Transformation control method and system for two-stage dynamic regulation induced draft fan

Abstract

The invention provides a two-stage dynamic regulation induced draft fan transformation control method and system, and the method comprises the steps: traversing an existing I / O channel of a DCS system, and recognizing an idle channel which is not referenced by logic and can be accessed by a physical terminal; based on idle channels, dynamically allocating the idle channels to newly-added fan monitoring points according to priorities, and generating a channel multiplexing mapping table; based on the channel mapping table, constructing a basic control layer comprising a fan start-stop and rotating speed adjusting loop; the safety protection layer is used for receiving data of the basic control layer in real time and generating hard protection logic of stall interlocking, vibration protection and oil station faults; constructing a collaborative optimization layer according to a safety protection layer state and a boiler load, and dynamically calculating a two-stage moving blade opening collaborative strategy; executing a moving blade opening instruction in the collaborative strategy through the basic control layer channel; based on the moving blade opening instruction, the response consistency of the safety protection layer and the collaborative optimization layer is verified by injecting the simulation fault signal, and the operation stability and reliability of the two-stage dynamic regulation induced draft fan control system are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of induced draft fan modification technology, and in particular to a two-stage dynamic adjustment induced draft fan modification control method and system. Background Technology

[0002] In modern industrial production, two-stage dynamic induced draft fans play a crucial role in many fields, such as thermal power generation and chemical industries. Their operational stability and control precision are of paramount importance to the efficiency and safety of the entire production system.

[0003] Currently, there is a significant technical problem in the control system of two-stage dynamically adjustable induced draft fans. With the expansion of production scale and the continuous improvement of process requirements, the requirements for the monitoring and control accuracy of induced draft fans are becoming increasingly stringent, necessitating the addition of a large number of fan monitoring points to achieve more comprehensive and accurate monitoring of operating status.

[0004] However, traditional DCS systems suffer from a shortage of existing I / O channel resources. On the one hand, it is difficult to find idle channels that are not logically referenced and can be physically connected to meet the needs of new monitoring points. On the other hand, even if some idle channels exist, there is a lack of a scientific and reasonable channel reuse mechanism, which makes it impossible to efficiently and orderly allocate them to new fan monitoring points. This seriously restricts the optimization and upgrading of the two-stage dynamic adjustment fan control system and affects the operational stability and reliability of the entire production system. Summary of the Invention

[0005] This invention provides a method and system for retrofitting a two-stage dynamically adjustable induced draft fan, which addresses the shortcomings of poor stability and reliability in the optimization and upgrading of existing two-stage dynamically adjustable induced draft fan control systems.

[0006] In a first aspect, the present invention provides a method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan, comprising:

[0007] Traverse the existing I / O channels of the DCS system to identify free channels that are not logically referenced and can be accessed by physical terminals;

[0008] Based on the available channels, they are dynamically allocated to new wind turbine monitoring points according to priority, and a channel reuse mapping table is generated.

[0009] Based on the channel mapping table, a basic control layer including fan start / stop and speed regulation loops is constructed; data from the basic control layer is received in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; a collaborative optimization layer is constructed based on the status of the safety protection layer and boiler load to dynamically calculate the two-stage blade opening collaborative strategy.

[0010] The blade opening command in the cooperative strategy is executed through the basic control layer channel;

[0011] Based on the blade opening command, the consistency of the response between the safety protection layer and the collaborative optimization layer is verified by injecting simulated fault signals.

[0012] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein the step of traversing the existing I / O channels of the DCS system and identifying idle channels that are not logically referenced and whose physical terminals can be connected includes:

[0013] At the physical layer, conduct continuity tests on the terminal blocks of the DCS system and mark the available channels;

[0014] At the logical layer, scan the channels of devices not associated with the database of the DCS system;

[0015] When there is a conflict between channels on the physical layer and the logical layer, the result of the physical layer shall prevail, and the database shall be updated to obtain an available channel.

[0016] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein the step of dynamically allocating monitoring points to newly added fans according to priority and generating a channel reuse mapping table includes:

[0017] The monitoring points for vibration and stall are assigned to the high reliability channel, while the monitoring points for temperature, oil station, and actuator are assigned to the low reliability channel.

[0018] Based on the location of the channel and the distance to local equipment, the cable laying path of the monitoring point is dynamically optimized.

[0019] A mapping table is generated based on the monitoring points of the high-reliability channel and the low-reliability channel, and the cable laying path.

[0020] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein the safety protection layer that receives data from the basic control layer in real time and generates hard protection logic for stall interlocking, vibration protection, and oil station faults includes:

[0021] Real-time monitoring of the blade opening output by the basic control layer;

[0022] If the blade opening exceeds the limit and a stall characteristic spectrum is continuously detected, a load reduction command is triggered, and the basic control layer is directly taken over to perform a trip.

[0023] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method includes the following methods for detecting the stall characteristic spectrum:

[0024] Collect the inlet pressure fluctuation signal of the fan;

[0025] When the energy change in a specific frequency band corresponding to the pressure fluctuation signal continues to exceed the threshold duration, a stall warning signal is generated.

[0026] The stall warning signal and the blade opening are logically ANDed to obtain the stall characteristic spectrum.

[0027] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein the dynamic calculation of the two-stage blade opening coordination strategy includes:

[0028] The primary moving blades respond to boiler main control commands;

[0029] Real-time acquisition of flue gas resistance change gradient, and calculation of secondary blade compensation opening based on the change gradient;

[0030] Output the coordination instructions of the first-stage blade and the second-stage blade to the basic control layer.

[0031] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein executing the blade opening command in the cooperative strategy includes:

[0032] When the blade opening command indicates the normal execution mode, the two-level blade opening command generated by the collaborative optimization layer is output through the AO channel of the basic control layer.

[0033] When the blade opening command indicates a protective layer intervention response, the command stream from the collaborative optimization layer to the AO channel is immediately intercepted, and the current opening output value is frozen.

[0034] When the blade opening command indicates that the safety command is overridden, the system switches to the dedicated command channel of the safety protection layer and outputs a preset safety position command to the actuator until the safety protection layer is reset.

[0035] According to the present invention, a two-stage dynamically adjustable induced draft fan retrofit control method is provided, wherein verifying the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals includes:

[0036] Flue gas parameters simulating ultra-low emission boundary conditions;

[0037] Based on the flue gas parameters, the time sequence chain from the triggering of the safety protection layer to the completion of the adjustment of the collaborative optimization layer is tracked;

[0038] When the deviation of the timing chain exceeds the tolerance, the cooperative strategy parameters are automatically corrected.

[0039] The two-stage dynamically adjustable induced draft fan retrofit control method provided by the present invention further includes:

[0040] The monitoring point labels are automatically loaded onto the DCS screen using the channel multiplexing mapping table.

[0041] Using the aforementioned tags, physical signals and logic configuration values ​​can be compared in real time during the debugging phase;

[0042] When the error of the real-time comparison exceeds the threshold, the channel self-test process is triggered.

[0043] Secondly, the present invention provides a two-stage dynamically adjustable induced draft fan retrofit control system, comprising:

[0044] The traversal module is used to traverse the existing I / O channels of the DCS system and identify free channels that are not logically referenced and can be accessed by physical terminals;

[0045] The generation module is used to dynamically allocate the idle channels to new wind turbine monitoring points according to priority, and generate a channel reuse mapping table.

[0046] The module is used to construct a basic control layer, including fan start / stop and speed regulation loops, based on the channel mapping table; receive data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; and construct a collaborative optimization layer based on the status of the safety protection layer and boiler load to dynamically calculate the two-stage blade opening collaborative strategy.

[0047] The coordination module is used to execute the blade opening command in the coordination strategy through the basic control layer channel;

[0048] The verification module is used to verify the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening command.

[0049] Thirdly, the present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the dual-stage dynamic adjustment induced draft fan modification control method as described above.

[0050] Fourthly, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the two-stage dynamic adjustment induced draft fan modification control method as described above.

[0051] Fifthly, the present invention also provides a computer program product, including a computer program that, when executed by a processor, implements the dual-stage dynamic adjustment induced draft fan modification control method as described above.

[0052] This invention provides a two-stage dynamically adjustable induced draft fan retrofit control method and system, including: traversing existing I / O channels of the DCS system to identify idle channels that are not logically referenced but physically accessible; dynamically allocating idle channels to new fan monitoring points according to priority, generating a channel reuse mapping table; constructing a basic control layer including fan start / stop and speed regulation loops based on the channel mapping table; receiving data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; constructing a collaborative optimization layer based on the safety protection layer status and boiler load, dynamically calculating the two-stage blade opening collaborative strategy; executing blade opening commands in the collaborative strategy through the basic control layer channels; verifying the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening commands; and effectively improving the operational stability and reliability of the two-stage dynamically adjustable induced draft fan control system by accurately identifying idle channels and intelligently allocating them to fan monitoring points. Attached Figure Description

[0053] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0054] Figure 1 This is a flowchart illustrating the two-stage dynamic adjustment induced draft fan modification control method provided in this embodiment;

[0055] Figure 2 This is a schematic diagram of the structure of the two-stage dynamically adjustable induced draft fan retrofit control system provided in this embodiment;

[0056] Figure 3 This is a schematic diagram of the structure of the electronic device provided in this embodiment. Detailed Implementation

[0057] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0058] Figure 1 This is a flowchart illustrating the two-stage dynamic adjustment induced draft fan modification control method provided in this embodiment.

[0059] like Figure 1As shown, the two-stage dynamically adjustable induced draft fan modification control method provided in this embodiment of the invention mainly includes the following steps:

[0060] 101. Traverse the existing I / O channels of the DCS system and identify free channels that are not logically referenced and can be accessed by physical terminals.

[0061] Specifically, at the physical layer, continuity tests are performed on the terminal blocks of the DCS system to mark available channels; at the logical layer, channels of devices not associated with the DCS system's database are scanned; when there is a conflict between channels at the physical and logical layers, the result at the physical layer prevails, and the database is updated to obtain available channels.

[0062] During the physical layer testing phase, based on the on-site terminal block wiring diagram, a loop continuity tester was used to test each channel on the DCS system terminal block point by point. For analog channels, the signal transmission loop between the channel and the corresponding I / O module was tested to ensure continuity and absence of short circuits. For digital channels, the integrity of the physical transmission path for switch signals was verified. Detected usable physical loop channels were marked as "physically usable channels," and their terminal block number, module location, and other physical information were recorded.

[0063] During the logic layer scanning phase, the control logic database is accessed through the DCS system configuration software to filter out channels that are not associated with any devices (such as existing sensors and actuators of the induced draft fan). Specifically, channels in the scanning database that are not referenced by ladder diagrams, function block diagrams, or other logic programs and have no historical data acquisition records are marked as "logically unreferenced channels," and their logical address information is recorded simultaneously.

[0064] During the conflict resolution phase, the numbering information of "physically available channels" and "logically unreferenced channels" is compared. If a channel is shown as unreferenced at the logical layer but is detected as unavailable at the physical layer (e.g., logically recorded as idle but the actual loop is disconnected), or is physically available but logically associated with a device (e.g., an obsolete association not updated in the database), the physical layer test result prevails. The logical database is then updated: physically unavailable "logically unreferenced channel" records are deleted, and information on physically available channels that are not logically marked is added, ultimately forming a "list of idle channels".

[0065] On the one hand, it accurately identifies physically accessible and logically unoccupied idle channels, solving the problem of "difficulty in finding channels" in the traditional approach, and providing directly usable resources for adding monitoring points to the two-stage dynamic induced draft fan; on the other hand, through the physical layer priority conflict handling mechanism, it ensures the actual availability of idle channels, avoids channel reuse failures caused by logical database lag, lays the foundation for subsequent scientific allocation of channels, effectively alleviates the predicament of DCS system I / O channel resource shortage, and helps optimize and upgrade the induced draft fan control system.

[0066] 102. Based on the available channels, dynamically allocate them to newly added wind turbine monitoring points according to priority, and generate a channel reuse mapping table.

[0067] Specifically, monitoring points for vibration and stall are assigned to high-reliability channels, while monitoring points for temperature, fuel stations, and actuators are assigned to low-reliability channels. The cable laying paths for monitoring points are dynamically optimized based on the channel location and the distance to local equipment. A mapping table is generated based on the monitoring points and cable laying paths of high-reliability and low-reliability channels.

[0068] First, the monitoring points were prioritized and matched with the channels. For newly added fan monitoring points, vibration and stall monitoring points were identified as key safety parameters. The accuracy of their data directly affects whether the induced draft fan triggers emergency shutdown protection. Therefore, they were classified as high-priority monitoring points and assigned to high-reliability channels in idle channels with high physical layer continuity test stability (e.g., signal transmission error ≤0.5% for three consecutive tests) and no frequent start-stop equipment associated with the logical layer. Monitoring points such as temperature, oil station level, and actuator position, although affecting operating efficiency, do not directly cause safety accidents. They were classified as low-priority monitoring points and assigned to other idle low-reliability channels. The correspondence between each monitoring point and channel was recorded.

[0069] Secondly, dynamic optimization of cable laying paths was carried out. Starting from the control cabinet where the DCS system I / O modules are located, and combining the actual locations of local equipment (such as vibration sensors installed in the fan bearing housing and temperature sensors located in the motor windings), a three-dimensional wiring diagram was drawn using CAD. The diagram simulated the cable length, number of bends, and intersections with power cables along different paths. The laying path with the shortest length (≥10% shorter than the initial plan), the least interference from high-voltage equipment (distance ≥0.5 meters), and the easiest access for later inspection and maintenance was selected. Especially for monitoring points connected to high-reliability channels, it was necessary to ensure that there were no strong electromagnetic interference sources (such as inverter output cables) in the path.

[0070] Finally, a channel multiplexing mapping table is generated. The matching relationship between high and low reliability channels and corresponding monitoring points, as well as the optimized cable laying path information, are integrated. The mapping table clearly records the monitoring point name, priority, physical terminal number of the corresponding channel, logical address, cable type and laying path node (such as "terminal block A1-3 → cable tray section B → wind turbine platform area C sensor interface"), and also marks the signal type (analog / digital) and sampling frequency after channel multiplexing.

[0071] On the one hand, by prioritizing and precisely matching high and low reliability channels, the stable transmission of key monitoring data is ensured. For example, the sampling error of vibration monitoring signals can be controlled within ±1%, which is more than 50% lower than the traditional random allocation method, providing reliable data support for the anti-stall and anti-vibration over-limit protection of the induced draft fan. On the other hand, the dynamically optimized cable laying path reduces signal transmission loss and interference. Combined with the clear record of the mapping table, it not only reduces cable material consumption (saving about 15%), but also shortens the fault location time during later channel maintenance to within 30 minutes. This effectively improves the deployment efficiency of new monitoring points for the dual-stage dynamically adjusted induced draft fan, provides an orderly and efficient channel reuse solution for the optimization and upgrading of the control system, and ensures the stable operation of the production system.

[0072] 103. Based on the channel mapping table, construct a basic control layer including fan start-up and shutdown and speed regulation loops; receive data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection and oil station faults; construct a collaborative optimization layer based on the safety protection layer status and boiler load, and dynamically calculate the two-stage blade opening collaborative strategy.

[0073] Specifically, during the basic control layer construction phase, based on the I / O channel information corresponding to the actuator monitoring points in the channel mapping table, the fan start-stop loop and speed regulation loop are configured in the DCS system. The start-stop loop uses the digital output channel associated with the mapping table to issue start-stop commands to the main motor of the induced draft fan, and links with the feedback channels monitoring the motor's operating status (such as current and voltage monitoring points) to form a closed-loop control. The speed regulation loop uses the analog output channel to connect to the blade adjustment actuator, and combines the input channel data of the speed feedback monitoring points in the mapping table to use a PID algorithm to achieve precise speed regulation, ensuring a linear correspondence between the output signal and the blade opening command.

[0074] During the safety protection layer construction phase, vibration and stall monitoring data transmitted through high-reliability channels in the channel mapping table are collected in real time. Hard protection logic is written in the logic configuration: when the vibration value exceeds a preset threshold (e.g., bearing vibration > 6.3 mm / s), vibration interlock protection is triggered, and an emergency shutdown is initiated via the start / stop loop of the basic control layer; when a stall characteristic curve is detected by the inlet air pressure, the stall suppression program is immediately activated, rapidly adjusting the blade opening. Simultaneously, low-reliability channel data from the oil station monitoring points are accessed; when the oil level is below the lower limit or the oil pressure is abnormal, a warning signal is issued and associated with the speed reduction logic of the basic control layer, forming a multi-level protection mechanism.

[0075] In the collaborative optimization layer construction phase, based on the real-time status of the safety protection layer (such as no protection action, early warning status, etc.), and combined with the boiler load command signal, the optimal opening coordination strategy for the two-stage moving blades is dynamically calculated through an algorithm model. Utilizing feedback data from monitoring points such as temperature and pressure in the channel mapping table, the moving blade opening adjustment parameters are corrected in real time to ensure that the opening difference between the two stages of moving blades is controlled within the optimal range (such as ≤5°) under different loads (such as 30% to 100% of rated load), achieving precise matching between the induced draft fan output and boiler demand.

[0076] The basic control layer achieves precise correlation between control commands and monitoring data through a channel mapping table, shortening the fan start-stop response time and improving speed regulation accuracy. The safety protection layer, through real-time data from highly reliable channels and hard protection logic, shortens the response time to severe faults such as excessive vibration and stall, reducing the risk of fault propagation compared to traditional protection logic. The collaborative optimization layer, based on a three-level linkage structure, reduces the induced draft fan's energy consumption during boiler load fluctuations while ensuring system stability, extending the continuous fault-free operation time of the induced draft fan and effectively supporting the optimization and upgrading of the two-stage dynamically adjustable induced draft fan control system.

[0077] 104. Execute the blade opening command in the cooperative strategy through the basic control layer channel.

[0078] Specifically, when the blade opening command is in normal execution mode, the basic control layer receives the two-level blade opening commands generated by the collaborative optimization layer through the analog output (AO) channel information recorded in the channel mapping table. After these commands are processed by the signal conversion module of the basic control layer, they are converted into standard control signals and transmitted to the blade actuator through the corresponding AO channel to adjust the blade opening in real time, ensuring that the induced draft fan's operating status is consistent with the collaborative optimization strategy.

[0079] When the blade opening command triggers the protection layer intervention response, the logic judgment module of the basic control layer immediately detects the intervention signal issued by the safety protection layer. At this time, the system automatically activates the command interception mechanism, cutting off the command transmission path between the collaborative optimization layer and the AO channel, and simultaneously freezing the current opening value output by the AO channel to keep the blade's current position unchanged. This process is achieved by locking the command register within the basic control layer, ensuring that during the safety hazard investigation period, the induced draft fan will not experience increased operational risks due to command fluctuations.

[0080] When the blade opening command enters the safety command overriding state, the basic control layer receives an emergency switching signal from the safety protection layer and quickly triggers the channel switching logic. Based on the predefined safety protection layer dedicated command channel information in the channel mapping table, the system disconnects the original AO channel and instead transmits the preset safety position command generated by the safety protection layer (such as a fixed value of 20% blade opening) to the actuator through the dedicated command channel. This state will continue until the safety protection layer issues a reset signal, at which point the system will release the dedicated channel and return to normal execution mode.

[0081] In normal operation mode, thanks to the stable transmission of the AO channel in the basic control layer, the response time for two-stage blade opening adjustment is shortened, ensuring the efficient implementation of the collaborative optimization strategy. During protection layer intervention, the command interception and opening freeze mechanism can prevent erroneous blade adjustment under abnormal conditions, reducing the risk of mechanical wear caused by frequent equipment movements. In safety command coverage mode, the blades can be quickly driven to a preset safe position through rapid switching of the dedicated command channel, such as emergency reduction to the minimum safe opening, effectively curbing the escalation of faults and significantly improving the safety protection capability of the induced draft fan under emergencies, ensuring the stable operation of the entire production system. Simultaneously, the seamless switching between the three modes ensures that the command execution of the basic control layer channel meets both the precise control requirements during normal operation and the safety and reliability under abnormal conditions, providing strong support for the safe and efficient operation of the two-stage dynamically adjustable induced draft fan control system.

[0082] 105. Based on the blade opening command, the consistency of response between the safety protection layer and the collaborative optimization layer is verified by injecting simulated fault signals.

[0083] Specifically, the first step is to inject simulated fault signals. Combined with ultra-low emission boundary conditions (such as a sudden rise in flue gas temperature exceeding 400°C or a sudden increase in flue gas dust content of 20%), preset simulated flue gas parameter signals are injected into the input channels of the basic control layer through the signal simulator of the DCS system. The injection must be correlated with the blade opening command status; for example, when the blade opening is in the high-load range of 50%–80%, abnormal flue gas parameter signals are injected synchronously to simulate boundary fault scenarios under high load in actual operation.

[0084] Next, the timing chain is traced. Starting from the triggering of protection logic by the safety protection layer (such as issuing a vibration warning or stall pre-alarm), the event logging function of the DCS system records in real time the action time of the safety protection layer (T1), the time when the collaborative optimization layer receives the protection signal (T2), the time when the collaborative optimization layer generates the adjustment command (T3), and the time when the basic control layer executes the adjustment command (T4), forming a complete timing chain of "T1-T2-T3-T4". At the same time, the monitoring point data associated with the channel mapping table is used to verify whether the signal transmission of each link is consistent with the adjustment direction of the blade opening command (e.g., the blade should be adjusted to the closing direction after protection is triggered).

[0085] Finally, timing chain deviations are addressed. Tolerance ranges are set for each stage of the timing chain (e.g., T2-T1 ≤ 100ms, T4-T3 ≤ 200ms). When the actual deviation exceeds the tolerance, the system automatically initiates a cooperative strategy parameter correction mechanism. For example, if the T3-T2 deviation is too large, the algorithm iteration frequency of the cooperative optimization layer can be increased; if T4-T3 exceeds the tolerance, the instruction conversion module parameters of the basic control layer can be optimized to ensure that the corrected cooperative strategy parameters can reduce the timing chain deviation to within the tolerance.

[0086] By simulating fault injection under ultra-low emission boundary conditions, extreme scenarios in actual operation can be accurately reproduced, providing a realistic testing environment for response consistency verification. Timing chain tracking directly reflects the linkage efficiency between the safety protection layer and the collaborative optimization layer, ensuring closed-loop coordination between the two during blade opening adjustment. The automatic correction mechanism reduces timing chain deviation by more than 30%, significantly improving the reliability of the collaborative strategy. Ultimately, this process ensures efficient synchronization between the safety protection layer's protective actions and the collaborative optimization layer's adjustment commands when flue gas parameters are abnormal, preventing the induced draft fan from deviating from the safe operating range due to response delays, further enhancing the stable operation capability of the two-stage dynamically adjustable induced draft fan under complex conditions.

[0087] Furthermore, based on the above embodiments, this embodiment receives data from the basic control layer in real time and generates a safety protection layer with hard protection logic for stall interlocking, vibration protection, and gas station faults. This includes: real-time monitoring of the blade opening output by the basic control layer; if the blade opening exceeds the limit and a stall characteristic spectrum is continuously detected, a load reduction command is triggered, directly taking over the basic control layer to execute a trip. The stall characteristic spectrum detection method includes: acquiring the turbine inlet pressure fluctuation signal; when the energy change in a specific frequency band corresponding to the pressure fluctuation signal continuously exceeds a threshold duration, a stall warning signal is generated; and a logical AND operation is performed between the stall warning signal and the blade opening to obtain the stall characteristic spectrum.

[0088] Specifically, firstly, the safety protection layer continuously receives the blade opening data output by the basic control layer through the real-time data transmission channel of the DCS system, including key parameters such as the current opening value and the rate of change of opening, and compares it in real time with the preset opening threshold (such as the 75% rated opening upper limit set for a two-stage dynamically adjustable induced draft fan).

[0089] In terms of stall characteristic spectrum detection, the system collects pressure fluctuation signals through the pressure sensor channel connected to the fan inlet in the basic control layer. The signal is processed using a spectrum analysis algorithm to extract the energy value of a preset frequency band (this frequency band is a typical characteristic frequency band for stall in a two-stage dynamically adjustable induced draft fan). When the detected energy mutation amplitude in this frequency band exceeds 30% of the normal fluctuation value and the duration reaches a preset threshold (e.g., 5 seconds), a stall warning signal is generated. Subsequently, the stall warning signal is logically ANDed with the real-time monitored blade opening—that is, only when both conditions are met simultaneously (the stall warning signal is valid and the blade opening exceeds the limit) is it determined that a stall characteristic spectrum has been detected.

[0090] Regarding the stall interlock protection logic, when the system detects a stall characteristic spectrum and the blade opening exceeds the threshold for 10 seconds, the safety protection layer immediately triggers a load reduction command, sending a signal to the basic control layer via a dedicated control channel to forcibly reduce the induced draft fan load to below 50% of the rated load. If the stall characteristics persist after load reduction and the duration reaches 20 seconds, the system directly takes over the execution authority of the basic control layer, triggering a trip command to cut off the power supply to the induced draft fan's main motor.

[0091] In the vibration protection and gas station fault protection logic, the safety protection layer receives real-time data from the fan bearing vibration sensor, gas station pressure, and liquid level sensor through a high-reliability channel. When the vibration value exceeds 6.3 mm / s, or the gas station pressure is lower than 0.3 MPa, or the liquid level is lower than the minimum scale line, a vibration over-limit signal and a gas station fault signal are generated respectively, triggering the corresponding hard protection logic, such as issuing an audible and visual alarm, linking the basic control layer to perform speed reduction adjustment, and executing trip protection if the fault continues to worsen.

[0092] By monitoring the correlation between the blade opening and the stall characteristic spectrum in real time, the response time of the stall interlock protection is shortened. Compared with the traditional detection method that relies solely on pressure signals, the false alarm rate is reduced, effectively avoiding production interruptions caused by malfunctions. Overall, the hard protection logic of the safety protection layer enables rapid identification and graded handling of critical faults in the two-stage dynamically adjustable induced draft fan, significantly improving the safety redundancy capability of the control system, ensuring the stable operation of the induced draft fan under complex operating conditions, and providing a solid guarantee for the reliability of the entire production system.

[0093] Furthermore, based on the above embodiments, the dynamic calculation strategy for the two-stage blade opening coordination in this embodiment includes: the first-stage blade responding to the boiler main control command; acquiring the flue gas resistance change gradient in real time, calculating the second-stage blade compensation opening based on the change gradient; and outputting the coordination command of the first-stage and second-stage blades to the basic control layer.

[0094] Specifically, in the primary blade adjustment stage, the collaborative optimization layer receives boiler master control commands (such as load command signals) in real time through the DCS system's data interface. Based on the preset load-opening curve (for example, when the boiler load is 80% of the rated value, the primary blade reference opening is set to 50%), it calculates the target opening of the primary blade. Simultaneously, combining the actual opening of the primary blade fed back from the basic control layer, it dynamically adjusts the output commands using a proportional-integral control algorithm to ensure that the primary blade responds quickly to the boiler master control requirements, keeping the deviation between the actual opening and the target opening within the error range.

[0095] In the secondary blade compensation opening calculation stage, the collaborative optimization layer collects flue gas pressure signals at the inlet and outlet of the induced draft fan through a high-reliability channel and calculates the flue gas resistance change gradient per unit time (e.g., in kPa / min). When the gradient is positive and exceeds a preset threshold (e.g., 0.5 kPa / min), it is determined that the flue gas resistance is increasing. At this time, the required compensation opening is calculated based on a preset compensation algorithm (e.g., for every 0.1 kPa increase in resistance, the secondary blade compensation opening increases by 1%). If the gradient is negative and the absolute value exceeds the threshold, the secondary blade opening is reduced proportionally to maintain the overall output stability of the induced draft fan.

[0096] In the collaborative command output stage, the collaborative optimization layer integrates the target opening command of the first-stage blades with the compensation opening command of the second-stage blades to form a collaborative control command that includes both. Through a data transmission protocol agreed upon with the basic control layer, this command is sent in real-time to the AO channel of the basic control layer, which then drives the corresponding blade actuator to complete the motion adjustment. Simultaneously, the collaborative optimization layer continuously receives the actual opening data of the two-stage blades from the basic control layer for dynamic correction of the collaborative strategy in the next round.

[0097] The reduced response time of the primary moving blades to boiler control commands ensures rapid matching of induced draft fan output with boiler load demand. The secondary moving blades, based on compensation adjustments for flue gas resistance gradient changes, quickly offset the impact of resistance fluctuations on induced draft fan operation, reducing the amplitude of pressure difference fluctuations at the fan inlet and outlet. This coordinated control of the two-stage moving blades effectively solves the response lag problem inherent in traditional single-stage regulation. When boiler load changes rapidly, induced draft fan operating efficiency is improved, while mechanical wear caused by frequent moving blade adjustments is reduced, extending the service life of the actuators. This provides strong support for the stable operation of the two-stage dynamically adjustable induced draft fan under complex operating conditions, thereby ensuring the energy efficiency and safety of the entire production system.

[0098] Furthermore, based on the above embodiments, this embodiment also includes: automatically loading monitoring point tags onto the DCS screen through a channel multiplexing mapping table; using the tags to compare physical signals and logic configuration values ​​in real time during the debugging phase; and triggering a channel self-test process when the error of the real-time comparison exceeds a threshold.

[0099] Specifically, during the automatic loading of monitoring point labels on the DCS screen, the system retrieves information such as the monitoring point name, corresponding channel physical terminal number, and logical address recorded in the channel multiplexing mapping table. Through the script interface of the DCS configuration software, this information is automatically associated with the corresponding data display unit on the screen. For example, the label for the "Exhaust Fan Bearing Vibration A" monitoring point, along with its associated physical terminal number and logical address, is automatically loaded into the vibration monitoring area of ​​the DCS real-time monitoring screen. The label display format remains consistent with the existing screen, ensuring that operators can intuitively identify the channel association information for each monitoring point.

[0100] During the real-time comparison phase of the commissioning stage, the system synchronously acquires physical layer signals (such as the current signal output by the vibration sensor) and logic configuration values ​​(the recorded values ​​of that channel in the database) through the DCS's real-time database interface. Numerical comparisons are performed periodically, and the absolute error between the two is calculated. Differentiated thresholds are set for different types of monitoring points; for example, the error threshold for critical monitoring points such as vibration and stall is stricter than that for general monitoring points such as temperature.

[0101] When the error in real-time comparison exceeds a set threshold, the system immediately triggers a channel self-test process. First, the configuration software checks whether the channel's logic configuration matches the mapping table, such as confirming whether parameters like signal type (analog / digital) and range match. Second, the physical layer continuity test module is automatically invoked to perform a secondary continuity test on the channel's terminal block circuit, verifying whether there are any loose or poor physical connections. Finally, a report is generated based on the self-test results. If a logic configuration error is found, maintenance personnel are prompted to correct the database association; if a physical connection problem is found, the specific terminal block location is identified and a maintenance warning is issued.

[0102] Automatic tag loading eliminates the need for manual tag configuration on the screen, significantly reducing screen configuration time and avoiding human input errors. Real-time comparison during the commissioning phase can quickly detect anomalies in channel data transmission, greatly improving efficiency compared to traditional manual inspections. The channel self-check process can quickly locate the cause of errors, significantly shortening troubleshooting time. Through this series of operations, the accuracy and reliability of the channel data at newly added monitoring points are ensured, providing technical support for the commissioning and stable operation of the two-stage dynamic adjustment induced draft fan control system, and further improving the monitoring accuracy and maintenance efficiency of the entire production system.

[0103] It should be noted that the specific values ​​in this embodiment are merely illustrative examples and do not constitute a specific limitation on the technical solution of the present invention.

[0104] Based on the same general inventive concept, this invention also protects a two-stage dynamically adjustable induced draft fan modification control system. The two-stage dynamically adjustable induced draft fan modification control system described below and the two-stage dynamically adjustable induced draft fan modification control method described above can be referred to in correspondence.

[0105] Figure 2 This is a schematic diagram of the structure of the two-stage dynamic adjustment induced draft fan modification control system provided by the present invention.

[0106] like Figure 2 As shown, this embodiment provides a two-stage dynamically adjustable induced draft fan retrofit control system, including:

[0107] Traversal module 201 is used to traverse the existing I / O channels of the DCS system and identify free channels that are not logically referenced and can be accessed by physical terminals;

[0108] The generation module 202 is used to dynamically allocate new wind turbine monitoring points according to priority based on idle channels and generate a channel reuse mapping table;

[0109] Module 203 is used to construct a basic control layer based on a channel mapping table, including fan start-up and speed regulation loops; receive data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; and construct a collaborative optimization layer based on the safety protection layer status and boiler load to dynamically calculate the two-stage blade opening collaborative strategy.

[0110] The coordination module 204 is used to execute the blade opening command in the coordination strategy through the basic control layer channel;

[0111] The verification module 205 is used to verify the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening command.

[0112] Figure 3 This is a schematic diagram of the structure of the electronic device provided in this embodiment.

[0113] like Figure 3As shown, the electronic device may include: a processor 310, a communication interface 320, a memory 330, and a communication bus 340, wherein the processor 310, the communication interface 320, and the memory 330 communicate with each other through the communication bus 340. The processor 310 can call logic instructions in the memory 330 to execute a two-stage dynamic adjustment induced draft fan retrofit control method. This method includes: traversing existing I / O channels of the DCS system to identify idle channels that are not logically referenced and whose physical terminals can be accessed; dynamically allocating these idle channels to new fan monitoring points according to priority, generating a channel reuse mapping table; constructing a basic control layer including fan start / stop and speed regulation loops based on the channel mapping table; receiving data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlocking, vibration protection, and oil station faults; constructing a collaborative optimization layer based on the safety protection layer status and boiler load, dynamically calculating a two-stage blade opening collaborative strategy; executing blade opening instructions in the collaborative strategy through the basic control layer channels; and verifying the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening instructions.

[0114] Furthermore, the logical instructions in the aforementioned memory 330 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0115] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer can execute the two-stage dynamic adjustment induced draft fan modification control method provided by the above methods. The method includes: traversing the existing I / O channels of the DCS system to identify idle channels that are not logically referenced and can be physically accessed; dynamically allocating the idle channels to new fan monitoring points according to priority based on the idle channels, and generating a channel reuse mapping table; constructing a basic control layer including fan start-stop and speed regulation loops based on the channel mapping table; receiving data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; constructing a collaborative optimization layer according to the status of the safety protection layer and boiler load, and dynamically calculating a two-stage blade opening collaborative strategy; executing the blade opening command in the collaborative strategy through the basic control layer channel; and verifying the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening command.

[0116] In another aspect, the present invention also provides a non-transitory computer-readable storage medium storing a computer program thereon. When executed by a processor, this computer program implements the two-stage dynamic adjustment induced draft fan retrofit control method provided by the above methods. The method includes: traversing the existing I / O channels of the DCS system to identify idle channels that are not logically referenced and whose physical terminals can be accessed; dynamically allocating the idle channels to new fan monitoring points according to priority based on the priority, and generating a channel reuse mapping table; constructing a basic control layer including fan start-stop and speed regulation loops based on the channel mapping table; receiving data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults; constructing a collaborative optimization layer according to the status of the safety protection layer and boiler load, and dynamically calculating a two-stage blade opening collaborative strategy; executing the blade opening command in the collaborative strategy through the basic control layer channel; and verifying the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening command.

[0117] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0118] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0119] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan, characterized in that, include: Traverse the existing I / O channels of the DCS system to identify free channels that are not logically referenced and can be accessed by physical terminals; Based on the available channels, they are dynamically allocated to new wind turbine monitoring points according to priority, and a channel reuse mapping table is generated. Based on the channel mapping table, a basic control layer including fan start / stop and speed regulation loops is constructed; data from the basic control layer is received in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and gas station faults. Based on the safety protection layer status and boiler load, a collaborative optimization layer is constructed, and a two-stage blade opening collaborative strategy is dynamically calculated. The blade opening command in the cooperative strategy is executed through the basic control layer channel; Based on the blade opening command, the consistency of the response between the safety protection layer and the collaborative optimization layer is verified by injecting simulated fault signals.

2. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The process of traversing the existing I / O channels of the DCS system to identify idle channels that are not logically referenced but are physically accessible includes: At the physical layer, conduct continuity tests on the terminal blocks of the DCS system and mark the available channels; At the logical layer, scan the channels of devices not associated with the database of the DCS system; When there is a conflict between channels on the physical layer and the logical layer, the result of the physical layer shall prevail, and the database shall be updated to obtain an available channel.

3. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The process of dynamically allocating new wind turbine monitoring points according to priority and generating a channel reuse mapping table includes: The monitoring points for vibration and stall are assigned to the high reliability channel, while the monitoring points for temperature, oil station, and actuator are assigned to the low reliability channel. Based on the location of the channel and the distance to local equipment, the cable laying path of the monitoring point is dynamically optimized. A mapping table is generated based on the monitoring points of the high-reliability channel and the low-reliability channel, and the cable laying path.

4. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The safety protection layer, which receives data from the basic control layer in real time and generates hard protection logic for stall interlocking, vibration protection, and gas station faults, includes: Real-time monitoring of the blade opening output by the basic control layer; If the blade opening exceeds the limit and a stall characteristic spectrum is continuously detected, a load reduction command is triggered, and the basic control layer is directly taken over to perform a trip.

5. The two-stage dynamically adjustable induced draft fan modification control method according to claim 4, characterized in that, The detection methods for the stall characteristic spectrum include: Collect the inlet pressure fluctuation signal of the fan; When the energy change in a specific frequency band corresponding to the pressure fluctuation signal continues to exceed the threshold duration, a stall warning signal is generated. The stall warning signal and the blade opening are logically ANDed to obtain the stall characteristic spectrum.

6. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The dynamic calculation strategy for the coordinated opening of the two-stage moving blades includes: The primary moving blades respond to boiler main control commands; Real-time acquisition of flue gas resistance change gradient, and calculation of secondary blade compensation opening based on the change gradient; Output the coordination instructions of the first-stage blade and the second-stage blade to the basic control layer.

7. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The execution of the blade opening command in the cooperative strategy includes: When the blade opening command indicates the normal execution mode, the two-level blade opening command generated by the collaborative optimization layer is output through the AO channel of the basic control layer. When the blade opening command indicates a protective layer intervention response, the command stream from the collaborative optimization layer to the AO channel is immediately intercepted, and the current opening output value is frozen. When the blade opening command indicates that the safety command is overridden, the system switches to the dedicated command channel of the safety protection layer and outputs a preset safety position command to the actuator until the safety protection layer is reset.

8. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to claim 1, characterized in that, The step of verifying the response consistency between the security protection layer and the collaborative optimization layer by injecting simulated fault signals includes: Flue gas parameters simulating ultra-low emission boundary conditions; Based on the flue gas parameters, the time sequence chain from the triggering of the safety protection layer to the completion of the adjustment of the collaborative optimization layer is tracked; When the deviation of the timing chain exceeds the tolerance, the cooperative strategy parameters are automatically corrected.

9. The method for retrofitting and controlling a two-stage dynamically adjustable induced draft fan according to any one of claims 1-8, characterized in that, Also includes: The monitoring point labels are automatically loaded onto the DCS screen using the channel multiplexing mapping table. Using the aforementioned tags, physical signals and logic configuration values ​​can be compared in real time during the debugging phase; When the error of the real-time comparison exceeds the threshold, the channel self-test process is triggered.

10. A two-stage dynamically adjustable induced draft fan retrofit control system, characterized in that, include: The traversal module is used to traverse the existing I / O channels of the DCS system and identify free channels that are not logically referenced and can be accessed by physical terminals; The generation module is used to dynamically allocate the idle channels to new wind turbine monitoring points according to priority, and generate a channel reuse mapping table. The module is used to construct a basic control layer, including the fan start / stop and speed regulation loops, based on the channel mapping table; and to receive data from the basic control layer in real time to generate a safety protection layer with hard protection logic for stall interlock, vibration protection, and oil station faults. Based on the safety protection layer status and boiler load, a collaborative optimization layer is constructed, and a two-stage blade opening collaborative strategy is dynamically calculated. The coordination module is used to execute the blade opening command in the coordination strategy through the basic control layer channel; The verification module is used to verify the response consistency between the safety protection layer and the collaborative optimization layer by injecting simulated fault signals based on the blade opening command.

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