Gas chamber capacity detection method and detection device

Abstract

The invention provides a gas chamber capacity detection method and device, and the method comprises the steps: obtaining the current height of a piston in a gas chamber, the diameter of the piston, and the maximum stroke of the piston after the gas chamber capacity detection device receives a chamber capacity detection instruction; calculating the cross sectional area of the piston based on the current height of the piston; calculating a first ratio of the piston stroke according to the piston cross section area and the maximum stroke; multiplying the first ratio by the unit stroke to obtain the unit volume of the gas chamber; calculating an actual cabinet capacity value based on the current height and the unit volume of the piston; and when the actual cabinet capacity value is higher than a preset threshold value, the gas cabinet capacity detection device sends a warning instruction to the gas cabinet, so that the gas cabinet adjusts the conveying switch to be in a closed state. By detecting various parameters of the piston of the gas holder in real time and combining model algorithms such as target value function approximation and mean filtering to calculate the capacity of the gas holder, the accuracy of the capacity data of the gas holder is improved.

Description

Technical Field

[0001] The present application relates to the field of gas technology, and in particular to a gas tank capacity detection method and detection device. Background Art

[0002] As one of the important facilities of chemical and steel enterprises, gas tanks play an important role in gas distribution and storage, gas pipe network pressure regulation, and reducing environmental pollution and carbon emissions. The gas tanks currently used by relevant enterprises at home and abroad can be divided into two types: dry type and wet type. Regardless of the type of gas tank, the detection requirements for the tank capacity parameters must be accurate, which is not only related to the safety of the equipment, but also to the life safety of production personnel. Therefore, the maintenance of the tank capacity meter and the reliability of the equipment are crucial.

[0003] At present, there are two ways to detect the capacity of gas tanks, one is the mechanical tank capacity meter, and the other is the ultrasonic tank position meter. The mechanical tank capacity meter uses a steel wire rope with one end fixed on the piston, and the other end is fixed on the outside of the cabinet wall with a guide rail and a counterweight after passing through the corresponding pulley group and gear group. When the gas tank piston moves up and down, the mechanical tank capacity meter detects the change of the gas tank volume in real time. However, the mechanical tank capacity meter is affected by the "slippage" between the steel wire rope and the wheel, which often causes the error to increase continuously, causing the value to be inconsistent with the actual value, and the workload is large during daily maintenance. It is necessary to use fixed pulleys frequently and continuously pull the steel wire rope to eliminate the deviation; while the ultrasonic tank position meter (including radar or laser type) uses the principle of sound wave echo to measure the distance to calculate the change of the cabinet capacity, but due to the influence of the emission and reflection angle direction of the ultrasonic wave, the accumulation of dirt on the reflector, foggy weather, etc., the measurement accuracy is insufficient or the signal is lost, and the deviation from the actual position is large.

[0004] Therefore, the current methods for detecting the capacity of gas tanks are mostly inaccurate, resulting in a deviation between the upper computer display and the actual tank capacity, which increases the probability of piston top impact accidents and leads to lower safety. Summary of the invention

[0005] The present application provides a gas tank capacity detection method and detection device to solve the problem that the current methods for detecting the gas tank capacity are mostly inaccurate, resulting in a deviation between the upper computer display and the actual tank capacity, which increases the probability of piston top impact accidents and leads to lower safety.

[0006] In a first aspect, the present application provides a gas tank capacity detection method, the method comprising:

[0007] After receiving the tank capacity detection instruction, the gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank;

[0008] The piston cross-sectional area is calculated based on the piston diameter;

[0009] Calculating a first ratio of the piston stroke according to the piston cross-sectional area and the maximum stroke;

[0010] Multiplying the first ratio by the unit stroke to obtain the unit volume of the gas tank;

[0011] The actual tank capacity is calculated based on the current height of the piston and the unit volume;

[0012] When the actual tank capacity value is higher than a preset threshold, the gas tank capacity detection device sends a warning instruction to the gas tank, so that the gas tank adjusts the delivery switch to a closed state.

[0013] In some possible implementations, the method includes:

[0014] The gas tank capacity detection device analyzes the tank capacity detection instruction to obtain a displacement signal of the piston;

[0015] Calculate the current height of the piston in the gas tank and the current piston movement rate based on the displacement signal;

[0016] The unit stroke of the piston is obtained based on the multiplication of the current piston movement rate and the unit time.

[0017] In some possible implementations, the method further includes:

[0018] After the gas cabinet receives the alarm command, the gas cabinet automatically closes the butterfly valve of the inlet pipeline and ignites and releases the residual gas in the inlet pipeline.

[0019] In some possible implementations, the method includes:

[0020] The gas tank capacity detection device uploads the actual tank capacity value to the server after calculating the actual tank capacity value each time;

[0021] The server calculates the number of abnormal times that the actual cabinet capacity value is higher than a preset threshold value within a preset duration at every preset time interval;

[0022] When the number of abnormalities exceeds a preset safety number, a maintenance instruction is generated and sent to a target person, so that the target person can inspect the gas cabinet.

[0023] In some possible implementations, the method includes:

[0024] The gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank at preset intervals, and

[0025] The packaged data packet is sent to the server in combination with the server communication protocol format.

[0026] In a second aspect, the present application provides a gas tank capacity detection device, the gas tank capacity detection device is used to perform the gas tank capacity detection method described in the first aspect, the gas tank capacity detection device comprises:

[0027] Box;

[0028] Touch screen for displaying target data and inputting piston related parameters;

[0029] Switches, used for data communication;

[0030] Power supplies, used to transmit electrical energy;

[0031] Controller, sends control instructions.

[0032] In some possible implementations, the controller and the switch are configured and communicated via PROFIBUS-DP, and the controller and the touch screen are connected using the Profinet Ethernet protocol.

[0033] In some possible implementations, the controller of the gas tank capacity detection device is electrically connected to an encoder, and the controller receives different analog and switch quantity signals decoded and calculated and output by the encoder based on BCD codes.

[0034] In some possible implementations, a door body is installed at the front end of the gas tank capacity detection device, and an explosion-proof glass window is hingedly installed on the upper side of the door body; wherein the frame of the explosion-proof glass window is tightly connected to the door body by bolts.

[0035] In some possible implementations, a cable entry hole is provided at the lower end of the gas tank capacity detection device, and the cable entry hole adopts a rubber sealing design. The power cord, PROFIBUS cable, and signal line pass through the entry hole in sequence and are connected to the box.

[0036] From the above content, it can be seen that the present application provides a gas tank capacity detection method and detection device, the method includes the following steps: the gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank after receiving the tank capacity detection instruction; calculates the piston cross-sectional area based on the current height of the piston; calculates the first ratio of the piston stroke according to the piston cross-sectional area and the maximum stroke; multiplies the first ratio by the unit stroke to obtain the unit volume of the gas tank; calculates the actual tank capacity value based on the current height of the piston and the unit volume; when the actual tank capacity value is higher than the preset threshold, the gas tank capacity detection device sends a warning instruction to the gas tank to make the gas tank adjust the delivery switch to the closed state. The present application calculates the gas tank capacity by real-time detection of multiple parameters of the gas tank piston, combined with target value function approximation, piston running speed and acceleration, mean filtering and other model algorithms, and stops the intake of gas in time when the gas tank capacity is higher than the critical value, thereby improving the accuracy of the gas tank capacity data and avoiding the occurrence of piston top collision accidents. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solution of the present application, the drawings required for use in the embodiments are briefly introduced below. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0038] Figure 1 A flow chart of a gas tank capacity detection method provided in an embodiment of the present application;

[0039] Figure 2 Schematic diagram of a gas tank capacity detection device provided in an embodiment of the present application.

[0040] Illustration Description:

[0041] 1-power indicator light, 2-main power switch, 3-controller, 4-touch screen, 5-fixing bolt hole, 6-switch, 7-air switch, 8-power supply, 9-glass window, 10-rubber seal, 11-washer, 12-tightening nut, 13-cables entering the cabinet. DETAILED DESCRIPTION

[0042] The following embodiments are described in detail, and examples thereof are shown in the accompanying drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementations described in the following embodiments do not represent all implementations consistent with the present application. They are only examples of systems and methods consistent with some aspects of the present application as detailed in the claims.

[0043] As one of the important facilities of chemical and steel enterprises, gas tanks play an important role in gas distribution and storage, gas pipe network pressure regulation, and reducing environmental pollution and carbon emissions. The gas tanks currently used by relevant enterprises at home and abroad can be divided into two types: dry type and wet type. Regardless of the type of gas tank, the detection requirements for the tank capacity parameters must be accurate, which is not only related to the safety of the equipment, but also to the life safety of production personnel. Therefore, the maintenance of the tank capacity meter and the reliability of the equipment are crucial.

[0044] At present, there are two ways to detect the capacity of gas tanks, one is the mechanical tank capacity meter, and the other is the ultrasonic tank position meter. The mechanical tank capacity meter uses a steel wire rope with one end fixed on the piston, and the other end is fixed on the outside of the cabinet wall with a guide rail and a counterweight after passing through the corresponding pulley group and gear group. When the gas tank piston moves up and down, the mechanical tank capacity meter detects the change of the gas tank volume in real time. However, the mechanical tank capacity meter is affected by the "slippage" between the steel wire rope and the wheel, which often causes the error to increase continuously, causing the value to be inconsistent with the actual value, and the workload is large during daily maintenance. It is necessary to use fixed pulleys frequently and continuously pull the steel wire rope to eliminate the deviation; while the ultrasonic tank position meter (including radar or laser type) uses the principle of sound wave echo to measure the distance to calculate the change of the cabinet capacity, but due to the influence of the emission and reflection angle direction of the ultrasonic wave, the accumulation of dirt on the reflector, foggy weather, etc., the measurement accuracy is insufficient or the signal is lost, and the deviation from the actual position is large.

[0045] Therefore, the current methods for detecting the capacity of gas tanks are mostly inaccurate, resulting in a deviation between the upper computer display and the actual tank capacity, which increases the probability of piston top impact accidents and leads to lower safety.

[0046] Based on this, the present application provides a gas tank capacity detection method and detection device. The present application calculates the gas tank capacity by real-time detection of various parameters of the gas tank piston, combining target value function approximation, piston running speed and acceleration, mean filtering and other model algorithms, thereby improving the accuracy of the gas tank capacity data; when the gas tank capacity is higher than the critical value, the air intake is stopped in time to avoid the occurrence of piston top impact accidents.

[0047] In some embodiments, Figure 1 As shown, the present application provides a gas tank capacity detection method, the method comprising:

[0048] S1: After receiving the tank capacity detection instruction, the gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank.

[0049] The gas tank capacity detection device is equipped with a process control-level S7-1200 PLC system and auxiliary components. The system receives the displacement signal (4-20mA after position code conversion) detected by the gas tank capacity encoder and calculates the current height of the piston in the tank in real time.

[0050] The gas tank capacity detection device analyzes the tank capacity detection instruction to obtain a displacement signal of the piston;

[0051] Calculate the current height of the piston in the gas tank and the current piston movement rate based on the displacement signal;

[0052] The unit stroke of the piston is obtained based on the multiplication of the current piston movement rate and the unit time.

[0053] Among them, the unit stroke of the piston is the product of the current piston movement rate and the unit time, and the unit is meter / minute. The movement rate value is the data detected by the cabinet capacity encoder. The positive and negative value indicates the direction of the piston's up and down movement, and the size represents the speed of the movement.

[0054] S2: Piston cross-sectional area calculated based on piston diameter.

[0055] The cross-sectional area depends on the piston diameter D, cross-sectional area S = π[1 / 2(D)] 2 .

[0056] S3: Calculating a first ratio of the piston stroke according to the piston cross-sectional area and the maximum stroke.

[0057] Among them, the maximum stroke of the piston is a preset value, which can be adjusted according to actual conditions.

[0058] S4: Multiply the first ratio by the unit stroke to obtain the unit volume of the gas tank.

[0059] S5: Calculate the actual tank capacity based on the current height of the piston and the unit volume.

[0060] In some embodiments, the method further comprises:

[0061] The gas tank capacity detection device uploads the actual tank capacity value to the server after calculating the actual tank capacity value each time;

[0062] The server calculates the number of abnormal times that the actual cabinet capacity value is higher than a preset threshold value within a preset duration at every preset time interval;

[0063] When the number of abnormalities exceeds a preset safety number, a maintenance instruction is generated and sent to a target person, so that the target person can inspect the gas cabinet.

[0064] The gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank at preset intervals, and

[0065] The packaged data packet is sent to the server in combination with the server communication protocol format.

[0066] S6: When the actual tank capacity value is higher than a preset threshold, the gas tank capacity detection device sends a warning instruction to the gas tank, so that the gas tank adjusts the delivery switch to a closed state.

[0067] After the gas cabinet receives the alarm command, it automatically closes the butterfly valve of the inlet pipeline and ignites and disperses the residual gas in the inlet pipeline.

[0068] In some embodiments, the maximum stroke of the piston is 92 meters. When the pressure in the gas tank reaches 95% of the maximum stroke, that is, the threshold is higher than 87.4 meters, the system will refuse to recover the gas, the PLC will output an alarm, and the butterfly valve at the gas tank inlet will be automatically closed. The excess gas will be ignited and released. At this time, as the external gas is output, the gas in the cabinet gradually decreases, and the piston position gradually decreases.

[0069] The gas tank capacity detection method provided in the above embodiment calculates the gas tank capacity by real-time detection of various parameters of the gas tank piston and combining target value function approximation, piston running speed and acceleration, mean filtering and other model algorithms, thereby improving the accuracy of the gas tank capacity data; when the gas tank capacity is higher than the critical value, the air intake is stopped in time to avoid the occurrence of piston top impact accidents.

[0070] In some embodiments, the present application provides a gas tank capacity detection device, which is used in the gas tank capacity detection method described in the above embodiment, and the gas tank capacity detection device includes:

[0071] Box;

[0072] Touch screen for displaying target data and inputting piston related parameters;

[0073] Switches, used for data communication;

[0074] Power supplies, used to transmit electrical energy;

[0075] Controller, sends control instructions.

[0076] The gas tank capacity detection device is arranged on the gas tank. The gas tank in this embodiment is provided with a gas tank piston, including a winch, a wire rope, and a coupling. One end of the wire rope is coiled on the winch drum, and the other end is fixed on the piston of the piston gas tank. The gas tank capacity detection device is wirelessly connected to the encoder arranged on the gas tank. The encoder is installed on the output shaft of the cabinet capacity indicator gearbox, and the shaft diameter is Φ10. The encoder consists of a connecting shaft, a code disk, a light source and an output circuit. After being softly connected to the rear shaft of the drum, it can still remember the original position after multiple disordered turns, so as to accurately locate. The encoder adopts parallel BCD code output to provide a unique coded digital value for each axis position, with extremely high anti-interference and reliability. The encoder adopts multi-turn absolute value measurement, allocates a fixed encoder address and bus terminal RT, and applies functions such as speed transfer and expansion scaling. The encoder uses a working voltage of DC10V-30V, a power of 2.5W, a bus interface of optocoupler insulated power supply, a baud rate range of 19.2KMBaud-12MBaud, and an accuracy of up to 14 bits.

[0077] The encoder is connected to the controller of the S7-1200 compact gas tank capacity detection device through the Profibus-DP bus, and sends the BCD code of the current code value and the code value change speed to the controller. After receiving the code, the controller calculates the height and running speed of the piston, and then communicates to the touch screen, and outputs the analog value to the DCS system.

[0078] In some embodiments, the controller and the switch are configured and communicated via PROFIBUS-DP, and the controller and the touch screen are connected using the Profinet Ethernet protocol.

[0079] In some embodiments, the controller of the gas tank capacity detection device is electrically connected to the encoder, and the controller receives different analog and switch signals that are decoded and calculated and output by the encoder based on BCD codes.

[0080] In some embodiments, a door body is installed at the front end of the gas tank capacity detection device, and an explosion-proof glass window is hingedly installed on the upper side of the door body; wherein the frame of the explosion-proof glass window is tightly connected to the door body by bolts.

[0081] In some embodiments, a cable entry hole is provided at the lower end of the gas tank capacity detection device, and the cable entry hole adopts a rubber sealing design. The power cord, PROFIBUS cable, and signal line pass through the entry hole in sequence and are connected to the box.

[0082] The gas tank capacity detection device described in this embodiment has an overall size (height*width*depth): 800mm*600mm*500mm. Two doors are installed on the front of the gas tank capacity detection device, which can be opened selectively. The upper part is twisted with a carbon steel explosion-proof circular glass window. The surrounding frame of the explosion-proof glass window is tightly connected to the door by bolts. The internal PLC CPU operation status can be seen through the glass. A 12-inch touch screen is installed above the glass window of the gas tank capacity detection device, and the dial opening size is: width 310mm, height 221mm; an AC220V power indicator light and a main power switch are installed on the door below the explosion-proof glass window. The gas tank piston operation parameters can be detected online through the touch screen screen. After the door below the gas tank capacity detection device is opened, the wiring terminals, circuit breakers, power modules and other equipment can be seen, which is conducive to daily equipment inspection and maintenance, and also avoids the problem that the S7-1200PLC, touch screen and other instrumentation and control equipment are not explosion-proof. The gas tank capacity detection device described in the present invention has a cable entry opening on the lower outer side, and a rubber seal design is adopted at the opening. The power cable, PROFIBUS cable, and signal cable enter the gas tank capacity detection device after passing through the clamping nut, washer, and sealing rubber ring in sequence. The device is installed near the on-site encoder, which also serves to isolate it from the surrounding gas area environment and achieve explosion-proof effect. Figure 2 As shown, the gas tank capacity detection device provided in this embodiment includes a power indicator light 1, a main power switch 2, an S7-1200 compact PLC 3, a touch screen 4, a fixing bolt hole 5, a switch 6, an air switch 7, a 220V / 24V power supply 8, a glass window and a box door sealing ring 9, a rubber seal 10, a gasket 11, a tightening nut 12, and a cabinet cable 13, thereby completing the installation and detection of the process detection explosion-proof device.

[0083] The gas tank capacity detection device provided in this application is suitable for the encoder tank capacity meter. The code value is output to the on-site explosion-proof device through PROFIBUSDP. With the help of the target value function approximation, the speed and acceleration of the piston operation, the mean filter and other model algorithms in the PLC program in the device, the gas tank piston height, piston speed and gas capacity, gas capacity change rate and piston high limit, piston high limit, piston low limit, piston low limit, piston speed high limit alarm and other functions are output to achieve data reliability processing; the encoder connected to the gas tank capacity detection device adopts a multi-turn photoelectric rotary structure of Pepperl+Fuss. Through photoelectric conversion, the mechanical quantities such as the angular displacement and angular velocity of the output shaft are converted into corresponding electrical pulses to output digital quantities (REP). The controller in the gas tank capacity detection device adopts a Siemens S7-1200 programmable controller, which communicates with the same type of Siemens touch screen, realizes rapid calibration on the visual interface, and realizes data transmission between the hard line and the DCS at the same time, and displays the value on the monitoring screen. It has the characteristics of small size, convenient on-site installation, strong anti-interference ability, safe explosion-proof, waterproof, anti-corrosion and maintenance-free. Based on the gas tank capacity detection device, the current piston height, maximum piston stroke, cross-sectional area of ​​the gas tank, high-high limit, high limit, low limit, and low-low limit alarm values ​​can be set through the touch screen.

[0084] As can be seen from the above embodiments, the present application provides a gas tank capacity detection method and detection device, the method comprising: the gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank after receiving the tank capacity detection instruction; calculates the piston cross-sectional area based on the current height of the piston; calculates the first ratio of the piston stroke according to the piston cross-sectional area and the maximum stroke; multiplies the first ratio by the unit stroke to obtain the unit volume of the gas tank; calculates the actual tank capacity value based on the current height of the piston and the unit volume; when the actual tank capacity value is higher than the preset threshold, the gas tank capacity detection device sends a warning instruction to the gas tank, so that the gas tank adjusts the delivery switch to a closed state. The present application calculates the gas tank capacity by real-time detection of multiple parameters of the gas tank piston, combined with target value function approximation, piston running speed and acceleration, mean filtering and other model algorithms, and stops the intake of gas in time when the gas tank capacity is higher than the critical value, thereby improving the accuracy of the gas tank capacity data and avoiding the occurrence of piston top collision accidents.

[0085] Similar parts between the embodiments provided in this application can be referenced to each other. The specific implementation methods provided above are only a few examples under the general concept of this application and do not constitute a limitation on the protection scope of this application. For those skilled in the art, any other implementation methods expanded based on the scheme of this application without creative work belong to the protection scope of this application.

Claims

1. A gas tank capacity detection method, characterized in that: The method comprises: After receiving the tank capacity detection instruction, the gas tank capacity detection device obtains the current height, piston diameter and maximum stroke of the piston in the gas tank; Calculate the piston cross-sectional area based on the piston diameter; Calculating a first ratio of the piston stroke according to the piston cross-sectional area and the maximum stroke; Multiplying the first ratio by the unit stroke to obtain the unit volume of the gas tank; The actual cabinet capacity is calculated based on the current height of the piston and the unit volume; When the actual tank capacity value is higher than a preset threshold, the gas tank capacity detection device sends a warning instruction to the gas tank, so that the gas tank adjusts the delivery switch to a closed state.

2. The gas tank capacity detection method according to claim 1, characterized in that: The method comprises: The gas tank capacity detection device analyzes the tank capacity detection instruction to obtain a piston displacement signal; Calculating the current height and current piston movement rate of the piston in the gas tank based on the displacement signal; The unit stroke of the piston is obtained by multiplying the current piston movement rate by the unit time.

3. The gas tank capacity detection method according to claim 1, characterized in that: The method further comprises: After the gas cabinet receives the alarm instruction, the gas cabinet automatically closes the butterfly valve of the inlet pipeline and ignites and disperses the residual gas in the inlet pipeline.

4. The gas tank capacity detection method according to claim 1, characterized in that: The method comprises: The gas tank capacity detection device uploads the actual tank capacity value to the server after calculating the actual tank capacity value each time; The server calculates the number of abnormal times that the actual cabinet capacity value exceeds a preset threshold value within a preset duration at every preset time interval; When the number of abnormalities exceeds a preset safety number, a maintenance instruction is generated and sent to a target person, so that the target person inspects the gas cabinet.

5. The gas tank capacity detection method according to claim 4, characterized in that: The gas tank capacity detection device obtains the current height, diameter and maximum stroke of the piston in the gas tank at preset intervals. as well as, The packaged data packet is sent to the server in combination with the server communication protocol format.

6. A gas tank capacity detection device, characterized in that: The gas tank capacity detection device is used to perform the gas tank capacity detection method according to any one of claims 1 to 5, and the gas tank capacity detection device includes: Box; Touch screen for displaying target data and inputting piston-related parameters; Switches, used for data communication; Power supply, used to transmit electrical energy; Controller, sends control instructions.

7. The gas tank capacity detection device according to claim 6, characterized in that: The controller and the switch are configured and communicated via PROFIBUS-DP, and the controller and the touch screen are connected using the Profinet Ethernet protocol.

8. The gas tank capacity detection device according to claim 7, characterized in that: The controller of the gas tank capacity detection device is electrically connected to the encoder, and the controller receives different analog and switch value signals decoded and calculated and output by the encoder based on BCD code.

9. The gas tank capacity detection device according to claim 6, characterized in that: A door body is installed at the front end of the gas tank capacity detection device, and an explosion-proof glass window is hingedly installed on the upper side of the door body; wherein, the frame of the explosion-proof glass window is tightly connected to the door body by bolts.

10. The gas tank capacity detection device according to claim 6, characterized in that: A cable entry hole is provided at the lower end of the gas tank capacity detection device. The cable entry hole adopts a rubber sealing design. The power cord, PROFIBUS cable and signal line pass through the entry hole in sequence and are connected to the box.

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