Manipulator for cleaning and calibrating instrument sensor in water treatment process and working method

Abstract

The invention belongs to the field of water treatment, and particularly relates to a water treatment process instrument sensor cleaning and calibration manipulator and a working method, the manipulator comprises a mechanical execution system, a power control system, a cleaning system, a calibration system and a central control system; the power control system is respectively connected with the mechanical execution system, the cleaning system and the calibration system, and the central control system is connected with the power control system. According to the invention, manual operation is replaced by full-automatic machinery, and personnel do not need to approach a dangerous area in the whole process of probe lifting, cleaning and calibration, so that the hidden danger of edge-to-water operation is fundamentally eliminated, the safety accident risk is reduced by more than 90%, and the working efficiency is improved. And the personal safety of operators is comprehensively guaranteed. The reclaimed water washing device is used for washing at a constant pressure of 0.3 MPa, the air pipe blowing device is used for drying at a fixed distance of 10cm and at a pressure of 0.2 MPa, and the washing-drying process is repeated for 2-3 times.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of water treatment, in particular to a cleaning and calibration mechanical arm for process instrument sensors in water treatment and a working method. BACKGROUND

[0002] In the water treatment industry, process instrument sensors, as the core equipment for water quality monitoring, directly affect the process control effect and the stability of effluent water quality in terms of measurement accuracy. Currently, the cleaning and calibration of process water quality analyzer sensors such as DO instruments, sludge concentration instruments, and ORP instruments in the industry have long relied on traditional manual operation mode. The specific process includes the following key links: The operator needs to manually disassemble the instrument probe in the dangerous area near the edge and water; use a cloth or cleaning liquid to manually wipe and clean the surface of the probe, and then use natural air drying or towel drying to process the probe; in order to ensure the accuracy of calibration, the probe needs to be exposed to the air for 15 minutes to adapt to the ambient temperature; the probe needs to be manually lifted to approach the liquid surface before calibration to maintain the humidity of its surface; finally, a special person operates the instrument button, selects the calibration menu, and manually injects the standard sample to complete the entire calibration work.

[0003] However, this traditional manual operation scheme has many defects that are difficult to overcome, which seriously restricts the efficient and stable operation of the water treatment process: Firstly, the safety is insufficient. The operation of manually removing the probe needs to be performed in the high-risk area near the edge and water, and the operator faces the safety risks of falling and drowning, which brings great hidden dangers to personal safety; Secondly, the cleaning effect is unstable. Since the intensity, range, and cleaning time of manual cleaning completely depend on the experience and responsibility of the operator, the cleaning effect of the probe operated by different batches and different personnel is uneven, which directly affects the subsequent measurement accuracy; Thirdly, the labor cost is high. Each calibration process needs two people to work together, and the process of waiting for the probe to adapt to the ambient temperature wastes a lot of invalid working hours. For example, for 6 instruments, 528 working hours are needed for calibration every year, and the labor cost is high; Fourthly, the operation standardization is poor. Most water plants do not strictly implement the technical specifications of probe temperature adaptation and humidity maintenance due to insufficient personnel training or loose process management, resulting in inconsistent calibration basis conditions; and fifthly, the calibration quality fluctuates greatly. The calibration result is significantly affected by individual differences such as the skill level and operation proficiency of the operator, and the process of manual work order distribution and on-site acceptance is complicated, which further reduces the efficiency and reliability of the calibration work.

[0004] Therefore, the present application provides a cleaning and calibration mechanical arm for process instrument sensors in water treatment and a working method. SUMMARY

[0005] To make up for the deficiencies of the prior art, solve at least one technical problem raised in the background art.

[0006] The technical scheme adopted by the present application to solve its technical problems is: a cleaning and calibration mechanical arm for a water treatment process instrument sensor, comprising a mechanical execution system, a power control system, a cleaning system, a calibration system and a central control system; The power control system is connected with the mechanical execution system, the cleaning system and the calibration system respectively, and the central control system is connected with the power control system.

[0007] Preferably, the mechanical execution system comprises a stainless steel chute device, a finger-shaped electric push rod and a stepping screw slide table. The stainless steel chute device adopts a chute structure with a gap of 1mm, and a limit switch is arranged at the bottom. The control accuracy of the finger-shaped electric push rod is 0.1mm, and a flexible silica gel head is installed at the end. The stepping screw slide table advances by 0.3mm each time, the control accuracy reaches 0.1mm, and the guide rail adopts a linear ball bearing.

[0008] Preferably, the power control system comprises a stepping pulse motor and a PLC control system. The single pulse rotation of the stepping pulse motor is 0.1 degree, one rotation lifts 5mm, the positioning accuracy is 0.2mm, and the stepping pulse motor is connected with the chute driving shaft through a shaft coupling.

[0009] Preferably, the cleaning system comprises a flushing device and an air blowing device of an air pipe. The flushing device is controlled by an electromagnetic valve to turn on and off, and the flushing pressure is 0.3MPa. The air blowing device of the air pipe is equipped with a blower with a power of 0.75kW, the blowing pressure is 0.2MPa, and the blowing port is kept at a distance of 10cm from the probe.

[0010] Preferably, the calibration system comprises a cylinder chute pushing device and a standard sample container. The cylinder chute pushing device adopts a double-acting cylinder with a cylinder diameter of 50mm and a stroke of 100mm, and the pushing speed can be adjusted. The standard sample container is made of corrosion-resistant PVC material, has a capacity of 500mL, and is equipped with a liquid level sensor.

[0011] Preferably, the central control system comprises a man-machine interface and a data shielding module. The man-machine interface can set the cleaning and calibration period, view the equipment running state and historical data. The data shielding module automatically shields the instrument data during cleaning and calibration.

[0012] Preferably, the stepping pulse motor arranged at the top of the manipulator is fixed above the instrument installation platform through a support; The stainless steel sliding groove device arranged at the middle of the manipulator is vertically installed at the edge of the platform, and the imitation finger electric push rod and the stepping screw sliding table are installed side by side on one side of the sliding groove; The cylinder sliding groove pushing device arranged at the bottom of the manipulator is fixed below the platform, and the flushing device and the air blowing device of the air pipe are installed on the two sides of the sliding groove, respectively. The PLC control system of the control part is installed near the platform and is connected with each execution element through a cable.

[0013] A working method of a water treatment process instrument sensor cleaning and calibration manipulator, the working method comprising the following steps: S1, after the central control system issues an instruction, the stepping pulse motor drives the stainless steel sliding groove device to lift the probe to a cleaning station; S2, the flushing device first flushes the probe, and then the air pipe air blowing device blows dry the probe, and the process is repeated 2-3 times; S3, the cylinder sliding groove pushing device pushes the standard sample container to below the probe, and the standard sample is injected into the calibration groove through gravity or pump pressure; S4, the imitation finger electric push rod and the stepping screw sliding table cooperate to operate the instrument button according to a preset program, and the calibration menu selection and confirmation are completed; S5, after the calibration is completed, the system automatically records data and shields, and restores data acquisition before the next calibration period.

[0014] In step S1, the probe lifting is driven by a stepping pulse motor, and the positioning accuracy is controlled within 0.2 mm; In step S2, the flushing time can be set through the central control system, and the default is 30 seconds each time.

[0015] In step S4, the imitation finger electric push rod simulates the finger pressing action, and the stepping screw sliding table pushes the rotary button to realize menu operation, and the control accuracy reaches 0.1 mm; In step S5, the data shielding module ensures that abnormal data does not participate in process control during cleaning and calibration.

[0016] The beneficial effects of the present application are as follows: 1. The water treatment process instrument sensor cleaning and calibration manipulator and the working method thereof replace manual operation with a fully automatic machine, the probe lifting, cleaning and calibration whole process do not need personnel to approach the dangerous area, fundamentally eliminate the edge and water operation hidden danger, reduce the safety accident risk by more than 90%, and fully guarantee the personal safety of the operator.

[0017] 2. The water treatment process instrument sensor cleaning, calibration mechanical hand and working method of the present application realizes accurate control through standardized mechanical structure: the reclaimed water flushing device flushes at a constant pressure of 0.3 MPa, the air pipe blowing device keeps a fixed distance of 10 cm and blows dry at a pressure of 0.2 MPa, and the flushing-drying process is repeated 2-3 times, ensuring that the cleaning strength, range and length of each probe are completely consistent, so that the residual rate of the probe after cleaning is stably controlled at ≤10%, solving the problem of fluctuation of manual cleaning effect.

[0018] 3. The water treatment process instrument sensor cleaning, calibration mechanical hand and working method of the present application realizes operation specification through programming: the standard sample container is equipped with a liquid level sensor to ensure that the moisturizing liquid is sufficient, and the probe humidity is automatically maintained during calibration; the equipment has a positioning accuracy of 0.2 mm through a stepping motor and an operating accuracy of 0.1 mm through an executing element, strictly follows the technical specification of probe adaptation to temperature and humidity, and eliminates the randomness of manual operation. At the same time, the standardized process avoids the influence of skill differences of operators, reduces the calibration error of DO, sludge concentration, ORP and other instruments by 50%, controls the error within ±5%, and solves the problem of fluctuation of calibration quality.

[0019] 4. The water treatment process instrument sensor cleaning, calibration mechanical hand and working method of the present application realizes data management of the whole process through the central control system, automatically records calibration data, running state and historical records, supports one-key query and analysis, and saves the manual work order circulation link; the calibration operation is accurately controlled by the PLC program and is not affected by the experience of personnel, ensuring that the calibration quality of each instrument is stable and consistent, and greatly improving the reliability of water treatment process monitoring data. BRIEF DESCRIPTION OF DRAWINGS

[0020] The present application will be further described below in conjunction with the drawings.

[0021] Figure 1 is the structural diagram in the present application.

[0022] In the figure: 1, mechanical executing system; 11, stainless steel chute device; 12, imitation finger electric push rod; 13, stepping screw slide table; 2, power control system; 21, stepping pulse motor; 22, PLC control system; 3, cleaning system; 31, flushing device; 32, air pipe air blowing device; 4, calibration system; 41, air cylinder chute pushing device; 42, standard sample container; 5, central control system; 51, man-machine interface; 52, data shielding module. DETAILED DESCRIPTION

[0023] In order to make the technical means, creative features, purposes and effects realized by the present application easy to understand, the present application will be further described below in conjunction with specific embodiments.

[0024] AsFigure 1 The mechanical hand for cleaning and calibrating a sensor of a water treatment process instrument according to an embodiment of the present application comprises a mechanical execution system 1, a power control system 2, a cleaning system 3, a calibration system 4 and a central control system 5. The power control system 2 is connected with the mechanical execution system 1, the cleaning system 3 and the calibration system 4 respectively, and the central control system 5 is connected with the power control system 2.

[0025] The mechanical execution system 1 comprises a stainless steel sliding groove device 11, a finger-imitating electric push rod 12 and a step lead screw sliding table 13. The stainless steel sliding groove device 11 adopts a sliding groove structure with a gap of 1 mm, and a limit switch is arranged at the bottom. The control accuracy of the finger-imitating electric push rod 12 is 0.1 mm, and a flexible silica gel head is arranged at the end. The step lead screw sliding table 13 is pushed by 0.3 mm each time, and the control accuracy reaches 0.1 mm, and a linear ball bearing is adopted for the guide rail.

[0026] The power control system 2 comprises a step pulse motor 21 and a PLC control system 22. The step pulse motor 21 rotates by 0.1 degree for a single pulse, and is lifted by 5 mm for one rotation, and the positioning accuracy is 0.2 mm, and the step pulse motor 21 is connected with the sliding groove driving shaft through a shaft coupling.

[0027] The cleaning system 3 comprises a flushing device 31 and an air blowing device 32 of an air pipe. The flushing device 31 is controlled by an electromagnetic valve to be turned on and off, and the flushing pressure is 0.3 MPa. The air blowing device 32 of the air pipe is equipped with a blower with a power of 0.75 kW, and the blowing pressure is 0.2 MPa, and the blowing port is kept at a distance of 10 cm from the probe.

[0028] The calibration system 4 comprises a cylinder sliding groove pushing device 41 and a standard sample container 42. The cylinder sliding groove pushing device 41 adopts a double-acting cylinder with a cylinder diameter of 50 mm and a stroke of 100 mm, and the pushing speed can be adjusted. The standard sample container 42 adopts a corrosion-resistant PVC material, has a capacity of 500 mL, and is equipped with a liquid level sensor.

[0029] The central control system 5 comprises a man-machine interactive interface 51 and a data shielding module 52. The man-machine interactive interface 51 can set the cleaning and calibration period, view the equipment running state and historical data. The data shielding module 52 automatically shields the instrument data during cleaning and calibration.

[0030] The step pulse motor 21 arranged at the top of the mechanical hand is fixed above the instrument installation platform through a support; The stainless steel sliding groove device 11 arranged in the middle of the mechanical hand is vertically installed at the edge of the platform, and the imitation finger electric push rod 12 and the stepping screw sliding table 13 are installed side by side on one side of the sliding groove; The cylinder sliding groove pushing device 41 arranged at the bottom of the mechanical hand is fixed below the platform, and the flushing device 31 and the air blowing device 32 of the air pipe are respectively installed on both sides of the sliding groove; The PLC control system 22 of the control part is installed near the platform and is connected with each execution element through a cable.

[0031] A working method of a water treatment process instrument sensor cleaning and calibration mechanical hand, the working method comprising the following steps: S1, after the central control system 5 issues an instruction, the stepping pulse motor 21 drives the stainless steel sliding groove device 11 to lift the probe to the cleaning station; S2, the flushing device 31 first flushes the probe, and then the air pipe air blowing device 32 blows dry the probe, and the process is repeated 2-3 times; S3, the cylinder sliding groove pushing device 41 pushes the standard sample container 42 to below the probe, and the standard sample is injected into the calibration groove through gravity or pump pressure; S4, the imitation finger electric push rod 12 and the stepping screw sliding table 13 cooperate to operate the instrument button according to the preset program, and complete the calibration menu selection and confirmation; S5, after the calibration is completed, the system automatically records data and shields, and restores data acquisition before the next calibration period.

[0032] In step S1, the probe lifting is driven by the stepping pulse motor 21, and the positioning accuracy is controlled within 0.2mm; In step S2, the flushing time can be set by the central control system 5, and the default is 30 seconds each time.

[0033] In step S4, the imitation finger electric push rod 12 simulates the finger pressing action, and the stepping screw sliding table 13 pushes the rotary button to realize menu operation, and the control accuracy reaches 0.1mm; In step S5, the data shielding module 52 ensures that abnormal data does not participate in process control during cleaning and calibration.

[0034] Specifically, The flushing device 31 is a reclaimed water or condensate water flushing device.

[0035] Through multi-system cooperative linkage and automatic program control, the full-process unmanned cleaning and calibration operation of water quality analysis instrument sensors is realized, and the specific principle is as follows: In the structural layout, the device adopts hierarchical integration design, the top step pulse motor 21 drives the stainless steel sliding groove device 11 through the shaft coupling, and provides power for the probe lifting; the middle part of the finger-shaped electric push rod 12 and the step lead screw sliding table 13 are calibrated in position, and the simulation of manual operation of the instrument button is realized; the bottom part of the cylinder sliding groove pushing device 41 and the cleaning device on both sides form a functional closed loop, which ensures the orderly operation of the standard sample injection and the probe cleaning; the central control system 5 and the PLC control cabinet are connected through the cable, which constitutes the 'central nerve' of the device, realizes the command issuing and state feedback.

[0036] In the working process, the central control system 5 starts the operation according to the preset period or manual instruction, and sends the instruction to the PLC control system 22 through the RS485 communication interface. The PLC program first drives the step pulse motor 21, and then the probe is lifted from the working position to the cleaning position through the stainless steel sliding groove device 11. The limit switch ensures the safe and controllable lifting stroke. After entering the cleaning stage, the electromagnetic valve of the flushing device 31 is opened, and the probe is flushed at 0.3MPa for 30 seconds. Then it is switched to the air blowing device 32, and the 0.2MPa airflow generated by the 0.75kW air blower blows the probe dry within a distance of 10cm. The flushing-drying process is repeated 2-3 times to ensure the cleaning effect.

[0037] After cleaning, the cylinder sliding groove pushing device 41 accurately pushes the PVC container containing the standard sample to the position below the probe, and the standard sample injection is completed by gravity or pump pressure. At this time, the finger-shaped electric push rod 12 and the step lead screw sliding table 13 work together to simulate the manual pressing and rotating operation, complete the selection and confirmation of the calibration menu. During the calibration process, the data shielding module 52 automatically isolates the abnormal data of the instrument to avoid interference with the process control. After all the operations are completed, the system automatically records the calibration data and stores it in the central control system 5, and the probe returns to the working position through the sliding groove device, waiting for the next operation period.

[0038] The basic principles, main features and advantages of the present application are shown and described above. Those skilled in the art should understand that the present application is not limited to the above examples, and the above examples and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A water treatment process instrument sensor cleaning, calibrating robot characterized by, The mechanical hand comprises a mechanical execution system (1), a power control system (2), a cleaning system (3), a calibration system (4) and a central control system (5); The power control system (2) is connected with the mechanical execution system (1), the cleaning system (3) and the calibration system (4) respectively, and the central control system (5) is connected with the power control system (2).

2. A cleaning and calibrating robot for sensors of process instrumentation for water treatment plants according to claim 1, characterized in that: The mechanical execution system (1) comprises a stainless steel sliding groove device (11), a simulated finger electric push rod (12) and a stepping screw sliding table (13); The stainless steel sliding groove device (11) adopts a sliding groove structure with a gap of 1mm, and a limit switch is arranged at the bottom; The control precision of the simulated finger electric push rod (12) is 0.1mm, and a flexible silica gel head is arranged at the tail end; The stepping screw sliding table (13) is pushed by 0.3mm each time, the control precision reaches 0.1mm, and a linear ball bearing is adopted for the guide rail.

3. A mechanical hand for cleaning and calibrating sensors of process instrumentation for water treatment according to claim 1, characterized in that: The power control system (2) comprises a stepping pulse motor (21) and a PLC control system (22); The single pulse rotation of the stepping pulse motor (21) is 0.1 degree, one rotation can lift 5mm, the positioning precision is 0.2mm, and the stepping pulse motor (21) is connected with the sliding groove driving shaft through a shaft coupling.

4. A cleaning and calibrating robot for sensors of process instrumentation in water treatment plants according to claim 1, characterized in that: The cleaning system (3) comprises a flushing device (31) and an air blowing device (32) of a wind pipe; The flushing device (31) is controlled by an electromagnetic valve to be turned on and turned off, and the flushing pressure is 0.3MPa; The air blowing device (32) of the wind pipe is provided with a blower with a power of 0.75kW, the blowing pressure is 0.2MPa, and the blowing port is kept at a distance of 10cm from the probe.

5. A cleaning and calibrating robot for sensors of process instrumentation in water treatment plants as defined in claim 1, characterized in that: The calibration system (4) comprises a cylinder sliding groove pushing device (41) and a standard sample container (42); The cylinder sliding groove pushing device (41) adopts a double-acting cylinder, the cylinder diameter is 50mm, the stroke is 100mm, and the pushing speed can be adjusted; The standard sample container (42) adopts a corrosion-resistant PVC material, the capacity is 500mL, and a liquid level sensor is arranged.

6. A cleaning and calibrating robot for sensors of process instrumentation in water treatment plants as defined in claim 1, characterized in that: The central control system (5) comprises a man-machine interactive interface (51) and a data shielding module (52); The man-machine interactive interface (51) can set the cleaning and calibration cycle, check the equipment running state and historical data; The data shielding module (52) automatically shields the instrument data during cleaning and calibration.

7. A mechanical hand for cleaning and calibrating sensors of process instrumentation for water treatment according to claim 1, characterized in that: The stepping pulse motor (21) arranged at the top of the mechanical hand is fixed above the instrument mounting platform through a support; The stainless steel sliding groove device (11) arranged at the middle of the mechanical hand is vertically arranged at the edge of the platform, and the simulated finger electric push rod (12) and the stepping screw sliding table (13) are arranged side by side on one side of the sliding groove; The cylinder sliding groove pushing device (41) arranged at the bottom of the mechanical hand is fixed below the platform, and the flushing device (31) and the air blowing device (32) of the wind pipe are arranged on both sides of the sliding groove respectively; The PLC control system (22) of the control part is arranged near the platform and connected with each execution element through a cable.

8. A method of operating a water treatment process instrument sensor cleaning and calibrating robot as claimed in any one of claims 1 to 7, wherein, The working method comprises the following steps: S1, after the central control system (5) issues an instruction, the stepping pulse motor (21) drives the stainless steel sliding groove device (11) to lift the probe to a cleaning station; S2, the flushing device (31) first flushes the probe, and then the air pipe air blowing device (32) dries the probe, and repeats 2-3 times; S3, the cylinder sliding groove pushing device (41) pushes the sample container (42) to the probe, and the sample is injected into the calibration groove by gravity or pump pressure; S4, the imitation finger electric push rod (12) and the stepping screw sliding table (13) cooperate to operate the instrument button according to the preset program, complete the calibration menu selection and confirmation; S5, after the calibration is completed, the system automatically records the data and shields, and restores the data acquisition before the next calibration period.

9. The method of claim 8, wherein the method further comprises: In the step S1, the probe lifting is driven by a stepping pulse motor (21), and the positioning accuracy is controlled within 0.2mm; ​ In the step S2, the flushing time can be set by the central control system (5), and the default is 30 seconds each time.

10. The method of claim 8, wherein the method further comprises: In the step S4, the imitation finger electric push rod (12) simulates the finger pressing action, and the stepping screw sliding table (13) pushes the rotary button to realize the menu operation, and the control accuracy reaches 0.1mm; ​ In the step S5, the data shielding module (52) ensures that the abnormal data does not participate in the process control when cleaning and calibrating.

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