Intelligent control system and method for rotary-vane vacuum pump

Abstract

The invention discloses an intelligent control system and method for a rotary-vane vacuum pump, the system comprises a vacuum chamber (1) and a pump body (5), the vacuum chamber (1) and the pump body (5) are connected through a vacuum pipeline (2), and a vacuum sensor (3) and a fine-tuning throttle valve (4) are arranged on the vacuum pipeline (2); the system further comprises an analysis control module (7) and a man-machine interaction module (8), the analysis control module (7) is connected with the vacuum sensor (3) and the fine adjustment throttle valve (4), and the man-machine interaction module (8) is connected with the analysis control module (7). According to the invention, multiple purposes of saving energy, reducing noise and prolonging the service life of equipment are achieved while diversified air exhaust requirements are met, and the air exhaust system has certain application value.

Description

Technical Field

[0001] This invention relates to the field of vacuum equipment control technology, and in particular to an intelligent control system and method for a rotary vane vacuum pump. Background Technology

[0002] A rotary vane vacuum pump is a basic vacuum-generating device that can be used to obtain vacuum or as a backing pump for other medium and high vacuum pumps. Compared with other vacuum pumps, rotary vane pumps have advantages such as compact structure, small size, and light weight, and can be widely used in vacuum smelting, vacuum coating, vacuum heat treatment, vacuum drying and other processes in industries such as metallurgy, machinery, electronics, chemical, petroleum, and pharmaceutical.

[0003] Traditional control methods for rotary vane vacuum pumps are relatively crude, meaning that the pump runs at a fixed speed after startup to eventually reach the ultimate vacuum level P. min This single-function capability limits the application of vacuum pumps in intelligent, specialized production lines. This is because users cannot set a target vacuum level P based on the needs of the production process or cycle time. t and the time to achieve T t The pump is required to be in T t Reaching P within a time limit t Furthermore, traditional vacuum pumps cannot customize the pumping process curve. Additionally, they cannot achieve a fully optimized vacuum level P. min Afterwards, the pump continues to operate at a fixed high speed, which results in a certain amount of energy waste, and the continuous high speed operation will generate constant high decibel noise, causing noise pollution to the working environment.

[0004] Therefore, there is a need in the field for a vacuum pump control scheme that can achieve any target vacuum level, precisely control the time to achieve it, plan the pumping process curve, and automatically maintain the vacuum level with low noise and low energy consumption after the target vacuum level is achieved. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent control system and method for a rotary vane vacuum pump, in order to solve the technical problem of how to automatically adjust the pumping process according to the user-planned target vacuum level, achievement time, and pumping curve, and automatically enter a low-energy-consumption, low-noise maintenance mode after the target vacuum level is reached.

[0006] The present invention is achieved by the following technical solution: an intelligent control system for a rotary vane vacuum pump, comprising a vacuum chamber and a pump body, wherein the vacuum chamber and the pump body are connected by a vacuum pipeline, and a vacuum sensor and a micro-adjustment flow valve are provided on the vacuum pipeline; it also includes an analysis and control module and a human-machine interaction module, wherein the analysis and control module is connected to the vacuum sensor and the micro-adjustment flow valve respectively, and the human-machine interaction module is connected to the analysis and control module.

[0007] Furthermore, it also includes a drive motor, which is connected to both the pump body and the analysis and control module.

[0008] Furthermore, the human-machine interaction module accepts the user's input of vacuum degree achievement time and planned curve, and transmits it to the analysis and control module; the analysis and control module issues instructions to adjust the speed of the drive motor and the flow rate of the fine-tuning valve, so that the real-time vacuum degree closely approaches the planned vacuum degree change curve over time.

[0009] Furthermore, the analysis and control module employs a bivariate coordinated control strategy to control the drive motor and the fine-tuning flow valve.

[0010] A method for intelligent control of a rotary vane vacuum pump, based on the aforementioned intelligent control system for a rotary vane vacuum pump, includes the following steps: S1: System initialization; S2: Parameter setting and air extraction process curve planning; S3: Dynamic air extraction; S4: Low power sustain.

[0011] Furthermore, step S2 specifically involves the user inputting the volume of the vacuum chamber through the human-machine interaction module. The analysis and control module then provides a pressure-time curve of that volume at the pump's highest speed as a boundary curve, sets the target vacuum level and the time required to achieve it within the boundary curve, and simultaneously generates a planned pumping curve.

[0012] Furthermore, step S3 specifically involves: reading the real-time data from the vacuum sensor through the analysis and control module, comparing it with the expected vacuum level at the current moment in the set pumping process curve, and then determining and controlling the speed of the drive motor and the flow rate of the fine-tuning valve to ensure that the actual vacuum level closely matches the set curve.

[0013] Furthermore, step S4 specifically involves: when the actual vacuum level is detected to be within the preset range, it is determined that the target vacuum level has been reached. At this time, the maintenance unit is activated to calculate the deviation between the real-time vacuum level and the target vacuum level by setting the control cycle, and to cyclically fine-tune the speed of the drive motor and the flow rate of the fine-tuning valve according to the deviation until the specified minimum maintenance speed is reached, and the target vacuum level is successfully stabilized.

[0014] The beneficial effects of this invention are as follows: 1. High precision and flexibility: It achieves precise control of the "three objectives" of target vacuum level, time to reach, and pumping process curve, enabling the vacuum pump to be perfectly integrated into intelligent and specific production processes, meeting the differentiated needs of different processes for vacuuming parameters and processes.

[0015] 2. Superior energy efficiency: By introducing a "vacuum maintenance mode" and significantly reducing pump speed, the system consumes less power for most of its operating time. Compared with traditional continuous high-speed operation, it can save up to 40%-70% of electrical energy, resulting in significant economic and environmental benefits.

[0016] 3. Significant noise reduction advantage: The low-speed operation in vacuum maintenance mode reduces the overall noise level of the pump by 5-10 decibels (A-weighted) compared to full-speed operation, fundamentally improving the working environment and meeting occupational health and safety standards.

[0017] 4. Intelligent and adaptive: The entire air extraction process is not passive or fixed, but can be planned and adjusted in real time. The system has adaptive capabilities and can cope with chambers of different volumes and different working conditions, making it highly versatile.

[0018] In summary, this invention provides a complete solution from "extensive control" to "refined and intelligent control," which achieves multiple goals of energy saving, noise reduction, and extended equipment life while ensuring that diverse air extraction needs are met, and has certain application value. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present 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 some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 This is a system block diagram of the present invention; Figure 2 This is a flowchart of the present invention; Figure 3 This is a schematic diagram of the air extraction curve; In the diagram, 1-vacuum chamber, 2-vacuum pipeline, 3-vacuum sensor, 4-micro-adjustment valve, 5-pump body, 6-drive motor, 7-analysis and control module, 8-human-machine interaction module. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0022] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0023] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0024] See Figure 1 A rotary vane vacuum pump intelligent control system includes a vacuum chamber 1 and a pump body 5, which are connected by a vacuum pipeline 2. A vacuum sensor 3 and a micro-adjustment valve 4 are installed on the vacuum pipeline 2. The vacuum sensor 3 is used to detect the system vacuum level P in real time, and the micro-adjustment valve 4 is used to adjust the inlet flow rate Q in real time. The system also includes an analysis and control module 7 and a human-machine interface module 8, wherein the human-machine interface module 8 receives the target vacuum level P input by the user. t and the time to achieve T t The analysis and control module 7 is connected to the vacuum sensor 3 and the micro-adjustment flow valve 4, respectively, and the human-machine interaction module 8 is connected to the analysis and control module 7. It also includes a drive motor 6, which is connected to the pump body 5 and the analysis and control module 7.

[0025] Specifically, vacuum sensor 3 monitors the vacuum level data of vacuum chamber 1 in real time and transmits it to analysis and control module 7. Human-machine interaction module 8 accepts the user's input of vacuum level achievement time and planned curve and transmits it to analysis and control module 7. Analysis and control module 7 issues instructions to adjust the speed of drive motor 6 and the flow rate of micro-adjustment valve 4 so that the real-time vacuum level closely approaches the planned vacuum level change curve over time. Analysis and control module 7 adopts a dual-variable coordinated control strategy to control drive motor 6 and micro-adjustment valve 4.

[0026] See Figure 2 A method for intelligent control of a rotary vane vacuum pump includes the following steps: S1: Initialization; S2: Parameter setting and pumping process curve planning stage: Receives target parameters input by the user through the human-machine interface. The target parameters include: vacuum chamber volume V, target vacuum level P. t and the time to achieve T t 1. Air extraction process curve. If the user does not require a specific air extraction process curve, the system will default to using a smooth curve.

[0027] S3: Dynamic Evacuation Stage: The analysis and control module analyzes and controls the airflow according to the user-defined P... t and T tThe system dynamically adjusts the drive motor speed and throttle valve flow rate based on the vacuum process curve and the real-time monitored actual system vacuum level P, ensuring that the real-time vacuum level meets the pre-planned vacuum level change curve over time. The core of this stage is: dynamic adjustment of speed and throttle valve flow rate: the controller dynamically adjusts the drive motor speed and throttle valve flow rate, rather than using fixed speed and flow rate. Precise vacuum-time control: the control algorithm ensures that the vacuum level P at each moment exactly reaches or is infinitely close to (allowing a small deviation range) the vacuum level at that moment in the planned pressure-time change curve. Specifically, the system starts pumping air at rated speed and with the throttle valve closed, frequently monitoring the actual system vacuum level P. Once the actual vacuum level P exceeds the deviation range, the controller issues instructions to adjust the motor speed and throttle valve flow rate to achieve the preset pumping process curve.

[0028] S4: Low-power maintenance phase: When the actual vacuum level P reaches the target vacuum level P t When this happens, the controller automatically switches the vacuum pump's operating mode from "dynamic pumping mode" to "vacuum maintenance mode." In this mode, the controller instructs the motor to gradually reduce its speed to the maintenance speed N. s During operation, the throttle valve dynamically adjusts to maintain the flow rate Q. s N s This is the minimum speed required for the vacuum pump to operate normally. Due to the significant reduction in speed, the motor's power consumption decreases dramatically, achieving energy savings. Simultaneously, the mechanical noise during pump operation is also significantly reduced, improving the working environment.

[0029] Specifically, step S1 involves checking the status and calibration of the vacuum sensor, verifying normal communication of the motor driver, and checking the zero position of the throttle valve actuator.

[0030] Step S2 involves the user inputting the vacuum chamber volume V through the human-machine interface module 8. The analysis and control module then provides a pressure-time curve of this chamber volume at the pump's highest speed, serving as a boundary curve. The user can then set the target vacuum level P within the boundary curve. t and the time to achieve T t At the same time, it can generate a line like Figure 3 The planned extraction curve is shown.

[0031] Step S3 specifically involves starting the vacuum pump at its rated speed of 1800 RPM and with the throttle valve closed. The analysis and control module 7 reads real-time data from the vacuum sensor 3 at a high frequency (1 kHz) and compares it with the expected vacuum level at the current moment in the set pumping process curve. This comparison determines and controls the increase or decrease of the drive motor speed and the flow rate of the fine-tuning valve, ensuring that the actual vacuum level closely matches the set curve. The specific determination and control methods are as follows: A two-variable coordinated control strategy is used. The deviation ΔP between the read real-time vacuum level P and the expected P(t) on the planned curve is calculated using a set control cycle, and the deviation level is determined. When |ΔP| > 15%, the motor speed dominates the control, the throttle valve remains nearly closed, and fast-response PID parameters are used. When 5%P(t) < |ΔP| ≤ 15%P(t), the motor speed and throttle valve are coordinated for control; the speed is coarsely adjusted, and the throttle valve is finely adjusted, using medium-response PID parameters. When |ΔP| ≤ 5%P(t), the throttle valve dominates the fine-tuning, using fine-tuning PID parameters.

[0032] Step S4 specifically occurs when the system calculates and detects that the actual vacuum level reaches Pt±1%P. t When the vacuum level is within the specified range, the target vacuum level P is determined to have been reached. t The maintenance unit is activated to calculate the deviation ΔP between the real-time vacuum level P and the target vacuum level Pt within a set control cycle. When |ΔP| ≤ 1%, the controller issues a command to reduce the rotational speed at a moderate gradient while keeping the throttle valve flow rate constant. This continues until |ΔP| > 1%, at which point the rotational speed temporarily stops decreasing, and the throttle valve flow rate decreases at a small gradient to restore the deviation to within 1%. This cycle repeats until the rotational speed decreases to the minimum maintenance speed N specified by the system. s It successfully stabilized at the target vacuum level. At this point, compared with the rated high speed operation of 1800 RPM, the noise level dropped from 57 dB(A) to 48 dB(A), and the power consumption dropped from 240W to 110W, significantly reducing noise pollution and energy consumption.

[0033] In some embodiments, if the user does not require a specific vacuum degree change curve over time during the parameter setting and evacuation process curve planning stages, the system defaults to planning with a power function smooth curve.

[0034] This invention introduces "arbitrary target vacuum level and achievement time, and planned pumping process curve" as its core control functions. This enables the system to plan and automatically execute a desired pumping process curve to meet user requirements, achieving the target vacuum level at a specific time. This makes the pumping process predictable and plannable, satisfying users' precise requirements for pumping targets and processes. Furthermore, this invention goes beyond simple frequent start-stop cycles; it dynamically optimizes and automatically adjusts the motor speed to maintain it at the lowest level that just overcomes system leakage, thereby ensuring stable vacuum while significantly reducing operating noise and energy consumption.

[0035] For the foregoing embodiments, in order to simplify the description, they are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, because according to this application, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to this application.

[0036] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. An intelligent control system for a rotary vane vacuum pump, characterized in that, It includes a vacuum chamber (1) and a pump body (5), which are connected by a vacuum pipeline (2). A vacuum sensor (3) and a micro-adjustment valve (4) are installed on the vacuum pipeline (2). It also includes an analysis and control module (7) and a human-machine interaction module (8). The analysis and control module (7) is connected to the vacuum sensor (3) and the micro-adjustment valve (4) respectively, and the human-machine interaction module (8) is connected to the analysis and control module (7).

2. The intelligent control system for a rotary vane vacuum pump as described in claim 1, characterized in that, It also includes a drive motor (6), which is connected to the pump body (5) and the analysis and control module (7) respectively.

3. The intelligent control system for a rotary vane vacuum pump as described in claim 2, characterized in that, The human-machine interaction module (8) accepts the user's vacuum degree achievement time and planning curve input and transmits it to the analysis and control module (7); the analysis and control module (7) issues instructions to adjust the speed of the drive motor (6) and the flow rate of the micro-adjustment valve (4) so ​​that the real-time vacuum degree closely approaches the planned vacuum degree change curve over time.

4. The intelligent control system for a rotary vane vacuum pump as described in claim 3, characterized in that, The analysis and control module (7) adopts a two-variable coordinated control strategy to control the drive motor (6) and the fine-tuning flow valve (4).

5. A method for intelligent control of a rotary vane vacuum pump, implemented based on an intelligent control system for a rotary vane vacuum pump as described in any one of claims 1 to 4, characterized in that, Includes the following steps: S1: System initialization; S2: Parameter setting and air extraction process curve planning; S3: Dynamic air extraction; S4: Low power sustain.

6. The intelligent control method for a rotary vane vacuum pump as described in claim 5, characterized in that, Step S2 is as follows: The user first inputs the volume of the vacuum chamber (1) through the human-computer interaction module (8), and the analysis and control module (7) gives the pressure change curve of the volume at the highest pump speed as the boundary curve, and sets the target vacuum degree and the time to achieve it within the boundary curve, and generates the planned pumping curve at the same time.

7. The intelligent control method for a rotary vane vacuum pump as described in claim 5, characterized in that, Step S3 specifically involves: reading the real-time data of the vacuum sensor (3) through the analysis control module (7), comparing it with the expected vacuum level at the current moment in the set pumping process curve, and then determining and controlling the speed of the drive motor (6) and the flow rate of the fine adjustment valve (4) to ensure that the actual vacuum level closely matches the set curve.

8. The intelligent control method for a rotary vane vacuum pump as described in claim 5, characterized in that, Step S4 is as follows: When the actual vacuum level is detected to be within the preset range, it is determined that the target vacuum level has been reached. At this time, the maintenance unit is activated to calculate the deviation between the real-time vacuum level and the target vacuum level by setting the control cycle, and to cyclically adjust the speed of the drive motor (6) and the flow rate of the fine-tuning valve (4) according to the deviation until the specified minimum maintenance speed is reached, and the target vacuum level is successfully stabilized.

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