Method for automatically counting frequency of manually and remotely adjusting frequency of frequency converter

Abstract

The invention discloses a method for automatically counting manual remote frequency regulation times of a frequency converter, and relates to the field of frequency converter control. The method comprises the following steps: receiving a manual remote frequency regulation instruction by using a controller, and regulating the operation frequency of the frequency converter according to the frequency regulation instruction, meanwhile, the controller collects the operation frequency of the frequency converter in real time and uploads the operation frequency to the industrial control database server; the frequency converter operation frequency value in the manual remote adjustment mode is screened from the industrial control database server based on the frequency modulation frequency calculation technology, deviation processing is carried out on the screening result, and the frequency modulation frequency of the frequency converter is counted according to the deviation processing result; and analyzing the frequency regulation times of the frequency converter by using an abnormal mode recognition technology, judging the operation state of the frequency converter, predicting the accuracy of the manual remote frequency regulation instruction based on a judgment result, and generating an early warning prompt according to an accuracy verification result. According to the invention, the safety and operation efficiency of the equipment are improved, and a scientific basis is provided for optimizing frequency modulation operation.

Description

Technical Field

[0001] The invention relates to the field of frequency converter control, and in particular to a method for automatically counting the number of times of manually remotely adjusting the frequency of a frequency converter. Background Art

[0002] Variable Frequency Drive (VFD) is an electric power control device used to control the running speed and output torque of AC motors. Its core function is to achieve stepless speed regulation and energy-saving control of the motor by changing the power supply frequency and voltage of the motor. As a core motor control device, the inverter has become an indispensable technical tool in modern industry, construction and home appliances due to its excellent speed regulation, energy saving and protection functions.

[0003] At present, in the basic automation system of the mining industry, the frequency of the frequency converter is mostly adjusted manually and remotely. With the development of intelligent technology in recent years, various mining companies are building intelligent production lines of their own brands, and basic automation is gradually upgrading in the direction of intelligence. During the implementation process, the first scenario to be sorted out and transformed is manual control.

[0004] The frequency converter is one of the devices with a higher frequency of manual control. In order to accurately develop a control model that can reasonably replace manual frequency modulation, it is necessary to count a large number of manual frequency modulation times and control frequency values. If a PLC controller is used to implement frequency modulation statistics, a large amount of historical data cannot be saved due to memory capacity limitations.

[0005] Currently, no effective solution has been proposed for the problems in the related technologies. Summary of the invention

[0006] In view of the problems in the related art, the present invention proposes a method for automatically counting the number of manual remote adjustments to the frequency of a frequency converter, so as to overcome the above technical problems existing in the existing related art.

[0007] To this end, the specific technical solution adopted by the present invention is as follows:

[0008] A method for automatically counting the number of times a frequency converter is manually remotely adjusted, the method comprising:

[0009] S1. Use the controller to receive manual remote frequency modulation instructions, and adjust the operating frequency of the inverter according to the frequency modulation instructions. At the same time, the controller collects the operating frequency of the inverter in real time and uploads it to the industrial control database server;

[0010] S2. Filter the inverter operating frequency value in the manual remote adjustment mode from the industrial control database server based on the frequency adjustment times calculation technology, perform deviation processing on the screening results, and count the frequency adjustment times of the inverter according to the deviation processing results;

[0011] S3. Analyze the frequency adjustment times of the inverter using abnormal pattern recognition technology to determine the operating status of the inverter, predict the accuracy of the manual remote frequency adjustment command based on the determination result, and generate an early warning prompt based on the accuracy verification result;

[0012] S4. Store the frequency adjustment result of the inverter, the operating status of the inverter and the early warning prompt in the industrial control database server and display them using visualization technology.

[0013] Preferably, based on the frequency modulation times calculation technology, the inverter operating frequency value in the manual remote adjustment mode is filtered from the industrial control database server, and deviation processing is performed on the filtering results. The frequency modulation times of the inverter are counted according to the deviation processing results, including:

[0014] S21. Filter out the inverter operating frequency records in the manual remote adjustment mode within a preset time period from the industrial control database server at the hour according to the frequency statistics requirement;

[0015] S22, frequency sampling is performed on each operating data in the inverter operating frequency record, an operating frequency correlation coefficient is obtained based on the frequency sampling result, and a sum of correlation coefficients corresponding to each frequency result in the operating frequency record is obtained according to the correlation coefficient;

[0016] S23, comparing the difference between the correlation coefficient sum and the standard coefficient sum, if the correlation coefficient sum is greater than or equal to the standard coefficient sum, performing deviation processing on the corresponding operating frequency, if the correlation coefficient sum is less than the standard coefficient sum, discarding the corresponding operating frequency;

[0017] S24. After the operation frequency deviation processing is completed, the operation frequencies are sorted in order of high to low, and the highest-ranked operation frequency is set as the frequency converter adjustment frequency statistics.

[0018] Preferably, frequency sampling is performed on each operating data in the inverter operating frequency record, the operating frequency correlation coefficient is obtained based on the frequency sampling result, and the correlation coefficient corresponding to each frequency result in the operating frequency record is obtained according to the correlation coefficient and includes:

[0019] S221, after defining the sampling time interval and abnormal filtering rules based on the sampling requirements, sort the operation data according to the timestamps, and extract the target frequency data according to the sampling time interval;

[0020] S222, using the target frequency data to set an index number, and obtaining a frequency sampling value corresponding to the index number, and calculating an operating frequency correlation coefficient based on the frequency sampling value;

[0021] S223. Normalize the operating frequency correlation coefficient, and obtain the sum of correlation coefficients corresponding to each frequency result in the operating frequency record based on the normalized operating frequency correlation coefficient.

[0022] Preferably, the calculation formula for the operating frequency correlation coefficient is:

[0023]

[0024] In the formula, R t1,t2 represents the index number t 1 and the operating frequency correlation coefficient corresponding to the index number t 2 , T represents the number of frequency points for frequency sampling, W t1 (l) represents the frequency sampling value of the target frequency data of the index number t 1 , W t2 (l) represents the frequency sampling value of the target frequency data of the index number t 2 , W t2 (l) * represents the conjugate transpose of W t2 (l).

[0025] Preferably, use the abnormal mode recognition technology to analyze the number of times the frequency converter adjusts the frequency, judge the operating state of the frequency converter, predict the accuracy of the manual remote frequency modulation command based on the judgment result, and generate a warning prompt according to the accuracy verification result, including:

[0026] S31. Obtain the average number of frequency modulation times when the frequency converter operates stably, and use the average number of frequency modulation times to construct a normal mode curve. At the same time, generate a comparison mode curve based on the obtained number of times the frequency converter adjusts the frequency;

[0027] S32. Analyze the similarity relationship between the comparison mode curve and the normal mode curve based on the abnormal mode recognition technology, and judge the operating state of the frequency converter according to the similarity result;

[0028] S33. Generate an evaluation model according to the operating state of the frequency converter and the historical frequency modulation command data, and use the evaluation model to predict the accuracy of the manual remote frequency modulation command, and output a rationality evaluation result to generate a warning prompt.

[0029] Preferably, in the process of constructing the normal mode curve or the comparison mode curve, the average number of frequency modulation times or the obtained number of times the frequency converter adjusts the frequency can be processed first to obtain a periodic target waveform, and the energy center of the periodic target waveform is judged. According to the energy center, a center point sequence is constructed, and the normal mode curve or the comparison mode curve is generated based on the center point sequence.

[0030] Preferably, analyze the similarity relationship between the comparison mode curve and the normal mode curve based on the abnormal mode recognition technology, and judge the operating state of the frequency converter according to the similarity result, including:

[0031] S321, obtaining a comparison mode curve and a normal mode curve, and selecting any point on the normal mode curve, drawing a circle with the arbitrary point as the center, and obtaining two intersection points between the circle and the comparison mode curve;

[0032] S322, calculating the straight-line distance between the two intersection points, analyzing the arc length between the arbitrary point and the two intersection points, and determining the curvature corresponding to the arbitrary point based on the straight-line distance and the arc length;

[0033] S323, selecting a random point on the comparison pattern curve, drawing a random circle with the random point as the center, and obtaining two connecting intersection points between the random circle and the comparison pattern curve;

[0034] S324, calculating the straight-line distance between the two connection intersections, analyzing the arc length between the random point and the two connection intersections, and determining the curvature corresponding to the random point based on the straight-line distance and the arc length;

[0035] S325. Calculate the similarity relationship between the comparison mode curve and the normal mode curve based on the curvature of any point and the curvature of random points, and determine the operating state of the inverter according to the similarity result.

[0036] Preferably, the expression for calculating the curve similarity is:

[0037]

[0038] In the formula, S xy Indicates the similarity relationship between the comparison mode curve x and the normal mode curve y, dx i Indicates the curvature corresponding to the i-th point on the comparison mode curve x, d yi Indicates the curvature corresponding to the i-th point on the comparison mode curve y, xy i represents the similarity set between the comparison mode curve x and the normal mode curve y, M represents the curve point set, and u represents an integer.

[0039] Preferably, generating an evaluation model based on the operating status of the frequency converter and historical frequency modulation instruction data, and using the evaluation model to predict the accuracy of the manual remote frequency modulation instruction, and outputting the rationality evaluation result to generate an early warning prompt includes:

[0040] S331, obtaining historical frequency modulation instruction data, and performing time alignment processing on the historical frequency modulation instruction data after preprocessing, combining the output frequency characteristics of the inverter's operating state, the frequency adjustment time characteristics, the instruction parameter characteristics, and the execution effect characteristics;

[0041] S332, using feature selection technology to select target features from output features, and determining the output target of the evaluation model according to the target features, and constructing an initial evaluation model based on support vector machine technology;

[0042] S333, inputting the target features as a training set into the initial evaluation model to obtain the accuracy of the historical frequency modulation instruction data, verifying the reliability of the initial evaluation model based on the output results, and optimizing the initial evaluation model according to the reliability results to obtain the evaluation model;

[0043] S334. Input the manual remote frequency modulation instruction into the evaluation model, predict the accuracy of the manual remote frequency modulation instruction, generate a rationality evaluation result based on the prediction result, and generate an early warning prompt based on the evaluation result.

[0044] Preferably, the rationality evaluation result includes normal operating status, abnormal operating status and seriously abnormal operating status; when the rationality evaluation result is normal operating status, it indicates that the accuracy of the manual remote frequency modulation instruction is high, and the operator is prompted to operate normally; when the rationality evaluation result is abnormal operating status, it indicates that the accuracy of the manual remote frequency modulation instruction is low, and the operator is prompted to operate normally after checking the target frequency; when the rationality evaluation result is seriously abnormal operating status, it indicates that the manual remote frequency modulation instruction is inaccurate, and the operator is prompted to stop executing the manual remote frequency modulation instruction and conduct an inspection.

[0045] The beneficial effects of the present invention are:

[0046] 1. The present invention adopts an industrial control database-based method to realize automatic statistics of the number of manual frequency converter adjustments, effectively solving the problem that the PLC controller cannot save a large amount of historical data. At the same time, the number of manual frequency adjustments is counted on the hour and the historical data is saved. Compared with the network information system, which directly searches, analyzes and calculates the database, the access load of the client to the database is greatly reduced. The automatic statistics of the number of manual remote frequency converter adjustments is realized and presented to the front-end screen. The PLC controller is used as a signal acquisition and output device. The command data of manual frequency adjustment in the PLC is collected and archived in real time through the industrial database server. The algorithm software is used to periodically calculate the number of frequency adjustments and the adjustment frequency, and finally the data is presented to the system screen. It also supports autonomous query, providing a data basis for analysis of intelligent remote frequency adjustment.

[0047] 2. The present invention realizes automation from data collection to analysis, storage and display in the process of automatic statistics of frequency times of the frequency converter, which greatly reduces the burden of manual operation and improves efficiency. It ensures the integrity and reliability of data through real-time collection, automatic screening and deviation processing, and provides a high-quality foundation for subsequent analysis. At the same time, it can also accurately predict the rationality of manual frequency modulation instructions and reduce the impact of invalid operations on equipment, thereby improving the overall operating efficiency of the equipment. It not only improves the safety and operating efficiency of the equipment, but also provides a scientific basis for optimizing frequency modulation operations and maintenance strategies. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] 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 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 work.

[0049] Figure 1 is a flow chart of a method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to an embodiment of the present invention;

[0050] Figure 2 This is a schematic diagram of a network structure in a method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to an embodiment of the present invention;

[0051] Figure 3 It is a statistical display interface of the number of manual frequency adjustment in a method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to an embodiment of the present invention. DETAILED DESCRIPTION

[0052] To further illustrate each embodiment, the present invention provides drawings, which are part of the disclosure of the present invention and are mainly used to illustrate the embodiments. They can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these contents, ordinary technicians in this field should be able to understand other possible implementation methods and advantages of the present invention.

[0053] According to an embodiment of the present invention, a method for automatically counting the number of manual remote adjustments to the frequency of a frequency converter is provided.

[0054] The present invention is further described with reference to the accompanying drawings and specific embodiments. Figure 1 As shown, according to the method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to an embodiment of the present invention, the method includes:

[0055] S1. Use the controller to receive manual remote frequency modulation instructions, and adjust the operating frequency of the inverter according to the frequency modulation instructions. At the same time, the controller collects the operating frequency of the inverter in real time and uploads it to the industrial control database server.

[0056] S2. Based on the frequency adjustment times calculation technology, the inverter operating frequency value in the manual remote adjustment mode is filtered from the industrial control database server, and deviation processing is performed on the filtering results. The frequency adjustment times of the inverter are counted according to the deviation processing results.

[0057] In one embodiment, based on the frequency modulation times calculation technology, the inverter operating frequency value in the manual remote adjustment mode is filtered from the industrial control database server, and deviation processing is performed on the filtering results. The frequency modulation times of the inverter are counted according to the deviation processing results, including:

[0058] S21. Filter out the inverter operating frequency records in the manual remote adjustment mode within a preset time period from the industrial control database server at the hour according to the frequency statistics requirement;

[0059] S22, frequency sampling is performed on each operating data in the inverter operating frequency record, an operating frequency correlation coefficient is obtained based on the frequency sampling result, and a sum of correlation coefficients corresponding to each frequency result in the operating frequency record is obtained according to the correlation coefficient;

[0060] S23, comparing the difference between the correlation coefficient sum and the standard coefficient sum, if the correlation coefficient sum is greater than or equal to the standard coefficient sum, performing deviation processing on the corresponding operating frequency, if the correlation coefficient sum is less than the standard coefficient sum, discarding the corresponding operating frequency;

[0061] S24. After the operation frequency deviation processing is completed, the operation frequencies are sorted in order of high to low, and the highest-ranked operation frequency is set as the frequency converter adjustment frequency statistics.

[0062] Specifically, frequency sampling is performed on each operating data in the inverter operating frequency record, the operating frequency correlation coefficient is obtained based on the frequency sampling result, and the correlation coefficient corresponding to each frequency result in the operating frequency record is obtained according to the correlation coefficient and includes:

[0063] S221. After defining the sampling time interval and abnormal filtering rules based on the sampling requirements, sort the operation data according to the timestamps, and extract the target frequency data according to the sampling time interval;

[0064] S222, using the target frequency data to set an index number, and obtaining a frequency sampling value corresponding to the index number, and calculating an operating frequency correlation coefficient based on the frequency sampling value;

[0065] S223: normalize the operating frequency correlation coefficient, and obtain the sum of the correlation coefficients corresponding to each frequency result in the operating frequency record based on the normalized operating frequency correlation coefficient.

[0066] Among them, the calculation formula of the operating frequency correlation coefficient is:

[0067]

[0068] In the formula, R t1,t2 Indicates index number t 1 With index number t 2 The corresponding operating frequency correlation coefficient, T represents the number of frequency points of frequency sampling, W t1 (l) indicates index number t 1 The frequency sampling value of the target frequency data, W t2 (l) indicates index number t 2 The frequency sampling value of the target frequency data, W t2 (l) * W t2 The conjugate transpose of (l).

[0069] Specifically, when comparing the difference between the correlation coefficient sum and the standard coefficient sum, if the correlation coefficient sum is greater than or equal to the standard coefficient sum, the corresponding operating frequency is subjected to deviation processing, and if the correlation coefficient sum is less than the standard coefficient sum, the corresponding operating frequency is discarded. A comparison rule can be pre-set: if the correlation coefficient sum is greater than or equal to the standard coefficient sum, the operating frequency meets the requirements and enters the next step of deviation processing; if the correlation coefficient sum is less than the standard coefficient sum, the operating frequency data does not meet the requirements and is directly discarded, and all frequency data are traversed, and classified and marked as "processed" or "discarded" according to the comparison results between the correlation coefficient sum and the standard coefficient sum; for data that meets the conditions (i.e., data with a correlation coefficient sum greater than or equal to the standard coefficient sum), enter the deviation processing link, calculate the frequency deviation value according to the deviation processing rule (such as the difference with the target frequency or expected frequency), and correct the operating frequency according to the deviation value to ensure that the corrected frequency is more in line with the standard.

[0070] S3. Use abnormal pattern recognition technology to analyze the number of times the inverter adjusts the frequency, determine the operating status of the inverter, predict the accuracy of the manual remote frequency adjustment command based on the judgment result, and generate an early warning prompt based on the accuracy verification result.

[0071] In one embodiment, the frequency adjustment times of the frequency converter are analyzed by using abnormal pattern recognition technology to judge the operating status of the frequency converter, the accuracy of the manual remote frequency adjustment instruction is predicted based on the judgment result, and an early warning prompt is generated according to the accuracy verification result, including:

[0072] S31, obtaining the average frequency modulation times when the frequency converter is running stably, and constructing a normal mode curve using the average frequency modulation times, and generating a comparison mode curve based on the obtained frequency modulation times of the frequency converter;

[0073] S32, analyzing the similarity relationship between the comparison mode curve and the normal mode curve based on the abnormal mode recognition technology, and judging the operating state of the inverter according to the similarity result;

[0074] S33. Generate an evaluation model based on the operating status of the frequency converter and historical frequency modulation instruction data, use the evaluation model to predict the accuracy of the manual remote frequency modulation instruction, output the rationality evaluation result and generate an early warning prompt.

[0075] Among them, in the process of constructing the normal mode curve or the comparison mode curve, the average frequency modulation times or the obtained inverter adjustment frequency times can be processed first to obtain a periodic target waveform, and the energy center of gravity of the periodic target waveform can be determined, and a center of gravity point sequence can be constructed according to the energy center of gravity, and a normal mode curve or a comparison mode curve can be generated based on the center of gravity point sequence.

[0076] Specifically, the similarity relationship between the analysis and comparison mode curve and the normal mode curve based on the abnormal mode recognition technology, and judging the inverter operation state according to the similarity result include:

[0077] S321, obtaining a comparison mode curve and a normal mode curve, and selecting any point on the normal mode curve, drawing a circle with the arbitrary point as the center, and obtaining two intersection points between the circle and the comparison mode curve;

[0078] S322, calculating the straight-line distance between the two intersection points, analyzing the arc length between the arbitrary point and the two intersection points, and determining the curvature corresponding to the arbitrary point based on the straight-line distance and the arc length;

[0079] S323, selecting a random point on the comparison pattern curve, drawing a random circle with the random point as the center, and obtaining two connecting intersection points between the random circle and the comparison pattern curve;

[0080] S324, calculating the straight-line distance between the two connection intersections, analyzing the arc length between the random point and the two connection intersections, and determining the curvature corresponding to the random point based on the straight-line distance and the arc length;

[0081] S325. Calculate the similarity relationship between the comparison mode curve and the normal mode curve based on the curvature of any point and the curvature of random points, and determine the operating state of the inverter according to the similarity result.

[0082] Among them, the expression for calculating curve similarity is:

[0083]

[0084] In the formula, S xy Indicates the similarity relationship between the comparison mode curve x and the normal mode curve y, dx i Indicates the curvature corresponding to the i-th point on the comparison mode curve x, d yi Indicates the curvature corresponding to the i-th point on the comparison mode curve y, xy i represents the similarity set between the comparison mode curve x and the normal mode curve y, M represents the curve point set, and u represents an integer.

[0085] Specifically, an evaluation model is generated based on the operating status of the inverter and historical frequency modulation instruction data, and the evaluation model is used to predict the accuracy of the manual remote frequency modulation instruction. The rationality evaluation result is output to generate early warning prompts, including:

[0086] S331, obtaining historical frequency modulation instruction data, and performing time alignment processing on the historical frequency modulation instruction data after preprocessing, combining the output frequency characteristics of the inverter's operating state, the frequency adjustment time characteristics, the instruction parameter characteristics, and the execution effect characteristics;

[0087] S332, using feature selection technology to select target features from output features, and determining the output target of the evaluation model according to the target features, and constructing an initial evaluation model based on support vector machine technology;

[0088] S333, inputting the target features as a training set into the initial evaluation model to obtain the accuracy of the historical frequency modulation instruction data, verifying the reliability of the initial evaluation model based on the output results, and optimizing the initial evaluation model according to the reliability results to obtain the evaluation model;

[0089] S334. Input the manual remote frequency modulation instruction into the evaluation model, predict the accuracy of the manual remote frequency modulation instruction, generate a rationality evaluation result based on the prediction result, and generate an early warning prompt based on the evaluation result.

[0090] Among them, the rationality evaluation results include normal operating status, abnormal operating status and seriously abnormal operating status; when the rationality evaluation result is normal operating status, it means that the accuracy of the manual remote frequency regulation instruction is high, and the operator is prompted to operate normally; when the rationality evaluation result is abnormal operating status, it means that the accuracy of the manual remote frequency regulation instruction is low, and the operator is prompted to check the target frequency and then operate normally; when the rationality evaluation result is seriously abnormal operating status, it means that the manual remote frequency regulation instruction is inaccurate, and the operator is prompted to stop executing the manual remote frequency regulation instruction and conduct an inspection.

[0091] S4. Store the frequency adjustment result of the inverter, the operating status of the inverter and the early warning prompt in the industrial control database server and display them using visualization technology.

[0092] In one embodiment, when the frequency adjustment result of the frequency converter, the operating status of the frequency converter and the early warning prompt are stored in the industrial control database server and displayed using visualization technology, the industrial control database server can be connected to ensure that the connection between the industrial control system and the database server is stable, and data is usually transmitted through an industrial communication protocol (such as OPC, Modbus or MQTT); a table for storing the frequency adjustment number, operating status and early warning prompt is created, and the example structure is as follows:

[0093] Frequency adjustment record table: timestamp (timestamp); inverter number (VFD_ID); frequency adjustment times (adjustment_count);

[0094] Operation status table: timestamp; inverter number; current frequency; output current, voltage, temperature; operation status (normal / abnormal);

[0095] Warning table: timestamp; inverter number; warning level (low / medium / high); prompt content; recommended operation;

[0096] The frequency modulation times, operating status and warning prompts are written into the corresponding database table in real time to ensure that the data records are complete and accurate. A scheduled task is configured to back up the database to prevent data loss.

[0097] Combine frequency modulation times, operation status and warning prompt information to provide a complete data set for visualization and further analysis. Perform aggregate analysis of frequency modulation times in the time dimension (such as counting frequency modulation times by hour, day, and week), analyze the trend of operation status changes (such as the frequency of abnormalities), and classify and summarize warning prompt information (such as the number of times different warning levels appear), determine the display content and form, and the main contents of the display include:

[0098] Frequency adjustment trend chart (line chart or bar chart); real-time monitoring of operating status (dashboard or status indicator); distribution of warning prompts (pie chart or bar chart), design different views for different users: operator view (real-time display of current operating status and warning prompts); manager view (display of frequency adjustment trend analysis and operating status statistics), use visualization tools commonly used in industrial control systems (such as SCADA system) or data visualization software (such as Tableau, PowerBI or Grafana); use intuitive layout and color coding (such as green for normal, yellow for warning, red for high risk):

[0099] The upper part shows the real-time running status of the current inverter;

[0100] The middle part shows the frequency modulation trend chart;

[0101] The most recent warning alerts are listed below.

[0102] This enables efficient storage, analysis and visual display of the frequency adjustment results, operating status and early warning prompts of the inverter.

[0103] It should be explained that the technical problem solved by the present embodiment is a set of processes designed specifically for the problem that PLC cannot save a large amount of historical data of statistical results of manual remote adjustment of the frequency converter. The process mainly includes a PLC controller, an industrial database server, a frequency modulation algorithm software, a terminal computer, and an industrial switch. The PLC controller collects the operating frequency of the frequency converter and drives the frequency adjustment of the frequency converter in real time. The remote frequency modulation command is sent to the PLC controller manually through the terminal computer. The industrial control database server collects and saves the command data of manual frequency modulation and the operating frequency data of the frequency converter in the PLC controller in real time. The frequency modulation algorithm software automatically retrieves the records of different operating frequency values ​​of the frequency converter in the manual frequency modulation mode of the previous hour in the database, and then performs abnormal data filtering. Finally, the number of records, frequency value change data, and frequency value change time are saved to the database. Finally, the data is presented to the interface according to the time range, and supports manual autonomous query.

[0104] The PLC controller and industrial switch are installed in the inverter distribution room, the terminal computer and industrial database server are installed in the centralized control room, the frequency modulation algorithm software is installed in the industrial database server, the inverter frequency signal is connected to the PLC controller through the control cable, and the terminal computer, industrial database server, and PLC controller are respectively wired with industrial Ethernet cables to the switch to form a data communication LAN communication structure.

[0105] like Figure 2 As shown, the PLC controller and the frequency converter are connected by control cables, the industrial control database server, the terminal computer and the PLC controller are connected by industrial Ethernet through a switch, the interactive signal between the PLC controller and the frequency converter is a standard 4-20mA current signal, and standard industrial communication protocol interfaces such as OPC and MBTCP are established between the industrial control database server, the terminal computer and the PLC controller to achieve data communication. An OLEDB data access permission interface is established between the frequency modulation algorithm software and the industrial control database to achieve frequency modulation statistics.

[0106] A data communication LAN is built between the industrial control database server and the PLC controller. The data in the PLC controller is collected in real time through standard industrial communication protocol interfaces such as OPC and MBTCP. The frequency modulation algorithm software needs to be installed in the industrial control database server. The historical data in the database is automatically extracted through the OLEDB interface for statistical calculation. The frequency modulation algorithm software is mainly responsible for automatically retrieving the historical data of manual frequency modulation instructions in the database and adjusting the frequency at the hour. After filtering and analyzing the abnormal data, the result data is saved in the database and presented to the system monitoring screen. The result data can be queried and browsed by selecting the time range, thereby providing a data basis for establishing a system autonomous regulation inverter control model.

[0107] For example Figure 3 The statistical chart of the number of manual controls of process equipment shown can be cleaned, browsed and queried for the number of manual controls and adjusted parameters of the adjusted equipment (such as the new 1# pedestal feeder for rod screen, the new 2# pedestal feeder, the old 1# pedestal feeder, the old 2# pedestal feeder, the 1# magnetic separator feed pump, the 2# magnetic separator feed pump, the thickener feed pump, the cyclone feed pump, the 1# feeding pump and the 2# feeding pump), and the specific control details and control logic can also be queried.

[0108] To sum up, with the help of the above technical scheme of the present invention, the present invention adopts an industrial control database-based method to realize automatic statistics of the number of manual frequency adjustment of the frequency converter, effectively solving the problem that the PLC controller cannot save a large amount of historical data. At the same time, the number of manual frequency adjustments is counted on the hour and the historical data is saved. Compared with the network information system that directly retrieves, analyzes and calculates the database, the access load of the client to the database is greatly reduced, and the automatic statistics of the number of manual remote frequency adjustment of the frequency converter is realized, and it is presented to the front-end screen. The PLC controller is used as a signal acquisition and output device, and the command data of manual frequency adjustment in the PLC is collected and archived in real time through the industrial database server, and the algorithm software is used to calculate the number of frequency adjustments and the adjustment frequency at regular intervals, and finally the data is presented to the system screen. It also supports autonomous query, providing a data basis for analysis for intelligent remote frequency adjustment. The present invention realizes automation from data collection to analysis, storage and display in the process of automatic statistics of frequency times of the frequency converter, which greatly reduces the burden of manual operation and improves efficiency. It ensures the integrity and reliability of data through real-time collection, automatic screening and deviation processing, and provides a high-quality basis for subsequent analysis. At the same time, it can also accurately predict the rationality of manual frequency modulation instructions and reduce the impact of invalid operations on equipment, thereby improving the overall operating efficiency of the equipment. It not only improves the safety and operating efficiency of the equipment, but also provides a scientific basis for optimizing frequency modulation operations and maintenance strategies.

[0109] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for automatically counting the number of manual remote frequency adjustment of a frequency converter, characterized in that: The method includes: S1. Use the controller to receive manual remote frequency modulation instructions, and adjust the operating frequency of the inverter according to the frequency modulation instructions. At the same time, the controller collects the operating frequency of the inverter in real time and uploads it to the industrial control database server; S2. Filter the inverter operating frequency value in the manual remote adjustment mode from the industrial control database server based on the frequency adjustment times calculation technology, perform deviation processing on the screening results, and count the frequency adjustment times of the inverter according to the deviation processing results; S3. Analyze the frequency adjustment times of the inverter using abnormal pattern recognition technology to determine the operating status of the inverter, predict the accuracy of the manual remote frequency adjustment command based on the determination result, and generate an early warning prompt based on the accuracy verification result; S4. Store the frequency adjustment result of the inverter, the operating status of the inverter and the early warning prompt in the industrial control database server and display them using visualization technology.

2. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 1, characterized in that: The frequency modulation times calculation technology is used to filter the inverter operating frequency value in the manual remote adjustment mode from the industrial control database server, and perform deviation processing on the filter results. The frequency modulation times of the inverter are counted according to the deviation processing results, including: S21. Filter out the inverter operating frequency records in the manual remote adjustment mode within a preset time period from the industrial control database server at the hour according to the frequency statistics requirement; S22, frequency sampling is performed on each operating data in the inverter operating frequency record, an operating frequency correlation coefficient is obtained based on the frequency sampling result, and a sum of correlation coefficients corresponding to each frequency result in the operating frequency record is obtained according to the correlation coefficient; S23, comparing the difference between the correlation coefficient sum and the standard coefficient sum, if the correlation coefficient sum is greater than or equal to the standard coefficient sum, performing deviation processing on the corresponding operating frequency, if the correlation coefficient sum is less than the standard coefficient sum, discarding the corresponding operating frequency; S24. After the operation frequency deviation processing is completed, the operation frequencies are sorted in order of high to low, and the highest-ranked operation frequency is set as the frequency converter adjustment frequency statistics.

3. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 2, characterized in that: The method of frequency sampling each operating data in the operating frequency record of the frequency converter, obtaining the operating frequency correlation coefficient based on the frequency sampling result, and obtaining the correlation coefficient corresponding to each frequency result in the operating frequency record according to the correlation coefficient includes: S221, after defining the sampling time interval and abnormal filtering rules based on the sampling requirements, sort the operation data according to the timestamps, and extract the target frequency data according to the sampling time interval; S222, using the target frequency data to set an index number, and obtaining a frequency sampling value corresponding to the index number, and calculating an operating frequency correlation coefficient based on the frequency sampling value; S223: normalize the operating frequency correlation coefficient, and obtain the sum of the correlation coefficients corresponding to each frequency result in the operating frequency record based on the normalized operating frequency correlation coefficient.

4. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 3, characterized in that: The calculation formula of the operating frequency correlation coefficient is: In the formula, R t1,t2 represents the operating frequency correlation coefficient corresponding to index number t1 and index number t2, T represents the number of frequency points of frequency sampling, W t1 (l) represents the frequency sampling value of the target frequency data with index number t1, W t2 (l) represents the frequency sampling value of the target frequency data with index number t2, W t2 (l) * W t2 The conjugate transpose of (l).

5. The method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to claim 1, characterized in that: The method of using abnormal pattern recognition technology to analyze the frequency adjustment times of the inverter, determine the operating status of the inverter, predict the accuracy of the manual remote frequency adjustment command based on the determination result, and generate an early warning prompt according to the accuracy verification result includes: S31, obtaining the average frequency modulation times when the frequency converter is running stably, and constructing a normal mode curve using the average frequency modulation times, and generating a comparison mode curve based on the obtained frequency modulation times of the frequency converter; S32, analyzing the similarity relationship between the comparison mode curve and the normal mode curve based on the abnormal mode recognition technology, and judging the operating state of the inverter according to the similarity result; S33. Generate an evaluation model based on the operating status of the frequency converter and historical frequency modulation instruction data, use the evaluation model to predict the accuracy of the manual remote frequency modulation instruction, output the rationality evaluation result and generate an early warning prompt.

6. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 5, characterized in that: In the process of constructing a normal mode curve or a comparison mode curve, the average frequency modulation times or the obtained frequency adjustment times of the frequency converter can be processed first to obtain a periodic target waveform, and the energy center of gravity of the periodic target waveform can be determined. A center of gravity point sequence can be constructed according to the energy center of gravity, and a normal mode curve or a comparison mode curve can be generated based on the center of gravity point sequence.

7. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 6, characterized in that: The analyzing and comparing the similarity relationship between the mode curve and the normal mode curve based on the abnormal mode recognition technology, and judging the inverter operation state according to the similarity result includes: S321, obtaining a comparison mode curve and a normal mode curve, and selecting any point on the normal mode curve, drawing a circle with the arbitrary point as the center, and obtaining two intersection points between the circle and the comparison mode curve; S322, calculating the straight-line distance between the two intersection points, analyzing the arc length between the arbitrary point and the two intersection points, and determining the curvature corresponding to the arbitrary point based on the straight-line distance and the arc length; S323, selecting a random point on the comparison pattern curve, drawing a random circle with the random point as the center, and obtaining two connecting intersection points between the random circle and the comparison pattern curve; S324, calculating the straight-line distance between the two connection intersections, analyzing the arc length between the random point and the two connection intersections, and determining the curvature corresponding to the random point based on the straight-line distance and the arc length; S325. Calculate the similarity relationship between the comparison mode curve and the normal mode curve based on the curvature of any point and the curvature of random points, and determine the operating state of the inverter according to the similarity result.

8. The method for automatically counting the number of manual remote frequency adjustment of the frequency converter according to claim 7, characterized in that: The expression for calculating the curve similarity is: In the formula, S xy Indicates the similarity relationship between the comparison mode curve x and the normal mode curve y, dx i Indicates the curvature corresponding to the i-th point on the comparison mode curve x, d yi Indicates the curvature corresponding to the i-th point on the comparison mode curve y, xy i represents the similarity set between the comparison mode curve x and the normal mode curve y, M represents the curve point set, and u represents an integer.

9. The method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to claim 8, characterized in that: The generating of the evaluation model according to the operating status of the frequency converter and the historical frequency modulation instruction data, and using the evaluation model to predict the accuracy of the manual remote frequency modulation instruction, and outputting the rationality evaluation result to generate an early warning prompt include: S331, obtaining historical frequency modulation instruction data, and performing time alignment processing on the historical frequency modulation instruction data after preprocessing, combining the output frequency characteristics of the inverter's operating state, the frequency adjustment time characteristics, the instruction parameter characteristics, and the execution effect characteristics; S332, using feature selection technology to select target features from output features, and determining the output target of the evaluation model according to the target features, and constructing an initial evaluation model based on support vector machine technology; S333, inputting the target features as a training set into the initial evaluation model to obtain the accuracy of the historical frequency modulation instruction data, verifying the reliability of the initial evaluation model based on the output results, and optimizing the initial evaluation model according to the reliability results to obtain the evaluation model; S334. Input the manual remote frequency modulation instruction into the evaluation model, predict the accuracy of the manual remote frequency modulation instruction, generate a rationality evaluation result based on the prediction result, and generate an early warning prompt based on the evaluation result.

10. The method for automatically counting the number of manual remote frequency adjustment of a frequency converter according to claim 9, characterized in that: The rationality evaluation results include normal operating status, abnormal operating status and seriously abnormal operating status; When the rationality assessment result is that the operating status is normal, it means that the accuracy of the manual remote frequency regulation instruction is high, and the operator is prompted to operate normally; when the rationality assessment result is that the operating status is abnormal, it means that the accuracy of the manual remote frequency regulation instruction is low, and the operator is prompted to check the target frequency and then operate normally; when the rationality assessment result is that the operating status is seriously abnormal, it means that the manual remote frequency regulation instruction is inaccurate, and the operator is prompted to stop executing the manual remote frequency regulation instruction and conduct an inspection.

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