Heat exchanger intelligent control system based on FPGA and MCGS configuration software

Abstract

The invention provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software. The heat exchanger intelligent control system comprises a heat exchanger body; the plurality of target sensors are used for collecting first sensing data of each target position in each heat exchanger main body and second sensing data of the environment where each heat exchanger is located; the FPGA main controller is used for determining the states of a plurality of parts of the heat exchanger main body according to the first sensing data, collected by the target sensor, of any heat exchanger main body and sending control information to the heat exchanger main body according to the states of the parts of the heat exchanger main body and the second sensing data; and the monitoring display screen is constructed through MCGS configuration software and used for receiving, updating and displaying the state of the at least one heat exchanger body. Through the implementation of the invention, the parallel processing of the FPGA shortens the data processing time, ensures the real-time performance and accuracy of control, can adapt to different working conditions, improves the energy conversion efficiency, and further improves the utilization efficiency of the heat exchanger.

Description

Technical Field

[0001] The present invention belongs to the technical field of information security, and particularly relates to an intelligent control system for heat exchangers based on FPGA and MCGS configuration software. Background Art

[0002] In the field of industrial production, as a key device for realizing heat exchange between fluids at different temperatures, heat exchangers are widely used in many industries such as chemical industry, electric power, food, and pharmaceuticals. In the early stage, the control of heat exchangers mostly relied on manual operation and simple instrument monitoring. Operators needed to conduct regular inspections and manually adjust the valve opening to control the fluid flow, thereby adjusting the heat exchange effect. This method not only consumed a lot of manpower, but also due to the subjectivity of human judgment and the untimely operation, it was difficult to maintain the heat exchange process at the optimal working condition, and energy waste was widespread.

[0003] With the development of technology, automation and intelligence have become the mainstream of heat exchanger control. Now, there are different ways to control frequency converters. Many use PLC or STM32 to control frequency converters. On this basis, improving the utilization efficiency of the heat exchanger system is a major means to save electricity, improve the process flow to improve the product quality of heat exchangers, improve the environment, and promote technological progress. However, due to the limitations of PLC or STM32, it is difficult to balance the accuracy and utilization efficiency of heat exchanger control. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide an intelligent control system for heat exchangers based on FPGA and MCGS configuration software to meet the requirements of simultaneously ensuring the accuracy and utilization efficiency of heat exchanger control.

[0005] To achieve the above object, the present invention provides the following technical solutions: The present invention provides an intelligent control system for heat exchangers based on FPGA and MCGS configuration software, including: at least one heat exchanger body; a plurality of target sensors for collecting first sensing data at each target position in each heat exchanger body and second sensing data of the environment where each heat exchanger is located; an FPGA main controller respectively connected to each target sensor and at least one heat exchanger body, for simultaneously determining the states of multiple components of a heat exchanger body according to the first sensing data of any heat exchanger body collected by the target sensor, and sending control information to the heat exchanger body according to the states of multiple components of the heat exchanger body and the second sensing data; a monitoring display screen including a monitoring display interface constructed by MCGS configuration software and connected to the FPGA main controller for receiving and updating the display of the states of at least one heat exchanger body.

[0006] Optionally, a circulation pump is included in the heat exchanger body, and the second sensor data includes the working environment temperature. According to the states of multiple components of the heat exchanger body and the second sensor data, control information is sent to the heat exchanger body, including: determining the control mode of the circulation pump; when the control mode is the fixed-frequency mode, inputting the heat exchanger fluid temperature, flow rate, and working environment temperature into the first target algorithm to determine the working frequency of the circulation pump, and taking the working frequency as the control information; when the control mode is the fixed-pressure-difference mode, inputting the heat exchanger fluid temperature, flow rate, and working environment temperature into the second target algorithm to determine the target pressure difference of the circulation pump, and using the PID control algorithm according to the difference between the target pressure difference and the actual pressure difference to determine the working frequency, and taking the working frequency as the control information.

[0007] Optionally, determining the control mode of the circulation pump includes: obtaining the environmental data of the environment where the heat exchanger is located, the process flow of the usage scenario, and the current process parameters; analyzing the current process parameters to determine the progress identification data; matching the process flow of the usage scenario according to the progress identification data to determine the current process progress; and determining the control mode of the circulation pump according to the current process progress and the environmental data of the environment where the heat exchanger is located.

[0008] Optionally, an electric valve is included in the heat exchanger body, and the second sensor data includes the working environment temperature. According to the states of multiple components of the heat exchanger body and the second sensor data, control information is sent to the heat exchanger body, including: determining the control mode of the electric valve; when the control mode is the fixed-valve-position mode, determining the opening degree of the electric valve according to the heat exchanger fluid temperature and the working environment temperature, and taking the opening degree of the electric valve as the control information; when the control mode is the fixed-temperature mode, determining the temperature set value according to the working environment temperature, determining the opening degree of the electric valve according to the temperature difference between the temperature set value and the heat exchanger fluid temperature, and taking the opening degree of the electric valve as the control information; when the control mode is the curve motion control mode, querying the opening degree change curve according to the heat exchanger fluid temperature and the working environment temperature to obtain the opening degree of the electric valve, and taking the opening degree of the electric valve as the control information.

[0009] Optionally, when the control mode is the curve motion control mode, based on the heat exchanger fluid temperature and the working environment temperature, query the opening change curve to obtain the electric valve opening, and use the electric valve opening as the control information, including: determining whether the heat exchanger fluid temperature is lower than the first temperature threshold; when the heat exchanger fluid temperature is lower than the first temperature threshold, call the change curve graph of time and opening, determine the first electric valve opening value corresponding to the time, and use the first electric valve opening value as the control information; when the heat exchanger fluid temperature is higher than the first temperature threshold, according to the difference between the heat exchanger fluid temperature and the working environment temperature, query the opening change curve to obtain the initial electric valve opening value; according to the currently determined initial electric valve opening value and the actual electric valve opening value obtained last time, determine the opening change rate; when the opening change rate exceeds the preset rate, then according to the change curve of time and opening, determine the second electric valve opening value corresponding to the current time; determine the difference between the initial electric valve opening value and the second electric valve opening value; according to the difference and the opening change rate, determine the optimal opening correction value at the current moment; according to the opening correction value, correct the initial electric valve opening value to obtain the final electric valve opening, and use this electric valve opening as the control information.

[0010] Optionally, the FPGA main controller includes: a fault identification module, configured to identify the fault cause of the corresponding heat exchanger body according to the first sensing data and / or the second sensing data collected by the target sensor; a repair strategy determination module, configured to determine a fault repair strategy according to the fault cause; a fault repair implementation module, configured to send the fault repair strategy to the corresponding heat exchanger body, and / or send the fault cause to the monitoring display screen for alarm.

[0011] Optionally, the first sensing data includes: the temperature data, pressure data of the primary and secondary side supply and return water, and the pressure data before and after the filter.

[0012] Optionally, the monitoring display interface includes a user window for receiving control parameters input by the user. The monitoring display screen sends the control parameters to the FPGA main controller, and the FPGA main controller controls the heat exchanger body according to the control parameters.

[0013] This embodiment provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software. Multiple target sensors are distributed at various target positions within the heat exchanger main body and its surrounding environment, capable of collecting first sensing data and second sensing data that reflect the operating state of the heat exchanger in real time and accurately. These data provide an accurate information basis for the FPGA main controller, enabling it to comprehensively analyze these data through a programmed logical judgment process and precisely determine the states of multiple components of the heat exchanger main body. Due to the powerful parallel processing ability of the FPGA main controller, which can simultaneously process data collected by multiple target sensors, it can analyze and process a large amount of sensing data in a short time and quickly determine the states of multiple components of each heat exchanger main body. Compared with the traditional sequential processing method, the parallel processing of FPGA greatly shortens the data processing time, ensuring the real-time and precision of control. At the same time, based on the data collected by the target sensors, the FPGA main controller can not only determine the states of the heat exchanger components but also send control information to the heat exchanger main body in combination with the environmental data, enabling the heat exchanger to always operate under the best working conditions. Through this intelligent control method, it can better adapt to different working conditions, improve the energy conversion efficiency, and thus enhance the utilization efficiency of the heat exchanger.

[0014] Other advantages, objectives, and features of the present invention will be described in the subsequent specification, and to some extent, will be obvious to those skilled in the art, or those skilled in the art can obtain teachings from the practice of the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the following specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to make the objectives, technical solutions, and beneficial effects of the present invention clearer, the present invention provides the following drawings for illustration: Figure 1 It is a schematic diagram of the modules of the heat exchanger intelligent control system based on FPGA and MCGS configuration software in the present invention; Figure 2 It is a specific example flowchart for querying the opening change curve according to the fluid temperature and working environment temperature of the heat exchanger to obtain the opening of the electric valve in the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art without creative efforts based on the embodiments of the present invention fall within the scope of protection of the present invention.

[0017] In the description of the present invention, it should be noted that, unless otherwise clearly specified and defined, the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can also be the communication inside two components. It can be a wireless connection or a wired connection. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0018] In addition, the technical features involved in different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0019] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software, as Figure 1 shown, including: At least one heat exchanger main body 101; Multiple target sensors 102, configured to collect first sensing data of each target position in each heat exchanger main body and second sensing data of the environment where each heat exchanger is located; An FPGA main controller 103, which is respectively connected to each target sensor and at least one heat exchanger main body, and is configured to simultaneously determine the states of multiple components of a heat exchanger main body according to the first sensing data of any heat exchanger main body collected by the target sensor, and send control information to the heat exchanger main body according to the states of multiple components of the heat exchanger main body and the second sensing data. A monitoring display screen 104, including a monitoring display interface, which is constructed by MCGS configuration software and is connected to the FPGA main controller, and is configured to receive and update the display of the states of at least one heat exchanger main body.

[0020] Exemplarily, the heat exchanger main body at least includes a heat exchange system, a power system, and a filtration system. The heat exchange system is responsible for heat exchange and can be a metal plate or a metal pipe. The power system includes devices such as a fan and a pump. The filtration system is used to filter impurities in the fluid.

[0021] For any heat exchanger, the Modbus protocol and Vivado software programming are used to enable the FPGA to receive real-time data from sensors on multiple heat exchanger systems to read their working status. At the same time, the FPGA development board can perform real-time settings on the working status of multiple heat exchanger devices. Specifically, corresponding sensors are installed at key positions inside the heat exchanger body. For example, temperature sensors can be placed in the inlet and outlet pipes, inside the heat exchange tubes, etc., pressure sensors are installed at the inlets and outlets, and flow sensors are installed on the pipes. An ambient temperature sensor is installed in the environment where the heat exchanger is located. After processing the output signals of all sensors through a signal conditioning circuit, such as amplification, filtering, etc., they are connected to the corresponding input pins of the FPGA main controller. The input pins of the FPGA main controller are connected to the output signals of each target sensor to ensure that data can be accurately transmitted to the FPGA main controller for processing. The output pins of the FPGA main controller are connected to the control components of the heat exchanger body, such as the electric control valve, the frequency converter of the circulation pump, etc., in order to send control information.

[0022] Write a data acquisition module program in the FPGA main controller to sample the output signals of each target sensor at regular intervals and convert the sampled data into digital quantities. According to the first sensed data collected, write a logical judgment process to judge the status of multiple components of the heat exchanger body. Then, combine the status of the heat exchanger body components and the second sensed data, and use a preset control algorithm, such as the PID control algorithm, to generate control information for the corresponding components of the heat exchanger body. For example, if it is detected that the outlet temperature of the heat exchanger is lower than the set value and the ambient temperature is low, then increase the rotation speed of the circulation pump or increase the opening degree of the electric control valve.

[0023] The connection between the monitoring display screen and the FPGA main controller is realized through the use of communication interfaces, such as serial ports, Ethernet, etc., to achieve data communication between the two. At the same time, the Modbus-RTU protocol is used to achieve parallel transmission and reception of data between the monitoring display screen and the FPGA main controller. The heat exchanger can be directly controlled in different time periods using the monitoring display screen, and the monitoring display screen can be a touch screen. At the FPGA main controller end, write a communication module program to achieve data communication between the FPGA main controller and the monitoring display screen. According to the selected communication interface protocol, pack the status data of the heat exchanger body to be displayed and send it to the monitoring display screen, and at the same time receive the control instructions sent by the monitoring display screen.

[0024] On the MCGS configuration software side, first, open the MCGS configuration software, create a new project, set the basic project parameters such as the project name and save path, add the device driver corresponding to the FPGA main controller in MCGS, and set the device connection according to the actual communication interface and parameters to ensure that MCGS can communicate with the FPGA main controller normally. Use the MCGS graphic editing tool to design the monitoring display interface, add various graphic elements on the interface, such as parameter display boxes for temperature, pressure, flow rate, etc., a schematic diagram of the heat exchanger, alarm indicator lights, etc., and set corresponding variables for each graphic element. These variables correspond to the data transmitted from the FPGA main controller to achieve real-time data update and display.

[0025] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software. Multiple target sensors are distributed at various target positions within the heat exchanger main body and its surrounding environment, capable of collecting first sensing data and second sensing data that reflect the operating state of the heat exchanger in real time and accurately. These data provide an accurate information basis for the FPGA main controller, enabling it to comprehensively analyze these data through a programmed logical judgment process and precisely determine the states of multiple components of the heat exchanger main body. Due to the powerful parallel processing ability of the FPGA main controller, it can simultaneously process the data collected by multiple target sensors. It can analyze and process a large amount of sensing data in a short time and quickly determine the states of multiple components of each heat exchanger main body. Compared with the traditional sequential processing method, the parallel processing of FPGA greatly shortens the data processing time, ensuring the real-time and precision of control. At the same time, based on the data collected by the target sensors, the FPGA main controller can not only determine the states of the heat exchanger components but also send control information to the heat exchanger main body in combination with the environmental data, enabling the heat exchanger to always operate under the best working conditions. Through this intelligent control method, it can better adapt to different working conditions, improve the energy conversion efficiency, and thus enhance the utilization efficiency of the heat exchanger.

[0026] The equipment control system of the heat exchanger system designed based on the MCGS touch screen and FPGA strives to efficiently achieve the automatic control of the heat exchange station equipment, improve the heating quality, save a large amount of human and material resources, and reduce unnecessary waste on the premise of meeting user needs. At the same time, the management personnel can more clearly understand the operation data of each heat exchange station, making the management more targeted and effectively improving the heating management level and the operation management level of the thermal system.

[0027] As an optional implementation method, the heat exchanger main body includes a circulation pump, and the second sensor data includes the working environment temperature. According to the states of multiple components of the heat exchanger main body and the second sensing data, sending control information to the heat exchanger main body includes: Determine the control mode of the circulation pump; When the control mode is the fixed - frequency mode, the heat exchanger fluid temperature, flow rate, and working environment temperature are input into the first target algorithm to determine the operating frequency of the circulation pump, and the operating frequency is used as the control information; When the control mode is the fixed - differential - pressure mode, the heat exchanger fluid temperature, flow rate, and working environment temperature are input into the second target algorithm to determine the target differential pressure of the circulation pump. According to the difference between the target differential pressure and the actual differential pressure, the PID control algorithm is used to determine the operating frequency, and the operating frequency is used as the control information.

[0028] Exemplarily, in the intelligent control system of the heat exchanger, the control mode can be determined in the following ways: The operator can manually select the control mode of the circulation pump, such as the fixed - frequency mode, the fixed - differential - pressure mode, or the PID control mode, through the human - machine interaction interface on the monitoring display screen. In addition, the control mode can also be automatically switched according to preset conditions and logic. For example, when the fluctuation range of the heat exchanger outlet fluid temperature exceeds the preset range, such as when the temperature fluctuation exceeds 3°C, the system automatically switches from the fixed - frequency mode to the PID control mode. In the fixed - frequency mode, the circulation pump operates at a fixed frequency. If the heat load changes greatly, it is difficult to accurately maintain the temperature stability, while the PID control mode can adjust the operating parameters of the circulation pump in real - time according to the temperature deviation, enhancing the accuracy of temperature control. The way of automatically switching the control mode according to preset conditions and logic in this embodiment is not limited, and those skilled in the art can determine it according to needs.

[0029] When the control mode is the fixed - frequency mode, a large amount of historical operation data is collected, including the heat exchanger fluid temperature, flow rate, working environment temperature under different working conditions, and the corresponding operating frequency of the circulation pump. By using the method of linear regression, a relational expression between the heat exchanger fluid temperature, flow rate, working environment temperature, and the corresponding operating frequency of the circulation pump is established. Then, the least - squares method is used to estimate the coefficients in the relational expression. In practical applications, the real - time collected heat exchanger fluid temperature, flow rate, and working environment temperature are substituted into the trained relational expression to calculate the operating frequency of the circulation pump, and it is sent to the circulation pump as the control information. The relational expression between the heat exchanger fluid temperature, flow rate, working environment temperature, and the corresponding operating frequency of the circulation pump can be the following formula: ; Wherein, represents the operating frequency of the circulation pump, represents the operating frequency of the circulation pump when the inlet fluid temperature is , respectively represent the system power matching coefficient and the environmental temperature correction term, represents the flow rate, represents the fluid density, represents the fluid constant - pressure specific heat capacity, respectively represent the heat exchanger inlet fluid temperature and the working environment temperature; It should be noted that The general value of can be 6. When the ambient temperature rises, it is necessary to enhance heat dissipation or heat exchange by increasing the pump frequency (increasing the flow rate). Therefore, setting as the numerator, represents the fluid heat load, can adjust the influence degree in the formula . When changes, will affect the value of the fraction, and then affect the calculation result of the final working frequency of the circulating pump. plays the role of a scaling factor, controlling the sensitivity of the influence of ambient temperature change on the working frequency of the circulating pump. At the same time, ensures that the denominator always maintains a certain value, ensuring that the formula can be reasonably calculated under various ambient temperature values. And different heat exchange systems have differences in the sensitivity to ambient temperature and the response mechanism. By adjusting value, the formula can better adapt to the characteristics of a specific system, flexibly change the action weight of ambient temperature on the working frequency of the circulating pump, and make the model calculation result more in line with the actual operation situation.

[0030] When the control mode is the constant pressure difference mode, according to the physical characteristics of the heat exchanger system, such as the flow resistance of the fluid, the pressure change in the heat exchange process, etc., based on the principle of fluid mechanics, establish the relationship between the pressure difference of the circulating pump and the fluid temperature, flow rate of the heat exchanger, and the working ambient temperature. The formula can be as follows: ; Among them, represents the target pressure difference setting value, respectively represent the flow rate square term coefficient, reflecting the pipe network resistance characteristics, the heat transfer efficiency correction coefficient, and the ambient temperature compensation coefficient. represents the flow rate, respectively represent the fluid temperature at the outlet of the heat exchanger, the fluid temperature at the inlet, and the working ambient temperature. It should be noted that value can be 0.1, value can be 0.2, is determined according to different fluid physical properties, and can be specifically determined through system comprehensive experiments. The reference value of its value can be 0.05. This embodiment does not limit the value. is used to describe the frictional resistance and local resistance of the pipe network. the temperature difference between the inlet and outlet in It reflects the heat transfer intensity. The change in temperature difference may indicate a change in the characteristics of the internal flow channels of the heat exchanger, such as fouling, uneven flow velocity distribution, etc., which will in turn affect the resistance. The pressure difference is corrected through this item. The ambient temperature reflects the heat transfer intensity. The change in temperature difference may indicate a change in the characteristics of the internal flow channels of the heat exchanger, such as fouling, uneven flow velocity distribution, etc., which will in turn affect the resistance. The pressure difference is corrected through this item. The ambient temperature The change may affect the physical properties of the fluid, such as viscosity. At low temperatures, the viscosity of the fluid increases, and the flow resistance increases. It is necessary to increase the pressure difference to ensure the flow rate. This item can compensate the pressure difference according to the ambient temperature.

[0031] After obtaining the set target pressure difference, according to the set target pressure difference and the actual pressure difference, determine the operating frequency of the circulation pump, and send the operating frequency as control information. The specific process is as follows: First, construct a deviation formula. The deviation formula is the difference between the target pressure difference and the actual pressure difference of the heat exchanger. Specifically: , the PID output formula is the prior art and will not be elaborated here. Input the result corresponding to the deviation formula into the PID output formula to obtain the PID control information.

[0032] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software. By determining different control modes of the circulation pump, it can flexibly adapt to the operating requirements of the heat exchanger under various working conditions. In the fixed-frequency mode, input the fluid temperature, flow rate, and working environment temperature of the heat exchanger into the first target algorithm to determine the operating frequency, which is applicable to scenarios with relatively stable working conditions and can reduce the control cost and complexity while ensuring the basic operating requirements. In the fixed-pressure-difference mode, first use the second target algorithm to combine the above three temperatures to determine the target pressure difference, and then use the PID control algorithm based on the difference between the target pressure difference and the actual pressure difference to determine the operating frequency, so that the circulation pump can adjust in real time and accurately according to the system pressure change, effectively maintaining the system pressure stability, improving the heat exchange efficiency and stability of the heat exchanger, ensuring the reliable operation of the system even when the working conditions fluctuate, and enhancing the adaptability and reliability of the entire system.

[0033] As an optional implementation method, determining the control mode of the circulation pump includes: Obtain the environmental data of the environment where the heat exchanger is located, the process flow of the usage scenario, and the current process parameters; Analyze the current process parameters to determine the progress identification data; Match the process flow of the usage scenario according to the progress identification data to determine the current process progress; Determine the control mode of the circulation pump according to the current process progress and the environmental data of the environment where the heat exchanger is located.

[0034] Exemplarily, environmental data of the environment where the heat exchanger is located are collected using various sensors, such as environmental temperature, humidity, air pressure, etc. These sensors can be installed around the heat exchanger to ensure that information on its actual operating environment can be accurately obtained. At the same time, the process flow of the usage scenario and the current process parameters are obtained from relevant production management systems or equipment control systems. The process flow may be stored in the form of documents, charts or program codes, containing information such as the steps and operating conditions of the entire production process. The current process parameters refer to the parameters monitored in real time during the production process, such as fluid flow rate, pressure, temperature, etc. For heat exchangers in chemical production, parameters such as the flow rate and temperature of the materials in the reaction kettle need to be obtained.

[0035] According to the characteristics of the process flow of the usage scenario, analyze the internal relationship between different process parameters and the process progress, and establish corresponding mathematical models or rule bases. For example, in the sterilization process of food processing, temperature and time are key parameters, and the process progress stage corresponding to different combinations of temperature and time can be determined according to historical data and process requirements. The currently collected process parameters are input into the established model or rule base for analysis to determine the progress identification data. This data can be a number, symbol or code, used to uniquely identify the stage where the current process is in the entire process. For example, in the process of brewing beer, according to parameters such as the temperature of the wort and the fermentation time, it is determined whether it is in the main fermentation, post-fermentation or filtration stage, and "1", "2", "3" are used as the progress identification data respectively.

[0036] Match the determined progress identification data with the process flow of the usage scenario. During the matching process, find the stage or step in the process flow corresponding to this progress identification data, which can be specifically achieved by traversing the process flow data and comparing the progress identification data. For example, in the electronic chip manufacturing process, match the progress identification data with each process step such as photolithography, etching, and packaging. When the matching progress identification data is found, the current process progress can be determined, clarifying which specific link in the process flow it is currently in, as well as the process requirements and expected goals of this link.

[0037] Establish a control mode decision model according to the influence of different process progress and environmental data on the control of the heat exchanger circulating pump. This model can be a rule set based on experience or an intelligent model trained through machine learning algorithms. Input the current process progress and environmental data into the control mode decision model, and the model outputs the corresponding circulating pump control mode. For example, in the concentration link of the pharmaceutical process, when the environmental temperature is high and the process progress is in the rapid concentration stage, the decision model determines to adopt the constant pressure difference mode to ensure the stability of the system pressure and improve the concentration efficiency; in winter when the environmental temperature is low, for the process stage that needs to rapidly increase the temperature, adopt the constant frequency mode and increase the frequency of the circulating pump.

[0038] This embodiment provides an intelligent control system for heat exchangers based on FPGA and MCGS configuration software, which realizes the accurate, intelligent and dynamic determination of the control mode of the heat exchanger circulation pump. By determining the progress identification data according to the process parameters and matching the process flow to clarify the current process progress, it can closely fit the control in different stages of actual production. By combining the process progress and environmental data to determine the circulation pump control mode, the selection of the control mode fully considers the real-time state of the system and the changes in the external environment, improves the adaptability and effectiveness of the circulation pump operation, avoids the limitations of a single control mode under complex working conditions, thereby optimizing the operation efficiency of the heat exchanger, reducing energy consumption, ensuring the stability of the production process and product quality, and enhancing the comprehensive performance and economic benefits of the entire system.

[0039] As an alternative implementation, the heat exchanger body includes an electric valve, and the second sensor data includes the working environment temperature. According to the states of multiple components of the heat exchanger body and the second sensor data, control information is sent to the heat exchanger body, including: Determine the control mode of the electric valve; When the control mode is the fixed valve position mode, according to the fluid temperature of the heat exchanger and the working environment temperature, determine the opening degree of the electric valve, and use the opening degree of the electric valve as the control information; When the control mode is the fixed temperature mode, according to the working environment temperature, determine the temperature set value, and according to the temperature difference between the temperature set value and the fluid temperature of the heat exchanger, determine the opening degree of the electric valve, and use the opening degree of the electric valve as the control information; When the control mode is the curve motion control mode, according to the fluid temperature of the heat exchanger and the working environment temperature, query the opening degree change curve to obtain the opening degree of the electric valve, and use the opening degree of the electric valve as the control information.

[0040] Exemplarily, in the intelligent control system of the heat exchanger, the control mode can be determined in the following ways: The operator can manually select the control mode of the electric valve, such as the fixed valve position mode, the fixed temperature mode or the curve motion control mode, through the human-machine interface on the monitoring display screen. In addition, the control mode can also be automatically switched according to preset conditions and logics. For example, when the heat exchanger is in the start-up stage or low-load operation, it is automatically switched to the fixed valve position mode for preliminary flow control; when the system enters the stable operation state, it is switched to the fixed temperature mode to maintain temperature stability; when specific process requirements or working conditions change, it is switched to the curve motion control mode.

[0041] In the fixed valve position mode, before the system is put into use, based on the design parameters of the heat exchanger, historical operation data, and actual working conditions testing, establish a database of the opening degrees of the electric valve corresponding to different combinations of the fluid temperature of the heat exchanger and the working environment temperature, or through mathematical modeling, obtain an empirical formula for calculating the opening degree of the electric valve based on the fluid temperature of the heat exchanger and the working environment temperature. When the system is in the fixed valve position mode, match the collected real-time fluid temperature of the heat exchanger and the working environment temperature data with the data in the database or substitute them into the empirical formula for calculation to determine the opening degree of the electric valve, and send the determined opening degree of the electric valve as control information to the driving device of the electric valve to adjust the electric valve to the corresponding opening position.

[0042] In the fixed temperature mode, determine the temperature set value according to the working environment temperature, combined with the process requirements and operation objectives of the heat exchanger. For example, through a temperature compensation function, use the working environment temperature as the input parameter to calculate the corresponding temperature set value. Then, collect the real-time fluid temperature of the heat exchanger and compare it with the determined temperature set value to calculate the temperature difference between the two. Finally, based on the PID control algorithm or other control algorithms, determine the opening degree of the electric valve according to the calculated temperature difference. The parameters of the control algorithm need to be debugged and optimized according to the characteristics of the heat exchanger and the actual operation conditions to achieve precise temperature control. Send the calculated opening degree of the electric valve as control information to the electric valve, and the electric valve adjusts the opening degree according to the control information, thereby regulating the fluid flow of the heat exchanger to make the fluid temperature of the heat exchanger gradually approach the temperature set value.

[0043] In the curve motion control mode, during the system design stage, based on the different working conditions and operation requirements of the heat exchanger, establish an opening degree change curve through theoretical calculation, experimental testing, or referring to the experience of similar systems. The opening degree change curve can be a function based on time or a function based on parameters such as the fluid temperature of the heat exchanger and the working environment temperature. Substitute the collected real-time fluid temperature of the heat exchanger and the working environment temperature data into the opening degree change curve for query to obtain the corresponding opening degree of the electric valve under the current working conditions, and send the queried opening degree of the electric valve as control information to the electric valve. The electric valve adjusts the opening degree according to the control information to adjust the operating state of the heat exchanger according to the preset opening degree change curve to meet the temperature or flow regulation requirements under different working conditions.

[0044] This embodiment provides an intelligent control system for heat exchangers based on FPGA and MCGS configuration software, which can flexibly select appropriate control strategies according to different working conditions and control objectives, improving the accuracy and adaptability of electric valve control. The fixed valve position mode determines the opening degree based on the fluid temperature of the heat exchanger and the working environment temperature, which can meet the fixed demand for the opening degree of the electric valve when the working conditions are relatively stable, ensuring the stable operation of the system; the fixed temperature mode determines the temperature set value based on the working environment temperature and adjusts the opening degree of the electric valve in combination with the difference from the fluid temperature, which can accurately control the fluid temperature of the heat exchanger, effectively cope with temperature changes, and ensure the temperature stability of the system; the curve motion control mode obtains the opening degree of the electric valve by querying the opening degree change curve, which is applicable to complex working conditions with specific requirements for the opening degree change of the electric valve, and can achieve more refined and intelligent control. The coexistence of multiple control modes enables the system to optimize operation in different scenarios and improve the reliability of the system.

[0045] As an alternative implementation, when the control mode is the curve motion control mode, according to the fluid temperature of the heat exchanger and the working environment temperature, query the opening degree change curve to obtain the opening degree of the electric valve, and use the opening degree of the electric valve as the control information, as Figure 2 shown, including: S1. Determine whether the fluid temperature of the heat exchanger is lower than the first temperature threshold. If it is lower than the first temperature threshold, then execute step S2; if it is equal to or higher than the first temperature threshold, then execute step S3; S2. Call the change curve of time and opening degree, determine the first opening degree value of the electric valve corresponding to the time, and use the first opening degree value of the electric valve as the control information; S3. According to the difference between the fluid temperature of the heat exchanger and the working environment temperature, query the opening degree change curve to obtain the initial opening degree value of the electric valve; S4. Determine the opening degree change rate according to the currently determined initial opening degree value of the electric valve and the actually obtained opening degree value of the electric valve in the previous time; S5. Judge whether the opening degree change rate exceeds the preset rate. If it exceeds, then execute steps S6 - S9; if it does not exceed, then execute step S10; S6. According to the change curve of time and opening degree, determine the second opening degree value of the electric valve corresponding to the current time; S7. Determine the difference between the initial opening degree value of the electric valve and the second opening degree value; S8. Determine the optimal opening degree correction value at the current moment according to the difference and the opening degree change rate; S9. Correct the initial opening degree value of the electric valve according to the opening degree correction value to obtain the final opening degree of the electric valve, and use the opening degree of the electric valve as the control information; S10. Use the initial opening degree value of the electric valve as the control information.

[0046] Exemplarily, before implementing this solution, a change curve graph of time and the opening degree of the electric valve is established through experimental tests or analysis of historical operation data, and an opening degree change curve determined by temperature is established. The change curve graph of time and the opening degree of the electric valve reflects the opening degree values that the electric valve should have at different time points when the fluid temperature of the heat exchanger is lower than the first temperature threshold. The opening degree change curve determined by temperature reflects the relationship between the difference between the fluid temperature of the heat exchanger and the working environment temperature and the opening degree.

[0047] According to the working requirements and process characteristics of the heat exchanger, the first temperature threshold is set. For example, for a heat exchanger used to heat a liquid, during the early low-temperature preheating process, time has a greater impact on the heat exchange process of the system. Adjusting the opening degree according to the time law can enable the system to quickly heat up to an appropriate state. Therefore, this specific value can be set as the first temperature threshold, assumed to be 50°C. The temperature sensor transmits the real-time measured fluid temperature data of the heat exchanger to the FPGA main controller, and the FPGA main controller continuously compares the measured temperature with the first temperature threshold to determine whether the fluid temperature of the heat exchanger is lower than the first temperature threshold.

[0048] When the FPGA main controller determines that the fluid temperature of the heat exchanger is lower than the first temperature threshold, it searches for the corresponding first electric valve opening degree value in the change curve graph of time and opening degree according to the current time. Assume that the corresponding opening degree value found in the graph at the current time is 30%. The determined first electric valve opening degree value is sent as control information to the electric valve actuator to adjust the electric valve to the corresponding opening degree.

[0049] When the fluid temperature of the heat exchanger is higher than the first temperature threshold, the initial opening degree value is determined by combining the difference between the fluid temperature and the working environment temperature, and then corrected according to the time curve. This can fully consider the temperature and time factors, make the opening degree of the electric valve more in line with the actual working conditions, and improve the control accuracy. Therefore, the FPGA main controller obtains the current fluid temperature and working environment temperature data of the heat exchanger and calculates the difference between the two. For example, the current fluid temperature of the heat exchanger is 60°C and the working environment temperature is 25°C, then the temperature difference is 60 - 25 = 35°C. According to the pre-established opening degree change curve, which reflects the relationship between the temperature difference and the initial opening degree value of the electric valve, the calculated temperature difference is used to query the corresponding initial opening degree value of the electric valve. For example, by querying the curve, when the temperature difference is 35°C, the initial opening degree value of the electric valve is 40%. When calculating the opening degree change rate, the previous actual opening degree value of the electric valve is obtained. For example, the previous actual opening degree value is 35%. According to the initial opening degree value of the electric valve determined this time, the previous actual opening degree value, and the time interval between the two measurements, the opening degree change rate is calculated.

[0050] Set a preset rate according to system requirements. The preset rate can be 4% per minute. Compare the calculated opening change rate with the preset rate to determine whether it exceeds. If the opening change rate exceeds the preset rate, determine the opening value of the second electric valve corresponding to the current time according to the change curve of time and opening. For example, the opening value of the second electric valve corresponding to the current time is found to be 45% from the figure. Calculate the difference between the initial opening value of the electric valve and the opening value of the second electric valve, that is, 45% - 40% = 5%.

[0051] Determine the optimal opening correction value at the current moment through a target algorithm, such as the proportional integral derivative algorithm, or according to the calculation rules set based on actual experience, based on the calculated difference and the opening change rate. For example, if a simple proportional algorithm is used and the proportional coefficient is assumed to be 0.5, then the optimal opening correction value = 5% × 0.5 = 2.5%. Add the optimal opening correction value to the initial opening value of the electric valve to obtain the final opening of the electric valve, that is, the final opening of the electric valve = 40% + 2.5% = 42.5%. Send the finally determined opening of the electric valve as control information to the electric valve actuator to control the actual opening adjustment of the electric valve.

[0052] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software, which adopts different control strategies by judging whether the fluid temperature of the heat exchanger is lower than the first temperature threshold. When the temperature is lower than the threshold, call the change curve graph of time and opening to determine the opening value of the first electric valve, and precise control can be carried out according to the time law in the low-temperature state. Because in the low-temperature stage, time has a greater impact on the heat exchange process of the system, and adjusting the opening according to the time law can quickly heat the system to a suitable state. When the temperature is higher than the threshold, determine the initial opening value by combining the difference between the fluid temperature and the working environment temperature, and then correct it according to the time curve, which can fully consider the temperature and time factors, make the opening of the electric valve more in line with the actual working conditions, and improve the control accuracy.

[0053] As an alternative implementation, the FPGA main controller includes: A fault identification module for identifying the fault cause of the corresponding heat exchanger body according to the first sensing data and / or the second sensing data collected by the target sensor; A repair strategy determination module for determining a fault repair strategy according to the fault cause; A fault repair implementation module for sending the fault repair strategy to the corresponding heat exchanger body and / or sending the fault cause to the monitoring display screen for alarm.

[0054] Exemplarily, based on the first sensing data and / or the second sensing data collected by the target sensor, where the first sensing data may include the temperature data, pressure data of the primary and secondary side supply and return water, and the pressure data before and after the filter. The way to identify the cause of the fault can be to use a machine learning algorithm to train the historical fault data to construct a fault identification model. For example, collect fault data from the historical data, including the temperature data, pressure data of the primary and secondary side supply and return water, the pressure data before and after the filter, and the cause of the fault, and use this as a training sample for supervised training. Then, input the real-time collected data into the trained model, and the model outputs the corresponding cause of the fault.

[0055] In addition, a fault rule library can be constructed to associate different combinations of sensing data with the corresponding causes of faults. Specifically, match the preprocessed data with the rules in the rule library to identify the cause of the fault. The fault repair strategy determination module determines the strategy corresponding to the cause of the fault by looking up a table. The fault repair implementation module sends the determined fault repair strategy to the heat exchanger main body through the communication interface. After receiving the strategy, the FPGA main controller of the heat exchanger main body automatically performs corresponding repair operations, such as adjusting the valve opening, starting the cleaning equipment, etc. At the same time, in case of an emergency, an alarm signal can be sent to the touch monitoring display interface and fed back to the management personnel in a timely manner. The management personnel can monitor the heat exchanger system in real time through this interface.

[0056] This embodiment provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software, which can realize the functions of self-checking for faults and self-repair.

[0057] As an optional implementation manner, the monitoring display interface includes a user window for receiving the control parameters input by the user. The monitoring display screen sends the control parameters to the FPGA main controller, and the FPGA main controller controls the heat exchanger main body according to the control parameters. The user window can receive the control parameters input by the user. The control parameters can be the opening of the electric valve, the frequency of the circulation pump, etc. set by the user according to the actual situation, or can be used to control other parts of the heat exchanger main body to complete the repair function.

[0058] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made in form and details without departing from the scope defined by the claims of the present invention.

Claims

1. An intelligent control system for a heat exchanger based on FPGA and MCGS configuration software, characterized in that, Including: At least one heat exchanger body; Multiple target sensors for collecting first sensing data at each target position within each heat exchanger body and second sensing data of the environment where each heat exchanger is located; An FPGA main controller, connected to each target sensor and at least one heat exchanger body respectively, for simultaneously determining the states of multiple components of a heat exchanger body according to the first sensing data of any heat exchanger body collected by the target sensor, and sending control information to the heat exchanger body according to the states of multiple components of the heat exchanger body and the second sensing data; A monitoring display screen, including a monitoring display interface, which is constructed by MCGS configuration software and connected to the FPGA main controller, for receiving and updating the display of the states of at least one heat exchanger body.

2. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 1, wherein A circulation pump is included in the heat exchanger body, and the second sensor data includes the working environment temperature. Sending control information to the heat exchanger body according to the states of multiple components of the heat exchanger body and the second sensing data includes: Determining the control mode of the circulation pump; When the control mode is the fixed frequency mode, inputting the heat exchanger fluid temperature, flow rate, and working environment temperature into a first target algorithm to determine the working frequency of the circulation pump, and taking the working frequency as the control information; When the control mode is the fixed pressure difference mode, inputting the heat exchanger fluid temperature, flow rate, and working environment temperature into a second target algorithm to determine the target pressure difference of the circulation pump, and using a PID control algorithm according to the difference between the target pressure difference and the actual pressure difference to determine the working frequency, and taking the working frequency as the control information.

3. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 2, characterized in that, Determining the control mode of the circulation pump includes: Obtaining the environmental data of the environment where the heat exchanger is located, the process flow of the usage scenario, and the current process parameters; Analyzing the current process parameters to determine progress identification data; Matching the process flow of the usage scenario according to the progress identification data to determine the current process progress; Determining the control mode of the circulation pump according to the current process progress and the environmental data of the environment where the heat exchanger is located.

4. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 1, wherein, An electric valve is included in the heat exchanger body, and the second sensor data includes the working environment temperature. Sending control information to the heat exchanger body according to the states of multiple components of the heat exchanger body and the second sensing data includes: Determining the control mode of the electric valve; When the control mode is the fixed valve position mode, determining the opening degree of the electric valve according to the heat exchanger fluid temperature and the working environment temperature, and taking the opening degree of the electric valve as the control information; When the control mode is the fixed temperature mode, determining the temperature set value according to the working environment temperature, determining the opening degree of the electric valve according to the temperature difference between the temperature set value and the heat exchanger fluid temperature, and taking the opening degree of the electric valve as the control information; When the control mode is the curve motion control mode, querying the opening degree change curve according to the heat exchanger fluid temperature and the working environment temperature to obtain the opening degree of the electric valve, and taking the opening degree of the electric valve as the control information.

5. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 4, wherein When the control mode is the curve motion control mode, querying the opening degree change curve according to the heat exchanger fluid temperature and the working environment temperature to obtain the opening degree of the electric valve, and taking the opening degree of the electric valve as the control information includes: Determining whether the heat exchanger fluid temperature is lower than a first temperature threshold; When the fluid temperature of the heat exchanger is lower than the first temperature threshold, call the change curve graph of time and opening degree, determine the opening degree value of the first electric valve corresponding to the time, and use the opening degree value of the first electric valve as the control information; When the fluid temperature of the heat exchanger is higher than the first temperature threshold, query the opening degree change curve according to the difference between the fluid temperature of the heat exchanger and the working environment temperature to obtain the initial opening degree value of the electric valve; Determine the opening degree change rate according to the initial opening degree value of the electric valve determined this time and the actual opening degree value of the electric valve obtained last time; When the opening degree change rate exceeds the preset rate, determine the opening degree value of the second electric valve corresponding to the current time according to the change curve of time and opening degree; Determine the difference between the initial opening degree value of the electric valve and the opening degree value of the second electric valve; Determine the optimal opening degree correction value at the current moment according to the difference and the opening degree change rate; According to the opening degree correction value, correct the initial opening degree value of the electric valve to obtain the final opening degree of the electric valve, and use the opening degree of the electric valve as the control information.

6. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 1, characterized in that, The FPGA main controller includes: A fault identification module, configured to identify the fault cause of the corresponding heat exchanger body according to the first sensing data and / or the second sensing data collected by the target sensor; A repair strategy determination module, configured to determine a fault repair strategy according to the fault cause; A fault repair implementation module, configured to send the fault repair strategy to the corresponding heat exchanger body, and / or send the fault cause to the monitoring display screen for alarm.

7. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to claim 6, wherein The first sensing data includes: the temperature data, pressure data of the primary and secondary side supply and return water, and the pressure data before and after the filter.

8. The intelligent control system for heat exchangers based on FPGA and MCGS configuration software according to any one of claims 1-7, characterized in that, The monitoring display interface includes a user window for receiving control parameters input by the user. The monitoring display screen sends the control parameters to the FPGA main controller, and the FPGA main controller controls the heat exchanger body according to the control parameters.

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