A multi-sensor fusion real-time flow deviation compensation control method

Abstract

The application discloses a kind of real-time flow deviation compensation control methods of multi-sensor fusion, comprising the following steps: S1, obtain set flow;S2, the actual flow of current header is obtained by flowmeter, and the deviation between actual flow and set flow is calculated;S3, the header number of deviation exceeding pre-set range is identified, and the valve positioner is dynamically adjusted until the actual flow is stable, and the actual valve opening degree and actual flow are recorded;S4, according to the actual valve opening degree and actual flow recorded, the data points in flow-valve opening degree corresponding relationship are reversely calculated and updated using traversal method.The application identifies the header with deviation and automatically corrects flow-valve opening degree corresponding relationship, so that the system can directly obtain actual flow meeting set flow requirement when next valve action, reduces the repeated adjustment of proportional regulator, and significantly reduces flow fluctuation.

Description

Technical Field

[0001] This invention relates to the field of industrial automation technology, and in particular to a real-time flow deviation compensation control method using multi-sensor fusion. Background Technology

[0002] Ultra-fast cooling equipment is a key piece of equipment in metal smelting plants used for the rapid cooling of steel plates. It cools the steel plate quickly by pouring water onto it, thereby altering its crystalline structure and improving its properties. Ultra-fast cooling equipment typically consists of a manifold, water tank, nozzles, valve positioners, and flow meters. The valve positioner is the actuator of the flow control system, and flow rate is the most direct control objective of the system. The ultra-fast cooling control system controls the flow rate by adjusting the opening degree of the valve positioner, ensuring that the steel plate properties meet process requirements.

[0003] In existing flow control processes, the control system typically calculates the required valve position based on a pre-stored "flow rate-valve opening degree correspondence." Once the flow rate stabilizes, a proportional adjustment method is used to further stabilize it. However, due to factors such as equipment wear, changes in media characteristics, and fluctuations in ambient temperature, there are discrepancies between the pre-stored flow rate-valve opening degree correspondence and the actual production conditions. If this correspondence is not corrected in a timely manner, the actual flow rate corresponding to each valve opening degree calculated based on this correspondence will deviate, requiring repeated adjustments via the proportional controller. This results in large flow rate fluctuations, making it difficult to ensure stable and consistent steel plate processing performance.

[0004] Therefore, there is an urgent need to develop a control method and system that can automatically identify flow deviations, automatically correct the flow-valve opening correspondence, and reduce flow fluctuations. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a real-time flow deviation compensation control method based on multi-sensor fusion.

[0006] To solve the above technical problems, the technical solution of the present invention is as follows: A real-time flow deviation compensation control method based on multi-sensor fusion includes the following steps: S1. Obtain the set flow rate, calculate the initial valve opening degree according to the preset flow rate-valve opening degree correspondence, and control the valve positioner to act; S2. Obtain the actual flow rate of the current manifold through the flow meter, and calculate the deviation between the actual flow rate and the set flow rate; S3. Identify and record the manifold number whose deviation exceeds the preset range, and use a stepless proportional control method to dynamically adjust the corresponding valve positioner until the actual flow rate stabilizes, and record the actual valve opening degree and actual flow rate when the flow rate stabilizes. S4. Based on the recorded actual valve opening degree and actual flow rate, use a traversal method to reverse calculate and update the data points associated with the actual valve opening degree and actual flow rate in the flow rate-valve opening degree correspondence relationship; S5. For the subsequently input set flow rate, based on the updated flow rate-valve opening degree correspondence, return to execute steps S1 to S4 until the deviation between the actual flow rate and the set flow rate is within the allowable range after the initial action of the control valve positioner.

[0007] As a preferred embodiment of the real-time flow deviation compensation control method of multi-sensor fusion described in this invention, in step S3, after identifying and recording the manifold number whose deviation exceeds the preset range, the method further includes: splitting the corresponding manifold number into the character code corresponding to the preset character code table, and outputting it to the digital tube for digital display.

[0008] As a preferred embodiment of the real-time flow deviation compensation control method based on multi-sensor fusion described in this invention, the method further includes triggering an audible and visual alarm device to issue a warning while simultaneously displaying the output to a digital tube.

[0009] This invention also provides a real-time flow deviation compensation control system based on multi-sensor fusion, employing the aforementioned real-time flow deviation compensation control method, comprising: Controller; Valve positioner, installed on the manifold; Flow meter, installed on manifold; The controller is communicatively connected to both the valve positioner and the flow meter; the controller receives the actual flow signal detected by the flow meter and outputs a control signal to the valve positioner to adjust the valve opening. The controller stores the flow rate-valve opening degree correspondence internally and is configured to execute the above-described real-time flow deviation compensation control method.

[0010] As a preferred embodiment of the real-time flow deviation compensation control system based on multi-sensor fusion described in this invention, the system further includes an alarm connected to the controller, comprising a seven-segment digital display tube for displaying the manifold number where flow deviation exists, and an audible and visual alarm for emitting sound and light warnings.

[0011] As a preferred embodiment of the multi-sensor fusion real-time flow deviation compensation control system of the present invention, it further includes a display terminal, which is communicatively connected to the controller and is used to display the actual flow rate of each manifold, the valve opening status, and flow deviation alarm record information in real time.

[0012] As a preferred embodiment of the real-time flow deviation compensation control system based on multi-sensor fusion described in this invention, it further includes a remote signal station. The valve positioner and flow meter on the manifold are connected to the remote signal station via cables, and the remote signal station is connected to the controller via a communication bus.

[0013] The beneficial effects of this invention are: (1) By identifying manifolds with deviations and automatically correcting the flow-valve opening correspondence, the present invention enables the system to directly obtain the actual flow that meets the set flow requirements when the valve is activated again, thereby reducing repeated adjustments of the proportional regulator and significantly reducing flow fluctuations.

[0014] (2) The present invention uses a stepless variable proportional control method to quickly adjust the deviation manifold, which can quickly stabilize the actual flow rate and shorten the adjustment time. At the same time, it uses a traversal method to reverse calculate the deviation data points in the corresponding relationship, which has high correction accuracy and can accurately restore the real flow rate-valve opening characteristics.

[0015] (3) The present invention improves the observability and maintainability of the system by using an alarm device to provide real-time alerts to operators of manifolds with deviations, facilitating timely monitoring and intervention. At the same time, the display terminal displays the flow rate, valve status and alarm records of each manifold in real time.

[0016] (4) The present invention realizes centralized control of multiple manifolds through remote signal stations and communication buses, and is suitable for application scenarios of large-scale manifold arrays. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the installation of the testing components and electrical cabinet in Example 2; Figure 2 This is a schematic diagram of the controller and alarm installation in Example 2; Figure 3 This is the control flowchart for automatic correction of flow rate-valve opening data in Example 2. Detailed Implementation

[0019] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0020] Example 1: This example provides a real-time flow deviation compensation control method based on multi-sensor fusion, including the following steps: S1. Obtain the set flow rate, calculate the initial valve opening degree according to the preset flow rate-valve opening degree correspondence, and control the valve positioner to operate.

[0021] S2. Obtain the actual flow rate of the current manifold through the flow meter, and calculate the deviation between the actual flow rate and the set flow rate.

[0022] S3. Identify and record the manifold numbers whose deviations exceed the preset range. Use a stepless proportional control method to dynamically adjust the corresponding valve positioner until the actual flow rate stabilizes, and record the actual valve opening and actual flow rate at the stable point. Simultaneously, decompose the corresponding manifold number into the corresponding character code in the preset character code table, output it to the digital tube for digital display, and trigger the audible and visual alarm device for warning.

[0023] Specifically, in this embodiment, when the actual flow exceeds ±2% of the set flow, it is determined that the actual flow exceeds the preset range.

[0024] S4. Based on the recorded actual valve opening degree and actual flow rate, use a traversal method to reverse calculate and update the data points associated with the actual valve opening degree and actual flow rate in the flow rate-valve opening degree correspondence.

[0025] S5. For the subsequently input set flow rate, based on the updated flow rate-valve opening degree correspondence, return to execute steps S1 to S4 until the deviation between the actual flow rate and the set flow rate is within the allowable range after the initial action of the control valve positioner.

[0026] Example 2: This example provides a real-time flow deviation compensation control system based on multi-sensor fusion. The system employs the real-time flow deviation compensation control method described in Example 1. The system includes a controller, a valve positioner, a flow meter, and a remote signal station.

[0027] Specifically, the controller is a Siemens S7-400 series controller, model 6ES7 416-2XN05-0AB0, installed in the control cabinet. The display screen is created using WinCC software and installed on the display terminal in the operator's room.

[0028] 108 flow meters are installed on 108 manifolds. The 4-20mA current signal from the flow meters is connected to the control system as the control target. 108 valve positioners are also installed on the 108 manifolds. The controller's output 4-20mA signal is connected to the valve positioners as the directly controlled target.

[0029] like Figure 1 As shown, both the flow meter and valve positioner are horizontally installed on the manifold. The flow meter is installed at the end furthest from the nozzle, and the valve positioner is installed at the end closest to the nozzle. Signals from both the flow meter and valve positioner are connected to a remote signal station on-site via a 60-meter, 4-core cable laid in the field. The remote signal station communicates with the S7-400 controller via a communication cable, transmitting the flow meter and valve positioner signals to the controller for logic function control.

[0030] like Figure 2 As shown, the control cabinet is installed in the electrical room, while the monitor and alarm are installed in the operator's room for easy operation. The monitor displays 108 manifolds, 108 valve positioners, and 108 flow meters, and shows in real time the valve opening degree, real-time flow rate, manifolds with flow deviation alarms, alarm information records, etc.

[0031] The alarm is located next to the monitor and includes two seven-segment digital displays and one audible and visual alarm. When the flow rate is normal, the seven-segment digital displays show "00"; when a flow alarm occurs, the seven-segment digital displays show the manifold number, for example, "12" indicates a flow deviation in manifold 12, requiring the controller to correct the flow-valve opening correspondence. The audible and visual alarm has a green indicator light when the flow rate is normal and a flashing red light when a flow deviation occurs, along with an audible sound to alert the operator to the flow deviation.

[0032] In the controller, data block DB600 stores the flow rate-valve opening ratio data. Function FC203 contains the control logic for flow rate and valve opening. When throwing steel plates, the valve is first opened to the calculated value according to the flow rate-valve opening ratio. After the flow rate stabilizes, the valve is adjusted using a continuously variable proportional controller based on the set flow rate and the actual deviation, rapidly reducing the flow rate deviation. Function FC204 contains a correction program for the flow rate-valve opening ratio relationship.

[0033] After adopting the technical solution of this application, the flow control effect of the ultra-fast cooling equipment was tracked and tested. The test results show that: 1. The accuracy rate of flow deviation identification reaches 100%, and it can promptly identify manifolds where the corresponding relationship is deviated due to equipment wear or changes in the medium; 2. The stepless proportional control method stabilizes the flow rate of the deviation manifold within 10 seconds, reducing the adjustment time by more than 50% compared to traditional methods; 3. By traversing and correcting backwards, the deviation between the actual flow rate and the set flow rate when the valve is activated for the next time is reduced from ±5% to ±8% to within ±1%, and the flow fluctuation is significantly reduced. 4. The pass rate of steel plate performance increased by about 3%, and the number of substandard products due to flow fluctuations was significantly reduced; 5. The alarm system responds promptly, enabling operators to quickly locate the problem and intervene.

[0034] Therefore, the technical solution of this application provides a real-time flow deviation compensation control method based on multi-sensor fusion, which solves the technical problem in the prior art that the deviation between the flow-valve opening degree correspondence and the actual working conditions leads to large flow fluctuations and unstable process performance. It achieves the technical effects of automatically identifying the deviation manifold, quickly stabilizing the flow, and automatically correcting the correspondence.

[0035] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A real-time flow deviation compensation control method based on multi-sensor fusion, characterized in that: Includes the following steps: S1. Obtain the set flow rate, calculate the initial valve opening degree according to the preset flow rate-valve opening degree correspondence, and control the valve positioner to act; S2. Obtain the actual flow rate of the current manifold through the flow meter, and calculate the deviation between the actual flow rate and the set flow rate; S3. Identify and record the manifold number whose deviation exceeds the preset range, and use a stepless proportional control method to dynamically adjust the corresponding valve positioner until the actual flow rate stabilizes, and record the actual valve opening degree and actual flow rate when the flow rate stabilizes. S4. Based on the recorded actual valve opening degree and actual flow rate, use a traversal method to reverse calculate and update the data points associated with the actual valve opening degree and actual flow rate in the flow rate-valve opening degree correspondence relationship; S5. For the subsequently input set flow rate, based on the updated flow rate-valve opening degree correspondence, return to execute steps S1 to S4 until the deviation between the actual flow rate and the set flow rate is within the allowable range after the initial action of the control valve positioner.

2. The real-time flow deviation compensation control method based on multi-sensor fusion according to claim 1, characterized in that: In step S3, after identifying and recording the manifold number whose deviation exceeds the preset range, the method further includes: splitting the corresponding manifold number into the character code corresponding to the preset character code table, and outputting it to the digital tube for digital display.

3. The real-time flow deviation compensation control method based on multi-sensor fusion according to claim 2, characterized in that: In addition to the digital display output to the digital tube, the system also includes triggering an audible and visual alarm device to issue a warning.

4. A real-time flow deviation compensation control system based on multi-sensor fusion, employing the real-time flow deviation compensation control method as described in any one of claims 1 to 3, characterized in that: include: Controller; Valve positioner, installed on the manifold; Flow meter, installed on manifold; The controller is communicatively connected to both the valve positioner and the flow meter; the controller receives the actual flow signal detected by the flow meter and outputs a control signal to the valve positioner to adjust the valve opening. The controller internally stores the flow rate-valve opening degree correspondence and is configured to execute the real-time flow deviation compensation control method as described in any one of claims 1 to 3.

5. The real-time flow deviation compensation control system based on multi-sensor fusion according to claim 4, characterized in that: It also includes an alarm connected to the controller, which includes a seven-segment digital display for displaying the manifold number where flow deviation exists and an audible and visual alarm for emitting sound and light warnings.

6. The real-time flow deviation compensation control system based on multi-sensor fusion according to claim 4, characterized in that: It also includes a display terminal, which is communicatively connected to the controller and is used to display the actual flow rate of each manifold, the valve opening status, and flow deviation alarm record information in real time.

7. The real-time flow deviation compensation control system based on multi-sensor fusion according to claim 4, characterized in that: It also includes a remote signal station, to which the valve positioner and flow meter on the manifold are connected via cable, and the remote signal station is connected to the controller via a communication bus.

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