唐山曹妃甸实业港务有限公司 | The operation quality guarantee of more reclaimer proportioning operating systems and operation quality detection method |
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| CN115824352B (en) * | 2022-10-31 | 2024-05-17 | 淮阴工学院 | Self-adaptive digital radio frequency admittance level meter |
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