Emulsion pump loading valve speed regulation control system and working method thereof

Abstract

The invention discloses an emulsion pump loading valve speed regulation control system and a working method thereof. The emulsion pump loading valve speed regulation control system comprises a servo motor, a servo driver and an upper computer. The working method comprises the following steps: S1, inputting a pressure set value of the loading valve of the emulsion pump; s2, the upper computer calculates the input pressure set value of the loading valve of the emulsion pump through a PID (Proportion Integration Differentiation) controller to obtain a required rotating state and a required rotating speed of a servo motor and transmits the required rotating state and the required rotating speed to a servo driver; s3, controlling a servo motor by a servo driver, and enabling the servo motor to drive an emulsion pump loading valve to work; s4, the pressure sensor feeds back the pressure acquisition value to the upper computer; s5, the upper computer carries out comparison calculation on the pressure parameters of the loading valve of the emulsion pump through a PID (Proportion Integration Differentiation) controller; and S6, the servo driver adjusts and controls the servo motor according to the comparison calculation result, and precise pressure control over the loading valve of the emulsion pump is achieved.

Description

Technical Field

[0001] The invention relates to the field of emulsion pumps, and in particular to an emulsion pump loading valve speed regulation control system and a working method thereof. Background Art

[0002] As an important energy resource, coal plays a key role in the national energy structure and has a profound impact on the economy and residents' lives. Although the proportion of coal in energy production is gradually decreasing, it still dominates industrial production and residents' consumption. With the continuous development of coal mining technology, the emulsion pumps in the fully mechanized mining face of thick coal seams are constantly developing towards high pressure and large flow, and the design pressure and flow demand for domestic emulsion pumps is imminent.

[0003] The commonly used emulsion pump automation control solutions on the market now mainly include the following:

[0004] PLC control system: Many emulsion pump systems are controlled by programmable logic controllers (PLCs). This solution usually combines sensors and actuators to control and monitor the loading valve through programming. Although PLC systems can achieve a certain degree of automation, their response speed and control accuracy are often not as good as servo motor systems based on host computers.

[0005] PID control scheme: Some existing technologies use PID (proportional-integral-differential) control algorithm to adjust the opening of the loading valve. This scheme adjusts the valve by real-time monitoring of pressure and flow. However, when faced with complex working conditions, there may be problems with adjustment lag and insufficient accuracy, and the PID parameters are not accurate enough.

[0006] Industrial robot control system: Some emulsion pump systems use industrial robots to perform precise valve operations. Although this solution has high flexibility, its scope of application is limited due to its complexity and cost.

[0007] Embedded system-based control solutions: Some solutions use embedded controllers to monitor and control loading valves. These systems are generally low cost and power consumption, but are relatively limited in their ability to handle complex control logic and data analysis.

[0008] Software control solution based on LabVIEW: Some research and industrial applications use software platforms such as LabVIEW to control the loading valve. Although this solution has advantages in data acquisition and processing, it may not be able to achieve the level of host computer control of servo motors in terms of real-time control accuracy and response speed.

[0009] In summary, the above existing schemes have achieved control of the emulsion pump loading valve to varying degrees, but there are still certain limitations in terms of control accuracy, dynamic response and safety, and it is necessary to improve them. Summary of the invention

[0010] The object of the present invention is to provide an emulsion pump loading valve speed control system and a working method thereof, which can realize automatic control and reduce the human error rate, in view of the above problems.

[0011] In order to achieve the above object, the technical solution of the present invention is:

[0012] A speed control system for an emulsion pump loading valve comprises a servo motor for driving the emulsion pump loading valve, a servo driver for monitoring and controlling the rotation state and rotation speed of the servo motor, and a host computer for transmitting control signals to the servo driver and receiving servo motor state feedback information; the host computer is connected to the servo driver via a 485 communication interface to realize data transmission; the servo driver is connected to the servo motor circuit to realize the rotation of the servo motor; the servo motor is transmission-connected to the emulsion pump loading valve to realize the pumping loading effect of the emulsion pump loading valve; a pressure sensor for collecting the outlet pressure is fixedly connected to the outlet position of the emulsion pump loading valve, and the pressure sensor is connected to the host computer to realize the transmission of pressure data.

[0013] Furthermore, an encoder is provided between the servo driver and the servo motor, and the servo motor is controlled by a signal from the encoder.

[0014] Furthermore, a speed reduction mechanism and a coupling mechanism are provided between the servo motor and the emulsion pump loading valve, and the servo motor is sequentially connected to the emulsion pump loading valve through the speed reduction mechanism and the coupling mechanism.

[0015] Furthermore, the speed reduction mechanism is a planetary gear reducer.

[0016] Furthermore, the coupling mechanism is one of a gear transmission mechanism, a cam transmission mechanism, a coupling transmission mechanism, and a synchronous belt transmission mechanism.

[0017] A working method of an emulsion pump loading valve speed control system comprises the following steps:

[0018] S1. The operator inputs the pressure setting value of the emulsion pump loading valve in the user interface of the host computer;

[0019] S2, the upper computer calculates the input emulsion pump loading valve pressure setting value through the PID controller, obtains the required rotation state and required speed of the servo motor and transmits them to the servo driver;

[0020] S3, the servo driver controls the servo motor according to the required rotation state and speed of the servo motor received, so that the servo motor drives the loading valve of the emulsion pump to work;

[0021] S4, the pressure sensor in the emulsion pump loading valve monitors the pressure collection value of the emulsion pump loading valve, and feeds the pressure collection value back to the host computer;

[0022] S5. The upper computer compares and adjusts the pressure setting value of the emulsion pump loading valve and the pressure acquisition value of the emulsion pump loading valve through the PID controller, obtains the adjusted rotation state and speed of the servo motor and transmits them to the servo driver, and stores the data in the TD database to facilitate PID parameter analysis.

[0023] S6. The servo driver controls the servo motor according to the received servo motor adjustment rotation state and the servo motor adjustment speed, so that the servo motor drives the emulsion pump loading valve to work, and finally makes the pressure collection value of the emulsion pump loading valve reach the pressure setting value of the emulsion pump loading valve, so as to realize the precise pressure control of the emulsion pump loading valve.

[0024] Furthermore, in step S5, the pressure setting value of the emulsion pump loading valve is compared and adjusted with the pressure acquisition value of the emulsion pump loading valve, which specifically includes the following steps:

[0025] S51, comparing the pressure setting value with the pressure acquisition value;

[0026] S52, determine whether there is a pressure setting value = 0 or a pressure acquisition value > 0; if so, set the adjustment speed of the servo motor to 1000 rpm, set the PID parameters, and make the servo motor reverse; if not, proceed to the next step;

[0027] S53, judging whether the pressure setting value is greater than the pressure collection value; if the pressure setting value is greater than the pressure collection value, proceed to the next step; if the pressure setting value is not greater than the pressure collection value, proceed to step S55;

[0028] S54, set the adjustment speed of the servo motor according to the pressure acquisition value; when 45≤pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters, and make the servo motor reverse; when 40≤pressure acquisition value<45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters, and make the servo motor reverse; when 35≤pressure acquisition value<40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters, and make the servo motor reverse; when 30≤pressure acquisition value<35, set the adjustment speed of the servo motor to 7 00rpm, set the PID parameters to make the servo motor reverse; when 20≤pressure acquisition value<30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters to make the servo motor reverse; when 10≤pressure acquisition value<20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters to make the servo motor reverse; when 0<pressure acquisition value<10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters to make the servo motor reverse; when the pressure acquisition value=0, set the adjustment speed of the servo motor to 0rpm;

[0029] S55. Set the adjustment speed of the servo motor according to the pressure acquisition value; when 0<pressure acquisition value≤10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters, and make the servo motor rotate forward; when 10<pressure acquisition value≤20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters, and make the servo motor rotate forward; when 20<pressure acquisition value≤30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters, and make the servo motor rotate forward; when 30<pressure acquisition value≤35, set the adjustment speed of the servo motor to 7 00rpm, set the PID parameters to make the servo motor rotate forward; when 35<pressure acquisition value≤40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters to make the servo motor rotate forward; when 40<pressure acquisition value≤45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters to make the servo motor rotate forward; when 45<pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters to make the servo motor rotate forward; when the pressure acquisition value≥50, set the adjustment speed of the servo motor to 0rpm.

[0030] Furthermore, the PID parameters are set by using the Ziegler-Nichols method for optimization, which specifically includes the following steps:

[0031] S511, convert the current PID controller into proportional control mode, and set the integral gain K i and differential gain K d Set to zero;

[0032] S512, gradually increase the proportional gain K p , until it shows continuous oscillation, at which point the proportional gain K p That is the critical gain K u ;

[0033] S513, in the proportional gain K p Reaching critical gain K u When the oscillation period T is recorded u ;

[0034] S514, use critical gain K u and the oscillation period T u To calculate the PID parameters of the PID controller; the calculation formula is as follows:

[0035] P control: K p =K u ;

[0036] PI control: K p =0.45K u ,

[0037] PID control: K p =0.6K u ,

[0038] After analyzing the experimental data, we concluded that:

[0039] K u =20, T u =5s.

[0040] Compared with the prior art, the present invention has the following advantages and positive effects:

[0041] 1. Simplify wiring complexity: The present invention optimizes electrical connections and simplifies the installation process through centralized management and control by the host computer, making system maintenance and expansion more convenient. Users can easily adjust and upgrade the system, ensuring higher system flexibility and reliability.

[0042] 2. Digital storage of experimental data: The present invention upgrades the experimental data from the traditional naked eye observation method to storage in the database through the host computer. This innovation enables all experimental data to be collected, stored and subsequently easily accessed in real time; users can trace back and review historical experimental data at any time, which is convenient for system performance evaluation and optimization analysis. This digital management ensures the accuracy and integrity of the data and provides a reliable foundation for subsequent data processing.

[0043] 3. PID parameter optimization based on data analysis: The present invention analyzes the experimental data stored in the database, uses scientific methods to automatically extract key features, and determines more accurate and adaptive PID parameters. This optimization method based on data analysis greatly improves the control accuracy and ensures that the servo motor system can achieve the best control effect under different working environments.

[0044] 4. The present invention controls the servo motor through the host computer to achieve rapid and accurate control of the emulsion pump loading valve to adapt to complex and rapidly changing working conditions; at the same time, through automated control, the risks brought by manual operation are reduced, thereby improving the safety and reliability of the entire system. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in 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 described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0046] Figure 1 It is a schematic diagram of hardware connection of the present invention;

[0047] Figure 2 It is a schematic diagram of the pressure interface of the present invention;

[0048] Figure 3 This is the control logic flow chart of the emulsion pump loading valve. DETAILED DESCRIPTION

[0049] 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, any modifications, equivalent substitutions, improvements, etc., should be included in the protection scope of the present invention.

[0050] The invention discloses an emulsion pump loading valve speed regulation control system, and its application in the emulsion pump loading valve speed regulation meets the demand for precise control of motors in the field of industrial automation.

[0051] The emulsion pump loading valve speed control system includes a servo motor for driving the emulsion pump loading valve, a servo driver for monitoring and controlling the rotation state and rotation speed of the servo motor, and a host computer for transmitting control signals to the servo driver and receiving servo motor state feedback information;

[0052] The host computer is connected to the servo driver through a 485 communication interface to realize data transmission; the servo driver is connected to the servo motor circuit through an encoder to realize the rotation of the servo motor; the servo motor is transmission-connected to the emulsion pump loading valve to realize the pumping loading effect of the emulsion pump loading valve; a pressure sensor for collecting the outlet pressure is fixedly connected to the outlet position of the emulsion pump loading valve, and the pressure sensor is connected to the host computer to realize the transmission of pressure data.

[0053] The working method of the above system is as follows:

[0054] S1. The operator inputs the pressure setting value of the emulsion pump loading valve in the user interface of the host computer;

[0055] S2, the upper computer calculates the input emulsion pump loading valve pressure setting value through the PID controller, obtains the required rotation state and required speed of the servo motor and transmits them to the servo driver;

[0056] S3, the servo driver controls the servo motor according to the required rotation state and speed of the servo motor received, so that the servo motor drives the loading valve of the emulsion pump to work;

[0057] S4, the pressure sensor in the emulsion pump loading valve monitors the pressure collection value of the emulsion pump loading valve, and feeds the pressure collection value back to the host computer;

[0058] S5. The upper computer compares and adjusts the pressure setting value of the emulsion pump loading valve and the pressure acquisition value of the emulsion pump loading valve through the PID controller, obtains the adjusted rotation state and speed of the servo motor and transmits them to the servo driver, and stores the data in the TD database to facilitate PID parameter analysis.

[0059] S6. The servo driver controls the servo motor according to the received servo motor adjustment rotation state and the servo motor adjustment speed, so that the servo motor drives the emulsion pump loading valve to work, and finally makes the pressure collection value of the emulsion pump loading valve reach the pressure setting value of the emulsion pump loading valve, so as to realize the precise pressure control of the emulsion pump loading valve.

[0060] The system design in the present invention mainly involves two key aspects: hardware and software, to ensure high efficiency and stable operation of the motor.

[0061] In terms of hardware design, the construction of the sensor interface circuit is crucial. This circuit can accurately collect the speed and position information of the motor and provide accurate feedback data for the control system. At the same time, the design of the control circuit lays a solid foundation for the generation and transmission of motor control signals, ensuring the reliability and stability of the signal.

[0062] In terms of software programming, the implementation of the control algorithm is the core of the system. The commonly used PID control algorithm can dynamically adjust the control output according to the actual feedback signal, thereby achieving precise regulation of the motor speed. In addition, in order to enhance the user interaction experience, the system has designed a friendly user interface, where users can easily set the target speed and monitor the motor status in real time, and store all data in the TD database for easy analysis of PID parameters. The coordinated design and optimization of the overall system has a direct impact on the performance and stability of the motor.

[0063] Hardware Hookup

[0064] In order to achieve high-precision positioning control of the servo motor by the host computer, it is essential to improve the hardware connection. A typical hardware connection solution should include a reliable interface between the host computer and the servo drive, as well as an effective connection between the servo motor and the controlled object. By optimizing these connections, the stability and response speed of the control system can be ensured, thereby improving the overall control accuracy.

[0065] The host computer and the servo drive control the servo drive through the 485 communication method, which is used to control the servo drive to start, stop and other control commands. At the same time, the motion feedback signal (such as torque, speed, position, etc.) of the servo drive needs to be connected to the host computer through the 485 communication interface, so that the host computer can monitor the actual operating status of the servo system in real time. This connection method can ensure that the host computer accurately obtains motion feedback information, thereby realizing dynamic monitoring and precise control of the servo system. The servo motor is usually connected to the loading valve through a coupling device to achieve effective transmission of control force or motion. The selection of coupling devices includes gears, cams, couplings and synchronous belts, etc., and the appropriate coupling method needs to be selected according to the specific application scenario. In applications with high speed control accuracy requirements, servo motors usually use reduction mechanisms (such as planetary gear reducers, etc.) to drive the load to achieve precise motion control. The power supply servo drive and other key components provide stable and reliable power support to ensure that these components work normally under the required voltage and current conditions. For high-power servo motor systems, it may be necessary to set up a dedicated power supply independently to meet their specific power requirements. At the same time, the cable is the link between the various parts of the servo system, including power cables, control cables and encoder cables, and its selection is also crucial. To ensure the stability and safety of the system, it is necessary to select the appropriate cable model and handle key details such as terminal connection and shield grounding.

[0066] Hardware connection as follows Figure 1 As shown in the figure, through the correct hardware connection, PLC is organically combined with servo motor, servo drive, encoder and other components to build a complete closed-loop control system, thus laying a solid hardware foundation for precise position control. In this process, reasonable hardware topology, reliable electrical connection and scientific component selection are all important prerequisites for ensuring efficient and stable operation of the system. These elements complement each other and jointly improve the performance and reliability of the system.

[0067] Host computer programming

[0068] (1) Control algorithm optimization

[0069] During the implementation process, the present invention focuses on the experimental verification and optimization of the control algorithm to ensure that the system can stably and accurately regulate the speed. First, the classic PID control algorithm was implemented and applied to the speed regulation system of the servo motor. By adjusting the PID parameters, the influence of different parameter combinations on the system performance was explored, and the stability and accuracy of the control algorithm were evaluated by comparing the deviation between the actual speed and the target speed. Then, in order to further optimize the control algorithm, a parameter adjustment experiment was carried out. Through the test of system performance and the analysis of experimental data, the proportional, integral and differential gains were gradually adjusted to obtain a more ideal speed regulation effect. The experimental results show that after parameter optimization, the overshoot and oscillation phenomena of the system are effectively suppressed, and the speed regulation performance of the motor is significantly improved. Finally, by comparing the PID control algorithm with other advanced control methods, such as fuzzy control and adaptive control, the influence of different control algorithms on system performance is evaluated, as shown in Table 1:

[0070] Table 1 Speed ​​regulation performance of different algorithms

[0071] Algorithm Name Performance Indicators Speed ​​Control Effect Adjust PID parameter control Reduced overshoot and improved stability Improved stability and accuracy Fuzzy Control Small error, slow response Stable speed regulation, slow response Adaptive Control Small overshoot and fast response Fast response and stable speed regulation

[0072] (2) Writing the host computer code

[0073] In the speed control system, the code structure is divided into two main parts: device agent and user interface. The device agent is the interactive bridge between the system and the hardware device, while the user interface provides intuitive control and monitoring functions for the operator. The following is a detailed description of these two parts:

[0074] The core function of the device agent is to communicate with the servo drive through the MODBUS RTU protocol. MODBUS RTU is a widely used serial communication protocol suitable for data transmission between devices in the field of industrial automation. It will read and write to specific register addresses of the servo drive. These registers are usually used to store control instructions and status data. With the precise register address, the system can perform the following operations:

[0075] Start and stop: Send corresponding signals to the driver to start or stop the servo motor.

[0076] Forward and reverse control: By setting specific control bits, the rotation direction of the servo motor can be changed to meet different process requirements.

[0077] Speed ​​setting: Write the target speed value into the driver register to adjust the motor running speed.

[0078] Fault information monitoring: Regularly read the drive status register to obtain fault information and handle potential problems in a timely manner.

[0079] Parameter setting: PID parameter setting.

[0080] The user interface is the interactive layer between the operator and the control system, which aims to provide convenient operation and real-time status feedback. The interface allows the user to directly input the required pressure value. The system will compare the input pressure with the real-time collected pressure value and automatically calculate the corresponding servo motor operating parameters. The pressure interface is set as follows: Figure 2 shown.

[0081] In summary, the device agent and the user interface complement each other and together form an efficient and reliable servo control system. The device agent is responsible for low-level hardware control with the servo drive through the MODBUS RTU protocol, while the user interface provides a friendly operating environment to ensure that users can easily set parameters, monitor status and solve problems. This architecture not only improves the flexibility and operability of the system, but also enhances the security and stability of the entire servo control system.

[0082] The code controls the loading valve logic flow chart as follows: Figure 3 As shown, it mainly includes the following steps:

[0083] 1. Compare the pressure setting value of the emulsion pump loading valve with the pressure collection value of the emulsion pump loading valve;

[0084] 2. Determine whether there is a pressure setting value = 0 or a pressure acquisition value > 0; if so, set the servo motor's adjustment speed to 1000rpm, set the PID parameters, and make the servo motor reverse; if not, proceed to the next step;

[0085] 3. Determine whether the pressure setting value is greater than the pressure collection value; if the pressure setting value is greater than the pressure collection value, proceed to the next step; if the pressure setting value is not greater than the pressure collection value, proceed to step 5;

[0086] 4. Set the adjustment speed of the servo motor according to the pressure acquisition value; when 45≤pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters, and make the servo motor reverse; when 40≤pressure acquisition value<45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters, and make the servo motor reverse; when 35≤pressure acquisition value<40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters, and make the servo motor reverse; when 30≤pressure acquisition value<35, set the adjustment speed of the servo motor to 70 0rpm, set the PID parameters to make the servo motor reverse; when 20≤pressure acquisition value<30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters to make the servo motor reverse; when 10≤pressure acquisition value<20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters to make the servo motor reverse; when 0<pressure acquisition value<10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters to make the servo motor reverse; when the pressure acquisition value=0, set the adjustment speed of the servo motor to 0rpm;

[0087] 5. Set the adjustment speed of the servo motor according to the pressure acquisition value; when 0<pressure acquisition value≤10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters, and make the servo motor rotate forward; when 10<pressure acquisition value≤20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters, and make the servo motor rotate forward; when 20<pressure acquisition value≤30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters, and make the servo motor rotate forward; when 30<pressure acquisition value≤35, set the adjustment speed of the servo motor to 70 0rpm, set the PID parameters to make the servo motor rotate forward; when 35<pressure acquisition value≤40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters to make the servo motor rotate forward; when 40<pressure acquisition value≤45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters to make the servo motor rotate forward; when 45<pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters to make the servo motor rotate forward; when the pressure acquisition value≥50, set the adjustment speed of the servo motor to 0rpm.

[0088] Data storage and PID parameter calculation

[0089] In modern control systems, especially in servo motor speed control applications, real-time acquisition and storage of system operation data is of great significance. By storing the actual speed and the corresponding response time during the execution process in the database, the parameter settings of the PID control algorithm can be analyzed more comprehensively and deeply, and the system performance can be further optimized.

[0090] By analyzing the deviation between the actual speed and the target speed, the effect of the algorithm control can be evaluated more intuitively. For example, if it is found that the overshoot, oscillation or steady-state error is large under certain PID parameter settings, engineers can adjust the values ​​of proportional, integral and differential gains accordingly to optimize the control performance. The measurement of response time can help researchers analyze the dynamic characteristics of the system. By comparing the response time under different PID parameter settings, it can be determined which set of parameters can make the system reach the target state within the target time, thereby improving the overall efficiency of the system; focus on the experimental effects of PID parameters as shown in Table 2:

[0091] Table 2 PID parameter settings and effects

[0092]

[0093] The experimental results show that the PID parameters of group 1 can quickly and accurately adjust the actual speed to close to or reach the target speed. Next, the Ziegler-Nichols method is used to further refine and optimize the parameters of group 1. The steps are as follows:

[0094] 1. Set the feedback controller to P control mode;

[0095] Convert the current PID controller to proportional (P) control mode and change K i and K d The purpose of this step is to find the critical gain K of the system. u and critical period T u .

[0096] 2. Adjust the proportional gain (K p );

[0097] Gradually increase the proportional gain (K p ) value until the system shows continuous oscillation (that is, the system fluctuates back and forth after reaching the set point). The gain value at this time is the critical gain K u .

[0098] 3. Measure the period of oscillation;

[0099] In K p Reach K u When the oscillation period T of the system is recorded u .

[0100] 4. Calculate PID parameters;

[0101] According to the Ziegler-Nichols empirical formula, using the recorded K u and T u To calculate the PID parameters. For the classic Ziegler-Nichols method, the formula is as follows:

[0102] P control: K p =K u

[0103] PI control: K p =0.45K u ,

[0104] PID control: K p =0.6K u ,

[0105] After multiple experimental data analyses, we concluded that:

[0106] K u =20, T u =5s

[0107] After the above calculations, the optimized parameters of Group 1 are shown in Table 3:

[0108] Table 3 Optimized parameters

[0109] PID Type Proportional Gain Integral gain Differential Gain P 20 0 0 PI 9 4.8 0 PID 12 8 12.5

[0110] The Ziegler-Nichols method can effectively refine and optimize the initial PID parameters to obtain parameter settings that are more suitable for specific applications. In the process of implementing the optimization, continuous testing and adjustment are required to ensure that the system always runs in the best state.

[0111] The present invention has the following beneficial advantages:

[0112] 1. Precise control: The present invention constructs an efficient feedback system. By installing a pressure sensor at the outlet of the loading valve, the position and state of the control valve can be monitored in real time to ensure that the control strategy can be adjusted quickly, thereby achieving precise control.

[0113] 2. Dynamic response: The present invention improves the speed at which the servo motor controls the loading valve at different pressure stages (0-10MPa, 10-20MPa, 20-30MPa, 30-35MPa, 35-40MPa, 40-45MPa, 45-50MPa) to adapt to rapidly changing working conditions.

[0114] 3. Data storage: In the process of servo motor speed regulation, accurate monitoring of actual speed and response time is the basis for evaluating the control effect. The actual speed can reflect the running status of the motor, while the response time is the reaction speed of the system to the change of control input. By storing the speed and response time in the TD database, the comparison between the actual speed and the target speed and the response time are analyzed, so as to better launch the PID parameters and meet the needs of customers.

[0115] 4. Human-machine interface: The present invention optimizes the user interface of the host computer to make the operation more simple and intuitive, while providing necessary monitoring and control functions to enhance the user experience.

[0116] Through the above-mentioned operation, the present invention can significantly improve the working efficiency and stability of the emulsion pump loading valve, effectively reduce the potential risks brought by manual control of the loading valve, thereby improving the safety of the entire working process. It can better meet the needs of efficiency, safety and precision, has great technical advantages, and provides important technical support for applications in related industries.

Claims

1. An emulsion pump loading valve speed control system, characterized in that: The emulsion pump loading valve speed control system includes a servo motor for power-driving the emulsion pump loading valve, a servo driver for monitoring and controlling the rotation state and rotation speed of the servo motor, and a host computer for transmitting control signals to the servo driver and receiving servo motor state feedback information; the host computer is connected to the servo driver through a 485 communication interface to realize data transmission; the servo driver is connected to the servo motor circuit to realize the rotation of the servo motor; the servo motor is transmission-connected to the emulsion pump loading valve to realize the pumping loading effect of the emulsion pump loading valve; a pressure sensor for collecting the outlet pressure is fixedly connected to the outlet position of the emulsion pump loading valve, and the pressure sensor is connected to the host computer to realize the transmission of pressure data.

2. The emulsion pump loading valve speed control system according to claim 1, characterized in that: An encoder is arranged between the servo driver and the servo motor, and the servo motor is controlled by a signal of the encoder.

3. The emulsion pump loading valve speed control system according to claim 2, characterized in that: A speed reduction mechanism and a coupling mechanism are arranged between the servo motor and the emulsion pump loading valve, and the servo motor is sequentially connected to the emulsion pump loading valve through the speed reduction mechanism and the coupling mechanism.

4. The emulsion pump loading valve speed control system according to claim 3, characterized in that: The speed reduction mechanism is a planetary gear reducer.

5. The emulsion pump loading valve speed control system according to claim 4, characterized in that: The coupling mechanism is one of a gear transmission mechanism, a cam transmission mechanism, a coupling transmission mechanism, and a synchronous belt transmission mechanism.

6. A working method of the emulsion pump loading valve speed control system according to claim 5, characterized in that: The following steps are involved: S1. The operator inputs the pressure setting value of the emulsion pump loading valve in the user interface of the host computer; S2, the upper computer calculates the input emulsion pump loading valve pressure setting value through the PID controller, obtains the required rotation state and required speed of the servo motor and transmits them to the servo driver; S3, the servo driver controls the servo motor according to the required rotation state and speed of the servo motor received, so that the servo motor drives the loading valve of the emulsion pump to work; S4, the pressure sensor in the emulsion pump loading valve monitors the pressure collection value of the emulsion pump loading valve, and feeds the pressure collection value back to the host computer; S5. The upper computer compares and adjusts the pressure setting value of the emulsion pump loading valve and the pressure acquisition value of the emulsion pump loading valve through the PID controller, obtains the adjusted rotation state and speed of the servo motor and transmits them to the servo driver, and stores the data in the TD database to facilitate PID parameter analysis. S6. The servo driver controls the servo motor according to the received servo motor adjustment rotation state and the servo motor adjustment speed, so that the servo motor drives the emulsion pump loading valve to work, and finally makes the pressure collection value of the emulsion pump loading valve reach the pressure setting value of the emulsion pump loading valve, so as to realize the precise pressure control of the emulsion pump loading valve.

7. The working method of the emulsion pump loading valve speed control system according to claim 6, characterized in that: In step S5, the pressure setting value of the emulsion pump loading valve is compared and adjusted with the pressure acquisition value of the emulsion pump loading valve, which specifically includes the following steps: S51, comparing the pressure setting value with the pressure acquisition value; S52, determine whether there is a pressure setting value = 0 or a pressure acquisition value > 0; if so, set the adjustment speed of the servo motor to 1000 rpm, set the PID parameters, and make the servo motor reverse; if not, proceed to the next step; S53, judging whether the pressure setting value is greater than the pressure collection value; if the pressure setting value is greater than the pressure collection value, proceed to the next step; if the pressure setting value is not greater than the pressure collection value, proceed to step S55; S54, set the adjustment speed of the servo motor according to the pressure acquisition value; when 45≤pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters, and make the servo motor reverse; when 40≤pressure acquisition value<45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters, and make the servo motor reverse; when 35≤pressure acquisition value<40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters, and make the servo motor reverse; when 30≤pressure acquisition value<35, set the adjustment speed of the servo motor to 7 00rpm, set the PID parameters to make the servo motor reverse; when 20≤pressure acquisition value<30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters to make the servo motor reverse; when 10≤pressure acquisition value<20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters to make the servo motor reverse; when 0<pressure acquisition value<10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters to make the servo motor reverse; when the pressure acquisition value=0, set the adjustment speed of the servo motor to 0rpm; S55. Set the adjustment speed of the servo motor according to the pressure acquisition value; when 0<pressure acquisition value≤10, set the adjustment speed of the servo motor to 1000rpm, set the PID parameters, and make the servo motor rotate forward; when 10<pressure acquisition value≤20, set the adjustment speed of the servo motor to 900rpm, set the PID parameters, and make the servo motor rotate forward; when 20<pressure acquisition value≤30, set the adjustment speed of the servo motor to 800rpm, set the PID parameters, and make the servo motor rotate forward; when 30<pressure acquisition value≤35, set the adjustment speed of the servo motor to 7 00rpm, set the PID parameters to make the servo motor rotate forward; when 35<pressure acquisition value≤40, set the adjustment speed of the servo motor to 600rpm, set the PID parameters to make the servo motor rotate forward; when 40<pressure acquisition value≤45, set the adjustment speed of the servo motor to 500rpm, set the PID parameters to make the servo motor rotate forward; when 45<pressure acquisition value<50, set the adjustment speed of the servo motor to 400rpm, set the PID parameters to make the servo motor rotate forward; when the pressure acquisition value≥50, set the adjustment speed of the servo motor to 0rpm.

8. The working method of the emulsion pump loading valve speed control system according to claim 7, characterized in that: When setting PID parameters, the Ziegler-Nichols method is used for optimization; It specifically includes the following steps: S511, convert the current PID controller into proportional control mode, and set the integral gain K i and differential gain K d Set to zero; S512, gradually increase the proportional gain K p , until it shows continuous oscillation, at which point the proportional gain K p That is the critical gain K u ; S513, in the proportional gain K p Reaching critical gain K u When the oscillation period T is recorded u ; S514, use critical gain K u and the oscillation period T u To calculate the PID parameters of the PID controller; the calculation formula is as follows: P control: K p =K u ; PI control: PID control: After analyzing the experimental data, we concluded that: K u =20,T u =5s。

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