Operation control and scheduling method for rotational flow pool pump set

Abstract

The invention provides an operation control and scheduling method for a rotational flow pool pump set, and belongs to the technical field of metallurgical equipment automation control. The operation control and scheduling method comprises the steps that S1, multi-dimensional data collection and persistent storage are conducted; s2, constructing a pump set working condition evaluation model; s3, executing an intelligent scheduling strategy; s4, performing adaptive processing on abnormal working conditions; and S5, manual intervention and maintenance decision support. According to the operation control and scheduling method for the rotational flow pool pump set, accurate sensing, balanced scheduling and energy consumption optimization of the operation state of the pump set are achieved by constructing the multi-dimensional working condition evaluation model and the multi-target intelligent scheduling algorithm, the operation efficiency is effectively improved, and the service life of equipment is prolonged; the system has a data full-life-cycle storage tracing and abnormity self-adaptive processing mechanism, supports predictive maintenance and rapid fault response, and gives consideration to the functions of full-automatic intelligent scheduling and manual intervention, thereby reducing the maintenance cost and the risk of non-planned shutdown while guaranteeing the operation reliability and continuity.

Description

Technical Field

[0001] This application relates to the field of automation control technology for metallurgical equipment, and in particular to a method for operation control and scheduling of a cyclone pool pump set. Background Technology

[0002] In the production of heavy plate steel rolling, the cyclone pool, as a key auxiliary facility, undertakes important tasks such as collecting, temporarily storing, and transporting cooling water, rinsing water, and rainwater from the rolling line. The stability of its water level directly affects the continuity and safety of the rolling line operation. The booster pump unit, as the core power equipment of the cyclone pool system, is responsible for promptly draining the accumulated water in the pool to the subsequent water treatment system, preventing overflow or excessively high water levels from affecting production. Currently, such pump unit systems in metallurgical enterprises mostly adopt operation methods based on fixed-sequence rotation, manual experience-based scheduling, or simple time-sequence control, lacking systematic, adaptive, and intelligent scheduling strategies.

[0003] The existing technologies have the following main shortcomings: 1) Uneven load distribution among pump sets. Most systems use simple time-sharing or sequential start-up methods without considering the actual operating status, historical working time, number of start-stop cycles, and performance degradation of each pump. This leads to some pumps operating at high loads for extended periods, exacerbating wear, while standby pumps, left idle for long periods, are prone to corrosion and jamming, affecting system reliability. 2) Insufficient energy efficiency optimization. Traditional control methods do not incorporate real-time flow, motor current, drainage efficiency, and other operating parameters for dynamic scheduling, making it difficult to achieve optimal overall pump set energy efficiency while ensuring drainage needs are met, resulting in energy waste. 3) Lack of status monitoring and early warning. Existing systems typically lack pump performance degradation identification functions based on the fusion of multiple parameters such as flow and current. They cannot determine in real time whether the pump's operation deviates from normal operating conditions, resulting in delayed anomaly detection, slow maintenance response, and a tendency for faults to escalate. 4) Weak data persistence and decision support. Key data such as pump and motor operating time and number of start-stop cycles are usually not stored non-volatilely. Data is lost after system restarts, making it impossible to support predictive maintenance and periodic maintenance planning based on accumulated data. 5) Poor scheduling flexibility. Under abnormal operating conditions (such as decreased pump efficiency or motor overcurrent), the system often cannot automatically adjust the scheduling sequence and will still call the abnormal pump in the original order, affecting drainage efficiency and increasing equipment risk.

[0004] As the steel industry transforms towards intelligent and green operations, higher demands are being placed on energy conservation, consumption reduction, and refined equipment management in steel rolling production lines. The shortcomings of existing cyclone pump unit operation control and scheduling methods in terms of intelligence, operational economy, and equipment reliability have become significant factors restricting the efficient and green operation of heavy plate steel rolling production lines. Therefore, developing an operation control and scheduling method capable of accurate assessment of pump unit operating conditions, intelligent scheduling optimization, full lifecycle management of equipment status, and adaptive handling of abnormal operating conditions has significant engineering application value and practical significance. Summary of the Invention

[0005] This application is made in view of the above-mentioned problems, and its purpose is to provide a method for operation control and scheduling of a cyclone pool pump set to solve the problems mentioned in the background art. To achieve the above objectives, the present invention provides the following technical solution: a method for operation control and scheduling of a cyclone pool pump group, comprising four lift pumps configured in the cyclone pool, each lift pump corresponding to an independent drive motor. The method is based on a PLC control system and a data acquisition module, integrating pump group operating parameters, motor status parameters, and cyclone pool liquid level parameters. Through a multi-dimensional operating condition evaluation model and an intelligent scheduling algorithm, it achieves intelligent control and scheduling of the pump group throughout the entire process, specifically including the following five core steps: S1. Multi-dimensional data acquisition and persistent storage: After the control system starts, it reads the historical running time and number of starts of the pump group, and performs data statistics based on the real-time running data; S2. Pump set operating condition assessment model construction: Based on the data during pump operation, calculate the efficiency assessment index and health status index of each pump set in real time, and give the comprehensive operating condition level; S3. Intelligent scheduling strategy execution: Based on the intelligent scheduling operation strategy, the number of pumps in operation and the starting sequence are determined by the liquid level height and its changing trend, and the pump's operating condition level. S4. Adaptive handling of abnormal operating conditions: Based on the abnormal judgment model, the operation status of the pump set is monitored in real time, the pump sequence is adjusted, and a fault abnormality file is generated. S5. Manual Intervention and Maintenance Decision Support: Based on the maintenance threshold of the running time, prompts and records the time log, and performs manual control and locking in special circumstances.

[0006] Furthermore, the specific operation of step S1 is as follows: the operating flow rate of each pump, the operating current of the motor, the start-up response time, and the real-time liquid level data of the vortex pool are collected in real time through the flow sensor, the current sensor, and the liquid level sensor. The cumulative running time and cumulative start-up count of each pump, as well as the cumulative running time and cumulative start-up count of the corresponding motor, are stored in a holding register. The data is not lost after the equipment is restarted, and is only cleared by authorized operation when the pump body or motor is replaced.

[0007] Furthermore, step S2 includes the following sub-steps: S21. Efficiency evaluation index: Calculate the ratio of the actual operating flow rate of the pump to the rated flow rate, and combine it with the motor input power to obtain the pump set operating efficiency; S22. Health status indicators: The operating status of the pump set is evaluated based on the pump start-up response time (time from start-up to the flow rate reaching the rated value), the flow rate fluctuation coefficient and the motor current fluctuation coefficient during operation, combined with historical data thresholds. S23. Comprehensive operating condition level: Based on efficiency evaluation indicators and health status indicators, a weighted scoring method is used to classify the operating conditions of each pump into four levels: optimal operating condition, good operating condition, general operating condition, and abnormal operating condition.

[0008] Furthermore, step S3 specifically includes: Fully automatic optimized scheduling mode: Prioritize the selection of pumps with optimal and good operating conditions to participate in operation. Combine the cumulative running time and number of starts of pumps and motors, and adopt a balanced scheduling algorithm to prioritize the scheduling of pumps with the shortest cumulative running time and the fewest starts, so as to ensure that the running time deviation of each pump and motor is controlled within the set threshold. At the same time, the number of operating pump groups is dynamically adjusted according to the liquid level change rate of the cyclone pool. Operating cycle switching mechanism: Set the upper limit of continuous operation time of a single pump group. When the continuous operation of a single pump reaches the set upper limit, it will automatically switch to the standby pump with the best operating conditions and the shortest cumulative operating time. Motor and pump coordinated scheduling mode: Two optional modes are provided: pump body priority scheduling and motor priority scheduling. When motor priority scheduling is selected, the core objective is to balance the cumulative running time and number of starts of the motor.

[0009] Furthermore, step S4 includes the following sub-steps: S41. Abnormality Identification: When the actual operating flow of the pump is lower than 75% of the rated flow, or the motor operating current exceeds 120% of the rated current, or the pump start-up response time exceeds 2.5 times the set threshold, the system automatically determines it to be an abnormal operating condition. S42. Abnormal Handling: The system immediately displays the abnormal pump number, abnormality type and fault prompt information on the monitoring screen, and lowers the scheduling priority of the pump to the lowest level. It will only be started as an emergency backup pump when the liquid level in the cyclone pool reaches the highest warning value. At the same time, the system automatically adjusts the operating parameters of the remaining pump sets to ensure that the liquid level in the cyclone pool is maintained within a safe range. S43. Fault Recording and Traceability: Automatically records the time of occurrence of abnormal operating conditions, duration, relevant parameter change curves and handling measures, forming a fault file.

[0010] Furthermore, in step S5, the cyclone pool pump system supports a manual intervention mode. Operators can manually adjust the pump operation sequence and lock the operating status of a specified pump through the monitoring interface. It also supports personalized configuration of scheduling parameters, including the upper limit of single continuous operation time, the operating time deviation threshold, and the abnormal operating condition judgment threshold. When the cumulative operating time of the pump or motor reaches the maintenance cycle, the system automatically prompts the offline maintenance information.

[0011] Compared with existing technologies, the present invention has the following advantages: By constructing a multi-dimensional operating condition evaluation model and a multi-objective intelligent scheduling algorithm, the present invention achieves accurate perception, balanced scheduling and energy consumption optimization of pump unit operating status, effectively improving operating efficiency and extending equipment service life; at the same time, the system has a data lifecycle storage and traceability and anomaly adaptive processing mechanism, supports predictive maintenance and rapid fault response, and takes into account fully automatic intelligent scheduling and manual intervention functions, thereby reducing maintenance costs and unplanned downtime risks while ensuring operational reliability and continuity. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this drawing 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 this drawing. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the system structure of the cyclone pool lift pump unit of the present invention; Figure 2 This is a flowchart of the operation control and scheduling method for the cyclone pool pump set of the present invention; Figure 3 This is a flowchart illustrating the operation control steps of the cyclone pool pump unit of the present invention.

[0014] The purpose, features, and advantages of this accompanying drawing will be further explained in conjunction with the embodiments and with reference to the accompanying drawing. Detailed Implementation

[0015] To make the objectives, technical solutions, and advantages of this application clearer, the following description and illustration are provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. All other embodiments obtained by those skilled in the art based on the embodiments provided in this application without inventive effort are within the scope of protection of this application.

[0016] Obviously, the following description is merely some examples or embodiments of this application. Those skilled in the art can apply this application to other similar scenarios without any inventive effort. Furthermore, it is understood that although the effort involved in such development may be complex and lengthy, for those skilled in the art related to the content disclosed in this application, any changes to design, manufacturing, or production based on the technical content disclosed in this application are merely conventional technical means and should not be construed as insufficient disclosure of the content of this application.

[0017] Unless otherwise specified, the terms "comprising" and "including" as used in this application can be open-ended or closed-ended. For example, "comprising" and "including" can mean that other components not listed may also be included, or that only the listed components may be included.

[0018] Unless otherwise specified, the term "or" is inclusive in this application. For example, the phrase "A or B" means "A, B, or both A and B". More specifically, the condition "A or B" is satisfied by any of the following conditions: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); or both A and B are true (or exist).

[0019] Terminology explanation: such as Figures 1-3 As shown, a method for operation control and scheduling of a cyclone pool pump set is presented. Based on the existing PLC control system of the cyclone pool and on-site pump outlet electromagnetic flow sensors, liquid level sensors, and motor current detection modules, all sensor data are transmitted to the PLC control system in real time through a data acquisition module. The monitoring terminal uses WinCC to display data, configure parameters, and perform manual operation. A scheduling algorithm program is written in the PLC, including a data acquisition module, a health assessment module, a pump count decision module, a working condition optimization module, and an anomaly handling module. The HMI interface displays the real-time operating status of each pump (running / standby / fault), parameter data (running time, number of starts, drainage flow, etc.), health score, scheduling sequence, and alarm information. It supports manual adjustment of scheduling priority and locking of specific pumps. All data is stored in a holding register with power-off protection. The register can be manually reset when a pump or motor is replaced, and a maintenance reminder is automatically triggered when the rated operating cycle is reached. The specific implementation steps are as follows: Step S1: Data Acquisition and Storage of Pump Set Statistical Information. The data acquisition module collects real-time data on the operating flow rate, outlet pressure, motor operating current, start-up response time, and real-time liquid level of the cyclone pool for the four pump sets according to the specified sampling period, and transmits the data to the PLC control system; the holding register stores the cumulative operating time, cumulative number of starts, and pump operating condition level information of the pump sets.

[0020] Step S2: Pump Set Operating Condition Assessment. The PLC control system calculates the operating condition assessment indicators for each pump in real time based on the pump operation data. These include: an efficiency assessment indicator (the ratio of the actual outlet flow rate to the rated flow rate); and a health status indicator (the ratio of the pump set's response time from startup to normal flow rate to the flow rate during operation, i.e., the ratio of the standard deviation to the average value, compared to a preset threshold). The overall operating condition level is calculated by weighting the efficiency assessment indicator (0.6), the response time (0.3), and the flow rate fluctuation (0.1) indicators. A score of 85 or above is considered optimal, 70-85 is good, 50-70 is average, and below 50 is abnormal.

[0021] Step S3: Execution of intelligent scheduling strategy. When the system is in fully automatic optimized scheduling mode, the intelligent scheduling module in the PLC control system schedules operation according to the following rules based on the cyclone pool level: When the liquid level is greater than L1, start one optimal operating pump unit; when it is less than L1-h, all pump units stop operating.

[0022] When the liquid level is greater than L2, start another pump unit with the highest operating condition and the highest number of pump unit runs; when the liquid level is less than L2-h, shut down one pump unit with the lowest operating condition and the highest number of pump unit runs.

[0023] When the liquid level is greater than L3, start another pump unit with the highest operating condition and the highest number of pump unit runs; when the liquid level is less than L3-h, shut down one pump unit with the lowest operating condition and the highest number of pump unit runs.

[0024] When the liquid level is greater than L4, start all non-faulty pump units; when it is less than L4-h, shut down one pump unit with the lowest combined operating condition and running time / number of cycles.

[0025] Meanwhile, when each pump's continuous operating time reaches 8 hours (set upper limit), or when the cumulative operating time deviates from that of other pumps by more than 10%, the system automatically switches to the pump with the optimal operating condition and the shortest cumulative operating time. When the motor priority scheduling mode is selected, the scheduling algorithm aims to balance the cumulative operating time and number of starts of the motor, prioritizing the pump with the shortest cumulative operating time to participate in operation, ensuring a balanced motor operating load.

[0026] Step S4: Abnormal Operating Condition Handling. When the actual operating flow rate of a pump is lower than 75% of the rated flow rate, or the motor operating current exceeds 120% of the rated current, or the start-up response time exceeds 2.5 times the set threshold, an abnormal operating condition is determined. The HMI terminal immediately displays the abnormal pump number, abnormal type, and fault message. The intelligent scheduling program lowers the scheduling priority of this pump to the lowest level, activating it only when the cyclone pool level exceeds the emergency threshold. Simultaneously, the system automatically adjusts the operating sequence of the remaining pump groups to ensure the stability of the cyclone pool level within the corresponding range. Fault data is automatically stored in the historical database, forming a fault file that supports querying and tracing.

[0027] Step S5: Maintenance Decision and Manual Intervention. When the running time reaches the maintenance threshold, a prompt message will pop up on the HMI terminal, and the event log will be recorded. When encountering special production needs or equipment maintenance, operators can switch to manual mode through the HMI terminal to manually select the pump to run, adjust the running sequence, or lock a specified pump to stop running. At the same time, parameters such as the upper limit of single continuous running time and the running time deviation threshold can be adjusted through the parameter configuration interface to adapt to different operating conditions.

[0028] Through the above implementation methods, this embodiment realizes intelligent operation control and scheduling of the cyclone pool pump group in the heavy plate rolling mill production line, effectively improving operational stability and economy, extending equipment service life, and providing a reliable guarantee for the efficient and green operation of the rolling mill production line.

[0029] It should be noted that this application is not limited to the above-described embodiments. The above embodiments are merely examples, and any embodiments with the same structure and effect as the technical concept within the scope of this application are included in the technical scope of this application. Furthermore, various modifications that can be conceived by those skilled in the art to the embodiments, and other ways of constructing by combining some of the constituent elements of the embodiments, without departing from the spirit of this application, are also included in the scope of this application.

Claims

1. A method for operation control and scheduling of a cyclone pool pump set, characterized in that, The cyclone pool is equipped with four lift pumps, each with an independent drive motor. The method, based on a PLC control system and data acquisition module, integrates pump operating parameters, motor status parameters, and cyclone pool liquid level parameters. Through a multi-dimensional operating condition evaluation model and intelligent scheduling algorithm, it achieves intelligent control and scheduling of the pump set throughout the entire process, specifically including the following five core steps: S1. Multi-dimensional data acquisition and persistent storage: After the control system starts, it reads the historical running time and number of starts of the pump group, and performs data statistics based on the real-time running data; S2. Pump set operating condition assessment model construction: Based on the data during pump operation, calculate the efficiency assessment index and health status index of each pump set in real time, and give the comprehensive operating condition level; S3. Intelligent scheduling strategy execution: Based on the intelligent scheduling operation strategy, the number of pumps in operation and the starting sequence are determined by the liquid level height and its changing trend, and the pump's operating condition level. S4. Adaptive handling of abnormal operating conditions: Based on the abnormal judgment model, the operation status of the pump set is monitored in real time, the pump sequence is adjusted, and a fault abnormality file is generated. S5. Manual Intervention and Maintenance Decision Support: Based on the maintenance threshold of the running time, prompts and records the time log, and performs manual control and locking in special circumstances.

2. The method for operation control and scheduling of a cyclone pool pump set according to claim 1, characterized in that, The specific operation of step S1 is as follows: The operating flow rate, motor operating current, start-up response time and real-time liquid level data of each pump are collected in real time through flow sensor, current sensor and liquid level sensor, and the cumulative running time and cumulative start-up number of each pump, as well as the corresponding motor, are stored in holding registers.

3. The method for operation control and scheduling of a cyclone pool pump set according to claim 2, characterized in that, The data stored in the holding register is not lost after the device is restarted, and is only cleared by authorized operation when the pump body or motor is replaced.

4. The method for operation control and scheduling of a cyclone pool pump set according to claim 1, characterized in that, Step S2 includes the following sub-steps: S21. Efficiency evaluation index: Calculate the ratio of the actual operating flow rate of the pump to the rated flow rate, and combine it with the motor input power to obtain the pump set operating efficiency; S22. Health status indicators: The operating status of the pump set is evaluated based on the pump start-up response time, flow fluctuation coefficient during operation, motor current fluctuation coefficient, and historical data thresholds. S23. Comprehensive operating condition level: Based on efficiency evaluation indicators and health status indicators, a weighted scoring method is used to classify the operating conditions of each pump into four levels: optimal operating condition, good operating condition, general operating condition, and abnormal operating condition.

5. The method for operation control and scheduling of a cyclone pool pump set according to claim 1, characterized in that, Step S3 specifically includes: Fully automatic optimized scheduling mode: Prioritize the selection of pumps with optimal and good operating conditions to participate in operation. Combine the cumulative running time and number of starts of pumps and motors, adopt a balanced scheduling algorithm to prioritize the scheduling of pumps with the shortest cumulative running time and the fewest number of starts. At the same time, dynamically adjust the number of operating pump groups according to the rate of change of liquid level in the cyclone pool. Operating cycle switching mechanism: Set the upper limit of continuous operation time of a single pump group. When the continuous operation of a single pump reaches the set upper limit, it will automatically switch to the standby pump with the best operating conditions and the shortest cumulative operating time. Motor and pump coordinated scheduling mode: Two optional modes are provided: pump body priority scheduling and motor priority scheduling. When motor priority scheduling is selected, the core objective is to balance the cumulative running time and number of starts of the motor.

6. The method for operation control and scheduling of a cyclone pool pump set according to claim 1, characterized in that, Step S4 includes the following sub-steps: S41. Abnormality Identification: When the actual operating flow of the pump is lower than 75% of the rated flow, or the motor operating current exceeds 120% of the rated current, or the pump start-up response time exceeds 2.5 times the set threshold, the system automatically determines it to be an abnormal operating condition. S42. Abnormal Handling: The system immediately displays the abnormal pump number, abnormal type and fault prompt information on the monitoring screen, and lowers the scheduling priority of the pump to the lowest level, while automatically adjusting the operating parameters of the remaining pump groups. S43. Fault Recording and Traceability: Automatically records the time of occurrence of abnormal operating conditions, duration, relevant parameter change curves and handling measures, forming a fault file.

7. The method for operation control and scheduling of a cyclone pool pump set according to claim 6, characterized in that, The pump with the lowest scheduling priority is activated only as an emergency backup pump when the liquid level in the vortex pool reaches the highest warning value.

8. The method for operation control and scheduling of a cyclone pool pump set according to claim 1, characterized in that, In step S5, the cyclone pool pump system supports a manual intervention mode. Operators can manually adjust the pump operation sequence and lock the operating status of a specified pump through the monitoring interface. It also supports personalized configuration of scheduling parameters, including the upper limit of single continuous operation time, the operating time deviation threshold, and the abnormal operating condition judgment threshold. When the cumulative operating time of the pump or motor reaches the maintenance cycle, the system will automatically prompt the offline maintenance information.

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