A multi-parameter collaborative response anti-shutdown control method and system for a magnetic suspension centrifugal blower of a fuming furnace process

Abstract

The present application relates to the technical field of metallurgical equipment control, and particularly relates to a kind of for fuming furnace process's magnetic suspension centrifugal blower multi-parameter collaborative response anti-shutdown control method and system, comprising the following steps: S1: setting blower operation baseline;S2: comparison is generated abnormal state result by comparing with operation baseline;S3: generating collaborative response instruction;S4: execute collaborative response instruction, to form temporary stable operation state;S5: when it is restored to operation baseline allowable range and keeps for a set length of time, generate back switch instruction;S6: execute back switch instruction, and switch back to constant flow control mode in operating mode.This application, by operation baseline setting, multi-parameter collaborative response and mode back switch closed-loop control, realizes the sustained stable operation of blower in fuming furnace condition and the improvement of anti-shutdown capability.

Description

Technical Field

[0001] This invention relates to the field of metallurgical equipment control technology, and in particular to a multi-parameter collaborative response anti-shutdown control method and system for magnetic levitation centrifugal blowers used in fuming furnace processes. Background Technology

[0002] Magnetic levitation centrifugal blowers are gradually replacing traditional Roots blowers in high-energy-consuming processes such as metallurgy and chemical engineering due to their advantages of high efficiency, low noise, and low maintenance costs. In smelting furnace processes, the blower provides a continuous and stable airflow supply for molten slag gasification, and its operating status directly affects the combustion stability and production efficiency of the furnace. However, smelting furnaces are characterized by high disturbance; uneven feed particle size and frequent slag fluctuations can cause rapid changes in pipeline pressure within seconds. If the blower approaches the surge zone during this process, conventional protection logic will trigger an emergency shutdown, which may lead to serious consequences such as nozzle blockage, slag backflow, and furnace shutdown.

[0003] Existing blower control methods generally employ protection strategies based on single parameters, often using pressure or displacement thresholds as shutdown criteria. While this approach can prevent equipment damage before surge occurs, it is prone to false shutdowns under strong disturbances in fuming furnaces, disrupting process continuity. Furthermore, existing control logic lacks multi-parameter coordinated response and mode adaptive switching mechanisms, failing to quickly escape the surge zone and maintain temporary stable operation after anomalies occur, resulting in frequent shutdowns, reduced energy efficiency, and insufficient system stability. Therefore, there is an urgent need for a multi-parameter coordinated response anti-shutdown control method and system for magnetic levitation centrifugal blowers used in fuming furnace processes to address these issues. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides a multi-parameter collaborative response anti-shutdown control method and system for magnetic levitation centrifugal blowers used in fuming furnace processes.

[0005] A multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process includes the following steps:

[0006] S1: Set the operating reference point for the blower, reserve a surge safety margin in the stable range of the performance curve, and form an operating baseline;

[0007] S2: Collect pipeline pressure, displacement amplitude, and temperature values, compare them with the operating baseline, and generate abnormal state results;

[0008] S3: When an abnormal state result triggers a preset risk condition, generate a coordinated response command, including increasing the vent valve opening and adjusting the blower speed;

[0009] S4: Switch the blower from constant flow control mode to constant speed control mode and execute the coordinated response command to form a temporary stable operating state;

[0010] S5: Continuously monitor the temporary stable operating status. When the pipeline pressure and displacement level recover to the allowable range of the operating baseline and remain there for a set time, generate a cut-back command.

[0011] S6: Execute the back-cut command, close the vent valve to the normal position, and switch the operating mode back to constant flow control mode.

[0012] Optionally, S1 specifically includes:

[0013] S11: Based on the pressure and flow performance curves of the magnetic levitation centrifugal blower, select a working range that is stable in flow, has high energy efficiency and is far from the surge boundary, and set a target operating point within the working range as the operating reference point of the blower. The parameters of the operating reference point include the set flow rate and the set pressure.

[0014] S12: Based on the operating reference point set by the blower, a pressure difference range is reserved in the direction of reduced flow as a surge safety margin. The lower limit of the pressure difference range is set as the surge judgment line, and the upper limit is set as the surge warning line. The distance between the two is used to form a surge safety buffer zone.

[0015] S13: Construct a standardized data set from the operating reference point, surge judgment line, and surge warning line, and use it as the operating baseline.

[0016] Optionally, S2 specifically includes:

[0017] S21: Install a measuring device for monitoring the operating status of the pipeline, including a pressure sensor for collecting the pressure of the main duct, a displacement sensor for collecting the rotor displacement, and a temperature sensor for collecting the temperature of the motor stator and shaft end.

[0018] S22: Compare the collected real-time pressure value, displacement amplitude and temperature value with the operating baseline formed in S1, and determine whether the pressure is close to or exceeds the surge warning line, whether the displacement is higher than the set threshold, and whether the temperature reaches the operating condition limit value. If any indicator exceeds the corresponding baseline range, the current state is marked as a critical abnormal state.

[0019] S23: Under the condition that the abnormal state persists for multiple consecutive sampling periods, generate the abnormal state result and mark its abnormal source and severity level in combination with the abnormal dimension.

[0020] Optionally, S23 specifically includes:

[0021] S231: In each sampling period, obtain the three judgment results of pressure deviation, displacement over-limit and temperature rise of the current period, and classify and mark them, and set the mark values ​​as P, V and T respectively, representing that their respective parameters have exceeded the warning threshold set by the operating baseline.

[0022] S232: Set a fixed threshold value N for the number of consecutive judgment periods. If at least M periods within N consecutive sampling periods exhibit an abnormal state for any marker value, then the abnormal state is determined to persist; where N and M satisfy 1 ≤ M ≤ N, and the judgment formula is as follows: Where R is the cumulative count of anomalies within a continuous period, and I i This indicates whether any flag value exists within the i-th period; 1 indicates existence, and 0 indicates non-existence. If R≥M, then the abnormal state is confirmed to persist.

[0023] S233: Based on the continued existence of the abnormal state, generate the abnormal state result by combining the types of abnormal parameters, and mark the source and severity level of the abnormality.

[0024] Optionally, S233 specifically includes:

[0025] When only the pressure deviation marker P appears within a continuous judgment period, and there is no accompanying displacement over-limit marker V or temperature rise marker T, the generated abnormal state result is marked as a warning level, and the abnormal source is marked as a single-cause pressure abnormality.

[0026] When pressure deviation from P and any auxiliary parameter anomaly occur simultaneously, i.e., at least one of V or T exists, the generated abnormal state result is marked as risk level, and the source of the anomaly is marked as pressure-dominated composite anomaly.

[0027] When P does not occur but V and T are both abnormal, the generated abnormal status result is marked as a warning level, and the abnormal source is marked as a non-stress-related dual-cause abnormality.

[0028] When all three anomaly markers P, V, and T appear, the anomaly status result is marked as high-risk, and the anomaly source is marked as all-cause coincidence anomaly.

[0029] Optionally, S3 specifically includes:

[0030] S31: Receive the abnormal status result output from S2, identify the abnormal level and abnormal source type, and enter the collaborative response process when the identification result is a warning level or a risk level.

[0031] S32: Set the target opening increase of the vent valve according to the abnormality level. If it is a warning level, the target opening is increased by 10% to 20% based on the current opening. If it is a risk level or a high risk level, the target opening is increased by no less than 30%, and the maximum increase is no more than 50%. The action response interval is set to 0.5 seconds, and the step command is executed continuously for 3 to 5 times.

[0032] S33: Synchronously set the target speed adjustment value of the blower. If it is a warning level, the current speed will be increased by 5% to 10%, while still maintaining constant flow control mode. If it is a risk level, it will be forcibly switched to constant speed operation mode, and the target speed will be adjusted to more than 95% of the rated speed upper limit.

[0033] S34: Integrate the opening command and speed adjustment command obtained in S32 and S33 into a coordinated response command, and construct a response data packet containing the target opening value, target speed value, execution timing and duration parameters.

[0034] Optionally, S4 specifically includes:

[0035] S41: Receive the coordinated response command generated in S3, pause the PID closed-loop control logic of the current blower constant flow control mode, set the current output speed to the frozen state, and then send a control mode switching signal to switch the operating mode to constant speed control mode.

[0036] S42: Based on the target speed value set in the coordinated response command, send a speed increase command to the frequency converter, set the speed ramp rate to be no less than 1000 rpm / s, and set the target speed value to be between 95% and 100% of the rated speed.

[0037] S43: Simultaneously, based on the opening target value set in the coordinated response command, drive the vent valve to increase the opening degree step by step in a stepping mode, with each step increasing by 3% to 5%, and the step interval not exceeding 0.5 seconds, until the set total opening degree increase is reached, with a maximum not exceeding 50% of the current opening degree.

[0038] S44: After the speed and vent valve are adjusted, record the current operating parameters, including outlet pressure, displacement amplitude and exhaust temperature. If the fluctuation amplitude is within the set range for two consecutive cycles and the pressure value is higher than the surge judgment line, then a temporary stable operating state is determined to be formed.

[0039] Optionally, S5 specifically includes:

[0040] S51: After a temporary stable operating state is achieved, the continuous monitoring process is initiated, collecting the current pipeline pressure value and displacement amplitude every 1 second, and recording them as P. i With V iand the pressure allowable range set by the operating baseline in step S1 [P] min P max ] and the upper limit of displacement V max Compare the samples to determine whether the current sampling point meets the recovery conditions;

[0041] S52: Set the continuous confirmation duration to T c Let N1 be the total number of sampling points within the corresponding time period. If each sampling point in N1 consecutive samplings satisfies the following logical condition:

[0042] P min ≤P i ≤P max And V i ≤V max For all i∈[1, N1], it is determined that the blower's operating status has been restored to the allowable range of the operating baseline;

[0043] S53: Once the blower's operating status has returned to the allowable range of the operating baseline, a back-cut command is immediately generated, including the target vent valve closing opening value and the blower's operating mode switching from constant speed control mode back to constant flow control mode.

[0044] Optionally, S6 specifically includes:

[0045] S61: Receive the back-cut command generated in S5, and gradually close the vent valve from the current opening degree in increments of 3% to 5% until it is restored to the initially set normal opening degree value, controlling the step interval to not exceed 1 second;

[0046] S62: Synchronously send the operating mode switching command, terminate the constant speed control mode, re-enable the constant flow control mode, and load the preset PID parameter group to restore the closed-loop regulation of the flow.

[0047] S63: After confirming that the vent valve is closed in place and the control mode is switched, record the current operating status label and mark it as continuous and stable operation to complete the anti-shutdown control closed loop.

[0048] A multi-parameter collaborative response anti-shutdown control system for a magnetic levitation centrifugal blower used in a fuming furnace process, for implementing the aforementioned multi-parameter collaborative response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process, includes the following modules:

[0049] Baseline setting module: used to set the operating reference point according to the blower performance curve, and to reserve a surge safety margin in the stable range to build the operating baseline;

[0050] Data acquisition module: used to collect pipeline pressure, blower displacement amplitude and motor bearing temperature in real time, and to filter the collected signals to output stable multi-parameter operating condition data;

[0051] Anomaly detection module: Connected to the data acquisition module, it is used to compare multi-parameter operating condition data with the operating baseline, generate anomaly status results, and attach anomaly level and anomaly source markers;

[0052] Command generation module: connected to the anomaly determination module, used to generate coordinated response commands when the abnormal state results reach the preset risk conditions, including vent valve opening adjustment commands and speed adjustment commands;

[0053] Mode switching and execution module: connected to the instruction generation module, used to respond to coordinated response instructions, switch the blower operating mode from constant flow control to constant speed control, and drive the vent valve to adjust synchronously with the blower to form a temporary stable operating state;

[0054] The cutback control module is connected to the mode switching and execution module. It is used to monitor the pressure and displacement levels under temporary stable conditions, determine whether the cutback conditions are met, and generate a cutback command after confirming continuous recovery.

[0055] Operation recovery module: Connected to the back-cut control module, it is used to execute back-cut commands, close the vent valve to the normal opening, switch back to constant flow control mode, and update the current operation status label to continuous stable operation.

[0056] The beneficial effects of this invention are:

[0057] This invention achieves comprehensive judgment of pipeline pressure, displacement level and temperature by setting an operating benchmark point on the blower performance curve and reserving a surge safety margin, combined with a multi-parameter real-time acquisition and comparison mechanism. When an abnormal state is triggered, the control logic can generate coordinated response commands including increasing the opening degree of the vent valve and adjusting the speed, and switch to a constant speed mode to form a temporary stable operating state, thereby effectively avoiding frequent shutdowns caused by misjudgment of a single parameter.

[0058] This invention, by setting continuous monitoring and cut-off judgment conditions under a temporary stable state, ensures that the pressure and displacement levels return to the operating baseline before resuming the constant flow control mode. This closed-loop control link guarantees the continuous operation and anti-shutdown capability of the blower under the fuming furnace operating conditions, which not only improves the stability and reliability of the system operation, but also takes into account energy utilization efficiency. Attached Figure Description

[0059] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0060] Figure 1 This is a schematic diagram of the cooperative response anti-shutdown control method according to an embodiment of the present invention;

[0061] Figure 2 This is a schematic diagram of the collaborative response anti-shutdown control system according to an embodiment of the present invention. Detailed Implementation

[0062] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should also be noted that, to make the embodiments more comprehensive, the following embodiments are the best and preferred embodiments, and those skilled in the art can use other alternative methods to implement some well-known technologies; moreover, the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0063] It should be noted that the use of terms such as "an embodiment," "an embodiment," "an exemplary embodiment," and "some embodiments" in the specification indicates that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments (whether explicitly described or not) should be within the knowledge of those skilled in the art.

[0064] Generally, terms can be understood at least partly from their use in context. For example, depending at least partly on the context, the term "one or more" as used herein can be used to describe any feature, structure, or characteristic in a singular sense, or a combination of features, structures, or characteristics in a plural sense. Additionally, the term "based on" can be understood not necessarily to convey an exclusive set of factors, but rather, alternatively, depending at least partly on the context, to allow for the presence of other factors that are not necessarily explicitly described.

[0065] like Figure 1 As shown, a multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process includes the following steps:

[0066] S1: Set the operating reference point for the blower, reserve a surge safety margin in the stable range of the performance curve, and form an operating baseline;

[0067] S2: Collect pipeline pressure, displacement amplitude and temperature values, compare them with the operating baseline, generate abnormal state results, and use them to determine whether the blower is close to the risk of surge.

[0068] S3: When an abnormal state result triggers a preset risk condition, generate a coordinated response command, including increasing the opening degree of the vent valve and adjusting the speed of the blower, as an emergency response action;

[0069] S4: Switch the blower from constant flow control mode to constant speed control mode and execute the coordinated response command to form a temporary stable operating state;

[0070] S5: Continuously monitor the temporary stable operating status. When the pipeline pressure and displacement level recover to the allowable range of the operating baseline and remain there for a set time, generate a cut-back command.

[0071] S6: Execute the back-cut command to close the vent valve to the normal position and switch the operating mode back to constant flow control mode, thereby completing one anti-shutdown control closed loop.

[0072] S1 specifically includes:

[0073] S11: Based on the pressure and flow performance curves of the magnetic levitation centrifugal blower, select the working range that is stable in flow, high in energy efficiency and far from the surge boundary, and set the target operating point in the working range as the operating reference point of the blower. The parameters of the operating reference point include the set flow rate and the set pressure.

[0074] S12: Based on the operating reference point set by the blower, a pressure difference range is reserved in the direction of reduced flow as a surge safety margin. The lower limit of the pressure difference range is set as the surge judgment line, and the upper limit is set as the surge warning line. The distance between the two is used to form a surge safety buffer zone.

[0075] S13: The operating reference point, surge judgment line, and surge warning line are constructed into a standardized data set, which is then used as the operating baseline input into the blower control logic and used as the basis for subsequent operating condition comparison and response action triggering. The above steps, by selecting the operating reference point in the stable range of the performance curve and setting a surge safety margin in combination with the surge judgment line and warning line, realize the systematic construction of the operating baseline, which helps to improve the blower's risk resistance capability in a disturbed environment and provides an accurate reference for dynamic judgment based on multiple parameters in subsequent steps.

[0076] S2 specifically includes:

[0077] S21: Set up a measuring device for monitoring the operating status of the pipeline, including a pressure sensor for collecting the pressure of the main duct, a displacement sensor for collecting the rotor displacement, and a temperature sensor for collecting the temperature of the motor stator and shaft end. All sensor signals are connected to the data acquisition channel of the blower main controller and are periodically sampled at fixed time intervals.

[0078] S22: Compare the collected real-time pressure value, displacement amplitude and temperature value with the operating baseline formed in S1, and determine whether the pressure is close to or exceeds the surge warning line, whether the displacement is higher than the set threshold, and whether the temperature reaches the operating condition limit value. If any indicator exceeds the corresponding baseline range, the current state is marked as a critical abnormal state.

[0079] S23: Under the condition that the abnormal state persists for multiple consecutive sampling periods, generate the abnormal state result, and mark its abnormal source and severity level in combination with the abnormal dimension (pressure, displacement, temperature), which serves as the trigger condition input for the coordinated response action in subsequent steps.

[0080] S23 specifically includes:

[0081] S231: In each sampling period, obtain the three judgment results of pressure deviation, displacement over-limit and temperature rise of the current period, and classify and mark them, and set the mark values ​​as P, V and T respectively, representing that their respective parameters have exceeded the warning threshold set by the operating baseline.

[0082] S232: Set a fixed threshold value N for the number of consecutive judgment periods. If at least M periods within N consecutive sampling periods exhibit an abnormal state for any marker value, then the abnormal state is determined to persist; where N and M satisfy 1 ≤ M ≤ N, and the judgment formula is as follows: Where R is the cumulative count of anomalies within a continuous period, and I i This indicates whether any flag value exists within the i-th period; 1 indicates existence, and 0 indicates non-existence. If R≥M, then the abnormal state is confirmed to persist.

[0083] S233: Based on the continued existence of the abnormal state, generate the abnormal state result by combining the types of abnormal parameters, and mark the source and severity level of the abnormality.

[0084] S233 specifically includes:

[0085] When only the pressure deviation marker P appears within a continuous judgment period, and there is no accompanying displacement over-limit marker V or temperature rise marker T, the generated abnormal state result is marked as a warning level, and the abnormal source is marked as a single-cause pressure abnormality.

[0086] When pressure deviation from P and any auxiliary parameter anomaly occur simultaneously, i.e., at least one of V or T exists, the generated abnormal state result is marked as risk level, and the source of the anomaly is marked as pressure-dominated composite anomaly.

[0087] When P does not occur but V and T are both abnormal, the generated abnormal status result is marked as a warning level, and the abnormal source is marked as a non-stress-related dual-cause abnormality.

[0088] When all three anomaly markers P, V, and T appear, the anomaly status result is marked as high-risk level, and the anomaly source is marked as all-cause coincidence anomaly.

[0089] The above steps, by introducing a multi-dimensional anomaly accumulation judgment mechanism with continuous cycles, can avoid the problem of false response caused by false triggering in a single cycle. At the same time, by using the marking method of anomaly source type combination, the response control strategy is enhanced to be more targeted, making the entire anti-stop mechanism more robust and adaptable.

[0090] S3 specifically includes:

[0091] S31: Receive the abnormal status result output in S2, identify the abnormal level and abnormal source type. When the identification result is a warning level or a risk level, enter the collaborative response process. The warning level corresponds to a medium-amplitude response strategy, and the risk level and high-risk level correspond to a high-intensity response strategy.

[0092] S32: Set the target opening increase of the vent valve according to the abnormality level. If it is a warning level, the target opening is increased by 10% to 20% based on the current opening. If it is a risk level or a high risk level, the target opening is increased by no less than 30%, and the maximum increase is no more than 50%. The action response interval is set to 0.5 seconds, and the step command is executed continuously for 3 to 5 times to achieve rapid pressure relief.

[0093] S33: Synchronously set the target speed adjustment value of the blower. If it is a warning level, the current speed will be increased by 5% to 10%, while still maintaining constant flow control mode. If it is a risk level, it will be forcibly switched to constant speed operation mode, and the target speed will be adjusted to more than 95% of the upper limit of the rated speed. Specifically, it will be set within the range of 95% to 100% of the rated value to ensure that the air volume output has sufficient inertia to get out of the surge boundary.

[0094] S34: Integrate the opening command and speed adjustment command obtained in S32 and S33 into a coordinated response command, construct a response data packet containing the target opening value, target speed value, execution timing and duration parameters, and send it to the vent valve driver and blower frequency converter in a structured format to ensure that the two are executed synchronously according to the set logic. The above steps, through the parameter setting strategy driven by the anomaly level, dynamically match the response amplitude and speed of the vent valve opening and the blower speed, which not only ensures rapid pressure relief and speed stabilization during pressure changes, but also avoids energy consumption fluctuations and control instability caused by over-adjustment. This gives the coordinated response mechanism multiple advantages of differentiation, speed and controllability, ensuring effective anti-surge control under different anomaly levels.

[0095] S4 specifically includes:

[0096] S41: Receive the collaborative response command generated in S3, pause the PID closed-loop control logic of the current blower constant flow control mode, set the current output speed to the frozen state, and then send a control mode switching signal to switch the operating mode to the constant speed control mode, set the speed control method to the target value direct setting method, and bypass the original flow feedback adjustment link.

[0097] S42: Based on the target speed value set in the coordinated response command, a speed increase command is sent to the frequency converter, setting the speed increase rate to be no less than 1000 rpm / s, and the target speed value to be between 95% and 100% of the rated speed, and finally the operation stabilizes in this speed range;

[0098] S43: Simultaneously, based on the opening target value set in the coordinated response command, drive the vent valve to increase the opening degree step by step in a stepping mode, with each step increasing by 3% to 5%, and the step interval not exceeding 0.5 seconds, until the set total opening degree increase is reached, with a maximum not exceeding 50% of the current opening degree.

[0099] S44: After the speed and vent valve are adjusted, record the current operating parameters, including outlet pressure, displacement amplitude and exhaust temperature. If the fluctuation amplitude is within the set range for two consecutive cycles and the pressure value is higher than the surge judgment line, a temporary stable operating state is determined and marked as a temporary stable state label for step S5 to monitor the drop. The above steps, through a clear mode switching control process and synchronized execution strategy, enable the blower to quickly switch from flow closed-loop control to high inertia constant speed operation in risky scenarios, and form a safety buffer mechanism with the vent valve pressure relief action. In non-stop state, the surge risk is effectively avoided, and the blower's response capability and process stability to sudden disturbances are improved.

[0100] S5 specifically includes:

[0101] S51: After a temporary stable operating state is achieved, the continuous monitoring process is initiated, collecting the current pipeline pressure value and displacement amplitude every 1 second, and recording them as P. i With V i and the pressure allowable range set by the operating baseline in step S1 [P] min P max ] and the upper limit of displacement V max Compare the samples to determine whether the current sampling point meets the recovery conditions;

[0102] S52: Set the continuous confirmation duration to T c Let N1 be the total number of sampling points within the corresponding time period. If each sampling point in N1 consecutive samplings satisfies the following logical condition:

[0103] P min ≤P i ≤P max And V i ≤V max For all i∈[1, N1], it is determined that the blower's operating status has been restored to the allowable range of the operating baseline;

[0104] S53: Once the blower's operating status has returned to the allowable range of the operating baseline, a cut-back command is immediately generated, including the target vent valve closing opening value and the blower's operating mode switching from constant speed control mode to constant flow control mode. The command is written into the controller buffer in the form of structured data, waiting to be executed in step S6. The above steps, by setting clear sampling intervals, fluctuation judgment conditions, and continuous maintenance duration judgment logic, achieve reliable confirmation of the temporary stable state returning to the safe operating area, avoid erroneous triggering of the cut-back operation due to brief stability, improve the stability and safety of the cut-back decision, and lay the foundation for subsequent operating status convergence and closed-loop recovery.

[0105] S6 specifically includes:

[0106] S61: Receive the back-cut command generated in S5, and gradually close the vent valve from the current opening degree in a step-by-step manner of decreasing by 3% to 5% until it is restored to the initially set normal opening degree value, and control the step interval to not exceed 1 second;

[0107] S62: Synchronously send the operating mode switching command, terminate the constant speed control mode, re-enable the constant flow control mode, and load the preset PID parameter group to restore the closed-loop regulation of the flow.

[0108] S63: After confirming that the vent valve is closed to the correct position and the control mode is switched, record the current operating status label and mark it as continuous and stable operation to complete the anti-shutdown control closed loop. This step realizes the synchronous switching back of the vent valve and the operating mode, so that the blower can smoothly return to the energy-saving control state and ensure the continuity of system operation and the complete closed loop of the control strategy.

[0109] like Figure 2 As shown, a multi-parameter collaborative response anti-shutdown control system for a magnetic levitation centrifugal blower used in a fuming furnace process is disclosed. This system implements the aforementioned multi-parameter collaborative response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process, and includes the following modules:

[0110] Baseline setting module: used to set the operating reference point according to the blower performance curve, and to reserve a surge safety margin in the stable range to build the operating baseline;

[0111] Data acquisition module: used to collect pipeline pressure, blower displacement amplitude and bearing temperature in real time, and to filter the collected signals to output stable multi-parameter operating condition data;

[0112] Anomaly detection module: Connected to the data acquisition module, it is used to compare multi-parameter operating condition data with the operating baseline, generate anomaly status results, and attach anomaly level and anomaly source markers;

[0113] Command generation module: connected to the anomaly determination module, used to generate coordinated response commands when the abnormal state results reach the preset risk conditions, including vent valve opening adjustment commands and speed adjustment commands;

[0114] Mode switching and execution module: connected to the instruction generation module, used to respond to coordinated response instructions, switch the blower operating mode from constant flow control to constant speed control, and drive the vent valve to adjust synchronously with the blower to form a temporary stable operating state;

[0115] The cutback control module is connected to the mode switching and execution module. It is used to monitor the pressure and displacement levels under temporary stable conditions, determine whether the cutback conditions are met, and generate a cutback command after confirming continuous recovery.

[0116] Operation recovery module: Connected to the back-cut control module, it is used to execute back-cut commands, close the vent valve to the normal opening, switch back to constant flow control mode, and update the current operation status label to continuous stable operation.

[0117] A smelter has installed a magnetic levitation centrifugal blower with a rated flow rate of 10700 Nm³ in its fuming furnace process. 3The blower has a rated speed of 20,000 rpm and a rated outlet pressure of 130 kPa. It needs to maintain a stable airflow during operation to avoid surge and shutdown. The multi-parameter coordinated response anti-shutdown control method proposed above is used for control, and the specific process is as follows:

[0118] S1: Based on the blower's performance curve, select 90% of the rated flow rate (i.e., 9600 Nm). 3 / h) is used as the operating reference point, and the corresponding reference pressure is 58kPa;

[0119] Based on this operating point, a surge safety margin should be reserved for the low flow rate side:

[0120] Set surge warning line = reference pressure + 20 kPa = 78 kPa;

[0121] Set surge detection line = reference pressure + 24 kPa = 82 kPa;

[0122] Therefore, the operating baseline is in the range of [58, 78] kPa, of which 78 kPa to 82 kPa is the warning zone and acceleration zone. After acceleration, the surge pressure will also increase. If it is higher than 130 kPa, it is judged as a risk zone.

[0123] S2: Install a pressure sensor (accuracy ±0.1kPa) in the outlet air duct, a displacement sensor (range ≤10μm) in the motor bearing housing, and a temperature sensor (accuracy ±0.5℃) in the motor shaft end.

[0124] The control system collects data once per second, and the comparison logic is set as follows:

[0125] If the pressure value P > 78 kPa, it is marked as a pressure warning.

[0126] If the pressure value P > 130 kPa, it is marked as a pressure risk.

[0127] If the displacement value V > 10 μm, it is marked as a displacement anomaly.

[0128] If the temperature value T > 125℃, it is marked as a temperature anomaly.

[0129] Example calculation: In a certain sampling, the detected values ​​are P = 78.2 kPa, V = 10.3 mm / s, and T = 121℃;

[0130] Comparison results: Pressure is in the range of [78, 82], triggering a pressure warning; displacement exceeds the threshold, triggering a displacement anomaly; temperature is normal. If this occurs for 5 consecutive cycles, the resulting abnormal state is a pressure-dominated composite anomaly, and the anomaly level is equal to the risk level.

[0131] S3: The controller matches the response strategy according to the anomaly level.

[0132] The vent valve opening is increased by 40% under the current risk level, which is 20%; the target opening is 60%.

[0133] The blower speed adjustment is as follows: the current speed is 16000 rpm, and it needs to be switched to constant speed mode and increased to 97% of the rated speed, which is 19400 rpm.

[0134] The vent valve is raised in steps, each step being 5% with a 0.5-second interval, for a total of 8 steps to reach the target opening; the rotational speed increases at a rate of 1000 rpm / s, taking approximately 3.4 seconds to complete.

[0135] The final coordinated response command data packet contains {opening target = 60%, step = 5%, interval = 0.5s; rotational speed target = 19400rpm, climb rate = 1000rpm / s}.

[0136] S4: When executing the coordinated response command, the controller pauses the constant flow PID, freezes the current output flow, sends a mode switching signal to the frequency converter, and enters the constant speed mode;

[0137] The engine speed increased to 19,400 rpm in 3.4 seconds;

[0138] The vent valve gradually increases to 60% opening within 4 seconds;

[0139] At this point, the outlet pressure recovered to below 78 kPa and the displacement decreased to 10 μm, indicating that a temporary stable operating state had been formed.

[0140] S5: The control system continues to monitor by sampling once per second, and the confirmation time is set to 10 seconds; if all sampling points meet the following conditions in 10 sampling cycles: pressure 58–78 kPa; displacement ≤ 10 μm; then the cut-off condition is met, and a cut-off command is generated: the vent valve is closed to the normal opening of 10%, and the operation mode is switched back to constant flow control.

[0141] S6: The vent valve closes from 60% to 10% in 5% increments with a 1-second interval, taking 10 seconds; the control mode is switched synchronously, the constant speed operation is terminated, the constant flow PID control is reactivated, and the preset parameters are loaded; after confirming that the valve and mode switching are completed, the system status is updated to "continuous and stable operation", completing a complete anti-shutdown closed loop.

[0142] In this practical case, when the pressure in the fuming furnace rapidly rises to above 78 kPa due to uneven feeding, the traditional control logic would trigger a shutdown protection. However, through this embodiment, the system completes the coordinated response of the vent valve and the speed within 4 seconds, ensuring stable operation of the blower, and automatically switches back to constant flow mode after confirming the return to normal operating conditions within 10 seconds. The entire process avoids the risk of shutdown and maintains continuous air supply to the fuming furnace.

[0143] Table 1 Comparison of traditional protection methods and the method of this invention under abnormal operating conditions.

[0144]

[0145] As shown in Table 1 above, traditional protection strategies directly shut down the furnace when the pressure drops below the threshold, leading to an interruption in the air supply to the fuming furnace. Recovery requires cleaning the pipelines, which is time-consuming and costly. In contrast, the method of this invention rapidly increases the rotational speed and vent valve opening through coordinated response commands when pressure and displacement are abnormal, achieving non-stop anti-surge operation. Furthermore, it can automatically switch back to constant flow mode within 10 seconds after the anomaly is resolved, ensuring continuous and stable operation of the furnace.

[0146] Table 2 Comparison of Reliability During Continuous Operation

[0147] Indicator Items Traditional protection methods Method of the present invention Number of downtimes (within 30 days) 2 times 0 times Single anomaly response time The shutdown takes effect immediately. Completed within 4 seconds Recovery time after an anomaly >2 days 10 seconds Furnace body airflow continuity retention rate 90％ 99.80％ Average energy efficiency 85％ 92％ Unplanned downtime losses The loss was huge. No downtime

[0148] As shown in Table 2 above, under the same operating conditions, traditional protection methods result in more shutdowns and longer recovery times due to frequent shutdowns, and the furnace airflow continuity rate is less than 90%. The method of this invention effectively avoids shutdowns through real-time multi-parameter judgment and coordinated response, achieving an airflow continuity rate of 99.8%, while improving energy efficiency by about 7%, significantly enhancing the system's operational reliability and economy.

[0149] This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the following preferred embodiments; however, those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0150] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process, characterized in that, Includes the following steps: S1: Set the operating reference point for the blower, reserve a surge safety margin in the stable range of the performance curve, and form an operating baseline; S2: Collect the pressure value of the main air duct, the rotor displacement amplitude, and the temperature of the motor stator and shaft end, and compare them with the operating baseline to generate abnormal state results; S3: When an abnormal state result triggers a preset risk condition, generate a coordinated response command, including increasing the vent valve opening and adjusting the blower speed; S4: Switch the blower from constant flow control mode to constant speed control mode and execute the coordinated response command to form a temporary stable operating state; S4 specifically includes: S41: Receive the coordinated response command generated in S3, pause the PID closed-loop control logic of the current blower constant flow control mode, set the current output speed to the frozen state, and then send a control mode switching signal to switch the operating mode to constant speed control mode. S42: Based on the target speed value set in the coordinated response command, send a speed increase command to the frequency converter, set the speed ramp rate to be no less than 1000 rpm / s, and set the target speed value to be between 95% and 100% of the rated speed; S43: Simultaneously, based on the target opening value set in the coordinated response command, drive the vent valve to increase the opening degree step by step in a stepping mode, with each step increasing by 3% to 5%, and the step interval not exceeding 0.5 seconds, until the set total opening degree increase is reached, with a maximum not exceeding 50% of the current opening degree; S44: After the speed and vent valve are adjusted, record the current operating status parameters, including the pressure value of the main air duct, the rotor displacement amplitude, and the temperature of the motor stator and shaft end. If the fluctuation amplitude is within the set range for two consecutive cycles and the pressure value of the main air duct is within the surge judgment line, then a temporary stable operating state is determined to be formed. S5: Continuously monitor the temporary stable operation status. When the pressure value of the main air duct and the rotor displacement amplitude return to the allowable range of the operating baseline and remain for a set time, a cut-back command is generated. S6: Execute the back-cut command, close the vent valve to the normal position, and switch the operating mode back to constant flow control mode.

2. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 1, characterized in that, S1 specifically includes: S11: Based on the pressure-flow performance curve of the magnetic levitation centrifugal blower, select a working range that is stable in flow, has high energy efficiency and is far from the surge boundary, and set a target operating point within the working range as the operating reference point of the blower. The parameters of the operating reference point include the set flow rate and the set pressure. S12: Based on the operating reference point set by the blower, a pressure difference range is reserved in the direction of reduced flow as a surge safety margin. The lower limit of the pressure difference range is set as the surge judgment line, and the upper limit is set as the surge warning line. The distance between the two is used to form a surge safety buffer zone. S13: Construct a standardized data set from the operating reference point, surge judgment line, and surge warning line, and use it as the operating baseline.

3. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 1, characterized in that, S2 specifically includes: S21: Install a measuring device for monitoring the operating status of the pipeline, including a pressure sensor for collecting the pressure value of the main duct, a displacement sensor for collecting the rotor position, and a temperature sensor for collecting the temperature of the motor stator and shaft end. S22: Compare the collected real-time duct main pressure value, rotor displacement amplitude, and motor stator and shaft end temperature with the operating baseline formed in S1, and determine whether the duct main pressure value is close to or exceeds the surge warning line, whether the rotor displacement amplitude is higher than the set threshold, and whether the motor stator and shaft end temperature have reached the operating condition limit value. If any indicator exceeds the corresponding baseline range, mark the current state as a critical abnormal state. S23: Under the condition that the abnormal state persists for multiple consecutive sampling periods, generate the abnormal state result and mark its abnormal source and severity level in combination with the abnormal dimension.

4. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 3, characterized in that, S23 specifically includes: S231: In each sampling period, obtain the three judgment results of pressure deviation, displacement over-limit and temperature rise of the current period, and classify and mark them, and set the mark values ​​as P, V and T respectively, representing that their respective parameters have exceeded the warning threshold set by the operating baseline. S232: Set a fixed threshold value N for the number of consecutive judgment periods. If at least M periods within N consecutive sampling periods exhibit an abnormal state for any marker value, then the abnormal state is determined to persist; where N and M satisfy... The formula for determining this is: ,in, This is the cumulative count of anomalies over a continuous period. Indicates the first Does any marker value exist within each period? If it exists, return 1; otherwise, return 0. If satisfied If so, the abnormal state is confirmed to persist. S233: Based on the continued existence of the abnormal state, generate the abnormal state result by combining the types of abnormal parameters, and mark the source and severity level of the abnormality.

5. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 4, characterized in that, S233 specifically includes: When only the pressure deviation marker P appears within a continuous judgment period, and there is no accompanying displacement over-limit marker V or temperature rise marker T, the generated abnormal state result is marked as a warning level, and the abnormal source is marked as a single-cause pressure abnormality. When pressure deviation from P and any auxiliary parameter anomaly occur simultaneously, i.e., at least one of V or T exists, the generated abnormal state result is marked as risk level, and the source of the anomaly is marked as pressure-dominated composite anomaly. When P does not occur but V and T are both abnormal, the generated abnormal status result is marked as a warning level, and the abnormal source is marked as a non-stress-related dual-cause abnormality. When all three anomaly markers P, V, and T appear, the anomaly status result is marked as high-risk, and the anomaly source is marked as all-cause coincidence anomaly.

6. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 5, characterized in that, S3 specifically includes: S31: Receive the abnormal status result output from S2, identify the abnormal level and abnormal source type, and enter the collaborative response process when the identification result is a warning level or a risk level. S32: Set the target opening increase of the vent valve according to the abnormality level. If it is a warning level, the target opening is increased by 10% to 20% based on the current opening. If it is a risk level or a high risk level, the target opening is increased by no less than 30%, and the maximum increase is no more than 50%. The action response interval is set to 0.5 seconds, and the step command is executed continuously for 3 to 5 times. S33: Synchronously set the target speed adjustment value of the blower. If it is a warning level, the current speed will be increased by 5% to 10%, while still maintaining constant flow control mode. If it is a risk level, it will be forcibly switched to constant speed operation mode, and the target speed will be adjusted to more than 95% of the rated speed upper limit. S34: Integrate the opening command and speed adjustment command obtained in S32 and S33 into a coordinated response command, and construct a response data packet containing the target opening value, target speed value, execution timing and duration parameters.

7. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 1, characterized in that, S5 specifically includes: S51: After a temporary stable operating state is achieved, the continuous monitoring process is initiated, collecting the current main duct pressure value and rotor displacement amplitude every 1 second, and recording them as follows: and and the pressure allowable range set by the operating baseline in step S1. and the upper limit of the allowable rotor displacement amplitude Compare the samples to determine whether the current sampling point meets the recovery conditions; S52: Set the continuous confirmation duration to Set the total number of all sampling points within the corresponding time period to 1. If continuous Each sampling point in this sampling process satisfies the following logical judgment condition: For all ,like and If so, it is determined that the blower's operating status has returned to the allowable range of the operating baseline; S53: Once the blower's operating status has returned to the allowable range of the operating baseline, a back-cut command is immediately generated, including the target vent valve closing opening value and the blower's operating mode switching from constant speed control mode back to constant flow control mode.

8. The multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process according to claim 1, characterized in that, S6 specifically includes: S61: Receive the back-cut command generated in S5, and gradually close the vent valve from the current opening degree in a step-by-step manner of decreasing by 3% to 5% until it is restored to the initially set normal opening degree value, and control the step interval to not exceed 1 second; S62: Synchronously send the operating mode switching command, terminate the constant speed control mode, re-enable the constant flow control mode, and load the preset PID parameter group to restore the closed-loop regulation of the flow. S63: After confirming that the vent valve is closed in place and the control mode is switched, record the current operating status label and mark it as continuous and stable operation to complete the anti-shutdown control closed loop.

9. A multi-parameter coordinated response anti-shutdown control system for a magnetic levitation centrifugal blower used in a fuming furnace process, used to implement the multi-parameter coordinated response anti-shutdown control method for a magnetic levitation centrifugal blower used in a fuming furnace process as described in any one of claims 1-8, characterized in that, Includes the following modules: Baseline setting module: used to set the operating reference point according to the blower performance curve, and to reserve a surge safety margin in the stable range to build the operating baseline; Data acquisition module: used to collect the pressure value of the main air duct, the rotor displacement amplitude, and the temperature of the motor stator and shaft end in real time, and to filter the collected signals to output stable multi-parameter operating condition data; Anomaly detection module: Connected to the data acquisition module, it is used to compare multi-parameter operating condition data with the operating baseline, generate anomaly status results, and attach anomaly level and anomaly source markers; Command generation module: connected to the anomaly determination module, used to generate coordinated response commands when the abnormal state results reach the preset risk conditions, including vent valve opening adjustment commands and speed adjustment commands; Mode switching and execution module: connected to the instruction generation module, used to respond to coordinated response instructions, switch the blower operating mode from constant flow control to constant speed control, and drive the vent valve to adjust synchronously with the blower to form a temporary stable operating state; The cutback control module is connected to the mode switching and execution module. It is used to monitor the pressure value of the main air duct and the rotor displacement amplitude under the temporary stable state, determine whether the cutback conditions are met, and generate a cutback command after confirming continuous recovery. Operation recovery module: Connected to the back-cut control module, it is used to execute back-cut commands, close the vent valve to the normal opening, switch back to constant flow control mode, and update the current operation status label to continuous stable operation.

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