Slurry pump adaptive control system and method based on current feedback

Abstract

A slurry pump self-adaptive control system based on current feedback comprises a signal detection unit, a core control unit and an execution mechanism unit, and the signal detection unit is used for collecting the running current value of a slurry pump motor in real time; the core control unit compares and calculates the real-time current value and a set current safety threshold value, generates a corresponding control instruction and sends the control instruction to the execution mechanism; the execution mechanism unit receives the instruction to control the opening degree of an electric valve on an outlet pipeline; a real-time, closed-loop and self-adaptive control loop is constructed, the opening degree of an outlet valve is dynamically adjusted, and the working current of a motor is accurately maintained in a preset safety interval, so that the problem of supercurrent caused by medium concentration fluctuation is thoroughly solved; by introducing an intelligent control algorithm, the system response is smoother and quicker, the trend can be predicted, the oscillation phenomenon in the control process is avoided, and the service life of actuating mechanisms such as a valve is prolonged.

Description

Technical Field

[0001] This invention relates to the field of equipment operation monitoring, and specifically to an adaptive control system and method for a mud pump based on current feedback. Background Technology

[0002] In industrial sectors such as power generation, mine tailings transportation, and municipal sludge treatment, mud pumps serve as core conveying equipment, and their operational stability and reliability directly affect the efficiency of the entire production system. The pumped media in these systems are generally characterized by complex composition, large viscosity fluctuations, and unstable solid particulate matter content (mud content), making them a time-varying and unpredictable source of strong disturbance.

[0003] Currently, to achieve automated start-up and shutdown, many mud pump systems are designed such that the outlet electric valve is fully open by default after the pump starts. This "open-loop" control mode works when the medium composition is stable, but when the mud content of the medium suddenly increases, its fluidity decreases sharply, causing a sudden increase in the pump's shaft power demand. To maintain the speed, the drive motor inevitably experiences a surge in operating current, which can exceed 150% of the rated current in severe cases. This "overcurrent" phenomenon can trigger a series of serious chain consequences, such as direct equipment damage: the motor windings burn out due to prolonged overload; the pump body experiences mechanical seal failure, bearing damage, or even shaft breakage due to excessive torque. Production interruption: the front-end circuit breaker or thermal relay trips to protect the motor, causing unplanned shutdowns and bringing the entire dredging or conveying process to a standstill. High maintenance costs: frequent fault repairs not only generate high costs for spare parts and labor, but also result in huge indirect economic losses due to production stoppages.

[0004] Existing monitoring and protection solutions for mud pumps mostly suffer from passive and delayed drawbacks: Monitoring and alarm type: The system only has current or pressure monitoring instruments, issuing audible and visual alarms when limits are exceeded. This solution relies entirely on manual operator response, proving ineffective at night or in unattended conditions, and cannot prevent accidents. Hard trip type: Overload protection components (such as thermal relays) in the electrical circuit cut off the power supply after sustained overcurrent. This is a "post-accident remedy," protecting the equipment but also causing production interruptions, and frequent hard starts and stops damage the motor and pump itself. Pressure control type: Some systems regulate operating conditions by monitoring pump outlet pressure. However, pressure changes are less sensitive than current changes, and the linear relationship between pressure and load is distorted when viscosity changes, resulting in poor control effectiveness.

[0005] Therefore, those skilled in the art have long faced a pressing technical challenge: how to design an intelligent control system that can proactively, in real time and smoothly adapt to changes in medium concentration, automatically adjust the operating load, and ensure that the mud pump always operates within a safe current range, thereby fundamentally eliminating "overcurrent" accidents and achieving a leap from "passive protection" to "active prevention". Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention aims to provide an adaptive control system and method for preventing overcurrent in mud pumps based on current feedback. Its core objective is to construct a real-time, closed-loop, adaptive control circuit to dynamically adjust the outlet valve opening, precisely maintaining the motor operating current within a preset safe range, thereby completely resolving the persistent overcurrent problem caused by fluctuations in medium concentration.

[0007] Another objective of this invention is to introduce intelligent control algorithms to make the system response smoother and faster, predict trends, avoid oscillations during the control process, and extend the service life of actuators such as valves.

[0008] The present invention also aims to provide a modular, easy-to-integrate, and widely applicable system architecture that can be flexibly adapted to various types of mud pumps based on different principles, such as plunger and centrifugal pumps, to enable low-cost and high-efficiency automated upgrades of existing equipment.

[0009] The technical solution adopted in this invention is: An adaptive control system for a mud pump based on current feedback, comprising: a signal detection unit, a core control unit, and an actuator unit, characterized in that: The signal detection unit is used to collect the operating current value of the mud pump motor in real time; The core control unit compares and calculates the real-time current value with the set current safety threshold, generates corresponding control commands, and sends them to the actuator. The actuator unit receives instructions to control the opening degree of the electric valve on the outlet pipeline.

[0010] Furthermore, it also includes a human-machine interface unit for setting the safe operating range of the current and displaying operating data in real time.

[0011] Furthermore, the signal detection unit includes a high-precision current transmitter coupled to the power line of the mud pump motor.

[0012] Furthermore, the core control unit adopts an industrial-grade programmable logic controller (PLC). The PLC's analog input module receives signals from the current transmitter and internally stores and runs pre-programmed control algorithms.

[0013] Furthermore, the actuator unit includes an electric actuator and an outlet pipeline regulating valve connected thereto. The actuator receives a control signal from the PLC and drives the valve core of the regulating valve to move, thereby realizing continuous adjustment of the valve opening within the range of 0% to 100%.

[0014] Furthermore, the human-machine interface unit uses a color touchscreen and is connected to the PLC via a communication bus.

[0015] Furthermore, the PLC is equipped with a PID control module and an intelligent optimization module. The intelligent optimization module works in conjunction with the PID control module and provides predictive analysis and drive optimization, including trend prediction algorithms and anti-oscillation algorithms.

[0016] Furthermore, the PID control module runs the PID control algorithm and outputs the corresponding electric actuator opening signal to control the electric actuator's action. When the current sensor detects that the motor current is close to or exceeds the set upper limit, the PLC immediately outputs a signal to reduce the opening of the outlet valve. By closing the valve, the pipeline resistance is increased, the pump load is reduced, and the motor current is thus reduced back to the safe range. Conversely, when the current is lower than the set lower limit, the output signal increases the valve opening, thereby reducing pipeline resistance, increasing flow, ensuring efficiency, and causing the current to rise again. Maintain the current valve opening when the current is within the safe zone between the upper and lower lines.

[0017] Furthermore, the trend prediction algorithm receives the data collected by the current sensor, stores the data, and makes trend predictions based on historical data. The predicted value is then used as a correction value and input into the PID control module. After correcting the real-time current data, the PID algorithm is executed to perform predictive adjustment.

[0018] Furthermore, the anti-oscillation algorithm preprocesses the signal output to the electric actuator, subdividing the adjustment signal into several small step adjustment amounts, which are applied sequentially to smoothly control the valve and avoid system oscillation.

[0019] Compared with the prior art, the present invention has the following beneficial effects: This system is specifically designed to address the industry pain point of "motor overload caused by large fluctuations in the mud content of the medium." It achieves direct, real-time, closed-loop linkage control between the "pump current signal" and the "outlet valve opening," dynamically adjusting the outlet valve opening to precisely maintain the motor operating current within a preset safe range, thus completely resolving the persistent problem of overcurrent caused by fluctuations in medium concentration. By introducing intelligent control algorithms, the system response is smoother and faster, and it can predict trends, avoiding oscillations during the control process, extending the service life of valves and other actuators. With high control precision, it represents a qualitative leap from "monitoring" to "control," fundamentally different from control systems that only monitor pressure or remotely start / stop. This system can be applied to different pump types, such as plunger-type mud pumps or anti-clogging mud pumps. Attached Figure Description

[0020] Figure 1 This is a flowchart. Detailed Implementation The present invention will be further described below with reference to the accompanying drawings and embodiments. The embodiments of the present invention include, but are not limited to, the following embodiments.

[0021] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is described as "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is described as "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," "top," "bottom," and similar expressions used in this document are for illustrative purposes only.

[0022] An adaptive control system for preventing overcurrent in mud pumps based on current feedback, comprising: The signal detection unit includes a high-precision current transmitter. This transmitter is precisely coupled to the power line of the mud pump motor to acquire the motor's operating current value in real time and continuously, and convert it into a standard analog signal (such as 4-20mA DC) that can be recognized by the controller.

[0023] The core control unit employs an industrial-grade programmable logic controller (PLC). The PLC's analog input module receives signals from the current transmitter, and internally stores and runs pre-programmed control algorithms. The PLC compares and calculates the real-time current value with user-defined safety thresholds (upper and lower limits), generates corresponding control commands, and sends them to the actuators through its analog output module.

[0024] The actuator unit includes an electric actuator and an outlet pipeline regulating valve connected to it. The actuator receives analog control signals (such as 4-20mA DC or 0-10V DC) from the PLC and drives the valve core of the regulating valve to achieve stepless, precise, and continuous adjustment of the valve opening within the range of 0% to 100%. Preferably, the valve should have wear-resistant properties (such as ceramic lining or hard alloy seal) to withstand the erosion of mud media.

[0025] The human-machine interface unit (HMI) uses a color touchscreen and connects to the PLC via a communication bus (such as RS485 or Ethernet) to provide the operator with a visual interface. The operator can flexibly set the safe operating upper limit (such as 95% of the rated current) and lower limit of the motor current on the HMI, and monitor key parameters such as the real-time current curve, valve opening percentage, and system alarm status in real time.

[0026] The auxiliary supporting units include a power module that supplies power to the entire system, a protective control cabinet that houses all electrical components, and compliant connection cables and terminals.

[0027] As shown in the figure, the control method of the present invention, based on the above hardware system, implements the following closed-loop control process, and its core logic is shown in the flowchart below.

[0028] After system initialization, the current safety value is set via the human-machine interface unit.

[0029] When a mud pump is operating on-site, changes in its load will cause corresponding changes in current. The current changes on the power line are collected in real time by a current sensor, converted into an analog signal, and then input into the PLC for control calculations.

[0030] The PLC is equipped with a PID control module and an intelligent optimization module.

[0031] The PID control module runs the PID (proportional-integral-derivative) control algorithm.

[0032] Proportional component (P): Deviation between fast response current and set value.

[0033] Integral section (I): Eliminates static error and ensures that the current eventually stabilizes at the set value.

[0034] Differential part (D): Predictive adjustment is made based on the trend and rate of current change, thereby suppressing overshoot, making valve operation smoother, significantly avoiding severe oscillations in the system, and protecting the equipment.

[0035] The PID control module outputs the corresponding electric actuator opening signal to control the electric actuator's operation.

[0036] When the current sensor detects that the motor current is close to or exceeds the set upper limit, the PLC immediately outputs a signal to reduce the opening of the outlet valve. By closing the valve, the pipeline resistance is increased, reducing the pump load and thus causing the motor current to drop back to a safe range. Conversely, when the current is lower than the set lower limit, the output signal increases the valve opening, thereby reducing pipeline resistance, increasing flow, ensuring efficiency, and causing the current to rise again.

[0037] Maintain the current valve opening when the current is within the safe zone between the upper and lower lines.

[0038] The intelligent optimization module works in conjunction with the PID control module, providing predictive analysis and drive optimization. This includes trend prediction algorithms and anti-oscillation algorithms.

[0039] The trend prediction algorithm receives data collected by the current sensor, stores it, and makes trend predictions based on historical data. These predictions are then input as correction values ​​into the PID control module. After correcting the real-time current data, the PID algorithm is executed, enabling predictive adjustment. For example, based on the current change trend and the rate of continuous increase, a negative correction value is derived from the prediction, thereby reducing the real-time current data and avoiding over-adjustment of the control valve.

[0040] In addition, the anti-oscillation algorithm preprocesses the signal output to the electric actuator, subdividing the adjustment signal into several small step adjustment amounts, which are applied sequentially to control the valve more smoothly and avoid system oscillation.

[0041] In the technical solution of the present invention, This system achieves closed-loop control of the control variable, using the "real-time motor current," the most direct electrical parameter reflecting the load, as the controlled variable. This, along with the "outlet valve opening," forms a direct, real-time, and efficient closed-loop negative feedback control system. This is fundamentally different from open-loop or semi-open-loop systems that only monitor pressure or remotely start / stop, representing a qualitative leap from "monitoring" to "control." It possesses excellent engineering applicability and economic efficiency; all core components are mature industrial products with reliable technology and controllable costs. This project offers extremely high cost-effectiveness and return on investment, and is easily promoted and popularized within the industry.

[0042] This invention provides a complete solution that is technologically advanced, logically rigorous, reliable in implementation, and economically beneficial. It precisely addresses the core pain points of mud pumps under complex working conditions, possessing strong practical value and broad industrial application prospects.

[0043] Finally, it should be noted that the above description is merely an explanation of the present invention and is not intended to limit the invention. Although the present invention has been described in detail, those skilled in the art can still modify the technical solutions described above or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An adaptive control system for a mud pump based on current feedback, comprising: The signal detection unit, core control unit, and actuator unit are characterized by: The signal detection unit is used to collect the operating current value of the mud pump motor in real time; The core control unit compares and calculates the real-time current value with the set current safety threshold, generates corresponding control commands, and sends them to the actuator. The actuator unit receives instructions to control the opening degree of the electric valve on the outlet pipeline.

2. The adaptive control system for a mud pump based on current feedback according to claim 1, characterized in that, It also includes a human-machine interface unit, which is used to set the safe operating range of the current and display the operating data in real time.

3. The adaptive control system for a mud pump based on current feedback according to claim 1, characterized in that, The signal detection unit includes a high-precision current transmitter, which is coupled to the power line of the mud pump motor.

4. The adaptive control system for a mud pump based on current feedback according to claim 1, characterized in that, The core control unit uses an industrial-grade programmable logic controller (PLC). The PLC's analog input module receives signals from the current transmitter and internally stores and runs pre-programmed control algorithms.

5. The adaptive control system for a mud pump based on current feedback according to claim 1, characterized in that, The actuator unit includes an electric actuator and an outlet pipeline regulating valve connected thereto. The actuator receives control signals from the PLC and drives the valve core of the regulating valve to move, so as to continuously adjust the valve opening within the range of 0% to 100%.

6. The adaptive control system for a mud pump based on current feedback according to claim 1, characterized in that, The human-machine interface unit uses a color touch screen and is connected to the PLC via a communication bus.

7. The adaptive control system for a mud pump based on current feedback according to claim 4, characterized in that, The PLC is equipped with a PID control module and an intelligent optimization module. The intelligent optimization module works in conjunction with the PID control module and provides predictive analysis and drive optimization, including trend prediction algorithms and anti-oscillation algorithms.

8. The adaptive control system for a mud pump based on current feedback according to claim 7, characterized in that, The PID control module runs the PID control algorithm and outputs the corresponding electric actuator opening signal to control the electric actuator's action. When the current sensor detects that the motor current is close to or exceeds the set upper limit, the PLC immediately outputs a signal to reduce the opening of the outlet valve. By closing the valve, the pipeline resistance is increased, the pump load is reduced, and the motor current is thus reduced back to the safe range. Conversely, when the current is lower than the set lower limit, the output signal increases the valve opening, thereby reducing pipeline resistance, increasing flow, ensuring efficiency, and causing the current to rise again. Maintain the current valve opening when the current is within the safe zone between the upper and lower lines.

9. The adaptive control system for a mud pump based on current feedback according to claim 7, characterized in that, The trend prediction algorithm receives data collected by the current sensor, stores the data, and makes trend predictions based on historical data. The predicted value is then used as a correction value and input into the PID control module. After correcting the real-time current data, the PID algorithm is executed to perform predictive adjustment.

10. The adaptive control system for a mud pump based on current feedback according to claim 7, characterized in that, The anti-oscillation algorithm preprocesses the signal output to the electric actuator, subdivides the adjustment signal into several small step adjustment amounts, and applies them sequentially to smoothly control the valve and avoid system oscillation.

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