Sludge direct-doping system and control method

Abstract

The sludge direct mixing system has the disadvantages of many control interlocking conditions, complex control algorithm, poor logic, many fault points, high maintenance cost, complicated man-machine interface, not humanized, and poor self-suction property. The sludge direct mixing system comprises a square silo (100), a sliding frame (200), a flashboard valve (300), a comprehensive hydraulic station (201) and a screw conveyor (400). A material level meter (600) is installed on the square silo, which is used for detecting the amount of material in the square silo. The sliding frame is installed at the lower end of the square silo. The screw conveyor is fixed at the lower end of the square silo. The screw conveyor is connected with the square silo through a hydraulic flashboard valve. A cone valve pump is installed at the lower end of the screw conveyor. The outlet of the cone valve pump is connected with a pipeline ball valve. The application is used for controlling the sludge direct mixing system.

Description

Technical Field

[0001] This invention belongs to the field of silo storage and transportation technology, specifically relating to a sludge direct blending system and control method. Background Technology

[0002] A cone valve pump is a device that continuously transports materials from a silo to the outside. It utilizes the forward and backward movement of the main cylinder of the cone valve pump in coordination with the auxiliary cylinder to push the material to be transported, thereby achieving the conveying operation.

[0003] In addition to the silo and cone valve pump, a silo storage and transportation system based on a cone valve pump generally includes a level gauge, a slide, a screw conveyor, and a gate valve. The level gauge is used to detect the material in the silo, the screw conveyor is used to transport the material output from the silo, and the gate valve is used to control the opening and closing of the material flow path.

[0004] The advantages of a silo storage and transportation system based on a cone valve pump are: compared with other silos, the cone valve pump silo has a higher rated pressure, higher speed, and higher pump drive power; higher efficiency; longer service life; lighter weight per unit power; and a more reliable, faster, and more stable control method.

[0005] However, the disadvantages of the sludge direct blending system are that there are many control interlocking conditions, complex control algorithms, poor logic, many failure points, high maintenance costs, cumbersome and unuser-friendly human-machine interface, and poor self-priming capability of the equipment.

[0006] Therefore, to address the aforementioned technical problems, it is necessary to provide a control method based on a sludge direct blending system. Summary of the Invention

[0007] The purpose of this invention is to provide a sludge direct blending system and control method to solve the above-mentioned technical problems.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A sludge direct blending system and control method are disclosed, comprising a square silo, a slide frame, a gate valve, a comprehensive hydraulic station, and a screw conveyor. A level gauge is installed on the square silo to detect the amount of material inside the silo. The slide frame is installed at the lower end of the square silo.

[0010] The screw conveyor is fixed at the lower end of the square silo. A hydraulic slide valve is connected between the screw conveyor and the square silo. A cone valve pump is installed at the lower end of the screw conveyor. The outlet of the cone valve pump is connected to a pipeline ball valve.

[0011] A control method based on a sludge direct blending system, the method comprising the following steps:

[0012] (1) Open the electric ball valve and start the pump hydraulic station;

[0013] (2) After the pump hydraulic station is running, start the first timer, and start the screw working after the delay;

[0014] (3) After the pump hydraulic station is running, the second timer is started, and after a delay, the auxiliary cylinder forward solenoid valve is started; after the auxiliary cylinder forward solenoid valve is activated, the third timer is started, and after a delay, it serves as the auxiliary cylinder position signal; after the auxiliary cylinder is in position, the main cylinder forward solenoid valve is started; after the main cylinder is in position, the No. 1 pump running interval time relay is started; next, the auxiliary cylinder retracts and the main cylinder retracts, repeating the cycle. The system ends when the system stop command is issued, and the main cylinder retracts to position and stops running.

[0015] (4) When the cumulative value of the number of times the master cylinder retracts is greater than the set value of the pump lubrication interval cycle, the lubrication solenoid valve is started; when the cumulative value of the number of times the master cylinder retracts is greater than the set value of the pump lubrication cycle, the lubrication solenoid valve is stopped.

[0016] (5) The carriage system is started, and the integrated hydraulic station is in operation;

[0017] (6) After the integrated hydraulic station is running, start the timer, and after the delay, start the slide forward solenoid valve; after the slide solenoid valve is in position, start the slide interval timer; after the timer expires, start the slide backward solenoid valve, and repeat the cycle. After the slide system stops, the slide continues to move to position, or the system stops after it moves backward to position.

[0018] In the control method based on the sludge direct blending system, the cone valve pump in step (3) mainly reciprocates and is generally controlled sequentially. The steps are as follows: the auxiliary cylinder moves forward, that is, the auxiliary cylinder forward solenoid valve is energized, and when the auxiliary cylinder moves forward to the position, it stops moving forward; the main cylinder moves forward, that is, the main cylinder forward solenoid valve is energized, and when it moves forward to the main cylinder forward limit switch, it stops moving forward; the auxiliary cylinder moves backward, that is, the auxiliary cylinder backward solenoid valve is energized, and when it moves backward to the auxiliary cylinder backward position, it stops moving backward; the main cylinder moves backward, that is, the main cylinder backward solenoid valve is energized, and when the main cylinder moves backward to the backward limit, it stops moving backward, and the auxiliary cylinder starts moving forward again, and so on in a reciprocating cycle; before controlling the solenoid valve, the cone valve pump hydraulic station motor must be started to provide hydraulic power; in order to adjust the pump's delivery volume, a proportional regulating valve is installed on the pump to control the speed of the pump's delivery volume, and its control signal is 0-10V.

[0019] In the control method based on the sludge direct blending system, step (3) involves starting the second timer and delaying for 5 seconds before starting the auxiliary cylinder forward solenoid valve.

[0020] In the control method based on the sludge direct blending system, step (3) involves starting a third timer and delaying for 2 seconds as a signal for the auxiliary cylinder to be in position.

[0021] In the control method based on the sludge direct blending system, step (2) involves starting the first timer and delaying for 10 seconds before starting the spiral operation.

[0022] In the control method based on the sludge direct blending system, after the integrated hydraulic station is running in step (6), the timer is started, and after a delay of 5 seconds, the slide forward solenoid valve is started. Beneficial effects

[0023] 1. The sludge direct blending system and control method represent a breakthrough in sludge co-firing methods. The system requires low investment, has low technical construction difficulty, occupies a small area, is simple, and has a short construction period. The system has low operating and maintenance costs and a short investment payback period.

[0024] 2. The sludge direct blending system and control method solves the problem of harmless disposal of a certain amount of urban sludge solid waste, and can also serve as a supplement to other sludge disposal methods in power plants, thus having value for comprehensive industry promotion. Attached Figure Description

[0025] Figure 1 This is the front view of the present invention;

[0026] Figure 2 This is a top view of the present invention;

[0027] Figure 3 This is a screenshot of a human-machine interface system in one embodiment of the present invention;

[0028] Figure 4 This is a human-machine interface parameter setting screen in one embodiment of the present invention;

[0029] Figure 5 This is a human-machine interface fault display screen in one embodiment of the present invention.

[0030] Figure 6 This is a schematic diagram illustrating the lubrication start and lubrication stop achieved by the comparison algorithm of this invention;

[0031] Figure 7 This is a schematic diagram of the lubrication interval count accumulation (master cylinder retraction count accumulation) and reset method of the present invention;

[0032] Figure 8 This is a schematic diagram of the lubrication cycle accumulation (accumulation of the number of times the master cylinder retracts after the lubrication command is issued) and reset method of the present invention;

[0033] Figure 9 This invention provides a schematic diagram of the algorithm for converting the analog input of the level gauge back to a percentage, displayed as a bar chart on the human-machine interface.

[0034] Figure 10 This is a schematic diagram of a fault in the main cylinder proximity switch of the present invention.

[0035] Figure 11 This is a schematic diagram of the analog output algorithm for setting displacement in this invention;

[0036] Figure 12 This is a flowchart of the control method of the present invention;

[0037] In the diagram: 100, square silo; 200, slide frame; 201, integrated hydraulic station; 300, slide gate valve; 400, screw conveyor; 500, cone valve pump; 501, cone valve pump hydraulic station; 600, level gauge; 700, electric ball valve. Implementation

[0038] Cone valve pump system:

[0039] When the cone valve pump system starts, the cone valve pump hydraulic station is started first, followed by the screw conveyor. The cone valve pump mainly operates in reciprocating motion, generally controlled sequentially. The steps are as follows: the auxiliary cylinder advances (i.e., the auxiliary cylinder advance solenoid valve is energized), and stops advancing when the auxiliary cylinder reaches its forward position; the main cylinder advances (i.e., the main cylinder advance solenoid valve is energized), and stops advancing when it reaches the main cylinder advance limit switch; the auxiliary cylinder retracts (i.e., the auxiliary cylinder retracts solenoid valve is energized), and stops retracting when it reaches its retracted position; the main cylinder retracts (i.e., the main cylinder retracts solenoid valve is energized), and stops retracting when it reaches the retract limit; the auxiliary cylinder then starts advancing again, and this cycle continues. Before controlling the solenoid valves, the cone valve pump hydraulic station motor must be started to provide hydraulic power. To adjust the pump's delivery rate, a proportional regulating valve is installed on the pump to control the pump's delivery speed; its control signal is 0-10V.

[0040] Call the police:

[0041] The system should be shut down under the following circumstances:

[0042] 1. The main cylinder does not provide a limit signal feedback after 120 seconds;

[0043] 2: Both the forward and backward limit switches provide signal feedback simultaneously;

[0044] 3: Oil suction alarm, oil return alarm, low oil level alarm, high pressure alarm, high temperature alarm, etc.

[0045] To ensure the reliability of the equipment, an automatic lubrication system is also configured. During normal pumping operation, lubrication can be performed according to the pumping cycle. The system can be set with lubrication cycle and interval, and the parameters can be set according to user needs.

[0046] Carriage system: When the carriage system starts to run, the integrated hydraulic station will be started first. The carriage mainly moves reciprocally, generally with sequential control, and the steps are as follows: The carriage moves forward (i.e., the forward solenoid valve is energized). When it reaches the forward limit, it stops moving forward and delays for a period of time (the time can be set). Then the carriage moves backward (i.e., the backward solenoid valve is energized). When it reaches the backward limit, it stops moving backward and delays for a period of time, and then starts moving forward again, repeating this cycle. The flap valve is manually controlled and is set to the normally open state during normal system operation and to the closed state during equipment maintenance.

[0047] Before controlling the solenoid valve, the motor of the integrated hydraulic station must be started first to provide hydraulic power. Generally, the solenoid valve can work 5S after the motor of the integrated hydraulic station is started.

[0048] An embodiment of the present invention discloses a bin storage and transportation system based on a cone valve pump. Refer Figures 1-2 As shown, it includes a square bin 100, a carriage 200, a flap valve 300, an integrated hydraulic station 201, a screw conveyor 400, a pump hydraulic station 501, and a 500 cone valve pump. A level gauge 600 is installed on the square bin 100, and the level gauge 600 is used to detect the amount of material in the square bin 100. The carriage is installed at the lower end of the square bin 100 and is used to realize the material feeding in the square bin 100. The integrated hydraulic station 201 provides power for the carriage 200 and the flap valve 300, and the pump hydraulic station 501 provides power for the cone valve pump 500.

[0049] Refer Figure 3 As shown, the figure is the touch screen system interface. On the right side of the interface are the automatic, manual, remote, and local knob selection states of the pump system; the running and fault states of the pump system; the start and stop buttons of the system and the valves; the automatic, manual, remote, and local knob selection states of the carriage system; the running and fault states of the carriage system; the start and stop buttons of the carriage and the pipeline tracing heat; the start and stop states of the integrated hydraulic station, the running states of the carriage, the pump hydraulic station, the pump cylinder, the screw conveyor, the lubrication system, and the tracing heat belt; the running state of the pipeline ball valve; the monitored values and parameter bin display of the pump hydraulic station; the interface is intuitive and clear at a glance.

[0050] Refer Figure 4As shown in the figure, it is the touch screen parameter setting. The parameters are set according to the on-site production process. The pump displacement setting can adjust the conveying volume of the pump. A proportional regulating valve is installed on the pump to control the speed of the pump's conveying volume. The lubrication refueling interval is how many cycles the pump runs before the lubrication system starts. The lubrication refueling cycle duration refers to how many cycles the pump runs after the lubrication system starts before it stops. The high pressure limit alarm means that when the pressure exceeds the set value, an alarm is triggered. The high oil temperature limit alarm means that when the oil temperature exceeds the set value, an alarm is triggered. The high material level limit alarm means that when the material level exceeds the set value, an alarm is triggered. The pump operation interval setting means that after the auxiliary cylinder advances and the main cylinder advances to the position, after a certain time interval, the actions of the auxiliary cylinder retreating and the main cylinder retreating are carried out. The carriage operation interval setting means that after the carriage advances to the position, after a certain time interval, the action of the carriage retreating is carried out. The screw rotation speed setting means that the screw rotates at the set frequency, and at 100% speed, the frequency is 50HZ.

[0051] Parameter Figure 5 As shown in the figure, it is the fault display interface, which is automatically displayed. The fault points that occur during the operation of the equipment are convenient for maintenance personnel to check and quickly eliminate the faults. For the main cylinder proximity switch fault, if the command to advance or retreat the main cylinder is issued and the command has not ended after 120S, it is determined as a proximity switch fault. For the oil suction alarm fault, it means that when the hydraulic station is running and the oil suction alarm switch acts and has not reset within 10S, it is determined as an oil suction alarm fault. For the oil return alarm fault, it means that when the hydraulic station is running and the oil return alarm switch acts and has not reset within 10S, it is determined as an oil return alarm fault. For the low oil level alarm fault, it means that when the hydraulic oil level is lower than the normal operating level and the liquid level float switch acts, an alarm is triggered. For the high pressure alarm fault, when the hydraulic station is running and the detected pressure is greater than the set alarm value, an alarm is triggered after 8S. For the high temperature alarm fault, when the hydraulic station is running and the detected temperature is greater than the set alarm value, an alarm is triggered after 8S. For the air switch alarm fault, an alarm is triggered after the motor air switch acts. For the screw frequency converter alarm, an alarm is triggered when the screw frequency converter relay fails to output. After the above faults occur, the system stops. After eliminating the fault points, click the fault reset button to解除 the fault. For the comprehensive hydraulic station air switch fault, an alarm is triggered after the comprehensive hydraulic station air switch acts. For the carriage proximity switch fault, if the command to advance or retreat the carriage is issued and the command has not ended after 120S, it is determined as a proximity switch fault. For the high material level limit alarm fault, an alarm is triggered after 30S when the material level is higher than the set value.

[0052] Parameter Figure 6 As shown, when the hydraulic station is running, when the cumulative value of the lubrication start interval cycle (the number of times the main cylinder retreats) is greater than or equal to the lubrication interval cycle, a lubrication start command is output; after the lubrication system starts, when the cumulative value of the lubrication number cycle (the number of times the main cylinder retreats) is greater than or equal to the set value of the lubrication number cycle, a lubrication stop command is output.

[0053] Parameter Figure 7As shown, when the lubrication system is not started, the accumulative algorithm for the number of times the master cylinder retreats; when the accumulated number of times is greater than the set value, the accumulated number of times is cleared.

[0054] Refer Figure 8 As shown, after the lubrication system is started, the accumulative algorithm for the number of times the master cylinder retreats; when the accumulated number of times is greater than the set value, the accumulated number of times is cleared.

[0055] Refer Figure 9 As shown, the analog input value is converted into a percentage number by using comparison instructions, integer subtraction instructions, and integer division instructions, which is used for the bar graph of the human-machine interface to visually display the material level height; the analog input value is converted into a specific material level height value through the S-ITR instruction to meet some on-site process requirements.

[0056] Refer Figure 10 As shown, in the program design, after the master cylinder advances and retreats are output, the timing starts. After 120S, if the master cylinder advance and retreat commands are still valid, the master cylinder proximity switch failure is output.

[0057] Refer Figure 11 As shown, the displacement setting range is 10~100%. Through the multiply integer instruction, add integer instruction, and transfer instruction, the set value is output to adjust the displacement size.

[0058] The key points and key parameters of the system control are as follows:

[0059] First, current detection devices are installed on both the disk feeder and the screw conveyor to detect the operating current of the disk feeder and the screw conveyor in real time. When the current exceeds the set value, the diverter stops working. When the current returns to the no-load value, the diverter restarts.

[0060] Second, the rated current of the diverter motor I = P / U*1.73*0.8 = 15 / 0.38*1.73*0.8 = 28.5A.

[0061] Where P is the motor power and U is the working voltage of 380V

[0062] The rated current of the screw motor I = P / U*1.73*0.8 = 7.5 / 0.38*1.73*0.8 = 14.3A.

[0063] The no-load current is taken as 0.5 times the rated current, 14.3*0.5 = 7.2A.

[0064] Considering various interference factors, the current value can be appropriately amplified. Take 8 - 9A. That is, when the screw current is less than 9A, it is considered that the screw is in the no-load state, and the disk feeder can be allowed to start.

[0065] 3. The feeder is programmed to run at intervals and times. Since the material has different flowability, the interval time is set to be adjustable and set on the touch screen. Each run should not be too long, preferably within 5 seconds, and the time should also be adjustable.

[0066] When performing current conversion, pay attention to the range of the measuring instrument to prevent measurement errors. In this embodiment, the current transformer has a measuring range of 25A, and the calculation method is as follows: Figures 4-5 As shown;

[0067] When comparing the magnitudes of the currents, the influence of motor starting current and interference current must be considered. In this embodiment, detection is achieved through a timer delay, with the timer duration set to 2-3 seconds. Figures 6-8 As shown.

Claims

1. A control method based on a sludge direct blending system, the sludge direct blending system comprising a square silo, a skid, a flashboard valve, a comprehensive hydraulic station and a screw conveyor, characterized in that: The square silo is provided with a material level meter for detecting the amount of material in the square silo, and the sliding frame is installed at the lower end of the square silo; the screw conveyor is fixed at the lower end of the square silo, and a hydraulic plug valve is connected between the screw conveyor and the square silo; the lower end of the screw conveyor is provided with a cone valve pump, and the outlet of the cone valve pump is connected with a pipeline ball valve. The method comprises the following steps: (1) open the electric ball valve, and start the pump hydraulic station; (2) after the pump hydraulic station is started, start the first timer, and after a delay, start the screw work; (3) after the pump hydraulic station is started, start the second timer, and after a delay, start the auxiliary cylinder forward electromagnetic valve; After the auxiliary cylinder forward electromagnetic valve is actuated, start the third timer, and after a delay, the auxiliary cylinder is regarded as a signal of reaching the position; after the auxiliary cylinder reaches the position, start the main cylinder forward electromagnetic valve; after the main cylinder reaches the position, start the 1# pump running interval time relay; next, the auxiliary cylinder retreats, the main cylinder retreats, and the cycle is repeated, and the system is stopped after a system stop command is sent, and the main cylinder retreats to the position and stops running; (4) when the main cylinder retreats for a number of times greater than the pump lubrication interval cycle set value, start the lubrication electromagnetic valve; when the main cylinder retreats for a number of times greater than the pump lubrication cycle set value, stop the lubrication electromagnetic valve; (5) start the sliding frame system, and start the comprehensive hydraulic station; (6) after the comprehensive hydraulic station is started, start the timer, and after a delay, start the sliding frame forward electromagnetic valve; after the sliding frame electromagnetic valve reaches the position, start the sliding frame interval timer; after the timer time is up, start the sliding frame retreat electromagnetic valve, and the cycle is repeated, and the sliding frame continues to reach the position or retreat to the position, and then the system is stopped; In step (3), the cone valve pump is reciprocated, and is sequentially controlled, and the steps are as follows: the auxiliary cylinder advances, the auxiliary cylinder advances to the position, and the advance is stopped; the main cylinder advances, the main cylinder advances to the main cylinder advance limit switch, and the advance is stopped; the auxiliary cylinder retreats, the auxiliary cylinder retreats to the position, and the retreat is stopped; the main cylinder retreats, the main cylinder retreats to the retreat limit, and the retreat is stopped; the auxiliary cylinder advances again, and the cycle is repeated; before the electromagnetic valve is controlled, the cone valve pump hydraulic station motor must be started to provide hydraulic power; in order to adjust the conveying amount of the pump, a proportional adjusting valve is installed on the pump to control the speed of the pump conveying amount, and the control signal is 0-10V.

2. The control method of a sludge direct-dosing system according to claim 1, characterized by: In step (3), the second timer is started, and after a delay of 5s, the auxiliary cylinder forward electromagnetic valve is started.

3. The control method of a sludge direct-dosing system according to claim 2, characterized by: In step (3), the third timer is started, and after a delay of 2s, the auxiliary cylinder is regarded as a signal of reaching the position.

4. The control method of a sludge direct-dosing system according to claim 3, characterized by: In step (2), the first timer is started, and after a delay of 10s, the screw work is started.

5. The control method of a sludge direct-dosing system according to claim 4, characterized by: In step (6), after the comprehensive hydraulic station is started, the timer is started, and after a delay of 5s, the sliding frame forward electromagnetic valve is started.

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