A high-viscosity fluid precision metering system and implementation method

Abstract

The application discloses a high-viscosity fluid precision metering system and an implementation method, which comprise an electric control module, wherein the electric control module is connected with a self-calibration module, a temperature compensation module, a power delivery module and a sensing module; the temperature compensation module, the power delivery module and the sensing module are all installed on a pipeline through which the high-viscosity fluid flows; an inlet of the pipeline is provided with an inlet electric one-way valve; and an outlet of the pipeline is provided with an outlet electric one-way valve.The application has the following advantages: through self-calibration and algorithm optimization, the influence of parameter changes such as fluid temperature, pressure, viscosity and density on metering precision is eliminated; through viscosity adjustment, the problems of stagnation and blockage are solved; through the use of an ultrasonic non-contact sensing sensor, the fluid flow speed has no influence, and high-precision, high-stability and high-speed liquid delivery and metering are realized.

Description

TECHNICAL FIELD

[0001] The application is a high-viscosity fluid precision metering system, belonging to the technical field of flow metering. BACKGROUND

[0002] High-viscosity fluids are widely used in application fields such as chemical industry, food industry, pharmaceutical industry, petroleum industry, environmental protection industry, and building industry, for example: in the chemical industry: rubber, asphalt, epoxy resin, adhesive, high-temperature molten polymer;

[0003] In the food industry: high-viscosity food raw materials such as syrup, honey, chocolate syrup, milk, and fruit juice;

[0004] In the pharmaceutical industry: collagen and gel medical materials;

[0005] In the petroleum industry: crude oil and lubricating oil: high-viscosity crude oil, heavy oil, and lubricating oil;

[0006] In the environmental protection industry: sludge and waste liquid: sewage sludge containing solid particles and industrial waste liquid (such as oil-containing sludge);

[0007] In the building material industry: clay, cement additive, and other high-viscosity building materials.

[0008] Measurement is the counting of the quantity of fluid, and the delivery of fluid cannot be separated from measurement. The physical properties of high-viscosity fluid are special, and compared with conventional viscosity fluid, its measurement faces many technical challenges in industrial applications:

[0009] High-viscosity fluid has a complex flow state due to its high viscosity, which can easily form blockage in the flow meter, resulting in inaccurate measurement or even equipment damage;

[0010] High-viscosity fluid has poor flowability, which can easily form stagnation inside the flow meter, adhere to the inner wall of the pipeline or pump body, and affect the stability and accuracy of measurement.

[0011] High-viscosity fluid is sensitive to temperature, and its viscosity changes significantly with temperature (for example, the viscosity of asphalt can decrease by 50% for every 10℃ increase in temperature), which causes the change of fluid delivery pressure to affect the measurement accuracy.

[0012] The difficulties in high-viscosity fluid measurement industry have caused many application pain points in various industries, for example: asphalt paving: temperature fluctuations cause unstable pump delivery flow, resulting in uneven paving thickness; food industry: chocolate coating measurement is affected by viscosity changes, causing product weight differences to exceed the standard; pharmaceutical filling: syrup pharmaceutical filling requires high precision, but residual wall hanging affects the consistency of the dose; electronic packaging: epoxy resin dispensing requires milligram-level precision, but the fluid thixotropy causes flow to suddenly change during start and stop.

[0013] Traditional high viscosity fluid metering is driven by screw pump, piston pump and other high viscosity fluid flow, through the flow meter with mechanical counter, fluid drive flow meter inside the rotor rotation, by calculating the number of revolutions of the rotor to measure the volume of fluid, but this way has the following shortcomings:

[0014] (1) fluid parameter change influence measurement accuracy: fluid temperature, pressure, viscosity, density and other parameters change has influence on the measurement accuracy. For example, the change of viscosity causes low measurement accuracy: the viscosity of high viscosity fluid changes with temperature, batch, the force of the rotor inside the flow meter changes, and the measurement accuracy decreases significantly; the change of flow rate causes the measurement accuracy to deviate: the thixotropy of high viscosity fluid. When the same volume of fluid with different flow rates passes through the flow meter, the force on the rotor inside the flow meter changes, and the measurement is not accurate;

[0015] (2) cannot measure super high viscosity fluid: super high viscosity fluid is prone to form stagnation and blockage in the flow meter;

[0016] (3) flow rate affects measurement accuracy: if the flow rate is too high, the rotor speed inside the flow meter will reach the limit, which will affect the measurement accuracy. SUMMARY

[0017] The technical problem to be solved by the present application is to provide a high viscosity fluid precision metering system, which eliminates the influence of fluid temperature, pressure, viscosity, density and other parameter changes on the measurement accuracy through self-calibration and algorithm optimization, solves the stagnation and blockage problem through viscosity adjustment, uses ultrasonic non-contact transmission sensor, and is not affected by fluid flow rate, realizes high precision, high stability, high speed liquid delivery and measurement.

[0018] To solve the above technical problems, the present application adopts the following technical solutions:

[0019] A high viscosity fluid precision metering system, comprising an electric control module, the electric control module is connected with a self-calibration module, a temperature compensation module, a power delivery module and a sensing module, the temperature compensation module, the power delivery module and the sensing module are installed on the pipeline through which the high viscosity fluid flows, the inlet of the pipeline is provided with an inlet electric one-way valve, and the outlet of the pipeline is provided with an outlet electric one-way valve;

[0020] The power delivery module comprises a gear pump, the gear pump is connected with a frequency converter, the power delivery module is connected with the temperature compensation module, and the fluid adjusted in viscosity by the temperature compensation module is driven by the gear pump with frequency conversion;

[0021] The self-calibration module includes a sampling cylinder, the bottom of the sampling cylinder is provided with an electronic scale S5, the sampling cylinder is connected with a sampling feeding pipeline, a sampling discharging pipeline and a pressurizing pipeline, the sampling feeding pipeline is connected with a pipeline feeding position of the high viscosity fluid flow, the sampling discharging pipeline is connected with a pipeline discharging position of the high viscosity fluid flow, the sampling feeding pipeline is provided with a 2# self-calibration electric one-way valve, the sampling discharging pipeline is provided with a 1# self-calibration electric one-way valve, the pressurizing pipeline is used for inputting compressed air into the sampling cylinder, and the pressurizing pipeline is provided with a compressed air electromagnetic valve.

[0022] Further, the electric control module includes a PLC and a power supply, one end of a stop button K1 is connected with a positive electrode of the power supply, the other end of the stop button K1 is connected with one end of a start button K2 and one end of a self-protection contact of a main relay KM1, the other end of the start button K2 and the other end of the self-protection contact of the main relay KM1 are connected with one end of a coil of the main relay KM1 and one end of a main contact of the main relay KM1, and the other end of the coil of the main relay KM1 is connected with a negative electrode of the power supply.

[0023] Further, the other end of the main contact of the main relay KM1 is connected with the PLC, a temperature compensation module, one end of a coil of a feeding electric one-way valve KS1, one end of a variable frequency speed regulator SQ, one end of a temperature sensor S1, one end of a pressure sensor S2, one end of a viscosity sensor S3, one end of an ultrasonic speed sensor S4, one end of an electronic scale S5 and one end of an electronic densimeter S6, the other end of the coil of the feeding electric one-way valve KS1, the other end of the variable frequency speed regulator SQ, the other end of the temperature sensor S1, the other end of the pressure sensor S2, the other end of the viscosity sensor S3, the other end of the ultrasonic speed sensor S4, the other end of the electronic scale S5 and the other end of the electronic densimeter S6 are connected with a negative electrode of the power supply.

[0024] Further, an input terminal IN1 of the PLC is connected with a signal output terminal OUT1 of the temperature sensor S1, an input terminal IN2 of the PLC is connected with a signal output terminal OUT2 of the pressure sensor S2, an input terminal IN3 of the PLC is connected with a signal output terminal OUT3 of the viscosity sensor S3, an input terminal IN4 of the PLC is connected with a signal output terminal OUT4 of the ultrasonic speed sensor S4, an input terminal IN5 of the PLC is connected with a signal output terminal OUT5 of the electronic scale S5, and an input terminal IN6 of the PLC is connected with a signal output terminal OUT6 of the electronic densimeter S6.

[0025] Further, the PLC is connected with one end of a coil of a 1# self-calibration electric one-way valve KS2, one end of a coil of a 2# self-calibration electric one-way valve KS3, one end of a coil of a compressed air electromagnetic valve KS4 and one end of a coil of a discharging electric one-way valve KS5, and the other end of the coil of the 1# self-calibration electric one-way valve KS2, the other end of the coil of the 2# self-calibration electric one-way valve KS3, the other end of the coil of the compressed air electromagnetic valve KS4 and the other end of the coil of the discharging electric one-way valve KS5 are connected with a negative electrode of the power supply.

[0026] A method for implementing a high-viscosity fluid precision metering system, comprising the following steps:

[0027] Step 1. Perform self-calibration inner loop:

[0028] Press the start button, the main relay coil is powered and self-protected, the main relay main contact is closed, and the feeding electric one-way valve is opened;

[0029] The PLC controls the discharge electric one-way valve to close, the 1# self-calibration one-way electric valve to open, and the 2# self-calibration one-way electric valve to open, and the high-viscosity fluid enters the pipeline through the feeding electric one-way valve;

[0030] The high-viscosity fluid flows through the temperature compensation module, the gear pump, the ultrasonic speed sensor S4, the 1# self-calibration one-way electric valve, the self-calibration module, the 2# self-calibration one-way electric valve, and then the high-viscosity fluid enters the temperature compensation module again for inner loop;

[0031] Step 2. System outer loop:

[0032] The PLC controls the 1# self-calibration one-way electric valve to close, the 2# self-calibration one-way electric valve to close, and the discharge electric one-way valve to open, and the fluid is switched from inner loop to outer loop;

[0033] The high-viscosity fluid feeding electric one-way valve enters the pipeline, passes through the temperature compensation module, the gear pump, the ultrasonic speed sensor S4, and the discharge electric one-way valve to flow out of the pipeline;

[0034] By monitoring the flow rate data obtained by the ultrasonic speed sensor S4, the fluid metering reference data FL_1 is obtained, and by calibrating the proportionality coefficient K, the real flow of the fluid is obtained ;

[0035] Step 3. Build a system self-adaptive big data model:

[0036] Since the calibration proportionality coefficient K is related to temperature T, pressure P, viscosity D, and density q, a data correlation model of each parameter proportionality factor is established:

[0037] K = T * k1 + P * k2 + D * k3 + q * k4;

[0038] Where k1 is the temperature proportionality factor, k2 is the pressure proportionality factor, k3 is the viscosity proportionality factor, and k4 is the density proportionality factor;

[0039] Through big data analysis, self-learning is carried out, and a parameter-proportion factor relationship curve is drawn, so that when production is changed or process parameters are changed, self-calibration is not needed again, and through the parameter-proportion factor relationship curve, corresponding proportion factors k1, k2, k3 and k4 values can be quickly obtained according to various sensor data, a calibration proportion coefficient K is obtained through the formula K=T*k1+P*k2+D*k3+q*k4, and through the calibration proportion coefficient K, the real and accurate metering data can be obtained by multiplying the flow data of the ultrasonic speed sensor S4.

[0040] Further, the step 1 specifically comprises the following steps:

[0041] Step 1.1: Temperature compensation, adjusting fluid viscosity;

[0042] The high-viscosity fluid itself has poor flowability, and the temperature compensation module is used to heat the high-viscosity fluid to 50-80 DEG C, so that the flowability is increased and the viscosity value is 15000-30000 centipoise;

[0043] The temperature sensor S1 and the viscosity sensor S3 obtain temperature and viscosity values and send data to the electric control module;

[0044] Step 1.2: Frequency conversion speed regulation, adjusting fluid flow rate;

[0045] The frequency conversion speed regulator of the power transmission module drives the gear pump to operate, and the high-viscosity fluid is transmitted in the pipeline at a certain flow rate; in order to adapt to different delivery amounts, the output frequency of the frequency conversion speed regulator is increased or decreased to adjust the flow rate of the high-viscosity fluid in the pipeline;

[0046] The ultrasonic speed sensor S4 monitors the fluid speed value in the pipeline and sends data to the electric control module;

[0047] Step 1.3: Metering calibration;

[0048] In theory, the fluid speed is obtained by the ultrasonic speed sensor S4 on the outer wall of the pipeline, and the fluid flow rate can be obtained by multiplying the cross-sectional area of the pipeline, but in actual situation, the temperature, pressure, viscosity and density of the fluid in the pipeline will affect the electric signal data of the ultrasonic detection, and the detection data accuracy is reduced, so metering calibration is needed.

[0049] Further, the metering calibration comprises the following steps:

[0050] Step 1.3.1: Obtaining fluid parameter data in the pipeline;

[0051] The temperature sensor S1 acquires temperature data T, the pressure sensor S2 acquires pressure data P, the viscosity sensor S3 acquires viscosity data D, the ultrasonic flow sensor S4 acquires flow rate data V, and the calibration of the metering needs to be carried out in a stable parameter environment, and after the above data fluctuation is less than 1%, the next step is carried out;

[0052] Step 1.3.2, calculating the fluid metering reference data;

[0053] According to the flow rate data V acquired by the ultrasonic flow sensor S4, multiplied by the pipe cross-sectional area S, the fluid metering reference data FL_1=V*S can be acquired.

[0054] Step 1.3.3, self-calibration, calculating the proportionality coefficient of the fluid metering reference data and the true value;

[0055] The high-viscosity fluid can be flowed into the sampling cylinder for multiple times, and the weight data is obtained by multiple weighing until the liquid level of the sampling cylinder reaches the upper limit, the sampling cylinder is emptied, and then the high-viscosity fluid is flowed in and weighed, and the cycle is repeated.

[0056] In a unit sampling time △t, the high-viscosity fluid flows into the sampling cylinder through the 1# self-calibration one-way electric valve, the electronic scale S5 acquires the weight w of the high-viscosity fluid flowed in, and the density q of the high-viscosity fluid is acquired by the built-in electronic densimeter S6 in the sampling cylinder, and the volume of the high-viscosity fluid flowed in per unit time is calculated , then the true flow data of the high-viscosity fluid is ;

[0057] The calibration proportionality coefficient is calculated as follows: ;

[0058] The above is repeated, and the electronic scale S5 is continuously zeroed, and the weight is weighed respectively, and the proportionality coefficient K is continuously acquired according to the above method, and when the difference value of the continuous value is less than 1%, the self-calibration is completed.

[0059] The built-in liquid level switch of the sampling cylinder is electrified when the container liquid level reaches the upper limit, and the compressed air electromagnetic valve coil is electrified, and the compressed air enters the sampling cylinder through the pressurizing pipeline, and the high-viscosity fluid is discharged through the 2# self-calibration one-way electric valve and enters the internal circulation.

[0060] Compared with the prior art, the above technical scheme has the following technical effects:

[0061] Through self-calibration optimization, the influence of changes in fluid parameters such as temperature, pressure, viscosity, and density on measurement accuracy is eliminated. Viscosity adjustment solves the problems of stagnation and blockage. Ultrasonic non-contact sensor removal is adopted, unaffected by fluid flow rate, achieving high-precision, high-stability, and high-speed liquid delivery and measurement. It is suitable for high-viscosity fluids, especially ultra-high viscosity fluids above 100,000 cP, with a measurement accuracy of ±0.3%. Changeover efficiency is improved, with fluid changeover time of less than 15 minutes. It is suitable for high-flow-rate and high-volume fluid measurement, and the measurement accuracy will not decrease with the increase of flow rate. Attached Figure Description

[0062] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0063] Figure 1 This is a schematic diagram of the high-viscosity fluid precision metering system of the present invention;

[0064] Figure 2 This is a schematic diagram of the self-calibration module in this invention;

[0065] Figure 3 This is the electrical schematic diagram of the electronic control module in this invention;

[0066] Figure 4 This is a flowchart illustrating the implementation method of the high-viscosity fluid precision metering system in this invention. Detailed Implementation

[0067] Examples, such as Figure 1 and Figure 2 As shown, a high-viscosity fluid precision metering system includes an electrical control module, which is connected to a self-calibration module 9, a temperature compensation module 6, a power transmission module 7, and a sensing module 8. The temperature compensation module 6, the power transmission module 7, and the sensing module 8 are all installed on the pipeline through which the high-viscosity fluid flows. The pipeline inlet is equipped with an electric inlet check valve KS1, and the pipeline outlet is equipped with an electric outlet check valve.

[0068] The temperature compensation module 6 is used to heat the high-viscosity fluid, reducing its viscosity to a threshold range, thereby improving the fluidity of the high-viscosity fluid in the pipeline and solving the problem that the high-viscosity fluid itself has poor fluidity and is not easy to transport in the pipeline.

[0069] The power delivery module 7 comprises a gear pump connected with a frequency converter for frequency conversion and speed regulation of the gear pump, the power delivery module 7 is connected with the temperature compensation module 6, the fluid with viscosity adjusted by the temperature compensation module is driven by the frequency-converted gear pump to be transmitted in the pipeline at a certain flow rate, by adjusting the frequency of the frequency-converted motor of the gear pump, the flow rate of the fluid in the pipeline can be changed, the greater the flow rate, the greater the flow.

[0070] The sensing module 8 comprises a viscosity sensor S3, a temperature sensor S1, a pressure sensor S2, an ultrasonic velocity sensor S4 and an electronic densimeter S6; the viscosity sensor S3 monitors viscosity data in real time and feeds back to the temperature compensation module, the temperature sensor S1 monitors temperature data in real time, and through adjustment of temperature and viscosity, a temperature / viscosity closed-loop adjustment system is formed; the pressure sensor S2 is installed in the pipeline to detect the pressure value of the fluid in the pipeline; the ultrasonic velocity sensor S4 is installed on the outer wall of the pipeline to obtain ultrasonic data electrical signals generated by the fluid flow, and through electrical signal processing, the fluid velocity in the pipeline is obtained; the electronic densimeter S6 can obtain the density of the fluid in the pipeline.

[0071] The self-calibration module 9 comprises a sampling cylinder 1, the bottom of the sampling cylinder 1 is provided with an electronic scale S5, the sampling cylinder 1 is connected with a sampling feed pipeline 3, a sampling discharge pipeline 4 and a pressurizing pipeline 5, the sampling feed pipeline 3 is connected with a pipeline feed of high-viscosity fluid flow, the sampling discharge pipeline 4 is connected with a pipeline discharge of high-viscosity fluid flow, the sampling feed pipeline 3 is provided with a 2# self-calibration electric one-way valve, the sampling discharge pipeline 4 is provided with a 1# self-calibration electric one-way valve, the pressurizing pipeline 5 is used for inputting compressed air into the sampling cylinder 1, the pressurizing pipeline 5 is provided with a compressed air electromagnetic valve, the actual flow of the fluid can be calculated by measuring the weight of the fluid, the data of the ultrasonic velocity sensor S4 is calibrated, and the measurement accuracy is improved.

[0072] The electric control module collects signals of various sensors and processes data, establishes dynamic compensation data through an adaptive algorithm, and constructs a process parameter and proportional factor big data model.

[0073] As Figure 3As shown, the electric control module includes PLC and power supply, the positive pole of the power supply is connected with one end of the stop button K1, the other end of the stop button K1 is connected with one end of the start button K2 and one end of the self-protection contact of the main relay KM1, the other end of the start button K2 and the other end of the self-protection contact of the main relay KM1 are connected with one end of the coil of the main relay KM1 and one end of the main contact of the main relay KM1, the other end of the coil of the main relay KM1 is connected with the negative pole of the power supply, the other end of the main contact of the main relay KM1 is connected with the PLC, the temperature compensation module, one end of the coil of the feeding electric one-way valve KS1, one end of the frequency converter SQ, one end of the temperature sensor S1, one end of the pressure sensor S2, one end of the viscosity sensor S3, one end of the ultrasonic speed sensor S4, one end of the electronic scale S5, one end of the electronic densimeter S6, the other end of the coil of the feeding electric one-way valve KS1, the other end of the frequency converter SQ, the other end of the temperature sensor S1, the other end of the pressure sensor S2, the other end of the viscosity sensor S3, the other end of the ultrasonic speed sensor S4, the other end of the electronic scale S5, the other end of the electronic densimeter S6 are connected with the negative pole of the power supply.

[0074] The signal output end OUT1 of the temperature sensor S1 is connected with the input terminal IN1 of the PLC, the signal output end OUT2 of the pressure sensor S2 is connected with the input terminal IN2 of the PLC, the signal output end OUT3 of the viscosity sensor S3 is connected with the input terminal IN3 of the PLC, the signal output end OUT4 of the ultrasonic speed sensor S4 is connected with the input terminal IN4 of the PLC, the signal output end OUT5 of the electronic scale S5 is connected with the input terminal IN5 of the PLC, and the signal output end OUT6 of the electronic densimeter S6 is connected with the input terminal IN6 of the PLC.

[0075] The PLC is connected with one end of the coil of the 1# self-calibration electric one-way valve KS2, one end of the coil of the 2# self-calibration electric one-way valve KS3, one end of the coil of the compressed air electromagnetic valve KS4 and one end of the coil of the discharging electric one-way valve KS5, and the other end of the coil of the 1# self-calibration electric one-way valve KS2, the other end of the coil of the 2# self-calibration electric one-way valve KS3, the other end of the coil of the compressed air electromagnetic valve KS4 and the other end of the coil of the discharging electric one-way valve KS5 are connected with the negative pole of the power supply.

[0076] As shown in the figure, Figure 4 The implementation method of the high-viscosity fluid precision metering system comprises the following steps:

[0077] Step 1. Perform self-calibration inner loop:

[0078] Press the start button, the main relay coil is powered and self-protected, the main relay main contact is closed, and the feeding electric one-way valve is opened;

[0079] PLC control the discharge electric one-way valve to close, 1# self-calibration one-way electric valve to open, 2# self-calibration one-way electric valve to open, high viscosity fluid enters the pipeline by the feed electric one-way valve;

[0080] High viscosity fluid flows through the temperature compensation module, gear pump, ultrasonic velocity sensor S4, 1# self-calibration one-way electric valve, self-calibration module, 2# self-calibration one-way electric valve, and then high viscosity fluid enters the temperature compensation module again for internal circulation.

[0081] Specifically comprising the following steps:

[0082] Step 1.1: temperature compensation, adjust the fluid viscosity;

[0083] High viscosity fluid itself has poor flowability, and is heated to 50-80℃ by the temperature compensation module to increase its flowability, so that its viscosity value is 15000-30000 centipoise;

[0084] Temperature sensor S1 and viscosity sensor S3 obtain temperature and viscosity values and send data to the electric control module.

[0085] Step 1.2: frequency conversion speed regulation, adjust the fluid flow rate;

[0086] The frequency conversion speed regulator of the power transmission module drives the gear pump to operate, and high viscosity fluid is transmitted in the pipeline at a certain flow rate; to adapt to different delivery amounts, the output frequency of the frequency conversion speed regulator is increased or decreased to adjust the flow rate of high viscosity fluid in the pipeline;

[0087] Ultrasonic velocity sensor S4 monitors the fluid velocity value in the pipeline and sends data to the electric control module.

[0088] Step 1.3: metering calibration;

[0089] In theory, the fluid velocity is obtained by ultrasonic velocity sensor S4 on the outer wall of the pipeline, multiplied by the cross-sectional area of the pipeline (the cross-sectional area of the pipeline is a constant), to obtain the fluid flow rate. In actual situations, the temperature, pressure, viscosity, density, etc. of the fluid in the pipeline will affect the electrical signal data of ultrasonic detection, reducing the accuracy of detection data, so metering calibration is required, and the steps are as follows:

[0090] Step 1.3.1: obtain fluid parameter data in the pipeline;

[0091] Temperature sensor S1 obtains temperature data T, pressure sensor S2 obtains pressure data P, viscosity sensor S3 obtains viscosity data D, and ultrasonic velocity sensor S4 obtains flow rate data V. The calibration of metering needs to be carried out in a stable parameter environment, and the next step is performed after the above data fluctuation is less than 1%.

[0092] Step 1.3.2 Calculate the fluid meter reference data;

[0093] According to the flow rate data V obtained by the ultrasonic velocity sensor S4, multiply the cross-sectional area S of the pipeline, the fluid meter reference data FL_1=V*S can be obtained;

[0094] The reason why it is called reference data is that the ultrasonic velocity sensor S4 is easy to be affected by the temperature, pressure, viscosity, density and other factors of the fluid, and the test data has error, that is, under the same fluid flow rate condition, the temperature, pressure, viscosity, density is different, the flow rate data V obtained by the ultrasonic velocity sensor S4 is also different.

[0095] Step 1.3.3 Self-calibration, calculate the proportionality coefficient of fluid meter reference data and true value;

[0096] The self-calibration module includes a sealed container sampling cylinder placed on the electronic scale S5, the electronic scale S5 has the function of zeroing, the high viscosity fluid can be flowed in for multiple times, and the weight data is obtained by weighing for multiple times until the liquid level of the sampling cylinder reaches the upper limit, the sampling cylinder is emptied, and then the high viscosity fluid is flowed in and weighed, and the cycle is repeated;

[0097] In unit sampling time△t, the high viscosity fluid flows into the sampling cylinder through 1# self-calibration one-way electric valve, the electronic scale S5 obtains the weight w of the high viscosity fluid flowed in, and the density q of the high viscosity fluid is obtained by the built-in electronic densimeter S6 in the sampling cylinder, and the volume of the high viscosity fluid flowed in per unit time is calculated , then the true flow data of the high viscosity fluid is ;

[0098] The calibration proportionality coefficient K is calculated as follows: ;

[0099] Repeat the above, continuous n times of sampling operation, the electronic scale S5 is continuously zeroed, weighed respectively, and the proportionality coefficient K is continuously obtained according to the above method, when the difference value of continuous value is less than 1%, the self-calibration is completed.

[0100] The built-in liquid level switch in the sampling cylinder is electrified when the container liquid level reaches the upper limit, the compressed air electromagnetic valve coil is electrified, the compressed air enters the sampling cylinder through the pressurizing pipeline, the high viscosity fluid is discharged through 2# self-calibration one-way electric valve, and enters the internal circulation.

[0101] Step 2. System external circulation:

[0102] The PLC control closes 1# self-calibration one-way electric valve, closes 2# self-calibration one-way electric valve, and opens the discharge electric one-way valve, and the fluid is turned from internal circulation to external circulation;

[0103] The high-viscosity fluid feed motorized one-way valve enters a pipeline, passes through a temperature compensation module, a gear pump, an ultrasonic velocity sensor S4, and a motorized one-way outlet pipeline;

[0104] By monitoring the flow rate data obtained by the ultrasonic velocity sensor S4, the fluid metering reference data FL_1 can be obtained, and by calibrating the proportionality coefficient K, the true flow rate of the fluid can be obtained .

[0105] Step 3. Constructing a system adaptive big data model:

[0106] Further, since the calibration proportionality coefficient K is related to temperature T, pressure P, viscosity D, and density q, a parameter proportionality factor data correlation model is established:

[0107] K=T*k1+P*k2+D*k3+q*k4;

[0108] Where k1 is the temperature proportionality factor, k2 is the pressure proportionality factor, k3 is the viscosity proportionality factor, and k4 is the density proportionality factor.

[0109] Through big data analysis, self-learning is performed, and a parameter-proportionality factor relationship curve (T-k1 curve, P-k2 curve, D-k3 curve, q-k4 curve) is drawn. In this way, when production is changed (the type of high-viscosity fluid is changed) or process parameters (temperature, pressure, viscosity, and density) are changed, self-calibration is no longer needed. Through the parameter-proportionality factor relationship curve, the corresponding proportionality factors k1, k2, k3, and k4 values can be quickly obtained according to the sensor data. The calibration proportionality coefficient K is obtained through the formula K=T*k1+P*k2+D*k3+q*k4, and the true and accurate metering data can be obtained by multiplying the ultrasonic velocity sensor S4 flow rate data by the calibration proportionality coefficient K. DETAILED DESCRIPTION

[0111] For example, a set of high-viscosity fluid precision metering systems mentioned in the present application have established a parameter-proportionality factor curve model (T-k1 curve, P-k2 curve, D-k3 curve, q-k4 curve) through big data collection and analysis. Now, a DN25 pipeline is needed to transport a high-viscosity fluid, and the temperature data measured by the sensors is 75 degrees Celsius, the pressure data is 0.55 MPa, the viscosity data is 17700 cP, the density data is 2.75 kg / m3, and the fluid velocity in the pipeline is 0.15 m / s.

[0112] The k1 value is 0.00393 at 75 degrees Celsius obtained through the T-k1 curve, the k2 value is 0.517 at 0.55 MPa obtained through the P-k2 curve, the k3 value is 0.0000182 at 17700 cP obtained through the D-k3 curve, and the k4 value is 0.0997 at 2.75 kg / m3 obtained through the q-k4 curve, and each data is brought into the formula:

[0113] K=T*k1+P*k2+D*k3+q*k4=75*0.00393+0.55*0.517+17700*0.0000182+2.75*0.0997=1.175415;

[0114] The DN25 pipeline cross-sectional area is S=0.000491 square meters, and the fluid metering reference data are:

[0115] FL_1=V*S=0.15*0.000491=0.000007365 cubic meters / second;

[0116] Real flow Cubic meters / second.

[0117] The description of the present application is given for the purpose of example and description, and is not exhaustive or limiting to the present application. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are chosen and described in order to best explain the principles of the present application and its practical application, and to enable others skilled in the art to understand the present application for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. A method for implementing a precision metering system for high-viscosity fluids, characterized in that: The high-viscosity fluid precision metering system includes an electrical control module, which is connected to a self-calibration module, a temperature compensation module, a power transmission module, and a sensing module. The temperature compensation module, the power transmission module, and the sensing module are all installed on the pipeline through which the high-viscosity fluid flows. The pipeline inlet is equipped with an electric check valve for feeding, and the pipeline outlet is equipped with an electric check valve for discharging. The power delivery module includes a gear pump, which is connected to a frequency converter. The power delivery module is connected to a temperature compensation module. The fluid whose viscosity has been adjusted by the temperature compensation module is driven by the frequency converter gear pump. The self-calibration module includes a sampling cylinder with an electronic scale S5 at the bottom. The sampling cylinder is connected to a sampling feed pipe, a sampling discharge pipe, and a pressurization pipe. The sampling feed pipe is connected to the feed inlet of the high-viscosity fluid flow pipe, and the sampling discharge pipe is connected to the discharge outlet of the high-viscosity fluid flow pipe. The sampling feed pipe is equipped with a #2 self-calibration electric check valve, and the sampling discharge pipe is equipped with a #1 self-calibration electric check valve. The pressurization pipe is used to input compressed air into the sampling cylinder and is equipped with a compressed air solenoid valve. The implementation method is applied to a high-viscosity fluid precision metering system, and includes the following steps: Step 1. Execute the self-calibration inner loop: Press the start button, the main relay coil is energized and self-holding, the main relay main contacts close, and the feed electric check valve opens; The PLC controls the discharge electric check valve to close, the first self-calibrating electric check valve to open, and the second self-calibrating electric check valve to open, allowing the high-viscosity fluid to enter the pipeline through the feed electric check valve. The high-viscosity fluid flows through the temperature compensation module, gear pump, ultrasonic speed sensor S4, first self-calibrating one-way electric valve, self-calibration module, and second self-calibrating one-way electric valve. Then, the high-viscosity fluid re-enters the temperature compensation module for internal circulation. Step 2. System external circulation: The PLC controls the closing of the first self-calibrating one-way electric valve and the second self-calibrating one-way electric valve, and opens the discharge electric one-way valve, so that the fluid changes from internal circulation to external circulation; High-viscosity fluid enters the pipeline via an electric one-way valve, passes through a temperature compensation module, a gear pump, an ultrasonic speed sensor S4, and then flows out of the pipeline via an electric one-way discharge valve. By monitoring the flow velocity data acquired by the ultrasonic velocity sensor S4, and using the fluid metering reference data FL_1, and calibrating the proportional coefficient K, the actual fluid flow rate can be determined. ; Step 3. Construct an adaptive big data model for the system: Since the calibration proportionality coefficient K is related to temperature T, pressure P, viscosity D, and density q, a data correlation model for the proportionality factors of each parameter is established: K = T*k1 + P*k2 + D*k3 + q*k4; Where k1 is the temperature proportionality factor, k2 is the pressure proportionality factor, k3 is the viscosity proportionality factor, and k4 is the density proportionality factor; Through big data analysis and self-learning, the system generates curves showing the relationship between each parameter and the scaling factor. This eliminates the need for self-calibration when changing production lines or process parameters. By analyzing the curves showing the relationship between each parameter and the scaling factor, the corresponding scaling factors k1, k2, k3, and k4 can be quickly derived from the data from each sensor. The calibration scaling factor K is then calculated using the formula K=T*k1+P*k2+D*k3+q*k4. Multiplying the calibration scaling factor K by the flow data from the ultrasonic speed sensor S4 yields accurate measurement data.

2. The method for implementing a high-viscosity fluid precision metering system as described in claim 1, characterized in that: Step 1 specifically includes the following steps: Step 1.1: Temperature compensation, adjusting fluid viscosity; High-viscosity fluids have very poor fluidity. By using a temperature compensation module to heat the high-viscosity fluid to 50-80℃, its fluidity is increased, and its viscosity value is reduced to 15,000-30,000 centipoise. Temperature sensor S1 and viscosity sensor S3 acquire temperature and viscosity values ​​and send the data to the electronic control module. Step 1.2: Variable frequency speed control to adjust the fluid flow rate; The variable frequency drive of the power delivery module drives the gear pump to operate, and the high-viscosity fluid is transported in the pipeline at a certain flow rate. In order to adapt to different delivery volumes, the flow rate of the high-viscosity fluid in the pipeline is adjusted by increasing or decreasing the output frequency of the variable frequency drive. The ultrasonic velocity sensor S4 monitors the velocity of the fluid inside the pipeline and sends the data to the electrical control module. Step 1.3: Metrological calibration; In theory, the fluid velocity can be obtained by using the ultrasonic velocity sensor S4 on the outer wall of the pipe, and multiplied by the cross-sectional area of ​​the pipe to obtain the fluid flow rate. In reality, the temperature, pressure, viscosity, and density of the fluid inside the pipe will affect the electrical signal data of the ultrasonic detection, reducing the accuracy of the detection data. Therefore, metrological calibration is required.

3. The method for implementing a high-viscosity fluid precision metering system as described in claim 2, characterized in that: The metrological calibration includes the following steps: Step 1.3.1 Obtain fluid parameter data inside the pipeline; Temperature sensor S1 acquires temperature data T, pressure sensor S2 acquires pressure data P, viscosity sensor S3 acquires viscosity data D, and ultrasonic velocity sensor S4 acquires flow rate data V. Measurement calibration needs to be performed under stable parameter conditions. The next step can only be carried out after the fluctuation of the above data is less than 1%. Step 1.3.2 Calculate fluid metering reference data; The fluid metering reference data FL_1 = V*S can be obtained by multiplying the flow velocity data V obtained by the ultrasonic velocity sensor S4 by the cross-sectional area S of the pipe. Step 1.3.3 Self-calibration: Calculate the scaling factor between the fluid metering reference data and the actual value; High-viscosity fluid can be flowed into the sampling tube in multiple portions, and the weight data can be obtained by weighing multiple times until the liquid level in the sampling tube reaches the upper limit. Then, the sampling tube is emptied, and the fluid is flowed in again and weighed. This cycle is repeated. Within a unit sampling time Δt, high-viscosity fluid flows into the sampling cylinder through the first self-calibrating one-way electric valve. The electronic scale S5 obtains the weight w of the flowing high-viscosity fluid, and the electronic densitometer S6 built into the sampling cylinder obtains the density q of the high-viscosity fluid, thus calculating the volume of high-viscosity fluid flowing in per unit time. The actual flow rate data of high viscosity fluid ; The calibration ratio coefficient is calculated as follows: ; Repeat the above steps for n consecutive sampling operations. The electronic scale S5 is continuously zeroed. Weigh the items separately and continuously obtain the proportional coefficient K according to the above method. When the difference between consecutive values ​​is less than 1%, the self-calibration is completed. The sampling tube has a built-in liquid level switch. When the liquid level in the container reaches the upper limit, the coil of the compressed air solenoid valve is energized, and the compressed air enters the sampling tube through the pressurization pipe. The high-viscosity fluid is discharged through the second self-calibrating one-way electric valve and enters the internal circulation.

4. The method for implementing a high-viscosity fluid precision metering system as described in claim 3, characterized in that: The electrical control module includes a PLC and a power supply. The positive terminal of the power supply is connected to one end of the stop button K1. The other end of the stop button K1 is connected to one end of the start button K2 and one end of the self-holding contact of the main relay KM1. The other end of the start button K2 and the other end of the self-holding contact of the main relay KM1 are connected to one end of the coil of the main relay KM1 and one end of the main contact of the main relay KM1. The other end of the coil of the main relay KM1 is connected to the negative terminal of the power supply.

5. The method for implementing a high-viscosity fluid precision metering system as described in claim 4, characterized in that: The other end of the main contact of the main relay KM1 is connected to a PLC, a temperature compensation module, one end of the coil of the feed electric check valve KS1, one end of the frequency converter SQ, one end of the temperature sensor S1, one end of the pressure sensor S2, one end of the viscosity sensor S3, one end of the ultrasonic speed sensor S4, one end of the electronic scale S5, and one end of the electronic densitometer S6. The other ends of the feed electric check valve KS1 coil, the frequency converter SQ, the temperature sensor S1, the pressure sensor S2, the viscosity sensor S3, the ultrasonic speed sensor S4, the electronic scale S5, and the electronic densitometer S6 are connected to the negative terminal of the power supply.

6. The method for implementing a high-viscosity fluid precision metering system as described in claim 5, characterized in that: The signal output terminal OUT1 of the temperature sensor S1 is connected to the input terminal IN1 of the PLC; the signal output terminal OUT2 of the pressure sensor S2 is connected to the input terminal IN2 of the PLC; the signal output terminal OUT3 of the viscosity sensor S3 is connected to the input terminal IN3 of the PLC; the signal output terminal OUT4 of the ultrasonic velocimeter S4 is connected to the input terminal IN4 of the PLC; the signal output terminal OUT5 of the electronic scale S5 is connected to the input terminal IN5 of the PLC; and the signal output terminal OUT6 of the electronic densitometer S6 is connected to the input terminal IN6 of the PLC.

7. The method for implementing a high-viscosity fluid precision metering system as described in claim 4, characterized in that: The PLC is connected to one end of the coil of self-calibrating electric check valve KS2, one end of the coil of self-calibrating electric check valve KS3, one end of the coil of compressed air solenoid valve KS4, and one end of the coil of discharge electric check valve KS5. The other ends of the coils of self-calibrating electric check valve KS2, self-calibrating electric check valve KS3, compressed air solenoid valve KS4, and discharge electric check valve KS5 are connected to the negative terminal of the power supply.

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