Intelligent control system for cooling circulating water in a forging plant

Abstract

The application is a forging workshop cooling circulating water intelligent control system according to load size, relates to the technical field of industrial cooling and intelligent control, and comprises: a multi-source load signal real-time acquisition module; a cooling pipeline electric butterfly valve linkage control module; a circulating water pressure PID control module; and a circulating water temperature monitoring and PID control module.In the application, the real-time acquisition of multi-source load signals and the linkage control of the cooling pipeline butterfly valve realize no-delay response of water supply when the equipment starts and water cut-off when the equipment stops, avoid energy waste caused by no-load water supply from the source; at the same time, the double-PID closed-loop control of circulating water pressure and temperature can dynamically adjust the frequency of the water pump frequency converter, the rotating speed of the cooling tower fan and the start-stop number of the units according to load changes, so that the running power of the cooling system is always accurately matched with the actual demand, and the energy consumption is reduced compared with the traditional constant-flow system.

Description

Technical Field

[0001] This invention relates to the field of industrial cooling and intelligent control technology, and in particular to an intelligent control system for cooling circulating water in forging workshops based on load. Background Technology

[0002] The cooling circulating water system in the forging workshop is a core supporting facility for ensuring the continuous and stable operation of forging equipment. Traditional systems generally adopt a constant flow water supply combined with manual experience-based adjustment. Under this mode, regardless of the load of the forging line in the workshop or the start-up and shutdown status of the equipment, the water pumps and cooling tower fans always maintain full load operation. This not only results in serious energy waste during idle periods (statistically, idle energy consumption accounts for more than 30%), but also, because it cannot dynamically match the cooling demand after load changes, it is prone to cooling response lag when the equipment load changes abruptly, leading to overheating and shutdown of the forging equipment, thereby affecting production efficiency and product precision.

[0003] In existing technologies, although some cooling systems have introduced PID closed-loop control technology to regulate pressure or temperature, such solutions have not achieved deep linkage between load signals and cooling actions, nor have they been adapted to the scenario of multiple parallel lines and frequent and large load fluctuations in forging workshops. They cannot fundamentally solve the core need for on-demand cooling and still have problems such as insufficient control accuracy and limited energy consumption optimization, making it difficult to meet the high-efficiency production requirements of modern forging workshops.

[0004] Therefore, an intelligent control system for the cooling circulating water in the forging workshop based on the load size is proposed to address the aforementioned problems. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent control system for cooling circulating water in forging workshops based on load size in order to solve the above-mentioned problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: The intelligent control system for cooling circulating water in the forging workshop, based on load size, includes: The multi-source load signal real-time acquisition module is configured to acquire the working status signals of each forging line in the workshop in real time; The cooling pipeline electric butterfly valve linkage control module is configured to automatically open and close the electric butterfly valve of the corresponding cooling circulation pipeline according to the on / off status of the equipment control button; The circulating water pressure PID control module is configured to monitor the pump outlet pressure through a pressure transmitter, and adjust the frequency of the water pump inverter and the start and stop of the standby pump in combination with the PID algorithm to stabilize the pressure within the set normal fluctuation range. The circulating water temperature monitoring and PID control module is configured to monitor the return water temperature through a temperature transmitter and adjust the operating status and frequency of the cooling tower fan in combination with the PID algorithm.

[0007] Preferably, the multi-source load signal real-time acquisition module specifically includes: Collect equipment start-up and shutdown signals from each forging line, including equipment load change signals and fault alarm signals; For switch signals: they are directly acquired through the PLC's digital input module; For analog signals: Acquire 4~20mA standard signals through the analog input module.

[0008] Preferably, the control logic of the electric butterfly valve linkage control module for the cooling pipeline is as follows: When the control button of the forging line equipment is pressed, the electric butterfly valve opens synchronously to provide cooling water to the pipeline; when the button is released, the butterfly valve closes.

[0009] Preferably, the circulating water pressure PID control module specifically includes: The core of PID control consists of a proportional term. Integral terms Differential term It consists of three parts; Install a pressure transmitter on the pump outlet pipe to monitor the outlet pressure in real time. ; To set pressure As a benchmark; The output adjustment amount is: ; in, For proportional gain; This is the deviation value; The integral time constant; This is the integral term for the deviation; The differential time constant; The rate of change of deviation; This is the controller's reference output.

[0010] Preferably, the deviation value The acquisition logic is as follows: Target pressure With actual pump outlet pressure The difference, that is: .

[0011] Preferably, the method further includes: Proportional Term for: ; Integral term for: ; Differential term for: .

[0012] Preferably, the total output is: ; Perform appropriate processing based on the output results.

[0013] Preferably, the circulating water temperature monitoring and PID control module specifically includes: The return water temperature after heat exchange in the equipment is collected in real time, filtered and calibrated, and then transmitted to the controller to provide sensing data for subsequent adjustment. When the return water temperature is lower than the set value, the system shuts down the cooling tower fan and relies mainly on natural heat dissipation to reduce ineffective energy consumption. When the temperature exceeds the set value, the speed of a single fan is first adjusted by PID frequency conversion to enhance heat dissipation. If the temperature still does not meet the standard, the standby fans are started in sequence, in conjunction with soft start and overload protection mechanisms.

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. This invention achieves a zero-delay response of water supply upon equipment startup and water shut-off upon equipment shutdown by real-time acquisition of multi-source load signals and linkage control of cooling pipeline butterfly valves, thus avoiding energy waste caused by no-load water supply from the source. At the same time, the dual PID closed-loop control of circulating water pressure and temperature can dynamically adjust the frequency of the water pump inverter and the speed and number of cooling tower fans to start and stop according to load changes, so that the operating power of the cooling system is always precisely matched with the actual demand, reducing energy consumption compared with traditional constant flow systems.

[0015] 2. This invention, through real-time monitoring by pressure and temperature transmitters combined with dynamic adjustment using a PID algorithm, can stabilize the circulating water pressure within the set range, solving the problem of insufficient precision in traditional manual adjustment. This precise control capability can effectively prevent overheating and deformation of forging equipment due to insufficient cooling, ensuring the equipment's operational accuracy and service life. At the same time, the real-time triggering of the load signal makes the cooling system's response time less than 1 second, which can quickly adapt to sudden load changes, avoiding the risk of equipment overheating and shutdown, thereby improving the continuity of workshop production and product yield. Attached Figure Description

[0016] Further details, features, and advantages of this application are disclosed in the following description of exemplary embodiments in conjunction with the accompanying drawings, in which: Figure 1 This is a system structure diagram of the present invention. Detailed Implementation

[0017] Several embodiments of this application will now be described in more detail with reference to the accompanying drawings to enable those skilled in the art to implement this application. This application may be embodied in many different forms and for various purposes and should not be limited to the embodiments set forth herein. These embodiments are provided to make this application thorough and complete, and to fully convey the scope of this application to those skilled in the art. The embodiments described do not limit this application.

[0018] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. It will be further understood that terms such as those defined in commonly used dictionaries shall be interpreted as having a meaning consistent with their meaning in the relevant field and / or the context of this specification, and shall not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0019] Example 1 Its specific implementation method is combined with the appendix Figure 1 Please provide a detailed explanation.

[0020] Appendix Figure 1 The block diagram of the intelligent control system for cooling circulating water in a forging workshop according to the load size provided in the embodiment of the present invention shows the connection relationship between the multi-source load signal real-time acquisition module and the circulating water temperature monitoring and PID control module, and marks the main functional interaction flow of each module.

[0021] In this embodiment, it includes: The multi-source load signal real-time acquisition module is configured to acquire the working status signals of each forging line in the workshop in real time, providing a basis for triggering and feedback for subsequent control actions; Specifically, it includes: The system collects equipment start-up and stop signals from each forging line (such as the running / stop status of presses and roll forging mills), as well as equipment load change signals (such as current / voltage feedback of forging cycle time and tonnage changes), fault alarm signals (such as equipment overload and emergency stop trigger signals), and operating status signals of some auxiliary equipment (such as hydraulic stations and robotic arms). For switch signals (such as start / stop, alarm): they are directly acquired through the PLC's digital input module, and opto-isolation technology is used to avoid electromagnetic interference; For analog signals (such as load current and equipment temperature): acquire 4~20mA standard signals through analog input modules, and improve signal stability with signal amplifiers and filtering circuits; For signals from smart devices: Real-time data from the device controller can be directly read using industrial communication protocols such as ModbusTCP / Profinet, achieving soft data acquisition.

[0022] The cooling pipeline electric butterfly valve linkage control module is configured to automatically open and close the electric butterfly valve of the corresponding cooling circulation pipeline according to the on / off status of the equipment control button, so as to achieve on-demand water supply; When the control button of the forging line equipment is pressed, the electric butterfly valve opens synchronously to provide cooling water to the pipeline; when the button is released, the butterfly valve closes, realizing on-demand water supply to match the production rhythm of the forging line.

[0023] The circulating water pressure PID control module is configured to monitor the pump outlet pressure through a pressure transmitter, and adjust the pump frequency converter frequency and the start and stop of the standby pump in combination with the PID algorithm to stabilize the pressure within the set normal fluctuation range (±0.2 bar). Specifically, it includes: The core of PID control consists of a proportional term. Integral terms Differential term It consists of three parts; Install a pressure transmitter on the pump outlet pipe (equipment water pipe) to monitor the outlet pressure in real time. ; To set pressure Based on this, the pressure deviation is controlled within ±0.2 bar to maintain pressure stability; The output adjustment amount is: ; in, The proportional gain (proportional coefficient) is the core parameter of the proportional element, which determines the strength of the response to deviation. The larger the value, the more drastic the adjustment to the deviation and the faster the response speed; however, an excessively large value can easily lead to system oscillation. In your pressure control system, it determines the adjustment range of the pump speed when a pressure deviation occurs. The deviation value is the system setpoint. ) and actual detected value ( The difference between the target pressure and the target pressure. ) and actual pump outlet pressure ( The difference between the two values ​​is the core input for PID control; The integral time constant (integral time) is a parameter of the integral element that determines the speed at which steady-state error is eliminated. The smaller the value, the stronger the integral action and the faster the error elimination; however, too small a value can easily lead to integral saturation and system overshoot. In your system, it is used to eliminate steady-state pressure deviations and ensure that the pressure remains stable at the set value over a long period. The integral term represents the deviation, from system startup time (0) to the current time ( ). The cumulative deviation value. Its function is to eliminate the steady-state error of the system by accumulating past deviations, so that the actual value eventually stabilizes at the setpoint; The differential time constant (differential time) is a parameter of the differential element used to predict the trend of deviation changes. The larger the value, the stronger the differential action, which can effectively suppress system overshoot, but an excessively large value can amplify noise signals. In your pressure control, it can predict sudden pressure changes and adjust the pump speed in advance to avoid excessive pressure fluctuations. This is the rate of change of deviation, the speed at which the deviation changes over time, reflecting how quickly the actual value deviates from the setpoint. The derivative element uses this rate of change to anticipate and suppress system oscillations and overshoot. The controller reference output (system steady-state output value) is used when the system is in a zero-bias state. The initial output value when (=0) is the baseline for stable system operation. In your system, it corresponds to the base inverter frequency when the water pump maintains steady-state pressure, ensuring stable system operation even without deviation.

[0024] Deviation value The acquisition logic is as follows: Target pressure With actual pump outlet pressure The difference, that is: .

[0025] Also includes: Proportional Term for: ; Integral term for: ; Differential term for: .

[0026] The total output is: ; Perform appropriate processing based on the output results: If the pressure is too low, increase the frequency of the inverter, increase the speed of the water pump, and increase the flow rate until the pressure rises. If the pressure is too high, the frequency of the inverter will be reduced, the pump speed will decrease, and the flow rate will be reduced until the pressure drops. When the pressure cannot be met even at the highest frequency of the PID output, the backup pump is automatically started to expand the capacity.

[0027] The circulating water temperature monitoring and PID control module is configured to monitor the return water temperature through a temperature transmitter and adjust the operating status and frequency of the cooling tower fan in combination with the PID algorithm to achieve precise and stable control of the water temperature. Specifically, it includes: It is the core of the closed-loop temperature control of the cooling system. By installing a Pt100 platinum resistance temperature transmitter in the return water pipeline, the return water temperature after heat exchange by the equipment is collected in real time. After filtering and calibration, the temperature is transmitted to the controller to provide accurate sensing data for subsequent adjustment. This module adopts a dual-sensor redundancy configuration for the characteristics of industrial sites, which not only ensures the continuity of monitoring, but also avoids the impact of environmental interference on temperature acquisition.

[0028] In terms of control logic, the principle of on-demand heat dissipation is followed: when the return water temperature is lower than the set value, the system shuts down the cooling tower fan and relies mainly on natural heat dissipation to reduce ineffective energy consumption; When the temperature exceeds the set value, the speed of a single fan is first adjusted by PID frequency conversion to enhance heat dissipation. If the temperature still does not meet the standard, the backup fans are started in sequence. With the soft start and overload protection mechanism, precise linkage of multiple machines is achieved. The entire adjustment process is derived from the pressure PID algorithm. It only optimizes parameters such as proportional gain and integral time to suit the characteristics of large inertia and slow response of temperature systems, which not only ensures control effect but also reduces development and maintenance costs.

[0029] On the one hand, it stabilizes the return water temperature within ±1℃, preventing the forging equipment from overheating and causing a decrease in precision or shutdown. On the other hand, through variable frequency speed control and dynamic start-stop of the fan, it saves 20%-35% more energy than the traditional constant speed mode, with particularly significant effects in low-temperature seasons. Simultaneously, it can work in conjunction with the pressure control module to predict temperature fluctuations caused by changes in flow rate, further improving the system's stability and energy efficiency.

[0030] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0031] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

[0032] It should be noted that, in this document, the use of relational terms such as "first" and "second" is merely for distinguishing one entity or operation from another, and does not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0033] It should be understood that in the various embodiments of this application, the order of the above-mentioned processes does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0034] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0035] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0036] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0037] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0038] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0039] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An intelligent control system for cooling circulating water in a forging workshop based on load size, characterized in that: include: The multi-source load signal real-time acquisition module is configured to acquire the working status signals of each forging line in the workshop in real time; The cooling pipeline electric butterfly valve linkage control module is configured to automatically open and close the electric butterfly valve of the corresponding cooling circulation pipeline according to the on / off status of the equipment control button; The circulating water pressure PID control module is configured to monitor the pump outlet pressure through a pressure transmitter, and adjust the frequency of the water pump inverter and the start and stop of the standby pump in combination with the PID algorithm to stabilize the pressure within the set normal fluctuation range. The circulating water temperature monitoring and PID control module is configured to monitor the return water temperature through a temperature transmitter and adjust the operating status and frequency of the cooling tower fan in combination with the PID algorithm.

2. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 1, characterized in that, The multi-source load signal real-time acquisition module specifically includes: Collect equipment start-up and shutdown signals from each forging line, including equipment load change signals and fault alarm signals; For switch signals: they are directly acquired through the PLC's digital input module; For analog signals: Acquire 4~20mA standard signals through the analog input module.

3. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 1, characterized in that, The control logic for the electric butterfly valve linkage control module in the cooling pipeline is as follows: When the control button of the forging line equipment is pressed, the electric butterfly valve opens synchronously to provide cooling water to the pipeline; when the button is released, the butterfly valve closes.

4. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 1, characterized in that, The circulating water pressure PID control module specifically includes: The core of PID control consists of a proportional term. Integral terms Differential term It consists of three parts; Install a pressure transmitter on the pump outlet pipe to monitor the outlet pressure in real time. ; To set pressure As a benchmark; The output adjustment amount is: ; in, For proportional gain; This is the deviation value; The integral time constant; This is the integral term for the deviation; The differential time constant; The rate of change of deviation; This is the controller's reference output.

5. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 4, characterized in that, Deviation value The acquisition logic is as follows: Target pressure With actual pump outlet pressure The difference, that is: .

6. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 5, characterized in that, Also includes: Proportional Term for: ; Integral term for: ; Differential term for: .

7. The intelligent control system for cooling circulating water in a forging workshop according to the load size as described in claim 6, characterized in that, The total output is: ； Perform appropriate processing based on the output results.

8. The intelligent control system for cooling circulating water in the forging workshop according to the load size as described in claim 1, characterized in that, The circulating water temperature monitoring and PID control module specifically includes: The return water temperature after heat exchange in the equipment is collected in real time, filtered and calibrated, and then transmitted to the controller to provide sensing data for subsequent adjustment. When the return water temperature is lower than the set value, the system shuts down the cooling tower fan and relies mainly on natural heat dissipation to reduce ineffective energy consumption. When the temperature exceeds the set value, the speed of a single fan is first adjusted by PID frequency conversion to enhance heat dissipation. If the temperature still does not meet the standard, the standby fans are started in sequence, in conjunction with soft start and overload protection mechanisms.

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