CN113188339A - Kiln operation equipment control system - Google Patents
Kiln operation equipment control system Download PDFInfo
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- CN113188339A CN113188339A CN202110590595.0A CN202110590595A CN113188339A CN 113188339 A CN113188339 A CN 113188339A CN 202110590595 A CN202110590595 A CN 202110590595A CN 113188339 A CN113188339 A CN 113188339A
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- 238000001514 detection method Methods 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 238000001035 drying Methods 0.000 claims abstract description 8
- 239000011449 brick Substances 0.000 claims abstract description 5
- 238000004891 communication Methods 0.000 claims description 15
- 238000000034 method Methods 0.000 claims description 11
- 238000002955 isolation Methods 0.000 claims description 10
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- 238000012896 Statistical algorithm Methods 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/04—Arrangements of indicators or alarms
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- General Engineering & Computer Science (AREA)
- Control Of Temperature (AREA)
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Abstract
The invention relates to a kiln operation equipment control system which comprises a fault detection system, a PLC automatic control system and an electric manual control system, wherein the fault detection system is respectively connected with the PLC automatic control system and the electric manual control system, and the PLC automatic control system is PLC automatic control linked with a limit switch and is used for realizing automatic entry of a wet blank vehicle into a drying kiln, automatic exit of a dry blank vehicle from the drying kiln, automatic entry of the dry blank vehicle into a roasting kiln and automatic exit of a finished brick vehicle from the roasting kiln. When the fault detection system detects that the PLC and the limit switch in the PLC automatic control system have faults, the electric manual control system is started to maintain production, and the electric manual control system opens the motor, so that the ferry vehicle travels, the kiln door is opened and closed, the tractor moves forwards and backwards, the pusher moves forwards and backwards, and the stepper moves forwards and backwards. The automatic control and manual control modes are adopted, so that the kiln operation equipment control system can stably and reliably operate for a long time.
Description
Technical Field
The invention relates to the technical field of control systems, in particular to a control system of kiln operation equipment.
Background
The kiln is a furnace for firing ceramic articles and sculptures or fusing enamel on the surface of metal articles, generally constructed of bricks and stones, and can be made in various sizes as required, and operated by using combustible gas, oil or electricity. The working environment of the electric control system of the industrial kiln is often severe, and the surrounding electromagnetic environment is quite complex, so that the reliability and the safety of equipment become very outstanding problems.
In the prior art, an electrical control system of an industrial kiln is generally a PID (proportion integration differentiation) strategy control system, which can basically meet the requirements of the control system and realize automatic temperature control, but due to the complex thermal characteristics of the kiln, the electric control system has the characteristics of large delay, nonlinearity, strong coupling, multivariable and the like, and the multivariable of temperature, pressure, atmosphere and the like among temperature regions are mutually restricted and interfered, so that the system has the advantages of low response speed, large overshoot, poor anti-interference capability and difficult control effect to achieve the expected target.
Under the influence of the working environment of electromagnetic interference, the PID strategy control system sometimes goes down to cause the shutdown of the kiln control system, the high output of the kiln economically requires the kiln control system to be stably and reliably operated for a long time, otherwise, the control error is increased, the whole control system is failed in serious conditions, and huge economic loss is directly caused.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a kiln operation equipment control system which adopts two modes of automatic control and manual control, and automatically switches to the mode of manual control when the automatic control fails, so that the kiln control system can stably and reliably operate for a long time, and the control effect of the system is improved.
The above object of the present invention is achieved by the following technical solutions:
a kiln operation equipment control system comprises a fault detection system, a PLC automatic control system and an electric manual control system, wherein the fault detection system is respectively connected with the PLC automatic control system and the electric manual control system, and the PLC automatic control system is PLC automatic control linked with a limit switch and is used for realizing automatic entry of a wet blank vehicle into a drying kiln, automatic exit of a dry blank vehicle from the drying kiln, automatic entry of the dry blank vehicle into a roasting kiln and automatic exit of a finished brick vehicle from the roasting kiln;
when the fault detection system detects that the PLC and the limit switch in the PLC automatic control system have faults, the electric manual control system is started to maintain production, and the electric manual control system opens the motor, so that the ferry vehicle can walk, the kiln door can be opened and closed, the tractor can move forwards and backwards, the pusher can move forwards and backwards, and the stepper can move forwards and backwards.
The present invention in a preferred example may be further configured to: the PLC automatic control system comprises a data monitoring module, a temperature control module, a feeding control module, an AI system controller module and an anti-interference module, wherein the AI system controller module is connected with the temperature control module and is used for controlling the gas quantity of the kiln so that the firing temperature of the kiln strictly reaches a standard temperature curve;
the anti-interference module is respectively connected with the data monitoring module, the temperature control module and the feeding control module, and is used for eliminating interference between the power supply end and the signal input channel.
The present invention in a preferred example may be further configured to: the AI system controller module comprises a PID controller, a kiln, an inference engine, a knowledge base, a self-learning mechanism, a database and an information acquisition and processing unit, wherein the information acquisition and processing unit is used for acquiring the state and data of the control system on line;
the database comprises a static database and a dynamic database, the static database stores parameters which are unchanged and started during the operation of the system, and the dynamic database stores system modeling parameters and temporary storage results of an inference process;
the knowledge base stores inference rules, provides rule information for the inference engine, obtains Kp, Ki and Kd parameters of the PID controller by using fuzzy inference, and transmits the parameters to the PID controller, so that a data online updating transformation control strategy is realized.
The present invention in a preferred example may be further configured to: the anti-interference module comprises a special line power supply device, a power supply filter, an isolation transformer and an instantaneous voltage suppressor, wherein the special line power supply device adopts a non-power supply line to supply power or directly draws a special line from the root of a non-power low-voltage transformer to supply power;
the power filter filters peak interference by installing capacitors at an input end and an output end, a primary side and a secondary side in the isolation transformer are respectively provided with a shielding layer, the shielding layer of the primary side is connected with the shielding layer of the secondary side through a capacitor and then connected to the ground of the secondary side, and the transient voltage suppressor is used for suppressing the lightning stroke induction high peak voltage invading into a power grid and the overvoltage caused by operation faults.
The present invention in a preferred example may be further configured to: the anti-interference module further comprises an analog input access anti-interference unit and a digital input channel anti-interference unit, the analog input access anti-interference unit comprises a controller input module with a differential input function, a twisted shielding wire and an analog filter, one end of a shielding layer of the twisted shielding wire is grounded on site, an amplitude limiting circuit is connected in parallel at the end close to the A/D converter, and the digital input channel anti-interference unit comprises a communication module based on a photoelectric isolation technology and a digital filter.
The present invention in a preferred example may be further configured to: the fault detection system comprises a communication module, a cable, an industrial personal computer and an alarm device, and the PLC automatic control system also comprises a CPU module, a DI module, a DO module and a programming computer;
the limit switch is connected to the CPU module through the DI module and the cable, the alarm device is connected to the CPU module through the DO module and the cable, the industrial personal computer and the programming computer are connected to the communication module through network cables, and the CPU module is connected to the communication module.
In summary, the invention includes at least one of the following beneficial technical effects:
1. through setting up two kinds of control methods that can switch over at will of PLC automatic control system and electric manual control system, in the normal production process, by the operation work of PLC automatic control system automatic control kiln operation equipment, when fault detection system detects PLC in the PLC automatic control system and limit switch and breaks down, automatic shutdown PLC automatic control system and open electric manual control system. The electric motor is turned on after the corresponding button is pressed by an operator, so that the kiln operation equipment can normally operate, the kiln control system can stably and reliably operate for a long time, and the control effect of the system is improved.
2. The kiln operation equipment as industrial process control has the characteristics of uncertainty, nonlinearity, coupling, large lag and the like, an AI system controller module is designed and applied to a temperature control module of the kiln aiming at the requirements of high precision, real-time adjustment, stable control and the like proposed by the production process, the process requirements of each stage in the firing of the tile products are used as the constraint conditions of the AI system controller module, a rule is made, and a combustion-supporting air proportional combustion burner is controlled to ensure that the firing temperature of the tile products strictly reaches the required temperature curve, so that the defects of long transition time, slow heating rate and the like of the traditional PID algorithm are improved.
3. The working environment of the industrial kiln equipment control system is often severe, and the surrounding electromagnetic environment is quite complex, so that the reliability and the safety of the equipment become very outstanding problems. The data monitoring module relates to data communication, the temperature control module relates to detection and control of micro-voltage signals, the feeding control module relates to detection and control of discrete signals, and each part has characteristics, so that anti-interference measures adopted must have strong pertinence. The anti-interference module can eliminate the interference between the power supply end and the signal input channel, so that the reliability of the kiln operation equipment is improved.
Drawings
Fig. 1 is a block diagram of the overall structure of the present invention.
Fig. 2 is a block diagram showing an AI system controller module according to the present invention.
Fig. 3 is a block diagram showing a fault detection system of the present invention.
Reference numerals: 1. a fault detection system; 11. a communication module; 12. an industrial personal computer; 13. an alarm device; 2. a PLC automatic control system; 21. a CPU module; 22. a DI module; 23. a DO module; 24. programming a computer; 25. a limit switch; 3. an electric manual control system; 4. an AI system controller module; 41. a PID controller; 42. a kiln; 43. an inference engine; 44. a knowledge base; 45. a self-learning mechanism; 46. a database; 47. an information acquisition and processing unit.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
Referring to fig. 1, the kiln operation equipment control system disclosed by the invention comprises a fault detection system 1, a PLC automatic control system 2 and an electric manual control system 3, wherein the fault detection system 1 is respectively connected with the PLC automatic control system 2 and the electric manual control system 3, and the PLC automatic control system 2 is a PLC automatic control linked with a limit switch 25 and is used for realizing that a wet blank vehicle automatically enters a drying kiln, a dry blank vehicle automatically exits the drying kiln, a dry blank vehicle automatically enters a roasting kiln and a finished brick vehicle automatically exits the roasting kiln.
When the fault detection system 1 detects that the PLC and the limit switch 25 in the PLC automatic control system 2 have faults, the electric manual control system 3 is started to maintain production, and the electric manual control system 3 opens the motor, so that the ferry vehicle travels, the kiln door is opened and closed, the tractor moves forwards and backwards, the car pusher moves forwards and backwards, and the stepper moves forwards and backwards.
Referring to fig. 3, the fault detection system 1 includes a communication module 11, a cable, an industrial personal computer 12, and an alarm device 13, and the PLC automatic control system 2 further includes a CPU module 21, a DI module 22, a DO module 23, and a programming computer 24. The limit switch 25 is connected to the CPU module 21 through the DI module 22 and a cable, the alarm device 13 is connected to the CPU module 21 through the DO module 23 and a cable, the industrial personal computer 12 and the programming computer 24 are connected to the communication module 11 through a network cable, and the CPU module 21 is connected to the communication module 11.
When the fault detection system 1 detects that the PLC automatic control system 2 has a fault, a picture in the alarm device 13 prompts a red light flash alarm in a fault state, so that electric maintenance personnel can find and solve the fault in a short time, and the fault processing time is shortened. When a fault occurs, the PLC automatic control system 2 can be automatically closed, the electric manual control system 3 is started, normal operation of production is guaranteed, and the control effect of the system is improved.
The PLC automatic control system 2 comprises a data monitoring module, a temperature control module, a feeding control module, an AI system controller module 4 and an anti-interference module, wherein the AI system controller module 4 is connected with the temperature control module and used for controlling the gas quantity of the kiln so that the firing temperature of the kiln strictly reaches a standard temperature curve. The kiln operation equipment as industrial process control has the characteristics of uncertainty, nonlinearity, coupling, large lag and the like, aiming at the requirements of high precision, real-time adjustment, stable control and the like proposed by the production process, an AI system controller module 4 is designed and applied to a temperature control module of a kiln, the process requirements of each stage in the firing of the tile products are used as the constraint conditions of the AI system controller module 4, a rule is made, and a combustion-supporting air proportional combustion burner is controlled to ensure that the firing temperature of the burner strictly reaches the required temperature curve, so that the defects of long transition time, slow heating rate and the like of the traditional PID algorithm are improved.
The anti-interference module is respectively connected with the data monitoring module, the temperature control module and the feeding control module, and is used for eliminating the interference between the power supply end and the signal input channel. The working environment of the industrial kiln equipment control system is often severe, and the surrounding electromagnetic environment is quite complex, so that the reliability and the safety of the equipment become very outstanding problems. The data monitoring module relates to data communication, the temperature control module relates to detection and control of micro-voltage signals, the feeding control module relates to detection and control of discrete signals, and each part has characteristics, so that anti-interference measures adopted must have strong pertinence. The anti-interference module can eliminate the interference between the power supply end and the signal input channel, so that the reliability of the kiln operation equipment is improved.
Referring to fig. 2, the AI system controller module 4 includes a PID controller 41, a kiln 42, an inference engine 43, a knowledge base 44, a self-learning mechanism 45, a database 46, and an information acquisition and processing unit 47, the information acquisition and processing unit 47 being used to acquire status and data of the control system online. The database 46 includes a static database 46 and a dynamic database 46, the static database 46 stores the parameters of the system which do not change and are self-started during the operation, and the dynamic database 46 stores the modeling parameters of the system and the temporary results of the reasoning process. The knowledge base 44 stores inference rules, provides rule information for the inference engine 43, obtains parameters Kp, Ki and Kd of the PID controller 41 by using fuzzy inference, and transmits the parameters Kp, Ki and Kd to the PID controller 41, so as to realize online updating and transformation control strategies of data.
The information obtaining and processing unit 47 can extract and process the controlled object information, obtain the related information of the error and the error change rate of the control system through transmission and feedback information, provide basis for the inference decision and self-learning mechanism 45, and mainly include extraction of dynamic process characteristic information, input of curve set values, feedback values, and adoption of a mixed digital filtering algorithm, a characteristic statistical algorithm and a zero-crossing detection algorithm after setting by the AI system. The static database 46 stores parameters that do not change as the system progresses, such as specification requirements, fixed standards, and the like. The dynamic database 46 stores system model parameters and intermediate results of the system reasoning process, and is a dynamic memory whose information changes during system operation, continuously replacing old information with new information. The system database 46 contains a large amount of static data and dynamic data generated during the firing process knowledge, which provides convenience for reasoning and solving. The AI system controller module 4 can meet the requirements of ensuring the control accuracy, real-time performance, stability and the like.
The anti-interference module comprises a special line power supply device, a power supply filter, an isolation transformer and an instantaneous voltage suppressor, wherein the special line power supply device adopts a non-power supply line to supply power or directly draws a special line from the root of a non-power low-voltage transformer to supply power. The power filter filters peak interference by installing capacitors at an input end and an output end, a primary side and a secondary side in the isolation transformer are respectively provided with a shielding layer, the shielding layer of the primary side is connected with the shielding layer of the secondary side together through a capacitor and then connected to the ground of the secondary side, and the instantaneous voltage suppressor is used for suppressing lightning stroke induction peak voltage invading into a power grid and overpressure caused by operation faults.
Many interferences in a kiln operation equipment control system come from a power supply, and the misoperation of a control device caused by the on-off of the power supply, instantaneous short circuit and the series-in dry reactance pulse of a power grid accounts for more than 90-96% of the various interferences. Because the 'peak interference' caused by the change of the production load and the transient high voltage generated by the lightning are very harmful in the operation of the system, the interference caused by the suppression of the power supply is very important for the reliable operation of each part of the electrical system. Through setting up private line power supply unit, power filter, isolation transformer and transient voltage suppressor, can eliminate the interference that the power produced to a great extent, improve the stability of system work, reduced the probability of the system phenomenon of dying.
Furthermore, the anti-interference module further comprises an analog input access anti-interference unit and a digital input channel anti-interference unit, the analog input access anti-interference unit comprises a controller input module with a differential input function, a twisted-pair shielding wire and an analog filter, one end of a shielding layer of the twisted-pair shielding wire is grounded on site, an amplitude limiting circuit is connected in parallel at the end close to the A/D converter, and the digital input channel anti-interference unit comprises a communication module based on a photoelectric isolation technology and a digital filter.
The control device applied to the kiln operation equipment control system generally comprises a computer, a programmable controller, a temperature controller and a digital display terminal, wherein the temperature detection module is arranged at the digital display terminal, the input object of the programmable controller is mainly on-off, the input objects of the temperature controller and the temperature detection module are mainly millivolt analog voltage signals, the computer is mainly communicated with the programmable controller, the temperature controller and the temperature detection module, the whole electric system is provided with an analog input channel and a digital input channel, and different anti-interference measures are required to be taken according to different types of input signals. By arranging the analog input access anti-interference unit and the digital input channel anti-interference unit, different types of interference in the signal input channel is effectively eliminated.
The implementation principle of the embodiment is as follows: through setting up two kinds of control methods that can switch over at will of PLC automatic control system 2 and electric manual control system 3, in the normal production process, by the operation work of PLC automatic control system 2 automatic control kiln operation equipment, when fault detection system 1 detects PLC in PLC automatic control system 2 and limit switch 25 and breaks down, automatic shutdown PLC automatic control system 2 and open electric manual control system 3. The electric motor is turned on after the corresponding button is pressed by an operator, so that the kiln operation equipment can normally operate, the kiln control system can stably and reliably operate for a long time, and the control effect of the system is improved.
The embodiments of the present invention are preferred embodiments of the present invention, and the scope of the present invention is not limited by these embodiments, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.
Claims (6)
1. A kiln operation equipment control system characterized by: the automatic control system comprises a fault detection system (1), a PLC automatic control system (2) and an electric manual control system (3), wherein the fault detection system (1) is respectively connected with the PLC automatic control system (2) and the electric manual control system (3), and the PLC automatic control system (2) is under PLC automatic control linked with a limit switch (25) and is used for realizing automatic entry of a wet blank vehicle into a drying kiln, automatic exit of a dry blank vehicle from the drying kiln, automatic entry of the dry blank vehicle into a roasting kiln and automatic exit of a finished brick vehicle from the roasting kiln;
when the fault detection system (1) detects that the PLC and the limit switch (25) in the PLC automatic control system (2) have faults, the electric manual control system (3) is started to maintain production, the electric manual control system (3) opens the motor, and the ferry vehicle travels, the kiln door is opened and closed, the tractor moves forwards and backwards, the car pusher moves forwards and backwards, and the stepper moves forwards and backwards.
2. A kiln operation equipment control system according to claim 1, characterized in that: the PLC automatic control system (2) comprises a data monitoring module, a temperature control module, a feeding control module, an AI system controller module (4) and an anti-interference module, wherein the AI system controller module (4) is connected with the temperature control module and is used for controlling the gas quantity of the kiln (42) to ensure that the firing temperature of the kiln strictly reaches a standard temperature curve;
the anti-interference module is respectively connected with the data monitoring module, the temperature control module and the feeding control module, and is used for eliminating interference between the power supply end and the signal input channel.
3. A kiln operation equipment control system according to claim 2, characterized in that: the AI system controller module (4) comprises a PID controller (41), a kiln (42), an inference engine (43), a knowledge base (44), a self-learning mechanism (45), a database (46) and an information acquisition and processing unit (47), wherein the information acquisition and processing unit (47) is used for acquiring the state and data of the control system on line;
the database (46) comprises a static database (46) and a dynamic database (46), the static database (46) stores the parameters which are unchanged and started automatically in the operation of the system, and the dynamic database (46) stores the modeling parameters of the system and the temporary storage results of the reasoning process;
the knowledge base (44) stores inference rules, provides rule information for the inference engine (43), obtains Kp, Ki and Kd parameters of the PID controller (41) by using fuzzy inference, and transmits the parameters to the PID controller (41) to realize online updating and transformation of data control strategies.
4. A kiln operation equipment control system according to claim 2, characterized in that: the anti-interference module comprises a special line power supply device, a power supply filter, an isolation transformer and an instantaneous voltage suppressor, wherein the special line power supply device adopts a non-power supply line to supply power or directly draws a special line from the root of a non-power low-voltage transformer to supply power;
the power filter filters peak interference by installing capacitors at an input end and an output end, a primary side and a secondary side in the isolation transformer are respectively provided with a shielding layer, the shielding layer of the primary side is connected with the shielding layer of the secondary side through a capacitor and then connected to the ground of the secondary side, and the transient voltage suppressor is used for suppressing the lightning stroke induction high peak voltage invading into a power grid and the overvoltage caused by operation faults.
5. A kiln operation equipment control system according to claim 4, characterized in that: the anti-interference module further comprises an analog input access anti-interference unit and a digital input channel anti-interference unit, the analog input access anti-interference unit comprises a controller input module with a differential input function, a twisted shielding wire and an analog filter, one end of a shielding layer of the twisted shielding wire is grounded on site, an amplitude limiting circuit is connected in parallel at the end close to the A/D converter, and the digital input channel anti-interference unit comprises a communication module based on a photoelectric isolation technology and a digital filter.
6. A kiln operation device control system according to claim 5, wherein: the fault detection system (1) comprises a communication module (11), a cable, an industrial personal computer (12) and an alarm device (13), and the PLC automatic control system (2) further comprises a CPU module (21), a DI module (22), a DO module (23) and a programming computer (24);
the limit switch (25) is connected to the CPU module (21) through the DI module (22) and the cable, the alarm device (13) is connected to the CPU module (21) through the DO module (23) and the cable, the industrial personal computer (12) and the programming computer (24) are connected to the communication module (11) through a network cable, and the CPU module (21) is connected to the communication module (11).
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