Suspension type continuous ion exchange device and system

Abstract

The invention discloses a suspension type continuous ion exchange device and system, and belongs to the technical field of ion exchange. The device comprises a rack, a driving system, a rotary distribution valve, a resin column and a connecting hose, and is characterized in that the resin column is suspended at the upper part of the rack through a turntable, and the rotary distribution valve is fixed above the center of the turntable; the driving system adopts a distribution valve driving motor and a turntable driving motor, and real-time synchronous control of the double motors is realized through a PLC (Programmable Logic Controller) control system; the connecting hose is restrained by the guide ring to prevent winding, and the resin column is of a fast-assembly structure and optimizes an internal flow channel. The device greatly reduces the occupied area through the vertical suspension layout, shortens the pipeline, reduces the operation energy consumption, solves the problems of inconvenient maintenance and phase out-of-step, is suitable for the industries of salt lake lithium extraction, pharmacy and the like, and has the characteristics of compact structure, reliable operation and wide process adaptability.

Description

Technical Field

[0001] This invention relates to the field of ion exchange technology, specifically to a suspended continuous ion exchange device and system. Background Technology

[0002] Compared with traditional fixed-bed technology, continuous ion exchange (CIX) technology has significant advantages such as high efficiency, high resin utilization, and low eluent consumption, and has been widely used in liquid-solid separation and purification processes in industries such as lithium extraction from salt lakes, pharmaceuticals, food, and chemicals.

[0003] Existing continuous ion exchange systems typically employ a structure of "multiple fixed resin columns + rotary distribution valves." During operation, the resin columns remain fixed, and the process state of each resin column is changed only by switching the rotary distribution valves. However, this type of system has the following key problems:

[0004] The resin columns need to be arranged in a planar layout, and a lot of space needs to be reserved for the maintenance of the rotary distribution valve, resulting in the entire system occupying a large area, which is not suitable for space-constrained scenarios.

[0005] The numerous, complex, and long pipelines connecting the rotary distribution valve to each resin column not only increase material costs but also generate significant fluid resistance, resulting in high system energy consumption.

[0006] The dense equipment layout and complex piping system make the inspection, replacement and maintenance of internal resin columns or pipes difficult and require a lot of time and manpower.

[0007] Some devices that use independent drive units are prone to problems of asynchronous switching between the distribution valve and the stepping motion of the resin column after long-term operation, which may lead to equipment failure or process failure.

[0008] The root cause of the above problems lies in the insufficient coordination between the "planar" layout design of traditional devices and the drive system. Therefore, the development of a continuous decoupling device that is compact, energy-efficient, easy to maintain, and reliable in operation has become an urgent need in the industry. Summary of the Invention

[0009] To address the shortcomings of existing technologies, this invention provides a suspended continuous derailment device and system, which solves the problems mentioned in the background section.

[0010] To achieve the above objectives, the present invention is implemented through the following technical solution: a suspended continuous decoupling device, comprising a frame, a drive system, a rotary distribution valve, a resin column assembly and a connecting hose, wherein the resin column assembly is suspended above the frame via a turntable, and the resin column assembly comprises multiple resin columns evenly distributed along the circumference of the turntable; the rotary distribution valve is fixedly installed on the top of the frame and located above the center of the turntable.

[0011] The turntable is connected to the frame via a large slewing bearing;

[0012] The drive system includes a distribution valve drive motor for controlling the start and stop of the rotary distribution valve and angle positioning, and a turntable drive motor for driving the turntable to perform intermittent rotational motion. The distribution valve drive motor and the turntable drive motor are electrically connected through the control system.

[0013] The multiple outlets of the rotary distribution valve are connected to the corresponding top inlet of the resin column through multiple independent connecting hoses, and the connecting hoses are in a natural hanging state.

[0014] The frame is equipped with guide rings consisting of two or more layers. The guide rings are fixed to the central column of the frame by brackets. Each guide ring has a number of slots equal to the number of resin columns and evenly spaced. Each connecting hose passes through a corresponding slot independently.

[0015] Optionally, each resin column is provided with a water distributor at its top and a resin support sieve plate and a water collection device at its bottom; the resin column is connected to the turntable by a quick-release clamp.

[0016] Optionally, the slewing bearing adopts a sealing method combining a labyrinth seal and a rubber sealing ring to prevent external impurities from entering the bearing and internal grease from leaking, and to resist corrosive gaseous and liquid media in the process environment.

[0017] Optionally, the control system is based on a programmable logic controller (PLC). The PLC receives real-time position feedback signals from the encoders of the distribution valve drive motor and the turntable drive motor, and compares them with a preset phase relationship. The preset phase relationship is that for every station angle θ rotated by the turntable, the rotary distribution valve needs to rotate synchronously by a corresponding process switching angle φ.

[0018] Optionally, the connecting hose is made of a material with chemical corrosion resistance, temperature resistance and fatigue resistance, with a temperature range of -10℃ to 80℃. Specifically, the material is a flexible hose lined with polytetrafluoroethylene (PTFE) or a special fluororubber hose.

[0019] Optionally, the guide ring is made of engineering plastic, and the groove on the guide ring is an arc-shaped groove. The groove spacing is equal to the angular spacing of adjacent resin columns to prevent the connecting hoses from getting tangled or rubbing against the equipment when the turntable rotates.

[0020] Optionally, the rotary distribution valve employs a multi-seal structure combining end-face mechanical seals and auxiliary elastic sealing rings between the valve core and valve seat. The contact surfaces of the valve core and valve seat undergo high-precision grinding to prevent liquid cross-flow under different process pressures.

[0021] Optionally, the turntable drive motor is a servo motor. The turntable drive motor drives a pinion through a reducer. The pinion meshes with the outer ring gear of the slewing bearing to drive the turntable to achieve intermittent rotation.

[0022] Optionally, the distribution valve drive motor is a servo motor, which directly drives the valve shaft of the rotary distribution valve through a coupling to achieve precise angular positioning of the rotary distribution valve.

[0023] A system for a suspended continuous switching device, the control system comprising a programmable logic controller (PLC), two servo drives, two encoders, and a human-machine interface unit, wherein the two servo drives are electrically connected to a distribution valve drive motor and a turntable drive motor respectively, and the two encoders are also respectively mounted to the valve shaft of the distribution valve drive motor and the output shaft of the turntable drive motor; the PLC establishes a bidirectional communication connection with the two servo drives and the human-machine interface unit via a PROFIBUS-DP bus, and the signal output terminals of the two encoders are electrically connected to the signal input terminals of the corresponding servo drives;

[0024] The PLC has a built-in synchronous control program, and the control logic is as follows:

[0025] The human-machine interface unit can preset the station angle θ, process switching angle φ, and phase tolerance (±0.5°), and the preset data is stored in the PLC register in real time;

[0026] When the device triggers the workstation switching command, the PLC sends action commands to two servo drives simultaneously via the bus. Specifically, it sends a position command of "rotate θ angle" to the servo drive corresponding to the turntable drive motor and a position command of "rotate φ angle" to the servo drive corresponding to the distribution valve drive motor, ensuring that the two motors start synchronously.

[0027] The encoder collects the operating data of the corresponding motor in real time, including the valve shaft rotation angle and speed of the distribution valve drive motor and the output shaft rotation angle and speed of the turntable drive motor, and converts the data into digital signals and transmits them to the corresponding servo driver; the servo driver filters and amplifies the data, and then uploads the real-time data to the PLC every 10ms via the PROFIBUS-DP bus.

[0028] The PLC uses a 10ms scan cycle to compare the real-time position data of the two motors with the preset θ and φ angles and calculates the current phase deviation value. If the deviation value is ≤ ±0.5°, the current motor operating parameters are maintained; if the deviation value is > ±0.5°, it is determined to be phase lag.

[0029] For motors with phase lag, the PLC sends fine-tuning instructions to their corresponding servo drivers. If the turntable drive motor lags, the servo driver is instructed to increase the motor speed by 0.5%-2%. If the distribution valve drive motor lags, the servo driver is instructed to increase the output pulse frequency by 50-200Hz until the phase deviation returns to within ±0.5°. The compensation process continues until both motors have completed the preset angle rotation and then stops.

[0030] When the PLC detects a phase deviation > ±1° for three consecutive scan cycles, or when the encoder has no data feedback, it immediately sends a stop command to the two servo drives and triggers an audible and visual alarm through the human-machine interface unit. At the same time, it stores the fault type (phase deviation / encoder failure) and the running data at the time of the fault in the PLC's fault log for easy maintenance and troubleshooting.

[0031] This invention provides a suspended continuous derailment device and system, which has the following advantages:

[0032] This suspended continuous decoupling device and system adopts a vertical suspension layout, making full use of three-dimensional space. It eliminates the need for planar arrangement of resin columns, significantly reducing the floor space compared to traditional devices, making it suitable for workshops with limited space. The rotary distribution valve is fixed above the center of the turntable, and the connecting hose directly suspends the valve outlet and the resin column inlet. The pipeline length is greatly shortened and the direction is natural, significantly reducing fluid resistance and thus reducing system operating energy consumption. Long-term use can reduce energy costs.

[0033] Furthermore, the device features an open overall structure, with the resin column connected to the turntable via quick-release clamps, allowing for rapid disassembly for resin filling, replacement, or column maintenance. All components are easily observable and accessible, avoiding the difficulty of accessing internal components in traditional devices and saving maintenance time and labor costs. Simultaneously, it employs a PLC-based dual-motor synchronous control logic, using encoders to provide real-time feedback on motor position and dynamically adjust phase deviations (allowing a tolerance of ±0.5°), fundamentally preventing the distribution valve and turntable from losing synchronization. The slewing bearing uses composite seals, and the rotary distribution valve uses multiple seals, ensuring a long lifespan for key components and further enhancing the device's operational stability.

[0034] The connecting hoses are made of chemically resistant (resistant to acids, alkalis, and salt solutions), temperature resistant (-10℃ to 80℃), and fatigue resistant materials (such as flexible hoses lined with PTFE). The resin column is equipped with a water distributor and a water collection device, which can be adapted to the stringent process requirements of different industries such as lithium extraction from salt lakes, pharmaceuticals, and food. The device adopts a compact design, which can realize modular production and standardized assembly, making it easy to quickly install and debug after being transported to the site, thus shortening the project implementation cycle. Attached Figure Description

[0035] Figure 1 This is a front view structural diagram of the invention;

[0036] Figure 2 This is a side view of the invention.

[0037] Figure 3 This is a top view of the turntable and resin column of the invention;

[0038] Figure 4 This is a schematic diagram of the control system process of the invention.

[0039] In the diagram: 1. Frame; 2. Rotary distribution valve; 3. Resin column assembly; 4. Connecting hose; 5. Turntable; 6. Distribution valve drive motor; 7. Turntable drive motor; 8. Guide ring; 9. Slewing bearing. Detailed Implementation

[0040] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0041] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0042] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0043] Please see Figures 1 to 3 The present invention provides a technical solution: a suspended continuous decoupling device, including a frame 1, a drive system, a rotary distribution valve 2, a resin column assembly 3 and a connecting hose 4. The resin column assembly 3 is suspended above the frame 1 by a turntable 5. The resin column assembly 3 includes a plurality of resin columns evenly distributed along the circumference of the turntable 5. The rotary distribution valve 2 is fixedly installed on the top of the frame 1 and located above the center of the turntable 5.

[0044] Turntable 5 is connected to frame 1 via a large slewing bearing 9;

[0045] The drive system includes a distribution valve drive motor 6 for controlling the start and stop of the rotary distribution valve 2 and angle positioning, and a turntable drive motor 7 for driving the turntable 5 to perform intermittent rotational motion. The distribution valve drive motor 6 and the turntable drive motor 7 are electrically connected through the control system.

[0046] The multiple outlets of the rotary distribution valve 2 are connected to the corresponding top inlet of the resin column through multiple independent connecting hoses 4, and the connecting hoses 4 are in a natural hanging state.

[0047] The frame 1 is provided with guide rings 8 consisting of two or more layers. The guide rings 8 are fixed to the central column of the frame 1 by brackets. Each guide ring 8 is provided with slots that are equal in number and evenly spaced to the number of resin columns. Each connecting hose 4 passes through a corresponding slot independently.

[0048] In this embodiment, each resin column is equipped with a water distributor at its top and a resin support sieve plate and a water collection device at its bottom; the resin column is connected to the turntable 5 by a quick-release clamp.

[0049] In this embodiment, the slewing bearing 9 adopts a sealing method combining a labyrinth seal and a rubber sealing ring to prevent external impurities from entering the bearing and internal grease from leaking, and to resist corrosive gaseous and liquid media in the process environment.

[0050] In this embodiment, the control system is based on a programmable logic controller (PLC). The PLC receives real-time position feedback signals from the encoders of the distribution valve drive motor 6 and the turntable drive motor 7, and compares them with a preset phase relationship. The preset phase relationship is that for every station angle θ that the turntable 5 rotates, the rotary distribution valve 2 needs to rotate synchronously by a corresponding process switching angle φ.

[0051] In this embodiment, the connecting hose 4 is made of a material with chemical corrosion resistance, temperature resistance and fatigue resistance, with a temperature range of -10℃ to 80℃. Specifically, the material is a flexible hose lined with polytetrafluoroethylene (PTFE) or a special fluororubber hose.

[0052] In this embodiment, the guide ring 8 is made of engineering plastic, and the groove on the guide ring 8 is an arc-shaped groove. The groove spacing is equal to the angular spacing between adjacent resin columns to prevent the connecting hoses 4 from getting tangled or rubbing against the equipment when the turntable 5 rotates.

[0053] In this embodiment, the valve core and valve seat of the rotary distribution valve 2 adopt a multi-seal structure that combines end face mechanical seal and auxiliary elastic sealing ring. The contact surfaces of the valve core and valve seat are subjected to high-precision grinding treatment to prevent liquid cross-flow under different process pressures.

[0054] In this embodiment, the turntable drive motor 7 is a servo motor. The turntable drive motor 7 drives a pinion through a reducer. The pinion meshes with the outer ring gear of the slewing bearing 9 to drive the turntable 5 to achieve intermittent rotation.

[0055] In this embodiment, the distribution valve drive motor 6 is a servo motor. The distribution valve drive motor 6 directly drives the valve shaft of the rotary distribution valve 2 through a coupling to achieve precise angular positioning of the rotary distribution valve 2.

[0056] Please see Figure 4 This invention provides a technical solution: a system for a suspended continuous switching device. The control system includes a programmable logic controller (PLC), two servo drives, two encoders, and a human-machine interface unit. The two servo drives are electrically connected to the distribution valve drive motor 6 and the turntable drive motor 7, respectively. The two encoders are also assembled to the valve shaft of the distribution valve drive motor 6 and the output shaft of the turntable drive motor 7, respectively. The PLC establishes a bidirectional communication connection with the two servo drives and the human-machine interface unit via a PROFIBUS-DP bus. The signal output terminals of the two encoders are electrically connected to the signal input terminals of the corresponding servo drives.

[0057] The PLC has a built-in synchronous control program, and the control logic is as follows:

[0058] The human-machine interface unit can preset the station angle θ, process switching angle φ, and phase tolerance (±0.5°), and the preset data is stored in the PLC register in real time;

[0059] When the device triggers the workstation switching command, the PLC sends action commands to two servo drives simultaneously via the bus. Specifically, it sends a position command of "rotate θ angle" to the servo drive corresponding to the turntable drive motor 7 and a position command of "rotate φ angle" to the servo drive corresponding to the distribution valve drive motor 6, ensuring that the two motors start synchronously.

[0060] The encoder collects the operating data of the corresponding motor in real time, including the valve shaft rotation angle and speed of the distribution valve drive motor 6 and the output shaft rotation angle and speed of the turntable drive motor 7, and converts the data into digital signals and transmits them to the corresponding servo driver; the servo driver filters and amplifies the data, and then uploads the real-time data to the PLC every 10ms via the PROFIBUS-DP bus.

[0061] The PLC uses a 10ms scan cycle to compare the real-time position data of the two motors with the preset θ and φ angles and calculates the current phase deviation value. If the deviation value is ≤ ±0.5°, the current motor operating parameters are maintained; if the deviation value is > ±0.5°, it is determined to be phase lag.

[0062] For motors with phase lag, the PLC sends fine-tuning instructions to their corresponding servo drivers. If the turntable drive motor 7 lags, the servo driver is instructed to increase the motor speed by 0.5%-2%. If the distribution valve drive motor 6 lags, the servo driver is instructed to increase the output pulse frequency by 50-200Hz until the phase deviation returns to within ±0.5°. The compensation process continues until both motors have completed the preset angle rotation and then stops.

[0063] When the PLC detects a phase deviation > ±1° for three consecutive scan cycles, or when the encoder has no data feedback, it immediately sends a stop command to the two servo drives and triggers an audible and visual alarm through the human-machine interface unit. At the same time, it stores the fault type (phase deviation / encoder failure) and the running data at the time of the fault in the PLC's fault log for easy maintenance and troubleshooting.

[0064] The method of using the present invention: The suspended continuous derailment device and system operates as follows:

[0065] like Figure 4 As shown, the control system 10 (with a PLC as its core) first starts the drive system according to a preset program. The turntable drive motor 7 drives the pinion to rotate through the reducer. The pinion meshes with the outer ring gear of the slewing bearing 9, driving the turntable 5 and the suspended resin column assembly 3 to rotate intermittently. At the same time, the distribution valve drive motor 6 drives the rotary distribution valve 2 to synchronously switch valve positions through a coupling. The PLC of the control system 10 receives the position feedback signals from the encoders of the distribution valve drive motor 6 and the turntable drive motor 7 in real time, compares them with the preset phase relationship (for every rotation of the turntable 5 by one workstation angle θ, the rotary distribution valve 2 synchronously rotates the corresponding process switching angle φ; if the phase difference exceeds ±0.5°, it immediately sends a fine-tuning command to the servo driver of the lagging motor to ensure precise synchronization between the two).

[0066] Process liquids (such as brine from salt lakes, pharmaceutical solutions, etc.) enter through the central inlet of rotary distribution valve 2. Based on the valve position switching result, they are precisely distributed to the top inlet of the resin column currently in the "adsorption station". After being evenly dispersed by the water distributor inside the resin column, the liquid flows from top to bottom through the resin bed inside the resin column to complete ion exchange (such as lithium ion adsorption). The exchanged liquid is filtered through the resin support sieve plate at the bottom of the resin column and collected by the water collection device before being discharged.

[0067] As the turntable 5 rotates intermittently, the resin column sequentially enters different process stations (adsorption → washing → desorption → rewashing). The rotary distribution valve 2 simultaneously switches to the corresponding fluid channel: in the "washing station," clean water enters the resin column to rinse away residual material; in the "desorption station," eluent enters the resin column to desorb the target ions; and in the "rewashing station," clean water rinses the resin column again to remove any remaining eluent. This cycle achieves a continuous and stable ion exchange purification process. Simultaneously, the vertical suspension layout and anti-tangling guide ring 8 ensure that the device operates without interference from the connecting hose 4.

[0068] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A suspended continuous decoupling device, comprising a frame (1), a drive system, a rotary distribution valve (2), a resin column assembly (3), and a connecting hose (4), characterized in that: The resin column assembly (3) is suspended above the frame (1) by a turntable (5). The resin column assembly (3) contains multiple resin columns evenly distributed along the circumference of the turntable (5). The rotary distribution valve (2) is fixedly installed on the top of the frame (1) and located above the center of the turntable (5). The turntable (5) is connected to the frame (1) via a large slewing bearing (9); The drive system includes a distribution valve drive motor (6) for controlling the start and stop of the rotary distribution valve (2) and angle positioning, and a turntable drive motor (7) for driving the turntable (5) to perform intermittent rotational motion. The distribution valve drive motor (6) and the turntable drive motor (7) are electrically connected through the control system. The multiple outlets of the rotary distribution valve (2) are connected to the corresponding resin column top inlet through multiple independent connecting hoses (4), and the connecting hoses (4) are in a natural hanging state. The frame (1) is provided with guide rings (8) consisting of two or more layers. The guide rings (8) are fixed to the central column of the frame (1) by brackets. Each guide ring (8) has a slot with the same number as the resin columns and uniform spacing. Each connecting hose (4) passes through a corresponding slot independently.

2. The apparatus according to claim 1, characterized in that, Each resin column has a water distributor at its top and a resin support sieve plate and a water collection device at its bottom; the resin column is connected to the turntable (5) by a quick-release clamp.

3. The apparatus according to claim 2, characterized in that, The slewing bearing (9) adopts a sealing method combining labyrinth seal and rubber seal ring to prevent external impurities from entering the bearing and internal grease from leaking, and to resist corrosive gaseous and liquid media in the process environment.

4. The apparatus according to claim 1, characterized in that, The control system is based on a programmable logic controller (PLC). The PLC receives real-time position feedback signals from the encoders of the distribution valve drive motor (6) and the turntable drive motor (7), and compares them with a preset phase relationship. The preset phase relationship is that for every station angle θ that the turntable (5) rotates, the rotary distribution valve (2) needs to rotate synchronously by a corresponding process switching angle φ.

5. The apparatus according to claim 1, characterized in that, The connecting hose (4) is made of a material with chemical corrosion resistance, temperature resistance and fatigue resistance, with a temperature range of -10℃ to 80℃. The material is a flexible hose lined with polytetrafluoroethylene (PTFE) or a special fluororubber hose.

6. The apparatus according to claim 1, characterized in that, The guide ring (8) is made of engineering plastic. The groove on the guide ring (8) is an arc-shaped groove. The groove spacing is equal to the angular spacing of adjacent resin columns to prevent the connecting hoses (4) from getting tangled or rubbing against the equipment when the turntable (5) rotates.

7. The apparatus according to claim 1, characterized in that, The rotary distribution valve (2) employs a multi-seal structure between the valve core and the valve seat, combining end-face mechanical seals with auxiliary elastic sealing rings. The contact surfaces of the valve core and the valve seat are subjected to high-precision grinding to prevent liquid cross-flow under different process pressures.

8. The apparatus according to claim 1, characterized in that, The turntable drive motor (7) is a servo motor. The turntable drive motor (7) drives a pinion through a reducer. The pinion meshes with the outer ring gear of the slewing bearing (9) to drive the turntable (5) to achieve intermittent rotation.

9. The apparatus according to claim 1, characterized in that, The distribution valve drive motor (6) is a servo motor. The distribution valve drive motor (6) directly drives the valve shaft of the rotary distribution valve (2) through a coupling to achieve precise angular positioning of the rotary distribution valve (2).

10. A system for the suspended continuous derailment device as described in claims 1 to 9, characterized in that, The control system includes a programmable logic controller (PLC), two servo drives, two encoders, and a human-machine interface unit. The two servo drives are electrically connected to the distribution valve drive motor (6) and the turntable drive motor (7) respectively. The two encoders are also assembled to the valve shaft of the distribution valve drive motor (6) and the output shaft of the turntable drive motor (7) respectively. The PLC establishes a bidirectional communication connection with the two servo drives and the human-machine interface unit through the PROFIBUS-DP bus. The signal output terminals of the two encoders are electrically connected to the signal input terminals of the corresponding servo drives respectively. The PLC has a built-in synchronous control program, and the control logic is as follows: The human-machine interface unit can preset the station angle θ, process switching angle φ, and phase tolerance (±0.5°), and the preset data is stored in the PLC register in real time; When the device triggers the workstation switching command, the PLC sends action commands to two servo drives simultaneously via the bus. The PLC sends a position command of "rotate θ angle" to the servo drive corresponding to the turntable drive motor (7) and a position command of "rotate φ angle" to the servo drive corresponding to the distribution valve drive motor (6), ensuring that the two motors start synchronously. The encoder collects the operating data of the corresponding motor in real time, including the valve shaft rotation angle and speed of the distribution valve drive motor (6) and the output shaft rotation angle and speed of the turntable drive motor (7), and converts the data into digital signals and transmits them to the corresponding servo driver; the servo driver filters and amplifies the data, and then uploads the real-time data to the PLC every 10ms via the PROFIBUS-DP bus. The PLC uses a 10ms scan cycle to compare the real-time position data of the two motors with the preset θ and φ angles and calculates the current phase deviation value. If the deviation value is ≤ ±0.5°, the current motor operating parameters are maintained; if the deviation value is > ±0.5°, it is determined to be phase lag. For motors with phase lag, the PLC sends a fine-tuning command to the corresponding servo driver. If the turntable drive motor (7) lags, the servo driver is instructed to increase the motor speed by 0.5%-2%. If the distribution valve drive motor (6) lags, the servo driver is instructed to increase the output pulse frequency by 50-200Hz until the phase deviation returns to within ±0.5°. The compensation process continues until both motors have completed the preset angle rotation and then stops. When the PLC detects a phase deviation > ±1° for three consecutive scan cycles, or when the encoder has no data feedback, it immediately sends a stop command to the two servo drives and triggers an audible and visual alarm through the human-machine interface unit. At the same time, it stores the fault type (phase deviation / encoder failure) and the running data at the time of the fault in the PLC's fault log for easy maintenance and troubleshooting.

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