CN110270442B - Automatic monitoring control system of hydrocyclone - Google Patents
Automatic monitoring control system of hydrocyclone Download PDFInfo
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- CN110270442B CN110270442B CN201910580350.2A CN201910580350A CN110270442B CN 110270442 B CN110270442 B CN 110270442B CN 201910580350 A CN201910580350 A CN 201910580350A CN 110270442 B CN110270442 B CN 110270442B
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Abstract
The invention provides an automatic monitoring control system of a hydrocyclone, comprising: the system comprises a main control module, a measuring module, a data conversion and storage module, an electric signal processing module, an adjusting module, a display module, a voice alarm module, an emergency braking module and a hydrocyclone matching device; the main control module is respectively connected with the data conversion and storage module, the voice alarm module, the display module and the adjustment module; the data conversion and storage module is connected with the measuring module, the measuring module is connected with the hydraulic cyclone corollary equipment, the adjusting module is connected with the emergency braking module, the emergency braking module is connected with the electric signal processing module, the scattering angle of the hydraulic cyclone is measured in real time, the working state of the hydraulic cyclone is reflected, and the operation parameters of the hydraulic cyclone are adjusted by using an optimization algorithm when the hydraulic cyclone works abnormally, so that the automatic monitoring of the hydraulic cyclone is realized, the influence of working condition fluctuation on the separation performance of the hydraulic cyclone is reduced, the working stability of the hydraulic cyclone is enhanced, and the automatic control level of a grading system is improved.
Description
Technical Field
The invention relates to the technical field of application and automatic control of a hydrocyclone, in particular to an automatic monitoring and controlling system of the hydrocyclone.
Background
The hydrocyclone is a high-efficiency separation device for separating mixtures with different densities and different particle sizes by using a centrifugal force field, can also be used for classification, desliming, concentration, clarification, sorting and washing, and has the advantages of simple structure, convenience in operation, no rotating parts, small floor area, large treatment capacity, high separation efficiency and the like. Therefore, the hydrocyclone has wide application in the separation fields of mineral processing, bioengineering, environmental protection, chemical engineering, medicament production and the like.
The separation performance of a hydrocyclone is determined by structural parameters, operational parameters and physical parameters. Generally, the structural parameters of the hydrocyclone are predetermined by the model selection design and remain substantially unchanged, and therefore the separation performance of the hydrocyclone is mainly related to the operating parameters and the physical properties. Wherein, the operation parameters mainly comprise concentration, treatment capacity and pressure, and the physical parameters mainly refer to the density and the granularity composition of the treated materials. In actual production engineering, the feed concentration and physical parameters usually fluctuate with the change of ore characteristics or the working state of the mill, and the separation performance and subsequent operation of the hydrocyclone are seriously affected. At present, the evaluation of the working state of the hydrocyclone is mainly judged by manually sampling, drying and testing the feed and the products respectively and then calculating corresponding indexes, and the problems of severe field working conditions, long detection period, asynchronous detection results and actual working conditions and the like exist. Therefore, the conventional assessment method cannot realize real-time monitoring and control of the hydrocyclone.
In recent years, researchers at home and abroad find that the shape of the underflow discharge of the hydrocyclone is closely related to parameters such as feed concentration, pressure, material granularity composition and the like, and the working state of the hydrocyclone can be reflected to a certain extent. In addition, with the popularization and development of a test technology and a single chip microcomputer control technology, the working state of the hydrocyclone is jointly judged by monitoring the operating parameters of the hydrocyclone and the underflow discharge condition in real time and correspondingly adjusted according to a database and an optimization algorithm, so that the possibility is provided for the automatic monitoring control of the hydrocyclone.
Disclosure of Invention
According to the technical problems provided by the invention, an intelligent, efficient, safe and stable automatic monitoring and control system for the hydrocyclone is provided. The invention mainly utilizes the principle of ultrasonic distance measurement to monitor the ore pulp scattering angle at the sand setting port of the hydrocyclone in real time, thereby overcoming the technical problem of monitoring the working state of the hydrocyclone in real time; the main control module, the data conversion and storage module, the display module, the voice alarm module, the emergency braking module, the adjusting module and the electric signal processing module are integrated in the single chip microcomputer, the working state of the hydrocyclone is analyzed and predicted, an adjusting scheme is provided for various abnormal conditions, parameters of the hydrocyclone are guaranteed to be timely restored to a normal range, and then the automatic control level and the working efficiency of the hydrocyclone are improved.
The technical means adopted by the invention are as follows:
an automated monitor and control system for a hydrocyclone comprising: the system comprises a main control module, a measuring module, a data conversion and storage module, an electric signal processing module, an adjusting module, a display module, a voice alarm module, an emergency braking module and a hydrocyclone matching device; the main control module is respectively connected with the data conversion and storage module, the voice alarm module, the display module and the adjustment module; the data conversion and storage module is connected with the measuring module, the measuring module is connected with the matching equipment of the hydrocyclone, the adjusting module is connected with the emergency braking module, and the emergency braking module is connected with the electric signal processing module.
Furthermore, the hydrocyclone complete equipment comprises a pump pool, a feeding pump, a hydrocyclone, a pressure detection element, a water storage pool, a water supply valve, a flow detection element and an ultrasonic distance measurement element, the hydrocyclone is small-sized equipment in a laboratory or large-sized equipment on site, the feeding pump is a variable frequency pump, the pressure detection element is installed on an inlet pipeline of the hydrocyclone and used for monitoring the inlet pressure of the hydrocyclone, the water supply valve is used for controlling the added water amount, and the flow detection element is used for measuring the added water amount.
Furthermore, the ultrasonic distance measuring elements are symmetrically arranged on two sides of the lower part of the sand settling opening of the hydrocyclone, and the ultrasonic emission direction is perpendicular to the axis of the hydrocyclone.
Furthermore, a scattering angle, a hydraulic cyclone working state database and a preset intelligent algorithm are arranged in the main control module, the working state of the hydraulic cyclone is analyzed by receiving data transmitted by the data conversion and storage module, the display module is controlled to display the working state and working parameters of the system, the automatic adjustment module is controlled to perform distributed regulation and control on the frequency of the feeding pump and the water replenishing flow, and the voice alarm module is controlled to give an alarm in real time on abnormal working states.
Furthermore, the measuring module is connected with the flow detecting element, the pressure detecting element and the ultrasonic distance measuring element, and packages and uploads real-time acquired data to the data conversion and storage module.
Furthermore, an optimization algorithm is arranged in the data conversion and storage module, and the distance value measured by the ultrasonic ranging element is converted into a scattering angle value and is transmitted to the main control module.
Furthermore, the adjusting module is divided into an automatic adjusting module and a manual adjusting module, and when the system is in an adjustable state, the automatic adjusting module performs step-by-step optimized adjustment on the frequency of the feeding pump and the supplemented water flow rate by controlling the electric signal processing module; when the system is in an unadjustable state, the automatic adjusting module carries out emergency treatment on the feeding pump machine and the water replenishing valve and automatically switches to the manual adjusting module.
Furthermore, the electric signal processing module is used for converting the numerical value signal into an electric signal, and is controlled by the adjusting module and used for regulating and controlling the frequency of the feeding pump and supplementing water flow; the emergency braking module may be triggered in case of an emergency.
Furthermore, the display module is used for displaying the working parameters and the states of all the devices in the system in real time; the voice alarm module is used for carrying out voice alarm prompt when the hydraulic cyclone is in a non-adjustable working state; and the emergency braking module is used for carrying out emergency braking on the pump and the supplemented water.
Compared with the prior art, the invention has the following advantages:
1. the automatic monitoring control system of the hydrocyclone provided by the invention adopts a method of combining the real-time monitoring of the underflow discharge condition of the hydrocyclone with the conventional monitoring data, more accurately and timely reflects the working state of the hydrocyclone, and lays a foundation for the regulation and control of the hydrocyclone;
2. the automatic monitoring control system of the hydrocyclone provided by the invention adopts the principle of ultrasonic distance measurement, converts the measured distance into a scattering angle, synchronously reflects the underflow discharge condition of the hydrocyclone, and simultaneously reduces the system measurement error due to the symmetrical arrangement of the ultrasonic distance measurement devices;
3. the automatic monitoring control system of the hydrocyclone fully considers various working states of the hydrocyclone, including an unloaded state, an underloaded state, a normal state, a full-load state, an overload state, a blocked state and a completely blocked state;
4. according to the automatic monitoring control system of the hydrocyclone, the automatic adjusting module and the electric signal processing module convert the numerical signals into the electric signals to adjust the frequency of the pump and the flow of the automatic water control valve. The frequency of a feeding pump is preferably initialized to complete the regulation and control of feeding pressure, and the supplemented water amount is regulated according to the working state of the hydrocyclone, so that the hydrocyclone is in a normal working state in real time, multi-factor step-by-step control is realized, and the stability of the system is improved;
5. the automatic monitoring control system of the hydrocyclone provided by the invention is provided with the display module and the voice alarm module, and the working state of the hydrocyclone is monitored in real time by combining vision and hearing, so that man-machine combination is effectively realized; when the hydraulic cyclone is in an unadjustable working state, the system automatically triggers the emergency braking module and simultaneously triggers the voice alarm module, so that production accidents are avoided;
in conclusion, the technical scheme of the invention solves the problems that the working state of the hydrocyclone can not be monitored in real time, the stability is caused by simultaneous control of multiple factors and the like in the conventional hydrocyclone automatic control system, and meanwhile, the system has high automation degree and convenient operation, and can fully improve the separation performance of the hydrocyclone.
Based on the reasons, the invention can be widely popularized in the fields of application of the hydraulic cyclone, automatic control of the hydraulic cyclone and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic diagram of the system of the present invention.
Fig. 2 is a schematic diagram of the calculation of the scattering angle in the data conversion and storage module according to the embodiment of the present invention.
Fig. 3 is a flowchart illustrating the main control module determining the operating state of the hydrocyclone according to the embodiment of the present invention.
Fig. 4 is a flowchart of an adjusting module according to an embodiment of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. Any specific values in all examples shown and discussed herein are to be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
The design principle of the invention is as follows: aiming at the important influence of the operation parameters and physical property parameters on the separation performance of the hydrocyclone and solving the problem that a control system cannot monitor and adjust the working state of the hydrocyclone in real time, the invention measures the bottom flow scattering shape parameters of the hydrocyclone by an ultrasonic distance measurement method, and simultaneously combines conventional monitoring parameters such as supplemented water quantity, pump frequency, pressure and the like, thereby realizing the purpose of monitoring the working state of the hydrocyclone in real time, enhancing the man-machine interaction by a display module and a voice alarm module and ensuring the safe production. Automatic and manual adjustment options are provided for different working states simultaneously by utilizing a built-in database and an optimization algorithm, wherein the automatic adjustment options sequentially adjust the pump frequency and the water replenishing amount, multi-factor step-by-step control is realized, and the stability of a control system is improved. In addition, the data conversion and storage module can be used for analyzing and forecasting the parameter change trend in a normal state in real time by matching with the main control system, so that the intelligent prediction and optimization of the working state of the hydrocyclone are realized.
Example 1
As shown in fig. 1, the present invention provides an automatic monitoring and control system for a hydrocyclone, comprising: the system comprises a main control module, a measuring module, a data conversion and storage module, an electric signal processing module, an adjusting module, a display module, a voice alarm module, an emergency braking module and a hydrocyclone matching device; the main control module is respectively connected with the data conversion and storage module, the voice alarm module, the display module and the adjustment module; the data conversion and storage module is connected with the measuring module, the measuring module is connected with the matching equipment of the hydrocyclone, the adjusting module is connected with the emergency braking module, and the emergency braking module is connected with the electric signal processing module.
The hydrocyclone corollary equipment comprises a pump pool, a feeding pump, a hydrocyclone, a pressure detection element, a water storage pool, a water supply valve, a flow detection element and an ultrasonic distance measurement element, the hydrocyclone provided in the embodiment is small-sized laboratory equipment or large-sized field equipment, the feeding pump is a variable frequency pump, the pressure detection element is installed on an inlet pipeline of the hydrocyclone and used for monitoring the inlet pressure of the hydrocyclone, the water supply valve is used for controlling the water addition amount, and the flow detection element is used for measuring the water addition amount. In this embodiment, as shown in fig. 1, the water storage tank adjusts the amount of the supplementary water fed into the pump tank through a water feed valve, and measures the amount of the supplementary water through a flow monitoring element; the feeding pump conveys the materials in the pump pool to the hydrocyclone, and a pressure detection element is arranged at the inlet of the hydrocyclone; the materials are classified by a hydrocyclone and then are respectively discharged from an overflow pipe and a sand setting port, and are sprayed in an umbrella shape or a rope shape at the sand setting port; as shown in fig. 2, two ultrasonic distance measuring elements are mounted at symmetrical positions with the distance of the lower part of the sand setting port being c and the distance of the axis of the hydrocyclone being a, and the jet range of the underflow is measured.
As shown in fig. 1, in this embodiment, the measurement module collects data such as supplemented water flow, feeding pressure, feeding pump frequency, and ultrasonic distance measurement in real time, and uploads the data to the data conversion and storage module, and the data conversion and storage module is responsible for converting and storing ultrasonic distance measurement data, supplemented water flow data, and feeding pump frequency data transmitted by the measurement module, and converts the distance measured by the ultrasonic element into an angle through a built-in algorithm. As shown in fig. 2, the data conversion and storage module obtains the average value b of the distances from the measurement module, and the judgment and calculation processes are as follows:
when b is less than or equal to a-0.5d, the composition is prepared from
Is calculated to
The bottom flow is umbrella-shaped injection;
when a-0.5d is more than b and less than a, making alpha equal to 0, and indicating that the underflow is in a rope-shaped jet;
when b > a, let α be-1, indicating that no underflow is discharged.
Example 2
As shown in fig. 3, the data conversion and storage module transmits the processed data to the main control module. The main control module is a core part of the system, analyzes the working state of the hydrocyclone by receiving data transmitted by the data conversion and storage module, controls the display module to display the working state and working parameters of the system, controls the automatic adjustment module to perform distribution regulation and control on the frequency of the feeding pump and the supplemented water flow, and controls the voice alarm module to alarm in real time on abnormal working states.
Specifically, in this embodiment, for a certain hydrocyclone, the structural parameters, the operating parameters and the material parameters are all determined, and the scattering angle range during normal operation of the hydrocyclone can be determined to be α through numerical simulation or physical experiment1～α2Pressure P and pump frequency f reference values, and determining the hydrocyclone operating state according to these predetermined parameter ranges:
when alpha is 0, the underflow flow of the hydrocyclone is extremely low, and the hydrocyclone is further judged to be in an underload state or a blocking state according to the pressure P and the pump frequency f data;
when alpha < alpha1When the flow is in a low-load state, the underflow flow of the hydrocyclone is low, the umbrella angle is small;
when alpha is1＜α＜α2When the hydraulic cyclone is in the normal working state, the hydraulic cyclone does not need to be adjusted;
when alpha is2＜α＜α22When the flow is in a full-load state, the underflow flow of the hydrocyclone is high, the umbrella angle is large;
when alpha > alpha22When the underflow of the hydrocyclone is out of limit, the hydrocyclone is positionedOverload conditions at low feed concentrations;
when alpha is equal to-1, the hydrocyclone has no underflow, and the hydrocyclone is further judged to be in an unloaded state or a completely blocked state according to the pressure P and the pump frequency f data.
The underload, the full load and the overload belong to adjustable working states, and the blockage, the complete blockage and the no-load are nonadjustable working states. Further, as shown in fig. 3, the main control module controls the display module to display the operating state and operating parameters of the hydrocyclone in real time, calculates the water replenishment flow rate and the frequency adjustment value of the feed pump, and transmits the command to the adjustment module.
Example 3
As shown in fig. 4, the adjusting module (based on embodiments 1 and 2) can be divided into an automatic adjusting module and a manual adjusting module, and is a module for adjusting the frequency of the feeding pump and the flow rate of the supplementing water in the system. The automatic adjusting module is controlled by the main control module and can adjust the frequency of the feeding pump and the replenishing water flow in real time; the manual adjusting module is manually operated by a worker and can also adjust the frequency of the feeding pump and the replenishing water flow in real time.
Specifically, in this embodiment, as shown in fig. 4, the adjusting module first determines whether the hydrocyclone is in an adjustable operating state; if the water pump is in an adjustable working state, the automatic adjusting module is triggered preferentially to adjust the frequency of the feeding pump and the supplementing water flow through the electric signal processing module according to a preset instruction; if the water supply device is in the unadjustable working state, the manual adjusting module and the emergency braking module are activated, the automatic adjusting module is closed, and meanwhile, feeding and water supplement are stopped. The automatic adjusting module adjusts the priority level according to the set parameters, namely: firstly, the pump frequency is adjusted to the pump frequency corresponding to the initial feeding pressure through the control electric signal processing module without changing the water replenishing flow, and then whether the hydrocyclone is in the normal working state or not is judged. If the hydrocyclone recovers to work normally, the automatic adjusting module stops working; if the normal state of the hydrocyclone is not recovered, controlling the electric signal processing module to regulate and control the water replenishing flow rate of the hydrocyclone, if the normal state of the hydrocyclone is recovered, stopping the automatic adjusting module, and maintaining the working parameters of the electric signal processing module; and if the hydrocyclone is still in an abnormal working state, triggering the emergency braking module and the voice alarm module. At this time, the source of the problem may be further determined by manually adjusting the module or checking whether the corresponding device malfunctions.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (6)
1. An automated hydrocyclone monitoring and control system, comprising: the system comprises a main control module, a measuring module, a data conversion and storage module, an electric signal processing module, an adjusting module, a display module, a voice alarm module, an emergency braking module and a hydrocyclone matching device; the main control module is respectively connected with the data conversion and storage module, the voice alarm module, the display module and the adjustment module; the data conversion and storage module is connected with the measuring module, the measuring module is connected with the matching equipment of the hydrocyclone, the adjusting module is connected with the emergency braking module, and the emergency braking module is connected with the electric signal processing module;
the hydrocyclone corollary equipment comprises a pump pool, a feeding pump, a hydrocyclone, a pressure detection element, a water storage pool, a water feeding valve, a flow detection element and an ultrasonic distance measurement element, wherein the hydrocyclone is small-sized laboratory equipment or large-sized field equipment, the feeding pump is a variable frequency pump machine, the pressure detection element is installed on an inlet pipeline of the hydrocyclone and used for monitoring the inlet pressure of the hydrocyclone, the water feeding valve is used for controlling the added water amount, and the flow detection element is used for measuring the added water amount;
the ultrasonic distance measuring elements are symmetrically arranged on two sides of the lower part of the sand setting port of the hydrocyclone, and the ultrasonic emission direction is vertical to the axis of the hydrocyclone;
and an optimization algorithm is arranged in the data conversion and storage module, and the distance value measured by the ultrasonic ranging element is converted into a scattering angle value and is transmitted to the main control module.
2. The automatic monitoring and control system of a hydrocyclone according to claim 1, wherein the main control module is internally provided with a scattering angle, a hydrocyclone working state database and a preset intelligent algorithm, analyzes the hydrocyclone working state by receiving data transmitted from the data conversion and storage module, controls the display module to display the system working state and working parameters, controls the automatic adjustment module to perform distribution regulation and control on the frequency of the feeding pump and the flow rate of supplemented water, and controls the voice alarm module to alarm in real time on abnormal working states.
3. The automated hydrocyclone monitoring and control system according to claim 1, wherein the measurement module is connected to the flow detection element, the pressure detection element and the ultrasonic distance measurement element, and the measurement module uploads real-time collected data packets to the data conversion and storage module.
4. The automatic monitoring and control system of a hydrocyclone according to claim 1, wherein the adjustment module is divided into an automatic adjustment module and a manual adjustment module, and when the system is in an adjustable state, the automatic adjustment module performs step-by-step optimized adjustment on the frequency of the feeding pump and the flow rate of the supplementing water by controlling the electric signal processing module; when the system is in an unadjustable state, the automatic adjusting module carries out emergency treatment on the feeding pump machine and the water replenishing valve and automatically switches to the manual adjusting module.
5. The automatic monitoring and control system of a hydrocyclone according to claim 1, wherein the electrical signal processing module is adapted to convert the digital signal into an electrical signal, which is controlled by the adjustment module to adjust the frequency of the feed pump and the flow rate of the make-up water; the emergency braking module may be triggered in case of an emergency.
6. The automatic monitoring and control system of a hydrocyclone according to claim 1, wherein the display module is adapted to display the operating parameters and status of each device in the system in real time; the voice alarm module is used for carrying out voice alarm prompt when the hydraulic cyclone is in a non-adjustable working state; and the emergency braking module is used for carrying out emergency braking on the pump and the supplemented water.
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