Overhead industrial sewer intelligent flow control device

Abstract

The application relates to an intelligent flow control device for an overhead industrial sewage pipe, which comprises an execution unit arranged on a pipe body and used for adjusting the on-off and flow size of fluid in the pipe, a driving unit arranged on the pipe body and connected with the execution unit and used for driving the execution unit to act, a sensing unit arranged on the pipe body and comprising a flow detection module used for detecting flow and a pressure detection module used for detecting pressure and used for collecting real-time operation parameters in the pipe, and a control unit which is internally provided with a programmable logic controller, the programmable logic controller is internally provided with a PID control algorithm and a water hammer protection logic, and the water hammer protection logic is used for controlling the opening and closing speed of the execution unit. Compared with the prior art, the application has the advantages of accurate flow control, stable pressure adjustment, flexible flow direction switching, safe interlocking protection and data integrated monitoring.

Description

Technical Field

[0001] This invention relates to the field of industrial wastewater treatment technology, and in particular to an intelligent flow control device for elevated industrial wastewater pipes. Background Technology

[0002] With the acceleration of industrial modernization, the production scale of industries such as chemical, metallurgy, and pharmaceuticals continues to expand, and the discharge of industrial wastewater is rising accordingly. The stable operation of wastewater collection, transportation, and treatment systems has become a key link in ensuring production safety and the ecological environment. As an important form of industrial wastewater pipeline network, elevated laying is widely used in site-constrained scenarios such as chemical industrial parks and industrial parks due to its advantages such as high space utilization, small footprint, and ease of crossing roads and water systems. It is the core carrier in the industrial wastewater transportation system.

[0003] Industrial wastewater has a complex composition, often containing particulate matter, fibrous impurities, and corrosive acids and alkalis. Existing flow control equipment lacks targeted design for its core components, making it prone to corrosion, wear, scaling, or blockage with prolonged use, leading to performance degradation and shortened lifespan. Furthermore, elevated pipelines are often exposed to the elements, and some industrial parks pose a risk of flammable and explosive gas emissions. Existing equipment lacks sufficient protection and environmental adaptability, making it susceptible to malfunctions caused by wind, rain, dust, and corrosive gases, further increasing the difficulty and cost of equipment maintenance in elevated environments.

[0004] Furthermore, existing elevated sewage pipeline systems are mostly decentralized and independently operated, lacking comprehensive parameter monitoring and centralized management capabilities. Key operating parameters such as flow rate and pressure are difficult to collect and receive in real time. Maintenance personnel must rely on on-site inspections to monitor equipment status, resulting in low work efficiency and an inability to promptly detect emergencies such as pipe ruptures, abnormal pressure, and hazardous gas leaks, hindering rapid emergency response and potentially escalating the accident. In addition, the existing systems have a low level of intelligence and cannot effectively integrate with smart water management platforms, failing to meet the development needs of industrial parks for refined scheduling and remote control of sewage pipe networks, thus restricting the upgrading and optimization of the overall water management system. Patent CN21773875U proposes an intelligent flow control system for industrial wastewater treatment, including a water storage section, a control system, a PID control unit, and a water pump. The water pump is connected to the water storage section, and water in the storage section can flow out through the pump. The control system can collect water level data in the storage section or flow rate data through the pump, and the PID control unit can adjust the pump speed based on the data collected by the control system. However, it still has shortcomings such as lack of water hammer protection mechanism, no pipeline pressure monitoring and protection, single control object, lack of multi-pipeline switching capability, and lack of industrial environment adaptability design such as explosion-proof and high protection level. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an intelligent flow control device for elevated industrial wastewater pipes that achieves precise flow control, stable pressure regulation, flexible flow direction switching, safety interlock protection, and integrated data monitoring.

[0006] The objective of this invention can be achieved through the following technical solutions: A smart flow control device for elevated industrial wastewater pipes includes: An execution unit, which is disposed on the pipeline body, is used to regulate the flow and flow rate of fluid within the pipeline; A drive unit is provided, wherein the execution unit is disposed on the pipe body and connected to the execution unit, and is used to drive the execution unit to perform actions; The sensing unit is installed on the pipeline body and includes a flow detection module for detecting flow rate and a pressure detection module for detecting pressure, for collecting real-time operating parameters inside the pipeline. The control unit is connected to the sensing unit and the drive unit respectively. The control unit has a built-in programmable logic controller. The programmable logic controller has a preset PID control algorithm and water hammer protection logic. The PID control algorithm is used to calculate the optimal valve opening of the execution unit, and the water hammer protection logic is used to control the opening and closing speed of the execution unit.

[0007] Furthermore, the actuating unit is a flow regulating valve, which is selected from any one of an electrically regulating butterfly valve, a V-type ball valve, and an eccentric rotary valve.

[0008] Furthermore, the current-carrying components of the execution unit are made of stainless steel or duplex steel.

[0009] Furthermore, the flow-through component is lined with at least one of rubber and polytetrafluoroethylene material.

[0010] Furthermore, the drive unit is an intelligent electric actuator, and the protection level of the intelligent electric actuator is not lower than IP67.

[0011] Furthermore, the explosion-proof rating of the drive unit conforms to the Ex standard.

[0012] Furthermore, the drive unit has a fail-safe mode and is configured to automatically switch the execution unit to one of the following states when the drive unit loses power or malfunctions: fully open, fully closed, or maintains the current position.

[0013] Furthermore, the control unit has a built-in programmable logic controller (PLC), which has a preset PID control algorithm and water hammer protection logic. The water hammer protection logic is used to control the opening and closing speed of the execution unit.

[0014] Furthermore, the control unit integrates a communication module, which is selected from industrial Ethernet modules, 4G communication modules and 5G communication modules, for data interaction with the remote monitoring platform.

[0015] Furthermore, the sensing unit is a monitoring instrument, which includes one or more of an electromagnetic flowmeter, a pressure transmitter, a level transmitter, and a water quality analyzer.

[0016] Furthermore, the control unit is pre-programmed with a safety interlock program, which is configured such that when the pressure detection module detects a sudden drop in pressure, the control unit sends an emergency cut-off signal to the drive unit to control the execution unit to shut down.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. Precise and efficient closed-loop control: The closed-loop control is formed by sensing unit, control unit and drive unit. It can automatically adjust the opening degree of the actuator according to the real-time flow and pressure of the pipeline, realize precise and stable control of industrial wastewater flow, and improve the response speed and control accuracy of flow regulation.

[0018] 2. Suppress water hammer effect and ensure pipeline safety: The control unit is equipped with water hammer protection logic, which can automatically adjust the opening and closing speed of the actuator according to pressure changes, effectively suppressing the water hammer effect, reducing pipeline pressure fluctuations, protecting the elevated pipeline and its supporting structure, and improving the safety of system operation.

[0019] 3. Corrosion and wear resistant, extending service life: The actuator can select different types of regulating valves according to the nature of the sewage, and uses corrosion-resistant and wear-resistant materials, which improves the adaptability of the device to industrial sewage containing particulate matter, fibers or corrosive substances, and extends the service life of the equipment.

[0020] 4. Enables remote control and enhances system security: Through the communication module, data interaction with the remote monitoring platform is achieved, allowing real-time uploading of operating status and receiving of remote commands. This enables intelligent and remote management of the sewage pipe network, improving operation and maintenance efficiency. At the same time, the safety interlock function automatically cuts off water flow in abnormal situations, further enhancing system security. Attached Figure Description

[0021] Figure 1 This is a structural block diagram of the present invention; The components include: 1. Sensing unit; 2. Control unit; 3. Drive unit; 4. Execution unit; 5. Flow detection module; 6. Pressure detection module; 7. Intelligent control cabinet; 8. Intelligent electric actuator; and 9. Flow regulating valve. Detailed Implementation

[0022] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0023] This embodiment discloses an intelligent flow control device for elevated industrial wastewater pipes, which is applicable to elevated industrial wastewater pipeline systems. It enables real-time monitoring, precise adjustment, pressure protection, and remote control of wastewater flow, meeting the safety and stability requirements of industrial wastewater transportation.

[0024] like Figure 1 As shown, the device includes a sensing unit 1, a control unit 2, a drive unit 3, and an execution unit 4. Each component is integrated and installed at the corresponding location on the elevated pipeline, adapting to the space constraints of elevated installation and forming an integrated electromechanical intelligent control system. The device, with its execution unit, drive unit, sensing unit, and control unit installed on the elevated pipeline, regulates flow rate, controls the valve opening of the execution unit, detects flow rate and pressure data, and receives data from the sensing unit, calculates the valve opening, and sends commands to the execution unit. It also features remote control capabilities and can transmit data to an online platform. By integrating the various units, it addresses the limitations of traditional equipment in elevated environments, thus solving the problem of limited installation space.

[0025] The actuator 4 is a flow regulating valve 9, which can be an electrically regulating butterfly valve, a V-type ball valve, or an eccentric rotary valve. The electrically regulating butterfly valve has a compact structure, good regulating performance, and is suitable for large-diameter pipelines, as well as for situations with limited space for overhead installation. The V-type ball valve is suitable for industrial wastewater containing particulate matter and fibers, has strong shear force, and good regulating characteristics. The eccentric rotary valve combines the advantages of ball valves and butterfly valves, offering good sealing, high regulating accuracy, and cavitation resistance. It is installed on the pipeline body and used to regulate the on / off state and flow rate of wastewater within the pipeline. This embodiment uses an electrically regulating butterfly valve. The valve body, valve plate, and sealing materials of this flow regulating valve 9 are made of corrosion-resistant, wear-resistant, and anti-scaling materials, adaptable to the erosion and operating conditions of industrial wastewater, ensuring regulating performance and service life.

[0026] The drive unit 3 is an intelligent electric actuator 8, connected to the flow regulating valve 9, used to receive control signals and precisely drive the flow regulating valve 9 to adjust to the corresponding opening degree. This electric actuator has a protection rating of no less than IP67, meeting the waterproof, dustproof, and corrosion-resistant requirements of elevated, open-air environments. The actuator has Ex explosion-proof certification and a fail-safe mode; in the event of power failure or malfunction, it can automatically drive the flow regulating valve 9 to switch to fully open, fully closed, or remain in its original position, ensuring safe system operation.

[0027] The sensing unit 1 includes a flow detection module 5 and a pressure detection module 6, which are installed on the pipeline body to collect real-time operating parameters within the pipeline and transmit them to the control unit 2. The flow detection module 5 uses an electromagnetic flowmeter to detect the instantaneous and cumulative flow of wastewater within the pipeline, featuring high accuracy and no obstruction components, making it suitable for industrial wastewater transportation. The pressure detection module 6 uses a pressure transmitter, installed upstream and downstream of the flow regulating valve 9, to monitor pipeline pressure data in real time, providing data support for pipeline pressure stabilization and water hammer protection.

[0028] The control unit 2 is an intelligent control cabinet 7, with a built-in programmable logic controller (PLC). As the core control component of the device, it is electrically connected to the sensing unit 1 and the drive unit 3. The control unit 2 has a preset PID control algorithm and water hammer protection logic. After receiving real-time flow and pressure data transmitted from the sensing unit 1, it calculates the optimal valve opening through the PID control algorithm and sends a precise control command to the drive unit 3. The drive unit 3 adjusts the opening of the flow regulating valve 9 according to the control command, forming a closed-loop flow control. At the same time, through the water hammer protection logic, it controls the opening and closing speed of the flow regulating valve 9 to suppress pressure surges and prevent water hammer effects.

[0029] In this embodiment, the flow of the preset PID control algorithm includes: The control unit collects the flow and pressure signals from the sensing unit in real time, compares the actual flow value with the set flow value to obtain the flow deviation; through the built-in PID closed-loop control, it performs proportional and integral calculations on the deviation to calculate the current optimal valve opening command and outputs it to the drive unit; the drive unit adjusts the opening size of the execution unit according to the opening command, so that the actual flow quickly and smoothly approaches the set flow, realizing precise constant flow control of the elevated industrial sewage pipeline.

[0030] In this embodiment, the specific process of the preset water hammer protection logic includes: The control unit monitors pressure changes upstream and downstream of the valve in real time. When a sudden pressure change, valve opening / closing, or system start / stop condition is detected, the water hammer protection logic is automatically triggered. Limit the startup and shutdown speed of the execution unit to avoid rapid startup and shutdown; The valve's operating rate is dynamically adjusted according to the pressure fluctuation amplitude; the greater the pressure fluctuation, the smoother the operation. When the pressure exceeds the limit or a negative pressure trend occurs, the valve is forced to enter the slow-closing mode, and the valve is closed in stages and segments. First, the valve is closed quickly to reduce the flow, and then it is closed slowly to eliminate the impact. In conjunction with pressure interlock protection, it prevents flow interruption, water hammer, and high-pressure impact, and protects the safety of elevated pipelines and support structures.

[0031] The intelligent control cabinet 7 integrates a communication module, which can be either an industrial Ethernet module or a wireless communication module, to achieve data interaction with the remote monitoring platform. It uploads real-time operating data such as pipeline flow, pressure, and valve opening to the remote monitoring platform, and at the same time receives control commands issued by the remote monitoring platform to realize remote monitoring and control of the device.

[0032] The working process of the above device is as follows: After startup, the electromagnetic flowmeter and pressure transmitter of sensing unit 1 start up synchronously, collect the flow and pressure data of sewage in the pipeline in real time, and continuously transmit them to control unit 2. After receiving the data, the control unit 2 compares the actual flow rate with the preset flow rate, calculates the adjustment deviation through the PID control algorithm, generates the corresponding control signal, and sends it to the drive unit 3. The drive unit 3 receives the control signal and precisely drives the flow regulating valve 9 to adjust to the target opening, changing the sewage flow cross section, so that the actual flow is stabilized within the preset range, and achieving precise flow regulation. Control unit 2 monitors the pressure data transmitted by the pressure transmitter in real time. When pressure fluctuation is detected, it adjusts the opening and closing speed of flow regulating valve 9 through water hammer protection logic to suppress pressure shock, ensure pipeline pressure stability and the safety of elevated pipelines and support structures. Control unit 2 uploads real-time operating data to the remote monitoring platform via the communication module, and responds to remote commands to realize intelligent and remote management of the device. If an emergency such as a sudden drop in pipeline pressure is detected, control unit 2 triggers the safety interlock program, sends an emergency cut-off signal to drive unit 3, and drives flow regulating valve 9 to close quickly to prevent the accident from escalating.

[0033] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. An intelligent flow control device for elevated industrial wastewater pipes, characterized in that, include: An execution unit, which is disposed on the pipeline body, is used to regulate the flow and flow rate of fluid within the pipeline; A drive unit is provided, wherein the execution unit is disposed on the pipe body and connected to the execution unit, and is used to drive the execution unit to perform actions; The sensing unit is installed on the pipeline body and includes a flow detection module for detecting flow rate and a pressure detection module for detecting pressure, for collecting real-time operating parameters inside the pipeline. The control unit is connected to the sensing unit and the drive unit respectively. The control unit has a built-in programmable logic controller. The programmable logic controller has a preset PID control algorithm and water hammer protection logic. The PID control algorithm is used to calculate the optimal valve opening of the execution unit, and the water hammer protection logic is used to control the opening and closing speed of the execution unit.

2. The intelligent flow control device for elevated industrial sewage pipes according to claim 1, characterized in that, The actuator is a flow regulating valve, which is selected from any one of an electrically regulating butterfly valve, a V-type ball valve, and an eccentric rotary valve.

3. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The current-carrying components of the execution unit are made of stainless steel or duplex steel.

4. The intelligent flow control device for elevated industrial wastewater pipes according to claim 3, characterized in that, The flow-through component is lined with at least one of rubber and polytetrafluoroethylene.

5. The intelligent flow control device for elevated industrial sewage pipes according to claim 1, characterized in that, The drive unit is an intelligent electric actuator, and the protection level of the intelligent electric actuator is not lower than IP67.

6. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The explosion-proof rating of the drive unit meets the Ex standard.

7. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The drive unit is configured to automatically switch the execution unit to one of the following states when the drive unit loses power or malfunctions: fully open, fully closed, or maintains the current position.

8. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The control unit integrates a communication module, which is selected from industrial Ethernet module, 4G communication module and 5G communication module, and is used to interact with the remote monitoring platform.

9. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The sensing unit is a monitoring instrument, which includes one or more of the following: electromagnetic flowmeter, pressure transmitter, level transmitter, and water quality analyzer.

10. The intelligent flow control device for elevated industrial wastewater pipes according to claim 1, characterized in that, The control unit has a preset safety interlock program, which is configured such that when the pressure detection module detects a sudden drop in pressure, the control unit sends an emergency cut-off signal to the drive unit to control the execution unit to shut down.

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