Circulating water automatic control system of wire drawing machine

Abstract

The invention discloses an automatic control system for circulating water of a wire drawing machine, and relates to the technical field of automatic control for external cooling of cooling water of a winding drum of the wire drawing machine, the automatic control system comprises an intelligent control unit, a wire drawing machine table, a circulating water device and sensors, and the sensors comprise a temperature sensor and a pressure sensor; a pressure sensor is installed at the wire drawing machine terminal, the intelligent control unit receives sensor data through a PLC and controls the circulating water device to operate, the input end of the intelligent control unit receives the sensor data, and the output end of the intelligent control unit transmits a control signal to control the circulating water device; the control program is controlled by using a PID algorithm, and the intelligent control unit establishes a self-adaptive mathematical model. Through the intelligent control unit, the function of unmanned intelligent operation of the circulating water control system is achieved, and the problem that water temperature and water pressure matched with a machine table cannot be achieved through manual control, and waste of a large amount of energy is caused is solved.

Description

Technical Field

[0001] The invention relates to the technical field of automatic control of external cooling of cooling water of a wire drawing machine drum, in particular to an automatic control system for circulating water of a wire drawing machine. Background Art

[0002] With the continuous development and progress of industrial production, the demand for metal products, plastic products, wires and cables and other products in various industries continues to grow. As an important equipment in the production process of these products, the operating efficiency and quality of the wire drawing machine are crucial to the entire production process. The circulating water automatic control system can provide stable cooling and lubrication for the wire drawing machine, ensure the normal operation of the wire drawing machine, and meet the needs of industrial production for efficient and high-quality production.

[0003] The working principle of the original circulating water cooling is described as follows: the circulating water pump sends 25°C water from the circulating water pool to each wire drawing machine. When the wire drawing machine is running, the wire drawing machine reel is cooled. After cooling, the high-temperature water flows back into the circulating water pool through the pipe, and enters the 3# pool after cooling and sedimentation in the 1# and 2# pools. The water in the 3# pool is pumped to the cooling tower by the pump and then cooled by the fan. All pumps and fans are controlled manually. This control method has the following defects: (1) Manual control cannot achieve the water temperature and water pressure that match the machine, resulting in energy waste; (2) There is no water pressure detection at the machine, and the number of circulating water pumps that are turned on cannot be controlled by water pressure data, resulting in energy waste; (3) The motor operates at industrial frequency, with low efficiency and high energy consumption.

[0004] Therefore, it is very necessary for the present application to propose an automatic control system for circulating water of a wire drawing machine to solve the problems in the background.

[0005] 1. Patent document CN105717965B discloses a constant temperature and constant pressure circulating water automatic control system for fluid-solid coupling model tests. The above patent realizes automatic control and adjustment of the temperature and pressure of the water body, maintains the constant temperature and pressure of the water body, and improves the accuracy of the simulation test. However, the above patent cannot realize the function of unmanned intelligent operation of the circulating water control system.

[0006] 2. Patent document CN117215255B discloses an automated energy-saving and consumption-reducing operation control system for an industrial circulating water system. The above patent realizes energy-saving and consumption-reducing and automated operation control of the industrial circulating water system, and can improve the energy efficiency performance of the circulating water system, reduce system energy consumption, and thus reduce factory operating costs. However, the above patent cannot realize the function of automatic control.

[0007] 3. Patent document CN112214044B discloses a circulating water automatic control system and method based on total amount control. The above patent can avoid the interference of the continuous fluctuation of make-up water quality on the circulating water system and stabilize the continuous operation of the circulating water system, but the above patent cannot realize the function of real-time monitoring of pressure value.

[0008] 4. Patent document CN114163068B discloses a control system for an added carbon source in a recirculating aquaculture. The above patent realizes the automatic addition of additional carbon sources during the aquaculture process. The amount of addition is precise and highly controllable, and can effectively extend the interval time for changing the aquaculture water body. However, the above patent cannot realize the function of accurately controlling the speed of the circulating water pump.

[0009] In summary, the above patent cannot realize the functions of unmanned intelligent operation of the circulating water control system, real-time monitoring of pressure values, precise control of the speed of the circulating water pump, and automatic control, resulting in the inability of manual control to achieve the water temperature and water pressure that match the machine, and the inability to control the number of circulating water pumps opened through water pressure data. The motor is operated at industrial frequency, and the circulating water automatic control system has low efficiency and high energy consumption.

[0010] To this end, the present application proposes a wire drawing machine circulating water automatic control system that can realize the functions of unmanned intelligent operation of the circulating water control system, real-time monitoring of pressure values, precise control of the circulating water pump speed and automatic control. Summary of the invention

[0011] The purpose of the present invention is to provide an automatic control system for circulating water of a wire drawing machine to solve the technical problems proposed in the above background technology that the functions of unmanned intelligent operation of the circulating water control system, real-time monitoring of pressure values, precise control of the speed of the circulating water pump and automatic control cannot be realized, resulting in manual control failing to achieve water temperature and water pressure that match the machine, failure to control the number of circulating water pumps opened through water pressure data, the motor operating at industrial frequency, low efficiency of the circulating water automatic control system and high energy consumption.

[0012] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an automatic control system for circulating water of a wire drawing machine, comprising an intelligent control unit, a wire drawing machine, a circulating water device and a sensor, wherein the sensor comprises a temperature sensor and a pressure sensor; a pressure sensor is installed at the terminal of the wire drawing machine, the intelligent control unit receives sensor data through a PLC and controls the operation of the circulating water device, the input end of the intelligent control unit receives the sensor data, and the output end of the intelligent control unit transmits a control signal to control the circulating water device; the control program of the intelligent control unit monitors the pressure and temperature on site in real time, the control program uses a PID algorithm for control, and the intelligent control unit establishes an adaptive mathematical model;

[0013] The pressure sensor measures the actual pressure value P of the circulating water. actual , convert the actual pressure value into an electrical signal and transmit it to the PLC, which stores the set pressure value P set , PLC calculates the deviation e(k) = P set -P actual (k), P actual (k) is the actual pressure value measured in the kth control cycle, k represents the kth sampling cycle; when the actual pressure value P actual (k) Less than the set pressure value P set , the deviation e(k) is positive, and the PLC positively feeds back to the circulating water device; when the actual pressure value P actual (k) Greater than the set pressure value P set , the deviation e(k) is negative, and the PLC reversely feeds back to the circulating water device;

[0014] The PID parameters are updated according to the adaptive adjustment rules. The adaptive adjustment rules establish a mathematical model of the automatic control system of the circulating water of the wire drawing machine according to the physical characteristics and historical operation data of the circulating water system of the wire drawing machine, and adjust the proportional coefficient K of the PID p The adaptive auxiliary circulating water automatic control system of the mathematical model is compatible with different types of wire drawing machines, circulating water equipment and auxiliary equipment.

[0015] Preferably, the PID algorithm inputs a deviation e(k), and outputs a control signal u(k) through proportion, integration and differentiation. The control behavior limit values ​​preset by the PLC are: low threshold T1 and high threshold T2; when u(k) is lower than the low threshold T1, a water pump is started; when u(k) exceeds the high threshold T2, two / more water pumps are started; the action of the water pump affects the value of the controlled variable, forming a feedback loop, and the intelligent control unit outputs a signal to control the actuator, which is fixedly installed inside the basic platform, and the basic platform is built 1-3 meters next to the circulating water pool. The circulating water pool is a kind of circulating water device, and the circulating water device is connected to the frequency converter through a shielded data cable. The analog output module of the PLC leads to the corresponding analog signal cable connected to the analog input terminal of the frequency converter, and the frequency converter adjusts the circulating water device by receiving the analog signal;

[0016] The circulating water device includes a circulating water pump, a cooling water pump, a cooling fan and a circulating water pool. The circulating water pump extracts water from the circulating water pool and transmits it to the wire drawing machine. The cooling water pump and the cooling fan work together to cool the water in the circulating water pool.

[0017] Pressure sensors are distributed at the inlet of the wire drawing machine, the outlet of the circulating water pump and the inlet of the cooling tower. The intelligent control unit receives the water pressure data from the pressure sensor. The intelligent control unit runs the PID algorithm for comprehensive analysis and then controls the speed and start and stop number of the circulating water pump. When the actual pressure value is lower than the set value, PID increases the speed of the water pump and feeds back the pressure sensor to increase the pressure.

[0018] Preferably, the circulating water pool includes pool 1#, pool 2# and pool 3#. Water enters pool 3# after cooling and settling in pool 1# and pool 2#. Temperature sensors are set at the return water inlet and middle of pool 1#, and temperature sensors are set at the water inlet and low / step depth of pool 3#.

[0019] The intelligent control unit dynamically adjusts the speed of the cooling fan, the flow rate of the circulating water pump and the water pump according to the data collected by the temperature sensor, so that the temperature of the circulating water in different areas can be kept in dynamic balance;

[0020] Mechanical filters are installed at the inlet and outlet of the circulating water system, and filters are installed at the front end of the water inlet of the circulating water pump to intercept metal chips and plastic fragments in the water;

[0021] An installation hole is opened on the circulating water pipeline, and the ultrasonic processor is fixedly installed on the wall of the circulating water pipeline through the installation hole. Ultrasonic waves produce cavitation effect in water, and tiny bubbles in the water burst, generating high temperature, high pressure and strong shock waves. The process of generating shock waves and the shock waves themselves kill microorganisms and help decompose organic matter and suspended particles in the water. The input end of the ultrasonic processor is connected to the output terminal of the inverter.

[0022] Preferably, the wire drawing machine is connected to a motor via a data line, the output terminal of the motor is connected to the output end of the frequency converter via the data line, and the PID algorithm feeds back the calculation result to the frequency converter to control the motor; a water flow sensor is set at the key nodes of the circulating water pipeline (the inlet and outlet of the water pump, the connection of the branch pipe and the total inlet and outlet of the system), the water flow sensor is connected to the intelligent control unit via wireless transmission, and the water flow sensor outputs a digital signal to the intelligent control unit;

[0023] The water flow sensor detects that the local water flow is too small / too large, and the intelligent control unit receives the digital signal to adjust the frequency and operation quantity of the water pump;

[0024] When the water flow rate exceeds 130% of the normal upper limit for 1-2 minutes, the water flow rate is lower than 70% of the normal lower limit for 3-5 minutes;

[0025] When the water pressure is higher than 120% of the normal upper limit for 1-3 minutes, the water pressure is lower than 80% of the normal lower limit for 2-5 minutes;

[0026] When the water temperature exceeds 110% of the normal upper limit for 1-3 minutes, and the water temperature is lower than 90% of the normal lower limit for 4-6 minutes; if the sensor detects any abnormal data, the intelligent control unit will initially determine that there is a fault;

[0027] The PLC control system sends out fault warning signals remotely through the communication network, and automatically adjusts (starts cooling fans, adjusts the number / speed of water pumps, and activates standby water pumps) for self-repair;

[0028] When self-repair is successful, the intelligent control unit transmits the fault condition and repair measures to the cloud storage platform through the network;

[0029] When self-repair fails, the intelligent control unit identifies different fault types and locations through fault codes, clearly indicating the fault location and type.

[0030] Preferably, the wire drawing machine circulating water automatic control system also includes a control cabinet panel, which is convenient for operators to view and operate during inspection / daily maintenance. A touch screen is fixedly installed on the outer wall of the control cabinet panel. The touch screen displays the changes of monitoring values ​​and set values. The operator views the operation status of the wire drawing machine circulating water automatic control system through the touch screen.

[0031] Preferably, the intelligent control unit optimizes the operating parameters of the circulating water device based on the historical circulating water automatic control system operating data and real-time sensor data according to the results of deviation analysis. When the wire drawing machine operates at low load, the intelligent control unit automatically reduces the circulating water flow rate, cooling intensity and the speed of the circulating water pump.

[0032] Preferably, the control cabinet panel is connected to the remote terminal via the network, and the operator views the real-time operating parameters (water pressure, water temperature, water flow) of the circulating water system through the terminal. Under authorization, the operator operates the wire drawing machine circulating water automatic control system (adjusting equipment parameters, starting / stopping equipment) through the remote terminal; the remote terminal integrates maintenance and fault management software, and the maintenance and fault management software includes fault diagnosis functions and maintenance plan generation; when the circulating water system detects a fault, the software performs fault diagnosis through the built-in knowledge base and provides a detailed repair guide; the software automatically generates maintenance logs and reminds maintenance personnel to perform preventive maintenance on a regular basis.

[0033] Preferably, the operating data of the circulating water automatic control system includes but is not limited to water pressure change curve, water temperature fluctuation, equipment operation time and frequency. The intelligent control unit analyzes the data and generates an operation report to provide data support for optimizing system performance, predicting equipment failures and formulating maintenance plans. The circulating water automatic control system is integrated with different models of wire drawing machines, circulating water equipment and auxiliary equipment, and the touch screen provides operating instructions and help documents.

[0034] Preferably, when the wire drawing machine is running at a low load, the intelligent control unit reduces the working intensity of the cooling water pump and the cooling fan by real-time monitoring the data of the multi-point temperature sensors. The cooling fan cools the water temperature by forced air flow during the water circulation process, thereby reducing the flow of air on the water surface, reducing evaporation and heat dissipation; the intelligent control unit also reduces the flow rate of the cooling water pump and reduces the wind speed of the cooling fan.

[0035] Preferably, the optimization system performance collects and analyzes water pressure, water temperature, water flow rate through sensors, PID parameters are fed back to the cloud solution, software generates periodic reports, and the remote terminal and touch screen display optimization suggestions and system status.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] 1. The present invention realizes the function of unmanned intelligent operation of the circulating water control system through an intelligent control unit, solving the problem that manual control cannot achieve the water temperature and water pressure that match the machine, resulting in a large amount of energy waste;

[0038] 2. The present invention realizes the functions of real-time monitoring and automatic control through the PLC control system, solves the problem of backward production and low quality caused by manual operation, improves the degree of automation, improves production efficiency, reduces human errors and reduces labor costs;

[0039] 3. The present invention realizes the function of real-time monitoring of pressure value through the pressure sensor, solves the problem that the number of circulating water pumps cannot be controlled by water pressure data, and improves the comfort of the audience;

[0040] 4. The present invention realizes the function of accurately controlling the speed of the circulating water pump through the frequency converter, and solves the problem that the motor runs at industrial frequency, resulting in low efficiency and high energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a schematic diagram of the flow of the automatic control system for circulating water of a wire drawing machine of the present invention. DETAILED DESCRIPTION

[0042] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0043] See also Figure 1, an embodiment provided by the present invention: an automatic control system for circulating water of a wire drawing machine, comprising an intelligent control unit, a wire drawing machine, a circulating water device and a sensor, wherein the sensor comprises a temperature sensor and a pressure sensor; a pressure sensor is installed at a terminal of the wire drawing machine, the intelligent control unit receives sensor data through a PLC and controls the operation of the circulating water device, the input end of the intelligent control unit receives the sensor data, and the output end of the intelligent control unit transmits a control signal to control the circulating water device;

[0044] The control program of the intelligent control unit monitors the on-site pressure and temperature in real time, and the control program uses a PID algorithm for control; the pressure sensor measures the actual pressure value P of the circulating water actual , convert the actual pressure value into an electrical signal and transmit it to the PLC, which stores the set pressure value P set , PLC calculates the deviation e(k) = P set -P actual (k), Pactual(k) is the actual pressure value measured in the kth control cycle, k represents the kth sampling cycle; when the actual pressure value P actual (k) Less than the set pressure value P set , the deviation e(k) is positive, and the PLC positively feeds back to the circulating water device; when the actual pressure value P actual (k) Greater than the set pressure value P set , the deviation e(k) is negative, and the PLC reversely feeds back the circulating water device; the PID parameters are updated according to the adaptive adjustment rules, and the adaptive adjustment rules establish a mathematical model of the automatic control system of the circulating water of the wire drawing machine according to the physical characteristics and historical operation data of the circulating water system of the wire drawing machine, and adjust the proportional coefficient K of the PID p , the adaptive auxiliary circulating water automatic control system of the mathematical model is compatible with different types of wire drawing machines, circulating water equipment and auxiliary equipment;

[0045] Furthermore, an intelligent control unit and a PLC control system are installed, pressure sensors are installed at the wire drawing machine terminal, the circulating water pump outlet and the cooling tower inlet, temperature sensors are installed at key locations of the 1# pool and the 3# pool, and water flow sensors are installed at key nodes of the circulating water pipeline. The existing circulating water pump, cooling water pump and cooling fan are connected to the frequency converter and connected to the PLC through a shielded data cable. A control cabinet panel is equipped with a touch screen for on-site operation and monitoring. The water pressure and water temperature are accurately controlled through the PID algorithm, which significantly improves the cooling effect of the wire drawing machine and makes the product quality more stable. The system automatically adjusts the operation of the water pump and fan according to the production load, achieving energy savings of about 20%.

[0046] See also Figure 1, an embodiment provided by the present invention: an automatic control system for circulating water of a wire drawing machine, the PID algorithm inputs a deviation e(k), and outputs a control signal u(k) through proportion, integration and differentiation, and the control behavior limit values ​​preset by the PLC are: low threshold value T1 and high threshold value T2; when u(k) is lower than the low threshold value T1, a water pump is started; when u(k) exceeds the high threshold value T2, two / more water pumps are started; the action of the water pump affects the value of the controlled variable to form a feedback loop, and the intelligent control unit outputs a signal to control the actuator, and the actuator is fixedly installed inside the basic platform, and the basic platform is built 1-3 meters next to the circulating water pool, and the circulating water pool is a kind of circulating water device, and the circulating water device is connected to the frequency converter through a shielded data line The analog output module of the PLC leads out the corresponding analog signal cable to the analog input terminal of the frequency converter. The frequency converter adjusts the circulating water device by receiving the analog signal. The circulating water device includes a circulating water pump, a cooling water pump, a cooling fan and a circulating water pool. The circulating water pump extracts water from the circulating water pool and transmits it to the wire drawing machine. The cooling water pump and the cooling fan work together to cool the water in the circulating water pool. The pressure sensors are distributed at the inlet of the wire drawing machine, the outlet of the circulating water pump and the inlet of the cooling tower. The intelligent control unit receives the water pressure data of the pressure sensor. The intelligent control unit runs the PID algorithm for comprehensive analysis and controls the speed and start and stop number of the circulating water pump. When the actual pressure value is lower than the set value, the PID increases the speed of the water pump to feedback the pressure sensor to increase the pressure.

[0047] The circulating water pool includes pool 1#, pool 2# and pool 3#. After cooling and settling in pool 1# and pool 2#, water enters pool 3#. Temperature sensors are set at the return water inlet and the middle of pool 1#, and temperature sensors are set at the water inlet and the bottom / step depth of pool 3#. The intelligent control unit dynamically adjusts the speed of the cooling fan, the flow rate of the circulating water pump and the water pump according to the data collected by the temperature sensor, so that the water temperature of the circulating water in different areas is kept in dynamic balance. Mechanical filters are installed at the inlet and outlet of the circulating water system, and a filter is installed at the front end of the water inlet of the circulating water pump to intercept metal chips and plastic fragments in the water. An installation hole is opened on the circulating water pipeline, and the ultrasonic processor is fixedly installed on the wall of the circulating water pipeline through the installation hole. Ultrasonic waves produce cavitation effect in the water, and tiny bubbles in the water burst, generating high temperature, high pressure and strong shock waves. The process of generating shock waves and the shock wave body kill microorganisms and help decompose organic matter and suspended particles in the water. The input end of the ultrasonic processor is connected to the output terminal of the inverter.

[0048] Furthermore, high-precision pressure, temperature and water flow sensors are selected to ensure the accuracy of data collection. The intelligent control unit is connected to the company's internal network to realize remote monitoring and operation functions. High-quality mechanical filters and ultrasonic processors are installed at the inlet and outlet of the circulating water pool and the water suction port of the circulating water pump. After production, the circulating water system operates stably, providing a stable cooling environment for the wire drawing machine, and the equipment failure rate is reduced by 30%. The remote monitoring function facilitates the management of the system by managers, and potential problems can be discovered and solved in time through data analysis, thereby improving production continuity.

[0049] See also Figure 1 , an embodiment provided by the present invention: an automatic control system for circulating water of a wire drawing machine, the wire drawing machine is connected to a motor through a data line, the output terminal of the motor is connected to the output end of the frequency converter through the data line, and the PID algorithm feeds back the calculation result to the frequency converter to control the motor; a water flow sensor is set at the key nodes of the circulating water pipeline (the inlet and outlet of the water pump, the connection of the branch pipe and the total inlet and outlet of the system), the water flow sensor is connected to the intelligent control unit through wireless transmission, and the water flow sensor outputs a digital signal to the intelligent control unit; the water flow sensor detects that the local water flow is too small / too large, and the intelligent control unit receives the digital signal to adjust the frequency and operation number of the water pump; when the water flow rate exceeds 130% of the normal upper limit for 1-2 minutes, and the water flow rate is lower than 70% of the normal lower limit for 3-5 minutes; when the water When the water pressure is higher than 120% of the normal upper limit for 1-3 minutes, and the water pressure is lower than 80% of the normal lower limit for 2-5 minutes; when the water temperature exceeds 110% of the normal upper limit for 1-3 minutes, and the water temperature is lower than 90% of the normal lower limit for 4-6 minutes; when the sensor detects any abnormal data, the intelligent control unit preliminarily determines that there is a fault; the PLC control system remotely sends a fault warning signal through the communication network, and automatically adjusts (starts the cooling fan, adjusts the number / speed of water pumps, and enables the standby water pump) for self-repair; when the self-repair is successful, the intelligent control unit transmits the fault situation and repair measures to the cloud storage platform through the network; when the self-repair fails, the intelligent control unit uses the fault code to identify different fault types and locations, and clearly indicates the fault location and type;

[0050] Furthermore, the entire circulating water system is divided into multiple sub-areas, each sub-area corresponds to one or more groups of wire drawing machines, and independent sensors are installed at key locations such as the wire drawing machines, circulating water pumps, cooling towers, etc. in each sub-area, and connected to their respective PLC control systems. The PLC control systems of each sub-area are connected to the intelligent control unit in the main control room through the network to achieve centralized management and zoning control. Zoning control enables the circulating water systems of different production areas to operate independently according to actual needs, thereby improving the flexibility and adaptability of the system. When the production tasks in some areas are lighter, the operating power of the circulating water system in that area can be reduced individually, achieving energy savings of approximately 25%.

[0051] See also Figure 1 , an embodiment provided by the present invention: an automatic control system for circulating water of a wire drawing machine, the automatic control system for circulating water of the wire drawing machine also includes a control cabinet panel, the control cabinet panel is convenient for operators to view and operate during inspection / daily maintenance, a touch screen is fixedly installed on the outer wall of the control cabinet panel, the touch screen screen displays the modification of monitoring values ​​and set values, and the operator views the operation status of the automatic control system for circulating water of the wire drawing machine through the touch screen;

[0052] The control cabinet panel is connected to the remote terminal through the network, and the operator can view the real-time operating parameters (water pressure, water temperature, water flow) of the circulating water system through the terminal. Under the authorization, the operator can operate the automatic control system of the circulating water of the wire drawing machine through the remote terminal (adjust equipment parameters, start / stop equipment); the remote terminal integrates maintenance and fault management software, and the maintenance and fault management software includes fault diagnosis function and maintenance plan generation; when the circulating water system detects a fault, the software performs fault diagnosis through the built-in knowledge base and provides a detailed repair guide; the software automatically generates a maintenance log and reminds maintenance personnel to perform preventive maintenance regularly;

[0053] The operating data of the circulating water automatic control system includes but is not limited to the water pressure change curve, water temperature fluctuation, equipment operation time and frequency. The intelligent control unit analyzes the data and generates an operation report to provide data support for optimizing system performance, predicting equipment failures and formulating maintenance plans. The circulating water automatic control system is integrated with different models of wire drawing machines, circulating water equipment and auxiliary equipment, and the touch screen provides operation instructions and help documents;

[0054] Furthermore, on the basis of the existing circulating water system, the software algorithm of the intelligent control unit is upgraded, the analysis function based on historical data and real-time data is strengthened, the circulating water pump, cooling water pump and cooling fan are comprehensively inspected and maintained, and some old equipment is replaced with more efficient energy-saving equipment. Liquid level sensors are added to the system to accurately control the water level of the circulating water pool to avoid energy waste caused by unreasonable water level. After the transformation, the system can more accurately adjust the equipment operation status according to the production load, achieving a reduction of about 30% in energy consumption. The addition of liquid level sensors ensures the stable operation of the circulating water system and reduces failures caused by water level problems.

[0055] See also Figure 1 , an embodiment provided by the present invention: a wire drawing machine circulating water automatic control system, the intelligent control unit optimizes the operating parameters of the circulating water device according to the result of deviation analysis based on the historical circulating water automatic control system operating data and real-time sensor data, and when the wire drawing machine is running at low load, the intelligent control unit automatically reduces the circulating water flow, cooling intensity and the speed of the circulating water pump;

[0056] When the wire drawing machine is running at low load, the intelligent control unit reduces the working intensity of the cooling water pump and the cooling fan by real-time monitoring the data of the multi-point temperature sensor. The cooling fan cools the water temperature by forced air flow during the water circulation process, reduces the flow of air on the water surface, and reduces evaporation and heat dissipation. The intelligent control unit also reduces the flow of the cooling water pump and the wind speed of the cooling fan.

[0057] The optimization system performance is collected and analyzed by sensors for water pressure, water temperature, water flow rate, PID parameter feedback to the cloud solution, software generates periodic reports, and remote terminals and touch screens display optimization suggestions and system status;

[0058] Furthermore, a special communication interface is developed for the circulating water automatic control system so that it can be seamlessly connected with the MES (manufacturing execution system) and SCADA (supervisory control and data acquisition) systems in the factory. The intelligent control unit uploads the real-time operating data of the circulating water system (such as water pressure, water temperature, water flow, etc.) to the MES and SCADA systems, and receives production plans and control instructions from these systems at the same time. According to the production plan, the circulating water automatic control system can adjust the operating parameters in advance, such as automatically increasing the cooling intensity before the production peak arrives. After being integrated with the factory's automated production system, the circulating water automatic control system can better match the production rhythm and ensure the efficient operation of wire drawing production. Managers can comprehensively monitor and manage the circulating water system through the MES and SCADA systems, thereby improving the efficiency of production management and the scientific nature of decision-making.

[0059] Working principle: The pressure sensors at the wire drawing machine terminal, the outlet of the circulating water pump and the inlet of the cooling tower measure the actual pressure value Pactual of the circulating water, and convert it into an electrical signal and transmit it to the PLC. The PLC uses the PID algorithm to control the number of starts of the circulating water pump according to the comparison result between u(k) and the preset control behavior limit value. The intelligent control unit dynamically adjusts the speed of the cooling fan, the flow rate of the circulating water pump and the water pump according to the data of the temperature sensor to achieve dynamic balance of the water temperature of the circulating water in different areas. The intelligent control unit receives the signal and adjusts the frequency and number of operations of the water pump. At the same time, when the water flow rate, water pressure and water temperature exceed the normal range for a certain period of time, the intelligent control unit preliminarily determines that there is a fault. The PLC control system remotely sends a fault warning signal through the communication network. The system first automatically adjusts and transmits the fault condition and repair measures to the cloud storage platform. If the self-repair fails, the intelligent control unit identifies the fault location and type through the fault code. The control cabinet panel is connected to the remote terminal through the network, and the operator can view the real-time operating parameters at the remote terminal.

[0060] An ultrasonic processor is installed on the circulating water pipeline, and its operation is controlled by a frequency converter. The cavitation effect generated by ultrasound in water is used to kill microorganisms and decompose organic matter and suspended particles in the water.

[0061] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A wire drawing machine circulating water automatic control system, characterized in that: It includes an intelligent control unit, a wire drawing machine, a circulating water device and a sensor, wherein the sensor includes a temperature sensor and a pressure sensor; a pressure sensor is installed at the terminal of the wire drawing machine, the intelligent control unit receives sensor data through a PLC and controls the operation of the circulating water device, the input end of the intelligent control unit receives the sensor data, and the output end of the intelligent control unit transmits a control signal to control the circulating water device; the control program of the intelligent control unit monitors the on-site pressure and temperature in real time, the control program uses a PID algorithm for control, and the intelligent control unit establishes an adaptive mathematical model; The pressure sensor measures the actual pressure value P of the circulating water. actual , convert the actual pressure value into an electrical signal and transmit it to the PLC, which stores the set pressure value P set , PLC calculates the deviation e(k) = P set -P actual (k), P actual (k) is the actual pressure value measured in the kth control cycle, k represents the kth sampling cycle; when the actual pressure value P actual (k) Less than the set pressure value P set , the deviation e(k) is positive, and the PLC positively feeds back to the circulating water device; when the actual pressure value P actual (k) Greater than the set pressure value P set , the deviation e(k) is negative, and the PLC reversely feeds back to the circulating water device; The PID parameters are updated according to the adaptive adjustment rules. The adaptive adjustment rules establish a mathematical model of the automatic control system of the wire drawing machine circulating water according to the physical characteristics of the wire drawing machine circulating water system and historical operation data, and adjust the proportional coefficient K of the PID p The adaptive auxiliary circulating water automatic control system of the mathematical model is compatible with different types of wire drawing machines, circulating water equipment and auxiliary equipment.

2. The automatic control system for circulating water of a wire drawing machine according to claim 1, characterized in that: The PID algorithm inputs a deviation e(k), and outputs a control signal u(k) through proportion, integration and differentiation. The control behavior limit values ​​preset by the PLC are: low threshold T1 and high threshold T2; when u(k) is lower than the low threshold T1, a water pump is started; when u(k) exceeds the high threshold T2, two / more water pumps are started; the action of the water pump affects the value of the controlled variable, forming a feedback loop, and the intelligent control unit outputs a signal to control the actuator, which is fixedly installed inside the basic platform, and the basic platform is built 1-3 meters next to the circulating water pool. The circulating water pool is a kind of circulating water device, and the circulating water device is connected to the frequency converter through a shielded data cable. The analog output module of the PLC leads to the corresponding analog signal cable connected to the analog input terminal of the frequency converter, and the frequency converter adjusts the circulating water device by receiving the analog signal; The circulating water device includes a circulating water pump, a cooling water pump, a cooling fan and a circulating water pool. The circulating water pump extracts water from the circulating water pool and transmits it to the wire drawing machine. The cooling water pump and the cooling fan work together to cool the water in the circulating water pool. Pressure sensors are distributed at the inlet of the wire drawing machine, the outlet of the circulating water pump and the inlet of the cooling tower. The intelligent control unit receives the water pressure data from the pressure sensor. The intelligent control unit runs the PID algorithm for comprehensive analysis and then controls the speed and start and stop number of the circulating water pump. When the actual pressure value is lower than the set value, PID increases the speed of the water pump and feeds back the pressure sensor to increase the pressure.

3. The automatic control system for circulating water of a wire drawing machine according to claim 2 is characterized in that: The circulating water pool includes pool 1#, pool 2# and pool 3#. Water enters pool 3# after cooling and settling in pool 1# and pool 2#. Temperature sensors are set at the return water inlet and middle of pool 1#, and temperature sensors are set at the water inlet and low / step depth of pool 3#. The intelligent control unit dynamically adjusts the speed of the cooling fan, the flow rate of the circulating water pump and the water pump according to the data collected by the temperature sensor, so that the temperature of the circulating water in different areas can be kept in dynamic balance; Mechanical filters are installed at the inlet and outlet of the circulating water system, and filters are installed at the front end of the water inlet of the circulating water pump to intercept metal chips and plastic fragments in the water; An installation hole is opened on the circulating water pipeline, and the ultrasonic processor is fixedly installed on the wall of the circulating water pipeline through the installation hole. Ultrasonic waves produce cavitation effect in water, and tiny bubbles in the water burst, generating high temperature, high pressure and strong shock waves. The process of generating shock waves and the shock waves themselves kill microorganisms and help decompose organic matter and suspended particles in the water. The input end of the ultrasonic processor is connected to the output terminal of the inverter.

4. The automatic control system for circulating water of a wire drawing machine according to claim 1, characterized in that: The wire drawing machine is connected to a motor via a data line, and the output terminal of the motor is connected to the output end of the frequency converter via the data line. The PID algorithm feeds back the calculation result to the frequency converter to control the motor; water flow sensors are set at key nodes of the circulating water pipeline (water pump inlet and outlet, branch pipe connection and system total inlet and outlet), and the water flow sensor is connected to the intelligent control unit via wireless transmission, and the water flow sensor outputs a digital signal to the intelligent control unit; The water flow sensor detects that the local water flow is too small / too large, and the intelligent control unit receives the digital signal to adjust the frequency and operation quantity of the water pump; When the water flow rate exceeds 130% of the normal upper limit for 1-2 minutes, the water flow rate is lower than 70% of the normal lower limit for 3-5 minutes; When the water pressure is higher than 120% of the normal upper limit for 1-3 minutes, the water pressure is lower than 80% of the normal lower limit for 2-5 minutes; When the water temperature exceeds 110% of the normal upper limit for 1-3 minutes, and the water temperature is lower than 90% of the normal lower limit for 4-6 minutes; if the sensor detects any abnormal data, the intelligent control unit will initially determine that there is a fault; The PLC control system sends out fault warning signals remotely through the communication network, and automatically adjusts (starts cooling fans, adjusts the number / speed of water pumps, and activates standby water pumps) for self-repair; When self-repair is successful, the intelligent control unit transmits the fault condition and repair measures to the cloud storage platform through the network; When self-repair fails, the intelligent control unit identifies different fault types and locations through fault codes, clearly indicating the fault location and type.

5. The automatic control system for circulating water of a wire drawing machine according to claim 1, characterized in that: The wire drawing machine circulating water automatic control system also includes a control cabinet panel, which is convenient for operators to view and operate during inspection / daily maintenance. A touch screen is fixedly installed on the outer wall of the control cabinet panel. The touch screen displays the changes of monitoring values ​​and set values. The operator views the operation status of the wire drawing machine circulating water automatic control system through the touch screen.

6. The automatic control system for circulating water of a wire drawing machine according to claim 1, characterized in that: The intelligent control unit optimizes the operating parameters of the circulating water device based on the historical circulating water automatic control system operating data and real-time sensor data according to the results of deviation analysis. When the wire drawing machine operates at low load, the intelligent control unit automatically reduces the circulating water flow, cooling intensity and the speed of the circulating water pump.

7. The automatic control system for circulating water of a wire drawing machine according to claim 5, characterized in that: The control cabinet panel is connected to the remote terminal through the network, and the operator can view the real-time operating parameters (water pressure, water temperature, water flow) of the circulating water system through the terminal. Under the authorization, the operator can operate the automatic control system of the circulating water of the wire drawing machine through the remote terminal (adjust equipment parameters, start / stop equipment); the remote terminal integrates maintenance and fault management software, and the maintenance and fault management software includes fault diagnosis function and maintenance plan generation; when the circulating water system detects a fault, the software performs fault diagnosis through the built-in knowledge base and provides a detailed repair guide; The software automatically generates maintenance logs and reminds maintenance personnel to perform preventive maintenance regularly.

8. The automatic control system for circulating water of a wire drawing machine according to claim 6, characterized in that: The operating data of the circulating water automatic control system includes but is not limited to water pressure change curve, water temperature fluctuation, equipment operation time and frequency. The intelligent control unit analyzes the data and generates an operation report to provide data support for optimizing system performance, predicting equipment failures and formulating maintenance plans. The touch screen provides operation instructions and help documents.

9. The automatic control system for circulating water of a wire drawing machine according to claim 6, characterized in that: When the wire drawing machine is running at low load, the intelligent control unit reduces the working intensity of the cooling water pump and the cooling fan by real-time monitoring the data of the multi-point temperature sensors. The cooling fan cools the water temperature by forced air flow during the water circulation process, reduces the flow of air on the water surface, and reduces evaporation and heat dissipation; the intelligent control unit also reduces the flow of the cooling water pump and reduces the wind speed of the cooling fan.

10. The automatic control system for circulating water of a wire drawing machine according to claim 8, characterized in that: The optimized system performance collects and analyzes water pressure, water temperature, and water flow rate through sensors, PID parameters are fed back to the cloud solution, the software generates periodic reports, and the remote terminal and touch screen display optimization suggestions and system status.

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