CN112947328A - Automatic control system for industrial furnace group - Google Patents
Automatic control system for industrial furnace group Download PDFInfo
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- 239000000779 smoke Substances 0.000 claims description 41
- 238000003860 storage Methods 0.000 claims description 27
- 230000017525 heat dissipation Effects 0.000 claims description 23
- 238000013500 data storage Methods 0.000 claims description 20
- 238000004458 analytical method Methods 0.000 claims description 13
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32252—Scheduling production, machining, job shop
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Abstract
The invention discloses an automatic control system for an industrial furnace group, which relates to the technical field of industrial control and solves the technical problem that the degree of improving the efficiency of the whole system is limited because the data of the industrial furnace group is not fully utilized in the prior scheme; the operation monitoring module is arranged, and the operation state of the industrial furnace is judged by combining the temperature in the furnace, the weather data and the derivative principle, so that the monitoring precision of the operation state of the industrial furnace is improved, and the operation fault of the industrial furnace can be found in time; the energy consumption monitoring module is arranged, and the energy consumption problem of the industrial furnace can be quickly and effectively determined; the invention is provided with the display scheduling module, the selected position is obtained according to the positions of the workers and the industrial furnace, the completion condition of maintenance is judged according to the feedback maintenance signal, the workers are guaranteed to be dispatched to the maintenance position quickly, and the operation efficiency of the industrial furnace group is improved.
Description
Technical Field
The invention belongs to the field of industrial control, relates to an automatic control technology, and particularly relates to an automatic control system for an industrial furnace group.
Background
The industrial furnace is an important heat energy power device, and as the boiler devices are numerous, wide in distribution range and far in distance, certain difficulties are caused to the monitoring, control and maintenance of the devices; therefore, it is necessary to perform remote online monitoring and remote equipment fault diagnosis on the industrial furnace group, so as to reduce equipment faults and improve the operation efficiency of the industrial furnace group.
The invention patent with publication number CN101916102A provides an information transmission system for group control of industrial furnaces, which comprises a PLC unit, a temperature control instrument, a display instrument, an industrial control computer, an industrial modem, a GSM network and a mobile phone; the PLC unit, the temperature control instrument and the display instrument are respectively connected with an industrial control computer, the industrial control computer is connected with an industrial modem, the industrial modem is connected with a GSM network, and the GSM network is connected with a mobile phone.
The scheme provides standardized enterprise short message service for enterprise customers and enterprise employees by using the characteristic that short messages are carried about at any time, realizes the acquisition of production data in an enterprise, and achieves the purposes of saving cost and improving production efficiency; however, the above scheme can only realize the acquisition and display of the industrial furnace group data, but does not make full use of the industrial furnace group data, so that the degree of improving the efficiency of the whole system is limited; therefore, the above solution still needs further improvement.
Disclosure of Invention
In order to solve the problems of the scheme, the invention provides an automatic control system for an industrial furnace group.
The purpose of the invention can be realized by the following technical scheme: an automatic control system for an industrial furnace group comprises a processor, a fault monitoring module, a display scheduling module, a data storage module, an operation monitoring module, a data acquisition module and an energy consumption monitoring module;
the data acquisition module is in communication connection with the control cabinet, the control cabinet is in communication connection with the acquisition sensor, and the control cabinet comprises a PLC (programmable logic controller), a data temporary storage unit and a signal transceiver; the PLC controls the acquisition sensor to acquire working data of the industrial furnace group, respectively transmits the working data to the operation monitoring module and the energy consumption monitoring module, and simultaneously transmits the working data to the data storage module and the data temporary storage unit for storage;
the operation monitoring module analyzes the operation state of the industrial furnace group according to the working data; the energy consumption monitoring module analyzes the energy consumption of the industrial furnace group according to the working data; the fault monitoring module analyzes the fault of the industrial furnace according to the working data;
the display scheduling module is used for scheduling early warning signals and scheduling workers, and comprises:
when the display scheduling module receives the scheduling early warning signal, acquiring the position i of the industrial furnace corresponding to the scheduling early warning signal and marking the position i as a maintenance position; the scheduling early warning signal comprises an industrial furnace abnormal signal, an energy consumption early warning signal and a fault early warning signal;
acquiring a position mark of an intelligent terminal of a worker as an initial position; the intelligent terminal is in communication connection with the display scheduling module and comprises an intelligent mobile phone, a tablet computer and a notebook computer;
the method comprises the steps of obtaining an initial position closest to a maintenance position, marking the initial position as a selected position, and sending a maintenance signal and the maintenance position to an intelligent terminal of a worker corresponding to the selected position;
after receiving the maintenance signal, the worker corresponding to the selected position goes to the maintenance position to maintain the industrial furnace i; meanwhile, displaying the position of the worker corresponding to the selected position through a display scheduling module;
after the maintenance is finished, the staff sends a maintenance finishing signal to the display scheduling module through the intelligent terminal;
when the display scheduling module does not receive the overhaul completion signal within N minutes after the overhaul signal is sent out, the selected position is obtained again; wherein N is more than or equal to 10.
Preferably, the fault analysis is implemented by a fault monitoring module, including:
when the industrial furnace i simultaneously generates an industrial furnace abnormal signal and an energy consumption early warning signal; acquiring a communication state of a control cabinet and a processor corresponding to an industrial furnace i, and acquiring an operation time YSi of the industrial furnace i when the communication state is normal;
when the operation time YSi is greater than or equal to the operation time threshold, judging that the industrial furnace i has a fault, generating a fault early warning signal and sending the fault early warning signal to a display scheduling module;
and sending the sending record of the fault early warning signal to a data storage module for storage through a processor.
Preferably, the energy consumption analysis is implemented by an energy consumption monitoring module, which includes:
after the energy consumption monitoring module receives the working data, extracting the exhaust smoke temperature PYi, the excess air coefficient GKxi and the furnace surface temperature LBwi in the working data;
when the excess air coefficient GKxi meets YGKxi-rho and GKxi-p and YGKxi + rho, judging that the excess air coefficient is normal; otherwise, judging that the excess air coefficient is abnormal, generating an excess air coefficient abnormal signal and sending the excess air coefficient abnormal signal to a display scheduling module; where YGKxi is the excess air coefficient threshold, ρ is the proportionality coefficient, and ρ > 0;
when the excess air coefficient is normal, analyzing the furnace surface temperature LBwi; when the furnace surface temperature LBwi meets the condition that LBwi is larger than or equal to alpha 3 multiplied by TWD, judging that the heat dissipation loss of the industrial furnace i is abnormal, generating a heat dissipation loss abnormal signal and sending the heat dissipation loss abnormal signal to a display scheduling module; otherwise, judging that the heat dissipation loss of the industrial furnace i is normal; wherein alpha 3 is more than or equal to 5;
when the heat dissipation loss of the industrial furnace i is normal, analyzing the heat loss of the exhaust smoke, and obtaining the heat loss of the exhaust smoke of the industrial furnace i through the exhaust smoke temperature PYi and the excess air coefficient GKxi and marking as PESi; when the heat loss PESi of the exhaust smoke is within the heat loss range, judging that the heat loss of the exhaust smoke of the industrial furnace i is normal; otherwise, judging that the heat loss of the exhaust smoke of the industrial furnace i is abnormal, and generating an abnormal signal of the heat loss of the exhaust smoke to a display scheduling module; the heat loss range is 10% -20% of the total heat consumption of the industrial furnace i;
sending the sending record of the energy consumption early warning signal to a data storage module for storage through a processor; the energy consumption early warning signal comprises an excess air coefficient abnormal signal, a heat dissipation loss abnormal signal and a smoke exhaust heat loss abnormal signal.
Preferably, the analyzing the operation state of the industrial furnace group according to the working data includes:
after the operation monitoring module receives the working data, extracting the temperature LNwi in the furnace from the working data;
acquiring weather data; the weather data comprises weather temperature, weather humidity and air pressure values;
respectively marking the weather temperature, the weather humidity and the air pressure as TWD, TSD and QY; acquiring a weather coefficient TX through a formula TX ═ alpha 1 × TWD × TSD × ln (alpha 2 × QY); wherein alpha 1 and alpha 2 are proportionality coefficients, and both alpha 1 and alpha 2 are real numbers greater than 0;
establishing a first analysis array; the first analysis array comprises a weather coefficient TX and a furnace temperature LNwi which are acquired at the same time, and the weather coefficient TX and the furnace temperature LNwi are in one-to-one correspondence;
establishing a furnace interior correlation curve LNXi by taking a weather coefficient TX as an independent variable and a furnace interior temperature LNWi as a dependent variable;
derivation is carried out on the related curve LNxi to obtain a furnace inner derivative curve LDxi; making the in-furnace derivative curve LDxi equal to 0 to obtain a corresponding weather coefficient TX and marking as a stagnation point;
when the temperature LNWi in the furnace meets the condition that the temperature LNWi-mu is smaller than or equal to the LNWi and smaller than or equal to YLLNWi + mu, and the difference value of the acquisition time corresponding to two adjacent stagnation points is larger than T2, judging that the industrial furnace corresponding to the temperature LNWi in the furnace runs normally; otherwise, judging that the industrial furnace corresponding to the temperature LNwi in the furnace is abnormally operated, acquiring the position of the abnormally operated industrial furnace and marking the position as a first target position; wherein YLNV is a furnace temperature threshold corresponding to the industrial furnace i, mu is a proportionality coefficient, T2 is a time threshold, mu is more than 0, and T2 is more than 2 min;
cutting off the fuel supply of the industrial furnace with abnormal operation and simultaneously generating an industrial furnace abnormal signal;
sending the abnormal signal of the industrial furnace and the first target position to a display scheduling module through a processor; sending the related curves in the furnace and the derivative curves in the furnace to a display scheduling module for displaying; and meanwhile, the first target position, the in-furnace correlation curve and the in-furnace derivative curve are sent to a data storage module for storage.
Preferably, the collecting sensor is used for collecting the working data of the industrial furnace group, and comprises:
marking the industrial furnace in the industrial furnace group as i, i ═ 1, 2, … …, n;
acquiring working data of an industrial furnace i through an acquisition sensor, wherein the working data comprises smoke exhaust temperature, an excess air coefficient, furnace temperature, furnace surface temperature and operation duration, and respectively marking the smoke exhaust temperature, the excess air coefficient, the furnace temperature, the furnace surface temperature and the operation duration as PYi, GKXi, LNwi, LBwi and YSi; and sending the working data to a display scheduling module for display.
Preferably, the processor is configured to analyze the communication status of the control cabinet in real time, and includes:
sending, by the processor, a first status signal to a signal transceiver in the control cabinet according to a period T1; the period T1 ∈ [0.1,10 ];
the signal transceiver acquires the receiving time of the first state signal after receiving the first state signal, and sends the receiving time to the data temporary storage unit for storage; meanwhile, sending a second state signal to the processor through the signal transceiver;
when the processor receives the second state signal, acquiring a time difference value between the sending time of the first state signal and the received time of the second state signal, marking the time difference value as SC, and generating a communication identifier;
when the time difference SC meets 0< SC ≦ T1, judging that the communication state of the processor and the control cabinet is normal, and assigning the communication identifier to 1; otherwise, judging that the communication state of the processor and the control cabinet is abnormal, and assigning the communication identifier to be 0;
establishing a communication state curve by taking the moment when the second state signal is received as an independent variable and taking the communication identifier as a dependent variable;
when the communication marks corresponding to the continuous three independent variables are negative values, generating a communication interrupt signal, and respectively sending the communication state curve and the communication interrupt signal to a display scheduling module through a processor;
and sending the time difference value, the communication identifier and the sending record of the communication interrupt signal to a data storage module for storage through a processor.
Preferably, the collection sensor comprises a temperature sensor, a humidity sensor and a gas analyzer.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention is provided with an operation monitoring module, which is used for analyzing the operation state of the industrial furnace group; the operation monitoring module judges the operation state of the industrial furnace by combining the temperature in the furnace, weather data and a derivative principle, so that the monitoring precision of the operation state of the industrial furnace is improved, and the operation monitoring module can find out the operation state of the industrial furnace in time when the operation of the industrial furnace breaks down;
2. the invention is provided with an energy consumption monitoring module, which is used for analyzing the energy consumption of the industrial furnace group; the energy consumption monitoring module judges the abnormality of the industrial furnace by analyzing the exhaust gas temperature, the excess air coefficient and the furnace surface temperature of the industrial furnace, and the selected parameters have pertinence and can quickly and effectively determine the energy consumption problem of the industrial furnace;
3. the invention is provided with a display scheduling module, which schedules the staff according to the scheduling early warning signal; the display scheduling module acquires the selected position according to the positions of the workers and the industrial furnace, judges the completion condition of maintenance according to the fed-back maintenance signal, ensures that the workers are rapidly dispatched to the maintenance position, and is favorable for improving the operation efficiency of the industrial furnace group.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic diagram of the principle of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, an automatic control system for an industrial furnace group includes a processor, a fault monitoring module, a display scheduling module, a data storage module, an operation monitoring module, a data acquisition module and an energy consumption monitoring module;
the data acquisition module is in communication connection with the control cabinet, the control cabinet is in communication connection with the acquisition sensor, and the control cabinet comprises a PLC (programmable logic controller), a data temporary storage unit and a signal transceiver; the PLC controls the acquisition sensor to acquire working data of the industrial furnace group, respectively transmits the working data to the operation monitoring module and the energy consumption monitoring module, and simultaneously transmits the working data to the data storage module and the data temporary storage unit for storage;
the operation monitoring module analyzes the operation state of the industrial furnace group according to the working data; the energy consumption monitoring module analyzes the energy consumption of the industrial furnace group according to the working data; the fault monitoring module analyzes the fault of the industrial furnace according to the working data;
the display scheduling module is used for scheduling the early warning signal and scheduling the staff, and comprises:
when the display scheduling module receives the scheduling early warning signal, acquiring the position i of the industrial furnace corresponding to the scheduling early warning signal and marking the position i as a maintenance position; the scheduling early warning signal comprises an industrial furnace abnormal signal, an energy consumption early warning signal and a fault early warning signal;
acquiring a position mark of an intelligent terminal of a worker as an initial position; the intelligent terminal is in communication connection with the display scheduling module and comprises an intelligent mobile phone, a tablet computer and a notebook computer;
the method comprises the steps of obtaining an initial position closest to a maintenance position, marking the initial position as a selected position, and sending a maintenance signal and the maintenance position to an intelligent terminal of a worker corresponding to the selected position;
after receiving the maintenance signal, the worker corresponding to the selected position goes to the maintenance position to maintain the industrial furnace i; meanwhile, displaying the position of the worker corresponding to the selected position through a display scheduling module;
after the maintenance is finished, the staff sends a maintenance finishing signal to the display scheduling module through the intelligent terminal;
when the display scheduling module does not receive the overhaul completion signal within N minutes after the overhaul signal is sent out, the selected position is obtained again; wherein N is more than or equal to 10.
Further, the fault analysis is realized by a fault monitoring module, which comprises:
when the industrial furnace i simultaneously generates an industrial furnace abnormal signal and an energy consumption early warning signal; acquiring a communication state of a control cabinet and a processor corresponding to an industrial furnace i, and acquiring an operation time YSi of the industrial furnace i when the communication state is normal;
when the operation time YSi is greater than or equal to the operation time threshold, judging that the industrial furnace i has a fault, generating a fault early warning signal and sending the fault early warning signal to a display scheduling module;
and sending the sending record of the fault early warning signal to a data storage module for storage through a processor.
Further, the energy consumption analysis is realized by an energy consumption monitoring module, which comprises:
after the energy consumption monitoring module receives the working data, extracting the exhaust smoke temperature PYi, the excess air coefficient GKxi and the furnace surface temperature LBwi in the working data;
when the excess air coefficient GKxi meets YGKxi-rho and GKxi-p and YGKxi + rho, judging that the excess air coefficient is normal; otherwise, judging that the excess air coefficient is abnormal, generating an excess air coefficient abnormal signal and sending the excess air coefficient abnormal signal to a display scheduling module; where YGKxi is the excess air coefficient threshold, ρ is the proportionality coefficient, and ρ > 0;
when the excess air coefficient is normal, analyzing the furnace surface temperature LBwi; when the furnace surface temperature LBwi meets the condition that LBwi is larger than or equal to alpha 3 multiplied by TWD, judging that the heat dissipation loss of the industrial furnace i is abnormal, generating a heat dissipation loss abnormal signal and sending the heat dissipation loss abnormal signal to a display scheduling module; otherwise, judging that the heat dissipation loss of the industrial furnace i is normal; wherein alpha 3 is more than or equal to 5;
when the heat dissipation loss of the industrial furnace i is normal, analyzing the heat loss of the exhaust smoke, and obtaining the heat loss of the exhaust smoke of the industrial furnace i through the exhaust smoke temperature PYi and the excess air coefficient GKxi and marking as PESi; when the heat loss PESi of the exhaust smoke is within the heat loss range, judging that the heat loss of the exhaust smoke of the industrial furnace i is normal; otherwise, judging that the heat loss of the exhaust smoke of the industrial furnace i is abnormal, and generating an abnormal signal of the heat loss of the exhaust smoke to a display scheduling module; the heat loss range is 10 to 20 percent of the total heat consumption of the industrial furnace i;
sending the sending record of the energy consumption early warning signal to a data storage module for storage through a processor; the energy consumption early warning signals comprise an excess air coefficient abnormal signal, a heat dissipation loss abnormal signal and a smoke exhaust heat loss abnormal signal.
Further, the operation state of the industrial furnace group is analyzed according to the working data, and the method comprises the following steps:
after the operation monitoring module receives the working data, extracting the temperature LNwi in the furnace from the working data;
acquiring weather data; the weather data comprises weather temperature, weather humidity and air pressure values;
respectively marking the weather temperature, the weather humidity and the air pressure as TWD, TSD and QY; acquiring a weather coefficient TX through a formula TX ═ alpha 1 × TWD × TSD × ln (alpha 2 × QY); wherein alpha 1 and alpha 2 are proportionality coefficients, and both alpha 1 and alpha 2 are real numbers greater than 0;
establishing a first analysis array; the first analysis array comprises a weather coefficient TX and a furnace temperature LNWis which are acquired at the same time, and the weather coefficient TX and the furnace temperature LNWis are in one-to-one correspondence;
establishing a furnace interior correlation curve LNXi by taking a weather coefficient TX as an independent variable and a furnace interior temperature LNWi as a dependent variable;
derivation is carried out on the related curve LNxi to obtain a furnace inner derivative curve LDxi; making the in-furnace derivative curve LDxi equal to 0 to obtain a corresponding weather coefficient TX and marking as a stagnation point;
when the temperature LNWi in the furnace meets the condition that the temperature LNWi-mu is smaller than or equal to the LNWi and smaller than or equal to YLLNWi + mu, and the difference value of the acquisition time corresponding to two adjacent stagnation points is larger than T2, judging that the industrial furnace corresponding to the temperature LNWi in the furnace runs normally; otherwise, judging that the industrial furnace corresponding to the furnace temperature YLLNWi is abnormally operated, acquiring the position of the abnormally operated industrial furnace and marking the position as a first target position; wherein YLNV is a furnace temperature threshold corresponding to the industrial furnace i, mu is a proportionality coefficient, T2 is a time threshold, mu is more than 0, and T2 is more than 2 min;
cutting off the fuel supply of the industrial furnace with abnormal operation and simultaneously generating an industrial furnace abnormal signal;
sending the abnormal signal of the industrial furnace and the first target position to a display scheduling module through a processor; sending the related curves in the furnace and the derivative curves in the furnace to a display scheduling module for displaying; and meanwhile, the first target position, the in-furnace correlation curve and the in-furnace derivative curve are sent to a data storage module for storage.
Further, the collecting sensor is used for collecting the working data of the industrial furnace group, and comprises the following components:
marking the industrial furnace in the industrial furnace group as i, i ═ 1, 2, … …, n;
acquiring working data of an industrial furnace i through an acquisition sensor, wherein the working data comprises smoke exhaust temperature, an excess air coefficient, furnace temperature, furnace surface temperature and operation duration, and marking the smoke exhaust temperature, the excess air coefficient, the furnace temperature, the furnace surface temperature and the operation duration as PYi, GKXi, LNwi, LBwi and YSi respectively; and sending the working data to a display scheduling module for display.
Further, the processor is used for real-time analysis control cabinet's communication state, includes:
sending, by the processor, a first status signal to a signal transceiver in the control cabinet according to a period T1; the period T1 ∈ [0.1,10 ];
the signal transceiver acquires the receiving time of the first state signal after receiving the first state signal, and sends the receiving time to the data temporary storage unit for storage; meanwhile, sending a second state signal to the processor through the signal transceiver;
when the processor receives the second state signal, acquiring a time difference value between the sending time of the first state signal and the received time of the second state signal, marking the time difference value as SC, and generating a communication identifier;
when the time difference SC meets 0< SC ≦ T1, judging that the communication state of the processor and the control cabinet is normal, and assigning the communication identifier to 1; otherwise, judging that the communication state of the processor and the control cabinet is abnormal, and assigning the communication identifier to be 0;
establishing a communication state curve by taking the moment when the second state signal is received as an independent variable and taking the communication identifier as a dependent variable;
when the communication marks corresponding to the continuous three independent variables are negative values, generating a communication interrupt signal, and respectively sending the communication state curve and the communication interrupt signal to a display scheduling module through a processor;
and sending the time difference value, the communication identifier and the sending record of the communication interrupt signal to a data storage module for storage through a processor.
Further, the collection sensor includes a temperature sensor, a humidity sensor, and a gas analyzer.
Furthermore, the processor is respectively in communication connection with the fault monitoring module, the display scheduling module, the data storage module, the operation monitoring module, the data acquisition module and the energy consumption monitoring module, the display scheduling module is respectively in communication connection with the data storage module and the fault monitoring module, and the data acquisition module is respectively in communication connection with the energy consumption monitoring module and the operation monitoring module; the communication connection mode comprises a wired network and a GPRS wireless network.
The above formulas are all calculated by removing dimensions and taking numerical values thereof, the formula is one closest to the real situation obtained by collecting a large amount of data and performing software simulation, and the preset parameters and threshold values in the formula are set by the technicians in the field according to the actual situation or obtained by simulating a large amount of data.
The working principle of the invention is as follows:
marking the industrial furnace in the industrial furnace group as i; acquiring working data of the industrial furnace i through an acquisition sensor, and sending the working data to a display scheduling module for displaying;
after the operation monitoring module receives the working data, extracting the temperature LNwi in the furnace from the working data; acquiring weather data; acquiring a weather coefficient TX; establishing a first analysis array; establishing a furnace interior correlation curve LNXi by taking a weather coefficient TX as an independent variable and a furnace interior temperature LNWi as a dependent variable; derivation is carried out on the related curve LNxi to obtain a furnace inner derivative curve LDxi; making the in-furnace derivative curve LDxi equal to 0 to obtain a corresponding weather coefficient TX and marking as a stagnation point; when the temperature LNWi in the furnace meets the condition that the temperature LNWi-mu is smaller than or equal to the LNWi and smaller than or equal to YLLNWi + mu, and the difference value of the acquisition time corresponding to two adjacent stagnation points is larger than T2, judging that the industrial furnace corresponding to the temperature LNWi in the furnace runs normally; otherwise, judging that the industrial furnace corresponding to the temperature LNwi in the furnace is abnormally operated, acquiring the position of the abnormally operated industrial furnace and marking the position as a first target position; cutting off the fuel supply of the industrial furnace with abnormal operation and simultaneously generating an industrial furnace abnormal signal; sending the abnormal signal of the industrial furnace and the first target position to a display scheduling module through a processor;
after the energy consumption monitoring module receives the working data, extracting the exhaust smoke temperature PYi, the excess air coefficient GKxi and the furnace surface temperature LBwi in the working data; when the excess air coefficient GKxi meets YGKxi-rho and GKxi-p and YGKxi + rho, judging that the excess air coefficient is normal; otherwise, judging that the excess air coefficient is abnormal, generating an excess air coefficient abnormal signal and sending the excess air coefficient abnormal signal to a display scheduling module; when the excess air coefficient is normal, analyzing the furnace surface temperature LBwi; when the furnace surface temperature LBwi meets the condition that LBwi is larger than or equal to alpha 3 multiplied by TWD, judging that the heat dissipation loss of the industrial furnace i is abnormal, generating a heat dissipation loss abnormal signal and sending the heat dissipation loss abnormal signal to a display scheduling module; otherwise, judging that the heat dissipation loss of the industrial furnace i is normal; when the heat dissipation loss of the industrial furnace i is normal, analyzing the heat loss of the exhaust smoke, and obtaining the heat loss of the exhaust smoke of the industrial furnace i through the exhaust smoke temperature PYi and the excess air coefficient GKxi and marking as PESi; when the heat loss PESi of the exhaust smoke is within the heat loss range, judging that the heat loss of the exhaust smoke of the industrial furnace i is normal; otherwise, judging that the heat loss of the exhaust smoke of the industrial furnace i is abnormal, and generating an abnormal signal of the heat loss of the exhaust smoke to a display scheduling module;
when the industrial furnace i simultaneously generates an industrial furnace abnormal signal and an energy consumption early warning signal; acquiring a communication state of a control cabinet and a processor corresponding to an industrial furnace i, and acquiring an operation time YSi of the industrial furnace i when the communication state is normal; when the operation time YSi is greater than or equal to the operation time threshold, judging that the industrial furnace i has a fault, generating a fault early warning signal and sending the fault early warning signal to a display scheduling module;
when the display scheduling module receives the scheduling early warning signal, acquiring the position i of the industrial furnace corresponding to the scheduling early warning signal and marking the position i as a maintenance position; acquiring a position mark of an intelligent terminal of a worker as an initial position; the method comprises the steps of obtaining an initial position closest to a maintenance position, marking the initial position as a selected position, and sending a maintenance signal and the maintenance position to an intelligent terminal of a worker corresponding to the selected position; after receiving the maintenance signal, the worker corresponding to the selected position goes to the maintenance position to maintain the industrial furnace i; meanwhile, displaying the position of the worker corresponding to the selected position through a display scheduling module; after the maintenance is finished, the staff sends a maintenance finishing signal to the display scheduling module through the intelligent terminal; and when the display scheduling module does not receive the maintenance completion signal within N minutes after the maintenance signal is sent out, the selected position is acquired again.
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (7)
1. An automatic control system for an industrial furnace group is characterized by comprising a processor, a fault monitoring module, a display scheduling module, a data storage module, an operation monitoring module, a data acquisition module and an energy consumption monitoring module;
the data acquisition module is in communication connection with the control cabinet, the control cabinet is in communication connection with the acquisition sensor, and the control cabinet comprises a PLC (programmable logic controller), a data temporary storage unit and a signal transceiver; the PLC controls the acquisition sensor to acquire working data of the industrial furnace group, respectively transmits the working data to the operation monitoring module and the energy consumption monitoring module, and simultaneously transmits the working data to the data storage module and the data temporary storage unit for storage;
the operation monitoring module analyzes the operation state of the industrial furnace group according to the working data; the energy consumption monitoring module analyzes the energy consumption of the industrial furnace group according to the working data; the fault monitoring module analyzes the fault of the industrial furnace according to the working data;
the display scheduling module is used for scheduling early warning signals and scheduling workers, and comprises:
when the display scheduling module receives the scheduling early warning signal, acquiring the position i of the industrial furnace corresponding to the scheduling early warning signal and marking the position i as a maintenance position; the scheduling early warning signal comprises an industrial furnace abnormal signal, an energy consumption early warning signal and a fault early warning signal;
acquiring a position mark of an intelligent terminal of a worker as an initial position; the intelligent terminal is in communication connection with the display scheduling module and comprises an intelligent mobile phone, a tablet computer and a notebook computer;
the method comprises the steps of obtaining an initial position closest to a maintenance position, marking the initial position as a selected position, and sending a maintenance signal and the maintenance position to an intelligent terminal of a worker corresponding to the selected position;
after receiving the maintenance signal, the worker corresponding to the selected position goes to the maintenance position to maintain the industrial furnace i; meanwhile, displaying the position of the worker corresponding to the selected position through a display scheduling module;
after the maintenance is finished, the staff sends a maintenance finishing signal to the display scheduling module through the intelligent terminal;
when the display scheduling module does not receive the overhaul completion signal within N minutes after the overhaul signal is sent out, the selected position is obtained again; wherein N is more than or equal to 10.
2. The automated control system for an industrial furnace complex of claim 1, wherein the fault analysis is implemented by a fault monitoring module comprising:
when the industrial furnace i simultaneously generates an industrial furnace abnormal signal and an energy consumption early warning signal; acquiring a communication state of a control cabinet and a processor corresponding to an industrial furnace i, and acquiring an operation time YSi of the industrial furnace i when the communication state is normal;
when the operation time YSi is greater than or equal to the operation time threshold, judging that the industrial furnace i has a fault, generating a fault early warning signal and sending the fault early warning signal to a display scheduling module;
and sending the sending record of the fault early warning signal to a data storage module for storage through a processor.
3. The automated control system for industrial furnace complexes of claim 1, wherein the energy consumption analysis is implemented by an energy consumption monitoring module comprising:
after the energy consumption monitoring module receives the working data, extracting the exhaust smoke temperature PYi, the excess air coefficient GKxi and the furnace surface temperature LBwi in the working data;
when the excess air coefficient GKxi meets YGKxi-rho and GKxi-p and YGKxi + rho, judging that the excess air coefficient is normal; otherwise, judging that the excess air coefficient is abnormal, generating an excess air coefficient abnormal signal and sending the excess air coefficient abnormal signal to a display scheduling module; wherein YGKxi is the excess air coefficient threshold, ρ is the proportionality coefficient, and ρ > 0;
when the excess air coefficient is normal, analyzing the furnace surface temperature LBwi; when the furnace surface temperature LBwi meets the condition that LBwi is larger than or equal to alpha 3 multiplied by TWD, judging that the heat dissipation loss of the industrial furnace i is abnormal, generating a heat dissipation loss abnormal signal and sending the heat dissipation loss abnormal signal to a display scheduling module; otherwise, judging that the heat dissipation loss of the industrial furnace i is normal; wherein alpha 3 is more than or equal to 5;
when the heat dissipation loss of the industrial furnace i is normal, analyzing the heat loss of the exhaust smoke, and obtaining the heat loss of the exhaust smoke of the industrial furnace i through the exhaust smoke temperature PYi and the excess air coefficient GKxi and marking as PESi; when the heat loss PESi of the exhaust smoke is within the heat loss range, judging that the heat loss of the exhaust smoke of the industrial furnace i is normal; otherwise, judging that the heat loss of the exhaust smoke of the industrial furnace i is abnormal, and generating an abnormal signal of the heat loss of the exhaust smoke to a display scheduling module; the heat loss range is 10% -20% of the total heat consumption of the industrial furnace i;
sending the sending record of the energy consumption early warning signal to a data storage module for storage through a processor; the energy consumption early warning signal comprises an excess air coefficient abnormal signal, a heat dissipation loss abnormal signal and a smoke exhaust heat loss abnormal signal.
4. The automated control system of claim 1, wherein the operational status of the industrial furnace cluster is analyzed based on operational data, comprising:
after the operation monitoring module receives the working data, extracting the temperature LNwi in the furnace from the working data;
acquiring weather data; the weather data comprises weather temperature, weather humidity and air pressure values;
respectively marking the weather temperature, the weather humidity and the air pressure as TWD, TSD and QY; acquiring a weather coefficient TX through a formula TX ═ alpha 1 × TWD × TSD × ln (alpha 2 × QY); wherein alpha 1 and alpha 2 are proportionality coefficients, and both alpha 1 and alpha 2 are real numbers greater than 0;
establishing a first analysis array; the first analysis array comprises a weather coefficient TX and a furnace temperature LNwi which are acquired at the same time, and the weather coefficient TX and the furnace temperature LNwi are in one-to-one correspondence;
establishing a furnace interior correlation curve LNXi by taking a weather coefficient TX as an independent variable and a furnace interior temperature LNWi as a dependent variable;
derivation is carried out on the related curve LNxi to obtain a furnace inner derivative curve LDxi; making the in-furnace derivative curve LDxi equal to 0 to obtain a corresponding weather coefficient TX and marking as a stagnation point;
when the temperature LNWi in the furnace meets the condition that the temperature LNWi-mu is smaller than or equal to the LNWi and smaller than or equal to YLLNWi + mu, and the difference value of the acquisition time corresponding to two adjacent stagnation points is larger than T2, judging that the industrial furnace corresponding to the temperature LNWi in the furnace runs normally; otherwise, judging that the industrial furnace corresponding to the temperature LNwi in the furnace is abnormally operated, acquiring the position of the abnormally operated industrial furnace and marking the position as a first target position; wherein YLLNWi is a furnace temperature threshold corresponding to the industrial furnace i, mu is a proportionality coefficient, T2 is a time threshold, mu is more than 0, and T2 is more than 2 min;
cutting off the fuel supply of the industrial furnace with abnormal operation and simultaneously generating an industrial furnace abnormal signal;
sending the abnormal signal of the industrial furnace and the first target position to a display scheduling module through a processor; sending the related curves in the furnace and the derivative curves in the furnace to a display scheduling module for displaying; and meanwhile, the first target position, the in-furnace correlation curve and the in-furnace derivative curve are sent to a data storage module for storage.
5. The automated control system for an industrial furnace cluster as claimed in claim 1, wherein the collection sensor is used for collecting the working data of the industrial furnace cluster, comprising:
marking the industrial furnace in the industrial furnace group as i, i ═ 1, 2, … …, n;
acquiring working data of an industrial furnace i through an acquisition sensor, wherein the working data comprises smoke exhaust temperature, an excess air coefficient, furnace temperature, furnace surface temperature and operation duration, and respectively marking the smoke exhaust temperature, the excess air coefficient, the furnace temperature, the furnace surface temperature and the operation duration as PYi, GKXi, LNwi, LBwi and YSi; and sending the working data to a display scheduling module for display.
6. The automated control system for an industrial furnace complex of claim 1, wherein the processor is configured to analyze the communication status of the control cabinet in real time, comprising:
sending, by the processor, a first status signal to a signal transceiver in the control cabinet according to a period T1; the period T1 ∈ [0.1,10 ];
the signal transceiver acquires the receiving time of the first state signal after receiving the first state signal, and sends the receiving time to the data temporary storage unit for storage; meanwhile, sending a second state signal to the processor through the signal transceiver;
when the processor receives the second state signal, acquiring a time difference value between the sending time of the first state signal and the received time of the second state signal, marking the time difference value as SC, and generating a communication identifier;
when the time difference SC is more than 0 and less than or equal to T1, judging that the communication state of the processor and the control cabinet is normal, and assigning the communication identifier to be 1; otherwise, judging that the communication state of the processor and the control cabinet is abnormal, and assigning the communication identifier to be 0;
establishing a communication state curve by taking the moment when the second state signal is received as an independent variable and taking the communication identifier as a dependent variable;
when the communication marks corresponding to the continuous three independent variables are negative values, generating a communication interrupt signal, and respectively sending the communication state curve and the communication interrupt signal to a display scheduling module through a processor;
and sending the time difference value, the communication identifier and the sending record of the communication interrupt signal to a data storage module for storage through a processor.
7. The automated control system for an industrial furnace complex of claim 1, wherein the collection sensors comprise a temperature sensor, a humidity sensor, and a gas analyzer.
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