A control method and system for a rock wool production line

Abstract

This application relates to the field of automatic control technology, and particularly to a control method and system for a rock wool production line. The method includes the steps of: calculating the finished product estimation error of the production speed of the rock wool production line at the current moment; obtaining the production line control signal at this moment using the PID algorithm based on the finished product estimation error to control the rock wool production line; the step of calculating the finished product estimation error includes: constructing a node error sequence between the preset production speed and the actual production speed of each node and a finished product error sequence between the preset production speed and the actual production speed of the finished product according to the operation data of the rock wool production line; calculating the error consistency between the node error sequence and the finished product error sequence; determining the influence degree of each node on the finished product production speed based on the error consistency of different nodes, calculating the estimated node error, and taking the sum of multiple estimated node errors as the finished product estimation error. This application has the effect of improving the accuracy and timeliness of controlling the finished product production speed of the rock wool production line.

Description

Technical Field

[0001] The present application relates to the field of automatic control technology, and in particular to a rock wool production line control method and system. Background Art

[0002] Rock wool is an inorganic fiber material made of basalt as the main raw material, which is used for insulation, heat insulation, fire prevention and other purposes in the fields of construction, industry, and shipbuilding. The main production process of rock wool includes: putting the raw materials into the furnace for melting, placing the molten rock in the ejector by rotation, and then ejecting the rock through the airflow to form fine fibers, and placing the ejected fibers in the curing chamber for curing and cutting. The rock wool production line is a rock wool production line specially used for the production of rock wool, which is composed of multiple equipment corresponding to the rock wool production process steps. There are many instabilities in the working process of the furnace, such as the wind pressure and oxygen content in the furnace, which leads to the unstable amount of fiber dispensed; therefore, the production speed of the rock wool production line needs to be adjusted and controlled during the rock wool production process to improve the quality of the rock wool after production. The commonly used rock wool production line control method is mainly to calculate the rock wool production speed through the flow rate of the finished rock wool product and the actual specifications of the rock wool, and control the overall operation speed of the rock wool production line according to the rock wool production speed.

[0003] During the actual adjustment process, the flow rate of finished rock wool products is calculated based on the actual mass of the rock wool products. In the process of adjusting the speed of the rock wool production line based on the flow rate of finished rock wool products, inconsistent weights of finished rock wool products may easily occur. For example, when it is detected that the finished product is heavier, the speed of the rock wool production line needs to be slowed down; but at the current moment, there is already heavier finished rock wool.

[0004] Of course, the operation of the rock wool production line can also be adjusted by directly adjusting the preset production speed of the rock wool production line, but usually there is an error between the preset production speed and the actual production speed. Therefore, the method of adjusting the rock wool production line in the related art has the problem of low control accuracy or delayed response in actual application. Summary of the invention

[0005] In order to solve the problem of low control accuracy or delayed response of a rock wool production line in the related art, the present application provides a rock wool production line control method and system.

[0006] In the first aspect, the present application provides a rock wool production line control method, which adopts the following technical solution:

[0007] A control method for a rock wool production line includes the steps of: calculating the finished product estimation error of the production speed of the rock wool production line at the current moment; obtaining the production line control signal at this moment using the PID algorithm based on the finished product estimation error, and controlling the rock wool production line; the step of calculating the finished product estimation error includes: constructing a node error sequence between the preset production speed and the actual production speed of each node and a finished product error sequence between the preset production speed and the actual production speed of the finished product according to the operation data of the rock wool production line; calculating the error consistency between the node error sequence and the finished product error sequence; determining the influence degree of each node on the finished product production speed based on the error consistency of different nodes, calculating the estimated node error, and taking the sum of multiple estimated node errors as the finished product estimation error; where the calculation formula for the error consistency is:

[0008] ; In the formula, represents the error consistency between the node error sequence and the finished product error sequence; represents the length of the node error sequence; represents the node The instantaneous difference between the node error sequence of and the finished product error sequence at the moment; represents the node at the moment, the error change rate, represents the error change rate of the finished product error sequence at the moment; represents the exponential function with the natural constant as the base.

[0009] Construct a node error sequence between the preset production speed and the actual production speed of each node, as well as a finished product error sequence between the preset production speed and the actual production speed of the finished product. Analyze the differences between the two sequences and calculate the consistency between different node sequences and the finished product error sequence. If the data changes in the two sequences are relatively consistent, it indicates that this node has a greater impact on the finished product error. If the difference between the node error sequence corresponding to a certain node and the finished product error sequence is large, that is, the error consistency between the two is low, it indicates that the error of the production speed generated by this node in the production process has a smaller impact on the error of the final finished product production speed. Combining this feature, estimate the error of the production speed of the finished product of the rock wool production line during real-time operation to obtain the estimated error of the finished product. Based on this estimated error of the finished product, obtain a control signal for controlling the rock wool production line, thereby improving the accuracy of controlling the production speed of the final finished product of the rock wool production line. In this application, during the process of controlling the rock wool production line, considering the error between the preset production speed and the actual production speed, the speed control of the rock wool production line is more accurate compared to the method of directly adjusting the preset production speed of the rock wool production line in the related art. At the same time, this application avoids the lag in the method of adjusting the speed of the rock wool production line based on measuring the flow rate of the finished product in the related art, and the control of the rock wool production line is more timely.

[0010] Optionally, the calculation formula for the instantaneous difference between the node error sequence and the finished product error sequence is:

[0011] ; where represents the instantaneous difference between the node error sequence and the finished product error sequence of historical data at the th moment, represents the error value of the node error sequence at the th moment, represents the error value of the rock wool finished product error sequence at the th moment.

[0012] represents the difference between the node error sequence and the finished product error sequence at the th moment; represents the accumulated difference between the two sequences at the th moment. The two work together to improve the accuracy of calculating the instantaneous difference between the two sequences. The smaller the difference between the two sequences, the greater the impact of the node error corresponding to this node on the error of the final finished product. Accurately calculating the instantaneous difference between the two sequences can improve the accuracy of calculating the estimated error of the finished product subsequently, thereby more precisely controlling the rock wool production line.

[0013] Optionally, the calculation formula for the instantaneous difference between the node error sequence and the finished product error sequence is:

[0014] ; wherein, represents the instantaneous difference between the node error sequence of historical data and the finished product error sequence at the th moment, represents the error value of the node error sequence at the th moment, represents the error value of the rock wool finished product error sequence at the th moment.

[0015] Optionally, the steps of determining the influence degree of each node on the finished product production speed based on the error consistency of different nodes include: taking the sum of the error consistencies corresponding to all nodes as the total error; taking the ratio of the error consistency corresponding to any node to the total error as the influence degree of this node on the finished product production speed.

[0016] There are different error consistencies between the node error sequences and the finished product error sequences corresponding to different nodes. The greater the error consistency, the more important the calculation of the estimated error of the finished product by this node. At the same time, the combined action of multiple nodes affects the error of the final finished product production speed. Therefore, the influence degree of different stages on the finished product production speed can be reflected by the proportion of the error consistency corresponding to different node error sequences in the total error.

[0017] Optionally, the steps of calculating the estimated node error include: obtaining the production speed error of each node at the current moment during the real-time operation of the rock wool production line; taking the product of the influence degree of any node and the production speed error of the corresponding node as the estimated node error.

[0018] During the real-time operation of the rock wool production line, there are different node errors for different nodes. This node error will ultimately cause an error between the actual finished product production speed and the preset finished product production speed. Therefore, through the influence degree of the node on the finished product production speed and the node error actually generated by this node during the real-time operation, the specific influence amount of the error of this node on the final finished product production speed can be estimated, that is, the finished product estimated error.

[0019] Optionally, the steps of obtaining the production speed error of each node at the current moment during the operation of the rock wool production line include: measuring the current flow rate of each node; taking the difference between the preset flow rate of this node and the measured flow rate as the production speed error of this node at the current moment.

[0020] Optionally, the steps of constructing the node error sequence between the preset production speed and the actual production speed of each node include: constructing the actual production speed sequence of each node; constructing the preset production speed sequence of each node; the difference between the speed values of the same sequence position in the actual production speed sequence and the preset production speed sequence is the node error, and the node errors at multiple moments constitute the node error sequence of this node.

[0021] Optionally, the steps of constructing the actual production speed sequence of each node include: collecting the operation data of any time period during the historical operation of the rock wool production line through sensors, obtaining the actual production speed of each node at any moment during this time period, and the actual production speeds at multiple moments form the actual production speed sequence of this node;

[0022] The steps of constructing the preset production speed sequence of each node include: obtaining the preset production speed of each moment of this node before production during the same time period; the preset production speeds at multiple moments form the preset production speed sequence.

[0023] Optionally, the calculation formula of the production line control signal is:

[0024] ; where, represents the control signal of the rock wool production line at the current moment , is the proportional gain parameter; is the integral gain parameter; is the derivative gain parameter; represents the finished product estimation error; represents the influence degree of node on the production speed of the finished product; represents node 's production speed error; represents the number of nodes.

[0025] During the process of obtaining the control signal, considering the error of the production speed of the finished product during the operation of the rock wool production line, it is possible to accurately control the production line in advance.

[0026] In a second aspect, the present application provides a control system for a rock wool production line, adopting the following technical solution:

[0027] A control system for a rock wool production line, including a processor and a memory, the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the above-mentioned control method for a rock wool production line is implemented.

[0028] Generate a computer program for the above-mentioned control method for a rock wool production line and store it in the memory to be loaded and executed by the processor. Thus, according to the memory and the processor, the system is convenient to use.

[0029] The present application has the following technical effects:

[0030] In this application, the estimated error between the final product production speed and the preset product production speed is estimated based on the influence degree of each node in the rock wool production line on the final product production speed in the historical data, and a control signal for the rock wool production line is obtained based on the estimated error of the product. The gap between the preset product production speed and the actual product production speed is compensated by the estimated error of the product, so as to achieve precise control of the speed of the rock wool production line. Description of the Drawings

[0031] Figure 1 is a flowchart of a method for controlling a rock wool production line according to this application.

[0032] Figure 2 is a flowchart of step S1 of a method for controlling a rock wool production line according to this application. Detailed Implementation Manner

[0033] An embodiment of this application discloses a method for controlling a rock wool production line, analyzes the data in the historical production process of the rock wool production line, calculates the influence degree of each node on the product production speed, estimates the error of the product production speed during the operation of the rock wool production line based on the influence degree, obtains the estimated error of the product, and adjusts the control signal of the rock wool production line according to the estimated error of the product, thereby improving the control accuracy of the product production speed of the rock wool production line.

[0034] Refer to Figure 1 , the method for controlling a rock wool production line includes step S1-step S2;

[0035] Step S1: Calculate the estimated error of the product of the production speed of the rock wool production line at the current moment;

[0036] Refer to Figure 2 , step S1 includes step S11-step S13;

[0037] Step S11: Construct a node error sequence between the preset production speed and the actual production speed of each node and a product error sequence between the preset production speed and the actual production speed of the product according to the operation data of the rock wool production line;

[0038] The rock wool production line includes a plurality of process equipment, and each process equipment corresponds to a process step. A production node (hereinafter referred to as a node) is formed between two adjacent process equipment.

[0039] Construct a node error sequence between the preset production speed and the actual production speed of each node;

[0040] Obtain the production speed of each node and the production speed of the final product during the historical operation of the rock wool production line. In this embodiment, the acquisition frequency is 60 ; The collection time is 6 hours. The production speeds of each node collected during this time period form the actual production speed sequence corresponding to each node.

[0041] In this embodiment, the flow rate of fibrous substances in the rock wool production process is detected by a flow sensor, so as to collect the production speed information of each node. After the historical operation data of the rock wool production line is collected, the production speed is filtered by the mean filtering method. Of course, in other embodiments, other methods can also be used to filter the data to facilitate subsequent data processing.

[0042] Before the rock wool production line operates, the staff will preset the speeds of each node of the rock wool production line to obtain the preset production speeds corresponding to the above-mentioned collection time period, which form the preset production speed sequence of each node.

[0043] The speed values in the actual production speed sequence corresponding to the same node are in one-to-one correspondence with the speed values in the preset production speed sequence; the speed value at any moment in the preset production speed sequence minus the speed value at that moment in the actual production speed sequence gives the node error at that moment, and the node errors at multiple moments form the node error sequence of the node.

[0044] Similarly, construct the actual production speed sequence of the rock wool finished product in the historical data and the corresponding finished product preset production speed sequence, and construct the finished product error sequence between the finished product actual production speed sequence and the finished product preset production speed.

[0045] Step S12: Calculate the error consistency between the node error sequence and the finished product error sequence;

[0046] First, calculate the instantaneous difference at any moment between the node error sequence and the finished product error sequence;

[0047] In one embodiment, the calculation formula for the instantaneous difference is:

[0048] ; represents the instantaneous difference between the node error sequence and the finished product error sequence of the historical data at the moment, represents the error value of the node error sequence at the moment, represents the error value of the rock wool finished product error sequence at the moment.

[0049] represents the error value difference between the historical node error sequence and the rock wool finished product error sequence at the moment; the larger this value is, the more it indicates that the node is at the The greater the difference between the node error and the finished product error at each moment; that is, during the operation of the rock wool production line, the error of this node has less impact on the error of the final finished product. If The smaller it is, the more the final finished product error is mainly affected by the node error. represents the difference between the node error and the finished product error, which is the error accumulated within moments. This part comprehensively considers the difference between the node errors accumulated over multiple moments and the finished product errors accumulated over multiple moments, reduces the influence of a single extreme data in the calculation process of the instantaneous difference, and improves the accuracy and robustness of the instantaneous difference calculation.

[0050] In another embodiment, the calculation formula for the instantaneous difference is:

[0051] ; where represents the instantaneous difference between the node error sequence and the finished product error sequence of historical data at the moment, represents the error value of the node error sequence at the moment, represents the error value of the rock wool finished product error sequence at the moment.

[0052] Then, calculate the error consistency between the node error sequence and the finished product error sequence;

[0053] In one embodiment, the calculation formula for the error consistency is:

[0054] ; where represents the error consistency between the node error sequence and the finished product error sequence; represents the length of the node error sequence; represents the node at the th moment of the instantaneous difference between the node error sequence and the finished product error sequence; represents the error change rate of the node at the moment, represents the error change rate of the finished product error sequence at the moment; represents the exponential function with the natural constant as the base.

[0055] The calculation of the change rate in the formula is a conventional technical means in the art and will not be elaborated here.

[0056] represents the node The difference in the degree of fluctuation between the corresponding node error sequence and the finished product error sequence can reflect the difference in the change trends of the data in the two sequences. The smaller the value of , the more consistent the changes in the data in the node error sequence and the finished product error sequence. Therefore, the error consistency between the two sequences is also greater. represents the instantaneous difference between the node error sequence and the finished product error sequence. The magnitude of this difference reflects the numerical difference between the two sequences. The smaller this value, the closer the two sequences are numerically, and therefore the greater the error consistency between the two sequences.

[0057] In the formula, the error consistency between the two sequences is calculated collaboratively from two aspects: instantaneous difference and degree of fluctuation, which further improves the accuracy and robustness of the error consistency calculation. Finally, the calculation result is mapped to a certain range through an exponential function for subsequent processing and calculation.

[0058] In another embodiment, the calculation formula for error consistency is:

[0059] ; where represents the error consistency between the node error sequence and the finished product error sequence; represents the number of corresponding node error sequences; represents the length of the node error sequence; represents the th node error sequence of and the instantaneous difference between the finished product error sequence at time represents the th error sequence of at time represents the error change rate of the th rock wool finished product error sequence at time ; represents the exponential function with the natural constant as the base.

[0060] In this embodiment, groups of historical data are collected. During the specific collection process, the operation data of the rock wool production line can be collected when the rock wool production line produces products in different batches, so as to obtain multiple groups of historical data.

[0061] A set of node error sequences and a finished product error sequence are extracted from each set of historical data. The error consistency between each node error sequence and the finished product error sequence is accumulated. Considering multiple sets of historical data comprehensively, the situation where a single data has a large impact on the calculation result is avoided, and the accuracy and robustness of the error consistency calculation are further improved.

[0062] S13: Determine the influence degree of each node on the production speed of the finished product based on the error consistency of different nodes, calculate the estimated node error, and take the sum of multiple estimated node errors as the estimated error of the finished product.

[0063] Take the sum of the error consistencies corresponding to all nodes as the total error; take the ratio of the error consistency corresponding to any node to the total error as the influence degree of this node on the production speed of the finished product.

[0064] Specifically, the calculation formula for the influence degree of a node on the production speed of the finished product can be expressed as:

[0065] represents the node 's influence degree on the production speed of the finished product, represents the node 's error consistency; represents the number of nodes.

[0066] Obtain the production speed error of each node at the current moment during the real-time operation of the rock wool production line; take the product of the influence degree of any node and the production speed error of the corresponding node as the estimated node error.

[0067] The production speed error of any node at the current moment during the real-time operation of the rock wool production line is the difference between the preset production speed and the actual production speed at the current moment.

[0068] S2: Based on the estimated error of the finished product, use the PID algorithm to obtain the production line control signal at this moment and control the rock wool production line;

[0069] The calculation formula for the production line control signal is:

[0070] ; In the formula, represents the control signal of the rock wool production line at the current moment , is the proportional gain parameter; is the integral gain parameter; is the derivative gain parameter; represents the estimated error of the finished product; represents the node 's influence degree on the production speed of the finished product; represents the node 's production speed error; Indicates the number of nodes.

[0071] Input the production line control signal into the control system of the rock wool production line to automatically regulate the overall speed of the rock wool production line and achieve real-time automatic control of the rock wool production line.

[0072] The embodiment of the present application also discloses a control method and system for a rock wool production line, including a processor and a memory. The memory stores computer program instructions, and when the computer program instructions are executed by the processor, a control method for a rock wool production line according to the present application is implemented.

[0073] The above system also includes other components well-known to those skilled in the art such as a communication bus and a communication interface. Their settings and functions are known in the art, so they will not be described in detail here.

[0074] The above are all the preferred embodiments of the present application. The protection scope of the present application is not limited thereby. Therefore, all equivalent changes made according to the structure, shape, and principle of the present application should be covered within the protection scope of the present application.

Claims

1. A control method for a rock wool production line, characterized in that, Including the steps of: calculating the finished product estimation error of the current production speed of the rock wool production line; Based on the finished product estimation error, using the PID algorithm to obtain the production line control signal at this moment and control the rock wool production line; The steps of calculating the finished product estimation error include: constructing a node error sequence between the preset production speed and the actual production speed of each node and a finished product error sequence between the preset production speed and the actual production speed of the finished product according to the operation data of the rock wool production line; calculating the error consistency between the node error sequence and the finished product error sequence; determining the influence degree of each node on the finished product production speed based on the error consistency of different nodes, calculating the estimated node error, and taking the sum of multiple estimated node errors as the finished product estimation error; where the calculation formula for the error consistency is: ; wherein, represents the error consistency between the node error sequence and the finished product error sequence; represents the length of the node error sequence; represents the node of the instantaneous difference between the node error sequence and the finished product error sequence at the moment; represents the node at the moment of the error change rate, represents the error change rate of the finished product error sequence at the moment; represents the exponential function with the natural constant as the base; The steps of calculating the estimated node error include: obtaining the production speed error of each node at the current moment during the real-time operation of the rock wool production line; taking the product of the influence degree of any node and the production speed error of the corresponding node as the estimated node error; The steps of obtaining the production speed error of each node at the current moment during the operation of the rock wool production line include: measuring the current flow rate of each node; taking the difference between the preset flow rate of the node and the measured flow rate as the production speed error of the node at the current moment.

2. The control method of a rock wool production line according to claim 1, characterized in that The calculation formula for the instantaneous difference between the node error sequence and the finished product error sequence is: ; wherein, represents the instantaneous difference between the node error sequence of historical data and the finished product error sequence at the moment, represents the error value of the node error sequence at the moment, represents the error value of the finished rock wool product error sequence at the moment.

3. A control method for a rock wool production line according to claim 1, characterized in that, The calculation formula for the instantaneous difference between the node error sequence and the finished product error sequence is: ; wherein, represents the instantaneous difference between the node error sequence of historical data and the finished product error sequence at the th moment, represents the error value of the node error sequence at the th moment, represents the error value of the finished rock wool product error sequence at the th moment.

4. A control method for a rock wool production line according to claim 1, characterized in that, The steps of determining the influence degree of each node on the finished product production speed based on the error consistency of different nodes include: taking the sum of the error consistencies corresponding to all nodes as the total error; taking the ratio of the error consistency corresponding to any node to the total error as the influence degree of the node on the finished product production speed.

5. A control method for a rock wool production line according to claim 1, characterized in that The steps of constructing a node error sequence between the preset production speed and the actual production speed of each node include: constructing an actual production speed sequence of each node; constructing a preset production speed sequence of each node; taking the difference between the actual production speed sequence and the preset production speed of the same position in the preset production speed sequence as the node error, and the node errors at multiple moments form the node error sequence of the node.

6. The control method of a rock wool production line according to claim 5, characterized in that, The steps of constructing an actual production speed sequence of each node include: collecting the operation data during any time period in the historical operation of the rock wool production line through sensors, obtaining the actual production speed of each node at any moment during this time period, and the actual production speeds at multiple moments form the actual production speed sequence of the node; The steps of constructing a preset production speed sequence of each node include: obtaining the preset production speed of each node before production at each moment during the same time period; the preset production speeds at multiple moments form the preset production speed sequence.

7. A control method for a rock wool production line according to claim 1, characterized in that, The calculation formula for the production line control signal is: ; wherein, represents the control signal of the rock wool production line at the current moment ; is the proportional gain parameter; is the integral gain parameter; is the derivative gain parameter; represents the finished product estimation error; represents the node 's influence degree on the production speed of the finished product; represents the node 's production speed error; represents the number of nodes.

8. A control system for a rock wool production line, characterized in that Including: A processor and a memory, the memory stores computer program instructions, and when the computer program instructions are executed by the processor, it realizes a method for controlling a rock wool production line according to any one of claims 1-7.

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