CN111307253B - Intelligent detection and control system and method for flow device commutator - Google Patents
Intelligent detection and control system and method for flow device commutator Download PDFInfo
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- CN111307253B CN111307253B CN201910973630.XA CN201910973630A CN111307253B CN 111307253 B CN111307253 B CN 111307253B CN 201910973630 A CN201910973630 A CN 201910973630A CN 111307253 B CN111307253 B CN 111307253B
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Abstract
The invention relates to a flow device commutator intelligent detection and control system and method; the system comprises an industrial personal computer, a camera, a PCI board card, a signal conditioning board, a stepping motor driver, a stepping motor, a commutator, a photoelectric switch and a standard meter. The invention adopts the electric commutator with controllable operation process, automatically identifies the state of the commutator by adopting the image processing technology, controls the stepping motor to accurately adjust the position of the commutator if the commutation position of the commutator deviates from the standard position, adjusts the commutator to a very accurate position, and can quickly maintain the commutator according to the prompt of a computer by non-professional technicians, thereby reducing the maintenance cost. The standard position of the diverter of the present invention is the working position of the diverter when the diverter uncertainty is no greater than 0.006%, and the flow device uncertainty is at a domestic leading level.
Description
Technical Field
The invention belongs to the field of flow detection and control, and particularly relates to an intelligent detection and control system and method for a flow device commutator.
Background
Flow measurement is widely applied to the fields of energy, environmental protection, medicine, trade, process control and the like. The water flow device is one of calibration equipment for measurement value transmission, traceability and calibration test work of metering departments and flowmeter manufacturing enterprises, and has important significance for ensuring the product quality of the flowmeter and developing novel flowmeters.
The uncertainty of the flow device is a very important technical index, and directly influences the calibration precision of the flow instrument. The flow calibration device uncertainty is primarily associated with the electronic scales and the diverter, and when the electronic scales are selected, the flow calibration device uncertainty is primarily associated with the diverter uncertainty, and the diverter uncertainty is primarily associated with the diverter symmetry, control scheme, and couplings. In order to ensure that the commutator operates at a high level with uncertainty of no more than 0.006%, it is important how to quickly diagnose the operating state of the commutator and adjust the commutator to a standard operating position.
The prior art commutator has the following disadvantages:
1, the failure of the commutator can not be detected in time, which affects the calibration and verification of the high-precision flowmeter.
2 if the commutator breaks down, a professional skilled person with rich experience is required to go to the site to carry out fault diagnosis and maintenance.
The prior art of 3-flow device commutators is generally pneumatic, and the movement process is uncontrollable; the electric commutator controls the commutator to operate by utilizing the characteristic that the speed of the stepping motor is adjustable, so that higher uncertainty level can be reached, but after the flow device operates for a period of time, the symmetry of the commutator changes, and the uncertainty level of the flow device is influenced. The symmetry of the commutator is determined by a signal sent by a photoelectric switch, when a photoelectric switch baffle plate arranged on a commutator shaft rotates to the position of the photoelectric switch, the photoelectric switch sends a control signal to control the commutation of the commutator, but the position of the photoelectric switch baffle plate sometimes changes, the position of the photoelectric switch baffle plate is adjusted manually at present, technicians need to climb to a very high position for arranging the commutator and observe working positions of the left side and the right side of the commutator by eyes, if the two sides are asymmetric, one person manually adjusts the position of one side of the commutator and fixes the position, the other person adjusts the photoelectric switch baffle plate arranged on the commutator shaft, sometimes when the photoelectric switch baffle plate is fixed, the position of the commutator side changes, sometimes the requirements can be met by repeating for many times, the asymmetry adjustment efficiency of the commutator is low, and more maintenance personnel are needed, even the asymmetry of two sides of the commutator caused by the error of eyes influences the uncertainty level of the flow device and the calibration and verification of the high-precision flow meter.
Disclosure of Invention
The traditional commutator technology can not monitor the working state of the commutator in time, and the symmetry of the commutator needs to be adjusted manually, so that the efficiency is low, the maintenance cost is high, and the calibration and verification of the high-precision flowmeter are influenced.
The invention can automatically diagnose the failure of the commutator of the flow device, automatically adjust the asymmetry of the commutation position of the commutator, ensure that the commutator works in a high-level state with uncertainty, and realize the high-precision and high-efficiency calibration and verification of the flow meter.
The invention adopts the electric commutator, the running process of the commutator is controllable, the image processing technology is adopted to automatically diagnose the state of the commutator, if the commutation position of the commutator deviates from the standard position, the stepping motor is used to accurately adjust the position of the commutator, the commutator is adjusted to a very accurate position, even non-professional technicians can quickly maintain the commutator according to the prompt of a computer, the standard position of the commutator is the working position of the commutator when the uncertainty of the commutator is not more than 0.006 percent, and the standard position is the domestic leading level.
An intelligent detection and control system for a flow device commutator comprises an industrial personal computer, a camera, a PCI card I, a signal conditioning board, a stepping motor driver, a stepping motor 1, a commutator 2, a photoelectric switch, a PCI card II and a standard meter;
the standard meter is connected with the signal conditioning board and is used for indicating the water flow of the current flow device and sending a signal of the standard meter to the signal conditioning board, and the signal conditioning board is used for filtering and isolating the signal;
the industrial personal computer is connected with the signal conditioning board through the PCI card I, the signal conditioning board is connected with the stepping motor driver, and the industrial personal computer is used for acquiring a reversing signal of the photoelectric switch through the PCI card II, sending a control signal to the stepping motor driver through the PCI card I and the signal conditioning board, and carrying out position recognition on a commutator image acquired by the camera through Ethernet to give fault information of the commutator;
the step motor driver is connected with the step motor 1 and used for controlling the operation of the step motor 1, and the step motor is connected with the commutator and used for driving the commutator 2 to realize commutation and commutation speed adjustment, so that calibration verification is performed on the flowmeter and the uncertainty of the commutator is tested; the commutator 2 is provided with a camera, the camera is connected with an industrial personal computer, and the camera is used for collecting commutator images and sending the commutator images to the industrial personal computer through the Ethernet; the commutator is connected with the photoelectric switch, the photoelectric switch is connected with the industrial personal computer through the PCI card II, and the photoelectric switch is used for sending a commutation signal to the industrial personal computer through the PCI card II.
On the basis of the scheme, the commutator is connected with a commutator shaft, and a left photoelectric switch baffle 5 and a right photoelectric switch baffle 6 are further mounted on the commutator shaft.
On the basis of the scheme, the left photoelectric switch baffle 5 and the right photoelectric switch baffle 6 are connected with the commutator shaft through jackscrews.
On the basis of the scheme, the photoelectric switch comprises a left photoelectric switch 4 and a right photoelectric switch 3, and the left photoelectric switch 4 and the right photoelectric switch 3 are respectively matched with a left photoelectric switch baffle 5 and a right photoelectric switch baffle 6 for use.
On the basis of the scheme, the type of the PCI card I is PCI-1780, and the type of the PCI card II is PCI-1750.
An intelligent detection and control method for a flow device commutator is applied to the intelligent detection and control system, and comprises the following steps:
step 1: closing an air source switch, and opening a valve when the air pressure reaches 0.5 Mpa;
step 2: adjusting a frequency converter to control a water pump, adjusting water flow, sending a direction signal and a frequency signal to a stepping motor according to a photoelectric switch signal when the water flow is stable, calculating the time for switching a commutator into a water weighing container and the time for switching the commutator out of the water weighing container, and calculating the uncertainty of the commutator;
step 3: judging whether the uncertainty of the commutator exceeds the standard:
if the uncertainty of the commutator is not more than 0.006 percent, calibrating and verifying the flowmeter;
if the uncertainty is greater than 0.006%, acquiring image information of the commutator stopping position through a camera, calculating the deviation between the commutator stopping position and the commutator standard position through image processing, turning off the water pump, and entering the step 4;
and 4, step 4: judging whether the position deviation between the stopping position of the commutator and the standard position of the commutator exceeds the standard or not:
if the absolute value of the position deviation between the commutator stop position and the commutator standard position is not more than 1.5mm, a coupling system of the commutator 2 is overhauled;
if the absolute value of the position deviation between the stopping position of the commutator and the standard position of the commutator is more than 1.5mm, entering the step 5;
and 5: judging whether the absolute value of the position deviation of the commutator on the right side is larger than 1.5mm, if so, entering a step 6; if not, entering step 9;
step 6: displaying the position overproof information of the commutator on the right, judging whether the commutator is on the right of the standard position, if so, entering step 8, and if not, entering step 7;
and 7: the commutator is arranged on the left side of the standard position, the position information of the commutator is prompted and adjusted, the industrial personal computer gives a rightward direction signal and a stepping signal to the stepping motor, the stepping motor drives the commutator to move one step, commutator images are collected, the position deviation between the commutator images and the standard position of the commutator is calculated through image processing, and if the absolute value of the position deviation is larger than 1.5mm, the step 7 is repeated; if the absolute value of the position deviation is not more than 1.5mm, entering the step 10;
and 8: the position of the commutator is on the right side of the standard position, the position information of the commutator is prompted to be adjusted, the industrial personal computer gives a leftward direction signal and a stepping signal of the stepping motor, the stepping motor drives the commutator to move one step, commutator images are collected, the position deviation of the commutator images and the standard position of the commutator is calculated through image processing, if the absolute value of the position deviation is larger than 1.5mm, the step 8 is repeated, and if the absolute value of the position deviation is not larger than 1.5mm, the step 10 is carried out;
and step 9: displaying the position overproof information of the commutator on the left, judging whether the commutator is on the left of the standard position, if so, entering step 7, otherwise, entering step 8;
step 10: locking the commutator, adjusting a photoelectric switch blocking piece of the commutator to a normal working position, and then returning to the step 2.
On the basis of the scheme, the uncertainty of the commutator in the step 2 is calculated as follows: the flow is adjusted to the verification flow of the commutator, and the verification flow comprises large flow points 575m3H, medium flow point 259m3H and a low flow point of 57.5m3H, stabilizing for 10 minutes, operating the commutator to enable the commutator to commutate for 10 times at each flow point, and respectively calculating the uncertainty of the corresponding flow point;
wherein, t1For cutting into the weighing container, t2Time for cutting out the weighing water container, t1aThe mean value of the time for 10 cuts into the weighing vessel, t2aThe average value of the time for weighing the water container is 10 times cut; s1Class A relative standard uncertainty, s, for cut-in weighing vessels2For cutting out the A-type relative standard uncertainty of the weighing water container, u is the B-type relative standard uncertainty, tmin30 seconds;
commutator uncertainty is: u shapeCommutator＝(s1 2+s2 2+u2)1/2And the uncertainty value of the commutator is the largest uncertainty value of the commutator among the large flow point, the medium flow point and the small flow point.
On the basis of the scheme, the image processing in the step 2 comprises gray processing, median filtering, edge detection and edge fitting on the commutator image; the gray level processing adopts a weighted average value method to carry out weighted average on the red, green and blue color components of the color image, wherein the green weight is 0.6, the red weight is 0.3 and the blue weight is 0.1; the median filtering is to filter noise by adopting median filtering; the edge detection specifically comprises the steps of detecting edge points of the commutator by adopting a multi-scale Marr operator; the edge fitting specifically comprises the step of performing straight line fitting on edge points of the commutator by adopting a least square method to obtain edge characteristics of the commutator.
The technical scheme of the invention has the following beneficial effects:
the invention provides an intelligent detection technology of a commutator of a flow standard device and an automatic adjustment method of the commutator, which can quickly diagnose the fault of the commutator, realize the normal work of the commutator on a standard working position by utilizing an image processing technology and a stepping motor control technology, ensure that the inaccuracy level of the commutator of the flow standard device is at the leading level in China, reduce the diagnosis time and the maintenance cost of the commutator, quickly maintain the commutator according to the prompt of a computer even if a non-professional technician can improve the calibration and verification efficiency of a high-precision flowmeter.
The technical key points and points to be protected of the invention are as follows:
(1) the working state of the commutator of the flow device is automatically monitored, the state information of the commutator is prompted, and the normal work of the commutator is timely and accurately ensured.
(2) The step motor is adopted to control the commutator and the image processing method, the commutator which is not at the standard working position is automatically adjusted to the correct position, the high level of uncertainty of the commutator is ensured, and the maintenance cost is saved.
Drawings
The invention has the following drawings:
FIG. 1 is a system diagram of a water flow device;
FIG. 2a is a left side view of the diverter of the water flow device;
FIG. 2b is a schematic view of the front view of the water flow device diverter;
FIG. 2c is a top view of the diverter of the water flow device;
FIG. 2d is a schematic view of a photoelectric switch and a photoelectric barrier of a commutator of the water flow device;
FIG. 3a is a left side view of the diverter of the water flow device;
FIG. 3b is a schematic view of the internal structure of the water flow device when the commutator moves to the right position on the left;
FIG. 3c is a top view of the water flow device diverter moving to the left;
FIG. 3d is a schematic view of the photoelectric switch and the photoelectric barrier when the commutator of the water flow device moves to the left;
FIG. 4a is a left side view of the diverter of the water flow device;
FIG. 4b is a schematic view of the internal structure of the water flow unit when the diverter moves to the right position;
FIG. 4c is a top view of the water flow device diverter moving to the right;
FIG. 4d is a schematic view of the photoelectric switch and the photoelectric barrier when the commutator of the water flow device moves to the right;
FIG. 5a is a left side view of the diverter of the water flow device;
FIG. 5b is a schematic view of the internal structure of the water flow device when the diverter moves to the right error position;
FIG. 5c is a top view of the water flow device diverter moving to the right error position;
FIG. 5d is a schematic view of the photoelectric switch and the photoelectric barrier when the commutator of the water flow device moves to the right wrong position;
FIG. 6a is a top view of the water flow device diverter adjusted to a correct operating position;
FIG. 6b is a schematic view of a photoelectric switch and a photoelectric barrier when the commutator of the water flow device is adjusted to a correct working position;
FIG. 6c is a schematic view of a photoelectric switch and a photoelectric barrier when the water flow device commutator is adjusted to a correct working position;
FIG. 7 is a block diagram of an intelligent commutator detection and control system;
fig. 8 is a flow chart of intelligent detection and automatic adjustment of the diverter of the flow device.
Reference numerals:
1. stepping motor 2, commutator 3, right photoelectric switch 4 and left photoelectric switch
5. Right photoelectric switch baffle 6, left photoelectric switch baffle 7 and nozzle
51. A right photoelectric switch blocking sheet error position 21, a right side 211 of the commutator, a right side position 22 of the commutator when the commutator moves to the right error position, and a left side of the commutator
221. The left position of the commutator when the commutator moves to the right error position.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings 1 to 8.
In order to explain the working process of the commutator in the flow device, the invention firstly provides a system diagram of the water flow standard device shown in FIG. 1, and then respectively introduces a commutator commutation method, a commutator commutation position adjusting method, commutator hardware system composition, a data processing system and a commutator intelligent detection and automatic adjusting method. The specific contents are as follows:
1.1 Water flow Standard device composition and working principle
Fig. 1 is a water flow device system diagram, taking DN200 flow device as an example, its working principle is: the PLC controls the operation of a frequency converter, the frequency converter controls the operation of a water pump, the water pump pumps water from a water pool, the water passes through a manual switch valve, a Y-shaped filter, a corrugated pipe, a water pump, the corrugated pipe, a check valve, a safety valve, a pressure stabilizing and degassing container, a detected meter pipeline, a standard meter pipeline, a pneumatic switch valve, a commutator and a backflow water pool, when the water flow is stable, the industrial personal computer controls the operation of a stepping motor, the stepping motor 1 drives the commutator 2 to rotate right to cut water into a water weighing container (figure 1), the stepping motor 1 drives the commutator 2 to rotate left to cut water into a bypass, a camera is arranged on the commutator 2, an image of the stop position of the commutator is sent to the industrial personal computer through the Ethernet, the uncertainty of the commutator can be obtained through a data acquisition and processing system, and the calibration and verification of the flow meter can also be carried out.
1.2 commutator operating Process
Fig. 2 is a diagram of a commutator system of a water flow device, and the commutator system comprises a stepping motor 1, a commutator 2, a right photoelectric switch 3, a left photoelectric switch 4, a right photoelectric switch baffle 5, a left photoelectric switch baffle 6 and a nozzle 7. When the commutator 2 is in the middle position, the angles between the left photoelectric switch blocking piece 5 and the right photoelectric switch blocking piece 6 and the horizontal line are the same, the left photoelectric switch blocking piece 5 and the right photoelectric switch blocking piece 6 are installed on a commutator shaft and connected with the commutator shaft through a jackscrew, and the rotation angle of the photoelectric switch blocking piece is the same as that of the commutator.
The working process of the commutator is as follows: when the water flow of the flow standard device is stable, the stepping motor 1 is started, and the stepping motor 1 drives the commutator 2 to rotate leftwards (figure 3) or rightwards (figure 4). When the commutator 2 rotates leftwards (figure 3), the left photoelectric switch blocking piece 6 rotates leftwards to block the light source of the left photoelectric switch 4, the left photoelectric switch 4 sends a signal to stop the stepping motor, the right position of the commutator and the left position of the commutator are shown in figure 3, and at the moment, water flows into the bypass pipeline from the nozzle 7 to the right side of the commutator 2; a reverse signal is given to the stepping motor 1, the stepping motor 1 is started to enable the commutator 2 to rotate rightwards, when the right commutator catch 5 blocks the right photoelectric switch 3 (figure 4), the right photoelectric switch 3 sends a signal to enable the stepping motor to stop, the right position of the commutator and the left position of the commutator are shown in figure 4, and at the moment, water flows to the left side of the commutator from the nozzle 7 and is injected into the water weighing container. Repeating the above process 10 times, and recording the time t of each water cut into the water weighing container1(from the time the left photoelectric switch sends out a signal to the time the right photoelectric switch sends out a signal) and the time t for switching into the bypass2(i.e. the time for cutting out the water weighing container: from the time when the right photoelectric signal is sent to the time when the left photoelectric signal is sent), the uncertainty of the commutator 2 can be calculated. When the reversing angle and symmetry of the commutator 2 and the rotation speed of the commutator 2 are adjusted, the uncertainty of the commutator 2 is calculated at the large flow point, the medium flow point and the small flow point of the commutator 2 respectively, the maximum uncertainty of the commutator is taken as the uncertainty of the commutator 2, when the uncertainty of the commutator 2 is less than 0.006 percent and the uncertainty of the electronic scale is less than 0.01 percent, the expansion uncertainty level of the flow device is better than 0.03 percent (an uncertainty coefficient K is 2), the commutator 2 is at a normal working position at the moment, and the working position of the commutator at the moment is shot by a camera to be used as a standard position for reversing the commutator.
When the commutator 2 moves repeatedly for a long time, the position of the photoelectric barrier may change, which causes the commutator 2 to deviate from the normal working position, as shown in fig. 5 and 6, the normal position of the right photoelectric switch barrier 5 deviates to the right photoelectric switch barrier error position 51, at this time, the angle of the right rotation of the commutator 2 becomes smaller (fig. 5 and 6), and it can be seen from fig. 5c and 6a that the commutator rotates to the right wrong position 211 of the commutator, which differs from the right correct position of the commutator by a certain distance, which causes the commutator 2 to be asymmetric, and the uncertainty becomes larger. The camera of the invention can identify the position of the commutator 2, and the position deviation of the commutator 2 is obtained by comparing with the standard position of the commutator 2 stored in the computer system, if the deviation exceeds the standard (the absolute value of the deviation is more than 1.5mm), the commutator is not in the correct position. If the deviation (now position minus the standard position) is negative, then the right photoelectric switch flap error position 51 is rotated to the horizontal position (FIG. 6 b); at this time, the direction of the commutator is kept unchanged, the operation state is a stepping mode, namely the stepping motor steps, the image is sent to the computer for re-recognition, if the absolute value of the deviation is still larger than 1.5mm, the process is repeated until the commutator moves to the correct position, namely the right wrong position 211 (dotted line in fig. 6) of the commutator changes to the right correct position (solid line in fig. 6) of the commutator, at this time, the wrong position 51 of the blocking piece of the right photoelectric switch rotates below the horizontal line (fig. 6c), at this time, the wrong position 51 of the blocking piece of the right photoelectric switch is manually adjusted to the normal position of the blocking piece 5 of the right photoelectric switch in a counterclockwise direction (the position is the moment when the photoelectric switch is turned from on to off), and at this time, the positions of the commutator 2 and the blocking piece of the photoelectric switch are rotated to the solid line position (standard position) from the dotted line position in fig. 6. If the difference value between the right position of the commutator 2 and the standard position is positive, the stepping motor is reversed, the commutator rotates back until the correct position, and then the light adjusting electric switch blocking piece is adjusted to the normal working position.
1.3 commutator intellectual detection system and control system
The intelligent commutator detecting and controlling system includes hardware system and data processing system.
As shown in fig. 7, an intelligent detecting and controlling system structure for a commutator includes: the system comprises an industrial personal computer, a camera, a PCI-1780, a signal conditioning board, a stepping motor driver, a stepping motor 1, a commutator 2, a photoelectric switch, a PCI-1750, a standard meter and the like, wherein the signal conditioning board is used for filtering and isolating signals, and the standard meter is used for indicating the water flow of the current flow device.
The intelligent detection and control system of the commutator has the working process as follows:
when the commutator 2 works normally, the industrial personal computer collects the commutation signals of the photoelectric switch through the PCI1750, sends direction signals and frequency signals of the stepping motor to the stepping motor driver through the PCI1780, and the stepping motor controls the commutation and commutation speed of the commutator, so that the calibration and verification of the flowmeter and the uncertainty test of the commutator are realized.
When the commutator 2 works abnormally or the starting detection commutator uncertainty (commutator uncertainty 0.006%) exceeds the standard, the industrial personal computer identifies the position of the commutator image acquired by the camera through the Ethernet and gives out fault information of the commutator, if the position of the commutator 2 deviates from the standard position, the industrial personal computer gives out corresponding direction signals and frequency signals of the stepping motor, and the operation of the stepping motor 1 is gradually adjusted according to the identified position information of the commutator 2 until the commutator 2 is controlled to reach the standard position.
1.4 Intelligent commutator detection and control method introduction
The intelligent commutator detecting and controlling method mainly comprises three parts of fault recognition, commutator image position detection and automatic adjustment.
1.4.1 commutator Fault identification
A fault condition occurs when the commutator uncertainty is greater than 0.006%. Commutator uncertainty is calculated as follows:
the flow is adjusted to the commutator verification flow (large flow point 575 m)3H, medium flow point 259m3H and a low flow point of 57.5m3H), stabilizing for 10 minutes, operating the commutator to enable the commutator to commutate for 10 times at the flow point, and respectively calculating the uncertainty of the corresponding flow point;
commutator uncertainty is: u shapeCommutator＝(s1 2+s2 2+u2)1/2，
Wherein t is1For cutting into the weighing container, t2Time for cutting out the weighing water container, t1aThe mean value of the time for 10 cuts into the weighing vessel, t2aThe average value of the time for weighing the water container is 10 times cut; s1Class A relative standard uncertainty, s, for cut-in weighing vessels2For cutting out the A-type relative standard uncertainty of the weighing water container, u is the B-type relative standard uncertainty, tminIt was 30 seconds. And finally, taking the largest commutator uncertainty value from the large flow point, the medium flow point and the small flow point as the uncertainty value of the commutator.
And when the industrial personal computer calculates and identifies that the uncertainty of the commutator 2 is more than 0.006%, detecting the position of the commutator 2, if the position of the commutator 2 is at a standard position, determining that the commutator fault is a commutator coupling system fault, and otherwise, analyzing and adjusting the position of the commutator 2.
1.4.2 commutator position detection
The commutator position detection is that according to a commutator image shot by a camera, an industrial personal computer obtains the position of the commutator 2 through image processing, the commutator image is subjected to position recognition, and then whether the commutator 2 is in a standard working position or not is analyzed.
The commutator image processing is to carry out gray level processing, median filtering, edge detection and edge fitting on the commutator image. The gray level processing of the image adopts a weighted average value method, namely, the red, green and blue color components of the color image are weighted and averaged, wherein the green weight is 0.6, the red weight is 0.3, the blue weight is 0.1, median filtering is adopted to filter noise, edge detection adopts a multi-scale Marr operator to detect the edge points of the commutator, and then the least square method is used to perform straight line fitting on the edge points of the commutator to obtain the edge characteristics of the commutator.
1.4.3 commutator autotuning
The industrial personal computer calculates the deviation between the site position of the commutator and the standard position of the commutator, if the deviation between the site position of the commutator and the standard position exceeds a given value, the direction of the stepping motor is adjusted according to the deviation of the commutator 2 on the left side and the right side of the standard position, the stepping motor works in a stepping mode, and the commutator 2 is adjusted to reach the standard working position through negative feedback after one step is taken each time.
1.5 the intelligent detection and control method of the commutator has the concrete processes:
fig. 8 is a flow device commutator intelligent detection and control flow chart, the implementation process is: and (3) closing an air source switch, opening a valve when the air pressure reaches 0.5Mpa, adjusting the frequency of a frequency converter to control a water pump, adjusting the water flow, sending a direction signal and a frequency signal to a stepping motor according to a photoelectric switch signal when the water flow is stable, calculating the time for switching the commutator into the water weighing container and the time for switching the commutator out of the water weighing container, calculating the uncertainty of the commutator 2, and calibrating and verifying the flowmeter if the uncertainty is not more than 0.006% (not exceeding the standard).
If the uncertainty exceeds the standard, acquiring images of the left stop position and the right stop position of the commutator 2, calculating the position deviation between the commutator stop position E and a commutator standard position E0 through image processing, turning off the water pump, and judging whether the position deviation between the commutator stop position E and the commutator standard position E0 exceeds the standard; and if the position deviation of the commutator 2 does not exceed the standard (the absolute value of the position deviation is less than or equal to the set value of 1.5mm), displaying and overhauling the coupling system of the commutator 2. And if the position deviation of the commutator 2 exceeds the standard, judging whether the position deviation of the commutator on the right exceeds the standard.
If the position deviation of the commutator 2 on the right side exceeds the standard, the standard position of the commutator is the right standard position; displaying the position standard exceeding information of the commutator 2 on the right, if the position of the commutator 2 is on the left of the standard position and the position deviation (the difference between the right position of the commutator and the standard right position of the commutator) is negative, prompting to adjust the position information of the commutator, sending a rightward direction signal and a step signal to the stepping motor 1 by the industrial personal computer, driving the commutator 2 to move one step by the stepping motor 1, acquiring the image information of the commutator 2, comparing the image information with the standard position of the commutator 2 again through image processing, if the position deviation exceeds the standard, continuing the process until the stepping motor 1 drives the commutator 2 to move to the right standard position, then locking the commutator 2, and adjusting the right photoelectric switch catch to the normal working position (the photoelectric switch lamp is turned on to off); if the position of the commutator 2 is right of the standard position, the position deviation (the difference between the right position of the commutator and the right standard position of the commutator) is positive, the industrial personal computer sends a leftward direction signal and a stepping signal to the stepping motor 1, the stepping motor 1 drives the commutator 2 to step, image information of the commutator 2 is collected and is compared with the standard position of the commutator again through image processing, if the deviation exceeds 1.5mm, the process is continued until the commutator reaches the right standard position, then the commutator 2 is locked, and a right photoelectric switch catch of the commutator is adjusted to a normal working position (the photoelectric switch lamp is turned on to off); and after the position of the commutator 2 is adjusted, restarting the water pump, testing the uncertainty of the commutator 2 after the water flow is stable, and prompting to calibrate and verify information of the flowmeter if the requirement is met.
If the position deviation of the commutator 2 on the left side exceeds the standard, the standard position of the commutator is the left standard position; displaying the position overproof information of the commutator 2 on the left, if the position of the commutator is on the right of the standard position, and the position deviation (the difference between the left position of the commutator and the left standard position of the commutator) is positive, prompting to adjust the position information of the commutator, sending a left direction signal and a step signal to the step motor 1, the step motor 1 driving the commutator 2 to move one step to the left, collecting the image of the commutator 2, comparing the image with the standard position of the commutator 2 again through image processing, if the deviation is overproof, continuing the process until the step motor 1 driving the commutator 2 to move to the left standard position, then locking the commutator 2, and adjusting the left photoelectric switch catch of the commutator to the normal working position (the photoelectric switch lamp is turned on to the moment); if the position of the commutator 2 is on the left side of the standard position, and the position deviation (the difference between the left position of the commutator and the left standard position of the commutator) is negative, the industrial personal computer gives a rightward direction signal and a stepping signal of the stepping motor 1, the stepping motor 1 drives the commutator 2 to walk one step at a time rightward until the commutator 2 reaches the normal working position on the left side, then the commutator 2 is locked, and the blocking piece of the left photoelectric switch of the commutator 2 is adjusted to the normal working position (the photoelectric switch lamp is turned on to off); and restarting the water pump after the position of the commutator 2 is adjusted, testing the uncertainty of the commutator 2 again after the water flow is stable, and prompting the information of calibration and verification of the flowmeter if the requirement is met.
Those not described in detail in this specification are within the skill of the art.
Claims (7)
1. The utility model provides a flow device commutator intellectual detection system and control system which characterized in that includes: the system comprises an industrial personal computer, a camera, a PCI card I, a signal conditioning board, a stepping motor driver, a stepping motor (1), a commutator (2), a photoelectric switch, a PCI card II and a standard meter;
the standard meter is connected with a signal conditioning board, the industrial personal computer is connected with the signal conditioning board through a PCI (peripheral component interconnect) card I, the signal conditioning board is connected with a stepping motor driver, the stepping motor driver is connected with a stepping motor (1), the stepping motor is connected with a commutator, a camera is arranged on the commutator (2), the camera is connected with the industrial personal computer, the commutator is connected with a photoelectric switch, and the photoelectric switch is connected with the industrial personal computer through a PCI card II;
the standard meter is used for indicating the water flow of the current flow device and sending a standard meter signal to the signal conditioning board; the signal conditioning board is used for filtering and isolating signals; the industrial personal computer is used for acquiring a reversing signal of the photoelectric switch through the PCI card II, sending a control signal to the stepping motor driver through the PCI card I, and performing position identification on a commutator image acquired by the camera through the Ethernet to give fault information of the commutator; the stepping motor driver is used for controlling the stepping motor (1); the stepping motor is used for driving the commutator (2) to realize commutation and adjustment of commutation speed, so that calibration verification is carried out on the flowmeter and uncertainty test is carried out on the commutator; the camera is used for acquiring an image of the commutator and transmitting the image to the industrial personal computer through the Ethernet; the photoelectric switch is used for sending a reversing signal to the industrial personal computer through the PCI card II; the commutator is connected with a commutator shaft, and a left photoelectric switch catch (5) and a right photoelectric switch catch (6) are further mounted on the commutator shaft.
2. The flow device diverter intelligent detection and control system of claim 1, wherein: and the left photoelectric switch blocking piece (5) and the right photoelectric switch blocking piece (6) are connected with the commutator shaft through jackscrews.
3. The flow device diverter intelligent detection and control system of claim 1, wherein: the photoelectric switch comprises a left photoelectric switch (4) and a right photoelectric switch (3), wherein the left photoelectric switch (4) and the right photoelectric switch (3) are respectively matched with a left photoelectric switch separation blade (5) and a right photoelectric switch separation blade (6) for use.
4. The flow device diverter intelligent detection and control system of claim 1, wherein: the model of the PCI card I is PCI-1780, and the model of the PCI card II is PCI-1750.
5. An intelligent detection and control method for a diverter of a flow device, applying the intelligent detection and control system of any one of claims 1-4, characterized by comprising the following steps:
step 1: closing an air source switch, and opening a valve when the air pressure reaches 0.5 Mpa;
step 2: adjusting a frequency converter to control a water pump, adjusting water flow, and when the water flow is stable, sending a direction signal and a frequency signal to a stepping motor by an industrial personal computer according to a photoelectric switch signal, calculating the time for switching in and switching out a water weighing container of a commutator, and calculating the uncertainty of the commutator;
step 3: judging whether the uncertainty of the commutator exceeds the standard:
if the uncertainty of the commutator is not more than 0.006 percent, calibrating and verifying the flowmeter;
if the uncertainty is greater than 0.006%, acquiring image information of the commutator stopping position through a camera, calculating the deviation between the commutator stopping position and the commutator standard position through image processing, turning off the water pump, and entering the step 4;
and 4, step 4: judging whether the position deviation between the stopping position of the commutator and the standard position of the commutator exceeds the standard or not:
if the absolute value of the position deviation between the stopping position of the commutator and the standard position of the commutator is not more than 1.5mm, a coupling system of the commutator is overhauled;
if the absolute value of the position deviation between the stopping position of the commutator and the standard position of the commutator is more than 1.5mm, entering the step 5;
and 5: judging whether the absolute value of the position deviation of the commutator on the right side is larger than 1.5mm, if so, entering a step 6; if not, entering step 9;
step 6: displaying the position overproof information of the commutator on the right, judging whether the commutator is on the right of the standard position, if so, entering step 8, and if not, entering step 7;
and 7: the commutator is arranged on the left side of the standard position, the position information of the commutator is prompted and adjusted, the industrial personal computer gives a rightward direction signal and a stepping signal to the stepping motor, the stepping motor drives the commutator to move one step, commutator images are collected, the position deviation between the commutator images and the standard position of the commutator is calculated through image processing, and if the absolute value of the position deviation is larger than 1.5mm, the step 7 is repeated; if the absolute value of the position deviation is not more than 1.5mm, entering the step 10;
and 8: the position of the commutator is on the right side of the standard position, the position information of the commutator is prompted to be adjusted, the industrial personal computer gives a leftward direction signal and a stepping signal of the stepping motor, the stepping motor drives the commutator to move one step, commutator images are collected, the position deviation of the commutator images and the standard position of the commutator is calculated through image processing, if the absolute value of the position deviation is larger than 1.5mm, the step 8 is repeated, and if the absolute value of the position deviation is not larger than 1.5mm, the step 10 is carried out;
and step 9: displaying the position overproof information of the commutator on the left, judging whether the commutator is on the left of the standard position, if so, entering step 7, otherwise, entering step 8;
step 10: locking the commutator, adjusting a photoelectric switch blocking piece of the commutator to a normal working position, and then returning to the step 2.
6. The intelligent flow device diverter detection and control method according to claim 5, wherein the uncertainty of the diverter is calculated in step 2 by the following method: the flow is adjusted to the verification flow of the commutator, and the verification flow comprises large flow points 575m3H, medium flow point 259m3H and a low flow point of 57.5m3H, stabilizing for 10 minutes, operating the commutator to enable the commutator to commutate for 10 times at each flow point, and respectively calculating the uncertainty of the corresponding flow point;
wherein, t1For cutting into the weighing container, t2Time for cutting out the weighing water container, t1aThe mean value of the time for 10 cuts into the weighing vessel, t2aThe average value of the time for weighing the water container is 10 times cut; s1Class A relative standard uncertainty, s, for cut-in weighing vessels2For cutting out the A-type relative standard uncertainty of the weighing water container, u is the B-type relative standard uncertainty, tmin30 seconds;
commutator uncertainty is: u shapeCommutator＝(s1 2+s2 2+u2)1/2And the uncertainty value of the commutator is the largest uncertainty value of the commutator among the large flow point, the medium flow point and the small flow point.
7. The flow device diverter intelligent detection and control method according to claim 5, wherein: step 2, the image processing comprises gray processing, median filtering, edge detection and edge fitting of the commutator image; the gray level processing adopts a weighted average value method to carry out weighted average on the red, green and blue color components of the color image, wherein the green weight is 0.6, the red weight is 0.3 and the blue weight is 0.1; median filtering, namely filtering noise by adopting median filtering; the edge detection adopts a multi-scale Marr operator to detect the edge points of the commutator; and performing linear fitting on the edge points of the commutator by adopting a least square method to obtain the edge characteristics of the commutator.
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