CN111551235A - Bed charge level monitoring device and monitoring method in dense phase filling process of solid catalyst - Google Patents
Bed charge level monitoring device and monitoring method in dense phase filling process of solid catalyst Download PDFInfo
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- CN111551235A CN111551235A CN202010452516.5A CN202010452516A CN111551235A CN 111551235 A CN111551235 A CN 111551235A CN 202010452516 A CN202010452516 A CN 202010452516A CN 111551235 A CN111551235 A CN 111551235A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/22—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
- G01F23/28—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring the variations of parameters of electromagnetic or acoustic waves applied directly to the liquid or fluent solid material
- G01F23/284—Electromagnetic waves
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/80—Arrangements for signal processing
- G01F23/802—Particular electronic circuits for digital processing equipment
- G01F23/804—Particular electronic circuits for digital processing equipment containing circuits handling parameters other than liquid level
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Abstract
The invention discloses a monitoring device for bed charge level state in dense phase filling process of solid catalyst, comprising a pulse radar level meter, a motion device and control unit, and a data transmission and processing system; the moving device comprises a bedplate, a step shaft, a rotating shaft, a large gear ring, a small gear ring, a rotating and swinging servo motor, a proximity switch and a detection piece; the radar level meter is arranged in a central hole of the fixed shaft above the gear ring, and the motor drives the step shaft to realize the circumferential rotation of the horizontal plane and the axial swing of the vertical plane of the radar level meter by respectively engaging the large gear ring and the shaft coupling through the pinion during working, so as to traverse and scan the whole material surface; the control unit comprises an electric control cabinet, wireless remote control equipment and a touch panel. The device can monitor the bed material level state in the dense phase filling process in real time by using one radar level meter, has simple structure form and convenient operation and maintenance, and has the advantages of low process cost and high product reliability.
Description
Technical Field
The invention relates to a device for monitoring bed charge level state by using an electromagnetic wave technology, in particular to a device and a method for monitoring bed charge level in a dense phase filling process of a solid catalyst, belonging to the field of energy and chemical engineering and being suitable for surface measurement and visualization in other fields.
Background
The development trend of large-scale, standardization and strength of energy chemical equipment effectively promotes the rapid development of the industry, and as important equipment in the energy chemical process industry, the dense phase filling technology of a fixed bed tower reactor is also widely concerned, and the quality of the filling quality directly influences the economic indexes of the production technology. Therefore, the method can accurately master the material level state information of the bed layer in the reactor in real time, adjust the filling density and position, further reduce the phenomena of channeling, bridging and the like, and has important significance for improving the productivity of enterprises and promoting the development of chemical process.
In addition to the traditional experience method and manhole detection method, measurement methods based on different technologies such as mechanical dipstick, laser detection, infrared imaging and high-speed camera shooting are introduced to reproduce the material level condition of the bed layer in the reactor at present, for example, Kuo et al, research and develop a monitoring device based on a laser detection technology, combine with an image processing technology, apply laser scanning to 3D material level monitoring and reconstruction, accurately and visually determine the thickness of a material level coke mine, and meet the requirement of analyzing the working condition. The yellow runt is provided with a furnace top infrared camera device on a new No. 6 steel blast furnace, so that the material level condition and the gas flow distribution condition of the furnace throat of the reactor can be known and mastered in time. However, due to the special working conditions in the tower reactor, the above methods all have certain limitations, including the problems of interference of dark and dust environments to measurement signals, damage of severe working conditions to equipment, high manufacturing cost, high maintenance cost and the like, and limit the practical application of the bed material level state monitoring device.
The microwave pulse radar level meter provides a simple platform for surface monitoring by utilizing an electromagnetic wave transmission technology, has extremely high signal-to-noise ratio and excellent solid surface reflection performance, can still keep good reflection signals under high-concentration dust and extremely low dielectric constant, and is not influenced by the atmospheric pressure or temperature condition in a reactor. The Chen first, the middle-aged and the like designed array radar charge level monitoring equipment, 6 single-point radar measuring instruments are installed at proper positions on the top of the reactor in a distributed mode, and the shape of a radial charge line is reconstructed. WeChadong et al utilize motor lead screw transmission, realize the stockline and measure. The development of a bed material level monitoring technology is urgently required in the filling process of chemical production, wherein the accuracy of a measuring result, the diversity of material level shape embodying modes, the robustness of a system and the performance of low cost and high benefit in industrial application are very important.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a monitoring device for the bed charge level state in the dense-phase filling process of a catalyst; the technical problems of high cost, low efficiency and high operation difficulty in monitoring the bed layer state in the reactor in the prior art are solved.
In order to solve the technical problems, the invention is realized by adopting the following technical scheme: a bed charge level monitoring device in a dense phase filling process of solid catalyst comprises:
the monitoring assembly comprises a pulse radar level meter, a rotary driving assembly, a swinging driving assembly and an annular bedplate, wherein the rotary driving assembly is used for driving the pulse radar level meter to rotate around a Z axis, and the swinging driving assembly is used for driving the pulse radar level meter to swing around the origin of an xyz space rectangular coordinate system in the vertical direction; the rotary driving component comprises a rotary servo motor arranged on the bedplate, and the output end of the rotary servo motor is provided with a small gear ring meshed with the large gear ring; the swing driving assembly comprises a swing servo motor fixedly mounted on the large gear ring relatively and a step shaft rotatably mounted on the large gear ring through a bearing seat, one end of the step shaft is in transmission connection with the output end of the swing servo motor, the axis of the step shaft is perpendicular to the axis of the rotating shaft, a through hole coaxial with the rotating shaft is formed in the step shaft, and the pulse radar level meter is axially mounted in the through hole; when the rotary servo motor is started, the rotary shaft can drive the swing driving assembly and the pulse radar level meter to rotate around the axis of the inner hole of the bedplate relative to the bedplate; in the initial state, an antenna of the pulse radar level meter is positioned in the z-axis direction;
the controller is in signal connection with the rotary servo motor and used for controlling the rotary angle β of the pulse radar level meter, the swing servo motor is in signal connection with the controller and used for controlling the swing angle theta of the pulse radar level meter, and the pulse radar level meter is in signal connection with the controller and used for obtaining the distance L measured by the pulse radar level meter when the rotary angle β and the swing angle theta are measured0And processing the obtained data to obtain the space coordinate of the point A to be measured.
Further, the rotation angle β is determined by a linear relationship between the number of rotation turns of the rotary servo motor and the rotation stroke of the large gear. The swing angle theta is determined by the linear relation between the number of rotation turns of the swing servo motor and the rotation stroke of the step shaft.
The device further comprises an input unit, wherein the input unit is used for inputting the rotation angle beta and the swing angle theta, is in signal connection or electric connection with the controller and is used for receiving and sending motion commands to the rotation servo motor and the swing servo motor respectively according to the input rotation angle beta and the input swing angle theta.
The device further comprises a rotation angle positioning device, wherein the rotation angle positioning device comprises a first detection piece fixedly mounted opposite to the swing servo motor, a first initial positioning switch and 2 first limit alarm switches, wherein the first initial positioning switch and the 2 first limit alarm switches are respectively mounted on the bedplate; the first initial positioning switch is arranged in a staggered manner with the first limit alarm switch and the rotary servo motor, and the first proximity switch can be in induction fit with the first detection piece and is used for positioning the swing servo motor and the step shaft in the initial state in the x-axis direction; the 2 first limit alarm switches are respectively arranged at two sides of the rotary servo motor, and the 2 first limit alarm switches can be respectively in induction fit with the first detection sheets and are used for limit alarm of a rotation angle beta to prevent the swing servo motor from colliding with the rotary servo motor or a mounting frame of the rotary servo motor; the first proximity switch and the 2 first limit alarm switches are respectively in signal connection with the controller. Before each measurement, the rotary servo motor can be retreated to the first initial positioning switch, and if the rotary servo motor is close to the first limit alarm switch, the rotary servo motor decelerates until the rotary servo motor stops moving.
The device further comprises a swing angle positioning device, wherein the swing angle positioning device comprises a second detection piece arranged on the step shaft, a semicircular mounting plate arranged on the large gear ring, 2 second limit alarm switches respectively arranged at two ends of the semicircular mounting plate and a second initial positioning switch arranged between the 2 second limit alarm switches; the semicircular mounting plate spans the step shaft and is fixedly connected with the large gear ring, the step shaft is perpendicular to a vertical surface where the semicircular mounting plate is located, a central axis of the step shaft penetrates through the circle center of a circle where the semicircular mounting plate is located, and the outer wall of the step shaft is in clearance fit with an inner ring of the semicircular mounting plate; the second initial positioning switch and the 2 second limit alarm switches are respectively in signal connection with the controller, the second detection piece is in induction fit with the second initial positioning switch and used for positioning the material level meter antenna in the initial state in the z-axis direction, and the second detection piece is in induction fit with the second limit alarm switch and used for limit alarm of the swing angle theta, so that the material level of the radar material level meter is guaranteed to be measured all the time, and the monitoring device is prevented from being damaged due to overlarge swing angle. Before each measurement, the swing servo motor is retreated to the second initial positioning switch, and if the swing servo motor is close to the second limit alarm switch, the swing servo motor decelerates until the swing servo motor stops moving.
Further, the controller is a PLC, an embedded control panel or a data acquisition card.
Furthermore, the pulse radar level gauge comprises a radar distance measuring unit, a simple sighting device, a horn antenna, a HART connection configuration and a handheld operator (the handheld operator is a parameter setting remote controller equipped for the radar, can adjust the measurement precision, the sampling surface, the echo control and the like of the radar, and is equipped for the radar when leaving the factory, and a user can adjust the parameters). The pulse radar level meter has the transmitting frequency of 24.2-25.2 GHz, the range of measurement is 0.35-100 m, 4-20 mA analog signals are output, the weight of a shell is 6.1kg by aluminum casting painting, the process temperature range is-40- +200 ℃, and the pulse radar level meter has excellent application in extreme dust, fly ash bins, coal powder and Lu Hua powder bins.
The controller is in signal connection with the input unit and is used for receiving and respectively sending motion instructions to the rotary servo motor and the swing servo motor according to the input rotary angle beta and the input swing angle theta, so that the pulse radar is controlled to automatically measure according to a set route, and full-material-level height data is obtained; the pulse radar can also be controlled to move to some specified points, and the height information of the specified points is measured, so that the specified point measurement and the specified material line measurement are realized.
Furthermore, the input unit is any one or more of an industrial computer, a touch panel and a handheld remote controller.
Furthermore, the system also comprises a signal acquisition module, wherein a signal input end of the signal acquisition module is connected with the pulse radar level meter, and a signal output end of the signal acquisition module is connected with the controller, and is used for converting analog quantity measured by the pulse radar level meter into digital quantity and transmitting the digital quantity to the programmable logic controller, so that L is obtained0. Further communicating with industrial computer via programmable logic controller to L0And processing and storing.
The device further comprises an electrical control cabinet, a switch device, a measuring instrument, a remote control receiving module, a protective electrical appliance and an auxiliary device group, wherein the switch device, the measuring instrument, the remote control receiving module, the protective electrical appliance and the auxiliary device group are integrally installed in the electrical control cabinet; and a servo driver, a programmable logic controller and other auxiliary equipment sets which are respectively used for driving the swing servo motor and the rotation servo motor are also integrally installed in the electric control cabinet. Specifically, the wireless remote control equipment is in signal connection with the controller through a remote control receiving module, and the touch panel is electrically connected with the controller and used for driving and controlling the starting and stopping of the swinging servo motor and the rotating servo motor and the rotation and swinging in the positive and negative directions; the wireless remote control equipment manually controls the starting and stopping of the movement device and the rotation and the swing in the positive and negative directions in a button mode; the touch panel can read the rotation and swing angle values of the current motion device in real time and display the current measured distance value of the pulse radar; the touch panel can send a position instruction to the moving device, appoint the pulse radar to move to a corresponding position and start automatic or manual measurement.
Furthermore, the data transmission and processing system comprises a radar information acquisition module, an upper computer and a programmable logic controller communication module.
Furthermore, the large gear ring is fixed on the bedplate through a rotating shaft, the step shaft is fixed on the large gear ring through a bearing seat, and the pulse radar is installed in a central hole of the step shaft and is clamped and fixed through double screws.
Furthermore, the swing servo motor is connected with an L-shaped plate fixed on the large gear ring, and a step shaft is driven to rotate through a coupler, so that the pulse radar can realize axial swing of a vertical surface; the rotary servo motor is fixed on a boss supported by the screw rod, and drives the pulse radar to realize circumferential rotation of a horizontal plane by meshing a pinion with the large gear ring.
Furthermore, the bed charge level monitoring device in the dense phase filling process of the solid catalyst is arranged on a tower plate in the tower reactor, and the selection of the installation position is based on that: the interference of the chute is avoided as much as possible, the influence of dense-phase filling equipment at the center and the edge of the reactor on radar echo is reduced, so that higher echo quality is obtained, the range of the monitoring device is enlarged as much as possible, and the monitoring device is prevented from being incapable of scanning the full charge level when the charge line is higher; optionally, the opening at 1/4 of the diameter of the tray in the column reactor, i.e., the dense phase packing device is installed with the opening at the center of the inner wall of the reactor.
Compared with the prior art, the bed charge level state monitoring device in the dense phase filling process of the solid catalyst provided by the invention has the following benefits: the pulse radar is used for outputting electromagnetic waves for ranging, so that the interference of dark and dust environments is avoided, and the accuracy and reliability of measuring results are improved; the carrying movement device and the control unit are used for scanning all bed material levels in real time by using a single radar, so that the visualization of a dense phase filling process is realized, the process cost is reduced, and the production efficiency is improved.
Drawings
The invention is further illustrated with reference to the following figures and examples.
FIG. 1 is a schematic diagram of the bed charge level monitoring device in the dense phase loading process of the present invention.
FIG. 2 is a schematic view of the bed level monitoring apparatus installed during dense phase loading of the present invention.
FIG. 3 is a schematic plan view of the bed charge level monitoring device in the dense phase loading process of the present invention.
FIG. 4 is a schematic view of the operation of the bed level monitoring device during dense phase loading of the present invention.
Fig. 5 is a signal acquisition module circuit.
Fig. 6 is an electrical control cabinet layout.
Fig. 7 is a monitoring device for bed charge level state in the dense phase loading process of solid catalyst of the present embodiment.
Fig. 8 is a schematic view of a rotating metal detection segment.
Fig. 9 is a schematic view of a wobble metal detection plate.
FIG. 10 is a schematic diagram of the electrical and signal connections between the controller and various components in the bed level monitoring apparatus during dense phase loading of solid catalyst in an embodiment of the present invention.
In the figure: 1. the device comprises a pulse radar level meter, 2 parts of a bedplate, 3 parts of a step shaft, 4 parts of a rotating shaft, 5 parts of a pinion, 6 parts of a large gear ring, 7 parts of a swing servo motor, 8 parts of a rotating servo motor, 9-1 parts of a first initial positioning switch, 9-2 parts of a first limit alarm switch, 10 parts of a first detection piece, 11 parts of a second detection piece, 12-1 parts of a second initial positioning switch, 12-2 parts of a second limit alarm switch, 13 parts of a semicircular mounting plate, 14 parts of an L-shaped plate, 15 parts of a signal acquisition module, 16 parts of a PLC (programmable logic controller), 17 parts of a touch panel, 18 parts of an industrial computer, 19 parts of a handheld remote controller, 20 parts of a fixed bed reactor, 21 parts of a tower reactor internal tower plate, 22 parts of a catalyst filling port, 23 parts of a reactor bed material level and 24 parts of a remote control.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and are not intended to limit the scope of the present invention.
As shown in FIG. 1, the device for monitoring bed charge level in dense phase loading process of solid catalyst of the present embodiment comprises a monitoring component and a controller. The controller is a PLC, an embedded control board or a data acquisition card, and in this embodiment, a PLC controller is selected, and more specifically, a mitsubishi FX5 programmable logic controller (called mitsubishi FX5PLC for short).
The monitoring assembly comprises a pulse radar level gauge 1, a rotary driving assembly used for driving the pulse radar level gauge 1 to rotate circumferentially around a Z-axis horizontal plane, a swinging driving assembly used for driving the pulse radar level gauge 1 to swing in the vertical direction around the origin of an xyz space rectangular coordinate system, and an annular bedplate 2. The rotary table further comprises a rotary shaft 4 rotatably installed in an inner hole of the table plate 2, the rotary shaft 4 is a hollow cylinder along the axis direction, a large gear ring 6 is arranged on the outer wall of the rotary shaft 4 in the circumferential direction, the rotary driving assembly comprises a rotary servo motor 8 installed on the table plate 2, and a small gear ring meshed with the large gear ring 6 is arranged at the output end of the rotary servo motor 8. The rotary servo motor 8 is fixed on a boss supported by a screw, the pinion 5 is positioned at the bottom of the boss, and the pinion 5 is meshed with the large gear ring 6 to drive the pulse radar level meter 1 to rotate around the Z axis in the circumferential direction of the horizontal plane.
Swing drive assembly includes relative fixed mounting swing servo motor 7 on bull gear 6 and rotates through the bearing frame and install step axle 3 on bull gear 6, and the one end of step axle 3 is connected with swing servo motor 7's output transmission, and the axis of step axle 3 is perpendicular with the axis of rotation 4, has seted up the perforating hole coaxial with axis of rotation 4 on the step axle 3, and the perforating hole diameter is 25mm, pulse radar level meter 1 is installed in the perforating hole and is fixed with 8 mm's diameter double-screw clamp along the axial. Specifically, the swing servo motor 7 is connected with the large gear ring 6 through an L-shaped plate 14 fixed on the large gear ring 6, moves along with the gear ring, and drives the step shaft 3 to rotate through a coupler, so that the pulse radar level meter 1 can swing axially on a vertical surface.
When the rotary servo motor 8 is started, the rotary shaft 4 can drive the swing driving assembly and the pulse radar level meter 1 to rotate around the axis of the inner hole of the bedplate 2 relative to the bedplate 2; in the initial state, the level gauge antenna of the pulsed radar level gauge 1 is located in the z-axis direction.
The pulse radar level gauge 11 has a transmitting frequency of 24.2-25.2 GHz, and the housing is generally painted with cast aluminum and weighs about 6.1 kg.
The rotary servo motor 8 is in signal connection with the controller and is used for controlling the rotation angle β of the pulse radar level gauge 1, the swing servo motor 7 is in signal connection with the controller and is used for controlling the swing angle theta of the pulse radar level gauge 1, the rotation angle β is determined by the linear relation between the number of rotation turns of the rotary servo motor 8 and the rotation stroke of the large gear wheel, the swing angle theta is determined by the linear relation between the number of rotation turns of the swing servo motor 7 and the rotation stroke of the step shaft, the pulse radar level gauge 1 is in signal connection with the controller and is used for obtaining the distance h measured when the pulse radar level gauge 1 is located on the z axis and obtaining the distance L measured when the pulse radar level gauge 1 is located on the rotation angle β and the swing angle theta0And processing the obtained data to obtain the space coordinate of the point A to be measured.
Specifically, the device also comprises a rotation angle positioning device, wherein the rotation angle positioning device comprises a first detection piece 10 fixedly installed opposite to the swing servo motor 7, a first initial positioning switch 9-1 and 2 first limit alarm switches 9-2 which are respectively installed on the bedplate 2; the first initial positioning switch 9-1 is staggered with the first limit alarm switch 9-2 and the rotary servo motor 8, and the first proximity switch 9-1 can be in induction fit with the first detection piece 10 and is used for positioning the swing servo motor 7 and the step shaft 3 in the initial state in the x-axis direction; the 2 first limit alarm switches 9-2 are respectively arranged at two sides of the rotary servo motor 8, and the 2 first limit alarm switches 9-2 can be respectively matched with the first detection piece 10 in an induction way and are used for limit alarm of a rotation angle beta; the first proximity switch 9-1 and the 2 first limit alarm switches 9-2 are respectively in signal connection with the controller.
The device also comprises a swing angle positioning device, wherein the swing angle positioning device comprises a second detection piece 11 arranged on the step shaft 3, a semicircular mounting plate 13 arranged on the large gear ring 6, 2 second limit alarm switches 12-2 respectively arranged at two ends of the semicircular mounting plate 13 and a second initial positioning switch 12-1 arranged between the 2 second limit alarm switches 12-2; the semicircular mounting plate 13 spans the step shaft 3 and is fixedly connected with the large gear ring 6, the vertical surface where the step shaft 3 is located is vertical to the semicircular mounting plate 13, the central axis of the step shaft 3 penetrates through the center of a circle where the semicircular mounting plate 13 is located, and the outer wall of the step shaft 3 is in clearance fit with the inner ring of the semicircular mounting plate; the second initial positioning switch 12-1 and the 2 second limit alarm switches 12-2 are respectively in signal connection with the controller, the second detection piece 11 is in induction fit with the second initial positioning switch 12-1 and used for positioning the level meter antenna in the initial state in the z-axis direction, and the second detection piece 11 is in induction fit with the second limit alarm switches 12-2 and used for limit alarm of the swing angle theta.
Referring to FIG. 7, which is a monitoring device for bed charge level status in dense phase loading process of solid catalyst of the present embodiment, the monitoring principle of the device is that a fixed bed reactor 20 has a diameter of 5m, a moving device is installed at 1/4 diameter to establish a spatial coordinate system as shown in FIG. 7, a rotation angle β and a swing angle theta are given, and the distance L between the installation position and a point A to be measured is measured0Then there is
L3＝l1*cosβ＝L0*sinθ*cosβ
l2＝l1*sinβ＝L0*sinθ*sinβ
h＝L0*cosθ；
I.e. point a has a spatial coordinate of (L)0*sinθ*cosβ，L0*sinθ*sinβ，L0*cosθ)。
A monitoring method for bed charge level state in solid catalyst dense phase filling process is carried out based on the bed charge level monitoring device in the solid catalyst dense phase filling process. Fig. 4 shows the working state of the bed charge level monitoring device, which specifically comprises the following steps:
an input unit and a signal acquisition module 15 are also included. The input unit comprises an industrial computer 18 in signal connection with the PLC controller 16, a touch panel 17 and a hand-held remote controller 19, specifically: the remote controller 19 can control the start, stop, swing and rotation of the bed material level monitoring device, and a stop button can emergently stop braking to interrupt the measurement process; the touch panel 17 and the industrial computer 18 can jointly send a control instruction to the bed material level monitoring device and receive and display feedback information, and the difference is that the touch panel 17 cannot post-process received material level data, only can display the current rotation angle beta, the swing angle theta and the measured point distance, namely other state information of the bed material level monitoring device, cannot reconstruct a material level image, the touch panel 17 is in wireless communication with the PLC 16, and the industrial computer 18 is in RS232 communication with the PLC 16. The controller is in signal connection with the input unit, and is used for receiving and inputting the rotation angle beta and the swing angle theta in the input unit according to the input rotation angle beta and the swing angle theta, specifically, inputting the rotation angle beta and the swing angle theta in the input unit according to a set value, and transmitting the rotation angle beta and the swing angle theta to the PLC controller, and controlling the rotation servo motor 8 and the swing servo motor 7 through the PLC controller to enable the pulse radar level meter 1 to reach a specified movement position and test a point A to be tested, specifically: the pulse radar level gauge 1 emits electromagnetic waves and returns an analog signal of 4-20 mA according to the received echo signal. The signal acquisition module 15 acquires analog quantity measured by the pulse radar, converts the analog quantity into a distance value, transmits the distance value to the programmable logic controller 16 (namely, the PLC controller 16), and then the programmable logic controller 16 communicates with the industrial control computer 18 or the touch panel 17) to process and store the distance value to obtain a space coordinate of a point A to be measured, so that material level height data is obtained; the pulse radar can also be controlled to move to a certain or a plurality of specified points, and the height information of the specified points is measured, thereby realizing the measurement of the specified points and the measurement of the specified stockline. And then the PLC controller controls the rotary servo motor 8 and the swing servo motor 7 to enable the pulse radar level gauge 1 to return to the initial state, and inputs the next set of rotary angle beta and swing angle theta to repeat the operation.
The pulsed radar level gauge 1 is suitable for use with pulsed radar level gauges 1 commonly used in the art, and may be selected by a person skilled in the art as desired. The pulsed radar level gauge of this embodiment includes radar distance measurement unit, simple and easy sight, horn antenna, HART connection configuration and handheld operation ware (handheld operation ware is the parameter setting remote controller that radar itself was equipped with, can adjust the measurement accuracy, the sampling face, the echo control etc. of radar, be equipped with when the radar leaves the factory, the user can to parameter adjustment). The pulse radar level meter has the transmitting frequency of 24.2-25.2 GHz, the range of measurement is 0.35-100 m, 4-20 mA analog signals are output, the weight of a shell is 6.1kg by aluminum casting painting, the process temperature range is-40- +200 ℃, and the pulse radar level meter has excellent application in extreme dust, fly ash bins, coal powder and Lu Hua powder bins.
Fig. 5 is a circuit diagram of the signal acquisition module 15 selected in this embodiment, in which the signal acquisition module converts analog quantity measured by the pulse radar into digital quantity, fits a distance conversion formula according to a mapping relationship, converts the digital quantity into a distance value, transmits the distance value to the programmable logic controller, and then communicates with the industrial computer or the touch panel through the programmable logic controller to process and store the distance value. The range values measured by the pulsed radar level gauge itself are not suitable for use in the present invention. Therefore, an acquisition circuit is added, see fig. 5, a sampling resistor is connected in series from two terminals at the top end of the pulsed radar level gauge, and the voltage value flowing through the resistor is acquired, based on the graph, L0 can be obtained, specifically: the pulse radar level meter of the embodiment adopts a Siemens SITRANSLR260 level meter which is supplied by two wires, in order to avoid overlarge load and other interferences of an acquisition circuit, a 500-ohm sampling resistor is connected in series in a current transmission loop, a 4-20 mA.DC current source is converted into a 1-5 V.DC voltage source, one end of the sampling resistor is connected with a voltage measurement port of a PLC, the other end of the sampling resistor is connected with a reference ground port of the PLC, voltage values at two ends of the sampling resistor are measured through the voltage acquisition port of a Mitsubishi FX5 programmable logic controller, the voltage values are converted into a digital quantity x through AD, and a mapping relation is established, so that a distance conversion formula L is obtained0A + x + b (in this example, a is-0.005, and b is 20).
FIG. 2 is a schematic diagram of the installation of a bed level monitoring device. The bed charge level monitoring device in the dense phase filling process of the solid catalyst is arranged on a tower plate 21 in the tower reactor, and the selection of the installation position is based on that: the interference of a chute is avoided as much as possible, the influence of dense-phase filling equipment at the center and the edge of the inner wall of the reactor on radar echo is reduced, so that higher echo quality is obtained, the measuring range of the pulse radar level meter 1 is enlarged as much as possible, and the situation that the pulse radar level meter 1 cannot scan the full level when the material line is higher is avoided; the opening at 1/4 of the diameter of the tray 20 in the tower reactor, namely the opening with the center distance of 1.25m, is selected for installation, and the diameter of the opening is 300 mm.
Fig. 3 shows the starting and stopping modes of the bed material level monitoring device, as shown in fig. 3, three first proximity switches 9 and three second proximity switches 12 are respectively arranged, the first proximity switch 9 is an inductance type square shell normally open proximity switch with the model number QIN-05P16NO3, and the second proximity switch 12 is an inductance type cylindrical normally closed proximity switch with the model number LJ18 A3-8-Z/AX.
As shown in fig. 8 and 9, the first detection piece 10 and the second detection piece 11 are formed by processing 67x10x1mm metal sheets, and are respectively fixed on the L-shaped plate 1415, the swing servo motor 7 is fixedly mounted on the large gear ring 6 and the step shaft 3 through the L-shaped plate 1415, the first detection piece 10 represents the current movement position of the rotary servo motor 8, and the second detection piece 11 represents the current movement position of the swing servo motor 7. Taking the rotational movement as an example, before starting the measurement each time, the controller controls the rotational servo motor 8 to return to the initial state, that is, the first detection piece 10 stays at the first initial positioning switch, and during the movement, if the first detection piece 10 approaches any one of the first limit alarm switches, the controller controls the rotational servo motor 8 to decelerate until the movement is stopped, so as to avoid mechanical damage.
As shown in fig. 6, the electrical control cabinet is further integrated with a switch device (button switch and emergency stop button), an indicator light (indicating whether the switch device is in a working state), a remote control receiving module (for signal connection with the wireless remote control device), an air circuit breaker, and a servo driver for controlling the rotation servo motor 8 and the swing servo motor 7. The movement of the radar level meter adopts a three-way controllable mode, and the wireless remote control equipment, the touch panel and the graphical user interface of the upper computer can control the work of the movement device, so that the convenience of operation of a user is improved. The Mitsubishi FX5 series programmable logic controller is selected as a central control unit and is integrally installed in an electrical control cabinet together with a switch device, a remote control receiving module, a servo driver, a protective electric circuit and other auxiliary equipment groups. The wireless remote control equipment manually controls the starting and stopping of the movement device and the rotation and the swing in the positive and negative directions in a key mode, so that the movement of the motor can be forced to be finally stopped, and the safety of the equipment is protected; the touch panel can not only read the rotation and swing angle values of the current motion device in real time and display the current measured distance value of the pulse radar, but also send a position instruction to the motion device to finish automatic or manual measurement; the upper computer graphic user interface can present images of single material line fitting and three-dimensional carpet graph reconstruction on the basis of the touch panel.
Compared with the prior art, the method utilizes the pulse radar to output electromagnetic waves to monitor the bed charge level state in the dense phase filling process, avoids the interference of dark and dust environments, and improves the accuracy and reliability of the measurement result; the mechanical structure of the monitoring device is optimized, the charge level is reconstructed, the moving device and the control unit are carried, and the charge level of all beds is scanned by using a single radar in real time, so that the visualization of the dense phase filling process is realized, the process cost is reduced, and the production efficiency is improved.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and their concepts should be equivalent or changed within the technical scope of the present invention.
Claims (8)
1. A bed charge level monitoring device in the dense phase filling process of solid catalyst is characterized in that: the method comprises the following steps:
the monitoring assembly comprises a pulse radar level gauge (1), a rotary driving assembly for driving the pulse radar level gauge (1) to rotate around a Z axis, a swinging driving assembly for driving the pulse radar level gauge (1) to swing around the origin of an xyz space rectangular coordinate system in the vertical direction, and an annular bedplate (2); the rotary table further comprises a rotary shaft (4) which is rotatably arranged in an inner hole of the table plate (2), the rotary shaft (4) forms a hollow cylinder along the axis direction, a large gear ring (6) is arranged on the outer wall of the rotary shaft (4) in a circumferential direction, the rotary driving component comprises a rotary servo motor (8) which is arranged on the table plate (2), and a small gear ring which is meshed with the large gear ring (6) is arranged at the output end of the rotary servo motor (8); the swing driving assembly comprises a swing servo motor (7) fixedly mounted on the large gear ring (6) relatively and a step shaft (3) rotatably mounted on the large gear ring (6) through a bearing seat, one end of the step shaft (3) is in transmission connection with the output end of the swing servo motor (7), the axis of the step shaft (3) is perpendicular to the axis of the rotating shaft (4), a through hole coaxial with the rotating shaft (4) is formed in the step shaft (3), and the pulse radar level meter (1) is axially mounted in the through hole; when the rotary servo motor (8) is started, the rotary shaft (4) can drive the swing driving assembly and the pulse radar level meter (1) to rotate around the axis of the inner hole of the bedplate (2) relative to the bedplate (2); in the initial state, an antenna of the pulse radar level gauge (1) is positioned in the z-axis direction;
the controller is connected with the rotary servo motor (8) through signals and used for controlling the rotary angle β of the pulse radar level gauge (1), the swing servo motor (7) is connected with the controller through signals and used for controlling the swing angle theta of the pulse radar level gauge (1), and the pulse radar level gauge (1) is connected with the controller through signals and used for obtaining the distance L measured by the pulse radar level gauge (1) in the rotary angle β and the swing angle theta0And processing the obtained data to obtain the space coordinate of the point A to be measured.
2. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: the rotation angle beta is determined by the linear relation between the rotation turn number of the rotation servo motor (8) and the rotation stroke of the large gear; the swing angle theta is determined by the linear relation between the number of rotation turns of the swing servo motor and the rotation stroke of the step shaft.
3. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: the device also comprises a rotation angle positioning device, wherein the rotation angle positioning device comprises a first detection piece (10) fixedly installed opposite to the swing servo motor (7), a first initial positioning switch (9-1) and 2 first limit alarm switches (9-2) which are respectively installed on the bedplate (2); the first initial positioning switch (9-1) is arranged in a staggered manner with the first limit alarm switch (9-2) and the rotary servo motor (8), and the first proximity switch (9-1) can be in induction fit with the first detection piece (10) and is used for positioning the swing servo motor (7) and the step shaft (3) in the initial state in the x-axis direction; 2 first limit alarm switches (9-2) are respectively arranged at two sides of the rotary servo motor (8), and the 2 first limit alarm switches (9-2) can be respectively in induction fit with the first detection sheets (10) and are used for limit alarm of a rotary angle beta; the first proximity switch (9-1) and the 2 first limit alarm switches (9-2) are respectively in signal connection with the controller.
4. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: the device also comprises a swing angle positioning device, wherein the swing angle positioning device comprises a second detection piece (11) arranged on the step shaft (3), a semicircular mounting plate (13) arranged on the large gear ring (6), 2 second limit alarm switches (12-2) respectively arranged at two ends of the semicircular mounting plate (13) and a second initial positioning switch (12-1) arranged between the 2 second limit alarm switches (12-2); the semicircular mounting plate (13) spans the step shaft (3) and is fixedly connected with the large gear ring (6), the step shaft (3) is perpendicular to a vertical surface where the semicircular mounting plate (13) is located, the central axis of the step shaft (3) penetrates through the circle center of a circle where the semicircular mounting plate (13) is located, and the outer wall of the step shaft (3) is in clearance fit with the inner ring of the semicircular mounting plate; the second initial positioning switch (12-1) and the 2 second limit alarm switches (12-2) are respectively in signal connection with the controller, the second detection piece (11) is in induction fit with the second initial positioning switch (12-1) and used for positioning the level meter antenna in the initial state in the z-axis direction, and the second detection piece (11) is in induction fit with the second limit alarm switches (12-2) and used for limit alarm of the swing angle theta.
5. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: the controller is a PLC, an embedded control panel or a data acquisition card.
6. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: the controller is in signal connection with the input unit and is used for receiving and sending motion instructions to the rotary servo motor and the swing servo motor respectively according to the input rotary angle beta and the input swing angle theta.
7. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 6, wherein: the input unit is any one or more of an industrial computer, a touch panel and wireless remote control equipment.
8. The device for monitoring bed charge level in dense phase filling process of solid catalyst as claimed in claim 1, wherein: still include signal acquisition module (15), signal acquisition module's signal input end is connected with pulse radar level meter, and signal acquisition module's signal output part is connected with the controller for with the analog quantity that pulse radar level meter surveyed, convert the digital quantity and transmit for programmable logic controller, and then obtain L0。
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010452516.5A CN111551235B (en) | 2020-05-26 | 2020-05-26 | Bed charge level monitoring device and monitoring method in dense phase filling process of solid catalyst |
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| CN202010452516.5A CN111551235B (en) | 2020-05-26 | 2020-05-26 | Bed charge level monitoring device and monitoring method in dense phase filling process of solid catalyst |
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1264033A (en) * | 2000-01-21 | 2000-08-23 | 曾征 | High-accuracy radar monitor system for material level in storage |
| CN102864263A (en) * | 2012-10-22 | 2013-01-09 | 北京科技大学 | Novel mechanical scanning radar device for measuring shape of shaft furnace charge level |
| CN103471554A (en) * | 2013-09-27 | 2013-12-25 | 唐山市建华自动控制设备厂 | Charge level three-dimensional imaging measurement and control system |
| DE202013012462U1 (en) * | 2013-11-05 | 2016-12-19 | Vega Grieshaber Kg | Swiveling horn antenna for a level radar |
| CN206311975U (en) * | 2016-12-27 | 2017-07-07 | 成都国卫通信技术有限公司 | A kind of Radar IF simulation device |
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2020
- 2020-05-26 CN CN202010452516.5A patent/CN111551235B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1264033A (en) * | 2000-01-21 | 2000-08-23 | 曾征 | High-accuracy radar monitor system for material level in storage |
| CN102864263A (en) * | 2012-10-22 | 2013-01-09 | 北京科技大学 | Novel mechanical scanning radar device for measuring shape of shaft furnace charge level |
| CN103471554A (en) * | 2013-09-27 | 2013-12-25 | 唐山市建华自动控制设备厂 | Charge level three-dimensional imaging measurement and control system |
| DE202013012462U1 (en) * | 2013-11-05 | 2016-12-19 | Vega Grieshaber Kg | Swiveling horn antenna for a level radar |
| CN206311975U (en) * | 2016-12-27 | 2017-07-07 | 成都国卫通信技术有限公司 | A kind of Radar IF simulation device |
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| CN111551235B (en) | 2022-05-17 |
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