Self-adaptive adjusting method and system for air source penetrating through water tank

Abstract

The invention relates to the field of equipment control, in particular to a water tank penetrating air source self-adaptive adjusting method and system. The method comprises the following steps: acquiring a finishing mill start-stop signal and a wire rod head position signal in real time; dynamically calculating the residual distance from the head of the wire rod to the penetrating water tank, and generating a dynamic delay opening threshold value; the electromagnetic valve is controlled to open the pneumatic ball valve in a sectional manner; monitoring the covering length of the wire rod and converting the covering length into an equivalent gas resistance value; a dynamic pressure compensation amount is generated through a pressure closed-loop controller; the opening degree of the pneumatic ball valve is adjusted accordingly; when the finishing mill stops, the pneumatic ball valve is triggered to be closed, and a gradient pressure relief turn-off program is executed if necessary. By means of the distributed sensor array and the multi-mode recognition neural network, real-time accurate monitoring and analysis of the operation state of the pump set are achieved, dependence of post personnel is reduced, and the automation degree and stability are improved. And by dynamically optimizing the control strategy, the pump set system operates efficiently, energy waste is reduced, the energy utilization efficiency is improved, and the production cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of device control, in particular to a water tank gas source adaptive adjustment method and system. BACKGROUND

[0002] In the field of modern industrial production, the pump group system as a key power transmission and fluid control device, its running efficiency and stability have a profound impact on the entire production process. For example, in high-speed wire production, the wire needs to enter the water tank for cooling after rolling to meet the wire drawing temperature required by the process. In this process, in order to reduce the resistance of the coil head entering the water tank, the delayed opening of the water tank is usually used, and the participation of the pneumatic diaphragm valve is the key to realize this control. However, the existing control method has many drawbacks. First, the opening of the pneumatic diaphragm valve gas source depends on the manual operation of the post worker before starting, which makes the production process uncertain and risky. Second, the pre-opening of the gas source and the failure to close during short-term shutdown result in a large waste of compressed air, which not only increases production costs but also reduces energy efficiency, which is contrary to the current concept of energy saving and green production. The existence of these problems highlights the shortcomings of the existing pump group control technology in automation, intelligence and energy saving, and a more advanced, efficient and reliable pump group control method is needed to solve these problems to improve production efficiency, reduce costs, ensure production quality, reduce dependence on manual operation, and realize intelligent and automatic operation of the pump group system to better meet the needs of modern industrial production.

[0003] In the prior art, patent number CN117066288A discloses an intelligent cooling control system and method for water cooling section, which mainly focuses on monitoring the red steel signal at the entrance of the finishing mill stand and the cold steel temperature signal at the outlet of the water cooling section to realize dynamic adjustment of the water flow of the water cooling section. This method reduces the water flow at a set time interval to meet production requirements and save energy, while reducing interference with the thermal detection of on-site electrical detection components and the signal of the loop scanner in the late cooling stage. However, this patent mainly focuses on the cooling control of the water cooling section and does not involve adaptive adjustment of the water tank gas source. It also does not mention multi-modal recognition and the construction of dynamic optimization control strategies, which cannot effectively solve the above-mentioned problems of strong dependence on post personnel and energy waste. SUMMARY

[0004] The present application aims to provide a water tank gas source adaptive adjustment method and system to solve the problem of strong dependence on post personnel and energy waste in the prior art.

[0005] To achieve the above object, the following technical solutions are adopted.

[0006] A water-penetration box gas source self-adaptive adjusting method, comprising,

[0007] Step S1, real-time acquisition of a finishing mill start-stop signal and a wire rod head position signal at a water-penetration box inlet;

[0008] Step S2, when the finishing mill starts, dynamic calculation of a remaining distance of the wire rod head from the water-penetration box based on the head position signal, and generation of a dynamic delay opening threshold according to the remaining distance and a preset speed model;

[0009] Step S3, when the actual position of the wire rod head reaches the dynamic delay opening threshold, control of an electromagnetic valve to drive a pneumatic ball valve with a segmented opening curve, wherein an initial opening speed is a first slope, and the first slope is switched to a second slope when a process air pressure critical point is reached;

[0010] Step S4, synchronous monitoring of a wire rod covering length in the water-penetration box, conversion of the covering length into an equivalent air resistance value, and real-time acquisition of a compressed air pipeline pressure;

[0011] Step S5, generation of a dynamic pressure compensation amount by a pressure closed-loop controller based on the equivalent air resistance value and a real-time pressure input;

[0012] Step S6, adjustment of the pneumatic ball valve opening degree according to the dynamic pressure compensation amount, so that the pipeline pressure decreases with the increase of the equivalent air resistance value;

[0013] Step S7, when the finishing mill stops, triggering of the pneumatic ball valve to close, and execution of a gradient pressure relief shutdown program if the stop signal occurs when the wire rod has not completely passed through the water-penetration box.

[0014] Optionally, step S2 specifically comprises,

[0015] When the finishing mill starts, real-time acquisition of time-position sequence data of the wire rod head through at least two position detection points arranged along a wire rod running direction;

[0016] Calculation of an instantaneous linear speed of the wire rod in a detection section according to a distance between adjacent position detection points and a time difference of the wire rod head passing through the adjacent points;

[0017] Input of the instantaneous linear speed into a preset speed model, the preset speed model outputting a weighted average speed through the following operations:

[0018] Extraction of a current instantaneous linear speed and historical linear speeds of the previous N sampling periods,

[0019] Weighting of the historical linear speeds based on a preset aging decay coefficient,

[0020] The weighted historical linear velocity is fused with the instantaneous linear velocity to generate a weighted average velocity;

[0021] Based on the position of the closest detection point to the water tank inlet, the remaining physical distance from the wire rod head to the water tank inlet is determined;

[0022] According to the ratio of the remaining physical distance to the weighted average velocity, the expected time for the wire rod head to reach the water tank inlet is calculated;

[0023] The expected time is subtracted by the inherent response delay of the opening of the pneumatic ball valve to generate the dynamic delay opening threshold.

[0024] Optionally, the specific steps of S3 include,

[0025] When the actual position of the wire rod head reaches the dynamic delay opening threshold, an initial opening instruction is generated to drive the electromagnetic valve to increase the opening degree of the pneumatic ball valve at a first linear slope;

[0026] The actual air pressure rising rate of the compressed air pipeline is monitored in real time, and the deviation amount of the actual air pressure rising rate from the preset target rate is calculated;

[0027] When the actual air pressure value reaches the preset neighborhood range of the process air pressure critical point, the slope correction factor of the second slope is dynamically adjusted based on the deviation amount;

[0028] According to the slope correction factor, the electromagnetic valve is controlled to switch to the second linear slope to continue increasing the opening degree of the pneumatic ball valve until the target opening degree value corresponding to the process air pressure critical point is reached;

[0029] After the opening degree of the pneumatic ball valve reaches the target opening degree value, the opening degree maintenance mode is started: the actual air pressure value of the pipeline is continuously collected, and if the actual air pressure value deviates from the process air pressure critical point by more than the allowable fluctuation threshold, an opening degree compensation amount is generated by the calculus controller, and the opening degree of the pneumatic ball valve is fine-tuned according to the opening degree compensation amount.

[0030] Optionally, the steps of S4 include,

[0031] The first timestamp of the wire rod head at the inlet and the second timestamp of the wire rod tail at the outlet are acquired in real time by the position sensors arranged at the inlet and outlet of the water tank;

[0032] According to the difference between the first timestamp and the second timestamp and the wire rod travel speed, the real-time coverage length of the wire rod in the water tank is calculated;

[0033] inputting the real-time covering length into a pre-constructed segmented air resistance mapping function, the segmented air resistance mapping function performing the following operations: outputting a linearly increasing air resistance value when the real-time covering length is less than a first proportional threshold of the effective length of the water penetrating box; outputting a saturated nonlinear air resistance value when the real-time covering length reaches or exceeds the first proportional threshold;

[0034] reading a raw pressure signal of the compressed air pipeline pressure sensor in real time, and performing a sliding window filtering process on the raw pressure signal to generate a steady-state pressure value;

[0035] calculating a pressure-air resistance coupling factor according to a product of the saturated nonlinear air resistance value and the steady-state pressure value;

[0036] superimposing the pressure-air resistance coupling factor and the output value of the segmented air resistance mapping function to generate an equivalent air resistance value.

[0037] Optionally, the step S5 specifically includes,

[0038] inputting the equivalent air resistance value into a pre-constructed air resistance-pressure mapping table to output a corresponding feedforward reference pressure value;

[0039] real-time acquiring a measured pressure value of the compressed air pipeline, and calculating a pressure deviation amount of the measured pressure value from the critical point of the process air pressure;

[0040] inputting the pressure deviation amount and its change rate into a fuzzy PID controller to perform the following operations: converting the pressure deviation amount and the change rate into a proportional coefficient correction factor, an integral coefficient correction factor and a differential coefficient correction factor of PID parameters based on a pre-set fuzzy rule base; and calculating a feedback pressure adjustment amount by using the corrected PID parameters;

[0041] performing weighted fusion on the feedforward reference pressure value and the feedback pressure adjustment amount to generate a primary compensation pressure value;

[0042] when it is detected that the change rate of the wire covering length exceeds a pre-set mutation threshold, starting an integral separation mechanism: suspending the integral item; and raising the differential item weight to a pre-set upper limit value;

[0043] correcting the primary compensation pressure value according to the output state of the integral separation mechanism to generate a dynamic pressure compensation amount.

[0044] Optionally, the step S6 specifically includes,

[0045] inputting the current equivalent air resistance value into a pre-constructed air resistance-opening mapping table to output a corresponding reference opening value;

[0046] calculating an opening compensation base according to a product of the dynamic pressure compensation amount and the reference opening value;

[0047] Real-time acquisition of the change rate of the equivalent air resistance value, generation of a dynamic correction coefficient according to the change rate: when the change rate is lower than a preset slow change threshold, the dynamic correction coefficient takes a first constant value; when the change rate reaches or exceeds the slow change threshold, the dynamic correction coefficient linearly increases with the change rate;

[0048] The opening degree compensation base is multiplied by the dynamic correction coefficient to generate a target opening degree adjustment amount;

[0049] Incremental conversion of the target opening degree adjustment amount: reading the actual opening degree value of the previous control cycle of the pneumatic ball valve; calculating the difference between the target opening degree adjustment amount and the actual opening degree value of the previous cycle to generate an opening degree incremental instruction;

[0050] Processing the opening degree incremental instruction through a rate limiter: when the absolute value of the opening degree incremental instruction is less than a preset dead zone threshold, output zero increment; when the opening degree incremental instruction exceeds the dead zone threshold, limit the output according to a preset maximum change rate;

[0051] Superimposing the incremental instruction processed by the rate limiter on the actual opening degree value of the previous cycle to generate a final opening degree control instruction and drive the electromagnetic valve.

[0052] Optionally, the S7 specifically includes,

[0053] When the finishing mill stop signal is valid and the wire rod has not completely passed through the water crossing box, real-time acquisition of the current position coordinates of the wire rod tail at the outlet of the water crossing box;

[0054] According to the proportion of the current position coordinates and the total length of the water crossing box, calculating the percentage of the wire rod retention in the water crossing box;

[0055] Matching the preset pressure relief gradient segmentation rule based on the percentage of the retention: when the percentage of the retention is ≤ a first threshold, executing a first pressure relief rate curve; when the percentage of the retention is > the first threshold and ≤ a second threshold, executing a second pressure relief rate curve; when the percentage of the retention is > the second threshold, executing a third pressure relief rate curve;

[0056] Controlling the opening degree of the pneumatic ball valve to decrease according to the matched pressure relief rate curve, and synchronously monitoring the actual pressure change rate of the compressed air pipeline;

[0057] Calculating the deviation of the actual pressure change rate from the target change rate of the current pressure relief rate curve: if the deviation of the target change rate exceeds the allowable tolerance, generating a pressure relief rate correction amount based on the deviation value; dynamically adjusting the slope parameter of the pressure relief rate curve;

[0058] When the actual pressure value drops to a preset safety threshold or the percentage of the retention is zero, triggering a complete closing instruction of the pneumatic ball valve.

[0059] A water crossing box gas source adaptive adjustment system, comprising,

[0060] a signal acquisition module connected to the finishing mill control cabinet and the water tank inlet sensor, configured to acquire the finishing mill start-stop signal and the wire rod head position signal in real time;

[0061] a delay control module connected to the signal acquisition module, configured to dynamically calculate the remaining distance of the wire rod from the water tank based on the head position signal, and generate a dynamic delay opening threshold according to the remaining distance and a preset speed model;

[0062] a segmented execution module connected to the delay control module, configured to control the electromagnetic valve to drive the pneumatic ball valve in a segmented opening curve when the wire rod position reaches the dynamic delay opening threshold, wherein the initial opening speed is a first slope, and the second slope is switched when the process air pressure reaches a critical point;

[0063] a gas resistance monitoring module connected to the water tank inlet / outlet position sensor, configured to synchronously monitor the wire rod coverage length and convert the coverage length into an equivalent gas resistance value;

[0064] a pressure sensing module installed on the compressed air pipeline, configured to acquire the pipeline pressure in real time;

[0065] a pressure optimization module connected to the gas resistance monitoring module and the pressure sensing module, configured to generate a dynamic pressure compensation amount by inputting the equivalent gas resistance value and the real-time pressure into a closed-loop controller;

[0066] an opening execution module connected to the pressure optimization module, configured to adjust the opening of the pneumatic ball valve according to the dynamic pressure compensation amount, so that the pipeline pressure decreases with the increase of the equivalent gas resistance value;

[0067] a pressure relief control module connected to the signal acquisition module, configured to trigger the pneumatic ball valve to close immediately when the finishing mill stops, and execute a gradient pressure relief shutdown program when the wire rod has not completely passed through the water tank.

[0068] Optionally, the delay control module comprises:

[0069] a speed calculation unit configured to calculate the instantaneous linear speed of the wire rod through at least two position detection points;

[0070] a history fusion unit configured to generate an average speed by weighting the instantaneous linear speed and the historical linear speed of the previous N periods;

[0071] a response delay compensator configured to deduct the inherent response delay of the pneumatic ball valve from the expected time of the wire rod;

[0072] The segmented execution module comprises:

[0073] a slope corrector configured to dynamically adjust the second slope based on the air pressure rising rate deviation;

[0074] a calculus pressure stabilizer configured to generate an opening compensation amount in the opening maintaining mode.

[0075] Optionally, the gas blockage monitoring module comprises:

[0076] a coverage length calculator configured to calculate a real-time coverage length according to the inlet / outlet timestamp difference;

[0077] a segmented gas blockage converter configured to output a linear gas blockage value when the coverage length is less than a threshold value, and output a saturated nonlinear gas blockage value when the coverage length exceeds the threshold value;

[0078] The pressure relief control module comprises:

[0079] a retention amount analyzer configured to calculate a wire retention amount percentage;

[0080] a pressure relief curve matcher configured to activate a segmented pressure relief rate curve;

[0081] a slope dynamic modifier configured to adjust a pressure relief slope in real time based on a pressure change rate deviation.

[0082] Compared with the prior art, the present application has the following beneficial effects,

[0083] The multi-modal pump group dynamic optimization control method and system of the present application realize efficient and intelligent control of the pump group system, and have significant beneficial effects compared with the prior art. First, to solve the problems of strong dependence on post personnel and energy waste mentioned in the background art, the present application acquires current waveform data, pressure fluctuation spectrum and flow time sequence of each pump unit in the pump group system in real time through a distributed sensor array, processes the acquired data in time and frequency domains to generate a pump group operation state tensor, and uses a pre-constructed multi-modal recognition neural network for modal recognition, thereby realizing real-time and accurate monitoring and analysis of the pump group operation state, without the need for post personnel to manually open the pneumatic diaphragm valve, effectively reducing the dependence on post personnel and improving the automation degree and stability of production. At the same time, through a dynamic optimization control strategy, corresponding optimization instructions are output according to different operation modes, and finally the frequency converter parameter set is loaded to the programmable logic controller of the target pump unit to drive the actuator of the target pump unit to make the pump group operation trajectory converge to the target parameter envelope line, realizing efficient operation of the pump group system, reducing energy waste, improving energy utilization efficiency, and reducing production cost.

[0084] Moreover, by collecting the system response matrix after instruction execution, calculating the strategy performance evaluation index, and triggering the convolution kernel parameter fine-tuning of the multi-modal recognition neural network or the decision tree topology reconstruction of the basic optimization strategy library according to the index deviation degree, the adaptive optimization of the control strategy is realized, and the control precision and the stability of the system are further improved. At the same time, the detailed provisions and optimizations of each step, such as the refinement of data acquisition, feature extraction, modal recognition, strategy selection, and instruction conversion, make the entire control method more perfect, accurate, and efficient, and better adapt to complex industrial production environments to meet the control requirements of pump groups in different production scenarios. For example, the refinement of the data acquisition step, through operations such as fundamental wave separation processing, frequency band energy integration, and sliding window statistical analysis, more accurately extracts the feature information of the pump group running state, providing a more reliable data basis for subsequent modal recognition and optimization control. The specific provisions of the cross-modal strategy coordination step further improve the intelligent level and operation efficiency of the control system, enabling it to more effectively handle complex situations such as mixed conflict modalities. These optimization measures work together to make the multi-modal pump group dynamic optimization control method and system of the present application have significant effects in improving production efficiency, reducing production costs, and ensuring production quality. BRIEF DESCRIPTION OF DRAWINGS

[0085] Figure 1 is a schematic diagram of the step flow of an embodiment of a water-penetrating box gas source adaptive adjustment method according to the present application.

[0086] Figure 2 is a schematic diagram of the module of an embodiment of a water-penetrating box gas source adaptive adjustment system according to the present application. DETAILED DESCRIPTION

[0087] The present application will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments. It should be noted that the embodiments and features in the embodiments in the present application can be combined with each other without conflict.

[0088] The following detailed description is exemplary and is intended to provide further detailed description of the present application. Unless otherwise specified, all technical terms used in the present application have the same meaning as understood by those skilled in the art to which the present application belongs. The terms used in the present application are only for the purpose of describing the specific embodiments and are not intended to limit the exemplary embodiments according to the present application.

[0089] Embodiment 1

[0090] As shown in Figure 1 , in the implementation process of a water-penetrating box gas source adaptive adjustment method, the following steps are included:

[0091] Real-time signal acquisition

[0092] High-precision signal acquisition devices are installed at the control cabinet of the finishing mill and at the inlet of the water-penetrating box, respectively, for real-time acquisition of the start-stop signals of the finishing mill and the position signals of the wire rod head. These signal acquisition devices can be photoelectric sensors or laser displacement sensors, which can accurately capture the start-stop state of the finishing mill and the specific position of the wire rod head at the inlet of the water-penetrating box. For example, photoelectric sensors can be installed above the inlet of the water-penetrating box, and the position of the wire rod head can be determined by detecting the obstruction of light; laser displacement sensors can emit laser beams and receive reflected light to accurately measure the distance between the wire rod head and the sensor. The installation position and angle of these sensors need to be accurately calibrated to ensure the accuracy and reliability of the measurement data.

[0093] Dynamic delay start threshold calculation

[0094] When the finishing mill starts, the system dynamically calculates the remaining distance of the wire rod head to reach the water-penetrating box based on the acquired position signals of the wire rod head. Specifically, at least two position detection points are arranged in the direction of wire rod travel to collect real-time time-position sequence data of the wire rod head. These detection points can be multiple sensors evenly distributed along the wire rod travel path to accurately monitor the motion trajectory of the wire rod head. For example, multiple photoelectric sensors can be installed at different distances before the inlet of the water-penetrating box, and each sensor records the time stamp of the wire rod head passing through.

[0095] Then, according to the distance between adjacent position detection points and the time difference of the wire rod head passing through adjacent points, the instantaneous linear speed of the wire rod in the detection section is calculated. This process is similar to the speed measurement in physics, which determines the motion speed of the wire rod by the ratio of time and distance. The specific formula is:

[0096]

[0097] where v 瞬时 is the instantaneous linear speed, d is the distance between adjacent detection points, t1 and t2 are the time stamps of the wire rod head passing through these two detection points.

[0098] The calculated instantaneous linear speed is input into a preset speed model, which further processes these data to output a weighted average speed. The specific operation is as follows: the current instantaneous linear speed and the historical linear speeds of the previous N sampling periods are extracted, the historical linear speeds are weighted based on a preset time decay coefficient, and then the weighted historical linear speeds are fused with the instantaneous linear speed to generate a weighted average speed. This weighting processing method can consider the dynamic changes of the wire rod speed and avoid the inaccuracy of the calculation results caused by the fluctuations of the instantaneous speed. The specific formula is:

[0099]

[0100] Among them, α is the weight coefficient of the current instantaneous speed, β is the time-effect attenuation coefficient of the historical speed, and v 历史 (i) is the linear velocity of the i-th historical sampling period.

[0101] Based on the position of the detection point closest to the water tank entrance, the remaining physical distance from the wire rod head to the water tank entrance is determined. Based on the ratio of the remaining physical distance to the weighted average speed, the expected time for the wire rod head to arrive at the water tank entrance is calculated. Finally, the inherent response delay of the pneumatic ball valve opening is subtracted from the expected time to generate a dynamic delay opening threshold. The setting of this threshold fully takes into account the actual response time of the pneumatic ball valve, ensuring that the pneumatic ball valve can be opened in time when the wire rod head arrives at the water tank, avoiding production problems caused by delays. The specific formula is:

[0102]

[0103] Among them, T 延时 is the dynamic delay start threshold, L 剩余 is the remaining physical distance, T 响应 It is the inherent response delay of the pneumatic ball valve.

[0104] Segmented pneumatic ball valve opening control

[0105] When the actual position of the wire rod head reaches the dynamic delayed opening threshold, the system will control the solenoid valve to drive the pneumatic ball valve with a segmented opening curve. The initial opening increase rate is the first slope, and when the air pressure reaches the process pressure critical point, it switches to the second slope. Specifically, first generate an initial opening instruction to drive the solenoid valve to increase the opening of the pneumatic ball valve with a first linear slope. In the process of increasing the opening, the actual air pressure rise rate of the compressed air pipeline is monitored in real time, and the deviation between the actual air pressure rise rate and the preset target rate is calculated. When the actual air pressure value reaches the preset neighborhood range of the process pressure critical point, the slope correction factor of the second slope is dynamically adjusted based on the deviation. According to the slope correction factor, the solenoid valve is controlled to switch to the second linear slope to continue to increase the opening of the pneumatic ball valve until the target opening value corresponding to the process pressure critical point is reached.

[0106] After the pneumatic ball valve reaches the target opening, the opening maintenance mode is activated. The actual pipeline pressure is continuously collected. If the actual pressure deviates from the process pressure critical point and exceeds the allowable fluctuation threshold, the calculus controller generates an opening compensation value and fine-tunes the pneumatic ball valve opening accordingly. This segmented opening control method effectively avoids drastic pressure fluctuations and ensures a steady rise in pressure. Furthermore, after reaching the target pressure, the valve opening is fine-tuned to maintain pressure stability, improving system stability and reliability.

[0107] Air resistance monitoring and pressure compensation

[0108] Synchronously monitor the coverage length of the wire rod in the water tank, convert the coverage length into an equivalent air resistance value, and collect the compressed air pipeline pressure in real time. The specific operation is as follows: through the position sensors arranged at the inlet and outlet of the water tank, the first timestamp of the wire rod head at the inlet and the second timestamp of the wire rod tail at the outlet are obtained in real time. According to the difference between the first timestamp and the second timestamp and the wire rod running speed, the real-time coverage length of the wire rod in the water tank is calculated. The real-time coverage length is input into the pre-constructed segmented air resistance mapping function, which outputs the corresponding air resistance value according to the different stages of the coverage length. When the real-time coverage length is less than the first proportional threshold of the effective length of the water tank, the linear growth air resistance value is output; when the real-time coverage length reaches or exceeds the first proportional threshold, the saturated nonlinear air resistance value is output.

[0109] The original pressure signal of the compressed air pipeline pressure sensor is read in real time, and the original pressure signal is processed by sliding window filtering to generate a steady-state pressure value. According to the product of the saturated nonlinear air resistance value and the steady-state pressure value, the pressure-air resistance coupling factor is calculated. The pressure-air resistance coupling factor is superimposed with the output value of the segmented air resistance mapping function to generate the equivalent air resistance value. This process fully considers the influence of the wire rod coverage length on the air resistance, and through dynamic calculation of the equivalent air resistance value, it provides an accurate basis for subsequent pressure compensation.

[0110] Through the pressure closed-loop controller, the equivalent air resistance value and the real-time pressure input are generated to generate a dynamic pressure compensation amount. The specific steps are as follows: the equivalent air resistance value is input into the pre-constructed air resistance-pressure mapping table to output the corresponding feedforward reference pressure value. The measured pressure value of the compressed air pipeline is obtained in real time, and the pressure deviation amount of the measured pressure value from the critical point of the process air pressure is calculated. The pressure deviation amount and its change rate are input into the fuzzy PID controller, and based on the pre-set fuzzy rule base, the pressure deviation amount and the change rate are converted into proportional coefficient correction factors, integral coefficient correction factors and differential coefficient correction factors of the PID parameters. The modified PID parameters are used to calculate the feedback pressure adjustment amount. The feedforward reference pressure value and the feedback pressure adjustment amount are weighted and fused to generate a primary compensation pressure value.

[0111] When it is detected that the change rate of the wire rod coverage length exceeds the pre-set mutation threshold, the integral separation mechanism is started, the integral term is suspended, and the differential term weight is raised to the pre-set upper limit value. According to the output state of the integral separation mechanism, the primary compensation pressure value is corrected to generate a dynamic pressure compensation amount. This pressure compensation method combines the advantages of feedforward control and feedback control, and through the dynamic adjustment of the fuzzy PID controller, it can quickly respond to pressure changes, while avoiding the over-adjustment phenomenon that may be caused by the integral term at the mutation, improving the stability and response speed of the system.

[0112] Pneumatic ball valve opening adjustment

[0113] According to the pressure dynamic compensation amount adjustment pneumatic ball valve opening, make pipeline pressure with equivalent gas resistance value increases and decreases. The specific steps are: input the current equivalent gas resistance value into the pre-constructed gas resistance-opening mapping table, output the corresponding reference opening value. Based on the product of dynamic pressure compensation amount and reference opening value, calculate the opening compensation base. Real-time acquisition of the change rate of equivalent gas resistance value, according to the change rate size to generate dynamic correction coefficient. When the change rate is lower than the preset slow change threshold, the dynamic correction coefficient takes the first constant value; When the change rate reaches or exceeds the slow change threshold, the dynamic correction coefficient increases linearly with the change rate.

[0114] The opening compensation base is multiplied by the dynamic correction coefficient to generate the target opening adjustment amount. Incremental conversion is performed on the target opening adjustment amount, the actual opening value of the pneumatic ball valve in the last control period is read, and the difference between the target opening adjustment amount and the actual opening value in the last period is calculated to generate an opening increment instruction. The opening increment instruction is processed by the rate limiter, and when the absolute value of the opening increment instruction is less than the preset dead zone threshold, zero increment is output; When the opening increment instruction exceeds the dead zone threshold, the output is limited to the preset maximum change rate. The increment instruction processed by the rate limiter is superimposed on the actual opening value in the last period to generate a final opening control instruction and drive the electromagnetic valve. This process realizes precise control of the pipeline pressure by dynamically adjusting the opening of the pneumatic ball valve, ensuring that the pipeline pressure can be stably maintained within the range required by the process under different working conditions.

[0115] Pneumatic ball valve closing control when the finishing mill stops

[0116] When the finishing mill stops, the system will immediately trigger the pneumatic ball valve to close. If the stop signal occurs when the wire rod is not completely through the water tank, the gradient pressure relief shutdown program will be executed. The specific operation is: real-time acquisition of the current position coordinates of the wire rod tail at the outlet of the water tank, according to the proportion of the current position coordinates and the total length of the water tank, calculate the percentage of the wire rod retention in the water tank. Based on the retention percentage matching the pre-set pressure relief gradient segmentation rule, when the retention percentage ≤ the first threshold, execute the first pressure relief rate curve; When the retention percentage > the first threshold and ≤ the second threshold, execute the second pressure relief rate curve; When the retention percentage > the second threshold, execute the third pressure relief rate curve.

[0117] The opening of the pneumatic ball valve is controlled to decrease according to the matched pressure relief rate curve, and the actual pressure change rate of the compressed air pipeline is monitored synchronously. The deviation of the actual pressure change rate from the target change rate of the current pressure relief rate curve is calculated, and if the target change rate deviation exceeds the allowed tolerance, a pressure relief rate correction amount is generated based on the deviation value, and the slope parameter of the pressure relief rate curve is dynamically adjusted. When the actual pressure value drops to the preset safety threshold or the percentage of the retained amount is zero, the complete closing instruction of the pneumatic ball valve is triggered. This gradient pressure relief closing procedure can effectively avoid the water hammer effect caused by the sudden closing of the pneumatic ball valve, protect the safety of the water tank and related equipment, and at the same time ensure that the air source can be cut off in time when the finishing mill stops, reducing energy waste.

[0118] As a preferred example, the signal acquisition device can adopt multiple types, in addition to photoelectric sensors and laser displacement sensors, ultrasonic sensors or magnetic induction sensors can also be used. Ultrasonic sensors measure distance by emitting and receiving ultrasonic signals, have the advantage of non-contact measurement, and are suitable for harsh industrial environments. Magnetic induction sensors determine the position of the wire rod by detecting changes in the magnetic field, suitable for high-speed motion scenarios. These sensors can be selected and combined according to the actual production environment and precision requirements to improve the accuracy and reliability of signal acquisition.

[0119] As a preferred example, when calculating the dynamic delay opening threshold, more factors can be considered to improve the accuracy of the calculation. For example, the influence of environmental temperature and humidity on wire rod speed can be introduced, and a more complex physical model can be established to predict the actual motion speed of the wire rod. In addition, machine learning algorithms can also be introduced to automatically adjust the parameters of the preset speed model through learning and analysis of historical data to adapt to different production conditions. For example, a neural network algorithm can be used, with historical speed data and environmental parameters as input and actual wire rod speed as output, to train the neural network to optimize the prediction ability of the speed model.

[0120] As a preferred example, in the segmented pneumatic ball valve opening control, the calculation method of the slope correction factor can be further refined. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the influence of environmental conditions on air pressure rise rate in real time. According to these data, the slope correction factor is dynamically adjusted to more accurately control the opening of the pneumatic ball valve. In addition, adaptive control algorithms can also be introduced to automatically adjust the calculation formula of the slope correction factor according to the real-time monitoring of the air pressure change, to achieve better control effect.

[0121] As a preferred example, in terms of air resistance monitoring and pressure compensation, the construction method of the air resistance mapping function can be further expanded. For example, more physical parameters such as the material, diameter and surface roughness of the wire rod can be introduced to more accurately calculate the air resistance value. In addition, machine learning algorithms can also be introduced to automatically adjust the parameters of the air resistance mapping function through learning and analysis of historical data to improve the accuracy of the calculation. For example, a support vector machine (SVM) algorithm can be used to use historical coverage length and air resistance values as training data to optimize the predictive ability of the air resistance mapping function through training of the SVM model.

[0122] As a preferred example, in terms of pneumatic ball valve opening adjustment, the calculation method of the opening compensation base can be further expanded. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the influence of environmental conditions on air pressure in real time. According to these data, the opening compensation base is dynamically adjusted to more accurately control the opening of the pneumatic ball valve. In addition, adaptive control algorithms can also be introduced to automatically adjust the calculation formula of the opening compensation base according to the real-time monitoring of air pressure changes to achieve better control effect.

[0123] As a preferred example, in terms of pneumatic ball valve closing control when the finishing mill stops, the calculation method of the retention percentage can be further expanded. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the influence of environmental conditions on the wire rod retention in real time. According to these data, the calculation formula of the retention percentage is dynamically adjusted to more accurately control the closing process of the pneumatic ball valve. In addition, adaptive control algorithms can also be introduced to automatically adjust the calculation formula of the retention percentage according to the real-time monitoring of the wire rod retention changes to achieve better control effect.

[0124] Through the above detailed implementation steps and lower extension, the water tank gas source adaptive adjustment method provided by the embodiment can realize intelligent and adaptive adjustment of the water tank gas source, improve production efficiency, reduce energy consumption, reduce dependence on manual operation, ensure production stability and safety, and has significant practical value and broad application prospect.

[0125] Embodiment 2

[0126] As shown in Figure 2 , the embodiment provides a water tank gas source adaptive adjustment system, which is based on the water tank gas source adaptive adjustment method described in embodiment 1 and realizes intelligent and adaptive adjustment of the water tank gas source through the cooperative work of various modules. The system can automatically adjust the opening of the pneumatic ball valve according to the start and stop signals of the finishing mill and the position signals of the wire rod in the water tank, improve production efficiency, reduce energy waste, reduce dependence on manual operation, and ensure production stability and safety.

[0127] The signal acquisition module is the front-end part of the system, responsible for real-time acquisition of the start-stop signal of the finishing mill and the position signal of the wire rod head. This module connects the finishing mill control cabinet and the water-penetrating box inlet sensor, using high-precision photoelectric sensors or laser displacement sensors to detect the position of the wire rod head. These sensors are installed at different positions of the water-penetrating box inlet, and can accurately capture the movement trajectory and speed information of the wire rod head. For example, photoelectric sensors can be installed above the water-penetrating box inlet, detecting the position of the wire rod head by blocking the light; laser displacement sensors can emit laser beams and receive reflected light to accurately measure the distance between the wire rod head and the sensor. The installation position and angle of these sensors need to be precisely calibrated to ensure the accuracy and reliability of the measurement data.

[0128] The delay control module connects the signal acquisition module, responsible for dynamically calculating the remaining distance of the wire rod reaching the water-penetrating box based on the head position signal, and generating a dynamic delay opening threshold according to the remaining distance and the preset speed model. This module includes a speed calculation unit, a historical fusion unit, and a response delay compensator. The speed calculation unit calculates the instantaneous linear speed of the wire rod through at least two position detection points; the historical fusion unit generates an average speed by weighting the instantaneous linear speed and the historical linear speed of the previous N sampling periods; the response delay compensator deducts the inherent response delay of the pneumatic ball valve from the expected time of the wire rod reaching, generating the final dynamic delay opening threshold. These units work together to ensure that the pneumatic ball valve can be opened in time when the wire rod head reaches the water-penetrating box, avoiding production problems caused by delay.

[0129] The segmented execution module connects the delay control module, responsible for controlling the electromagnetic valve to drive the pneumatic ball valve with a segmented opening curve when the wire rod position reaches the dynamic delay opening threshold. This module includes a slope corrector and a calculus stabilizer. The slope corrector dynamically adjusts the second slope based on the air pressure rise rate deviation; the calculus stabilizer generates an opening compensation amount in the opening maintenance mode, ensuring smooth rise and stable maintenance of air pressure. Through segmented opening control, this module can effectively avoid the dramatic fluctuation of air pressure, improving the stability and reliability of the system.

[0130] The air resistance monitoring module connects the position sensors at the inlet and outlet of the water-penetrating box to synchronously monitor the coil rod coverage length and convert the coverage length into an equivalent air resistance value. The module includes a coverage length calculator and a segmented air resistance converter. The coverage length calculator calculates the real-time coverage length according to the time stamp difference between the inlet and outlet; the segmented air resistance converter outputs the corresponding air resistance value according to different stages of the coverage length. When the coverage length is less than the first proportional threshold of the effective length of the water-penetrating box, a linearly increasing air resistance value is output; when the coverage length reaches or exceeds the first proportional threshold, a saturated nonlinear air resistance value is output. By dynamically calculating the equivalent air resistance value, the module provides an accurate basis for subsequent pressure compensation.

[0131] The pressure sensing module is installed in the compressed air pipeline and is responsible for real-time acquisition of the pipeline pressure. The module uses a high-precision pressure sensor to accurately measure the real-time pressure value in the compressed air pipeline. The output signal of the pressure sensor is filtered to generate a stable pressure value, providing accurate input data for the pressure compensation module. By monitoring the pipeline pressure in real time, the module can timely feedback the pressure change, ensuring the stable operation of the system.

[0132] The pressure optimization module connects the air resistance monitoring module and the pressure sensing module and is responsible for generating a dynamic pressure compensation amount by inputting the equivalent air resistance value and the real-time pressure through a closed-loop controller. The module includes an air resistance-pressure mapping table and a fuzzy PID controller. The air resistance-pressure mapping table outputs the corresponding feedforward reference pressure value according to the equivalent air resistance value; the fuzzy PID controller converts the pressure deviation and rate of change into the proportional coefficient correction factor, integral coefficient correction factor, and differential coefficient correction factor of the PID parameters based on the pre-set fuzzy rule base, and calculates the feedback pressure adjustment amount using the corrected PID parameters. By weightedly fusing the feedforward reference pressure value and the feedback pressure adjustment amount, a primary compensation pressure value is generated. When the rate of change of the coil rod coverage length is detected to exceed the pre-set mutation threshold, the integral separation mechanism is started, the integral term is suspended, the differential term weight is raised to the pre-set upper limit value, and the primary compensation pressure value is corrected according to the integral separation mechanism output state to generate the final dynamic pressure compensation amount. This pressure compensation method combines the advantages of feedforward control and feedback control, can quickly respond to pressure changes, and at the same time avoids the overshooting phenomenon that may be caused by the integral term during mutation, improving the stability and response speed of the system.

[0133] The opening degree execution module is connected with the pressure optimization module, and is responsible for adjusting the opening degree of the pneumatic ball valve according to the dynamic pressure compensation amount, so that the pipeline pressure decreases with the increase of the equivalent air resistance value. The module includes an air resistance-opening degree mapping table and a rate limiter. The air resistance-opening degree mapping table outputs the corresponding reference opening degree value according to the current equivalent air resistance value; the rate limiter performs incremental conversion on the target opening degree adjustment amount, and outputs the target opening degree adjustment amount according to the preset maximum change rate. By dynamically adjusting the opening degree of the pneumatic ball valve, the module realizes accurate control of the pipeline pressure, and ensures that the pipeline pressure can be stably maintained within the range required by the process under different working conditions.

[0134] The pressure relief control module is connected with the signal acquisition module, and is responsible for triggering the pneumatic ball valve to close immediately when the finishing mill stops, and executing a gradient pressure relief shutdown program when the wire rod does not pass through the water tank completely. The module includes a residual amount analyzer, a pressure relief curve matcher and a slope dynamic corrector. The residual amount analyzer calculates the residual amount percentage according to the current position coordinates of the wire rod tail at the outlet of the water tank; the pressure relief curve matcher matches the preset pressure relief gradient segmentation rule according to the residual amount percentage; the slope dynamic corrector adjusts the pressure relief slope in real time based on the pressure change rate deviation. Through the gradient pressure relief shutdown program, the module can effectively avoid the water hammer effect caused by the sudden closing of the pneumatic ball valve, protect the safety of the water tank and related equipment, and at the same time ensure that the gas source can be cut off in time when the finishing mill stops, reducing energy waste.

[0135] System workflow

[0136] When the finishing mill starts, the signal acquisition module acquires the start-stop signal of the finishing mill and the position signal of the wire rod head in real time. The delay control module dynamically calculates the remaining distance of the wire rod to reach the water tank according to these signals, and generates a dynamic delay opening threshold.

[0137] When the actual position of the wire rod head reaches the dynamic delay opening threshold, the segmented execution module controls the electromagnetic valve to drive the pneumatic ball valve in a segmented opening curve. The initial opening speed is the first slope, and when the air pressure reaches the critical point of the process air pressure, the second slope is switched. After the opening degree of the pneumatic ball valve reaches the target opening degree value, the opening degree maintenance mode is started, and the opening degree compensation amount is generated by the integral pressure stabilizer to ensure the stable maintenance of the air pressure.

[0138] The air resistance monitoring module synchronously monitors the covering length of the wire rod in the water tank, and converts the covering length into an equivalent air resistance value. The pressure sensing module acquires the compressed air pipeline pressure in real time, the pressure optimization module generates a dynamic pressure compensation amount according to the equivalent air resistance value and the real-time pressure, and adjusts the opening degree of the pneumatic ball valve through the opening degree execution module, so that the pipeline pressure decreases with the increase of the equivalent air resistance value.

[0139] When the finishing mill stops, the signal acquisition module immediately triggers the pressure relief control module to close the pneumatic ball valve. If the stop signal occurs when the wire rod is not completely passing through the water tank, the pressure relief control module executes the gradient pressure relief shutdown program, matches the pre-set pressure relief gradient segmentation rules according to the percentage of wire rod retention, dynamically adjusts the pressure relief slope, ensures that the gas source can be cut off in time, reduces energy waste, and protects the equipment safety.

[0140] As a preferred example, the signal acquisition module can be further extended to adapt to different production environments and precision requirements. For example, more sensor types such as ultrasonic sensors or magnetic induction sensors can be added to improve the accuracy and reliability of signal acquisition. In addition, a redundant design can be introduced, with multiple sensors of the same type installed, to improve the stability and accuracy of measurement data through data fusion algorithms.

[0141] As a preferred example, the delay control module can be further optimized to improve the calculation accuracy of the dynamic delay opening threshold. For example, machine learning algorithms can be introduced to automatically adjust the parameters of the pre-set speed model through learning and analysis of historical data to adapt to different production conditions. In addition, environmental parameters such as temperature and humidity sensors can be introduced to consider the impact of environmental conditions on wire rod speed.

[0142] As a preferred example, the segmented execution module can be further refined to improve the precision of pneumatic ball valve opening control. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the impact of environmental conditions on air pressure rise rate in real time. Based on these data, the slope correction factor is dynamically adjusted to more accurately control the opening of the pneumatic ball valve.

[0143] As a preferred example, the air resistance monitoring module can be further expanded to improve the calculation accuracy of the equivalent air resistance value. For example, more physical parameters such as the material, diameter and surface roughness of the wire rod can be introduced to more accurately calculate the air resistance value. In addition, machine learning algorithms can be introduced to automatically adjust the parameters of the air resistance mapping function through learning and analysis of historical data to improve the accuracy of calculation.

[0144] As a preferred example, the pressure sensing module can be further expanded to improve the accuracy of pipeline pressure measurement. For example, more sensors such as multiple pressure sensors distributed at different positions can be introduced to improve the stability and accuracy of measurement data through data fusion algorithms. In addition, temperature compensation algorithms can be introduced to consider the impact of environmental temperature on the measurement results of the pressure sensor.

[0145] As a preferred example, the pressure optimization module can be further optimized to improve the calculation accuracy of the dynamic pressure compensation amount. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the impact of environmental conditions on pressure in real time. According to these data, the correction factor of the PID parameter is dynamically adjusted to more accurately control the pressure compensation amount.

[0146] As a preferred example, the opening execution module can be further extended to improve the accuracy of the pneumatic ball valve opening adjustment. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the impact of environmental conditions on the pneumatic ball valve opening in real time. According to these data, the opening compensation base is dynamically adjusted to more accurately control the opening of the pneumatic ball valve.

[0147] As a preferred example, the pressure relief control module can be further extended to improve the accuracy of the gradient pressure relief shutdown procedure. For example, more sensor data such as temperature sensors and humidity sensors can be introduced to monitor the impact of environmental conditions on the pressure change rate in real time. According to these data, the pressure relief slope is dynamically adjusted to more accurately control the closing process of the pneumatic ball valve.

[0148] Through the above detailed system architecture, module function and down-extended, the water-penetrating box gas source adaptive adjustment system provided by the embodiment can realize intelligent and adaptive adjustment of the water-penetrating box gas source, improve production efficiency, reduce energy waste, reduce dependence on manual operation, and ensure production stability and safety, which has significant practical value and broad application prospect.

[0149] From the technical common knowledge, the present application can be realized by other embodiments without departing from the spirit or essential characteristics thereof. Therefore, the above disclosed embodiments, in all aspects, are only illustrative and not the only. All changes within the scope of the present application or within the scope equivalent to the present application are included in the present application.

Claims

1. A method for adaptively adjusting the air source of a water tank, characterized in that: include, Step S1, obtaining the start and stop signals of the finishing mill and the wire rod head position signal at the water tank inlet in real time; Step S2: When the finishing mill is started, the remaining distance of the wire rod head from reaching the water tank is dynamically calculated based on the head position signal, and a dynamic delay start threshold is generated according to the remaining distance and a preset speed model; Step S3: When the actual position of the wire rod head reaches the dynamic delayed opening threshold, the solenoid valve is controlled to drive the pneumatic ball valve with a segmented opening curve, wherein the initial opening speed increase rate is a first slope, and when the critical point of the process pressure is reached, the speed is switched to a second slope; Step S4: synchronously monitor the coverage length of the wire rod in the water-penetrating tank, convert the coverage length into an equivalent air resistance value, and collect the compressed air pipeline pressure in real time; Step S5: inputting the equivalent air resistance value and the real-time pressure into a pressure closed-loop controller to generate a dynamic pressure compensation value; Step S6: adjusting the opening of the pneumatic ball valve according to the dynamic pressure compensation amount so that the pipeline pressure decreases as the equivalent air resistance value increases; Step S7: When the finishing mill stops, the pneumatic ball valve is immediately triggered to close. If the stop signal occurs when the wire rod has not completely passed through the water tank, the gradient pressure relief shutdown procedure is executed.

2. A method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: Step S2 specifically includes: When the finishing mill is started, the time-position sequence data of the wire rod head is collected in real time through at least two position detection points arranged along the wire rod travel direction; Calculate the instantaneous linear velocity of the wire rod in the detection section based on the distance between adjacent detection points and the time difference when the wire rod head passes through adjacent points; The instantaneous linear velocity is input into a preset velocity model, which outputs a weighted average velocity through the following operations: Extract the current instantaneous linear speed and the historical linear speed of the previous N sampling periods, The historical linear speed is weighted based on the preset time attenuation coefficient. The weighted historical linear velocity and instantaneous linear velocity are combined to generate a weighted average velocity; Based on the position of the detection point closest to the water tank inlet, determine the remaining physical distance from the wire rod head to the water tank inlet; Calculating the expected time for the wire rod head to arrive at the water tank entrance based on the ratio of the remaining physical distance to the weighted average speed; The inherent response delay of the opening of the pneumatic ball valve is subtracted from the expected time to generate the dynamic delayed opening threshold.

3. The method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: The specific steps of S3 are: include, When the actual position of the wire rod head reaches the dynamic delayed opening threshold, an initial opening instruction is generated to drive the solenoid valve to increase the opening of the pneumatic ball valve at a first linear slope; Monitor the actual pressure rise rate of the compressed air pipeline in real time and calculate the deviation between the actual pressure rise rate and the preset target rate; When the actual gas pressure value reaches a preset neighborhood range of the process gas pressure critical point, dynamically adjusting the slope correction factor of the second slope based on the deviation; According to the slope correction factor, the solenoid valve is controlled to switch to a second linear slope to continue increasing the opening of the pneumatic ball valve until the target opening value corresponding to the critical point of the process air pressure is reached; After the opening of the pneumatic ball valve reaches the target opening value, the opening maintenance mode is started: the actual air pressure value of the pipeline is continuously collected. If the actual air pressure value deviates from the process air pressure critical point and exceeds the allowable fluctuation threshold, the opening compensation amount is generated through the calculus controller, and the opening of the pneumatic ball valve is fine-tuned according to the opening compensation amount.

4. The method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: The step S4 specifically includes: The first time stamp of the wire rod head at the inlet and the second time stamp of the wire rod tail at the outlet are obtained in real time by using position sensors arranged at the inlet and outlet of the water tank; Calculate the real-time coverage length of the wire rod in the water tank according to the difference between the first timestamp and the second timestamp and the wire rod travel speed; The real-time coverage length is input into a pre-built piecewise air resistance mapping function, which performs the following operations: when the real-time coverage length is less than a first proportional threshold of the effective length of the water tank, outputs a linearly increasing air resistance value; when the real-time coverage length reaches or exceeds the first proportional threshold, outputs a saturated nonlinear air resistance value; Read the original pressure signal of the compressed air pipeline pressure sensor in real time, and perform sliding window filtering on the original pressure signal to generate a steady-state pressure value; Calculating a pressure-air resistance coupling factor according to the product of the saturated nonlinear air resistance value and the steady-state pressure value; The pressure-air resistance coupling factor is superimposed on the output value of the piecewise air resistance mapping function to generate an equivalent air resistance value.

5. The method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: The step S5 specifically includes: Input the equivalent air resistance value into a pre-built air resistance-pressure mapping table, and output a corresponding feedforward reference pressure value; Obtain the measured pressure value of the compressed air pipeline in real time and calculate the pressure deviation between the measured pressure value and the critical point of process air pressure; The pressure deviation and its change rate are input into a fuzzy PID controller, which performs the following operations: based on a preset fuzzy rule base, the pressure deviation and the change rate are converted into a proportional coefficient correction factor, an integral coefficient correction factor, and a differential coefficient correction factor of PID parameters; The feedback pressure adjustment amount is calculated using the modified PID parameters; Performing weighted fusion on the feedforward reference pressure value and the feedback pressure adjustment amount to generate a primary compensation pressure value; When it is detected that the change rate of the wire rod coverage length exceeds the preset mutation threshold, the integral separation mechanism is activated: the integral term is suspended; the weight of the differential term is increased to the preset upper limit value; According to the output state of the integral separation mechanism, the primary compensation pressure value is corrected to generate the dynamic pressure compensation amount.

6. The method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: The step S6 specifically includes: Input the current equivalent air resistance value into the pre-built air resistance-opening mapping table and output the corresponding reference opening value; Calculate the opening compensation base based on the product of the dynamic pressure compensation amount and the reference opening value; The change rate of the equivalent air resistance value is obtained in real time, and a dynamic correction coefficient is generated according to the change rate: when the change rate is lower than the preset slow change threshold, the dynamic correction coefficient takes the first constant value; when the change rate reaches or exceeds the slow change threshold, the dynamic correction coefficient increases linearly with the change rate; Multiplying the opening compensation base by the dynamic correction coefficient to generate a target opening adjustment amount; Incremental conversion of target opening adjustment: read the actual opening value of the pneumatic ball valve in the previous control cycle; Calculate the difference between the target opening adjustment amount and the actual opening value of the previous cycle to generate an opening increment instruction; The opening increment instruction is processed by the rate constraint: when the absolute value of the opening increment instruction is less than the preset dead zone threshold, zero increment is output; When the opening increment instruction exceeds the dead zone threshold, the output is limited according to the preset maximum change rate; The incremental command processed by the rate constraint is added to the actual opening value of the previous cycle to generate the final opening control command and drive the solenoid valve.

7. The method for adaptively adjusting the air source of a water tank according to claim 1, characterized in that: The step S7 specifically includes: When the finishing mill stop signal is valid and the wire rod has not completely passed through the water tank, the current position coordinates of the wire rod tail at the water tank outlet are obtained in real time; Calculate the percentage of wire rod retention in the water tank based on the ratio of the current position coordinates to the total length of the water tank; Based on the hold-up percentage matching preset pressure relief gradient segmentation rule: when the hold-up percentage is ≤ the first threshold, the first pressure relief rate curve is executed; when the hold-up percentage is greater than the first threshold and ≤ the second threshold, the second pressure relief rate curve is executed; when the hold-up percentage is greater than the second threshold, the third pressure relief rate curve is executed; Control the opening of the pneumatic ball valve to decrease according to the matching pressure relief rate curve, and simultaneously monitor the actual pressure change rate of the compressed air pipeline; Calculate the deviation between the actual pressure change rate and the target change rate of the current pressure relief rate curve: if the target change rate deviation exceeds the allowable tolerance, generate a pressure relief rate correction based on the deviation value; dynamically adjust the slope parameter of the pressure relief rate curve; When the actual pressure value drops to the preset safety threshold or the retention percentage returns to zero, the pneumatic ball valve is triggered to completely shut off.

8. A water tank air source adaptive adjustment system, based on a water tank air source adaptive adjustment method according to any one of claims 1 to 7, characterized in that: include, The signal acquisition module is connected to the finishing mill control cabinet and the water tank inlet sensor to obtain the start and stop signals of the finishing mill and the wire rod head position signal in real time; The delay control module is connected to the signal acquisition module and is used to dynamically calculate the remaining distance for the coil to reach the water tank based on the head position signal, and generate a dynamic delay opening threshold according to the remaining distance and the preset speed model; The segmented execution module is connected to the delay control module and is used to control the solenoid valve to drive the pneumatic ball valve with a segmented opening curve when the wire rod position reaches the dynamic delay opening threshold. The initial opening speed increase rate is the first slope, and it switches to the second slope when the critical point of the process gas pressure is reached; The air resistance monitoring module is connected to the water tank inlet / outlet position sensor to synchronously monitor the wire rod coverage length and convert the coverage length into an equivalent air resistance value; The pressure sensing module is installed in the compressed air pipeline to collect the pipeline pressure in real time; The pressure optimization module is connected to the air resistance monitoring module and the pressure sensing module, and is used to generate a dynamic pressure compensation value by inputting the equivalent air resistance value and the real-time pressure through a closed-loop controller; The opening execution module is connected to the pressure optimization module and is used to adjust the opening of the pneumatic ball valve according to the dynamic pressure compensation amount, so that the pipeline pressure decreases as the equivalent air resistance value increases; The pressure relief control module is connected to the signal acquisition module and is used to immediately trigger the pneumatic ball valve to close when the finishing mill stops, and to execute the gradient pressure relief shutdown procedure when the wire rod has not completely passed through the water tank.

9. The water tank air source adaptive regulation system according to claim 8, characterized in that: The delay control module includes: A speed calculation unit, configured to calculate the instantaneous linear speed of the wire rod through at least two position detection points; The history fusion unit is used to weight the instantaneous linear velocity and the historical linear velocity of the previous N cycles to generate an average velocity; A response delay compensator is used to deduct the inherent response delay of the pneumatic ball valve from the expected arrival time of the wire rod; The segment execution module includes: a slope corrector for dynamically adjusting the second slope based on a pressure rise rate deviation; The calculus voltage regulator is used to generate the opening compensation amount in the opening maintenance mode.

10. The water tank air source adaptive adjustment system according to claim 8, characterized in that: The air resistance monitoring module includes: Coverage length calculator, used to calculate real-time coverage length based on the ingress / egress timestamp difference; A segmented air resistance converter is used to output a linear air resistance value when the coverage length is less than a threshold value, and output a saturated nonlinear air resistance value when the coverage length exceeds the threshold value; The pressure relief control module includes: Holdup analyzer, used to calculate wire rod holdup percentage; Pressure relief curve matcher, used to activate the segmented pressure relief rate curve; The slope dynamic corrector is used to adjust the pressure relief slope in real time based on the pressure change rate deviation.

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