Proactive control method and system for emulsion pump station

Abstract

The present application provides a forward-looking control method and system for an emulsion pump station, which relates to the field of emulsion pump station control technology, including: obtaining the installed configuration of the emulsion pump station, performing configuration equalization, and determining the substructure of the pump station; setting the control logic and performing PLC program conversion, performing mirror twinning and paralleling of substructure control, and determining the distributed control module; performing expected off-axis analysis by running a prediction model to determine predictive control characteristics; executing control adjustment decisions and determining control adjustment strategies in a manner of substructure control complementarity; and the distributed control module performs forward-looking regulation management. The present application can solve the technical problem in the prior art that, due to the limited processing capacity and hysteresis effect caused by sudden load or environmental changes in the face of feedback-based control, the control accuracy is reduced. Through forward-looking control, adjustment decisions are made in advance, and load distribution is dynamically adjusted, thereby improving control accuracy.

Description

Technical Field

[0001] The present application relates to the technical field of emulsion pump station control, and in particular to a forward-looking control method and system for an emulsion pump station. Background Art

[0002] Emulsion pump station is a key equipment in coal mine mechanization. It is used for emulsion delivery and pressurization system of coal mine hydraulic support or other equipment. It is mainly composed of emulsion tank, emulsion pump group (usually two groups) and hydraulic control system. The main function is to deliver emulsion (usually a mixture of water and emulsified oil) to the equipment through high-pressure pump, provide hydraulic support and ensure the normal operation of the equipment. Existing emulsion pump station control methods usually include quantitative control, pressure control, flow control, liquid level control, feedback control, multi-pump automatic switching control, intelligent control, etc. These control methods are mainly based on real-time monitoring data. After detecting the operating status, they are adjusted only when changes or errors occur. Although they can maintain stability, they will cause lag effects when facing sudden load changes or external interference. Pump stations usually directly adjust the operating status of the pump based on current demand, without considering the upcoming load changes. In some cases, the pump station may start and stop frequently, affecting the stability of the pump station and increasing energy consumption. The lack of predictive capabilities means that there is no way to proactively respond before interference occurs, which may lead to problems such as insufficient hydraulic support and untimely emulsion supply. In emergencies, the response may not be fast enough, resulting in unstable operation or pressure or flow fluctuations in a short period of time.

[0003] In summary, the prior art has technical problems in that, because it is usually based on feedback control, it has limited processing capabilities when faced with sudden load or environmental changes, and it is difficult to take timely measures to compensate when the changes just begin, resulting in a lag effect, causing the operation to deviate from the optimal state, thereby affecting the control accuracy. Summary of the invention

[0004] The purpose of this application is to provide a forward-looking control method and system for an emulsion pump station, in order to solve the technical problems in the prior art that, because the control is usually based on feedback, the processing capacity is limited when faced with sudden load or environmental changes, and it is difficult to take timely measures to compensate at the beginning of the change, resulting in a lag effect, causing the operation to deviate from the optimal state, thereby affecting the control accuracy.

[0005] In view of the above problems, the present application provides a forward-looking control method and system for an emulsion pump station.

[0006] In a first aspect, the present application provides a forward-looking control method for an emulsion pump station, which is implemented by a forward-looking control system for an emulsion pump station, wherein the forward-looking control method for an emulsion pump station comprises: obtaining the installed configuration of the emulsion pump station, performing configuration averaging, and determining the substructure of the pump station, wherein the configuration averaging is performed based on the distribution of the number of plungers, and the emulsion pump station is a large-flow pump station; setting the control logic of the substructure of the pump station and performing PLC program conversion, performing mirror twinning and parallel connection of the substructure control, and determining a distributed control module; Receive the operating data sent back by the front-end sensor, perform expected off-axis analysis of the control response of the operating data through the supervised training operation prediction model, and determine the predictive control characteristics, wherein the operating data at least includes the hydraulic support motion data and the pump station operation data; in a manner of substructure control complementarity, execute control adjustment decisions based on the predictive control characteristics, and determine the control adjustment strategy, wherein the control adjustment is transformed from the initialized pump station substructure balanced control to unbalanced control; the distributed control module responds to the control adjustment strategy and executes the forward-looking regulation and management of the emulsion pump station.

[0007] In the second aspect, the present application also provides a forward-looking control system for an emulsion pumping station, which is used to execute the forward-looking control method for an emulsion pumping station as described in the first aspect, wherein the forward-looking control system for an emulsion pumping station includes: a configuration division module, which is used to obtain the installed configuration of the emulsion pumping station, perform configuration averaging, and determine the substructure of the pumping station, wherein the configuration averaging is performed based on the distribution of the number of plungers, and the emulsion pumping station is a large-flow pumping station; a control conversion module, which is used to set the control logic of the substructure of the pumping station and perform PLC program conversion, perform mirror twinning and parallel connection of substructure control, and determine a distributed control module; a model building module, which is used to Receive the operating data sent back by the front-end sensor, perform expected off-axis analysis of the control response of the operating data through the supervised training operation prediction model, and determine the predictive control characteristics, wherein the operating data at least includes the hydraulic support motion data and the pump station operation data; a decision determination module is used to execute control adjustment decisions based on the predictive control characteristics in a manner of substructure control complementarity, and determine the control adjustment strategy, wherein the control adjustment is transformed from the initialized pump station substructure balanced control to unbalanced control; a forward-looking control module is used for the distributed control module to respond to the control adjustment strategy and execute forward-looking control management of the emulsion pump station.

[0008] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0009] The installed configuration of the emulsion pump station is obtained, and the configuration is evenly divided to determine the substructure of the pump station, wherein the configuration is evenly divided according to the distribution of the number of plungers, and the emulsion pump station is a large-flow pump station; the control logic of the substructure of the pump station is set and the PLC program is converted, and the mirror twin and parallel of the substructure control are performed to determine the distributed control module; the operation data sent back by the front-end sensor is received, and the expected off-axis analysis of the control response of the operation data is performed through the supervised training operation prediction model to determine the predictive control characteristics, wherein the operation data at least includes the hydraulic support motion data and the pump station operation data; in a manner of substructure control complementarity, a control adjustment decision based on the predictive control characteristics is executed to determine the control adjustment strategy, wherein the control adjustment is transformed from the initialized balanced control of the pump station substructure to the unbalanced control; the distributed control module responds to the control adjustment strategy to perform the forward-looking regulation and management of the emulsion pump station. In other words, by configuring the distribution of the number of plungers equally, dynamic control and unbalanced regulation of the pump station substructure can be achieved. The operating data can be analyzed through the prediction model, and adjustment decisions can be made in advance before the load changes occur, avoiding delayed response and dynamically adjusting the load distribution of the substructure to cope with changes in the movement of the hydraulic support and other operating conditions, thereby achieving more flexible load management and improving control accuracy.

[0010] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented according to the contents of the specification, and in order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are specifically cited below. It should be understood that the content described in this section is not intended to identify the key or important features of the embodiments of the present application, nor is it intended to limit the scope of the present application. Other features of the present application will become easy to understand through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In order to more clearly illustrate the technical solutions in the present application or the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.

[0012] Figure 1 A schematic diagram of the flow chart of the forward-looking control method for an emulsion pump station in this application;

[0013] Figure 2 This is a schematic diagram of the structure of the forward-looking control system used in the emulsion pump station in this application.

[0014] Explanation of the reference numerals: configuration division module 11 , control conversion module 12 , model building module 13 , decision determination module 14 , forward-looking regulation module 15 . DETAILED DESCRIPTION

[0015] This application provides a forward-looking control method and system for an emulsion pump station, which solves the technical problem in the prior art that the processing capacity is limited when facing sudden load or environmental changes, and it is difficult to take timely measures to compensate when the changes just start, resulting in a hysteresis effect, causing the operation to deviate from the optimal state, thereby affecting the control accuracy. By configuring the distribution of the number of plungers to be evenly distributed, dynamic control and non-balanced regulation of the pump station substructure are achieved, and the operation data is analyzed through a predictive model, and adjustment decisions are made in advance before the load changes occur, avoiding hysteresis responses, and dynamically adjusting the load distribution of the substructure to cope with changes in the movement of the hydraulic support and other operating conditions, achieving more flexible load management and improving control accuracy.

[0016] Below, the technical solutions in the present application will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments of the present application. It should be understood that the present application is not limited to the example embodiments described herein. Based on the embodiments of the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present application. It should also be noted that, for the convenience of description, only the parts related to the present application are shown in the accompanying drawings, rather than all of them.

[0017] For example, please refer to the attached Figure 1 The present application provides a forward-looking control method for an emulsion pump station, wherein the forward-looking control method for an emulsion pump station is implemented by a forward-looking control system for an emulsion pump station, and the forward-looking control method for an emulsion pump station specifically comprises the following steps:

[0018] Step 1: Obtain the installed configuration of the emulsion pump station, perform configuration averaging, and determine the substructure of the pump station, wherein the configuration averaging is performed based on the distribution of the number of plungers, and the emulsion pump station is a large-flow pump station.

[0019] Specifically, collect and record detailed information on all hardware and software components of the emulsion pump station, including the number of pumps, type (such as plunger pumps), number of plungers, capacity, motor power, control system configuration, etc. The emulsion pump station is a large-flow pump station used to transport large amounts of emulsions. It needs to handle the delivery and pressure requirements of a large amount of emulsions. It is usually used in large coal mines or places where high-flow hydraulic systems are required. The configuration of the pump station is evenly divided, and the pump station is sub-structured according to the distribution of the number of plungers. The installed configuration of the pump station is evenly distributed to different sub-structures to ensure that each sub-structure can work independently and efficiently. The number of plungers is an important indicator reflecting the flow output capacity of the pump station. By evenly dividing the number of plungers, the load distribution of each sub-structure can be ensured to be more balanced. The sub-structure of the pump station means that the pump station is divided into several parts, each of which has independent control and operation capabilities, and is responsible for the delivery of part of the flow, forming a relatively independent control unit. For example, suppose an emulsion pump station has 10 pumps, each with 5 plungers. When performing configuration averaging, the pumps are divided into two substructures, each containing 5 pumps, each with 5 plungers, and each substructure has the same processing capacity, that is, each substructure can handle the equivalent of 25 plungers. By performing configuration averaging based on the number of plungers and determining the pump station substructure, it is ensured that each substructure maintains consistency in flow output and pressure capacity, thereby improving the efficiency and stability of the entire pump station.

[0020] Step 2: Set the control logic of the pump station substructure and perform PLC program conversion, perform mirror twinning and parallel connection of the substructure control, and determine the distributed control module.

[0021] Specifically, a corresponding control logic is set for each pump station substructure to determine how the substructure operates, under what conditions it starts and stops, and how it works together. Control logic is a set of rules and algorithms that guide the operation of the pump station, such as starting and stopping pumps, adjusting flow and pressure, monitoring equipment status, etc. These control logics are converted into program codes that can be understood and executed by PLC (Programmable Logic Controller). Create the same control unit for each pump station substructure, and integrate these control units in parallel so that they can communicate and coordinate with each other. Mirror twin refers to creating one or more copies that are exactly the same as the original substructure, and parallel connection is to connect multiple substructures or components together so that they can work simultaneously. Distributed control module refers to integrating these parallel control units into a pump station, each unit is responsible for controlling a specific substructure, but the whole is uniformly monitored and managed through the upper bus. By constructing the control unit through the PLC logic program, combining parallel integration and upper bus coordination, a flexible and efficient distributed control module is generated, which solves the problem of collaborative work and overall optimization between control units in the emulsion pump station, improves the operating efficiency and reliability of the pump station, and enables the pump station to cope with complex and changeable working conditions.

[0022] Step three: Receive the operation data sent back by the front-end sensor, perform expected off-axis analysis of the control response of the operation data through the supervised training operation prediction model, and determine the predictive control characteristics. The operation data at least includes the hydraulic support motion data and the pump station operation data.

[0023] Specifically, front-end sensors (such as pressure sensors, flow sensors, temperature sensors, etc.) are responsible for real-time monitoring of the operation of the emulsion pump station and its associated equipment. The data sent back include at least hydraulic support motion data and pump station operation data, reflecting the current operation status of the pump station. Hydraulic support motion data is the real-time motion data generated by the hydraulic support during coal mining, reflecting the working status of the support, such as support force, lifting or lowering speed, position and other information, which directly determines the hydraulic demand of the pump station. The pump station operation data includes key parameters such as flow, pressure, temperature of the emulsion pump station, reflecting the current operation status of the pump station, and is used to determine whether the pump station is working as expected, whether there is excessive load or insufficient hydraulic pressure. The operation prediction model is trained through historical operation records to predict future operation status.

[0024] Compare the current operating state with the standard or ideal state, and analyze the deviation between the actual operating data and the output of the prediction model. Determine whether the current operating state of the pump station deviates from the expected control target, such as whether the pump station pressure is too low, whether the hydraulic support support force is insufficient, etc. The expected off-axis analysis only evaluates the current off-axis state, the degree and direction of this deviation, and also analyzes possible deviations in the future based on the output of the prediction model. According to the results of the expected off-axis analysis, determine the predictive control characteristics, that is, predict the upcoming changes in the pump station in advance and make corresponding control decisions. The predictive control characteristics are key parameters or indicators determined based on the results of the expected off-axis analysis, which are used to adjust the operating state of the pump station to achieve the expected performance goals. The predictive control characteristics can not only identify future trends, but also make advance control decisions based on these trends to prevent the pump station from deviating from the optimal working state. For example, before the predicted load increase, increase the output pressure and flow of the pump station in advance to ensure that the hydraulic support can be hydraulically supported in time when demand increases. By receiving the operating data sent back by the front-end sensor and combining it with the supervised training operation prediction model, off-axis analysis is performed to predict the pump station deviation in advance and determine the predictive control characteristics, so as to make advance control decisions and ensure that the working status of the emulsion pump station and hydraulic support always remains stable and efficient.

[0025] Step 4: In the form of substructure control complementarity, a control adjustment decision based on the predictive control feature is executed to determine a control adjustment strategy, wherein the control adjustment is transformed from the initialized balanced control of the pump station substructure to unbalanced control. Specifically, based on the operation prediction model, the predictive control feature is identified, the control adjustment decision is made, and the pump station substructure is complementary controlled, which means that according to the working state and performance of the substructure, its control parameters are adjusted to optimize the operation performance of the pump station. In the initial state, each substructure of the pump station is usually configured in a balanced control mode, which means that each substructure (plunger pump) will operate in the same or similar output state when working, ensuring that all substructure loads are evenly distributed, the hydraulic output and flow are stable and consistent, and the pressure, flow and power distribution are relatively balanced during initial operation. By analyzing the real-time monitoring information such as the hydraulic support motion data and the pump station operation data, and combining the output of the prediction model, possible load changes or operation deviations are predicted in advance. When the load of a substructure increases or decreases, other substructures can automatically adjust their working state to maintain the overall balance by increasing or decreasing the output.

[0026] Complementary regulation is used to prevent overload or insufficient pressure of a single substructure, and to avoid problems caused by hydraulic imbalance in local areas. During operation, according to the dynamic changes of the load, the requirements and load states of each substructure will gradually differ. Therefore, it is necessary to change from the initialized balanced control state to unbalanced control, that is, to adjust the workload of each substructure as needed to optimize the overall performance or cope with the performance degradation of a specific substructure. In the balanced control stage, each substructure works under the same or similar load, and the parameters such as pressure and flow are relatively consistent. The unbalanced control stage refers to the different control of the substructure according to its working state and performance to optimize the operating performance. Unbalanced control can dynamically adjust according to the specific load requirements of each substructure to ensure efficient operation under complex working conditions. For example, monitoring the hydraulic state of the plunger pump, when there is a hydraulic difference, it indicates that there may be a problem with the pump station itself that causes imbalance, resulting in abnormal hydraulic response. At this time, the pump station with the problem is suspended, and a maintenance instruction is generated, while the workload of other non-faulty substructures is adjusted to maintain balance. Through the complementarity of substructure control and based on the predictive control characteristics, dynamic adjustment from initial balanced control to unbalanced control is achieved, which can flexibly respond to load changes, optimize the load distribution of substructures, and ensure the efficient operation of the emulsion pump station under various complex working conditions.

[0027] Step 5: The distributed control module responds to the control and regulation strategy to perform forward-looking regulation and management of the emulsion pump station.

[0028] Specifically, the distributed control module is a control structure that combines the advantages of centralized control and distributed control. The control of each substructure (such as a plunger pump) is relatively independent, but at the same time, it is also globally coordinated and managed through the upper bus. When the control adjustment strategy proposes that a substructure needs to increase or decrease the load, the distributed control module responds quickly and performs the adjustment. Through the centralized control part of the distributed module, the state changes of all substructures will be monitored and adjusted. Even if a substructure fails or needs maintenance, its load can be compensated by coordinating other substructures to ensure uninterrupted operation of the pump station. Proactive control management refers to making control decisions and adjustments in advance based on the prediction of the future state of the pump station, which can effectively prevent potential problems and ensure stable operation. According to the predictive control characteristics, the operation trend is analyzed in advance, and active adjustments are made before the actual load changes occur to ensure that the pump station is always in the best operating state. Through proactive control management, the working state of the substructure can be dynamically adjusted at any time to avoid efficiency loss or failure caused by delayed response. For example, when a high load demand is predicted for a period of time, the distributed module will increase the output capacity of the corresponding substructure in advance. Through the response control adjustment strategy, forward-looking control management is implemented to ensure that the emulsion pump station adjusts the working status of each substructure in advance before the load changes. Through active control methods, the response speed is improved, energy consumption is optimized, and the reliability and efficiency of the overall operation are improved.

[0029] Further, step 2 of this application includes:

[0030] Based on the PLC logic program of the first pumping station substructure, a first control unit is constructed; according to the number of pumping station substructures, the first control unit is multi-bit mirrored twinned to determine N control units, and the N control units correspond one-to-one to the pumping station substructures; the N control units are integrated in parallel and coordinated on the upper bus to generate the distributed control module.

[0031] Specifically, the PLC logic program is applied to the first pump station substructure to create the first control unit. The first pump station substructure is any pump station substructure after uniform configuration, which contains a certain number of pumps and other related equipment. The PLC logic program is the core control logic of each pump station substructure, which is responsible for controlling each operation of the substructure according to the set working conditions. The PLC program has real-time performance and high reliability, and is suitable for complex industrial control scenarios. The first control unit is based on the control requirements of the first pump station substructure, manages all operations related to it, and includes all functions from sensor data reading to actuator control. It is an independent control module. According to the pump station substructure, multi-bit mirror twinning is performed, that is, the control logic of the first control unit is copied into multiple control units, so that each pump station substructure has a corresponding control unit. Assuming that the pump station has N substructures, then N control units need to be created, and each control unit independently controls a substructure. Each control unit corresponds to a substructure of the pump station, ensuring that each substructure has independent control logic and operation mechanism, can flexibly handle the workload of each substructure, and does not need to develop control logic for each substructure separately.

[0032] Connect multiple control units to the pump station at the same time, and each unit can work independently and in coordination with other units. Through parallel integration, each control unit can operate independently of each other, and can also share information to achieve coordination and load distribution between substructures. For example, when the load of a substructure increases, other substructures can be automatically adjusted to maintain the balanced operation of the pump station. The upper bus is the main communication line connecting multiple control units. Overall planning means coordinating and managing each control unit through the upper bus so that information can be exchanged to form a distributed control module, which has both distributed substructure control and overall coordination capabilities to ensure that the emulsion pump station can operate flexibly, stably and efficiently. The distributed control module combines the advantages of distributed and centralized control, ensuring that each control unit can independently control the corresponding substructure, while achieving global control through bus coordination, improving fault tolerance and stability, and avoiding single point failures.

[0033] Further, step three of this application includes:

[0034] Construct an operation feature map and obtain historical operation records; based on the operation feature map, decompose and determine the standard map and the multiple bias map and establish a map mapping; with the standard map and the multiple bias map as the benchmark, and vector deviation and trend deviation as the target, perform sample regularization and supervised training on the historical operation records to determine the operation prediction model.

[0035] Specifically, create a map to display the characteristic parameters of the emulsion pump station under different operating conditions, such as pressure, flow, temperature, etc. The operating characteristic map is a comprehensive data map that reflects the operating status, including trends, change characteristics, deviations, etc. of various key operating parameters. Historical operation records refer to the data accumulated during the past operation of the pump station, including but not limited to operation time, operation volume, maintenance records, fault records, etc., which can determine the rules, abnormal conditions, and typical control deviations in operation. The operating characteristic map is decomposed into a standard map and a multiple bias map. The standard map represents the characteristics under the ideal operating state, while the multiple bias map reflects the characteristics under different fault states or non-ideal states. Spectrum mapping refers to establishing a corresponding relationship between the standard map and the multiple bias map, and corresponding the actual operation data with the standard map and the multiple bias map.

[0036] Based on the standard map and multiple bias maps, the historical operation records are sampled and regularized. By analyzing the deviation data, regularity problems are found, unrepresentative data are removed, and a cleaned data set is provided for the supervised learning model. Vector deviation refers to the numerical deviation between the current state and the standard map. For example, if the pressure is higher than the standard value by a certain range, the flow rate is lower. This difference can be regarded as a vector deviation. Trend bias refers to the changing trend of the operation data. Even if there is a certain deviation, the overall trend is returning to the normal state, and the trend bias is considered to be optimal. For example, although a certain control node has a certain deviation, the trend shows that the node is returning to the standard state, then no adjustment can be made at this time to avoid unnecessary control actions. Trend bias can avoid frequent adjustments, reduce unnecessary "ineffective work", and maintain smooth operation. According to the vector deviation and trend bias, the data in the historical operation records are regularized and classified. By using the regularized data set for supervised training, an operation prediction model is established to predict the future operation status of the emulsion pump station, especially the trend changes under load changes or environmental interference. By constructing an operation feature map and combining it with standard and bias maps, historical operation records were analyzed and supervised, and finally an operation prediction model based on vector deviation and trend bias was determined. This model can not only predict deviations in advance, but also avoid unnecessary adjustments, reduce ineffective work, and ensure efficient and smooth operation.

[0037] Further, step 4 of this application includes:

[0038] The operating conditions are obtained, and a linear function of the fluid supply flow rate and the support follow-up speed is excavated. The operating conditions include the number of hydraulic supports and the follow-up requirements. Based on the linear function, hydraulic frequency conversion control is performed according to the real-time motion state of the hydraulic support. The frequency conversion control includes the flow increase direction and the flow decrease direction.

[0039] Specifically, information about the operating conditions is collected, including the number of hydraulic supports and the need for follow-up. The operating conditions refer to the operating status of the emulsion pump station and its associated hydraulic supports under different operating conditions. In coal mine operations, the number of hydraulic supports directly affects the demand for emulsion. The more supports there are, the greater the demand for fluid supply of the overall hydraulic pump station. The follow-up demand refers to the need for the hydraulic support to automatically adjust the support position as the coal mining progresses during coal mine operations. The faster the follow-up speed, the greater the emulsion flow rate that the hydraulic pump station needs to provide. The motion data (follow-up speed) of the hydraulic support and the fluid supply flow data of the pump station are collected by sensors, and a linear relationship function between the fluid supply flow rate and the support follow-up speed is fitted using linear regression or other statistical methods. A linear function is a simple mathematical model, usually in the form of y=mx+b, where y is the follow-up speed, x is the fluid supply flow rate, and m and b are parameters obtained by data fitting. The linear function is used to predict how the follow-up speed of the hydraulic support affects the fluid supply flow rate of the pump station. For example, when the fluid supply flow rate is 1000 liters / minute, the support follow-up speed is 2 meters / minute; when the fluid supply flow rate is 1500 liters / minute, the support follow-up speed is 3 meters / minute, and so on. Assuming that the relationship between the fluid supply flow rate x (unit: liters / minute) and the hydraulic support follow-up speed y (unit: meters / minute) can be expressed as a linear function y=0.002x+0.5, the current hydraulic support follow-up speed is 4 meters / minute. If the follow-up speed needs to be increased, the linear function calculates that the fluid supply flow rate needs to be increased to 1750 liters / minute=(4-0.5) / 0.002. According to the calculation results, the inverter setting of the hydraulic pump station will be adjusted to ensure that the fluid supply flow rate is 1750 liters / minute, so that the support can follow up at a speed of 4 meters / minute. Using the linear function, control is performed according to the real-time motion state of the hydraulic support. Frequency conversion control refers to adjusting the flow rate by changing the speed of the pump, which is divided into the direction of increasing flow and the direction of decreasing flow. When the follow-up speed of the hydraulic support increases, the emulsion supply flow rate is automatically increased according to the linear function. By increasing the frequency of the pump station, it is ensured that sufficient hydraulic support can be provided in time to avoid the support from being unable to follow up due to insufficient hydraulic pressure; when the follow-up speed of the hydraulic support slows down or stops, the supply flow rate is reduced according to the linear function, the pump station frequency is reduced, unnecessary energy consumption is avoided, the working pressure of the pump station is reduced when the load is light, and the service life of the equipment is extended. Through the support motion sensor, the displacement, speed and other dynamic data of the hydraulic support are accurately obtained. Based on these dynamic data, the working frequency of the pump station is dynamically adjusted through the frequency converter to ensure that the supply matches the demand. The supply flow rate is automatically adjusted according to the needs of the operating conditions to optimize the follow-up speed of the hydraulic support, thereby improving the operating efficiency and response speed, which helps to ensure that the pump station can operate efficiently and stably under various working conditions.

[0040] Furthermore, the present application also includes the following steps:

[0041] Monitor the pipeline hydraulic status of the plunger pump and generate a hydraulic time-space curve; traverse the hydraulic time-space curve and locate abnormal hydraulic nodes by analyzing relative curve differences; generate control adjustment instructions based on the abnormal hydraulic nodes, and perform deviation correction, source tracing and sub-structure complementary adjustment on the relative curve differences.

[0042] Specifically, the hydraulic state of the connecting pipeline of the plunger pump machine can be monitored in real time. Monitoring equipment such as pressure sensors can be used. The monitoring points usually cover multiple locations, including the output end of the pump, the middle and end of the pipeline, to obtain the hydraulic state of the pipeline, including parameters such as pressure and flow. According to the collected hydraulic data, a curve of hydraulic pressure changing with time and space (i.e., time-space curve) is generated, which reflects the distribution and dynamic changes of the hydraulic system in the entire pump station and can show the pressure fluctuations in different areas. The hydraulic time-space curve is traversed to check the hydraulic changes of the entire pump station. Under normal circumstances, the hydraulic pressure of all plunger pumps should be evenly distributed without obvious differences. Compare and analyze the hydraulic curves at different locations, calculate the relative curve difference, reveal the hydraulic differences between different pipelines or pump stations, and find out the points that deviate greatly from the normal state, which are abnormal hydraulic nodes. If the hydraulic pressure in some areas is significantly different from that in other areas, it may indicate that there is an abnormality in a plunger pump or a section of pipeline, which is not limited to a single moment, but may also show a certain time trend. Through relative difference analysis, the node location of hydraulic anomaly is determined, which may be due to hydraulic imbalance caused by aging, leakage of pump station equipment or abnormal working condition of the pump.

[0043] According to the determined abnormal hydraulic nodes, corresponding control and adjustment instructions are generated to restore the hydraulic balance state of the pump station and correct the pressure deviation of the abnormal nodes. The control and adjustment instructions may include adjusting the output pressure of the plunger pump, changing the flow distribution in the pump station, or adjusting the working frequency of the pump to ensure that the hydraulic system returns to normal. At the same time, the root causes of the abnormal hydraulic nodes are tracked and analyzed to determine the root causes of the hydraulic abnormalities, such as pump station equipment failure, pump control system problems, or pipeline leakage. Source tracing analysis refers to further tracing the source of hydraulic imbalance based on the hydraulic time-space curve and curve difference to determine whether it is caused by the failure of a plunger pump or the blockage of a section of the hydraulic equipment pipeline. According to the results of deviation correction and tracing, the relevant substructures are complementary adjusted according to the status of each substructure (plunger pump). For example, when a pump outputs insufficient hydraulic pressure, other pumps can appropriately increase the output to balance the pressure distribution of the entire pump station and avoid failures caused by local low pressure. Substructure complementarity means that when a substructure is abnormal, other substructures make corresponding adjustments according to their own capabilities to ensure that the whole can still operate smoothly.

[0044] In the initial state, the pump station is usually configured in a balanced control mode, that is, the output of each plunger pump should be as uniform as possible so that deviations can be detected in subsequent operations. Once the initialized balanced state is broken, it indicates that an abnormality may occur, so balanced control is an important means to verify whether the operation is normal. When hydraulic imbalance is detected, it is not only necessary to adjust the pressure, but also to trace the specific cause of the imbalance and correct it through substructure complementation and local adjustment. By monitoring the hydraulic state of the pipeline of the plunger pump, a hydraulic time-space curve is generated, and the abnormal hydraulic node is located by analyzing the relative curve difference, and control adjustment instructions are generated to perform deviation correction tracing and substructure complementary adjustment to ensure the stable operation of the pump station under various working conditions.

[0045] Furthermore, the present application also includes the following steps:

[0046] Obtain the deviation correction and tracing results, identify the abnormal operation characteristics of the plunger pump; set the fault operation and maintenance standards, and determine the abnormal operation characteristics of the plunger pump. If the fault operation and maintenance standards are met, the parallel branch control of the pump station substructure corresponding to the plunger pump is suspended, and a maintenance instruction is generated, and complementary adjustment of the non-faulty substructure is performed; if the fault operation and maintenance standards are not met, complementary adjustment of the pump station substructure is performed.

[0047] Specifically, obtain the results of deviation correction and tracing, determine the source of the hydraulic anomaly, analyze it, and identify the specific operating characteristics of the plunger pump under abnormal conditions, such as pressure fluctuations, abnormal flow, temperature changes, etc. A set of fault operation and maintenance standards are set according to the operating requirements of the pump station and the durability of the equipment, including the upper and lower pressure limits, power consumption range, temperature threshold, etc. of the plunger pump. When the abnormal operating characteristics of the equipment exceed these standards, it is determined that the plunger pump has a serious abnormality or failure and requires maintenance. When the abnormal operating characteristics of the plunger pump reach the fault operation and maintenance standard, the parallel branch control of the corresponding pump station substructure is suspended, that is, the operation of the faulty substructure is suspended to isolate the fault point.

[0048] Since the control units of each pump station substructure are connected in parallel, they cooperate with each other and are independent of each other. Pausing one substructure will not affect the normal operation of other substructures. By pausing the faulty substructure, it is possible to prevent the hydraulic anomaly from spreading further or affecting other substructures. At the same time, a maintenance instruction is generated, including the specific fault characteristics of the equipment, the cause of the anomaly and maintenance suggestions, to notify the operation and maintenance personnel to repair the faulty plunger pump. Due to the mutual coordination of the parallel structures, the operating status of the non-faulty substructures is automatically adjusted, and the hydraulic system is complementary adjusted. For example, when one substructure is paused, other substructures will automatically increase their output pressure or flow to supplement the insufficient pressure of the paused substructure and ensure the hydraulic stability of the pump station.

[0049] If the abnormal operation characteristics of the plunger pump do not meet the fault operation and maintenance standards, that is, although the equipment is abnormal, it does not need to be shut down for maintenance immediately, there are certain deviations or potential problems, and only complementary adjustments need to be performed. By adjusting the working status of other substructures, the deficiencies of the abnormal substructure can be compensated. For example, if the pressure of a substructure is slightly low, other substructures can increase their pressure output to avoid problems with the hydraulic system of the entire pump station due to insufficient local pressure, avoid unnecessary shutdowns, and ensure that the equipment can continue to operate under minor abnormal conditions and remain stable as a whole. For example, plunger pump A: pressure 150bar, flow 1000L / min; plunger pump B: pressure 130bar, flow 1100L / min; plunger pump C: pressure 170bar, flow 900L / min; plunger pump D: pressure 160bar, flow 950L / min. Assuming that the pressure fluctuation of plunger pump B is monitored to be abnormal, it is found through deviation correction and tracing analysis that it is caused by internal wear of the pump. Identifying abnormal operation characteristics, it is found that the pressure of pump B is lower than that of other pumps, and the flow is higher than that of other pumps. The fault operation and maintenance standard is set as a pressure fluctuation of more than 20% and a flow change of more than 30%. Pump B is judged to have reached the fault standard. The pump station substructure corresponding to plunger pump B is suspended to prevent the spread of the fault; a maintenance instruction is generated to notify maintenance personnel to check pump A; the operating parameters of other pumps are adjusted to compensate for the impact of the shutdown of pump A.

[0050] By identifying the abnormal operating characteristics of the plunger pump and determining whether it is necessary to suspend the faulty substructure and perform maintenance based on the set fault operation and maintenance standards, and utilizing the coordination and independence of the parallel control structure, flexible management and efficient control of faulty and non-faulty substructures are achieved, ensuring that the emulsion pump station can maintain stable and efficient operation in the event of a fault.

[0051] Further, step five of this application includes:

[0052] The balanced control of the pump station substructure is used as the normal operation mode, and the unbalanced control is used as the feedback adjustment mode; the control time limit and the balanced control condition are set, the control time limit is the time interval of the adjustment response, and the balanced control condition is determined based on the mechanical state of the emulsion pump station; the control adjustment strategy is executed, and the balanced control is restored and initialized based on the control time limit and the balanced control condition.

[0053] Specifically, the balanced control of the substructure of the pump station is used as a regular operating mode, that is, each plunger pump bears an equal load, ensuring the stability of the pump station and the balance of equipment life, and can reflect the hydraulic status of the plunger pump. However, in some cases (such as detecting a minor fault in a plunger pump in a substructure), it automatically switches to the unbalanced control mode. When a substructure cannot bear its assigned load due to mechanical problems or insufficient hydraulic flow, the unbalanced control mode compensates for the deficiencies of the faulty substructure by adjusting the output of other substructures to maintain the overall stability of the pump station. The feedback regulation mode is enabled when an abnormality is detected or optimization is required, and more load is distributed to the normally operating substructure to ensure that the pump station continues to operate stably without completely shutting down for maintenance.

[0054] The control time limit is set, that is, the time interval for feedback regulation or balanced recovery, which is a specific time window, indicating that the load adjustment or balanced control recovery needs to be completed within this time. Based on the mechanical state of the pump station, the balanced control conditions are determined, including the operating parameters of the pump station, the working state of the equipment, etc., which are used to determine when the pump station switches to the balanced control mode. When the mechanical state returns to the preset stable range, or the pressure and flow of the substructure are rebalanced, the balanced control can be re-enabled. When hydraulic fluctuations or minor faults in the substructure are detected, the control strategy is executed, and each substructure is adjusted based on the predictive control characteristics. In the case of a minor fault in a substructure, other substructures will compensate for the load by increasing the flow or pressure during this period to prevent the entire pump station from being affected. After the control time limit expires, re-evaluate whether the balanced control conditions are met. If met, the balanced control state will be automatically restored, and the loads of all substructures will be newly allocated, so that the pressure and flow of each substructure return to the balanced state, ensuring the stability of the pump station in long-term operation and the extension of the equipment life. If not met, non-balanced control will continue until the conditions are met. By setting the balanced control as the normal operation mode and the unbalanced control as the feedback adjustment mode, the working state of the pump station substructure is dynamically adjusted based on the control time limit and balanced control conditions. Under balanced control, the load is evenly distributed to ensure the optimal operation of the equipment. In the case of minor faults or load fluctuations, the overall stability is maintained through complementary adjustments of other substructures, and the balanced control is restored and initialized after the fault is eliminated to ensure the continuous and efficient operation of the pump station.

[0055] In summary, the forward-looking control method for an emulsion pump station provided in this application has the following technical effects:

[0056] The installed configuration of the emulsion pump station is obtained, and the configuration is evenly divided to determine the substructure of the pump station, wherein the configuration is evenly divided according to the distribution of the number of plungers, and the emulsion pump station is a large-flow pump station; the control logic of the substructure of the pump station is set and the PLC program is converted, and the mirror twin and parallel of the substructure control are performed to determine the distributed control module; the operation data sent back by the front-end sensor is received, and the expected off-axis analysis of the control response of the operation data is performed through the supervised training operation prediction model to determine the predictive control characteristics, wherein the operation data at least includes the hydraulic support motion data and the pump station operation data; in a manner of substructure control complementarity, a control adjustment decision based on the predictive control characteristics is executed to determine the control adjustment strategy, wherein the control adjustment is transformed from the initialized balanced control of the pump station substructure to the unbalanced control; the distributed control module responds to the control adjustment strategy to perform the forward-looking regulation and management of the emulsion pump station. In other words, by configuring the distribution of the number of plungers equally, dynamic control and unbalanced regulation of the pump station substructure can be achieved. The operating data can be analyzed through the prediction model, and adjustment decisions can be made in advance before the load changes occur, avoiding delayed response and dynamically adjusting the load distribution of the substructure to cope with changes in the movement of the hydraulic support and other operating conditions, thereby achieving more flexible load management and improving control accuracy.

[0057] Embodiment 2: Based on the same inventive concept as the forward-looking control method for an emulsion pump station in the previous embodiment, the present application also provides a forward-looking control system for an emulsion pump station, see the attached Figure 2 , the forward-looking control system for the emulsion pump station comprises:

[0058] The configuration division module 11 is used to obtain the installed configuration of the emulsion pump station, perform configuration equalization, and determine the substructure of the pump station, wherein the configuration equalization is performed based on the distribution of the number of plungers. The emulsion pump station is a large flow pump station.

[0059] The control conversion module 12 is used to set the control logic of the pump station substructure and perform PLC program conversion, perform mirror twinning and parallel connection of the substructure control, and determine the distributed control module.

[0060] The model building module 13 is used to receive the operation data sent back by the front-end sensor, and perform expected off-axis analysis of the control response of the operation data through the supervised training operation prediction model to determine the predictive control characteristics. The operation data at least includes the hydraulic support movement data and the pump station operation data.

[0061] The decision determination module 14 is used to execute the control adjustment decision based on the predictive control characteristics in a substructure control complementarity manner and determine the control adjustment strategy, wherein the control adjustment is transformed from the initialized pump station substructure balanced control to unbalanced control.

[0062] The forward-looking control module 15 is used for the distributed control module to respond to the control and regulation strategy and perform forward-looking control management of the emulsion pump station.

[0063] Furthermore, the control conversion module 12 in the forward-looking control system for the emulsion pump station is also used for:

[0064] Based on the PLC logic program of the first pumping station substructure, a first control unit is constructed; according to the number of pumping station substructures, the first control unit is multi-bit mirrored twinned to determine N control units, and the N control units correspond one-to-one to the pumping station substructures; the N control units are integrated in parallel and coordinated on the upper bus to generate the distributed control module.

[0065] Furthermore, the model building module 13 in the forward-looking control system for the emulsion pump station is also used for:

[0066] Construct an operation feature map and obtain historical operation records; based on the operation feature map, decompose and determine the standard map and the multiple bias map and establish a map mapping; with the standard map and the multiple bias map as the benchmark, and vector deviation and trend deviation as the target, perform sample regularization and supervised training on the historical operation records to determine the operation prediction model.

[0067] Furthermore, the decision-making module 14 in the forward-looking control system for the emulsion pump station is also used for:

[0068] The operating conditions are obtained, and a linear function of the fluid supply flow rate and the support follow-up speed is excavated. The operating conditions include the number of hydraulic supports and the follow-up requirements. Based on the linear function, hydraulic frequency conversion control is performed according to the real-time motion state of the hydraulic support. The frequency conversion control includes the flow increase direction and the flow decrease direction.

[0069] Furthermore, the decision-making module 14 in the forward-looking control system for the emulsion pump station is also used for:

[0070] Monitor the pipeline hydraulic status of the plunger pump and generate a hydraulic time-space curve; traverse the hydraulic time-space curve and locate abnormal hydraulic nodes by analyzing relative curve differences; generate control adjustment instructions based on the abnormal hydraulic nodes, and perform deviation correction, source tracing and sub-structure complementary adjustment on the relative curve differences.

[0071] Furthermore, the decision-making module 14 in the forward-looking control system for the emulsion pump station is also used for:

[0072] Obtain the deviation correction and tracing results, identify the abnormal operation characteristics of the plunger pump; set the fault operation and maintenance standards, and determine the abnormal operation characteristics of the plunger pump. If the fault operation and maintenance standards are met, the parallel branch control of the pump station substructure corresponding to the plunger pump is suspended, and a maintenance instruction is generated, and complementary adjustment of the non-faulty substructure is performed; if the fault operation and maintenance standards are not met, complementary adjustment of the pump station substructure is performed.

[0073] Furthermore, the forward-looking control module 15 in the forward-looking control system for the emulsion pump station is also used for:

[0074] The balanced control of the pump station substructure is used as the normal operation mode, and the unbalanced control is used as the feedback adjustment mode; the control time limit and the balanced control condition are set, the control time limit is the time interval of the adjustment response, and the balanced control condition is determined based on the mechanical state of the emulsion pump station; the control adjustment strategy is executed, and the balanced control is restored and initialized based on the control time limit and the balanced control condition.

[0075] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. Figure 1 The forward-looking control method and specific examples for the emulsion pump station in the first embodiment are also applicable to the forward-looking control system for the emulsion pump station in the present embodiment. Through the above detailed description of the forward-looking control method for the emulsion pump station, those skilled in the art can clearly know the forward-looking control system for the emulsion pump station in the present embodiment, so for the sake of brevity of the specification, it will not be described in detail here. For the system disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part description.

[0076] The above description of the disclosed embodiments enables professionals and technicians in the field to implement or use the present application. Various modifications to these embodiments will be apparent to professionals and technicians in the field, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features disclosed herein. Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the present application and its equivalents, the present application is also intended to include these modifications and variations.

Claims

1. A forward-looking control method for an emulsion pump station, characterized in that: include: Obtaining the installed capacity configuration of the emulsion pump station, performing configuration equalization, and determining the substructure of the pump station, wherein the configuration equalization is performed based on the distribution of the number of plungers, and the emulsion pump station is a large flow pump station; Setting the control logic of the pump station substructure and performing PLC program conversion, performing mirror twinning and parallel connection of substructure control, and determining the distributed control module; Receive the operation data transmitted back by the front-end sensor, perform expected off-axis analysis of the control response on the operation data through the supervised training operation prediction model, and determine the predictive control characteristics, wherein the operation data at least includes the hydraulic support motion data and the pump station operation data; In a manner of substructure control complementation, a control adjustment decision based on the predictive control feature is executed to determine a control adjustment strategy, wherein the control adjustment is transformed from an initialized pump station substructure balanced control to an unbalanced control; The distributed control module responds to the control and regulation strategy to perform forward-looking regulation and management of the emulsion pump station; The step of determining a distributed control module comprises: Based on the PLC logic program of the first pump station substructure, a first control unit is constructed; According to the number of pump station substructures, multi-bit mirror twinning is performed on the first control unit to determine N control units, and the N control units correspond one-to-one to the pump station substructures; The N control units are integrated in parallel, and upper bus coordination is performed to generate the distributed control module.

2. The forward-looking control method for an emulsion pump station according to claim 1, characterized in that: Supervised training runs the prediction model, including: Build an operation feature map and obtain historical operation records; Based on the running characteristic spectrum, decomposing and determining the standard spectrum and the multiple biased spectrum and establishing spectrum mapping; Based on the standard map and the multiple bias maps, and taking the vector deviation and the trend deviation as the target, the historical operation records are subjected to sample regularization and supervised training to determine the operation prediction model.

3. The forward-looking control method for an emulsion pump station according to claim 1, characterized in that: Executing a control adjustment decision based on the predictive control feature includes: Obtaining the operating conditions and mining the linear function of the fluid supply flow rate and the support follow-up speed, wherein the operating conditions include the number of hydraulic supports and the follow-up requirements; Based on the linear function, hydraulic frequency conversion control is performed according to the real-time motion state of the hydraulic support, and the frequency conversion control includes a flow increase direction and a flow decrease direction.

4. The forward-looking control method for an emulsion pump station according to claim 1, characterized in that: Executing a control adjustment decision based on the predictive control feature includes: Monitor the hydraulic status of the piston pump pipeline and generate hydraulic time-space curve; Traversing the hydraulic time-space curve, and locating abnormal hydraulic nodes by analyzing relative curve differences; A control adjustment instruction based on the abnormal hydraulic node is generated, and the relative curve difference is corrected, traced and adjusted complementary to the substructure.

5. The forward-looking control method for an emulsion pump station according to claim 4, characterized in that: After the relative curve difference is corrected and traced, it includes: Obtain deviation correction and traceability results and identify abnormal operation characteristics of the plunger pump; Setting a fault operation and maintenance standard, determining the abnormal operation characteristics of the plunger pump, and if the fault operation and maintenance standard is reached, suspending the parallel branch control of the pump station substructure corresponding to the plunger pump, generating a maintenance instruction, and executing complementary adjustment of the non-fault substructure; If the fault operation and maintenance standard is not met, complementary adjustments of the pump station substructure are performed.

6. The forward-looking control method for an emulsion pump station according to claim 1, characterized in that: After executing the forward-looking control management of the emulsion pump station, it includes: The balanced control of the pump station substructure is used as the normal operation mode, and the unbalanced control is used as the feedback regulation mode; Setting a control time limit and a balance control condition, wherein the control time limit is a time interval for adjusting a response, and the balance control condition is determined based on a mechanical state of the emulsion pump station; The control adjustment strategy is executed, and based on the regulation time limit and the balance control condition, the balance control is restored and initialized.

7. A forward-looking control system for an emulsion pump station, characterized in that: Steps for implementing the forward-looking control method for an emulsion pumping station according to any one of claims 1 to 6, wherein the forward-looking control system for an emulsion pumping station comprises: A configuration division module is used to obtain the installed configuration of the emulsion pump station, perform configuration equalization, and determine the substructure of the pump station, wherein the configuration equalization is performed based on the distribution of the number of plungers, and the emulsion pump station is a large flow pump station; A control conversion module, used to set the control logic of the pump station substructure and perform PLC program conversion, perform mirror twinning and parallel connection of substructure control, and determine the distributed control module; A model building module is used to receive the operation data transmitted back by the front-end sensor, and to perform expected off-axis analysis of the control response on the operation data through the supervised training operation prediction model to determine the predictive control characteristics, wherein the operation data at least includes the hydraulic support motion data and the pump station operation data; A decision determination module, used to execute a control adjustment decision based on the predictive control feature in a manner of substructure control complementation, and determine a control adjustment strategy, wherein the control adjustment is transformed from the initialized pump station substructure balanced control to the unbalanced control; The forward-looking control module is used for the distributed control module to respond to the control and regulation strategy and perform forward-looking control management of the emulsion pump station.

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