Liquid separation control system and method

Abstract

The invention belongs to the field of industrial automation control, and discloses a liquid separation control system and method, and the system comprises a color recognition sensor, a data processing unit, a DCS system, and a phase layering device. The color identification sensor is mounted at a first position and is used for collecting color information at a layering interface in real time; the data processing unit is connected with the color recognition sensor and used for converting the collected color features into recognizable color signals; and the DCS system is connected with the data processing unit and the phase layering equipment, and is used for receiving the color signal sent by the data processing unit and controlling the phase layering equipment according to a preset control strategy and the color signal. According to the system provided by the embodiment of the invention, the phase layering process and the DCS system can be linked based on color identification, and automatic and precise control of the phase layering process is realized.

Description

Technical Field

[0001] The present application relates to the field of industrial automation control, and in particular to a liquid separation control system and method. Background Art

[0002] In many industrial production processes, phase separation is a common operation link. For example, in the chemical and petroleum refining industries, substances of different phases need to be separated. Traditional phase separation judgment methods often rely on manual experience, and roughly judge the phase separation situation by observing parameters such as liquid level, flow rate, and color. This method has low accuracy and consumes manpower. Especially for materials with similar colors, it is impossible to monitor and adjust the phase separation process in real time and accurately. With the development of industrial automation technology, DCS (distributed control system) is more and more widely used in industrial production, which can realize centralized management and decentralized control of the production process.

[0003] However, the current integration of the phase separation process with DCS systems lacks an efficient and precise control method, preventing the full utilization of the DCS system's advantages to optimize the phase separation process. Furthermore, color is a key characteristic of materials, and during the phase separation process, materials in different phases often exhibit different color characteristics. However, there is currently no mature solution that effectively applies color recognition technology to the phase separation process and the linked control of the DCS system.

[0004] It should be noted that the information disclosed in the above background technology section is only used to enhance the understanding of the background of this application, and therefore may include information that does not constitute prior art known to ordinary technicians in this field. Summary of the Invention

[0005] In order to provide a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. The summary is not an extensive review, nor is it intended to identify key / critical elements or delineate the scope of protection of these embodiments, but rather serves as a prelude to the detailed description that follows.

[0006] The embodiments of the present application provide a liquid separation control system and method, the purpose of which is to link the phase stratification process based on color recognition with the DCS system to solve the problems of inaccurate phase stratification process judgment and poor linkage with the DCS system in the prior art, and to achieve automated and precise control of the phase stratification process.

[0007] In some embodiments, a liquid separation control system is provided, comprising: a color recognition sensor, a data processing unit, a DCS system, and a phase stratification device; the color recognition sensor is installed at a first position, and is used to collect color information at the phase stratification interface in real time; the data processing unit is connected to the color recognition sensor, and is used to convert the collected color features into recognizable color signals; the DCS system is connected to the data processing unit and the phase stratification device, and is used to receive the color signal sent by the data processing unit, and control the phase stratification device according to a preset control strategy and color signal.

[0008] Optionally, the first position is located outside the phase stratification device, and there are at least two color recognition sensors, which are relatively arranged at the same horizontal position outside the phase stratification device.

[0009] Optionally, the model of the color recognition sensor includes one or more of SS1-70K5, SCR-A11-485, TCS34725, TCS3200, SJ02-JDCL-003, and U295.

[0010] In some embodiments, a liquid separation control method is also provided, which is applied to the above-mentioned liquid separation control system, including: collecting color through the color recognition sensor to obtain original color data; correcting the original color data to obtain corrected color data; comparing the corrected color data with a pre-stored color feature template through a pattern recognition algorithm to determine the material phase state of the current phase stratification interface; when it is determined that the phase state has changed or the phase stratification has reached a specific state, a phase stratification signal is issued.

[0011] Optionally, there are multiple color recognition sensors, and after the color is collected by the color recognition sensors to obtain the original color data, the method further includes: constructing an original data set S based on the multiple original color data; calculating the mean Q of the original data set S; calculating the proportion Wi of each original color data in the original data set S based on the mean Q; and performing weighted fusion of the multiple original color data according to the proportion to obtain the fused original color data.

[0012] Optionally, the correcting the original color data to obtain corrected color data includes: performing basic optical correction on the original color data to obtain first corrected data; performing color correction on the original color data to obtain second corrected data; fusing the first corrected data and the second corrected data to obtain corrected color data; or, performing basic optical correction on the original color data to obtain first corrected data; and performing color correction on the first corrected data to obtain corrected color data.

[0013] Optionally, basic optical correction is performed on the original color data, including determining the R component, G component and B component in the original color data; dividing the R component, the G component and the B component by preset values ​​respectively to obtain R resolution, G resolution and B resolution; setting the smallest resolution as the system resolution; adjusting the distance between the color recognition sensor and the phase stratification device so that the value of the system resolution is controlled within a preset range, and obtaining the corrected color data after correction.

[0014] Optionally, the method further includes: after receiving the phase stratification signal, adjusting the operating parameters of the phase stratification device according to a preset control strategy.

[0015] Optionally, the operating parameters of the phase stratification device include: one or more of a pump flow rate, a valve opening, and a pump flow rate.

[0016] In some embodiments, an electronic device is also provided, including a processor and a memory, wherein the memory stores computer-executable instructions that can be executed by the processor, and the processor executes the computer-executable instructions to implement the above-mentioned liquid dispensing control method.

[0017] In some embodiments, a computer-readable storage medium is further provided, wherein the computer-readable storage medium stores computer-executable instructions. When the computer-executable instructions are called and executed by a processor, the computer-executable instructions prompt the processor to implement the above-mentioned liquid dispensing control method.

[0018] The liquid separation control system and method provided in the embodiments of the present application can achieve the following technical effects:

[0019] The phase stratification process based on color recognition is linked with the DCS system, thereby solving the problems of inaccurate judgment of the phase stratification process and poor linkage with the DCS system in the existing technology, and realizing automated and precise control of the phase stratification process.

[0020] The above general description and the following description are exemplary and explanatory only and are not intended to limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] One or more embodiments are exemplarily described by corresponding drawings. These exemplary descriptions and drawings do not limit the embodiments. Elements with the same reference numerals in the drawings are shown as similar elements. The drawings do not constitute a scale limitation. In addition,

[0022] Figure 1 Schematic diagram of the structure of a liquid separation control system according to an embodiment of the present application;

[0023] Figure 2is a flow chart of a liquid separation control method according to an embodiment of the present application;

[0024] Figure 3 A schematic diagram of the structure of an electronic device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0025] In order to be able to understand the features and technical contents of the embodiments of the present application in more detail, the implementation of the embodiments of the present application is described in detail below in conjunction with the accompanying drawings. The accompanying drawings are for reference only and are not used to limit the embodiments of the present application. In the following technical description, for the sake of convenience of explanation, a full understanding of the disclosed embodiments is provided through multiple details. However, one or more embodiments can still be implemented without these details. In other cases, to simplify the drawings, well-known structures and devices can be simplified for display.

[0026] In the description and claims of the embodiments of the present application and the accompanying drawings, the terms "first," "second," and the like are used to distinguish similar objects and are not necessarily used to describe a particular order or precedence. It should be understood that the terms used in this manner are interchangeable where appropriate for the purposes of describing the embodiments of the present application. In addition, the terms "including," "having," and any variations thereof are intended to cover non-exclusive inclusions.

[0027] Unless otherwise stated, the term "plurality" means two or more.

[0028] In the embodiments of the present application, the character " / " indicates that the preceding and following objects are in an "or" relationship. For example, A / B means: A or B.

[0029] The term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0030] Combine Figure 1 As shown, it is a schematic diagram of a liquid separation control system provided in an embodiment of the present application, and the liquid separation control system includes: a color recognition sensor, a data processing unit, a DCS system and a phase stratification device; the color recognition sensor is installed in a first position, and is used to collect color information at the phase stratification interface in real time; the data processing unit is connected to the color recognition sensor, and is used to convert the collected color features into recognizable color signals; the DCS system is connected to the data processing unit and the phase stratification device, and is used to receive the color signal sent by the data processing unit, and control the phase stratification device according to a preset control strategy and color signal.

[0031] One position is located outside the phase separation device, and at least two color recognition sensors are relatively arranged at the same horizontal position outside the phase separation device. In this way, multiple color recognition sensors can be used to avoid the inability of a single color recognition sensor to quickly recognize phase changes due to environmental factors such as lighting and angle.

[0032] The model of the color recognition sensor includes one or more of SS1-70K5, SCR-A11-485, TCS34725, TCS3200, SJ02-JDCL-003, and U295.

[0033] Specifically, during equipment installation and commissioning, install a color recognition sensor at a suitable location near the phase interface of the phase stratification equipment to ensure it can clearly and stably capture color information from the phase interface. Connect the color recognition sensor to the data processing unit via a data transmission cable and check that the connection is secure. Calibrate the color recognition sensor to ensure accurate color data collection. Simultaneously, establish a communication connection between the data processing unit and the DCS system to ensure proper data transmission. Enter the relevant parameters of the phase stratification equipment and the pre-set control strategy into the DCS system.

[0034] The above-mentioned device provided in the embodiments of the present application utilizes color recognition technology to directly determine phase stratification based on the color characteristics of a substance. This significantly improves accuracy compared to traditional methods that rely on indirect parameters such as liquid level and flow rate. Furthermore, it enhances interoperability with the DCS system, achieving seamless integration of color recognition data with the DCS system. This enables the DCS system to promptly adjust device operating parameters based on the real-time phase stratification, thereby improving the automation level and control precision of the production process.

[0035] Combine Figure 2 As shown, a liquid separation control method provided in an embodiment of the present application is applied to the above liquid separation control system, such as Figure 2 As shown, the method includes the following steps:

[0036] S201: Collecting color through the color recognition sensor to obtain original color data;

[0037] S202: Correcting the original color data to obtain corrected color data;

[0038] S203: comparing the corrected color data with a pre-stored color feature template using a pattern recognition algorithm to determine the material phase state of the current phase stratification interface;

[0039] Specifically, the color feature templates of different phases of materials pre-stored in the database are HSV fusion histograms of different phases. Determining the material phase at the current phase interface includes drawing an HSV histogram of the current material. When the overlap between the current HSV histogram and the HSV fusion histogram exceeds a threshold, the material phase corresponding to the overlapping HSV histogram is determined as the current material phase.

[0040] The data processing unit pre-processes the data and extracts color features, then compares them with the color feature templates in the database. The Bhattacharyya coefficient is used to calculate the histogram overlap.

[0041] The matching color features are determined by histogram overlap. The threshold is usually set to 0.7-0.9. This is the color histogram of different phases of matter pre-stored in the database. Specifically, the method for calculating the histogram matching degree includes: using the chi-square distance algorithm to search for similar images, calculating the similarity distance of the histogram feature points between the two images according to the changes in the relative distances between the various feature quantities, and finding the most similar image by traversing and calculating the chi-square distance with existing images in the database. The smaller the chi-square distance, the more similar the two images are.

[0042] S204: When it is determined that the phase state has changed or the phase stratification has reached a specific state, a phase stratification signal is issued.

[0043] In some embodiments, there are multiple color recognition sensors, and after the color is collected by the color recognition sensors to obtain the original color data, it also includes: constructing an original data set S based on the multiple original color data; calculating the mean Q of the original data set S; calculating the proportion Wi of each original color data in the original data set S based on the mean Q; and performing weighted fusion of the multiple original color data according to the proportion to obtain the fused original color data.

[0044] When the phase separation process is running, the color recognition sensor collects the color of the phase separation interface at a set time interval (for example, once per second), and transmits the collected color data to the data processing unit in real time.

[0045] In the embodiment of the present application, two or more color recognition sensors are provided, thereby collecting multiple raw color data. Since each color recognition sensor has different accuracies and is located in different positions, it is possible to obtain color information of the current substance under different lighting angles and different lighting intensities. By fusing these multiple raw color data, the obtained color data can more accurately reflect the phase state of the substance.

[0046] Specifically, Wi can be set based on experience, or adjusted based on multiple test data. The specific gravity Wi can also be calculated using the following formula:

[0047]

[0048] Where N is the number of sensors.

[0049] In some embodiments, the correcting the original color data to obtain corrected color data includes: performing basic optical correction on the original color data to obtain first corrected data; performing color correction on the original color data to obtain second corrected data; and fusing the first corrected data and the second corrected data to obtain corrected color data.

[0050] In some embodiments, the correction of the original color data may also be performed in the following manner: performing basic optical correction on the original color data to obtain first corrected data; and performing color correction on the first corrected data to obtain corrected color data.

[0051] In some embodiments, performing basic optical correction on the original color data may specifically include: determining the R component, G component and B component in the original color data; dividing the R component, the G component and the B component by preset values ​​respectively to obtain R resolution, G resolution and B resolution; setting the smallest resolution as the system resolution; adjusting the distance between the color recognition sensor and the phase stratification device so that the value of the system resolution is controlled within a preset range, and obtaining the corrected color data.

[0052] Specifically, basic optical correction and color correction can be performed sequentially on the original color data to obtain corrected color data, which allows for efficient correction of the original color data. Alternatively, basic optical correction and color correction can be performed separately, and the resulting first and second corrected data can be merged. This allows errors in the first corrected data to be corrected promptly, resulting in more accurate corrected color data.

[0053] In some embodiments, the method further includes: after receiving the phase stratification signal, adjusting the operating parameters of the phase stratification device according to a preset control strategy.

[0054] When it is determined that the phase state has changed, such as the separation of the water phase from the oil phase, the data processing unit sends a signal to the DCS system.

[0055] The operating parameters of the phase stratification device include: one or more of a pump flow rate, a valve opening, and a pump flow rate.

[0056] The DCS system uses pre-set control strategies. For example, if it detects the beginning of the water phase, it reduces the pump flow rate to prevent excessive mixing of the water phase with the oil phase. The DCS also records and displays relevant operating data and control information, allowing operators to monitor the phase separation process in real time.

[0057] The above method realizes the seamless connection between color recognition data and DCS system, enabling the DCS system to adjust equipment operating parameters in time according to the real-time situation of phase stratification, thereby improving the automation level and control accuracy of the production process.

[0058] The embodiment of the present invention further provides an electronic device, such as Figure 3 As shown, it is a structural diagram of the electronic device, wherein the electronic device includes a processor 301 and a memory 302, the memory 302 stores computer executable instructions that can be executed by the processor 301, and the processor 301 executes the computer executable instructions to implement the above-mentioned liquid separation control method.

[0059] exist Figure 3 In the illustrated embodiment, the electronic device further includes a bus 303 and a communication interface 304 , wherein the processor 301 , the communication interface 304 and the memory 302 are connected via the bus 303 .

[0060] Among them, the memory 302 may include high-speed random access memory (RAM), and may also include non-volatile memory (non-volatile memory), such as at least one disk storage. The communication connection between the system network element and at least one other network element is realized through at least one communication interface 304 (which can be wired or wireless), and the Internet, wide area network, local area network, metropolitan area network, etc. can be used. The bus 303 can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus or an EISA (Extended Industry Standard Architecture) bus, etc. The bus 403 can be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 3 Only one bidirectional arrow is used in the diagram, but this does not mean that there is only one bus or one type of bus.

[0061] The processor 301 may be an integrated circuit chip with signal processing capabilities. During implementation, each step of the above method can be completed by hardware integrated logic circuits in the processor 301 or by software instructions. The above processor 301 may be a general-purpose processor, including a central processing unit (CPU), a network processor (NP), etc.; it may also be a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. The general-purpose processor may be a microprocessor or any conventional processor. The steps of the method disclosed in conjunction with the embodiments of the present invention can be directly implemented and executed by a hardware decoding processor, or by a combination of hardware and software modules in the decoding processor. The software module can be located in a storage medium mature in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, registers, etc. The storage medium is located in the memory, and the processor 301 reads the information in the memory and completes the steps of the liquid separation control method of the above embodiment in combination with its hardware.

[0062] An embodiment of the present invention also provides a computer-readable storage medium, which stores computer-executable instructions. When the computer-executable instructions are called and executed by the processor, the computer-executable instructions prompt the processor to implement the above-mentioned liquid separation control method. The specific implementation can be found in the aforementioned method embodiment, which will not be repeated here.

[0063] The above description and the accompanying drawings fully illustrate the embodiments of the present application so that those skilled in the art can practice them. Other embodiments may include structural, logical, electrical, process and other changes. The embodiments represent only possible variations. Unless explicitly required, separate components and functions are optional, and the order of operations may vary. Parts and features of some embodiments may be included in or replace parts and features of other embodiments. Moreover, the words used in this application are only used to describe the embodiments and are not used to limit the claims. As used in the description of the embodiments and claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to also include plural forms. Similarly, the term "and / or" as used in this application refers to any and all possible combinations of one or more associated listings. In addition, when used in this application, the term "comprise" and its variations "comprises" and / or comprising refer to the presence of stated features, wholes, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or groups of these. In the absence of further restrictions, an element defined by the sentence "comprising a..." does not exclude the presence of other identical elements in the process, method or device that includes the element. In this article, each embodiment may focus on the differences from other embodiments, and the same and similar parts between the various embodiments can be referenced to each other. For the methods, products, etc. disclosed in the embodiments, if they correspond to the method part disclosed in the embodiments, then the relevant parts can be found in the description of the method part.

[0064] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented with electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software may depend on the specific application and design constraints of the technical solution. The technicians may use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the embodiments of the present application. The technicians will clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0065] In the embodiments disclosed herein, the disclosed methods and products (including but not limited to devices, equipment, etc.) can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of the units can be merely a logical functional division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between each other shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms. The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the units may be selected according to actual needs to implement this embodiment. In addition, the functional units in the embodiments of the present application may be integrated into a processing unit, or each unit may exist physically alone, or two or more units may be integrated into one unit.

[0066] The flowcharts and block diagrams in the accompanying drawings show the possible architecture, functions and operations of the systems, methods and computer program products according to the embodiments of the present application. In this regard, each box in the flowchart or block diagram can represent a module, a program segment or a part of the code, and the part of the module, program segment or code contains one or more executable instructions for realizing the specified logical function. In some alternative implementations, the functions marked in the box can also occur in an order different from that marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, which can depend on the functions involved. In the description corresponding to the flowcharts and block diagrams in the accompanying drawings, the operations or steps corresponding to different boxes can also occur in an order different from that disclosed in the description, and sometimes there is no specific order between different operations or steps. For example, two consecutive operations or steps can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, which can depend on the functions involved. Each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, may be implemented by a dedicated hardware-based system that performs the specified function or action, or may be implemented by a combination of dedicated hardware and computer instructions.

Claims

1. A liquid separation control system, characterized in that: include: Color recognition sensors, data processing units, DCS systems, and phase stratification equipment; The color recognition sensor is installed at the first position and is used to collect color information at the phase stratification interface in real time; The data processing unit is connected to the color recognition sensor and is used to convert the collected color features into recognizable color signals; The DCS system is connected to the data processing unit and the phase stratification device, and is used to receive the color signal sent by the data processing unit and control the phase stratification device according to a preset control strategy and the color signal.

2. The system according to claim 1, wherein: The first position is located outside the phase separation device, and there are at least two color recognition sensors that are relatively arranged at the same horizontal position outside the phase separation device.

3. The system according to claim 1, wherein: The model of the color recognition sensor includes one or more of SS1-70K5, SCR-A11-485, TCS34725, TCS3200, SJ02-JDCL-003, and U295.

4. A liquid separation control method, applied to the liquid separation control system according to any one of claims 1 to 3, characterized in that: include: Color is collected by the color recognition sensor to obtain original color data; Correcting the original color data to obtain corrected color data; Comparing the corrected color data with a pre-stored color feature template using a pattern recognition algorithm to determine the material phase state of the current phase stratification interface; When it is determined that the phase state has changed or the phase separation has reached a specific state, a phase separation signal is issued.

5. The liquid separation control method according to claim 4, characterized in that: There are multiple color recognition sensors. After color is collected by the color recognition sensors and original color data is obtained, the method further includes: Constructing an original data set S based on the plurality of original color data; Calculate the mean Q of the original data set S; Calculate the proportion Wi of each of the original color data in the original data set S based on the mean Q; The plurality of original color data are weightedly fused according to the proportions to obtain fused original color data.

6. The liquid separation control method according to claim 5, characterized in that: Correcting the original color data to obtain corrected color data includes: Performing basic optical correction on the original color data to obtain first corrected data; Performing color correction on the original color data to obtain second corrected data; Merging the first correction data and the second correction data to obtain corrected color data; or, Performing basic optical correction on the original color data to obtain first corrected data; Color correction is performed on the first correction data to obtain corrected color data.

7. The liquid separation control method according to claim 6, characterized in that: Performing basic optical correction on the original color data, including: Determining an R component, a G component, and a B component in the original color data; Dividing the R component, the G component, and the B component by preset values ​​respectively to obtain R resolution, G resolution, and B resolution; Set the smallest resolution as the system resolution; The distance between the color recognition sensor and the phase separation device is adjusted so that the value of the system resolution is controlled within a preset range, thereby obtaining corrected color data.

8. The method according to claim 4, characterized in that Also includes: After receiving the phase stratification signal, the operating parameters of the phase stratification device are adjusted according to a preset control strategy.

9. The method according to claim 8, characterized in that The operating parameters of the phase stratification device include: one or more of a pump flow rate, a valve opening, and a pump flow rate.

10. An electronic device, characterized in that: The method comprises a processor and a memory, wherein the memory stores computer-executable instructions that can be executed by the processor, and the processor executes the computer-executable instructions to implement the method according to any one of claims 4 to 9.

Images