Underwater granulator hydraulic system with closed-loop pressure compensation function

Abstract

The invention relates to the technical field of underwater granulator, in particular to an underwater granulator hydraulic system with a closed-loop pressure compensation function. Comprising a hydraulic power module, a pressure monitoring module, a closed-loop control module, a pressure compensation module, an actuator module, a feedback module, a temperature management module, a filtration and purification module, a fault diagnosis module, an alarm module, an oil-liquid isolation module, a management module, a login module and an authority control module. The hydraulic power module is connected with the pressure compensation module, the pressure compensation module is connected with the actuator module, the pressure monitoring module is connected with the actuator module, and the closed-loop control module is connected with the pressure monitoring module and the pressure compensation module. The actuator module is used for driving a cutting part of the underwater granulator; in this way, the technical problems that in the prior art, due to the fact that a hydraulic system lacks closed-loop real-time pressure compensation, the pressure stability is insufficient, and the system adaptability is poor are solved.

Description

Technical Field

[0001] This invention relates to the field of underwater pelletizer technology, and in particular to a hydraulic system for an underwater pelletizer with closed-loop pressure compensation function. Background Technology

[0002] Underwater pelletizing technology is a crucial step in the granulation process of polymer materials (such as plastics and rubber). Its basic principle is to cool the molten polymer underwater and cut it into uniform particles using a high-speed rotating cutter. This technology is widely used due to its advantages such as high production efficiency, good particle quality, and no dust pollution. As the core driving component of an underwater pelletizer, the performance of the hydraulic system directly determines the stability, accuracy, and reliability of the cutting process, thus affecting the quality of the final product and the system's energy consumption.

[0003] However, existing hydraulic systems lack closed-loop real-time pressure compensation, resulting in insufficient pressure stability and poor system adaptability. Summary of the Invention

[0004] The purpose of this invention is to provide a hydraulic system for an underwater pelletizer with closed-loop pressure compensation, which solves the technical problem that existing hydraulic systems lack closed-loop real-time pressure compensation, resulting in insufficient pressure stability and poor system adaptability.

[0005] To achieve the above objectives, the present invention provides a hydraulic system for an underwater pelletizer with closed-loop pressure compensation function, including a hydraulic power module, a pressure monitoring module, a closed-loop control module, a pressure compensation module, an actuator module, a feedback module, a temperature management module, a filtration and purification module, a fault diagnosis module, an alarm module, an oil-liquid isolation module, a management module, a login module, and an access control module. The hydraulic power module is connected to the pressure compensation module, the pressure compensation module is connected to the actuator module, the pressure monitoring module is connected to the actuator module, and the closed-loop control module is connected to both the pressure monitoring module and the pressure compensation module. The actuator module drives the cutting components of the underwater pelletizer. The feedback module is connected to both the actuator module and the closed-loop control module. The temperature management module and the filtration and purification module are connected to the hydraulic power module. The fault diagnosis module is connected to the closed-loop control module, the alarm module is connected to the fault diagnosis module, the oil-liquid isolation module is connected to the actuator module, the management module is connected to the closed-loop control module, and the login module is connected to both the management module and the access control module. The hydraulic power module is used to provide the power source for the hydraulic system, and the pressure monitoring module is used to monitor the pressure in the hydraulic system in real time. The closed-loop control module is used to receive feedback from the pressure monitoring module and control the pressure compensation module to achieve closed-loop pressure control. The actuator module is used to drive the cutting components of the underwater pelletizer.

[0006] The pressure compensation module includes a high-pressure micro-flow compensation unit and an electro-hydraulic proportional valve. The high-pressure micro-flow compensation unit adopts an independent electro-hydraulic valve structure based on dual closed-loop redundant control. It dynamically calculates the control current based on the collected valve core displacement, oil temperature and oil pressure data, so as to achieve precise compensation of the actuator module's millimeter-level stroke. The electro-hydraulic proportional valve is used to finely adjust the hydraulic oil flow and pressure according to the signal from the closed-loop control module.

[0007] The closed-loop control module employs a system-level simulation engine based on digital twins and a time-series prediction stress compensation algorithm that integrates deep learning. The system-level simulation engine based on digital twins is used to synchronously run a high-fidelity model consistent with the physical system. Based on the data from the pressure monitoring module and the multimodal feedback module, it generates a digital image of the system in real time, including back pressure, flow pulsation, and component dynamic characteristics, and simulates the system state in advance, outputting predictive compensation commands. The stress compensation algorithm includes the following steps: The historical and current pressure data sequences of the pressure monitoring module are acquired in real time, and the pressure fluctuation trend in the future is predicted using a trained recurrent neural network (RNN) model. The predicted pressure deviation and the real-time deviation are input together into the improved fuzzy PID controller to achieve parameter self-tuning. The feedforward-feedback composite control signal is output to the dynamic pressure compensation module to achieve proactive suppression of pressure fluctuations.

[0008] The pressure monitoring module includes a deep-sea back pressure sensing unit and a high-precision pressure sensor. The deep-sea back pressure sensing unit is used to collect the channel pressure, coolant density and cutter shaft displacement of the model in real time, and generate a digital back pressure fingerprint. The high-precision pressure sensor is installed at the pressure node of the hydraulic system for multi-point pressure detection and transmits the pressure signal to the closed-loop control module.

[0009] The temperature management module includes a temperature sensor and an oil cooler. The temperature sensor is located at the outlet of the hydraulic power module and is used to monitor the hydraulic oil temperature. The closed-loop control module adjusts the operating status of the oil cooler based on temperature data to maintain the hydraulic oil temperature within the set range.

[0010] The fault diagnosis module includes a data acquisition unit and an anomaly analysis unit. The data acquisition unit is connected to the pressure monitoring module and is used to collect pressure and temperature data; The anomaly analysis unit uses a pattern recognition algorithm to identify data anomalies. When the pressure or temperature exceeds the threshold, the alarm module is triggered. The alarm module is used to issue alarm signals and execute safety shutdown procedures.

[0011] The oil-liquid isolation module includes a direct-acting pressure compensation valve based on the principle of internal and external pressure balance and a floating double-lip sealing sleeve that works in conjunction with it. The direct-acting pressure compensation valve uses a rolling diaphragm and a constant force spring in the seawater environment pressure-sensitive component to ensure that the internal oil pressure is always slightly higher than the external water pressure, thereby achieving active pressure compensation. The floating double-lip seal is used to physically isolate the coolant and hydraulic oil at a microscopic scale based on the pressure compensation; at the same time, it monitors the leakage and reports the event to the closed-loop control module when the leakage exceeds the standard.

[0012] The actuator module includes a double-piston rod hydraulic cylinder for locking the front and rear covers of the water chamber and a hydraulic motor for driving the pelletizing blade.

[0013] This invention discloses a hydraulic system for an underwater pelletizer with closed-loop pressure compensation. In practical use, by introducing this closed-loop pressure compensation function, the system can monitor hydraulic pressure in real time and dynamically adjust the pressure compensation module, thereby significantly improving pressure stability and ensuring that the cutting process is carried out under constant pressure. This effectively overcomes the problem of reduced cutting quality caused by pressure fluctuations in existing systems. Simultaneously, the system's adaptability is enhanced, enabling rapid response to changes in external load and operating conditions, improving the reliability and efficiency of the underwater pelletizer in different environments, thus improving the overall adaptability and performance of the system. This approach solves the technical problem of insufficient pressure stability and poor system adaptability in existing hydraulic systems due to the lack of closed-loop real-time pressure compensation. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0015] Figure 1 This is a schematic diagram of the hydraulic system of the underwater pelletizer with closed-loop pressure compensation function of the present invention.

[0016] In the diagram: 1-Hydraulic power module, 2-Pressure monitoring module, 3-Closed-loop control module, 4-Pressure compensation module, 5-Actuator module, 6-Feedback module, 7-Temperature management module, 8-Filtration and purification module, 9-Fault diagnosis module, 10-Alarm module, 11-Oil-liquid isolation module, 12-Management module, 13-Login module, 14-Access control module, 15-Blockchain recording module, 16-Data mining module, 17-Predictive maintenance module, 18-High-pressure micro-flow compensation unit, 19-Electro-hydraulic proportional valve, 20-Deep-sea back pressure sensing unit, 21-High-precision pressure sensor, 22-Temperature sensor, 23-Oil cooler, 24-Data acquisition unit, 25-Anomaly analysis unit. Detailed Implementation

[0017] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0018] Please see Figure 1 , Figure 1 This is a schematic diagram of the hydraulic system of the underwater pelletizer with closed-loop pressure compensation function of the present invention.

[0019] This invention provides a hydraulic system for an underwater pelletizer with closed-loop pressure compensation, comprising a hydraulic power module 1, a pressure monitoring module 2, a closed-loop control module 3, a pressure compensation module 4, an actuator module 5, a feedback module 6, a temperature management module 7, a filtration and purification module 8, a fault diagnosis module 9, an alarm module 10, an oil-liquid isolation module 11, a management module 12, a login module 13, an access control module 14, a blockchain recording module 15, a data mining module 16, and a predictive maintenance module 17. The pressure compensation module 4 includes a high-pressure micro-flow compensation unit 18 and an electro-hydraulic proportional valve 19. The pressure monitoring module 2 includes a deep-sea back pressure sensing unit 20 and a high-precision pressure sensor 21. The temperature management module 7 includes a temperature sensor 22 and an oil cooler 23. The fault diagnosis module 9 includes a data acquisition unit 24 and an anomaly analysis unit 25. This solution addresses the technical problem in existing hydraulic systems where the lack of closed-loop real-time pressure compensation leads to insufficient pressure stability and poor system adaptability.

[0020] In this specific embodiment, the pressure compensation module 4 is used to adjust the hydraulic pressure according to the instructions of the closed-loop control module 3 to compensate for system pressure fluctuations and ensure the stable operation of the actuator module 5. The feedback module 6 is used to collect the status information of the actuator module 5 and feed it back to the closed-loop control module 3 to achieve more precise closed-loop control. The temperature management module 7 is used to monitor and regulate the temperature of the hydraulic oil in the hydraulic power module 1 to prevent overheating or overcooling and ensure normal system operation. The filtration and purification module 8 is used to filter the hydraulic oil in the hydraulic power module 1, remove impurities and contaminants, keep the oil clean, and extend the system life. The fault diagnosis module 9 is used to monitor the system status of the closed-loop control module 3, identify and diagnose potential faults, and provide fault information. The alarm module 10 is used to receive the fault signal from the fault diagnosis module 9 and trigger the alarm device to notify the operator to take action; The oil-hydraulic isolation module 11 is used to isolate hydraulic oil from the external water environment, prevent water from entering the actuator module 5, and ensure the reliability of underwater operations; The management module 12 is used to configure and monitor the parameters of the closed-loop control module 3, and provides a system management interface for easy operation and maintenance; The login module 13 is used to verify the user's identity and allow authorized users to access the management module 12; The access control module 14 is used to manage user permissions and grant different levels of system access rights based on the verification results of the login module 13.

[0021] The hydraulic power module 1 is connected to the pressure compensation module 4, the pressure compensation module 4 is connected to the actuator module 5, the pressure monitoring module 2 is connected to the actuator module 5, and the closed-loop control module 3 is connected to both the pressure monitoring module 2 and the pressure compensation module 4. The actuator module 5 drives the cutting components of the underwater pelletizer. The feedback module 6 is connected to both the actuator module 5 and the closed-loop control module 3. The temperature management module 7 and the filtration and purification module 8 are connected to the hydraulic power module 1. The fault diagnosis module 9 is connected to the closed-loop control module 3, the alarm module 10 is connected to the fault diagnosis module 9, and the oil-liquid isolation module 11... The system is connected to the actuator module 5, the management module 12 is connected to the closed-loop control module 3, and the login module 13 is connected to both the management module 12 and the access control module 14. In practical use, this invention introduces a closed-loop pressure compensation function, enabling the system to monitor hydraulic pressure in real time and dynamically adjust the pressure compensation module 4, thereby significantly improving pressure stability and ensuring that the cutting process is carried out under constant pressure. This effectively overcomes the problem of reduced cutting quality caused by pressure fluctuations in existing systems. Simultaneously, the system's adaptability is enhanced, enabling rapid response to changes in external load and operating conditions, improving the reliability and efficiency of the underwater pelletizer in different environments, thus enhancing the overall adaptability and performance of the system. This approach solves the technical problem in existing hydraulic systems where the lack of closed-loop real-time pressure compensation leads to insufficient pressure stability and poor system adaptability.

[0022] Secondly, the high-pressure micro-flow compensation unit 18 adopts an independent electro-hydraulic valve structure based on dual closed-loop redundant control. According to the collected valve core displacement, oil temperature and oil pressure data, the control current is dynamically calculated to achieve precise compensation of the millimeter-level stroke of the actuator module 5. The electro-hydraulic proportional valve 19 is used to finely adjust the hydraulic oil flow and pressure according to the signal from the closed-loop control module 3.

[0023] Furthermore, the closed-loop control module 3 employs a system-level simulation engine based on digital twins and a time-series prediction stress compensation algorithm that integrates deep learning. The system-level simulation engine based on digital twins is used to synchronously run a high-fidelity model consistent with the physical system. Based on the data from the pressure monitoring module 2 and the multimodal feedback module 6, it generates a digital image of the system in real time, including back pressure, flow pulsation, and component dynamic characteristics, and simulates the system state in advance, outputting predictive compensation commands. The stress compensation algorithm includes the following steps: The historical and current pressure data sequences of the pressure monitoring module 2 are acquired in real time, and the pressure fluctuation trend in the future is predicted using a trained recurrent neural network (RNN) model. The predicted pressure deviation and the real-time deviation are input together into the improved fuzzy PID controller to achieve parameter self-tuning. The feedforward-feedback composite control signal is output to the dynamic pressure compensation module 4 to achieve proactive suppression of pressure fluctuations.

[0024] Meanwhile, the deep-sea back pressure sensing unit 20 is used to collect the channel pressure, coolant density and cutter shaft displacement of the model in real time, and generate a digital back pressure fingerprint; The high-precision pressure sensor 21 is installed at the pressure node of the hydraulic system for multi-point pressure detection and transmits the pressure signal to the closed-loop control module 3.

[0025] The temperature sensor 22 is located at the outlet of the hydraulic power module 1 and is used to monitor the temperature of the hydraulic oil. The closed-loop control module 3 adjusts the operating status of the oil cooler 23 according to the temperature data to maintain the hydraulic oil temperature within the set range.

[0026] Furthermore, the data acquisition unit 24 is connected to the pressure monitoring module 2 and is used to collect pressure and temperature data; The anomaly analysis unit 25 uses a pattern recognition algorithm to identify data anomalies. When the pressure or temperature exceeds the threshold, the alarm module 10 is triggered. The alarm module 10 is used to issue alarm signals and execute a safety shutdown procedure.

[0027] The direct-acting pressure compensation valve uses a rolling diaphragm and a constant force spring in the seawater environment pressure-sensitive component to ensure that the internal oil pressure of the system is always slightly higher than the external water pressure, thus achieving active pressure compensation. The floating double-lip seal is used to physically isolate the coolant and hydraulic oil at a microscopic scale based on the pressure compensation; at the same time, it monitors the leakage and reports the event to the closed-loop control module 3 when the leakage exceeds the standard.

[0028] The actuator module 5 includes a double-piston rod hydraulic cylinder for locking the front and rear covers of the water chamber and a hydraulic motor for driving the pelletizing blade.

[0029] Furthermore, the closed-loop control module 3 controls the hydraulic motor through an integrated energy recovery buffer braking circuit. Based on the traditional bidirectional fixed-displacement hydraulic motor and direct-acting relief valve, the buffer braking circuit introduces a supercapacitor and a reversible motor / pump unit to convert the hydraulic energy during the braking process into electrical energy and store it, thereby realizing the integrated design of buffer braking and energy recovery, while eliminating the impact and vibration during the motor braking process.

[0030] The blockchain storage module 15 is connected to the closed-loop control module 3, and the data mining module 16 is connected to the blockchain storage module 15. The blockchain storage module 15 uses its immutable distributed ledger algorithm to permanently and reliably store key pressure data, control commands, and equipment status during the closed-loop control process, ensuring the transparency and traceability of operation records. On this basis, the data mining module 16 uses intelligent algorithms such as machine learning to perform in-depth analysis on the massive historical data accumulated on the chain, which facilitates the optimization of the closed-loop control module 3.

[0031] The predictive maintenance module 17 constructs a life prediction model based on the operating data of key components such as actuators and pumps. It issues early warnings for maintenance or replacement before component failure occurs, achieving an upgrade from "prevention" to "prediction".

[0032] Using the underwater pelletizer hydraulic system with closed-loop pressure compensation function of this invention, in practical use, this invention introduces a closed-loop pressure compensation function. This system can monitor the hydraulic pressure in real time and dynamically adjust the pressure compensation module 4, thereby significantly improving pressure stability and ensuring that the cutting process is carried out under constant pressure. This effectively overcomes the problem of decreased cutting quality caused by pressure fluctuations in existing systems. Simultaneously, the system's adaptability is enhanced, enabling rapid response to changes in external load and operating conditions, improving the reliability and efficiency of the underwater pelletizer in different environments, thus improving the overall adaptability and performance of the system. This approach solves the technical problem of insufficient pressure stability and poor system adaptability in existing hydraulic systems due to the lack of closed-loop real-time pressure compensation.

[0033] The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art can understand that all or part of the processes for implementing the above embodiments and equivalent changes made in accordance with the claims of this application still fall within the scope of this application.

Claims

1. An underwater pelletizer hydraulic system with closed-loop pressure compensation function, characterized in that, it comprises a hydraulic power module, a pressure monitoring module, a closed-loop control module, a pressure compensation module, an actuator module, a feedback module, a temperature management module, a filtration and purification module, a fault diagnosis module, an alarm module, an oil-liquid isolation module, a management module, a login module and a permission control module; the hydraulic power module is connected with the pressure compensation module, the pressure compensation module is connected with the actuator module, the pressure monitoring module is connected with the actuator module, and the closed-loop control module is connected with the pressure monitoring module and the pressure compensation module; the actuator module is used to drive the cutting components of the underwater pelletizer; the feedback module is connected with the actuator module and the closed-loop control module; the temperature management module and the filtration and purification module are connected with the hydraulic power module; the fault diagnosis module is connected with the closed-loop control module, the alarm module is connected with the fault diagnosis module, the oil-liquid isolation module is connected with the actuator module, the management module is connected with the closed-loop control module, and the login module is connected with the management module and the permission control module; the hydraulic power module is used to provide the power source of the hydraulic system, and the pressure monitoring module is used to monitor the pressure in the hydraulic system in real time; the closed-loop control module is used to receive the feedback of the pressure monitoring module and control the pressure compensation module to realize the closed-loop control of the pressure; the actuator module is used to drive the cutting components of the underwater pelletizer.

2. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 1, characterized in that, the pressure compensation module comprises a high-pressure micro-flow compensation unit and an electro-hydraulic proportional valve; the high-pressure micro-flow compensation unit adopts a valve port independent electro-hydraulic valve structure based on double closed-loop redundant control, dynamically calculates the control current according to the collected valve core displacement, oil temperature and oil pressure data, and realizes the accurate compensation of the millimeter-level stroke of the actuator module; the electro-hydraulic proportional valve is used to finely adjust the hydraulic oil flow and pressure according to the signal of the closed-loop control module.

3. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 2, characterized in that, the closed-loop control module adopts a system-level simulation engine based on digital twinning and a time series prediction pressure compensation algorithm fused with deep learning; the system-level simulation engine based on digital twinning is used to synchronously run a high-fidelity model consistent with the physical system, generate a system digital mirror containing back pressure, flow pulsation and component dynamic characteristics in real time according to the data of the pressure monitoring module and the multi-modal feedback module, and output predictive compensation instructions by simulating the system state in advance; the pressure compensation algorithm comprises the following steps: real-time acquisition of historical and current pressure data sequences of the pressure monitoring module, prediction of the pressure fluctuation trend at the future time by using a trained recurrent neural network (RNN) model; input of the predicted pressure deviation and the real-time deviation into an improved fuzzy PID controller to realize the self-tuning of parameters; The feedforward-feedback compound control signal is output to the dynamic pressure compensation module to realize the prospective suppression of pressure fluctuation.

4. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 3, wherein, The pressure monitoring module comprises a deep-sea back pressure sensing unit and a high-precision pressure sensor; The deep-sea back pressure sensing unit is used to collect the die face hole pressure, coolant density and cutter shaft displacement in real time and generate digital back pressure fingerprint; The high-precision pressure sensor is installed at the pressure node of the hydraulic system for multi-point pressure detection and transmits the pressure signal to the closed-loop control module.

5. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 4, wherein, The temperature management module comprises a temperature sensor and an oil cooler; The temperature sensor is arranged at the outlet of the hydraulic power module for monitoring the hydraulic oil temperature; The closed-loop control module adjusts the operating state of the oil cooler according to the temperature data to maintain the hydraulic oil temperature within the set range.

6. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 5, wherein, The fault diagnosis module comprises a data acquisition unit and an abnormality analysis unit; The data acquisition unit is connected with the pressure monitoring module for collecting pressure and temperature data; The abnormality analysis unit uses a pattern recognition algorithm to identify data anomalies, and when it detects that the pressure or temperature exceeds the threshold, it triggers the alarm module; The alarm module is used to send an alarm signal and execute a safety shutdown program.

7. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 6, wherein, The oil-liquid isolation module comprises a direct-acting pressure compensation valve based on the principle of internal and external pressure balance and a floating double-lip seal sleeve cooperating therewith; the direct-acting pressure compensation valve makes the internal oil pressure of the system always slightly higher than the external water pressure through the rolling diaphragm and constant force spring in the seawater environment pressure sensitive component, realizing active pressure compensation; The floating double-lip seal sleeve is used to physically isolate the coolant and the hydraulic oil at the microscale level on the basis of pressure compensation; at the same time, it monitors the leakage and reports the event to the closed-loop control module when the leakage exceeds the standard.

8. The underwater pelletizer hydraulic system with closed-loop pressure compensation function according to claim 7, wherein, The actuator module comprises a double-piston rod hydraulic cylinder for locking the front and rear covers of the water chamber and a hydraulic motor for driving the pelletizing cutter.

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