Intelligent control system and method for UV smoke hood

Abstract

The invention relates to the crossing field of industrial automation and environmental protection technology, in particular to an intelligent control system and method for a UV smoke hood, and the system comprises a main control unit which comprises a PLC controller, an HMI touch screen, a power module and a communication gateway. The at least one IO control box is connected with the main control unit through an RS-485 bus; the wind pressure sensing network comprises a differential pressure sensor and a signal conditioning module which are arranged in a distributed manner; the executing mechanism group comprises a UV lamp array, an air curtain unit, a centrifugal fan and an auxiliary lighting unit; the safety interlocking module is integrated with an emergency stop circuit, an electric leakage protection unit and an electric arc detection device; wherein the PLC is used for operating a special control program developed by a MagicWorks V2.20 platform, so that an equipment cooperative control algorithm is realized. Compared with the prior art, the intelligent control system and method for the UV smoke hood solve the technical problems that a traditional centralized control system is complex in wiring and poor in expansibility.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial automation and environmental protection technology, in particular to a UV smoke hood intelligent control system and method.

BACKGROUND

[0002] The existing UV smoke hood control system has the following technical defects:

[0003] 1. Centralized control architecture leads to complex wiring, with thousands of cables laid for a single system, resulting in high installation and maintenance costs.

[0004] 2. The device linkage logic is simple and cannot dynamically adjust control parameters according to real-time working conditions.

[0005] 3. Lack of effective safety protection mechanism, UV lamp failure rate as high as 15%-20%.

[0006] 4. Poor system scalability, adding control nodes requires redesign of the control cabinet.

[0007] 5. Insufficient program security, with the risk of technical solution leakage.

SUMMARY

[0008] To overcome the above problems, the present application provides a UV smoke hood intelligent control system that can effectively solve the above problems.

[0009] A technical solution provided by the present application to solve the above technical problems is to provide a UV smoke hood intelligent control system, which includes a main control unit, the main control unit including a PLC controller, an HMI touch screen, a power module and a communication gateway; at least one IO control box connected to the main control unit through an RS-485 bus; a wind pressure sensing network including a distributed differential pressure sensor and a signal conditioning module; an actuator group including a UV lamp array, a wind curtain unit, a centrifugal fan and an auxiliary lighting unit; a safety interlock module integrating an emergency stop circuit, a leakage protection unit and an arc detection device; wherein the PLC controller runs a special control program developed on the MagicWorks V2.20 platform to implement a device collaborative control algorithm.

[0010] Preferably, the.

[0011] Preferably, the.

[0012] Compared with the existing technology, the UV smoke hood intelligent control system and method of the present invention solve the technical problems of complex wiring and poor scalability of traditional centralized control systems. Through the innovative dual-bus architecture and dynamic scheduling algorithm, it solves the contradiction between distributed control and real-time performance, and can effectively reduce signal interference. Due to the use of the highest baud rate of 485 communication, the refresh speed is fast. Because there is no line coming out of the main control cabinet, and the communication method is adopted, the number of cables is reduced, saving a lot of cable costs. Using a modular IO control box, by increasing or decreasing the communication address, the number of smoke hood sections can be flexibly matched, and segmented control can be used to flexibly increase and decrease the number of smoke hood sections. Since the number of control systems and replacement modules is reduced, the cost is reduced. It is easy to operate and manufacture, modular installation, and unified specifications. The maintenance cost is low, it is very easy to replace and modify, there are few cables, the alarm release is clear, and the maintenance cost is low. [Specific implementation method]

[0013] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the following embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0014] In the present invention, references to "first," "second," and the like are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features being referenced. Therefore, features specified as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two or three, unless otherwise specifically defined.

[0015] The UV smoke hood intelligent control system of the present invention includes a main control box (including a PLC controller, an HMI human-machine interface), multiple groups of expandable IO control boxes, a wind pressure sensor network and an intelligent linkage module. The ModbusRTU communication protocol is innovatively adopted to build a dual-bus architecture, and the equipment collaborative control algorithm is implemented through a dedicated control program developed through the MagicWorks platform. Combined with hardware confidentiality storage technology, it solves the technical problems of complex wiring and poor scalability of traditional centralized control systems. Key technologies include: 1. Dynamic load balancing communication scheduling mechanism; 2. Fuzzy control algorithm based on wind pressure difference; 3. Multi-level safety interlock protection system; 4. Modular and expandable hardware architecture. Compared with traditional solutions, the wiring cost is reduced by 67%, the system response speed is improved to 120ms, and online hot-swap maintenance is supported.

[0016] Specifically, the UV smoke hood intelligent control system of the present invention includes a main control unit, which includes a PLC controller, an HMI touch screen, a power module and a communication gateway;

[0017] At least one IO control box connected to the main control unit via RS-485 bus;

[0018] Wind pressure sensing network, which includes distributed differential pressure sensors and signal conditioning modules;

[0019] Actuator group, the actuator group includes UV lamp array, air curtain unit, centrifugal fan and auxiliary lighting unit;

[0020] Safety interlock module, which integrates emergency stop circuit, leakage protection unit and arc detection device;

[0021] The PLC controller runs a dedicated control program developed on the MagicWorks V2.20 platform to implement a device collaborative control algorithm.

[0022] The IO control box includes:

[0023] Communication interface module, the communication interface module supports ModbusRTU protocol and PPI network protocol dual mode;

[0024] Programmable digital input and output unit, the programmable digital input and output unit is equipped with 16 DI and 12 DO channels;

[0025] Analog acquisition module, the analog acquisition module supports 4-20mA and 0-10V dual signal input;

[0026] Address coding switch, the address coding switch adopts a rotary BCD encoder;

[0027] Hot-swap protection circuit, the hot-swap protection circuit includes an overvoltage suppressor and a transient voltage suppression diode array.

[0028] The communication interface module uses the CO-trust UDP protocol to implement data encapsulation. The communication frame structure includes:

[0029] 2-byte start code (0xAA55);

[0030] 1-byte address field;

[0031] 1-byte function code;

[0032] N-byte data field (N≤252);

[0033] 2-byte CRC check code;

[0034] 1-byte end code (0x0D).

[0035] The device collaborative control algorithm includes:

[0036] Air pressure-flow closed-loop control algorithm, establishing ΔP=K1·Q 2 +K2·Q mathematical model;

[0037] UV lamp soft start control sequence, with three-level stepped voltage boost (30% → 60% → 100%);

[0038] Fault prediction module, which analyzes equipment operating characteristic parameters based on LSTM neural network;

[0039] Dynamic priority scheduling mechanism adopts improved EDF real-time scheduling algorithm.

[0040] The UV lamp soft start control sequence specifically includes:

[0041] a) The first stage (t0-t1): 30% rated voltage is applied, duration T1 = 5 ± 0.5 s;

[0042] b) Second stage (t1-t2): linearly boost to 60% of rated voltage, with a boost rate of ≤5V / s;

[0043] c) The third stage (t2-t3): maintain 60% voltage, duration T2 = 10 ± 1s;

[0044] d) The fourth stage (t3-t4): the voltage is stepped up to 100% of the rated voltage, and the overshoot is controlled within 3%. The safety interlock module is used to achieve:

[0045] Three-level interlock protection mechanism:

[0046] Level Ⅰ: Cut off UV power supply when wind pressure is abnormal;

[0047] Level II: Arc detection triggers rapid power off within <100ms;

[0048] Level III: The water cooling system is activated when the temperature exceeds the limit;

[0049] Safety status encoding mechanism, using 8-bit status word encoded in Gray code;

[0050] Self-diagnosis function, performs a system integrity check every 500ms.

[0051] The main control unit includes a hardware encryption module, which uses:

[0052] Physically unclonable function (PUF) generates a unique device identification code;

[0053] AES-256 encryption engine for data encryption in program storage area;

[0054] Dynamic key exchange protocol, based on ECDH algorithm to achieve key negotiation;

[0055] Tamper detection circuit, monitor PCB micro-strain and temperature anomalies.

[0056] A UV hood intelligent control method, comprising:

[0057] Step S10: system power initialization, load security library parameters and device configuration table;

[0058] Step S20: establish communication link, poll each IO control box state;

[0059] Step S30: acquisition of wind pressure sensor data, calculation of dynamic control parameters;

[0060] Step S40: execute device collaborative control algorithm, generate control instruction set;

[0061] Step S50: through the double-redundancy bus to issue control instructions;

[0062] Step S60: monitoring the feedback of the actuator, closed-loop control adjustment;

[0063] Step S70: record running log, update device life prediction model.

[0064] The step S30 specifically includes:

[0065] The wind pressure sampling data is processed by using the sliding window method, and the window size N=8;

[0066] The standard deviation σ=√(Σ(x_i-μ) 2 / (N-1)) is calculated;

[0067] When σ> threshold σ_th, the Kalman filter algorithm is started;

[0068] The pressure-flow characteristic curve is constructed, and the optimal working point Q_opt is solved.

[0069] A computer readable storage medium, storing program instructions, when the instructions are executed by a processor to realize the steps of the UV hood intelligent control method, the medium adopts:

[0070] Physical layer: hybrid storage architecture of FRAM ferroelectric memory and NOR Flash;

[0071] Logical layer: divided into three independent storage areas:

[0072] Code area: store encrypted control program;

[0073] Configuration area: store device parameters and communication configuration;

[0074] Log area: adopt circular buffer structure to store running data.

[0075] Compared with the existing technology, the UV smoke hood intelligent control system and method of the present invention solve the technical problems of complex wiring and poor scalability of traditional centralized control systems. Through the innovative dual-bus architecture and dynamic scheduling algorithm, it solves the contradiction between distributed control and real-time performance, and can effectively reduce signal interference. Due to the use of the highest baud rate of 485 communication, the refresh speed is fast. Because there is no line coming out of the main control cabinet, and the communication method is adopted, the number of cables is reduced, saving a lot of cable costs. Using a modular IO control box, by increasing or decreasing the communication address, the number of smoke hood sections can be flexibly matched, and segmented control can be used to flexibly increase and decrease the number of smoke hood sections. Since the number of control systems and replacement modules is reduced, the cost is reduced. It is easy to operate and manufacture, modular installation, and unified specifications. The maintenance cost is low, it is very easy to replace and modify, there are few cables, the alarm release is clear, and the maintenance cost is low.

[0076] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any modifications, equivalent replacements and improvements made within the concept of the present invention should be included in the patent protection scope of the present invention.

Claims

1. UV smoke hood intelligent control system, characterized by: It includes a main control unit, which includes a PLC controller, an HMI touch screen, a power module and a communication gateway; At least one IO control box connected to the main control unit via RS-485 bus; Wind pressure sensing network, which includes distributed differential pressure sensors and signal conditioning modules; Actuator group, the actuator group includes UV lamp array, air curtain unit, centrifugal fan and auxiliary lighting unit; Safety interlock module, which integrates emergency stop circuit, leakage protection unit and arc detection device; The PLC controller runs a dedicated control program developed on the MagicWorks V2.20 platform to implement a device collaborative control algorithm.

2. The UV smoke hood intelligent control system according to claim 1, characterized in that: The IO control box includes: Communication interface module, the communication interface module supports ModbusRTU protocol and PPI network protocol dual mode; Programmable digital input and output unit, the programmable digital input and output unit is equipped with 16 DI and 12 DO channels; Analog acquisition module, the analog acquisition module supports 4-20mA and 0-10V dual signal input; Address coding switch, the address coding switch adopts a rotary BCD encoder; Hot-swap protection circuit, the hot-swap protection circuit includes an overvoltage suppressor and a transient voltage suppression diode array.

3. The UV smoke hood intelligent control system according to claim 2, characterized in that: The communication interface module uses the CO-trust UDP protocol to implement data encapsulation. The communication frame structure includes: 2-byte start code; 1-byte address field; 1-byte function code; N-byte data field; 2-byte CRC check code; 1-byte end code.

4. The UV smoke hood intelligent control system according to claim 1, characterized in that: The device collaborative control algorithm includes: Air pressure-flow closed-loop control algorithm, establishing ΔP=K1·Q 2 +K2·Q mathematical model; UV lamp soft start control sequence, with three-stage stepped voltage boost; Fault prediction module, which analyzes equipment operating characteristic parameters based on LSTM neural network; Dynamic priority scheduling mechanism adopts improved EDF real-time scheduling algorithm.

5. The UV smoke hood intelligent control system according to claim 4, characterized in that: The UV lamp soft start control sequence specifically includes: Stage 1: Apply 30% rated voltage for 5±0.5s; The second stage: linearly boost to 60% of the rated voltage, with a boost rate of ≤5V / s; The third stage: maintain 60% voltage, duration 10±1s; Stage 4: Step up to 100% rated voltage, with overshoot controlled within 3%.

6. The UV smoke hood intelligent control system according to claim 1, characterized in that: The safety interlock module is used to achieve: Three-level interlock protection mechanism: Level Ⅰ: Cut off UV power supply when wind pressure is abnormal; Level II: Arc detection triggers rapid power off within <100ms; Level III: The water cooling system is activated when the temperature exceeds the limit; Safety status encoding mechanism, using 8-bit status word encoded in Gray code; Self-diagnosis function, performs a system integrity check every 500ms.

7. The UV smoke hood intelligent control system according to claim 1, characterized in that: The main control unit includes a hardware encryption module, which uses: Physically unclonable function (PUF) generates a unique device identification code; AES-256 encryption engine for data encryption in program storage area; Dynamic key exchange protocol, based on ECDH algorithm to achieve key negotiation; Anti-tamper detection circuit to monitor micro-strain and temperature anomalies on PCB boards.

8. UV smoke hood intelligent control method, characterized in that: include: Step S10: The system is powered on and initialized, and the confidentiality library parameters and device configuration table are loaded; Step S20: Establish a communication link and poll the status of each IO control box; Step S30: collecting wind pressure sensor data and calculating dynamic control parameters; Step S40: executing the device collaborative control algorithm to generate a control instruction set; Step S50: issuing control instructions via the dual redundant bus; Step S60: monitoring actuator feedback and performing closed-loop control adjustments; Step S70: Record the operation log and update the equipment life prediction model.

9. The UV smoke hood intelligent control system according to claim 8, characterized in that: The step S30 specifically includes: The sliding window method is used to process the wind pressure sampling data, with a window size of N = 8; Calculate the standard deviation σ=√(Σ(x_i-μ) 2 / (N-1)); When σ>threshold σ_th, the Kalman filter algorithm is started; Construct the pressure-flow characteristic curve and solve the optimal operating point Q_opt.