CN110425326B - Multi-liquid mixing accurate batching control method based on electronic scale signals - Google Patents
Multi-liquid mixing accurate batching control method based on electronic scale signals Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/04—Actuating devices; Operating means; Releasing devices electric; magnetic using a motor
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Abstract
The invention discloses a method for controlling accurate batching of a plurality of mixed liquids based on electronic scale signals, which comprises the following steps of S100: weighing the mixed mass of each raw material by using an electronic scale according to the order information, and calculating the required mass of each raw material according to the characteristics of a mixing valve; s200: entering a flow mode, adopting a PLC to timely adjust the height of a valve rod of the batching valve, and matching with a PI controller to realize stepless adjustment on the height of the valve rod of the batching valve, thereby realizing accurate control on each batching flow; s300: and entering a dripping amount mode, dividing into a multi-stage dripping formula according to the mass range of each ingredient, estimating the initial value of the dripping amount in each stage, including the maximum value of the target weight and the minimum value of the target weight, and dripping and mixing each ingredient in each stage respectively to finish liquid ingredient. The method of the invention realizes the accurate control of the flow, solves the problems of unstable dropping value and more overshoot times in the liquid batching production process, and greatly improves the batching precision and stability of the full-automatic liquid batching system.
Description
Technical Field
The invention belongs to the field of liquid batching control, and particularly relates to a multi-liquid mixing accurate batching control method based on electronic scale signals.
Background
At present, in the flavor and fragrance industry, a high-precision dispensing valve used in high-precision liquid dispensing automation equipment mainly uses a valve opener mechanism to complete a dispensing flow mode and a dropping amount mode, wherein the flow mode needs to accurately control the flow to be 3-40 g/s, and the dropping amount mode needs to accurately control the unequal mass of 50-800 mg per dropping amount.
In the flow mode, the higher the valve rod height of the proportioning valve is, the larger the flow is; the lower the valve stem height, the smaller the flow rate. The current common method for controlling the flow is to install an electromagnetic flowmeter and other instruments for measuring the real-time flow in a pipeline, and a PLC directly acquires the current value of the flowmeter, and the current value is used as the feedback control valve rod lifting height to control the current flow. However, in the flavor and fragrance industry, there are many kinds of raw materials, each raw material has a pipe connected with a dispensing valve, and if an electronic flowmeter is installed on the pipe between each raw material tank and the dispensing valve, the cost is relatively high, and the wiring and the pipe arrangement are extremely complicated.
During the dropping amount mode, the dropping amount value is decided by two key factors of the initial height of the valve rod of the proportioning valve and the valve opening time, but because of various reasons such as the precision of valve rod processing, the levelness of a valve beam, the viscosity of raw materials and the like, each proportioning valve can not obtain stable and same dropping amount value under the condition of the same initial height of the valve rod and the valve opening time, so that the overshoot times are more, and the precision and the reliability of equipment can not be ensured.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a multi-liquid mixing accurate batching control method based on electronic scale signals, wherein flow control combines a flow mode and a dropping quantity mode according to a feedback value of an electronic scale, the height of a valve rod of a batching valve is adjusted in real time through a PI (proportional integral) regulator in a PLC (programmable logic controller), the dropping quantity value is controlled through the PLC in multiple stages, accurate control of the flow is realized, the problems of unstable dropping quantity value and excessive overshoot times in the liquid batching production process are solved, and the batching accuracy and stability of a full-automatic liquid batching system are greatly improved.
In order to achieve the aim, the invention provides a method for controlling the accurate mixing of multiple liquids based on signals of an electronic scale, which comprises the following steps:
s100: weighing the mixed mass of each raw material by using an electronic scale according to the order information, and calculating the required mass of each raw material according to the characteristics of a mixing valve;
s200: entering a flow mode, adopting a PLC to timely adjust the height of a valve rod of the batching valve, and matching with a PI controller to realize stepless adjustment on the height of the valve rod of the batching valve, thereby realizing accurate control on each batching flow;
s300: and entering a dripping amount mode, dividing into a multi-stage dripping formula according to the mass range of each ingredient, estimating the initial value of the dripping amount in each stage, including the maximum value of the target weight and the minimum value of the target weight, and dripping and mixing each ingredient in each stage respectively to finish liquid ingredient.
Further, S200 further includes:
s201: judging the relation between the weight t of the remaining ingredients and a threshold value:
s202: if t is greater than 400g, the valve rod of the batching valve is controlled by the PLC to be lifted to a height H1 for batching, wherein H1 refers to the height of the valve rod corresponding to the maximum flow of the secondary valve core;
s203: if t is more than or equal to 200g and less than 400g, the PLC controls the valve rod of the batching valve to lift to the height H2 for batching, wherein H2 refers to the height of the valve rod corresponding to the maximum flow of the primary valve core;
s204: if t is less than 200g, the PI controller performs closed-loop control on the batching valve and performs stepless adjustment on the height of the valve rod;
s205: judging that the weight t of the rest ingredients is less than or equal to 4g, if so, entering a dropping quantity mode; if not, the process returns to step S201.
Further, the PI controller realizes flow control, and the method comprises the following steps:
s210: weighing actual mass W of each ingredient by using high-precision electronic scale1According to the actual mass W of each ingredient1And target ingredient weight W0Calculating an expected ingredient flow value, q (t):
Q(t)＝(W0-W1)/T (1)
in the formula: t is a constant;
s211: according to the actual value W of the electronic scale1And performing flow conversion to obtain the current flow Q:
Q＝ΔW1/ΔT,(ΔT＝0.1) (2)
in the formula: Δ W1Is mass per unit time
S212: calculating the deviation e (t) of the target value from the actual value:
e(t)＝(Wo-W1)/T-Q (3)
s213: obtaining the output value u (t) of the PI controller:
u(t)＝Kp×e(t)+Ki∫e(t)dt (4)
in the formula: kp represents the proportional gain coefficient of the PI controller; ki represents the integral coefficient of the PI controller;
s214: and (3) applying the output value u (t) of the PI controller to a valve opening servo motor of the valve opener, and adjusting the height of a valve rod of the batching valve to finally realize accurate control on the flow.
Further, S300 includes the steps of:
s301: estimating a plurality of initial values of the dropping quantity according to the batching quality and the batching valve characteristics, wherein the initial values comprise a target weight maximum value and a target weight minimum value;
s302: judging the relation between the current dropping amount actual value and the target weight maximum value or the target weight minimum value:
s303: when the actual value of the current dropping amount is smaller than the minimum value of the target weight, the initial height of the valve opener is increased by 0.1mm, or the valve opening time is increased by 10 ms;
s304: when the current dropping amount actual value is larger than the maximum value of the target weight, the initial height of the valve opener is reduced by 0.1mm, or the valve opening time is reduced by 10 ms;
s305: and (4) dripping according to the current dripping actual value if the target weight minimum value < the current dripping actual value < the target weight maximum value.
Further, in S301, five initial values of the droplet amount are included, and:
the maximum target weight value of the first initial value is less than the minimum target weight value of the second initial value;
the maximum target weight value of the second initial value is less than the minimum target weight value of the third initial value;
the maximum target weight value of the third initial value is less than the minimum target weight value of the fourth initial value;
the target weight maximum value of the fourth initial value is less than the target weight minimum value of the fifth initial value.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. according to the control method, the flow control combines the flow mode and the dropping quantity mode according to the feedback value of the electronic scale, the height of the valve rod of the batching valve is adjusted in real time through a PI (proportional integral) regulator in the PLC, the dropping quantity value is controlled through the PLC in multiple stages, the accurate control of the flow is realized, the problems of unstable dropping quantity value and excessive overshoot times in the liquid batching production process are solved, and the batching precision and the stability of a full-automatic liquid batching system are greatly improved.
2. The control method of the invention calculates the drop volume value of each time according to the electronic scale and PLC data acquisition, sets a plurality of different drop volume target intervals aiming at different stages of the production process, continuously adjusts the initial height and the valve opening time of the valve rod according to the comparison result of the current drop volume and the target intervals,
3. according to the control method, in the flow mode, when the weight of the non-ingredient is more than 200g, open-loop control is adopted, so that the ingredient mixing efficiency is improved; when the weight of the un-burdened material is less than 200g, closed-loop control is adopted, and the burdened precision is improved.
4. The control method, the dripping amount mode and the high-precision liquid batching valve are characterized in that in the dripping process, a certain dripping amount value is influenced by various factors such as valve core processing precision, raw material barrel pressure, beam installation levelness and the like, and the influence of the factors on the dripping amount of the valve is reduced to be within an acceptable range.
5. According to the control method, the qualification rate of the high-precision batching orders is improved from eighty percent to ninety-nine percent in the batching process.
Drawings
FIG. 1 is a schematic diagram of a general flow chart of a method for controlling precise mixing of multiple liquids based on signals from an electronic scale according to an embodiment of the present invention;
FIG. 2 is a flow chart illustrating the flow control of the traffic pattern according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a PI controller according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a flow chart of the drop volume mode control according to an embodiment of the present invention;
FIG. 5 is a schematic view of one embodiment of the dropping amount mode of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 1, an embodiment of the present invention provides a method for controlling precise ingredients of a mixture of multiple liquids based on signals of an electronic scale, including the following steps:
step 1: firstly, weighing the mass of each ingredient by using an electronic scale according to an order, and calculating the flow of each ingredient according to the characteristics of an ingredient valve;
step 2: entering a flow mode, adopting a PI controller in a PLC, and timely adjusting the height of a valve rod of a batching valve to realize accurate control of each batching flow;
specifically, as shown in fig. 2, after entering the flow mode, the relationship between the weight t of the remaining ingredients and the threshold is determined:
(1) if t is greater than 400g, the valve rod of the batching valve is controlled by the PLC to be lifted to a height H1 for batching, wherein H1 refers to the height of the valve rod corresponding to the maximum flow of the secondary valve core;
(2) if 200g < t <400g, the valve rod of the batching valve is controlled by the PLC to be lifted to a height H2 for batching, wherein H2 refers to the height of the valve rod corresponding to the maximum flow of the primary valve core;
(3) and if t is less than 200g, the PI controller performs closed-loop control on the proportioning valve to perform stepless regulation.
Wherein, the PI control basic principle is as shown in FIG. 3, the actual mass W1 of each ingredient is weighed by a high-precision electronic scale, and the actual mass W of each ingredient is calculated1And target ingredient weight W0Calculating an expected ingredient flow value, q (t):
Q(t)＝(W0-W1)/T (1)
in the formula: t is a constant.
Meanwhile, according to the actual value W of the electronic scale1And performing flow conversion to obtain the current flow Q:
Q＝ΔW1/ΔT,(ΔT＝0.1) (2)
in the formula: Δ W1Is mass per unit time
Then, the deviation e (t) of the target value from the actual value is calculated:
e(t)＝(Wo-W1)/T-Q (3)
thus obtaining the output value u (t) of the PI controller:
u(t)＝Kp×e(t)+Ki∫e(t)dt (4)
in the formula: kp represents the proportional gain coefficient of the PI controller; ki represents the integral coefficient of the PI controller;
and then, the output value u (t) of the PI controller acts on a valve opening servo motor of the valve opener, the height of a valve rod of the batching valve is adjusted, and finally, the accurate control of the flow is realized.
And step 3: and entering a dripping amount mode, dividing into a multi-stage dripping formula according to the mass range of each ingredient, estimating the initial value of the dripping amount in each stage, including the maximum value of the target weight and the minimum value of the target weight, and dripping and mixing each ingredient in each stage respectively to finish liquid ingredient.
Specifically, as shown in fig. 4, a plurality of initial values of the amount of drops are estimated according to the quality of the ingredient and the characteristics of the ingredient valve, for example, in the embodiment of the present invention, the amount of drops mode is divided into five stages for dispensing, five different target ranges of the amount of drops strategies are set, and each amount of drops strategy includes the following parameters: the method comprises the steps of checking times of a current strategy, initial height of a valve opener, valve opening time, a current dropping amount actual value, a target weight minimum value and a target weight maximum value. And storing the strategy parameters in an upper computer and binding the strategy parameters with corresponding raw materials. The initial values of all the stages comprise the maximum value important to the target and the minimum value of the target weight, the maximum value of the target weight of the strategy 1 is smaller than the minimum value of the target weight of the strategy 2, the minimum value of the target weight of the strategy 2 is smaller than the maximum value of the target weight of the strategy 3, and the setting is finished by analogy in sequence.
Further, according to the principle of priority of production efficiency, when the actual batching value is smaller than the target value, a large-dropping-amount strategy is preferentially selected for carrying out dropping batching. The higher the batching precision is, when the batching precision is gradually close to the target value, the dripping amount strategy is selected for dripping batching. In the process of each dripping batching:
(1) if the actual value of the current dropping amount is smaller than the minimum value of the target weight, the initial height of a valve opener in the current strategy is increased by 0.1mm, or the valve opening time is increased by 10 ms;
(2) if the actual value of the current dropping amount is larger than the maximum value of the target weight, the initial height of a valve opener in the current strategy is reduced by 0.1, or the valve opening time is reduced by 10 ms;
(3) and if the current actual dropping amount value is larger than the target weight minimum value and smaller than the maximum value, the initial height and the valve opening time of the valve opener of the current strategy are not changed.
In the process of completing drip batching of each raw material, the PLC can adjust the parameter values in the drip strategy in real time, and after batching is completed, the PLC sends the parameter values to the upper computer to store related parameters and data, and an operator can inquire the parameter values through an interface and manually modify the parameter values in the drip strategy.
For example, as shown in FIG. 5:
(1) an operator pre-estimates initial values of 5 dropping strategies according to the characteristics of the batching valve through an upper computer interface, sets corresponding target weight maximum values and target weight minimum values for the 5 dropping strategies, wherein the target weight maximum value of the strategy 1 is smaller than the target weight minimum value of the strategy 2, the target weight minimum value of the strategy 2 is smaller than the target weight maximum value of the strategy 3, and the setting is finished by analogy in sequence, specifically see table 1.
TABLE 15 maximum and minimum target weights for the drop size strategy
(2) Wherein the weight of the non-ingredients is the target weight-the actual weight;
1) when the weight of the un-mixed materials is more than or equal to 1 gram, the dropping amount strategy 5 is selected for dropping;
2) when the weight of the un-dosed materials is more than or equal to 0.5 g and less than 1 g, the dripping strategy 4 is selected for dripping;
3) when the weight of the un-dosed materials is more than or equal to 0.3 g and less than 0.5 g, the dropping amount strategy 3 is selected for dropping;
4) when the weight of the un-dosed materials is more than or equal to 0.15 g and less than 0.3 g, the dripping strategy 2 is selected for dripping;
5) drop strategy 1 was selected for dropping when the undosed weight was less than 0.15 grams.
In the drip process of the strategy 1 and the strategy 2, if the weight of the current drip is smaller than the minimum value of the target weight, the initial height of the valve opener is increased by 0.1mm, and the valve opening time is kept unchanged; and if the current drip weight is larger than the maximum target weight, the initial height of the valve opener is reduced by 0.1mm, and the valve opening time is kept unchanged.
In the strategy 3-5 dripping process, if the current dripping weight is smaller than the minimum value of the target weight, the initial height of a valve opener is increased by 0.1mm, and the valve opening time is increased by 10 ms; and if the current drip weight is larger than the maximum target weight, the initial height of the valve opener is reduced by 0.1mm, and the valve opening time is reduced by 10 ms.
After the batching is finished, the PLC sends the calibrated drip strategy 1-5 parameters to the upper computer for storage. The operator inquires the current drip value of each strategy through the interface, compares the current drip value with a set target range, and manually sets related strategy parameters according to production experience so as to achieve the aim of quickly correcting the drip strategy.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (5)
1. A multi-liquid mixing accurate batching control method based on electronic scale signals is characterized by comprising the following steps:
s100: weighing the mixed mass of each raw material by using an electronic scale according to the order information, and calculating the required mass of each raw material according to the characteristics of a mixing valve;
s200: entering a flow mode, adopting a PLC to timely adjust the height of a valve rod of the batching valve, and matching with a PI controller to realize stepless adjustment on the height of the valve rod of the batching valve, thereby realizing accurate control on each batching flow;
s300: entering a dripping amount mode, dividing into a multi-stage dripping formula scheme according to each ingredient quality range, and setting corresponding dripping amount strategies in different target ranges, wherein each dripping amount strategy comprises the following parameters: checking times of a current strategy, initial height of a valve opener, valve opening time, a current dropping amount actual value, a target weight maximum value and a target weight minimum value, and sequentially carrying out dropping distribution on all the ingredients in stages to finish liquid ingredients;
in the process of completing drip batching of each raw material, the PLC can adjust the parameter values in the drip strategy in real time, and after batching is completed, the PLC sends the parameter values to the upper computer to store related parameters and data, and an operator can inquire the parameter values through an interface and manually modify the parameter values in the drip strategy.
2. The method for controlling precise mixing of multiple liquids based on electronic scale signal as claimed in claim 1, wherein S200 further comprises:
s201: judging the relation between the weight t of the remaining ingredients and a threshold value:
s202: if t is greater than 400g, the valve rod of the batching valve is controlled by the PLC to be lifted to a height H1 for batching, wherein H1 refers to the height of the valve rod corresponding to the maximum flow of the secondary valve core;
s203: if t is more than or equal to 200g and less than 400g, the PLC controls the valve rod of the batching valve to lift to the height H2 for batching, wherein H2 refers to the height of the valve rod corresponding to the maximum flow of the primary valve core;
s204: if t is less than 200g, the PI controller performs closed-loop control on the batching valve and performs stepless adjustment on the height of the valve rod;
s205: judging that the weight t of the rest ingredients is less than or equal to 4g, if so, entering a dropping quantity mode; if not, the process returns to step S201.
3. The method for controlling precise mixing of multiple liquids based on electronic scale signals as claimed in claim 1 or 2, wherein said PI controller implementing flow control comprises the steps of:
s210: weighing actual mass W of each ingredient by using high-precision electronic scale1According to the actual mass W of each ingredient1And target ingredient weight W0Calculating an expected ingredient flow value, q (t):
Q(t)＝(W0-W1)/T (1)
in the formula: t is a constant;
s211: according to the actual value W of the electronic scale1And performing flow conversion to obtain the current flow Q:
Q＝ΔW1/ΔT,(ΔT＝0.1) (2)
in the formula: Δ W1Is mass per unit time
S212: calculating the deviation e (t) of the target value from the actual value:
e(t)＝(Wo-W1)/T-Q (3)
s213: obtaining the output value u (t) of the PI controller:
u(t)＝Kp×e(t)+Ki∫e(t)dt (4)
in the formula: kp represents the proportional gain coefficient of the PI controller; ki represents the integral coefficient of the PI controller;
s214: and (3) applying the output value u (t) of the PI controller to a valve opening servo motor of the valve opener, and adjusting the height of a valve rod of the batching valve to finally realize accurate control on the flow.
4. The method for controlling precise mixing of multiple liquids based on electronic scale signal as claimed in claim 1, wherein S300 comprises the steps of:
s301: estimating a plurality of initial values of the dropping quantity according to the batching quality and the batching valve characteristics, wherein the initial values comprise a target weight maximum value and a target weight minimum value;
s302: judging the relation between the current dropping amount actual value and the target weight maximum value or the target weight minimum value:
s303: when the actual value of the current dropping amount is smaller than the minimum value of the target weight, the initial height of the valve opener is increased by 0.1mm, or the valve opening time is increased by 10 ms;
s304: when the current dropping amount actual value is larger than the maximum value of the target weight, the initial height of the valve opener is reduced by 0.1mm, or the valve opening time is reduced by 10 ms;
s305: and (4) dripping according to the current dripping actual value if the target weight minimum value < the current dripping actual value < the target weight maximum value.
5. The method for controlling precise mixing of multiple liquids based on electronic scale signal as claimed in claim 1, wherein S301 comprises five initial values of drop volume, and:
the maximum target weight value of the first initial value is less than the minimum target weight value of the second initial value;
the maximum target weight value of the second initial value is less than the minimum target weight value of the third initial value;
the maximum target weight value of the third initial value is less than the minimum target weight value of the fourth initial value;
the target weight maximum value of the fourth initial value is less than the target weight minimum value of the fifth initial value.
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