A controller for a baghouse

Abstract

The application provides a controller of a cloth bag dust collector, relates to the technical field of dust removal control, and comprises a warehouse top control system, a warehouse bottom control system, a leak bag detection system and a communication system connected with a main control system; the warehouse top control system is connected with a differential pressure sensor arranged in each dust removal warehouse, an offline valve arranged in each dust removal warehouse and a pulse valve arranged in each dust removal warehouse; the warehouse top control system is used for blowing each dust removal warehouse and obtaining the optimal blowing combination according to the differential pressure result; the leak bag detection system is connected with a visual recognition system, a fluorescent powder adding device and a dust sensor arranged in each dust removal warehouse; the leak bag detection system is used for detecting the leak bag condition; and the communication system comprises a wireless communication module and a wired communication module; the application utilizes the sensor technology, enhances the blowing effect, reduces the blowing frequency under the premise of ensuring the dust removal effect, effectively prolongs the service life of the cloth bag, and saves the use cost.

Description

Technical Field

[0001] This invention relates to the field of dust control technology, and more particularly to a controller for a bag filter dust collector. Background Technology

[0002] With increasingly stringent national environmental policies and advancements in science and technology, users are demanding higher levels of control from dust collectors. Existing dust collector control systems are no longer sufficient to meet these stringent requirements. Pulse cleaning and ash removal are limited to simple differential pressure or time control, and ash removal is performed on all compartments, wasting air and electricity while significantly impacting filter bag lifespan. For filter bag leaks, only the presence of leak points can be detected, without pinpointing which specific bag is leaking. There is no personalized control for each compartment, and no big data monitoring of pulse cleaning data, pulse valves, filter bags, and offline valve operating status and lifespan, hindering intelligent big data management. Summary of the Invention

[0003] To address the aforementioned technical problem that existing baghouse dust collectors lack bag leakage detection capabilities, this invention provides a controller for a baghouse dust collector. This invention primarily utilizes sensor technology to achieve functions such as bag leakage detection, bag leakage location positioning, bag life detection, and replacement reminders.

[0004] The technical means employed in this invention are as follows:

[0005] A controller for a bag filter dust collector includes a silo top control system, a silo bottom control system, a bag leakage detection system, and a communication system connected to a main control system.

[0006] The silo top control system is connected to differential pressure sensors, offline valves, and pulse valves installed in each dust removal chamber; the silo top control system is used to perform pulse jet cleaning on each dust removal chamber and obtain the optimal pulse jet combination based on the differential pressure result.

[0007] The bin bottom control system is connected to the ash removal device, which includes a scraper conveyor, a pneumatic ash conveying system, a level gauge installed in each dust removal bin, a vibrating motor installed in each dust removal bin, and a grid valve installed in each dust removal bin. The bin bottom control system is used to control the ash removal device to process the dust generated during dust removal. The bin bottom control system optimizes the frequency of ash unloading actions based on the rate of increase in ash volume in each dust removal bin.

[0008] The leak detection system is connected to a visual recognition system, a fluorescent powder adding device, and dust sensors installed in each dust removal chamber; the leak detection system is used to detect leaks in bags.

[0009] The communication system includes a wireless communication module and a wired communication module.

[0010] Furthermore, the differential pressure sensor collects the differential pressure inside the dust removal chamber in real time and generates a differential pressure signal which is sent to the top control system. The top control system then blows air into the dust removal chamber according to a set differential pressure blowing threshold. The differential pressure blowing threshold includes the blowing interval, the blowing time, and the blowing sequence. The blowing modes include manual mode, time mode, and differential pressure mode.

[0011] Furthermore, when using time-based or differential-pressure-based purging, a self-learning method is employed to automatically optimize the purging interval and purging time. This self-learning method includes the following steps:

[0012] S1. Set the initial jet column interval time range and the initial jet time range respectively, and set the time step of the initial jet column interval time range and the initial jet time range respectively.

[0013] S2. The silo top control system uses the minimum value in the initial range of jet interval time and the minimum value in the initial range of jet time as fixed values, and performs jetting according to these fixed values.

[0014] S3. After the pulse jetting is completed in a single dust removal chamber, the pulse jetting interval time range and the pulse jetting time range time step are increased to obtain the pulse jetting interval time and pulse jetting time at this time as fixed values, and pulse jetting is performed according to these fixed values.

[0015] S4. Repeat S3. When the value of the blowing time reaches the maximum value of the blowing time range, increase the time step of the blowing column interval time range and take the minimum value of the blowing time range as the blowing time, and blow according to the fixed value at this time.

[0016] S5. The differential pressure sensor records the differential pressure value before and after each injection and sends it to the silo top control system. The silo top control system calculates the differential pressure change value before and after each injection, compares all differential pressure change values, and when the differential pressure change value before and after the injection is the largest, the injection interval and injection time at this time are the optimal injection combination.

[0017] Furthermore, the silo top control system controls the operation of the offline valves and the blowing sequence of each dust collection chamber. When multiple dust collection chambers are ready for blowing, priority control is implemented, and the specific steps are as follows:

[0018] First, based on the time principle, the compartments that meet the conditions for injection first will be injected first;

[0019] If two or more dust collection chambers meet the conditions for pulse jetting at the same time, the chamber closest to the flue gas inlet will be pulsed first.

[0020] Furthermore, the specific steps of the bin bottom control system in optimizing the frequency of ash unloading actions based on the rate of increase in ash volume in each dust removal chamber are as follows:

[0021] The silo bottom control system counts the growth rate of ash in each silo. Taking the silo with the growth rate close to the average as the benchmark, a single ash unloading is performed when the ash reaches 1 / 3 of the accumulated ash. If it reaches 4 / 5 of the accumulated ash, continuous ash unloading is performed until 1 / 4 is unloaded. When more than half of the silos are ready for ash unloading, ash unloading operations begin. If a silo reaches 4 / 5 of the accumulated ash, the ash unloading time is extended and continuous ash unloading is performed on that silo.

[0022] Furthermore, the dust concentration sensor is installed in the clean air chamber of the dust removal chamber. The dust concentration sensor sends a dust concentration signal to the bag leakage detection system. The bag leakage detection system compares the dust concentration signal with a specified dust concentration threshold and determines the bag damage status.

[0023] The fluorescent powder adding device is installed at the inlet pipe of the bag filter. The fluorescent powder adding device adds fluorescent powder to the dust collector. The visual recognition system detects and analyzes the fluorescent powder data of this dust collection chamber in real time. The visual recognition system determines the location of the damage to the filter bag based on the analysis results.

[0024] Compared with the prior art, the present invention has the following advantages:

[0025] This invention, through the use of advanced sensor technology and specialized equipment and algorithms, achieves the following effects: ① Enhanced pulse-jet cleaning effect, reducing the number of pulse-jet cycles while ensuring dust removal efficiency, eliminating ineffective cleaning, reducing energy consumption of electricity and gas during the pulse-jet process, effectively extending the service life of the filter bags, and saving operating costs; ② Realized functions such as leak detection, filter bag leakage location, filter bag life detection, and replacement reminders; ③ Big data collection for personalized management of each dust collection chamber, providing differentiated pulse-jet data for tailored solutions. Dynamic life monitoring is implemented for pulse valves, filter bags, and offline valves; ④ A dedicated controller communicates with the upper-level control system for data transmission, reducing hard-wired connection points and optimizing the network architecture of the dust collector's electrical control system. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the system structure of the present invention. Detailed Implementation

[0028] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0031] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0032] like Figure 1 As shown, the present invention provides a controller for a bag filter dust collector, including a bin top control system, a bin bottom control system, a bag leakage detection system, and a communication system connected to the main control system;

[0033] The silo top control system connects differential pressure sensors, offline valves, and pulse valves installed in each dust collection chamber. It performs pulse-jet cleaning of each chamber and determines the optimal cleaning combination based on the differential pressure. A differential pressure sensor is installed in each chamber, and its signal is transmitted to the silo top control system in real time. The system performs cleaning based on the set differential pressure thresholds for each chamber. The cleaning interval, cleaning time, and cleaning sequence are set according to the specific parameters of each dust collection chamber. Cleaning modes include manual, time-based, and differential pressure modes. When time-based or differential pressure mode is selected, a self-learning function is enabled to automatically optimize the cleaning interval and cleaning time to find the optimal combination. The self-learning function requires setting the cleaning interval range and cleaning time range, and then setting the corresponding time step. After activation, the control system initially uses the minimum cleaning interval range as a fixed value, and the cleaning time starts at the minimum value. After each chamber cleaning is completed, the time step is increased accordingly before the next cleaning cycle. Once the cumulative step size of the injection time reaches the maximum value within the injection time range, the injection train interval time is increased by the step size, and the injection time restarts from the minimum value, repeating this cycle. The pressure difference change value before and after each injection is recorded. Once all data for a single compartment is completed, the optimal combination of injection train interval time and injection time is obtained.

[0034] The silo top control system controls the operation of the offline valves in each dust collection chamber and the pulse jet sequence of each chamber, and has a coordination and scheduling function. When multiple dust collection chambers meet the pulse jet conditions, priority control is implemented. Priority control is first based on the time principle, with the dust collection chamber that meets the pulse jet conditions first being purged; if two or more dust collection chambers meet the pulse jet conditions at the same time, the dust collection chamber closest to the flue gas inlet is purged first.

[0035] The silo bottom control system is connected to the ash removal device, which includes a scraper conveyor, a pneumatic ash conveying system, level gauges installed in each dust removal silo, vibrating motors installed in each dust removal silo, and ash discharge valves installed in each dust removal silo. The silo bottom control system is used to control the ash removal device to process the dust generated during dust removal. The silo bottom control system collects the level signals of each dust removal silo and simultaneously controls the ash discharge ash discharge valves (electric slide gate valves), vibrating motors, scraper conveyors (pneumatic ash conveying system), and other ash discharge equipment, and links with the silo top control system for control. Based on the ash volume growth rate of each dust removal silo, the frequency of ash discharge operations is optimized to reduce wear and tear on the ash discharge equipment and energy consumption, while avoiding single-time overload operation of the ash discharge system. The control system counts the ash volume growth rate of each silo, and takes the silo with the growth rate close to the average as a benchmark. When the ash volume reaches 1 / 3 of the accumulated ash, a single ash discharge is performed (based on the time from 1 / 3 to 1 / 4 of the accumulated ash). If the ash volume reaches 4 / 5 of the accumulated ash, continuous ash discharge is performed until 1 / 4 of the accumulated ash is discharged. When more than half of the compartments are ready for ash removal, the ash removal operation will begin. If any compartment reaches 4 / 5 of its accumulated ash, the ash removal time will be extended and the ash will be continuously removed from that compartment.

[0036] The leaky bag detection system connects to a visual recognition system, a fluorescent powder adding device, and dust sensors installed in each dust collection chamber. The leaky bag detection system detects leaks. A dust concentration sensor is added to the clean air chamber of each dust collection chamber. The leaky bag detection system compares the dust concentration signal with pre-set thresholds and operating conditions to accurately locate the bag damage in each dust collection chamber. A visual recognition system is added to each dust collection chamber to interact with the leaky bag detection system. The fluorescent powder adding device is located at the dust collector inlet pipe. It uses the negative pressure at the front end of the dust collector to draw fluorescent powder into the dust collector. The controller sends a start command to the visual recognition terminal, which then initiates leaky bag detection and analysis for that dust collection chamber. Simultaneously, the controller controls the fluorescent powder adding device to add fluorescent powder to the front end pipe of the dust collector. The visual recognition system detects and analyzes the fluorescent powder data in this dust collection chamber in real time, accurately locating the damaged location of a specific bag in that chamber based on the analysis results.

[0037] The communication system includes a wireless communication module and a wired communication module.

[0038] The main control system collects data from each dust collection chamber, analyzes and calculates the optimal parameters for pulse-jet cleaning and ash removal in each chamber, and forms a control model for each chamber for differentiated control. The main control system uses a microcontroller as its hardware foundation and exchanges data with the upper-level control system through a communication system. The main control system is equipped with a touchscreen, allowing users to set parameters for pulse-jet cleaning, ash removal, and configuration, and to monitor the system's operating status in real time. The main control system has equipment lifespan monitoring and expert diagnostic functions. It can monitor the operating status and usage frequency of equipment such as filter bags, pulse-jet valves, offline valves, vibrators, grid valves, and slide gate valves, calculate the remaining lifespan based on the inherent lifespan of the equipment, and determine whether maintenance or repair is needed. Simultaneously, it can diagnose the dust collection system and provide solutions based on historical data such as pulse-jet cleaning and ash removal effects.

[0039] The advantages of this invention are as follows: This invention reduces the energy consumption of electricity and gas during the blowing process by 20%, effectively extends the service life of the filter bag by 10%, and reduces the energy consumption of the bottom equipment by 10%.

[0040] This invention adopts modular technology and can be combined with up to 127 dust collection chambers. Each chamber can control up to 20 pulse jet valves and 2 offline valves, and can coordinate the pulse jet, vibration and ash discharge of the dust collection chamber. It also has functions such as bag leakage detection and personalized management of dust collection chambers.

[0041] This invention reduces the cost of the dust removal control system by approximately 5% and reduces the amount of control cables used in the dust collector body by 30%.

[0042] This invention realizes modularization, intelligence, and networking of the dust removal control system, thereby improving the technical level of the dust removal control system.

[0043] 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 or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A controller for a bag filter dust collector, characterized in that: This includes the warehouse top control system, warehouse bottom control system, leak detection system, and communication system, all connected to the main control system. The silo top control system is connected to differential pressure sensors, offline valves, and pulse valves installed in each dust removal chamber; the silo top control system is used to perform pulse jet cleaning on each dust removal chamber and obtain the optimal pulse jet combination based on the differential pressure result. The bin bottom control system is connected to the ash removal device, which includes a scraper conveyor, a pneumatic ash conveying system, a level gauge installed in each dust removal bin, a vibrating motor installed in each dust removal bin, and a grid valve installed in each dust removal bin. The bin bottom control system is used to control the ash removal device to process the dust generated during dust removal. The bin bottom control system optimizes the frequency of ash unloading actions based on the rate of increase in ash volume in each dust removal bin. The leak detection system is connected to a visual recognition system, a fluorescent powder adding device, and dust sensors installed in each dust removal chamber; the leak detection system is used to detect leaks in bags. The communication system includes a wireless communication module and a wired communication module.

2. The controller for the bag filter dust collector according to claim 1, characterized in that, The differential pressure sensor collects the differential pressure inside the dust removal chamber in real time and generates a differential pressure signal, which is sent to the top control system. The top control system blows air into the dust removal chamber according to the set differential pressure blowing threshold. The differential pressure blowing threshold includes the blowing interval, the blowing time, and the blowing sequence. The blowing modes include manual mode, time mode, and differential pressure mode.

3. The controller for the bag filter dust collector according to claim 2, characterized in that, When using time-based or differential pressure-based injection, a self-learning method is employed to automatically optimize the injection column interval and injection time. The self-learning method includes the following steps: S1. Set the initial jet column interval time range and the initial jet time range respectively, and set the time step of the initial jet column interval time range and the initial jet time range respectively. S2. The silo top control system uses the minimum value in the initial range of jet interval time and the minimum value in the initial range of jet time as fixed values, and performs jetting according to these fixed values. S3. After the pulse jetting is completed in a single dust removal chamber, the pulse jetting interval time range and the pulse jetting time range time step are increased to obtain the pulse jetting interval time and pulse jetting time at this time as fixed values, and pulse jetting is performed according to these fixed values. S4. Repeat S3. When the value of the blowing time reaches the maximum value of the blowing time range, increase the time step of the blowing column interval time range and take the minimum value of the blowing time range as the blowing time, and blow according to the fixed value at this time. S5. The differential pressure sensor records the differential pressure value before and after each injection and sends it to the silo top control system. The silo top control system calculates the differential pressure change value before and after each injection, compares all differential pressure change values, and when the differential pressure change value before and after the injection is the largest, the injection interval and injection time at this time are the optimal injection combination.

4. The controller for the bag filter dust collector according to claim 2, characterized in that, The silo top control system controls the operation of the offline valves and the blowing sequence of each dust collection chamber. When multiple dust collection chambers are ready for blowing, priority control is implemented. The specific steps are as follows: First, based on the time principle, the compartments that meet the conditions for injection first will be injected first; If two or more dust collection chambers meet the conditions for pulse jetting at the same time, the chamber closest to the flue gas inlet will be pulsed first.

5. The controller for the bag filter dust collector according to claim 1, characterized in that, The specific steps of the silo bottom control system to optimize the frequency of ash unloading actions based on the rate of increase in ash volume in each dust removal chamber are as follows: The silo bottom control system counts the growth rate of ash in each silo. Taking the silo with the growth rate close to the average as the benchmark, a single ash unloading is performed when the ash reaches 1 / 3 of the accumulated ash. If it reaches 4 / 5 of the accumulated ash, continuous ash unloading is performed until 1 / 4 is unloaded. When more than half of the silos are ready for ash unloading, ash unloading operations begin. If a silo reaches 4 / 5 of the accumulated ash, the ash unloading time is extended and continuous ash unloading is performed on that silo.

6. The controller for the bag filter dust collector according to claim 1, characterized in that, The dust concentration sensor is installed in the clean air chamber of the dust removal chamber. The dust concentration sensor sends a dust concentration signal to the bag leakage detection system. The bag leakage detection system compares the dust concentration signal with a specified dust concentration threshold and determines the bag damage status. The fluorescent powder adding device is installed at the inlet pipe of the bag filter. The fluorescent powder adding device adds fluorescent powder to the dust collector. The visual recognition system detects and analyzes the fluorescent powder data of this dust collection chamber in real time. The visual recognition system determines the location of the damage to the filter bag based on the analysis results.

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