CN109634104A - The intelligent optimal control device and its control method of cement raw mix proportioning process - Google Patents
The intelligent optimal control device and its control method of cement raw mix proportioning process Download PDFInfo
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- CN109634104A CN109634104A CN201910078014.8A CN201910078014A CN109634104A CN 109634104 A CN109634104 A CN 109634104A CN 201910078014 A CN201910078014 A CN 201910078014A CN 109634104 A CN109634104 A CN 109634104A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B11/00—Automatic controllers
- G05B11/01—Automatic controllers electric
- G05B11/36—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential
- G05B11/42—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential for obtaining a characteristic which is both proportional and time-dependent, e.g. P.I., P.I.D.
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
- G05B13/042—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators in which a parameter or coefficient is automatically adjusted to optimise the performance
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D7/00—Control of flow
- G05D7/06—Control of flow characterised by the use of electric means
Abstract
The present invention is using PLC controller as the intelligent optimal control device of the cement raw mix proportioning process of core design and its control method.The optimal control method of cement raw mix proportioning process includes optimal setting layer and bottom raw material flow circuit control layer.Optimal setting layer establishes the optimized mathematical model of cement raw mix proportioning according to using ingredient cost as optimization aim, and the optimal setting value for obtaining each raw material is solved using Sequential Quadratic Programming method；Bottom raw material flow circuit control layer is to control various raw material flow actual values using PID control method and reach flow setting value.Using SIMATIC S7-400 PLC and the related softwares such as relevant hardware devices and STEP7 and WinCC, the optimal control device of cement raw mix proportioning process is developed.Of the invention has an effect are as follows: establishes by optimal setting layer and bottom raw material flow circuit control layer double-layer structure institute compositional optimization control method.Optimal control method can keep blending process cost minimum while guaranteeing ingredient product quality.
Description
Technical field
The present invention provides the intelligent optimal control device and its control method of a kind of cement raw mix proportioning process, belongs to industry
Automatic field.
Background technique
Cement raw mix proportioning process is the first procedure in manufacture of cement, and the finished product index that cement slurry is prepared determines
The quality of final cement finished product.Existing cement ingredient method is mostly to lack blending process based on pid loop control mode
In optimal control method, do not account for the factors such as ingredient cost.
Summary of the invention
In order to solve the above-mentioned technical problem, the present invention is using least cost as optimization object function, with the quality of cement slurry
Index request is that constraint condition establishes mathematics computing model, and application sequence Novel Algorithm carries out optimizing to mathematical model and asks
Then solution conveys data to bottom control circuit to get the formula of each raw material flow setting value out.Bottom control circuit uses
Pid control mode carries out the flow setting value that parameter tuning tracked optimal setting transmission later to the actual flow value of each raw material.
And devise the control device that can be realized above-mentioned optimal control method.
Cement raw mix proportioning optimal control control method of the invention uses double-layer structure, including optimal setting layer and circuit
Control layer.Optimal setting layer is solved using Sequential Quadratic Programming method, finds out raw material optimal proportion, obtains the original of feed proportioning system
Expect that flow is adjusted by the PI controller of PLC control system after setting value, circuit control layer receive raw material setting value, most
The actual flow of whole output raw material, and flow actual value is fed back into PI controller, form control loop.PLC control system pair
Batching control circuit, which carries out logic control and continuous control, logic control, the start and stop and alarm of the equipment such as weighing belt, continuous to control
System is to carry out revolving speed control by PI controller to weighing belt motor, is finally reached the stabilization and tracking flow of raw material actual flow
Setting value.
The present invention is achieved by the following technical solutions:
The intelligent optimal control device and its control method of cement raw mix proportioning process, cement raw mix proportioning optimal control side
The structure of method includes system optimization setting layer and bottom raw material flow circuit control layer, optimal setting layer include raw material Optimized model
With adjustment model, is required according to raw meal proportioning process production target and technique establishes Optimized model, calculated using sequential quadratic programming
Method optimizes calculating, obtains the optimum proportioning of each material quality as a result, if the total amount of feeding changes, can be according to tune
Integral mould carries out relevant adjustment；Raw meal proportioning process matches to reach optimal as a result, it is desirable to be controlled by bottom circuit
Layer is controlled to adjust, and bottom raw material flow circuit control layer with PID control method to each original on belted electronic balance
The flow of material is controlled；Specifically includes the following steps:
Step 1: in optimal setting layer cement raw mix proportioning Optimized model and derivation algorithm
1.1 establish using production cost as the mathematics objective function of constraint condition:
In formula: the totle drilling cost of each raw material during y-cement raw mix proportioning；
biThe market price of-each raw material；
yiIn-the unit time in blending process each raw material dosage；
The raw materials used species number of n-raw material, takes 4 here；
1.2 chemical component during cement raw mix proportioning in last raw material finished product requires the error range in calculating
Interior, the mass content error range expression formula of each chemical component is as follows in raw material finished product:
C-Δ≤C*≤C+Δ (2)
S*≤S (3)
A*≤A (4)
F*≤F (5)
L*≤L (6)
In formula: C*The actual content value of-CaO in finished cement；
S*—SiO2Actual content value in finished cement；
A*—Al2O3Actual content value in finished cement；
F*—Fe2O3Actual content value in finished cement；
L*The actual ratio value of basicity in-raw material finished product；
Δ-chemical component actual content value and target set point deviation, generally takes ± 0.5；
1.3 need to be converted into the general of General constrained optimization problem to constraint condition function before with Sequential Quadratic Programming method
Expression-form:
C*≥C-Δ (7)
-C*≥-C-Δ (8)
-S*≥-S (9)
-A*≥-A (10)
-F*≥-F (11)
-L*≥-L (12)
After model foundation, established mathematical model is converted into General constrained optimization problem expression-form, with sequence
Column quadratic programming optimizes calculating,
Step 2: in optimal setting layer cement raw mix proportioning adjustment model and derivation algorithm
The function of adjusting model is to give the dosage total amount of raw material according to designer to carry out the variation of related ratio, adjustment
The input of model is the setting value and given total amount of unit time each raw material initial flow, and output is each raw material flow being adjusted
Measure setting value；Adjustment model is the relationship of a ratio, and expression formula is as follows:
K=L/100 (22)
Step 3: in the control layer of bottom raw material flow circuit cement raw mix proportioning Controlling model and derivation algorithm
By the flow setting value for each raw material that the optimization of optimal setting layer is calculated, need to control by bottom circuit
Layer carries out the actual flow setting value of each raw material of tracing control, reaches the actual flow setting value of each raw material or close to raw material
The set target value of flow；Bottom raw material flow circuit control layer includes four kinds of lime stone, clay, Iron Ore Powder, correction material etc.
Raw material flow control loop layer；General execution mechanism is the frequency converter for adjusting control motor speed, and controlled device is driving four
The motor of kind raw material weighing belt；And feedback signal is then the error amount of actual flow and setting flow, generally uses flow sensor
It is detected；Control algolithm is PID control method, specific steps are as follows:
Step (1): the input of cement raw mix proportioning flow PID control method is the inclined of flow setting value and flow actual value
Difference, export by connection control frequency converter frequency variation, in step (1), the size of input flow rate deviation；
Step (2): after calculating by proportional-integral-differential, show that frequency converter adjusts the size of frequency；
Step (3): by adjusting frequency, the revolving speed of weighing belt motor is controlled, flow actual value is steadily decreasing
And the deviation of setting value to keep the actual value of flow and setting value of substantially equal, and guarantees that stablizing for flow exports.
Further, the calculating step of the Sequential Quadratic Programming method is specific as follows:
Step 1: given initial point (x0,μ0,λ0)∈Rn×Rl×Rm, symmetrical positive definite matrix is A0∈Rn×n, calculate as follows
Expression formula:
Parameter η ∈ (0,1/2), ρ ∈ (0,1), 0≤ε of error range1,ε2< 1, enable ki=0；
Step 2: solving one optimal solution d of subproblemk；
Step 3: if | | dk||≤ε1And | | hk||1+||gk||1≤ε2Stop calculating, the approximate solution KT of a former problem can be acquired
=(xk,μk,λk)；
Step 4: for certain cost function φ (x, σ), selecting penalty function σk, so that dkIt is it in functionThe descent direction at place；
Step 5: it is scanned for using Armijo method, reduces objective function sufficiently, mkMeet following inequality
Minimum nonnegative integer m；
It enables
Step 6: calculatingWith least square multiplier；
If AkIt is not row full rank, when calculating least square multiplier, needs the skill using generalized computing, it will be public above
Formula replaces withWhereinIt is Bk+1Penrose-Moore generalized inverse matrix；
Step 7: setting AkCorrection matrix be Ak+1, then:
V in formulak=θkyk+(1-θk)Aksk, parameter θkIt may be defined as:
Step 8: enabling k=k+1, go to step (2).
Further, the optimal control device includes optimization system, control system, monitoring system；
Optimization system controls the minimum mesh of production cost using chemical element content index in raw material finished product as constraint condition
Mark, the flow setting value of various raw materials is calculated with Sequential Quadratic Programming method, and then these raw material flow setting values are transmitted
PID is carried out to bottom raw material flow circuit control layer and adjusts control, i.e., is controlled by controlling the output frequency size of frequency converter
The revolving speed of raw material weighing belt driving motor realizes the actual flow value tracking setting flow value of raw material, completes cement raw mix proportioning
Process；
Control system includes logic control and continuous control, and logic control includes to vertical mill, powder concentrator, belted electronic balance
Etc. equipment start and stop；During logic control, it should be noted that the operating status of various control equipment establishes equipment room start and stop, connection
The logic controls such as lock avoid equipment damage；Continuous control is to control electronics by the output frequency of PID control frequency converter
The real-time flow data variation of each raw material, enables each raw material real-time flow data real-time and accurately to track the setting of raw material on weighing belt
Value；
Monitoring system is that the monitored picture of design is developed with WinCC software, and basic function is to cement raw mix proportioning mistake
The monitoring of technological parameter and equipment running status in journey, including various raw material flow setting values, actual value parameter monitoring, and
The fluid level condition of raw material silo, raw material real-time online tendency chart, the monitoring of alarm system and vertical mill weighing belt motor, powder concentrator
Etc. equipment start and stop；Monitoring system can monitor the entire blending process of control in time, transport whole system more accurately
Row.
Further, the optimization system includes:
Power module uses S7-400PLC power module, and selection is 407-10A model, and power module can only be placed in
The place that leftmost No. 1 slot starts；The power supply for inputting AC220V is converted to DC24V/5V power supply by power module, for controller
CPU module and I/O module and communication module and expansion module use；Since S7-400 controller power supply energy itself is limited,
When having accessed more distribution I/O modules, it is necessary to spare others power modules；
CPU uses S7-400 controller, selection be medium-performance CPU 412-2DP, have in CPU module integrated
MPI/DP and two PROFIBUS-DP master station communication interface；MPI is for connecting computer, CE/operator panel and other S7-300/
400 controllers at most can connect 32 slave stations；PROFIBUS-DP interface for connect distributed ET200 series I/O module,
PG/OP and other DP main websites are at best able to 16 dynamic nodes of connection, operating voltage DC24V；
What Analog input mModule was selected is the SM331 analog input emulation in distributed I/O module ET200M model
Module has programmable diagnosis to interrupt, is electrically isolated with core bus electricity and load voltage, the mould of power rating load voltage DC24V
Block；Analog input mModule mainly converts analog signals into digital signal；Each analog input channel shares an A/D and turns
Parallel operation is usually the direct current that analog input interface can receive different range with multi-analog input module input signal
Pressure and DC current signal；
What analog output module was selected is the SM332 analog output emulation in distributed I/O module ET200M model
Module, loaded load voltage are the module of DC24V；SM332 analog output module has diagnosis middle-end function, uses red LED
Indicate failure, diagnostic alarms message is transmitted in programmable controller CPU by module when mistake occurs；
What digital quantity input module was selected is the SM321 digital quantity input emulation module in ET200M model, nominal load
Module that voltage is DC24V, the module that input current is generally 7mA, rated disspation is 3.5W；Digital quantity input module includes straight
Stream input module and exchange input module, SM321 can from the external digital signal level conversion come in is inputted in controller
The signal level that portion needs；
What digital output module was selected is the SM322 digital output emulation module in ET200M model, nominal load
Voltage is generally the module of 0.5A, rated disspation position 4.9W for the module of DC24V, output electric current；SM322 digital output module
For micro-machine, the loads such as valve driving；Digital output module converts the signal to the level signal needed then conduct
The input signal of other equipment；
Frequency converter model MM440 controls three-phase alternating-current motor speed；MM440 frequency converter has control function, packet
Include linear U/f control, flux current control, without the vector controlled that tests the speed.
Further, the control system carries out cement raw mix proportioning with trapezoidal pattern programming language by STEP7 software
Logic control program and continuous control program are write；
Logic control program be used for equipment start and stop and interlocked control, wherein start-up and shut-down control include vertical mill, powder concentrator,
Feed system belt, lime stone belted electronic balance, clay belted electronic balance, Iron Ore Powder belted electronic balance, correction material electronics
The start-up and shut-down control of the equipment such as weighing belt operates, and interlocked control is sought to when starting or stop some equipment, cannot
It is activated individually or stops some equipment, it is necessary to while starting and stopping relevant several equipment；
Continuous control is the flow control to various raw materials, is exactly that control drives the big of each raw material weighing belt motor speed
It is small；Flow control circuit program includes the flow control circuit of lime stone, clay, Iron Ore Powder, correction material；By controlling belt
Scale motor speed realizes the real-time control to raw material flow size each on weighing belt, is requiring each raw material actual flow stabilization
Error range in；Each raw material flow actual value feeds back to PLC control by close loop control circuit on each donor electron weighing belt
System PID controller input terminal is compared, and obtained flow deviation value is set by PI attitude conirol to track to reach
Constant current magnitude；Due to the motor speed of the belt relationship directly proportional to frequency, the revolving speed size of belt motor can be according to change
The output frequency of frequency device controls.
Further, the monitoring system is to monitor the operating status of various equipment in raw meal proportioning Optimal Control System,
And in blending process related process parameters monitoring, the picture of monitoring system includes the login screen of monitoring system, ingredient work
Skill introduces picture, main window, grinder system interface, equipment running status interface, raw material silo liquid-level interface and in order to guarantee to supervise
The online tendency chart interface of Subscriber Management System, four kinds of raw material actual flow values controlling system interface safety and being arranged.
Compared with prior art, of the invention to have an effect are as follows: to establish and returned by optimal setting layer and bottom raw material flow
Circuit control layer double-layer structure institute compositional optimization control method.Optimal control method can while guaranteeing ingredient product quality,
Keep blending process cost minimum.
Detailed description of the invention
Fig. 1 is optimal control method structure chart of the present invention.
Fig. 2 is pid control circuit block diagram.
Fig. 3 is the structure chart of cement raw mix proportioning optimal control device.
Fig. 4 is each raw material weighing belt Booting sequence figure.
Fig. 5 is that each raw material weighing belt stops flow chart.
Fig. 6 is raw material silo upper limit alarm flow figure.
Specific embodiment
The present invention is described further in the following with reference to the drawings and specific embodiments.
Embodiment
One, the intelligent optimized control method of cement raw mix proportioning process
The structure of cement raw mix proportioning optimal control method includes system optimization setting layer and the control of bottom raw material flow circuit
Two parts of preparative layer form.Optimal setting layer includes raw material Optimized model and adjustment two mathematical models of model, is matched according to raw material
Material process production target requires and technique establishes Optimized model, optimizes calculating using sequential quadratic programming algorithm, obtains each
The optimum proportioning of material quality can carry out relevant adjustment according to adjustment model as a result, if the total amount of feeding changes.
Raw meal proportioning process is to reach optimal proportion as a result, it is desirable to be controlled to adjust by bottom circuit control layer, and bottom
Layer raw material flow circuit control layer is mainly controlled with flow of the PID control method to each raw material on belted electronic balance.
The structure of optimal control method is as shown in Figure 1.
(1) optimal setting layer
1. the effect of optimal setting layer
Optimal setting layer is made of Optimized model and adjustment two parts of model, Optimized model be according to material composition and
Product index requires to be calculated with optimization method, selects one group of optimum proportioning result that the total production cost of raw material can be made to reach
It is minimum.Adjustment model is exactly lime stone, clay, Iron Ore Powder, the proportion of correction material according to the practical feed total amount of raw material, in real time
Property is adjusted the actual flow setting value of every kind of raw material.
2. Optimized model and derivation algorithm
It establishes using production cost as the mathematics objective function of constraint condition:
In formula: the totle drilling cost of each raw material during y-cement raw mix proportioning；
biThe market price of-each raw material；
yiIn-the unit time in blending process each raw material dosage；
The raw materials used species number of n-raw material, takes 4 here.
Chemical component during cement raw mix proportioning in last raw material finished product requires in the error range of calculating, main
The target goals value wanted has CaO, SiO2、Fe2O3、Al2O3Mass percentage, only these index requests, which meet, just can control
In unit time on belted electronic balance each raw material flow, so that the quality of last finished cement is reached production target and want
It asks, and the mass content error range expression formula of each chemical component is as follows in raw material finished product.
C-Δ≤C*≤C+Δ (2)
S*≤S (3)
A*≤A (4)
F*≤F (5)
L*≤L (6)
In formula: C*The actual content value of-CaO in finished cement；
S*—SiO2Actual content value in finished cement；
A*—Al2O3Actual content value in finished cement；
F*—Fe2O3Actual content value in finished cement；
L*The actual ratio value of basicity in-raw material finished product；
Δ-chemical component actual content value and target set point deviation, generally takes ± 0.5.
Need to be converted into constraint condition function the general table of General constrained optimization problem before with Sequential Quadratic Programming method
Up to form:
C*≥C-Δ (7)
-C*≥-C-Δ (8)
-S*≥-S (9)
-A*≥-A (10)
-F*≥-F (11)
-L*≥-L (12)
After model foundation, established mathematical model is converted into General constrained optimization problem expression-form, with sequence
Column quadratic programming optimizes calculating, and it is specific as follows that sequential quadratic programming method calculates step:
Step 1: given initial point (x0,μ0,λ0)∈Rn×Rl×Rm, symmetrical positive definite matrix is A0∈Rn×n, calculate as follows
Expression formula:
Parameter η ∈ (0,1/2), ρ ∈ (0,1), 0≤ε of error range1,ε2< 1, enable ki=0；
Step 2: solving one optimal solution d of subproblemk；
Step 3: if | | dk||≤ε1And | | hk||1+||gk||1≤ε2Stop calculating, the approximate solution KT of a former problem can be acquired
=(xk,μk,λk)；
Step 4: for certain cost function φ (x, σ), selecting penalty function σk, so that dkIt is it in functionThe descent direction at place；
Step 5: it is scanned for using Armijo method, reduces objective function sufficiently, mkMeet following inequality
Minimum nonnegative integer m；
It enables
Step 6: calculatingWith least square multiplier；
If AkIt is not row full rank, when calculating least square multiplier, needs the skill using generalized computing, it will be public above
Formula replaces withWhereinIt is Bk+1Penrose-Moore generalized inverse matrix；
Step 7: setting AkCorrection matrix be Ak+1, then:
V in formulak=θkyk+(1-θk)Aksk, parameter θkIt may be defined as:
Step 8: enabling k=k+1, go to step (2).
3. adjusting model
Adjusting model major function is to give the dosage total amount of raw material according to designer to carry out the variation of related ratio, is adjusted
The input of integral mould has the setting value and given total amount of unit time each raw material initial flow, and output is each raw material being adjusted
Flow setting value.Adjustment model is the relationship of a ratio, and expression formula is as follows:
K=L/100 (22)
(2) circuit control layer
By the flow setting value for each raw material that the optimization of optimal setting layer is calculated, need to control by bottom circuit
Layer carries out the actual flow setting value of each raw material of tracing control, reaches the actual flow setting value of each raw material or close to raw material
The set target value of flow.Raw material control loop layer includes four kinds of raw material flows such as lime stone, clay, Iron Ore Powder, correction material
Control loop layer.General execution mechanism is the frequency converter for adjusting control motor speed, and controlled device is four kinds of raw material skins of driving
The motor of belt scale.And feedback signal is then the error amount of actual flow and setting flow, is generally detected with flow sensor.
Control algolithm is PID control method, specific steps are as follows:
Step (1): the input of cement raw mix proportioning flow PID control method is the inclined of flow setting value and flow actual value
Difference, export by connection control frequency converter frequency variation, in step (1), the size of input flow rate deviation；
Step (2): after calculating by proportional-integral-differential, show that frequency converter adjusts the size of frequency；
Step (3): by adjusting frequency, the revolving speed of weighing belt motor is controlled, flow actual value is steadily decreasing
And the deviation of setting value to keep the actual value of flow and setting value of substantially equal, and guarantees that stablizing for flow exports.
The basic functional principle of flow control circuit is the flow setting value and flow detection that optimal setting layer calculates
The actual flow that device detected is compared the output valve for showing that deviation passes through PID controller adjustment, as frequency converter
Input value change its frequency, change the revolving speed of the control motor of belted electronic balance by the variation of frequency converter.
PID control block diagram in flow control is as shown in Figure 2.
Two, intelligent optimal control device
The optimal control device of cement raw mix proportioning process is as shown in Figure 3.Optimal control device mainly include optimization system,
Three control system, monitoring system parts.
Optimization system controls the minimum mesh of production cost using chemical element content index in raw material finished product as constraint condition
Mark, the flow setting value of various raw materials is calculated with Sequential Quadratic Programming method, and then these raw material flow setting values are transmitted
PID is carried out to bottom circuit and adjusts control, i.e., the driving of raw material weighing belt is controlled by controlling the output frequency size of frequency converter
The revolving speed of motor realizes the actual flow value tracking setting flow value of raw material, completes cement raw mix proportioning process.
Control system mainly includes logic control and continuous control, and logic control mainly includes to vertical mill, powder concentrator, electricity
The start and stop of the equipment such as sub- weighing belt.During logic control, it should be noted that the operating status of various control equipment establishes equipment room
The logic controls such as start and stop, interlocking avoid equipment damage.Continuous control is mainly the output frequency for passing through PID control frequency converter
Change to control the real-time flow data of each raw material on belted electronic balance, each raw material real-time flow data is enable real-time and accurately to track
The setting value of raw material.
Monitoring system is mainly that the monitored picture of design is developed with WinCC software, and basic function is matched to cement slurry
The monitoring of technological parameter and equipment running status during material mainly includes various raw material flow setting values, practical value parameter
The fluid level condition of monitoring and raw material silo, raw material real-time online tendency chart, the monitoring of alarm system and vertical mill weighing belt electricity
The start and stop of the equipment such as machine, powder concentrator.Monitoring system can monitor the entire blending process of control in time, keep whole system more accurate
Errorless operation.
The hardware design of control device
1. power module uses S7-400PLC power module, selection is 407-10A model, and power module can only be placed
In the place that leftmost No. 1 slot starts.The power supply for inputting AC220V can be converted to DC24V/5V power supply by power module, be supplied
Controller CPU module and I/O module and communication module and expansion module use.Due to S7-400 controller power supply energy itself
Measure it is limited, when having accessed more distribution I/O modules, it is necessary to spare others power modules.
2.CPU uses S7-400 controller, selection be medium-performance CPU 412-2DP, have in CPU module integrated
MPI/DP and two PROFIBUS-DP master station communication interface.MPI can connect computer, CE/operator panel and other S7-300/
400 controllers at most can connect 32 slave stations.PROFIBUS-DP interface can connect distributed ET200 series I/O module,
PG/OP (programmable device/CE/operator panel) and other DP main websites are at best able to 16 dynamic nodes of connection, operating voltage DC24V.
3. what Analog input mModule was selected is that SM331 analog input in distributed I/O module ET200M model is imitative
True module has programmable diagnosis to interrupt, is electrically isolated with core bus electricity and load voltage, power rating load voltage DC24V's
Module.Analog input mModule mainly says that analog signal is converted to digital signal.Each analog input channel shares an A/D
Converter is usually the direct current that analog input interface can receive different range with multi-analog input module input signal
Voltage and DC current signal.
4. what analog output module was selected is that SM332 analog output in distributed I/O module ET200M model is imitative
True module, loaded load voltage are the module of DC24V.SM332 analog output module has diagnosis middle-end function, with red
LED indication failure, diagnostic alarms message is transmitted in programmable controller CPU by module when mistake occurs.
5. what digital quantity input module was selected is the SM321 digital quantity input emulation module in ET200M model, specified negative
Carry the module that voltage is DC24V, the module that input current is generally 7mA, rated disspation is 3.5W.Digital quantity input module is main
Including direct current input module with exchange input module, SM321 can be the external digital signal level conversion come in from input at control
The signal level needed inside device processed.
6. what digital output module was selected is the SM322 digital output emulation module in ET200M model, specified negative
Carry the module that voltage is generally 0.5A, rated disspation position 4.9W for the module of DC24V, output electric current.SM322 digital output mould
Block is mainly used for micro-machine, the loads such as valve driving.It is right that digital output module converts the signal to the level signal needed
Afterwards as the input signal of other equipment.
7. frequency converter selects model MM440 to control three-phase alternating-current motor speed.MM440 frequency converter has many complete
It is apt to powerful control function, including linear U/f control, flux current control, without the vector controlled etc. that tests the speed.
The software design of control device
Cement raw mix proportioning logic control program and continuous control are carried out with trapezoidal pattern programming language by STEP7 software
Program is write.
1. logic control program designs
The start and stop and interlocked control of equipment of logic control program major embodiment, wherein start-up and shut-down control mainly includes Vertical Mill
Machine, powder concentrator, feed system belt, lime stone belted electronic balance, clay belted electronic balance, Iron Ore Powder belted electronic balance, correction
The start-up and shut-down control of the equipment such as the belted electronic balance of raw material operates, and interlocked control is sought to starting or stop certain each equipment
When, it cannot be activated individually or stop some equipment, it is necessary to while starting and stopping relevant several equipment.
Need to carry out logic control mainly in the present invention include each donor electron weighing belt start and stop and the material bin upper limit
Process controls, the start and stop of equipment such as position alarm are not the start and stop of subjective consciousness, and the start and stop of donor electron weighing belt are mainly deferred to suitable
The principle of sequence start and stop.Such as when starting the belted electronic balance of four kinds of raw materials, it would be desirable to whether determine raw material silo first
Whether upper limit, frequency converter work normally, and after the equipment such as starting vertical mill, powder concentrator, feed system, could start four kinds of raw materials
The starting motor of belted electronic balance will result in feed system belt and feed again to vertical mill if the sequencing not started
Feeding is uneven during material, influences vertical mill to the crushing efficiency of raw material, is more likely to accelerate the damaged condition to equipment,
During stopping be also same reason need first to stop donor electron weighing belt, finally successively stop vertical mill, powder concentrator,
The equipment such as feed system.Each equipment starting after need to pay attention to constantly raw material silo liquid level variation, ingredient Parameters variation and
The problems such as whether each equipment breaks down timely finds handling failure, the operating condition of adjusting device.Various equipment open
Stop program to be designed in accordance with these principles respectively, the start and stop program flow diagram of donor electron weighing belt is respectively such as Fig. 4 and Fig. 5 institute
Show.
After the alarm of 1 upper limit of raw material silo, need to stop immediately first the operation of powder concentrator, close raw material silo not into
Material.Then vertical mill, feed system and raw material weighing belt are successively closed, until opening spare 2 Transfer pipe of raw material silo, then
The production equipment for successively starting entire control system carries out the ingredient of raw material.It can also be by manually mode in monitored picture
Upper carry out start stop operation, start and stop program are as shown in Figure 6.
2. continuous control programming
Continuous control is the flow control to various raw materials, is after all exactly that control drives each raw material weighing belt motor to turn
The size of speed.Flow control circuit program includes the flow control circuit of lime stone, clay, Iron Ore Powder, correction material.Pass through control
Weighing belt motor speed processed realizes the real-time control to raw material flow size each on weighing belt, stablizes each raw material actual flow
In desired error range.Each raw material flow actual value is fed back to by close loop control circuit on each donor electron weighing belt
PLC control system PID controller input terminal is compared, and obtained flow deviation value is tracked by PI attitude conirol
Reach setting flow value.Due to the motor speed of the belt relationship directly proportional to frequency, the revolving speed size of belt motor can
It is controlled according to the output frequency of frequency converter.
The setting method of pid parameter is that I and D are first set to zero, then adjusts the size of proportionality coefficient (KP), disturbance is allowed to believe
Number make Spline smoothing, then keep proportionality coefficient constant, adjusts the size of differential coefficient (TI), manipulated signal is made to make step change
Change, observes waveform overshoot and regulating time.If overshoot is too big, by repeatedly adjust waveform still it is stable do not get off or
Oscillation answers reduction controller proportionality coefficient (KP) appropriate and increases the time of integration (TI).If waveform does not generate needs
The overshoot too slow or stable time that perhaps waveform rises is long, when Ying Zeng great controller proportionality coefficient (KP) and reduction integrate
Between (TI).It is appropriate to reduce the time of integration (TI) if the time that the deviation that controller generates is eliminated is too long, enhance integral action.
3. the Supervisory Control Drawings Design of optimal control device
Monitored picture major function is to monitor the operating status of various equipment in raw meal proportioning Optimal Control System, Yi Jipei
The monitoring of related process parameters during material uses the software of data acquisition monitoring system in the design of monitoring system picture
Platform WinCC is developed, and the login screen including monitoring system, proportioning process introduces picture, main window, grinder system circle
Face, equipment running status interface, raw material silo liquid-level interface and the user's pipe being arranged to guarantee monitoring system picture safety
The online tendency chart interface of reason system, four kinds of raw material actual flow values.
Claims (6)
1. the intelligent optimal control device and its control method of cement raw mix proportioning process, it is characterised in that: cement raw mix proportioning
The structure of optimal control method includes system optimization setting layer and bottom raw material flow circuit control layer, and optimal setting layer includes life
Expect Optimized model and adjustment model, is required according to raw meal proportioning process production target and technique establishes Optimized model, utilize sequence
Novel Algorithm optimizes calculating, obtains the optimum proportioning of each material quality as a result, if the total amount of feeding changes,
Relevant adjustment can be carried out according to adjustment model；Raw meal proportioning process matches to reach optimal as a result, it is desirable to the bottom of by
Layer circuit control layer is controlled to adjust, and bottom raw material flow circuit control layer with PID control method to electronic belt
The flow of each raw material on scale is controlled；Specifically includes the following steps:
Step 1: in optimal setting layer cement raw mix proportioning Optimized model and derivation algorithm
1.1 establish using production cost as the mathematics objective function of constraint condition:
In formula: the totle drilling cost of each raw material during y-cement raw mix proportioning；
biThe market price of-each raw material；
yiIn-the unit time in blending process each raw material dosage；
The raw materials used species number of n-raw material, takes 4 here；
1.2 chemical component during cement raw mix proportioning in last raw material finished product requires in the error range of calculating, raw
Expect that the mass content error range expression formula of each chemical component in finished product is as follows:
C-Δ≤C*≤C+Δ (2)
S*≤S (3)
A*≤A (4)
F*≤F (5)
L*≤L (6)
In formula: C*The actual content value of-CaO in finished cement；
S*—SiO2Actual content value in finished cement；
A*—Al2O3Actual content value in finished cement；
F*—Fe2O3Actual content value in finished cement；
L*The actual ratio value of basicity in-raw material finished product；
Δ-chemical component actual content value and target set point deviation, generally takes ± 0.5；
1.3 need to be converted into constraint condition function before with Sequential Quadratic Programming method the general table of General constrained optimization problem
Up to form:
C*≥C-Δ (7)
-C*≥-C-Δ (8)
-S*≥-S (9)
-A*≥-A (10)
-F*≥-F (11)
-L*≥-L (12)
After model foundation, established mathematical model is converted into General constrained optimization problem expression-form, with sequence two
Secondary law of planning optimizes calculating,
Step 2: in optimal setting layer cement raw mix proportioning adjustment model and derivation algorithm
The function of adjustment model is to give the dosage total amount of raw material according to designer to carry out the variation of related ratio, adjusts model
Input be unit time each raw material initial flow setting value and given total amount, output is that each raw material flow being adjusted is set
Definite value；Adjustment model is the relationship of a ratio, and expression formula is as follows:
K=L/100 (22)
Step 3: in the control layer of bottom raw material flow circuit cement raw mix proportioning Controlling model and derivation algorithm
By the flow setting value for each raw material that the optimization of optimal setting layer is calculated, need by bottom circuit control layer into
Line trace controls the actual flow setting value of each raw material, reaches the actual flow setting value of each raw material or close to raw material flow
Set target value；Bottom raw material flow circuit control layer includes four kinds of raw materials such as lime stone, clay, Iron Ore Powder, correction material
Flow control circuit layer；General execution mechanism is the frequency converter for adjusting control motor speed, and controlled device is four kinds of originals of driving
Expect the motor of weighing belt；And feedback signal is then the error amount of actual flow and setting flow, is generally carried out with flow sensor
Detection；Control algolithm is PID control method, specific steps are as follows:
Step (1): the input of cement raw mix proportioning flow PID control method is the deviation of flow setting value and flow actual value,
Output for connection control frequency converter frequency variation, in step (1), the size of input flow rate deviation；
Step (2): after calculating by proportional-integral-differential, show that frequency converter adjusts the size of frequency；
Step (3): by adjusting frequency, the revolving speed of weighing belt motor is controlled, flow actual value is steadily decreasing and sets
The deviation of definite value to keep the actual value of flow and setting value of substantially equal, and guarantees that stablizing for flow exports.
2. the intelligent optimal control device and its control method of cement raw mix proportioning process according to claim 1, special
Sign is: the calculating step of the Sequential Quadratic Programming method is specific as follows:
Step 1: given initial point (x0,μ0,λ0)∈Rn×Rl×Rm, symmetrical positive definite matrix is A0∈Rn×n, calculate following expression
Formula:
Parameter η ∈ (0,1/2), ρ ∈ (0,1), 0≤ε of error range1,ε2< 1, enable ki=0；
Step 2: solving one optimal solution d of subproblemk；
Step 3: if | | dk||≤ε1And | | hk||1+||gk||1≤ε2Stop calculating, the approximate solution KT=(x of a former problem can be acquiredk,
μk,λk)；
Step 4: for certain cost function φ (x, σ), selecting penalty function σk, so that dkIt is it in functionThe descent direction at place；
Step 5: it is scanned for using Armijo method, reduces objective function sufficiently, mkBe meet following inequality minimum it is non-
Negative integer m；
It enables
Step 6: calculatingWith least square multiplier；
If AkIt is not row full rank, when calculating least square multiplier, needs the skill using generalized computing, will replace formula above
It is changed toWhereinIt is Bk+1Penrose-Moore generalized inverse matrix；
Step 7: setting AkCorrection matrix be Ak+1, then:
V in formulak=θkyk+(1-θk)Aksk, parameter θkIt may be defined as:
Step 8: enabling k=k+1, go to step (2).
3. the intelligent optimal control device and its control method of cement raw mix proportioning process according to claim 1, special
Sign is: the optimal control device includes optimization system, control system, monitoring system；
Optimization system controls the minimum target of production cost, fortune using chemical element content index in raw material finished product as constraint condition
The flow setting value of various raw materials is calculated with Sequential Quadratic Programming method, these raw material flow setting values are then sent to bottom
Raw material flow circuit control layer carries out PID and adjusts control, i.e., controls raw material skin by controlling the output frequency size of frequency converter
The revolving speed of belt scale driving motor realizes the actual flow value tracking setting flow value of raw material, completes cement raw mix proportioning process；
Control system includes logic control and continuous control, and logic control includes setting to vertical mill, powder concentrator, belted electronic balance etc.
Standby start and stop；During logic control, it should be noted that the operating status of various control equipment establishes equipment room start and stop, interlocking etc.
Logic control avoids equipment damage；Continuous control is to control electronic belt by the output frequency of PID control frequency converter
The real-time flow data variation of each raw material, enables each raw material real-time flow data real-time and accurately to track the setting value of raw material on scale；
Monitoring system is that the monitored picture of design is developed with WinCC software, and basic function is to during cement raw mix proportioning
The monitoring of technological parameter and equipment running status, including various raw material flow setting values, actual value parameter monitoring and raw material
The fluid level condition in storehouse, raw material real-time online tendency chart, the monitoring of alarm system and vertical mill weighing belt motor, powder concentrator etc. are set
Standby start and stop；Monitoring system can monitor the entire blending process of control in time, run whole system more accurately.
4. the intelligent optimal control device and its control method of cement raw mix proportioning process according to claim 3, special
Sign is: the optimization system includes:
Power module uses S7-400 PLC power module, and selection is 407-10A model, and power module can only be placed in most left
The place that No. 1 slot on side starts；The power supply for inputting AC220V is converted to DC24V/5V power supply by power module, for controller CPU
Module and I/O module and communication module and expansion module use；Since S7-400 controller power supply energy itself is limited, when
More distribution I/O modules are accessed, it is necessary to spare others power module；
CPU uses S7-400 controller, selection be medium-performance CPU 412-2DP, have integrated MPI/DP in CPU module
With two PROFIBUS-DP master station communication interfaces；MPI is for connecting computer, CE/operator panel and other S7-300/400 control
Device processed at most can connect 32 slave stations；PROFIBUS-DP interface is for connecting distributed ET200 series I/O module, PG/OP
With other DP main websites, it is at best able to 16 dynamic nodes of connection, operating voltage DC24V；
What Analog input mModule was selected is the SM331 analog input emulation module in distributed I/O module ET200M model,
There is programmable diagnosis to interrupt, is electrically isolated with core bus electricity and load voltage, the module of power rating load voltage DC24V；Mould
Analog quantity input module mainly converts analog signals into digital signal；Each analog input channel shares an A/D converter,
With multi-analog input module input signal be usually analog input interface can receive different range DC voltage and
DC current signal；
What analog output module was selected is the SM332 analog output emulation module in distributed I/O module ET200M model,
Loaded load voltage is the module of DC24V；SM332 analog output module has diagnosis middle-end function, indicates event with red LED
Barrier, diagnostic alarms message is transmitted in programmable controller CPU by module when mistake occurs；
What digital quantity input module was selected is the SM321 digital quantity input emulation module in ET200M model, loaded load voltage
7mA is generally for the module of DC24V, input current, the module that rated disspation is 3.5W；Digital quantity input module includes that direct current is defeated
Enter module with exchange input module, SM321 can be the external digital signal level conversion come in from input at needing inside controller
The signal level wanted；
What digital output module was selected is the SM322 digital output emulation module in ET200M model, loaded load voltage
The module of 0.5A, rated disspation position 4.9W are generally for the module of DC24V, output electric current；SM322 digital output module is used for
Micro-machine, the loads such as valve driving；Digital output module converts the signal to the level signal needed and is then used as other
The input signal of equipment；
Frequency converter model MM440 controls three-phase alternating-current motor speed；MM440 frequency converter has control function, including line
Property U/f control, flux current control, without testing the speed vector controlled.
5. the intelligent optimal control device and its control method of cement raw mix proportioning process according to claim 3, special
Sign is: the control system carries out cement raw mix proportioning logic control journey with trapezoidal pattern programming language by STEP7 software
Sequence and continuous control program are write；
Logic control program is used for the start and stop and interlocked control of equipment, and wherein start-up and shut-down control includes vertical mill, powder concentrator, feeding
System belt, lime stone belted electronic balance, clay belted electronic balance, Iron Ore Powder belted electronic balance, correction material electronic belt
The start-up and shut-down control of the equipment such as scale operates, and interlocked control is sought to when starting or stop some equipment, cannot be independent
Start or stop some equipment, it is necessary to while starting and stopping relevant several equipment；
Continuous control is the flow control to various raw materials, is exactly the size that control drives each raw material weighing belt motor speed；Stream
Amount control loop program includes the flow control circuit of lime stone, clay, Iron Ore Powder, correction material；Pass through control weighing belt electricity
Machine revolving speed realizes the real-time control to raw material flow size each on weighing belt, stablizes each raw material actual flow in desired mistake
In poor range；Each raw material flow actual value feeds back to PLC control system by close loop control circuit on each donor electron weighing belt
PID controller input terminal is compared, and obtained flow deviation value is tracked by PI attitude conirol reaches setting stream
Magnitude；Due to the motor speed of the belt relationship directly proportional to frequency, the revolving speed size of belt motor can be according to frequency converter
Output frequency control.
6. the intelligent optimal control device and its control method of cement raw mix proportioning process according to claim 3, special
Sign is: the monitoring system is to monitor the operating status and ingredient mistake of various equipment in raw meal proportioning Optimal Control System
The monitoring of related process parameters in journey, the picture of monitoring system include the login screen of monitoring system, proportioning process introduce picture,
Main window, grinder system interface, equipment running status interface, raw material silo liquid-level interface and in order to guarantee monitoring system picture
Safety and the online tendency chart interface of Subscriber Management System, four kinds of raw material actual flow values being arranged.
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