Intelligent control system of heat exchanger based on FPGA and MCGS configuration software

Abstract

The present invention provides an intelligent heat exchanger control system based on FPGA and MCGS configuration software, comprising: a heat exchanger body; multiple target sensors for collecting first sensor data of each target position in each heat exchanger body and second sensor data of the environment in which each heat exchanger is located; an FPGA main controller for simultaneously determining the status of multiple components of any heat exchanger body based on the first sensor data of the heat exchanger body collected by the target sensors, and sending control information to the heat exchanger body based on the status of the multiple components of the heat exchanger body and the second sensor data; a monitoring display screen constructed using MCGS configuration software for receiving and updating the display of the status of at least one heat exchanger body. By implementing the present invention, the parallel processing of the FPGA shortens data processing time, ensures the real-time and accuracy of control, can adapt to different working conditions, improves energy conversion efficiency, and thus improves the utilization efficiency of the heat exchanger.

Description

Technical Field

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

[0002] In industrial production, heat exchangers, as key equipment for heat exchange between fluids of varying temperatures, are widely used in numerous industries, including chemical, power, food, and pharmaceuticals. Early heat exchanger control relied heavily on manual operation and simple instrument monitoring. Operators were required to conduct regular inspections and manually adjust valve openings to control fluid flow and, in turn, the heat exchange effect. This approach was not only labor-intensive, but also, due to subjective judgment and untimely operation, made it difficult to maintain optimal heat exchange conditions, leading to widespread energy waste.

[0003] With the development of technology, automation and intelligence have become the mainstream of heat exchanger control. There are now different ways to control inverters. Many of them are controlled by PLC or STM32. On this basis, improving the utilization efficiency of heat exchanger systems is a major means of saving electricity, improving process flow to enhance heat exchanger product quality, improve the environment, and promote technological progress. However, due to the limitations of PLC or STM32, it is difficult to balance the control of heat exchangers between accuracy and utilization efficiency. Summary of the Invention

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

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] The present invention provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software, comprising: at least one heat exchanger body; a plurality of target sensors, for collecting first sensor data of each target position in each heat exchanger body and second sensor data of the environment in which 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 status of multiple components of any heat exchanger body based on the first sensor data of the heat exchanger body collected by the target sensor, and sending control information to the heat exchanger body based on the status of the multiple components of the heat exchanger body and the second sensor data; a monitoring display screen, comprising a monitoring display interface, the monitoring display interface being constructed through the MCGS configuration software, connected to the FPGA main controller, and for receiving and updating the display of the status of at least one heat exchanger body.

[0007] Optionally, the heat exchanger body includes a circulation pump, and the second sensor data includes the working environment temperature. According to the status 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 a fixed frequency mode, the heat exchanger fluid temperature, flow rate and working environment temperature are input into the first target algorithm to determine the working frequency of the circulation pump, and the working frequency is used as the control information; when the control mode is a constant pressure difference mode, the heat exchanger fluid temperature, flow rate and working environment temperature are input into the second target algorithm to determine the target pressure difference of the circulation pump, and according to the difference between the target pressure difference and the actual pressure difference, a PID control algorithm is used to determine the working frequency, and the working frequency is used as the control information.

[0008] Optionally, determining the control mode of the circulation pump includes: obtaining environmental data of the environment in which the heat exchanger is located, the process flow of the usage scenario, and 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 in which the heat exchanger is located.

[0009] Optionally, the heat exchanger body includes an electric valve, and the second sensor data includes the working environment temperature. Control information is sent to the heat exchanger body based on the status of multiple components of the heat exchanger body and the second sensor data, including: determining the control mode of the electric valve; when the control mode is a fixed valve position mode, determining the opening of the electric valve based on the heat exchanger fluid temperature and the working environment temperature, and using the electric valve opening as control information; when the control mode is a fixed temperature mode, determining a temperature set value based on the working environment temperature, determining the electric valve opening based on the temperature difference between the temperature set value and the heat exchanger fluid temperature, and using the electric valve opening as control information; when the control mode is a curve motion control mode, querying the opening change curve based on the heat exchanger fluid temperature and the working environment temperature, obtaining the electric valve opening, and using the electric valve opening as control information.

[0010] Optionally, when the control mode is a curve motion control mode, the opening change curve is queried according to the heat exchanger fluid temperature and the working environment temperature to obtain the electric valve opening, and the electric valve opening is used as control information, including: determining whether the heat exchanger fluid temperature is lower than a first temperature threshold; when the heat exchanger fluid temperature is lower than the first temperature threshold, calling the time and opening change curve to determine the first electric valve opening value corresponding to the time, and using the first electric valve opening value as control information; when the heat exchanger fluid temperature is higher than the first temperature threshold, querying the opening change according to the difference between the heat exchanger fluid temperature and the working environment temperature curve to obtain the initial opening value of the electric valve; determine the opening change rate based on the initial opening value of the electric valve determined this time and the actual electric valve opening value obtained last time; when the opening change rate exceeds the preset rate, determine the second electric valve opening value corresponding to the current time based on the time and opening change curve; determine the difference between the initial opening value of the electric valve and the second electric valve opening value; determine the optimal opening correction value at the current moment based on the difference and the opening change rate; correct the initial opening value of the electric valve based on the opening correction value to obtain the final electric valve opening, and use the electric valve opening as control information.

[0011] Optionally, the FPGA main controller includes: a fault identification module, which is used to identify the cause of the fault of the corresponding heat exchanger body based on the first sensor data and / or second sensor data collected by the target sensor; a repair strategy determination module, which is used to determine the fault repair strategy according to the fault cause; a fault repair implementation module, which is used 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.

[0012] Optionally, the first sensing data includes: temperature data and pressure data of the primary and secondary side supply and return water, and pressure data before and after the filter.

[0013] 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.

[0014] This embodiment provides an intelligent heat exchanger control system based on an FPGA and MCGS configuration software. Multiple target sensors are distributed at various target locations within the heat exchanger body and its surrounding environment. These sensors can accurately and in real time collect first and second sensor data reflecting the operating status of the heat exchanger. This data provides an accurate information basis for the FPGA main controller, enabling it to comprehensively analyze this data through a programmed logical judgment process to accurately determine the status of multiple components within the heat exchanger body. Due to the FPGA main controller's powerful parallel processing capabilities, it can simultaneously process data collected by multiple target sensors. It can analyze and process large amounts of sensor data in a short period of time and quickly determine the status of multiple components within each heat exchanger body. Compared with traditional sequential processing methods, FPGA parallel processing significantly shortens data processing time, ensuring real-time and accurate control. Furthermore, based on the data collected by the target sensors, the FPGA main controller can not only determine the status of heat exchanger components but also send control information to the heat exchanger body in combination with environmental data, ensuring that the heat exchanger always operates under optimal conditions. This intelligent control method can better adapt to different operating conditions, improve energy conversion efficiency, and thus enhance the utilization efficiency of the heat exchanger.

[0015] Other advantages, objectives and features of the present invention will be described in the following description and will be apparent to those skilled in the art to some extent, or those skilled in the art can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to make the purpose, technical solutions and beneficial effects of the present invention more clear, the present invention provides the following drawings for illustration:

[0017] Figure 1 Schematic diagram of the module of the heat exchanger intelligent control system based on FPGA and MCGS configuration software in the present invention;

[0018] Figure 2 This is a specific example flow chart of obtaining the electric valve opening by querying the opening change curve according to the heat exchanger fluid temperature and the working environment temperature in the present invention. DETAILED DESCRIPTION

[0019] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0020] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; internal connections between two components; wireless connections or wired connections. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0021] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0022] This embodiment provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software, such as Figure 1 Shown, including:

[0023] at least one heat exchanger body 101;

[0024] A plurality of target sensors 102 for collecting first sensor data of each target position in each heat exchanger body and second sensor data of the environment in which each heat exchanger is located;

[0025] The FPGA main controller 103 is connected to each target sensor and at least one heat exchanger body, and is used to simultaneously determine the status of multiple components of any heat exchanger body based on the first sensor data collected by the target sensor, and send control information to the heat exchanger body based on the status of the multiple components of the heat exchanger body and the second sensor data;

[0026] The monitoring display screen 104 includes a monitoring display interface, which is constructed through MCGS configuration software and connected to the FPGA main controller for receiving and updating the status of at least one heat exchanger body.

[0027] For example, the heat exchanger body includes at least 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 metal pipe. The power system includes equipment such as fans and pumps. The filtration system is used to filter impurities in the fluid.

[0028] For any heat exchanger, the Modbus protocol and Vivado software are used to program the FPGA to receive real-time data from multiple heat exchanger system sensors to read their operating status. The FPGA development board can also set the operating status of multiple heat exchanger devices in real time. Specifically, corresponding sensors are installed at key locations within the heat exchanger body. For example, temperature sensors can be placed in the inlet and outlet pipes and inside the heat exchange tubes, pressure sensors are installed at the inlet and outlet, and flow sensors are installed on the pipes. Ambient temperature sensors and other sensors are installed in the heat exchanger's environment. All sensor output signals are processed through signal conditioning circuits such as amplification and filtering, and then connected to the corresponding input pins of the FPGA main controller. The FPGA main controller input pins are connected to the output signals of each target sensor to ensure that the data is accurately transmitted to the FPGA main controller for processing. The FPGA main controller output pins are connected to the heat exchanger's main control components, such as the electric control valve and the inverter of the circulation pump, to transmit control information.

[0029] A data acquisition module is programmed in the FPGA main controller to periodically sample the output signals of each target sensor and convert the sampled data into digital quantities. Based on the collected primary sensor data, a logic judgment process is developed to determine the status of multiple components in the heat exchanger. Then, combining the status of the heat exchanger components with the secondary sensor data, a preset control algorithm, such as the PID control algorithm, is applied to generate control information for the corresponding components of the heat exchanger. For example, if the heat exchanger outlet temperature is detected to be lower than the set value and the ambient temperature is low, the circulation pump speed is increased or the electric control valve opening is widened.

[0030] The connection between the monitoring display and the FPGA main controller uses communication interfaces such as serial ports and Ethernet to achieve data communication between the two. The Modbus-RTU protocol is also used to enable parallel data transmission and reception between the monitoring display and the FPGA main controller. This allows for time-segmented control of the heat exchanger directly through the monitoring display, which can be a touch screen. On the FPGA main controller side, a communication module is programmed to enable data communication between the FPGA main controller and the monitoring display. Based on the selected communication interface protocol, the heat exchanger status data to be displayed is packaged and sent to the monitoring display, while control commands from the monitoring display are also received.

[0031] On the MCGS configuration software side, first, open the MCGS configuration software, create a new project, set the basic project parameters, such as project name, save path, etc., 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 normally with the FPGA main controller. Use the MCGS graphic editing tool to design the monitoring display interface, add various graphic elements to the interface, such as temperature, pressure, flow and other parameter display boxes, heat exchanger schematics, alarm indicators, etc., set corresponding variables for each graphic element, and these variables correspond to the data transmitted from the FPGA main controller to achieve real-time data update and display.

[0032] This embodiment provides an intelligent heat exchanger control system based on FPGA and MCGS configuration software. Multiple target sensors are distributed at various target locations within the heat exchanger body and its surrounding environment. They can accurately collect first and second sensor data reflecting the operating status of the heat exchanger in real time. This data provides an accurate information basis for the FPGA main controller, allowing it to comprehensively analyze this data through a programmed logical judgment process to accurately determine the status of multiple components of the heat exchanger body. Because the FPGA main controller has powerful parallel processing capabilities and can simultaneously process data collected by multiple target sensors, it can analyze and process large amounts of sensor data in a short period of time and quickly determine the status of multiple components of each heat exchanger body. Compared with traditional sequential processing methods, FPGA parallel processing greatly shortens data processing time and ensures real-time and accurate control. At the same time, based on the data collected by the target sensors, the FPGA main controller can not only determine the status of the heat exchanger components but also send control information to the heat exchanger body in combination with environmental data, so that the heat exchanger always operates under optimal conditions. This intelligent control method can better adapt to different working conditions, improve energy conversion efficiency, and thus enhance the utilization efficiency of the heat exchanger.

[0033] The heat exchanger system equipment control system designed based on MCGS touch screen and FPGA strives to achieve efficient automatic control of heat exchange station equipment, improve the quality of heating, save a lot of manpower and material resources and reduce unnecessary waste while meeting user needs; at the same time, management personnel can have a clearer understanding of the operating data of each heat exchange station, making management more targeted, and effectively improving the level of heating management and the operation management level of the thermal system.

[0034] As an optional embodiment, the heat exchanger body includes a circulation pump, the second sensor data includes the working environment temperature, and control information is sent to the heat exchanger body based on the status of multiple components of the heat exchanger body and the second sensor data, including:

[0035] Determine the control mode of the circulation pump;

[0036] When the control mode is 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;

[0037] When the control mode is the constant pressure difference mode, the heat exchanger fluid temperature, flow rate and working environment temperature are input into the second target algorithm to determine the target pressure difference of the circulation pump. According to the difference between the target pressure difference and the actual pressure difference, the PID control algorithm is used to determine the operating frequency, and the operating frequency is used as the control information.

[0038] For example, 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 constant pressure difference mode or the PID control mode, through the human-computer interaction interface on the monitoring display screen. In addition, the control mode can be automatically switched according to preset conditions and logic. For example, when the temperature fluctuation amplitude of the fluid at the outlet of the heat exchanger exceeds the preset range, for example, 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 temperature stability. The PID control mode can adjust the operating parameters of the circulation pump in real time according to the temperature deviation, thereby enhancing the accuracy of temperature control. This embodiment does not limit the method of automatically switching the control mode according to the preset conditions and logic, and those skilled in the art can determine it as needed.

[0039] When the control mode is fixed frequency mode, a large amount of historical operating data is collected, including the heat exchanger fluid temperature, flow rate, working environment temperature and the corresponding circulating pump operating frequency under different working conditions. The linear regression method is used to establish the relationship between the heat exchanger fluid temperature, flow rate, working environment temperature and the corresponding circulating pump operating frequency. Then, the least squares method is used to estimate the coefficients in the relationship. In actual applications, the real-time collected heat exchanger fluid temperature, flow rate and working environment temperature are substituted into the trained relationship to calculate the operating frequency of the circulating pump and send it to the circulating pump as control information. The relationship between the heat exchanger fluid temperature, flow rate, working environment temperature and the corresponding circulating pump operating frequency can be as follows: ;

[0040] in, Indicates the operating frequency of the circulation pump, Indicates that the inlet fluid temperature is The operating frequency of the circulating pump is Represent the system power matching coefficient and the ambient temperature correction term respectively, Indicates flow rate, represents the fluid density, represents the specific heat capacity of the fluid at constant pressure, Respectively represent the heat exchanger inlet fluid temperature and working environment temperature; it should be noted that, The general value of can be 0.8, The value can be 6. When the ambient temperature When the pressure rises, it is necessary to increase the pump frequency (increase the flow) to enhance the heat dissipation or heat exchange, so the setting As a molecule, represents the fluid heat load, Can be used in the formula The degree of influence is adjusted. When changes, The change of will affect the value of the fraction, and thus affect the final operating frequency of the circulating pump The calculation results are: It plays the role of scaling factor, controlling the sensitivity of ambient temperature changes to the operating frequency of the circulating pump. The existence of keeps the denominator constant, ensuring that the formula can be calculated reasonably under various ambient temperature values. In addition, different heat exchange systems have different sensitivity and response mechanisms to ambient temperature. By adjusting The value of can make the formula better adapt to the characteristics of a specific system, flexibly change the weight of the effect of ambient temperature on the operating frequency of the circulating pump, and make the model calculation results more consistent with the actual operating conditions.

[0041] When the control mode is constant pressure differential mode, based on the physical characteristics of the heat exchanger system, such as the flow resistance of the fluid, the pressure change during the heat exchange process, etc., the relationship between the circulating pump pressure difference and the heat exchanger fluid temperature, flow rate and working environment temperature is established based on the principles of fluid mechanics. The formula can be as follows: ;

[0042] in, Indicates the target pressure difference setting value, They represent the flow square coefficient, reflecting the pipe network resistance characteristics, heat exchange efficiency correction coefficient, and ambient temperature compensation coefficient. Indicates flow rate, Respectively represent the heat exchanger outlet fluid temperature, inlet fluid temperature and working environment temperature. It should be noted that, The value of can be 0.1, The value of can be 0.2, It is determined according to different physical properties of the fluid, and can be specifically determined through system comprehensive experiments. The reference value can be 0.05, and this embodiment does not limit the value. Used to describe the resistance along the pipeline network and the local resistance. Temperature difference between inlet and outlet Reflects the intensity of heat exchange. The temperature difference change may mean that the flow characteristics of the heat exchanger have changed, such as scaling, uneven distribution of flow velocity, etc., which in turn affects the resistance. The pressure difference is corrected by this item. The ambient temperature reflects the intensity of heat exchange. The temperature difference change may mean that the flow characteristics of the heat exchanger have changed, such as scaling, uneven distribution of flow velocity, etc., which in turn affects the resistance. The pressure difference is corrected by this item. The ambient temperature Changes may affect the physical properties of the fluid, such as viscosity. At low temperatures, the viscosity of the fluid increases, the flow resistance increases, and the pressure difference needs to be increased to ensure the flow rate. This item can compensate for the pressure difference according to the ambient temperature.

[0043] After obtaining the set target pressure difference, the operating frequency of the circulation pump is determined based on the set target pressure difference and the actual pressure difference, and the operating frequency is sent as control information. The specific process is: first, a deviation formula is constructed. 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 an existing technology and will not be described in detail. The result corresponding to the deviation formula is input into the PID output formula to obtain PID control information.

[0044] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software. By determining different circulation pump control modes, it can flexibly adapt to the operating requirements of the heat exchanger under various working conditions. In 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. It is suitable for scenarios with relatively stable working conditions and can reduce control costs and complexity while ensuring basic operating requirements. In the constant pressure difference mode, the target pressure difference is first determined by combining the above three temperatures with the second target algorithm, and then the PID control algorithm is used to determine the operating frequency based on the difference between the target pressure difference and the actual pressure difference, so that the circulation pump can be accurately adjusted in real time according to the system pressure changes, effectively maintaining the system pressure stability, improving the heat exchange efficiency and stability of the heat exchanger, and ensuring the reliable operation of the system even when the working conditions fluctuate, thereby enhancing the adaptability and reliability of the entire system.

[0045] As an optional implementation manner, determining the control mode of the circulation pump includes:

[0046] Obtain environmental data of the heat exchanger's environment, process flow of the usage scenario, and current process parameters;

[0047] Analyze current process parameters and determine progress identification data;

[0048] Match the process flow of the usage scenario according to the progress identification data to determine the current process progress;

[0049] The control mode of the circulation pump is determined according to the current process progress and the environmental data of the environment in which the heat exchanger is located.

[0050] For example, various sensors are used to collect environmental data of the environment in which the heat exchanger is located, such as ambient temperature, humidity, air pressure, etc. These sensors can be installed around the heat exchanger to ensure that information about its actual operating environment can be accurately obtained. At the same time, the process flow and current process parameters of the usage scenario are obtained from the relevant production management system or equipment control system. 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. Current process parameters refer to parameters monitored in real time during the production process, such as fluid flow, pressure, temperature, etc. For heat exchangers in chemical production, it is necessary to obtain parameters such as the flow rate and temperature of the material in the reactor.

[0051] According to the process flow characteristics of the usage scenario, the intrinsic relationship between different process parameters and process progress is analyzed, and a corresponding mathematical model or rule base is established. For example, in the sterilization process of food processing, temperature and time are key parameters. The process progress stages corresponding to different temperature and time combinations can be determined based on historical data and process requirements. The collected current 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, which is used to uniquely identify the stage of the current process in the entire process. For example, in the process of brewing beer, the temperature of the wort, fermentation time and other parameters are used to determine whether it is currently in the main fermentation, post-fermentation or filtration stage, and "1", "2" and "3" are used as progress identification data respectively.

[0052] Match the identified progress identification data with the process flow of the usage scenario. During the matching process, the stage or step in the process flow that corresponds to the progress identification data is found. This can be achieved by traversing the process flow data and comparing the progress identification data. For example, in the electronic chip manufacturing process, the progress identification data is matched with various process steps such as lithography, etching, and packaging. Once the matching progress identification data is found, the current process progress can be determined, and the specific link in the process flow can be clearly identified, as well as the process requirements and expected goals of that link.

[0053] A control mode decision model is established based on the impact of different process schedules and environmental data on the control of the heat exchanger's circulating pump. This model can be based on an empirical rule set or an intelligent model trained through a machine learning algorithm. The current process schedule and environmental data are input 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 ambient temperature is high and the process schedule is in the rapid concentration stage, the decision model determines the use of a constant pressure differential mode to ensure system pressure stability and improve concentration efficiency. In winter, when the ambient temperature is low, a fixed frequency mode is used for process stages that require rapid temperature increase, and the circulating pump frequency is increased.

[0054] This embodiment provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software, which realizes the accurate, intelligent and dynamic determination of the heat exchanger circulation pump control mode. The progress identification data is determined according to the process parameters and the process flow is matched to clarify the current process progress. It can closely follow the different stages of actual production for control. The circulation pump control mode is determined by combining the process progress and environmental data. The control mode selection fully considers the real-time status of the system and changes in the external environment, improves the adaptability and effectiveness of the circulation pump operation, and avoids the limitations of a single control mode under complex working conditions, thereby optimizing the operating efficiency of the heat exchanger, reducing energy consumption, ensuring the stability of the production process and product quality, and improving the overall performance and economic benefits of the entire system.

[0055] As an optional embodiment, the heat exchanger body includes an electric valve, the second sensor data includes the working environment temperature, and control information is sent to the heat exchanger body based on the status of multiple components of the heat exchanger body and the second sensor data, including:

[0056] Determine the control mode of the electric valve;

[0057] When the control mode is fixed valve position mode, the opening of the electric valve is determined according to the fluid temperature of the heat exchanger and the working environment temperature, and the opening of the electric valve is used as the control information;

[0058] When the control mode is the constant temperature mode, the temperature set value is determined according to the working environment temperature, and the electric valve opening is determined according to the temperature difference between the temperature set value and the temperature of the heat exchanger fluid, and the electric valve opening is used as the control information;

[0059] When the control mode is the curve motion control mode, the opening change curve is queried according to the heat exchanger fluid temperature and the working environment temperature to obtain the electric valve opening, and the electric valve opening is used as the control information.

[0060] For example, in an intelligent heat exchanger control system, the control mode can be determined in the following ways: the operator can manually select the control mode of the electric valve, such as fixed valve position mode, fixed temperature mode, or curved motion control mode, through the human-machine interface on the monitor display. Furthermore, the control mode can be switched automatically based on preset conditions and logic. For example, when the heat exchanger is in the startup phase or operating at low load, it automatically switches to fixed valve position mode for preliminary flow control; when the system enters a stable operating state, it switches to fixed temperature mode to maintain temperature stability; and when specific process requirements or operating conditions change, it switches to curved motion control mode.

[0061] In the fixed valve position mode, before the system is put into use, a database of electric valve openings corresponding to different combinations of heat exchanger fluid temperature and working environment temperature is established based on the design parameters, historical operating data and actual working condition tests of the heat exchanger, or an empirical formula for calculating the electric valve opening based on the heat exchanger fluid temperature and working environment temperature is obtained through mathematical modeling. When the system is in the fixed valve position mode, the real-time heat exchanger fluid temperature and working environment temperature data collected are matched with the data in the database or substituted into the empirical formula for calculation to determine the opening of the electric valve. The determined electric valve opening is sent as control information to the drive device of the electric valve, so that the electric valve is adjusted to the corresponding opening position.

[0062] In the constant temperature mode, the temperature set value is determined based on the working environment temperature, combined with the process requirements and operating objectives of the heat exchanger. For example, a temperature compensation function can be used to calculate the corresponding temperature set value using the working environment temperature as an input parameter. Then, the heat exchanger fluid temperature is collected in real time and compared with the determined temperature set value to calculate the temperature difference between the two. Finally, based on the PID control algorithm or other control algorithm, the electric valve opening is determined 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 operating conditions to achieve precise temperature control. The calculated electric valve opening is sent to the electric valve as control information. The electric valve adjusts the opening according to the control information, thereby regulating the fluid flow of the heat exchanger so that the heat exchanger fluid temperature gradually approaches the temperature set value.

[0063] In the curve motion control mode, during the system design phase, an opening variation curve is established based on the different operating conditions and operational requirements of the heat exchanger through theoretical calculations, experimental testing, or reference to the experience of similar systems. The opening variation curve can be a function based on time or a function based on parameters such as the heat exchanger fluid temperature and the operating environment temperature. The collected real-time heat exchanger fluid temperature and operating environment temperature data are substituted into the opening variation curve for query to obtain the corresponding electric valve opening under the current operating conditions. The obtained electric valve opening is sent to the electric valve as control information. The electric valve adjusts the opening based on the control information, so that the operating state of the heat exchanger is adjusted according to the preset opening variation curve to meet the temperature or flow regulation requirements under different operating conditions.

[0064] 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, thereby improving the accuracy and adaptability of electric valve control. The fixed valve position mode determines the opening according to the heat exchanger fluid temperature and the working environment temperature, which can meet the fixed demand for the electric valve opening when the working conditions are relatively stable, ensuring stable system operation; the fixed temperature mode determines the temperature constant based on the working environment temperature, and adjusts the electric valve opening based on the difference with the fluid temperature, which can accurately control the heat exchanger fluid temperature, effectively respond to temperature changes, and ensure the temperature stability of the system; the curve motion control mode obtains the electric valve opening by querying the opening change curve, which is suitable for complex working conditions with specific requirements for the electric valve opening change, 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.

[0065] As an optional implementation, when the control mode is the curve motion control mode, the opening change curve is queried according to the heat exchanger fluid temperature and the working environment temperature to obtain the electric valve opening, and the electric valve opening is used as the control information, such as Figure 2 Shown, including:

[0066] S1, determining whether the temperature of the heat exchanger fluid is lower than a first temperature threshold, if it is lower than the first temperature threshold, executing step S2, if it is equal to or higher than the first temperature threshold, executing step S3;

[0067] S2, calling a curve chart showing changes in time and opening, determining the opening value of the first electric valve corresponding to the time, and using the opening value of the first electric valve as control information;

[0068] S3, according to the difference between the heat exchanger fluid temperature and the working environment temperature, query the opening change curve to obtain the initial opening value of the electric valve;

[0069] S4, determining the opening change rate based on the initial opening value of the electric valve determined this time and the actual opening value of the electric valve obtained last time;

[0070] S5, determine whether the opening change rate exceeds the preset rate, if it exceeds, execute steps S6-S9, if it does not exceed, execute step S10;

[0071] S6, determining the opening value of the second electric valve corresponding to the current time based on the time-opening variation curve;

[0072] S7, determining the difference between the initial opening value of the electric valve and the second opening value of the electric valve;

[0073] S8, determining the optimal opening correction value at the current moment based on the difference and the opening change rate;

[0074] S9, correcting the initial opening value of the electric valve according to the opening correction value to obtain a final electric valve opening, and using the electric valve opening as control information;

[0075] S10: The initial opening value of the electric valve is used as control information.

[0076] For example, before implementing this solution, through experimental tests or analysis of historical operating data, a curve diagram of the change in time and the opening of the electric valve and a curve of the opening change determined by temperature are established. The curve diagram of the change in time and the opening of the electric valve reflects the opening value of the electric valve at different time points when the temperature of the heat exchanger fluid is lower than the first temperature threshold. The opening change curve determined by temperature reflects the relationship between the difference between the temperature of the heat exchanger fluid and the working environment temperature and the opening.

[0077] The first temperature threshold is set based on the heat exchanger's operating requirements and process characteristics. For example, in a heat exchanger used to heat liquids, time significantly impacts the system's heat exchange process during the initial low-temperature preheating process. Adjusting the opening according to a time pattern allows the system to quickly reach the desired temperature. Therefore, a specific value, assuming 50°C, can be set as the first temperature threshold. The temperature sensor transmits real-time measured heat exchanger fluid temperature data to the FPGA main controller, which continuously compares the measured temperature with the first temperature threshold to determine whether the heat exchanger fluid temperature is below the first temperature threshold.

[0078] When the FPGA main controller determines that the heat exchanger fluid temperature is below the first temperature threshold, it searches the time-to-opening curve for the corresponding first electric valve opening value based on the current time. Assuming the corresponding opening value found in the curve is 30% at the current time, the determined first electric valve opening value is sent as control information to the electric valve actuator, causing the electric valve to adjust to the corresponding opening.

[0079] When the heat exchanger fluid temperature exceeds the first temperature threshold, the initial opening value is determined based on the difference between the fluid temperature and the ambient temperature. Correction is then made based on a time curve. This fully accounts for temperature and time factors, ensuring that the electric valve opening more closely matches actual operating conditions and improving control accuracy. Therefore, the FPGA main controller obtains the current heat exchanger fluid temperature and ambient temperature data and calculates the difference between them. For example, if the current heat exchanger fluid temperature is 60°C and the ambient temperature is 25°C, the temperature difference is 60-25 = 35°C. Based on a pre-established opening change curve, which reflects the relationship between the temperature difference and the initial opening value of the electric valve, the calculated temperature difference is used to query the corresponding initial opening value of the electric valve. For example, the curve shows that when the temperature difference is 35°C, the initial opening value of the electric valve is 40%. To calculate the opening change rate, the previous actual electric valve opening value is obtained. For example, if the previous actual electric valve opening value was 35%, the opening change rate is calculated based on the current initial opening value, the previous actual electric valve opening value, and the time interval between the two measurements.

[0080] A preset rate is set based on system requirements; the preset rate can be 4% per minute. The calculated opening change rate is compared with the preset rate to determine whether it exceeds the preset rate. If the opening change rate exceeds the preset rate, the corresponding opening value of the second electric valve at the current time is determined based on the time-to-opening curve. For example, the corresponding opening value of the second electric valve at the current time is 45% as shown in the graph. The difference between the initial opening value of the electric valve and the opening value of the second electric valve is calculated: 45% - 40% = 5%.

[0081] Based on the calculated difference and the rate of change in the valve opening, the optimal valve opening correction value at the current moment is determined using a target algorithm, such as a proportional-integral-differential algorithm, or a calculation rule established based on practical experience. For example, if a simple proportional algorithm is used, assuming a proportional coefficient of 0.5, the optimal valve opening correction value = 5% × 0.5 = 2.5%. The optimal valve opening correction value is added to the initial valve opening value to obtain the final valve opening: 40% + 2.5% = 42.5%. The final valve opening is sent as control information to the valve actuator to control the actual valve opening adjustment.

[0082] This embodiment provides an intelligent control system for a heat exchanger based on FPGA and MCGS configuration software. Different control strategies are adopted by judging whether the temperature of the heat exchanger fluid is lower than the first temperature threshold. When the temperature is lower than the threshold, the time and opening change curve is called to determine the opening value of the first electric valve. Precise control can be performed according to the time law under low temperature conditions. Because at low temperatures, time has a greater impact on the heat exchange process of the system, adjusting the opening according to the time law can allow the system to quickly heat up to a suitable state. When the temperature is higher than the threshold, the initial opening value is determined based on 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 electric valve opening more in line with the actual working conditions, and improve control accuracy.

[0083] As an optional implementation, the FPGA main controller includes:

[0084] a fault identification module, configured to identify a fault cause of the corresponding heat exchanger body based on the first sensor data and / or the second sensor data collected by the target sensor;

[0085] A repair strategy determination module is used to determine a fault repair strategy based on the cause of the fault;

[0086] The fault repair implementation module is used 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.

[0087] For example, based on the first sensor data and / or second sensor data collected by the target sensor, where the first sensor data may include temperature and pressure data of the primary and secondary supply and return water, as well as pressure data before and after the filter, the cause of the fault may be identified by training historical fault data using a machine learning algorithm to construct a fault identification model. For example, fault data, including temperature and pressure data of the primary and secondary supply and return water, as well as pressure data before and after the filter, and the cause of the fault, may be collected from historical data and used as training samples for supervised training. The real-time collected data is then input into the trained model, which then outputs the corresponding fault cause.

[0088] In addition, a fault rule library can be constructed to associate different sensor data combinations with corresponding fault causes. Specifically, the pre-processed data is matched with the rules in the rule library to identify the cause of the fault. The repair strategy determination module determines the strategy corresponding to the fault cause by looking up the table. The fault repair implementation module sends the determined fault repair strategy to the heat exchanger body with the help of the communication interface. After receiving the strategy, the FPGA main controller of the heat exchanger body automatically executes the corresponding repair operations, such as adjusting the valve opening, starting the cleaning equipment, etc. At the same time, when an emergency occurs, the alarm signal can be sent to the touch monitoring display interface and fed back to the management personnel in time. The management personnel can use this interface to realize real-time monitoring of the heat exchanger system.

[0089] This embodiment provides a heat exchanger intelligent control system based on FPGA and MCGS configuration software, which can realize fault self-checking and self-repair functions.

[0090] As an optional embodiment, the monitoring display interface includes a user window for receiving user-entered control parameters. The monitoring display then transmits these control parameters to the FPGA main controller, which then controls the heat exchanger based on these control parameters. The user window can receive user-entered control parameters, such as the electric valve opening and circulating pump frequency, as well as parameters used to control other components of the heat exchanger to complete the repair function.

[0091] 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. The heat exchanger intelligent control system based on FPGA and MCGS configuration software is characterized by: include: at least one heat exchanger body; A plurality of target sensors for collecting first sensor data of each target position in each heat exchanger body and second sensor data of the environment in which each heat exchanger is located; an FPGA main controller, connected to each target sensor and at least one heat exchanger body, and configured to simultaneously determine the status of multiple components of any heat exchanger body based on first sensor data of the heat exchanger body collected by the target sensor, and send control information to the heat exchanger body based on the status of the multiple components of the heat exchanger body and the second sensor data; A monitoring display screen, including a monitoring display interface, which is constructed using MCGS configuration software and connected to the FPGA main controller, and is used to receive and update the status of at least one heat exchanger body; The heat exchanger body includes an electric valve, and the second sensor data includes the working environment temperature. According to the status 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 fixed valve position mode, the opening of the electric valve is determined according to the fluid temperature of the heat exchanger and the working environment temperature, and the opening of the electric valve is used as the control information; When the control mode is the constant temperature mode, the temperature setting value is determined according to the working environment temperature, and the electric valve opening is determined according to the temperature difference between the temperature setting value and the temperature of the heat exchanger fluid, and the electric valve opening is used as the control information; When the control mode is the curve motion control mode, the opening change curve is queried according to the heat exchanger fluid temperature and the working environment temperature to obtain the electric valve opening, and the electric valve opening is used as the control information; When the control mode is the curve motion control mode, the opening change curve is queried according to the heat exchanger fluid temperature and the working environment temperature to obtain the electric valve opening, and the electric valve opening is used as the control information, including: determining whether the heat exchanger fluid temperature is below a first temperature threshold; When the temperature of the heat exchanger fluid is lower than the first temperature threshold, a time-to-opening change curve is called to determine the first electric valve opening value corresponding to the time, and the first electric valve opening value is used as control information; When the temperature of the heat exchanger fluid is higher than the first temperature threshold, the opening change curve is queried according to the difference between the heat exchanger fluid temperature and the working environment temperature to obtain the initial opening value of the electric valve; Determine the opening change rate based on the initial opening value of the electric valve determined this time and the actual opening value of the electric valve obtained last time; When the opening change rate exceeds the preset rate, the opening value of the second electric valve corresponding to the current time is determined according to the time and opening change curve; Determining a difference between an initial electric valve opening value and a second electric valve opening value; According to the difference and the opening change rate, the optimal opening correction value at the current moment is determined; The initial opening value of the electric valve is corrected according to the opening correction value to obtain the final electric valve opening, which is used as control information.

2. The heat exchanger intelligent control system based on FPGA and MCGS configuration software according to claim 1 is characterized in that: The heat exchanger body includes a circulation pump, and the second sensor data includes the working environment temperature. According to the status 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 circulation pump; When the control mode is 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 constant pressure difference mode, the heat exchanger fluid temperature, flow rate and working environment temperature are input into the second target algorithm to determine the target pressure difference of the circulation pump. According to the difference between the target pressure difference and the actual pressure difference, the PID control algorithm is used to determine the operating frequency, and the operating frequency is used as the control information.

3. The heat exchanger intelligent control system based on FPGA and MCGS configuration software according to claim 2 is characterized in that: Determine the control mode of the circulation pump, including: Obtain environmental data of the heat exchanger's environment, process flow of the usage scenario, and current process parameters; Analyze current process parameters and determine progress identification data; Match the process flow of the usage scenario according to the progress identification data to determine the current process progress; The control mode of the circulation pump is determined according to the current process progress and the environmental data of the environment in which the heat exchanger is located.

4. The heat exchanger intelligent control system based on FPGA and MCGS configuration software according to claim 1 is characterized in that: The FPGA master controller includes: a fault identification module, configured to identify a fault cause of the corresponding heat exchanger body based on the first sensor data and / or the second sensor data collected by the target sensor; A repair strategy determination module is used to determine a fault repair strategy based on the cause of the fault; The fault repair implementation module is used 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.

5. The heat exchanger intelligent control system based on FPGA and MCGS configuration software according to claim 4 is characterized in that: The first sensing data includes: temperature data and pressure data of the supply and return water on the primary and secondary sides, and pressure data before and after the filter.

6. The heat exchanger intelligent control system based on FPGA and MCGS configuration software according to any one of claims 1 to 5, 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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