CN106919127B - Material level detection method based on software virtual technology - Google Patents

Material level detection method based on software virtual technology Download PDF

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CN106919127B
CN106919127B CN201710060072.9A CN201710060072A CN106919127B CN 106919127 B CN106919127 B CN 106919127B CN 201710060072 A CN201710060072 A CN 201710060072A CN 106919127 B CN106919127 B CN 106919127B
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material level
virtual
model
blanking
feeding
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CN106919127A (en
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丛铁地
郭晓强
赵庆玉
杨红海
王允
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Benxi Steel Group Information Automation Co ltd
Bengang Steel Plates Co Ltd
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Bengang Steel Plates Co Ltd
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/04Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/048Monitoring; Safety

Abstract

The invention relates to a material level detection method based on a software virtual technology, which comprises the following steps: establishing an information acquisition platform, counting the input and output conditions of the material, and recording the working condition information of the tested object; establishing a feeding model, respectively modeling materials according to types, performing integral processing according to material flow data acquired in the early stage, and inputting the material flow data into the feeding model; establishing a blanking model, and counting a blanking accumulated value; establishing a virtual material level detection model, wherein a virtual material level value displayed by a virtual material level in the virtual material level detection model is formed by a difference value output by a loading module and a blanking module in real time; and formulating an automatic calibration module of the virtual material level meter, analyzing errors, adjusting parameters and realizing closed-loop control. The invention can greatly save the hardware investment cost, greatly improve the material waiting condition, avoid the situation of stacking caused by excessive material loading and ensure that the material supply is smoother; the dust operation time of workers is greatly reduced, the occupational health condition is improved, and the production requirement is completely met.

Description

Material level detection method based on software virtual technology
Technical Field
The invention relates to a material level detection method, in particular to a material level detection method based on a software virtual technology.
Background
At present, in enterprises such as metallurgy chemical industry, the material supply process generally adopts the physics charge level indicator to carry out the material level detection, and the physics charge level indicator includes for following several according to usage and structural style: the device comprises a rotation-resistant level indicator, a capacitance level indicator, a permanent magnet level indicator, an ultrasonic level indicator, a guided wave radar level indicator, a laser level indicator, a radio frequency admittance level indicator, a weight type level indicator, a ray type level indicator, a weighing type level indicator and the like, wherein the various physical level indicators have advantages and disadvantages, such as the rotation-resistant level indicator depends on detection, but is not durable; on the contrary, the capacitance type level gauge is durable, but has poor reliability; the permanent magnet type level indicator is reliable, sensitive and durable, but is strictly vertical in installation and needs to be frequently corrected; the ultrasonic level meter and the laser level meter are both in a non-contact type, and are influenced by dust, concave-convex surfaces and noise, so that the measurement accuracy is poor; the measurement of a certain point by a guided wave radar level gauge needle and a radio frequency admittance level gauge has higher requirements on the dielectric constant of a measured medium, and the accuracy of the measurement is easily influenced by hanging materials, tension or time drift and temperature drift; the ray type charge level indicator is in non-contact type, has pollution to the environment and has high price; the weight type material level meter has two types of cable type and belt type, and the phenomena of hammer breaking, hammer burying, rope disorder and the like sometimes occur; the weighing type charge level indicator can measure mass/volume, but has poor shock resistance and influences the accuracy of measurement.
The service life of the physical level indicator is further shortened due to the fact that the environment of a detection point is severe and the conditions of dust, electromagnetism, public grounding system interference and the like are further shortened. Physical level gauges have failed to meet production needs. The physical level indicator has large loading capacity and large maintenance workload, enterprises are difficult to realize automatic feeding, and the feeding operation is mainly carried out manually. And feeding workers visually observe the material level to feed in dangerous environments such as dust altitude and the like every day. The feeding efficiency and accuracy can not be ensured. The occupational health of workers is difficult to guarantee, and the material deviation brought by manual feeding cannot be overcome. Meanwhile, because the system parameters are more and the error types are different, the manual parameter adjustment workload is large, and the operation is complicated.
The current screenshot of the material information displayed on the man-machine picture is shown in fig. 3, the material level display range (unit: ton) needs to manually convert the percentage of the remaining material level, the display range is not intuitive, and part of the material level meter on the picture of the blanking system is damaged.
Disclosure of Invention
Aiming at the defects of short service life, large loading capacity, difficulty in realizing automatic loading and the like of a physical level indicator adopted for material supply in the prior art, the invention aims to solve the technical problem of providing a material level detection method based on a software virtual technology, which can replace the original physical level indicator and display on a human-computer picture.
In order to solve the technical problems, the invention adopts the technical scheme that:
the invention relates to a material level detection method based on a software virtual technology, which comprises the following steps of:
establishing an information acquisition platform, counting the input and output conditions of the material, and recording the working condition information of the tested object;
establishing a feeding model, respectively modeling materials according to types, performing integral processing according to material flow data acquired in the early stage, and inputting the material flow data into the feeding model;
establishing a blanking model, and counting a blanking accumulated value;
establishing a virtual material level detection model, wherein a virtual material level value displayed by a virtual material level in the virtual material level detection model is formed by a difference value output by a loading module and a blanking module in real time;
and formulating an automatic calibration module of the virtual material level meter, analyzing errors, adjusting parameters and realizing closed-loop control.
The actual input loss of the feeding model is input in a weighted average mode, and a manual weight modifying interface is reserved to adapt to the change of temperature or working conditions.
The total input amount of the feeding model is determined by the product of the feeding electric vibration electrifying time and the feeding material flow of the material seeds or a belt scale metering device.
The blanking model calculates a blanking accumulated value by subtracting the numerical value of the weighing bin before blanking from the numerical value of the weighing bin after blanking; and after the blanking is finished, subtracting the accumulated blanking value from the virtual material level value, and updating the residual value of the current stock bin.
A first-order lag filtering link is added in the blanking model, so that errors caused by slow and random addition of the residual materials after the feeding electric vibration is stopped are eliminated.
The virtual material level is displayed in a percentage mode, and the percentage is the measuring range of the storage bin divided by the virtual material level value.
The feeding amount is not more than 85% of the volume of the storage bin so as to prevent the occurrence of stockpiling; and when the virtual material level is less than 15%, alarming to remind timely feeding.
The increase of the virtual material level value is added at one time by the accumulated material loading amount output by the material loading module, and the decrease of the virtual material level value is determined by the difference value of the material unloading module before and after weighing, so that the material loading and the material unloading are carried out simultaneously without mutual influence.
The automatic calibration module of the virtual material level meter periodically performs manual calibration, and the material level of the storage bin can be input manually every week through field observation.
The system also has a system exception processing and self-diagnosis program, enumerates and captures various exception conditions, responds to the interrupt caused by the exception by setting a software trap, and automatically outputs a fault diagnosis code so as to facilitate the judgment and processing of the fault.
The invention has the following beneficial effects and advantages:
1. the virtual material level indicator completely meets the production requirement, a mode of combining virtual and manual regular calibration can completely replace a physical material level indicator, and under the working conditions of more material detection nodes and larger loading amount, the hardware investment cost, spare part cost and equipment maintenance cost can be greatly saved; by adopting the technology, the hardware investment of the physical charge level indicator can be saved by about 2 ten thousand yuan for a single node, the replacement of spare parts can be saved every three years by referring to the actual situation on site and the average service life of the physical charge level indicator, and the maintenance cost of equipment is about 3 ten thousand yuan; in addition, after the virtual material detection technology is applied, the material waiting condition is greatly improved, the stacking condition caused by excessive feeding is completely eradicated, and the material supply is smoother.
2. After the method is adopted, the efficiency of feeding personnel is greatly improved, the surplus condition and the adding condition of the materials can be observed more visually, and important preconditions are provided for realizing automatic refining operation; the dust operation time of workers is greatly reduced, and the occupational health condition is greatly improved.
3. After the method is adopted, the feeding process adopts full-automatic operation, the post standard operation reaches the standard, the feeding personnel does not need to judge and estimate according to experience, the feeding accuracy is greatly improved, the feeding can be controlled within 1 ton, and the production requirement is completely met.
4. Compared with a physical level indicator, the automatic blanking device can realize simultaneous feeding and blanking operations at the same time, and overcomes the defect of inaccurate blanking detection caused by simultaneous blanking in the feeding process of the physical level indicator.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a schematic diagram of the system architecture of the present invention;
FIG. 3 is a prior art bin condition display interface for use by an operator;
fig. 4 is a bin condition display interface used by an operator of the present invention.
Detailed Description
Generally, before a material level detection system is modified, feasibility evaluation is performed on an original material level detection system, namely, feasibility analysis is performed on detection elements of a higher-level process and a lower-level process of a detected object, measurement accuracy of virtual material detection is evaluated, the lower-level process of the detected object needs to be provided with a physical detection link, and operation and accuracy are relatively reliable. The material detection of the upper process can be detected by a physical element or calculated by the running time of the feeding equipment. Several typical bins were used for testing during the evaluation. Loss and error are subtracted from the feeding amount of the upper-level process through preliminary calculation, and the loss and the error are compared with the consumption amount of the lower-level material. If the deviation is 80% or less, the modification is possible within the range of the process accuracy, and then the following method is performed.
As shown in FIG. 1, the invention relates to a material level detection method based on a software virtual technology, which comprises the following steps:
establishing an information acquisition platform, counting the input and output conditions of the material, and recording the working condition information of the tested object;
establishing a feeding model, respectively modeling materials according to types, performing integral processing according to material flow data acquired in the early stage, and inputting the material flow data into the feeding model;
establishing a blanking model, and counting a blanking accumulated value;
establishing a virtual material detection model, wherein a virtual material level display value in the virtual material detection model is formed by a difference value output by a loading module and a blanking module in real time;
and formulating an automatic calibration module of the virtual material level meter, analyzing errors, adjusting parameters and realizing closed-loop control.
The virtual material level detection technology is a non-physical detection technology, and is a soft measurement method for calculating the residual quantity of materials in real time according to the principle of conservation of mass of the materials. The method is suitable for the middle process link of metering the upper-level and lower-level materials of the process, and the material level information of the materials can be calculated according to the loss deviation by means of metering means of the upper-level and lower-level processes. Compared with a physical material level meter, the virtually generated material level meter can display material level information on the premise of not investing in hardware.
In order to realize the material level detection function, the method of the invention firstly establishes necessary virtual modules, as shown in figure 2, establishes a material virtual detection model, a loading model, a unloading model and an automatic calibration module, takes the material virtual detection model as a main module of the virtual material level detection, uses the virtual material level detection technology to measure the material level after the original physical material level meter is damaged or fails, replaces the original damaged physical material level meter, measures the input and output of the material through the loading model and the unloading model, adds a feedback link of an automatic calibration module realization system, improves the closed-loop control precision, and displays the material information on a man-machine picture.
In this embodiment, the operating condition information includes material type, feeding form, number of bins, measuring range of bins, detection link of bin subordinate process, material flow of feeding and unloading, material leakage condition, error type, and feeding and discharging period and other parameters.
And establishing a feeding model, and respectively modeling materials according to types. And performing integral processing according to the material flow data collected in the earlier stage and inputting the material flow data into a feeding model. The actual input loss of the feeding system is input into the model in a weighted average mode, and a manual weight modifying interface is reserved to adapt to the change of temperature or working conditions. The total input amount of the feeding model is determined by the product of the feeding electric vibration electrifying time and the feeding material flow of the material seeds or metering devices such as a belt weigher and the like.
And establishing a blanking model. The blanking model has the main function of measuring the subtraction between the numerical value of the weighing bin before blanking and the numerical value of the weighing bin after blanking, so as to count the accumulated value of blanking. And after the blanking is finished, subtracting the accumulated blanking value from the virtual material level value, and updating the residual value of the current stock bin. In the module, the situation that after the feeding electric vibration stops, the surplus materials are slowly and randomly added is considered, so that a first-order lag filtering link is designed to eliminate the error.
And establishing a material virtual detection model. In the module, the value (unit: ton) displayed by the virtual material level is formed by the difference value output by the feeding module and the blanking module in real time. The percentage displayed by the virtual level is the measurement range (unit: ton) of the silo divided by the virtual level value. The residual material is more intuitively reflected in the form of percentage. Considering the safety factor, the feeding amount is not more than 85% of the volume of the storage bin so as to prevent the occurrence of stockpiling and blockage. And when the virtual material level is less than 15%, alarming to remind timely feeding. The increase of the virtual material level value is added at one time by the accumulated material loading amount output by the material loading module, and the decrease of the virtual material level value is determined by the difference value before and after the material unloading module is weighed. The feeding and the discharging can be simultaneously carried out without mutual influence.
And formulating an automatic calibration module of the virtual material level meter. The automatic calibration module is similar to the traditional instrument in error calibration, when the deviation between the system output value and the actual physical value is large, calibration is required to be carried out periodically in order to improve the measurement precision, and the actual value is manually modified into the system output value for correction. The difference lies in that the virtual material level detection technology can automatically analyze the reasons of error generation through the size and the change rule of the deviation value, modify the system parameters, count the errors of the last 10 times into an array, and automatically calculate the average error. When the latest error integrated value is larger than 10% of the average error, the temperature drift and zero-crossing drift check are performed on the physical detection element in the next process. When the lower-stage detection element works normally, the material leakage coefficient is automatically improved by 2% under the condition that the output value of the system is higher, and the gain of the first-order lag filtering system is reduced by 1%. And the material leakage coefficient is automatically reduced by 2% under the condition that the system output is low, and the gain of the first-order lag filtering system is improved by 1%. If the lower-level detection element works abnormally, the maintenance is carried out in time, and the parameters of the controller are not adjusted.
In order to ensure the measurement accuracy, the virtual material level detection needs to be manually calibrated regularly. Because the system parameters are more and the error types are different, the manual parameter adjustment workload is large, and the operation is complicated. The automatic calibration module can automatically complete parameter setting work, and the material level of the storage bin can be input only by manual work per week through field observation. The introduction of the module increases the feedback link of the control system, and the precision is further improved by realizing closed-loop control.
And (4) system exception handling and self-diagnosis programs. And setting a software trap to respond to the interrupt caused by the exception. Various abnormal situations are enumerated and captured. And automatically outputting fault diagnosis codes to facilitate fault judgment and processing.
And carrying out system integration and software testing. After the design of each sub-module is finished, firstly, the input and output simulation test of the single module is carried out, and after the test is finished, the system integration linkage test run is carried out. And testing the running result of the programmable controller and the display condition of the human-computer interface in production running. The errors in the test are corrected one by one and are continuously perfected. And correcting the model parameters, and repeating iteration until the detection precision of the virtual material is adjusted to meet the production requirement.
In the method, the virtual charge level indicator of the blast furnace (LF ladle refining) is calculated in a mode of descending and accumulating the actual value of the weighing bin corresponding to the high-level bin. The method comprises the steps of carrying out initial calibration once when the bin is vibrated empty, automatically calculating a loading value by a program according to the conditions of material leakage, empirical loss coefficient and the like, displaying the loading value on a human-computer interface, calculating a residual percentage value according to the measuring range of the bin, displaying the residual percentage value on the human-computer interface, and alarming when the residual value of the material is less than 15% to remind production personnel to demand the material in time. In order to ensure that the virtual material level truly and accurately reflects the condition of the stock bin, the refining workshop carries out manual calibration once per week, and the accuracy is obviously improved after calibration. In order to ensure accurate weighing, an error correction module is introduced in a program link, and the temperature drift and the zero drift of a detection element in a lower procedure are automatically compensated and peeled. And (4) delaying and compensating the increase of the material after the electric vibration is stopped.
The virtual material level meter also provides a virtual weighing function except displaying the percentage value of the material level, an operator does not need to convert the remaining percentage value, the kilogram number of the remaining material is directly displayed, in addition, the numerical value of each high-level bin is added into a historical data group after modification, and the operator can analyze and inquire through a historical trend analysis module.
For example, as shown in fig. 4, the remaining kg of the material is added to the blanking screen and the remaining percentage of the material is recovered. Because the material loading is finished by the raw material workshop, the material loading weighing information is not available in the material loading process, the accuracy is slightly low, the control is in a 1T range, the accuracy of other stations can reach 0.6T, and the adverse effect on the production caused by the insufficient cost of spare parts is greatly relieved.
In practice, the total number of the modified virtual level meters is 26, and the spare part declaration cost is saved by 104 ten thousand yuan.

Claims (7)

1. A material level detection method based on a software virtual technology is characterized by comprising the following steps:
establishing an information acquisition platform, counting the input and output conditions of the material, and recording the working condition information of the tested object;
establishing a feeding model, respectively modeling materials according to types, performing integral processing according to material flow data acquired in the early stage, and inputting the material flow data into the feeding model;
establishing a blanking model, and counting a blanking accumulated value;
establishing a virtual material level detection model, wherein a virtual material level value displayed by a virtual material level in the model is formed by a difference value output by a loading model and a blanking model in real time;
formulating an automatic calibration module of the virtual charge level indicator, analyzing errors, adjusting parameters and realizing closed-loop control;
the actual input loss of the feeding model is input in a weighted average mode, and a manual weight modifying interface is reserved to adapt to the change of temperature or working conditions;
the blanking model calculates a blanking accumulated value by subtracting the numerical value of the weighing bin before blanking from the numerical value of the weighing bin after blanking; after the blanking is finished, subtracting the accumulated value of the blanking from the virtual material level value, and updating the residual value of the current stock bin;
and a first-order lag filtering link is added in the feeding model, so that errors caused by slow and random addition of a small amount of excess materials after the feeding electric vibration is stopped are eliminated.
2. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the total input amount of the feeding model is determined by the product of the feeding electric vibration electrifying time and the feeding material flow of the material seeds or a belt scale metering device.
3. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the virtual material level is displayed in a percentage mode, and the percentage is the measuring range of the bin divided by the virtual material level value.
4. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the feeding amount is not more than 85% of the volume of the storage bin so as to prevent the occurrence of stockpiling; and when the virtual material level is less than 15%, alarming to remind timely feeding.
5. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the increase of the virtual material level value is added at one time by the accumulated material loading amount output by the material loading model, and the decrease of the virtual material level value is determined by the difference value before and after the material unloading model is weighed, so that the material loading and the material unloading are carried out simultaneously without mutual influence.
6. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the automatic calibration module of the virtual material level meter periodically performs manual calibration, and the material level of the storage bin can be input manually every week through field observation.
7. The material level detection method based on the software virtual technology as claimed in claim 1, characterized in that: the system also has a system exception processing and self-diagnosis program, enumerates and captures various exception conditions, responds to the interrupt caused by the exception by setting a software trap, and automatically outputs a fault diagnosis code so as to facilitate the judgment and processing of the fault.
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CN107462302B (en) * 2017-08-02 2019-06-21 浙江中产科技有限公司 A kind of method of laser material position data processing
CN107909270A (en) * 2017-11-15 2018-04-13 云南云天化农业科技股份有限公司 A kind of material method for measuring and calculating and device and material production equipment, storage device
CN108363353B (en) * 2018-03-12 2020-07-07 唐山曹妃甸实业港务有限公司 Operation quality guarantee and operation quality detection method for multi-reclaimer proportioning operation system
CN110108333B (en) * 2019-04-08 2020-06-26 中联重科股份有限公司 Material level detection method and device for stirring container
CN115418475B (en) * 2022-09-09 2024-03-01 苏州新凌电炉有限公司 Intelligent monitoring management method and device for mesh belt furnace

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JP3874349B2 (en) * 2002-07-08 2007-01-31 日本碍子株式会社 How to operate the silo
CN1657397A (en) * 2005-02-03 2005-08-24 烟台金建设计研究工程有限公司 Digital automatic control system of single wire winding type mine direct current lifter
CN101893887A (en) * 2010-07-30 2010-11-24 沈阳天成自动化工程有限公司 Intelligent control management system of concrete materials
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