Centralized negative pressure supply system with redundant backup

Abstract

The invention discloses a centralized negative pressure supply system with redundant backup, and relates to the technical field of industrial control, and the system comprises a data sensing module which obtains the negative pressure value of a negative pressure unit and the state of a pipeline valve in real time, evaluates the operation state and gives an alarm to remind an abnormity unit; the self-adaptive regulation and control module is used for regulating and controlling the output power of the main vacuum pump by calculating the qualified ratio of the negative pressure unit so as to maintain the stability of the negative pressure, and collecting a negative pressure numerical value for feedback regulation and control; when the main output power exceeds the limit, the redundant cooperation module regulates and controls the standby vacuum pump to be connected and set the output power, and cooperates with the main vacuum pump to maintain negative pressure; the intelligent quit module continuously monitors the qualified ratio, and when the qualified ratio is stabilized in a threshold value interval, a standby vacuum pump quit mechanism is executed; the system ensures the stability and reliability of negative pressure supply through the cooperative work of all modules, improves the production efficiency, and reduces the fault risk.

Description

Technical Field

[0001] This invention belongs to the field of industrial control technology, specifically, it relates to a centralized negative pressure supply system with redundant backup. Background Technology

[0002] With the booming development of the photovoltaic industry, the level of automation and intelligence of photovoltaic production lines is constantly improving. In the production process, the negative pressure supply system is crucial to ensuring the stable operation of the process.

[0003] In photovoltaic production lines, existing centralized negative pressure supply systems typically lack integrated intelligent monitoring and control mechanisms. Their shortcomings and drawbacks are mainly reflected in several aspects. For example, existing methods often rely on simple sensors to collect negative pressure values, failing to comprehensively assess the status of pipeline valves. This leads to inaccurate judgments of the negative pressure unit's operating status. When the negative pressure is zero, false alarms may occur because the system cannot distinguish between normal valve closure and abnormal malfunctions, increasing the intervention burden on operators and reducing the response speed to real problems. Secondly, in terms of control, existing technologies mostly use fixed power output or manual adjustments based on experience, failing to dynamically adjust the main power supply in real time according to the qualified percentage of negative pressure units. The output power of the empty pump means that when the negative pressure demand changes, the system either has excessive power, resulting in energy waste, or insufficient power, affecting production stability. Regarding the redundancy backup mechanism, the standby vacuum pumps in existing systems often rely on preset pressure thresholds for startup rather than intelligent decisions based on the qualified ratio. This leads to inaccurate timing of the standby pump's connection, which may result in excessive redundancy due to premature startup or production interruption due to delayed startup. Furthermore, the output power of the standby pump is often set to a fixed value, making it impossible to work with the main pump to achieve negative pressure maintenance with minimal energy consumption. In addition, existing technologies lack intelligent shutdown functions. After the system stabilizes, the standby pump often continues to run until it is manually shut down, which not only increases energy consumption and equipment wear but also raises maintenance costs.

[0004] To address the aforementioned problems, this invention proposes a centralized negative pressure supply system with redundant backup. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a centralized negative pressure supply system with redundant backup, solving the problems of inaccuracy, lack of intelligence in redundancy, and low energy efficiency in the control of negative pressure systems in existing technologies.

[0006] The objective of this invention can be achieved through the following technical solutions: A centralized negative pressure supply system with redundant backup, the system comprising: The data sensing module acquires the negative pressure values ​​of all negative pressure units in the photovoltaic production line that are supplied with negative pressure by the centralized negative pressure supply module in real time. Combined with the valve status of the pipeline valves associated with the corresponding negative pressure unit, the module assesses the operating status of the negative pressure unit and provides alarm reminders for negative pressure units in abnormal states. The adaptive control module extracts the negative pressure values ​​of all negative pressure units in normal state, calculates the qualified percentage of negative pressure units by combining the negative pressure redundancy range, and adjusts the main output power of the main vacuum pump based on the qualified percentage. It also collects the negative pressure values ​​of each negative pressure unit to calculate the qualified percentage and feeds back to adjust the main output power of the main vacuum pump. The redundant coordination module adjusts the backup vacuum pump to the negative pressure pipeline based on the qualified percentage when the main output power of the main vacuum pump exceeds the limit, and sets the backup output power corresponding to the qualified percentage to maintain negative pressure together with the main vacuum pump. The intelligent exit module continuously monitors the pass rate. When the pass rate remains within a stable threshold range for a monitoring period, the backup vacuum pump exit mechanism is executed.

[0007] As a further aspect of the present invention, the specific method for evaluating the operating status of the negative pressure unit in the data sensing module is as follows: Identify all negative pressure units in the photovoltaic production line. Extract the centralized negative pressure supply module associated with all negative pressure units; The negative pressure values ​​of each negative pressure unit are collected based on the negative pressure sensors pre-installed at the valves of each negative pressure unit pipeline; Extract the valve status of the pipeline valves of the negative pressure unit with a negative pressure value of 0; The valve is closed, and the corresponding negative pressure unit is marked as operating normally. When the valve is in an open state, the corresponding negative pressure unit is marked as being in an abnormal operating state. Extract the negative pressure value of the negative pressure unit when the valve is closed; A negative pressure value of 0 indicates that the corresponding negative pressure unit is in normal operating condition. Conversely, the operating status of the corresponding negative pressure unit is marked as abnormal.

[0008] As a further aspect of the present invention, the specific method by which the data sensing module provides an alarm reminder for the negative pressure unit in an abnormal state is as follows: All negative pressure units marked as abnormal are retrieved, and their negative pressure unit numbers and the timestamps indicating abnormality are extracted to form an alarm notification for the corresponding negative pressure unit, which is then transmitted to the operator.

[0009] As a further aspect of the present invention, the specific method for calculating the qualified proportion of the negative pressure unit in the adaptive control module, combined with the negative pressure redundancy interval, is as follows: Extract negative pressure units that are in normal operating status in real time, and record the total number as j; Randomly arrange j negative pressure units, denoted as the negative pressure unit sequence Q1, Q2, ..., Qj; Extract the current time, denoted as t0; At the current time t0, the negative pressure values ​​of j negative pressure units are collected and recorded as the negative pressure value sequence P1, P2, ..., Pj according to the sequence order of the negative pressure units; Obtain the operator's preset minimum negative pressure P_low and negative pressure redundancy range [P_min, P_max]; Extract any negative pressure unit Qi from the negative pressure unit sequence Q1, Q2, ..., Qj, where i is the counting index, and its value ranges from 1 to j; Extract the negative pressure value Pi of the negative pressure unit Qi, and use Pi-P_low=P_ry to obtain the redundant negative pressure P_ry of the negative pressure unit Qi; Compare the redundant negative pressure P_ry with the negative pressure redundancy interval. If P_ry∈[P_min,P_max], mark the negative pressure unit Qi as qualified; otherwise, mark it as unqualified. Similarly, determine the total number of qualified negative pressure units among j negative pressure units, denoted as u; The pass rate HG of the negative pressure unit sequence Q1, Q2, ..., Qj is calculated using HG=u / j×100%.

[0010] As a further aspect of the present invention, the specific method for adjusting the main output power of the main vacuum pump based on the qualified ratio in the adaptive control module is as follows: S51, obtain the preset qualified percentage threshold HG_yu; The total number of redundant negative pressure units with a redundancy of less than P_min is obtained, denoted as x, and the total number of redundant negative pressure units with a redundancy of greater than P_max is denoted as y. If x > y, extract the qualified percentage HG at the current time t0; HG≥HG_yu, generate main output power hold command; HG < HG_yu, generate main output power increase command; If x≤y and HG≥HG_yu, generate the main output power hold command; If HG < HG_yu, a command to reduce the main output power is generated. Among them, when generating the main output power hold command, the current main output power of the main vacuum pump is kept unchanged; S52, when generating the main output power increase command, extract the main output power W_cur and the preset single power increase step size ΔW_up; S53, calculate the adjusted main output power W_adj=W_cur+ΔW_up, obtain the maximum allowable working power W_max of the main vacuum pump. If W_adj≤W_max, the main output power is increased to W_adj at a preset adjustment rate, otherwise it is increased to W_max. S54, when generating the main output power reduction command, extract the current main output power of the main vacuum pump, record it as W_cur and the preset single power reduction step size ΔW_down; S55, calculate the adjusted main output power W_adj=W_cur-ΔW_down, obtain the minimum allowable operating power W_min of the main vacuum pump. If W_adj≥W_min, decrease the main output power to W_adj at a preset adjustment rate; otherwise, decrease it to W_min. S56, after the main output power is adjusted, continuously monitors for one control cycle, where the control cycle is a preset time period.

[0011] As a further aspect of the present invention, the adaptive control module collects the negative pressure values ​​of each negative pressure unit to calculate the qualified percentage, and then uses this information to adjust the main output power of the main vacuum pump in the following specific way: S61 extracts the negative pressure value of each negative pressure unit in real time within one control cycle after the main output power is adjusted, and calculates the qualified percentage. S62, take the current time t0 as the start time of a control cycle and determine the end time t1 of a control cycle; S63, extract the total number of times from the current time t0 to the end time t1, and denote it as m; S64, determine the m qualified percentages corresponding to m time points, and record them in time order as the qualified percentage sequence HG1,HG2,...,HGm; S65. Construct a two-dimensional coordinate system with the timeline as the horizontal axis and the qualified percentage value as the vertical axis. Mark the qualified percentage sequence HG1, HG2, ..., HGm as data points in the constructed two-dimensional coordinate system to obtain m data points. Fit the curve to obtain the qualified percentage change curve L_HG. S66, extract the qualified percentage HGn corresponding to the highest peak on the curve L_HG, where n is the counting index, and the value range is from 1 to m. If the number of highest peaks is greater than 1, then take the qualified percentage of the highest peak closest to the current time t0. S67, if HGn≥HG_yu, take the main output power corresponding to the qualified percentage HGn as the preferred main output power, adjust the main output power to the preferred main output power, stop the adjustment, and monitor the qualified percentage in real time. S68, where if the highest peak occurs at the end time t1, and the qualified proportion HGm corresponding to the end time t1 is less than HG_yu, then the control method of this control cycle will be repeated in the next control cycle.

[0012] As a further aspect of the present invention, in the redundant coordination module, the specific method for adjusting the backup vacuum pump connected to the negative pressure pipeline based on the qualified percentage and setting the backup output power corresponding to the qualified percentage is as follows: If, during the adjustment of the main output power, the main output power reaches the maximum main output power allowed by the main vacuum pump, and the qualified percentage is less than HG_yu, record the current time as t2, and mark the qualified percentage at time t2 as HG_t2. At time t2, the standby vacuum pump is connected to the negative pressure pipeline, and the standby output power is recorded as W_bc; Calculate the difference between the pass rates HG_t2 and HG_yu, ΔHG = HG_yu - HG_t2; The standby output power is calculated using W_bc=(ΔHG / K)×W_max, where K is the power negative voltage compensation coefficient, which is preset by the operator. Obtain the maximum permissible operating power W_bc_max of the standby vacuum pump; If W_bc ≤ W_bc_max, adjust the standby output power to W_bc; otherwise, adjust the standby output power to W_bc_max.

[0013] As a further aspect of the present invention, the specific method for executing the backup vacuum pump exit mechanism in the intelligent exit module is as follows: After the standby vacuum pump is connected to the negative pressure pipeline, the current time is extracted and recorded as t3; Using time t3 as the start time of a control cycle, determine the end time t4 of the control cycle; The percentage of qualified output power is monitored in real time from time t3 to time t4, and the total output power is marked as the sum of the standby output power and the main output power in accordance with the method described in steps S51 to S56. This total output power is then used as the control object to generate a total output power maintenance command or a total output power increase command. Then, following the steps S61 to S68, adjust the total output power using feedback. Among them, the standby output power is adjusted first, and when the standby output power is less than the minimum allowable operating power W_bc_min of the standby vacuum pump, the standby vacuum pump is shut down and disconnected from the negative pressure pipeline.

[0014] The beneficial effects of this invention are: This invention achieves efficient and stable negative pressure supply and energy saving through real-time sensing and intelligent control mechanisms. Its core advantage lies in its dynamic redundancy backup capability, which can automatically diagnose abnormalities and issue timely alarms based on real-time negative pressure data and valve status, thereby ensuring production safety. By calculating the qualified ratio, the power of the main vacuum pump is adaptively adjusted, and the backup pump is intelligently activated when the demand exceeds the limit. This ensures the continuous and reliable supply of negative pressure and avoids long-term high-load operation of the equipment. In addition, the intelligent shutdown module can automatically shut down the backup pump after the system recovers stability, effectively reducing energy consumption. Overall, it achieves a high degree of unity between operation and maintenance automation, energy efficiency optimization, and production assurance. This invention achieves an optimal balance between system energy efficiency and stability by dynamically monitoring whether the redundant negative pressure of each negative pressure unit is within a preset range, calculating the qualified percentage in real time, and intelligently adjusting the output power of the main vacuum pump accordingly. Its core advantage lies in the introduction of an adaptive feedback mechanism, which can automatically adjust the power according to actual negative pressure fluctuations, avoiding energy waste and ensuring the reliability of negative pressure supply. By setting the control cycle and analyzing the qualified percentage change curve, the system can accurately capture the optimal operating point and lock the preferred power, thereby significantly reducing energy consumption and human intervention during long-term operation, while maintaining the system's high efficiency and stability. This invention achieves intelligent coordination and energy efficiency optimization of redundant vacuum pump systems by introducing a dynamic threshold response and precise power matching mechanism. When the main pump, even at full load, cannot meet the required negative pressure compliance rate for the process, the seamless connection of the standby pump is automatically triggered. Based on the deviation between real-time operating conditions and the set threshold, the optimal standby output power is dynamically calculated through a built-in compensation algorithm. This ensures system stability and compliance while minimizing the risk of overload or inefficient operation of the standby equipment. It enhances the system's reliability and adaptability to high-load conditions, strengthens production continuity assurance, and achieves energy savings and reduced equipment wear through refined power control. This invention improves the precision and energy efficiency of vacuum system operation and maintenance after the backup pump intervenes by introducing a time-cycle-based dynamic control strategy. Its core advantage lies in using the total output power as a unified control object to achieve coordinated load management between the main and backup pumps, ensuring the continuous stability of the system's negative pressure. Secondly, power priority scheduling ensures the smoothness and safety of the exit process. By setting a lower limit threshold for the backup pump power to trigger the exit command, the ineffective operation and energy waste of backup equipment are avoided, enhancing the system's adaptability and reliability. Attached Figure Description

[0015] The invention will now be further described with reference to the accompanying drawings.

[0016] Figure 1 This is a schematic diagram of the system described in this invention. Detailed Implementation

[0017] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1 A centralized negative pressure supply system with redundant backup, such as Figure 1 As shown, this system includes the following: This system is a centralized negative pressure supply system with redundancy backup, mainly used for negative pressure supply in photovoltaic production lines. Its purpose is to achieve intelligent monitoring and control, so as to achieve the technical effect of stable, efficient and energy-saving operation of the negative pressure system.

[0019] This system mainly includes the following four modules: data perception module, adaptive control module, redundancy coordination module, and intelligent exit module. The data sensing module is used to acquire in real time the negative pressure values ​​of all negative pressure units in the photovoltaic production line that are supplied with negative pressure by the centralized negative pressure supply module. Combined with the valve status of the pipeline valves associated with the corresponding negative pressure unit, it assesses the operating status of the negative pressure unit and issues alarms for negative pressure units in abnormal states. Specifically: The core function of the data sensing module is to monitor the negative pressure value of each negative pressure unit and the valve status of the pipeline valve in real time, determine whether it is operating normally, and alarm for abnormal negative pressure units. The negative pressure unit acts on a specific processing station in the photovoltaic production line, using negative pressure to complete specific process operations. Each negative pressure unit is a point of consumption of negative pressure. The negative pressure unit is connected to a centralized negative pressure supply module through a negative pressure pipeline, and the centralized negative pressure supply module provides negative pressure uniformly, which is then delivered to the negative pressure unit through the negative pressure pipeline.

[0020] The pipeline valves and negative pressure units are in a corresponding relationship, with one negative pressure unit corresponding to one pipeline valve. The pipeline valves are electrically connected and controlled. The negative pressure unit also integrates a negative pressure sensor, which is used to collect the negative pressure value associated with each negative pressure unit in real time at the pipeline valve corresponding to the negative pressure unit.

[0021] In the adaptive control module, the negative pressure values ​​of all negative pressure units in normal state are extracted, and the qualified percentage of negative pressure units is calculated by combining the negative pressure redundancy range. Based on the qualified percentage, the main output power of the main vacuum pump is adjusted. The negative pressure values ​​of each negative pressure unit are collected to calculate the qualified percentage, and the main output power of the main vacuum pump is adjusted accordingly. Specifically: The adaptive control module dynamically adjusts the output power of the main vacuum pump based on the negative pressure data of the current normal negative pressure unit in order to maintain overall negative pressure stability; The negative pressure redundancy range needs to be determined by the operator based on the actual situation.

[0022] In the redundant coordination module, when the main output power of the main vacuum pump exceeds the limit, the backup vacuum pump is connected to the negative pressure pipeline based on the qualified percentage, and the backup output power corresponding to the qualified percentage is set to maintain the negative pressure together with the main vacuum pump. Specifically: The redundant coordination module is used to automatically activate the backup vacuum pump when the main vacuum pump power has been adjusted to the upper limit but still cannot meet the negative pressure requirement, so as to achieve dual pump coordinated pressure supply. The conditions for activating the backup vacuum pump are: the main pump power has reached the maximum, but the qualified rate is still lower than the target value.

[0023] In the intelligent exit module, the pass rate is continuously monitored. When the pass rate remains within a stable threshold range for a monitoring period, the backup vacuum pump exit mechanism is executed. Specifically: After the overall negative pressure returns to stability, the load on the standby pump is gradually reduced and eventually it is taken out of operation to achieve energy saving and equipment protection. Specifically, the standby pump will only be automatically shut down and withdrawn from the negative pressure pipeline when the output of the standby pump drops below its minimum allowable operating power.

[0024] Example 2 This embodiment further discloses the detailed steps of the data perception module based on Embodiment 1, specifically including the following: This embodiment takes a photovoltaic production line as the main research object and provides a detailed description. First, the centralized negative pressure supply module is determined. The centralized negative pressure supply module is a module pre-built by the operator. It mainly includes a main vacuum pump and a backup vacuum pump, which are connected to each negative pressure unit through negative pressure pipelines. First, all negative pressure units in the photovoltaic production line are counted. Then, the centralized negative pressure supply module associated with all negative pressure units is determined. Based on the negative pressure sensor described in Example 1, the negative pressure value at the pipeline valve of each negative pressure unit is collected in real time using this negative pressure sensor. The collected negative pressure value is used as the negative pressure value associated with the corresponding negative pressure unit. The negative pressure sensor is pre-installed at the pipeline valve of the corresponding negative pressure unit.

[0025] Monitor negative pressure units with a negative pressure value of 0 in real time and check the valve status of the pipeline valves of these negative pressure units; If the valve is closed, the corresponding negative pressure unit is marked as operating normally. This is because a closed valve means that the negative pressure unit has actively cut off the connection with the negative pressure pipeline. Theoretically, the air pressure at the valve in the pipeline should be the same as atmospheric pressure, so the negative pressure value is displayed as 0. If the valve is in an open state, the corresponding negative pressure unit is marked as an abnormal state. This is because the valve is closed, but negative pressure still exists, indicating that the valve has not been completely closed, there is a leak, or the negative pressure sensor reading is inaccurate and there is a false alarm. Then, extract all negative pressure units whose valve status is closed in real time, and read the negative pressure value of the corresponding negative pressure unit through the negative pressure sensor. If the negative pressure value is 0, the operating status of the corresponding negative pressure unit is marked as normal. If the negative pressure value is not 0, the operating status of the corresponding negative pressure unit is marked as abnormal.

[0026] Finally, all negative pressure units marked as abnormal are obtained, and their negative pressure unit numbers and timestamps marking them as abnormal are extracted. Based on the determined negative pressure unit numbers (which will be explained in detail in subsequent embodiments) and the timestamps marking them as abnormal, an alarm notification associated with the corresponding negative pressure unit is generated and transmitted to the operator to remind them to perform timely maintenance.

[0027] Example 3 This embodiment further discloses the detailed steps of the adaptive control module based on embodiment 2, specifically including the following: Based on the content described in Example 2, the negative pressure values ​​of all negative pressure units in abnormal states and negative pressure units in normal states can be obtained in real time. Extract all negative pressure units that are in normal operating status, count their total number, and label them as j; Then, the selected j negative pressure units are randomly arranged into a sequence, denoted as the negative pressure unit sequence Q1, Q2, ..., Qj, where Q1 to Qj are the negative pressure unit numbers.

[0028] Next, determine the current time, and denote it as t0; Then, at the current time t0, obtain the negative pressure values ​​corresponding to each of the j negative pressure units, for a total of j negative pressure values. Sort the j negative pressure values ​​according to the sorting method of the corresponding negative pressure unit sequence Q1, Q2, ..., Qj, and denote it as the negative pressure value sequence P1, P2, ..., Pj. Next, obtain the minimum negative pressure P_low preset by the operator and the negative pressure redundancy range [P_min, P_max]. The minimum negative pressure P_low represents the basic negative pressure requirement of the corresponding negative pressure unit. Under normal circumstances, the negative pressure value of the negative pressure unit should be higher than this minimum negative pressure P_low to prevent negative pressure fluctuations from causing the negative pressure value of the negative pressure unit to fall below the minimum negative pressure P_low, thereby causing the production line to stop.

[0029] The negative pressure redundancy range [P_min, P_max] is defined by P_min and P_max to ensure that there is still a buffer when there is a small leak or fluctuation in the pipeline, so as not to fall below the minimum negative pressure P_low, while preventing the negative pressure margin from being too large, which would lead to a surge in energy consumption and equipment wear.

[0030] Extract any negative pressure unit from the negative pressure unit sequence Q1, Q2, ..., Qj, denoted as Qi, where i is the counting index, with a value ranging from 1 to j; Based on the negative pressure sensor integrated in the negative pressure unit Qi, the negative pressure value associated with the negative pressure unit Qi is extracted and denoted as Pi. The redundant negative pressure P_ry is obtained by subtracting the lowest negative pressure P_low from the actual measured negative pressure value. The calculation formula is: P_ry = Pi - P_low.

[0031] Next, the calculated redundant negative pressure P_ry is compared with the negative pressure redundancy interval [P_min, P_max]. If the redundant negative pressure P_ry is within the negative pressure redundancy interval [P_min, P_max], then the negative pressure unit Qi is marked as qualified. Conversely, if the calculated redundant negative pressure P_ry falls outside the negative pressure redundancy interval [P_min, P_max], then the negative pressure unit Qi is marked as unqualified. If the redundant negative pressure P_ry is less than P_min, it indicates insufficient redundancy and a risk of low negative pressure. If the redundant negative pressure P_ry is greater than P_max, it indicates excessive redundancy and energy waste. At this point, it was determined whether the negative pressure unit Qi was a qualified negative pressure unit or an unqualified negative pressure unit; Following the above method, determine whether all negative pressure units are qualified negative pressure units, and count the total number of qualified negative pressure units, which is denoted as u; Next, the percentage of qualified negative pressure units in the negative pressure unit sequence Q1, Q2, ..., Qj is calculated by using HG=u / j×100%, and is recorded as the qualified percentage HG.

[0032] Next, obtain the qualified percentage threshold HG_yu preset by the operator; Next, calculate the total number of redundant negative pressures less than P_min in the unqualified negative pressure units among the j negative pressure units, and record it as x. Then calculate the total number of redundant negative pressures greater than P_max, and record it as y, where x+y=ju.

[0033] When x > y, it means that most of the unqualified negative pressure units are in a state of insufficient redundancy. Extract the qualified percentage HG at the current time t0. If HG≥HG_yu, it means the overall situation is acceptable, and then the main output power hold command is generated; If HG < HG_yu, it indicates that the overall output power is insufficient, and a command to increase the main output power is generated. When x≤y, most of the unqualified negative pressure units are in a state of excessive redundancy. Extract the qualified percentage HG at the current time t0. If HG≥HG_yu, it means the overall situation is acceptable, and then the main output power hold command is generated; If HG < HG_yu, it indicates that the overall output power is insufficient, and a main output power reduction command is generated. Specifically, when a main output power hold command is generated, the current main output power of the main vacuum pump is kept unchanged; Next, the instructions for increasing and decreasing the main output power will be explained separately, as follows: When the main output power increase command is generated, the single power increase step size ΔW_up preset by the operator is first extracted, and the output power of the main vacuum pump is collected at the same time and marked as the main output power W_cur. The main output power W_adj that needs to be adjusted is calculated by using the formula: W_adj=W_cur+ΔW_up, and then the maximum allowable working power W_max of the main vacuum pump is obtained (generally the rated output power of the main vacuum pump). The calculated main output power W_adj is compared with the maximum working power W_max. If the main output power W_adj is less than or equal to the maximum working power W_max, the current main output power of the main vacuum pump is adjusted to W_adj at a constant and incremental rate preset by the operator. If the main output power W_adj is greater than the maximum operating power W_max, then the current main output power of the main vacuum pump will be adjusted to W_max at a constant speed and incrementally.

[0034] When a main output power reduction command is generated, the current main output power of the main vacuum pump is also obtained and marked as W_cur. Then, the single power reduction step size ΔW_down preset by the operator is obtained. The main output power W_adj that needs to be adjusted is calculated by using the formula: W_adj=W_cur-ΔW_down. Then, the minimum allowable operating power W_min of the main vacuum pump is obtained. If the main output power W_adj is greater than or equal to the minimum operating power W_min, the current main output power of the main vacuum pump is adjusted to W_adj at a constant and decreasing rate. If the main output power W_adj is less than the minimum operating power W_min, then the current main output power of the main vacuum pump will be adjusted to W_min at a constant and decreasing rate.

[0035] After the main output power of the main vacuum pump is adjusted, it is necessary to continuously monitor it for a control cycle. The control cycle represents a time period, and the duration of the control cycle is preset and determined by the operator.

[0036] This completes the adjustment of the main output power of the main vacuum pump based on the qualified ratio. As mentioned above, it is necessary to continue monitoring for one adjustment cycle. During this cycle, the following operations are also required: Within one control cycle after the main output power is adjusted, the negative pressure value of each negative pressure unit is monitored and determined in real time, and the qualified percentage is calculated. Taking the main output power adjustment being completed at the current time t0 as an example, we will conduct an example analysis: Obtain the duration of the control period, and take the current time t0 as the start time of the control period. Combine the duration of the control period to determine the end time of the control period, and record it as the end time t1. Then, calculate the total number of moments from the current time t0 to the end time t1, that is, the total number of moments within one control cycle, and denot it as m; In real time, determine the m qualified percentages corresponding to m moments within the control cycle, and sort the m qualified percentages in chronological order to obtain a sequence, denoted as qualified percentage sequence HG1, HG2, ..., HGm.

[0037] Construct a two-dimensional coordinate system with the timeline as the horizontal axis and the percentage of qualified participants as the vertical axis. The time span on the horizontal axis is the total number of times from the current time t0 to the end time t1.

[0038] The m qualified percentages in the qualified percentage sequence HG1, HG2, ..., HGm are plotted as data points on the horizontal axis in chronological order in the constructed two-dimensional coordinate system. Finally, m data points can be obtained in the two-dimensional coordinate system. The qualified percentage change curve L_HG is obtained by fitting the plotted m data points with a curve.

[0039] Then extract the percentage of qualified products corresponding to the highest peak on the curve L_HG and label it as HGn, where n is the counting index, and the value range is from 1 to m; If the number of highest peaks is greater than 1, then the percentage of qualified highest peaks closest to the current time t0 is taken. The qualified percentage HGn of the highest peak is compared with the qualified percentage threshold HG_yu. If the qualified percentage HGn is greater than or equal to HG_yu, the main output power corresponding to the qualified percentage HGn is taken as the preferred main output power, the current main output power of the main vacuum pump is adjusted to the preferred main output power, and the adjustment operation is stopped. The change of the qualified percentage is monitored in real time.

[0040] It should be noted that if the highest peak occurs at the end time t1, the qualified rate corresponding to the end time t1 is HGm. If the qualified rate HGm is still less than HG_yu, the above-mentioned control method will be repeated in the next control cycle.

[0041] Example 4 This embodiment further discloses the detailed steps of the redundant coordination module and the intelligent exit module based on embodiment 3, specifically including the following: The redundant coordination module and intelligent shutdown module described in this embodiment jointly realize the on-demand start-up, intelligent coordination, and smooth shutdown of the backup vacuum pump. The entire process is fully automated and requires no manual intervention. While ensuring stability during peak demand, it avoids the waste of energy and equipment resources. Specifically: First, clarify the connection conditions of the backup vacuum pump, as described in Example 1: the main pump power has reached its maximum, but the qualified rate is still lower than the target value.

[0042] Example 3 discloses the regulation of the main output power of the main vacuum pump. If, during the regulation of the main output power, the main output power reaches the maximum allowable main output power of the main vacuum pump, but the qualified percentage is still less than HG_yu, the connection of the standby vacuum pump is triggered. First, record the moment when the main output power reaches the maximum allowable main output power of the main vacuum pump, mark it as t2, and record the percentage of qualified products at time t2 as HG_t2; At time t2, the standby vacuum pump is connected to the negative pressure pipeline, and the standby output power of the standby vacuum pump at time t2 is recorded as W_bc. The standby output power W_bc is determined in the following way: First, the difference in the pass rate between HG_t2 and HG_yu at time t2 is calculated using the formula: ΔHG = HG_yu - HG_t2. Then, the standby output power W_bc is calculated using W_bc=(ΔHG / K)×W_max. It should be noted that K is the power negative pressure compensation coefficient, which is determined by the operator in combination with the minimum allowable operating power W_bc_min and the maximum allowable operating power W_bc_max of the standby vacuum pump.

[0043] Next, obtain the maximum allowable operating power W_bc_max of the backup vacuum pump, and compare the calculated backup output power W_bc with the maximum operating power W_bc_max. If W_bc ≤ W_bc_max, then adjust the backup output power of the backup vacuum pump to W_bc; otherwise, adjust the backup output power to W_bc_max. Since the backup vacuum pump has been connected, it will operate at least at the minimum operating power W_bc_min, so the comparison between the backup output power W_bc and the minimum operating power W_bc_min is not necessary here.

[0044] When the standby vacuum pump is connected to the negative pressure pipeline with standby output power W_bc, the current time is recorded in real time and marked as t3; Then, take time t3 as the start time of a control cycle, and determine the end time t4 of this control cycle by combining the duration of the control cycle. Real-time monitoring of the percentage of qualified applicants at each time point from time t3 to time t4; Calculate the sum of the standby output power and the main output power, mark it as the total output power, and use it as the control target; According to the complete method described in Example 3, a total output power hold command or a total output power increase command is generated with the total output power as the control object; Then, the total output power is adjusted based on the total output power hold command or the total output power increase command.

[0045] During this process, it is important to note that when the total output power needs to be increased, the backup output power should be increased first. Similarly, when the total output power needs to be decreased, the backup output power should be decreased first. When the backup output power is less than the minimum allowable operating power W_bc_min of the backup vacuum pump, the backup vacuum pump should be shut down and disconnected from the negative pressure pipeline.

[0046] All data in the formulas described above have been calculated with dimensions removed. Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0047] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

[0048] It should be stated that all user data collected in this application was collected with the user's consent and authorization. Furthermore, the uses of user data are legal and compliant, and the use and processing of user data comply with the relevant laws, regulations, and standards of the relevant regions.

Claims

1. A centralized negative pressure supply system with redundant backup, characterized in that, The system comprises: A data sensing module, which acquires in real time the negative pressure values of all negative pressure units supplied with negative pressure by the centralized negative pressure supply module in the photovoltaic production line, combines the valve states of the pipeline valves associated with the corresponding negative pressure units, evaluates the operating states of the negative pressure units, and alarms and reminds the abnormal state negative pressure units; An adaptive control module, which extracts the negative pressure values of all normal state negative pressure units, combines the negative pressure redundancy interval to calculate the qualified proportion of the negative pressure units, controls the main output power of the main vacuum pump based on the value of the qualified proportion, collects the negative pressure values of each negative pressure unit to calculate the qualified proportion, and feeds back to control the main output power of the main vacuum pump; A redundancy coordination module, which, when the main output power of the main vacuum pump is controlled beyond the limit, controls the standby vacuum pump to access the negative pressure pipeline based on the value of the qualified proportion, and sets the standby output power corresponding to the qualified proportion to maintain the negative pressure together with the main vacuum pump; An intelligent exit module, which continuously monitors the qualified proportion, and when the qualified proportion is within the stable threshold interval in a monitoring period, executes the standby vacuum pump exit mechanism.

2. The system of claim 1, wherein, In the data sensing module, the specific way to evaluate the operating state of the negative pressure unit is: Determine all negative pressure units in the photovoltaic production line, Extract the centralized negative pressure supply module associated with all negative pressure units; Collect the negative pressure values of each negative pressure unit based on the negative pressure sensors pre-disposed at the pipeline valves of each negative pressure unit; Extract the valve state of the pipeline valve of the negative pressure unit with a negative pressure value of 0; If the valve state is closed, mark the operating state of the corresponding negative pressure unit as normal state; If the valve state is open, mark the operating state of the corresponding negative pressure unit as abnormal state; Extract the negative pressure value of the negative pressure unit with the valve state closed; If the negative pressure value is 0, mark the operating state of the corresponding negative pressure unit as normal state; Otherwise, mark the operating state of the corresponding negative pressure unit as abnormal state.

3. The system of claim 2, wherein, In the data sensing module, the specific way to alarm and remind the abnormal state negative pressure unit is: Get all negative pressure units marked as abnormal state, extract the negative pressure unit number and the time stamp marked as abnormal state of the corresponding negative pressure unit, compose the alarm notification of the corresponding negative pressure unit, and transmit it to the operator.

4. The system of claim 2, wherein, In the adaptive control module, the specific way to calculate the qualified proportion of the negative pressure unit combined with the negative pressure redundancy interval is: Real-time extract the negative pressure units with normal state, and the total number is j; Randomly arrange j negative pressure units, denoted as negative pressure unit sequence Q1, Q2,..., Qj; Extract the current time, denoted as t0; At the current time t0, collect the negative pressure values of j negative pressure units respectively, and denote them as negative pressure value sequence P1, P2,..., Pj in the order of negative pressure unit sequence; Get the lowest negative pressure P_low and the negative pressure redundancy interval [P_min, P_max] preset by the operator; Extract any negative pressure unit Qi in the negative pressure unit sequence Q1, Q2,..., Qj, where i is the count index, and the value range is 1 to j; Extract the negative pressure value Pi of the negative pressure unit Qi, and get the redundancy negative pressure P_ry of the negative pressure unit Qi by Pi-P_low=P_ry. The redundant negative pressure P_ry is compared with the negative pressure redundancy interval. If P_ry∈[P_min, P_max], the negative pressure unit Qi is marked as qualified, otherwise, it is marked as unqualified; Similarly, the total number of negative pressure units marked as qualified in the j negative pressure units is determined, denoted as u; The qualified proportion HG of the negative pressure unit sequence Q1, Q2,..., Qj is calculated by HG=u / j×100%.

5. The system of claim 4, wherein, In the adaptive control module, the specific way of regulating the main output power of the main vacuum pump based on the value of the qualified proportion is: S51, obtain a preset qualified proportion threshold HG_yu; Obtain the total number of unqualified negative pressure units with redundant negative pressure less than P_min, denoted as x, and the total number of redundant negative pressure greater than P_max, denoted as y; If x>y, extract the qualified proportion HG at the current time t0; HG≥HG_yu, generate a main output power maintenance instruction; HG<HG_yu, generate a main output power up instruction; If x≤y and HG≥HG_yu, generate a main output power maintenance instruction; HG<HG_yu, generate a main output power down instruction; When generating the main output power maintenance instruction, the current main output power of the main vacuum pump is kept unchanged; S52, when generating the main output power up instruction, extract the main output power W_cur and the preset single power up step ΔW_up; S53, calculate the adjusted main output power W_adj=W_cur+ΔW_up, obtain the maximum working power W_max allowed by the main vacuum pump, if W_adj≤W_max, increase the main output power to W_adj at a preset adjustment rate, otherwise, increase it to W_max; S54, when generating the main output power down instruction, extract the current main output power of the main vacuum pump, denoted as W_cur and the preset single power down step ΔW_down; S55, calculate the adjusted main output power W_adj=W_cur-ΔW_down, obtain the minimum working power W_min allowed by the main vacuum pump, if W_adj≥W_min, decrease the main output power to W_adj at a preset adjustment rate, otherwise, decrease it to W_min; S56, after adjusting the main output power, continuously monitor for a control period, wherein the control period is a preset time period.

6. The system of claim 5, wherein, In the adaptive control module, the negative pressure values of each negative pressure unit are collected to calculate the qualified proportion, and the specific way of feeding back and controlling the main output power of the main vacuum pump is: S61, during a control period after adjusting the main output power, real-time extract the negative pressure values of each negative pressure unit and calculate the qualified proportion; S62, take the current time t0 as the start time of a control period, and determine the end time t1 of a control period; S63, extract the total number of time points from the current time t0 to the end time t1, denoted as m; S64, determine the m qualified proportions corresponding to the m time points, denoted as the qualified proportion sequence HG1, HG2,..., HGm in time order; S65, a two-dimensional coordinate system is constructed with the timeline as the horizontal axis and the qualified proportion value as the vertical axis, and the qualified proportion sequence HG1, HG2,..., HGm is marked in the form of data points in the constructed two-dimensional coordinate system, m data points are obtained, a curve fitting is performed, and a qualified proportion change curve L_HG is obtained; S66, the qualified proportion HGn corresponding to the highest peak on the curve L_HG is extracted, wherein n is a count index, and the value range is 1 to m, if the number of the highest peak is greater than 1, the qualified proportion of the highest peak closest to the current time t0 is taken; S67, if HGn≥HG_yu, the main output power corresponding to the qualified proportion HGn is taken as the preferred main output power, the main output power is regulated to the preferred main output power, the regulation is stopped, and the qualified proportion is monitored in real time; S68, wherein if the highest peak is at the end time t1, and the qualified proportion HGm corresponding to the end time t1 is HG_yu, the regulation mode of the current regulation period is repeated in the next regulation period.

7. The system of claim 6, wherein, In the redundancy coordination module, the standby vacuum pump is connected to the negative pressure pipeline based on the value of the qualified proportion, and the specific way of setting the standby output power corresponding to the qualified proportion is: If the main output power reaches the maximum main output power allowed by the main vacuum pump during the regulation of the main output power, and the qualified proportion is less than HG_yu, record the current time as t2, and mark the qualified proportion at time t2 as HG_t2; At time t2, the standby vacuum pump is connected to the negative pressure pipeline, and the standby output power is recorded as W_bc; Calculate the qualified proportion difference ΔHG=HG_yu-HG_t2 between the qualified proportion HG_t2 and HG_yu; The value of the standby output power is calculated by W_bc=(ΔHG / K)×W_max, wherein K is a power negative pressure compensation coefficient, which is preset by an operator; Get the maximum working power W_bc_max allowed by the standby vacuum pump; If W_bc≤W_bc_max, regulate the standby output power to W_bc, otherwise, regulate the standby output power to W_bc_max.

8. The system of claim 7, wherein, In the intelligent exit module, the specific way of implementing the standby vacuum pump exit mechanism is: After the standby vacuum pump is connected to the negative pressure pipeline, the current time is recorded as t3; Take time t3 as the start time of a regulation period, and determine the end time t4 of the regulation period; Real-time monitor the qualified proportion at each time from time t3 to time t4, and mark the sum of the standby output power and the main output power as the total output power according to the way described in steps S51 to S56, and take the total output power as the regulation object to generate a total output power maintaining instruction or a total output power up-regulation instruction; Then, adjust the total output power according to the way described in steps S61 to S68; Wherein, the standby output power is adjusted preferentially, and when the standby output power is less than the minimum working power W_bc_min allowed by the standby vacuum pump, the standby vacuum pump is turned off and exits the negative pressure pipeline.

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