A warehouse temperature and humidity partition synchronous regulation and energy consumption optimization control system

Abstract

The present application relates to warehouse environment control technical field, disclose a kind of warehouse temperature and humidity zoning synchronous regulation and energy consumption optimization control system, including industrial controller, temperature and humidity transmitter, variable frequency air conditioning unit and proportional-integral electric guide vane valve.The present application is by industrial controller to map environment dry bulb temperature and relative humidity into air specific enthalpy and absolute humidity, establishes heat and humidity exchange coupling matrix to generate enthalpy difference gradient;According to mass flow mapping table to obtain estimated value and calculate virtual state, meet the enthalpy drop condition and virtual mixed state is in dew point boundary line safety side when drive proportional-integral electric guide vane valve action to introduce low enthalpy air;Using enthalpy disturbance quantity to shift dew point critical boundary line to generate dynamic safety envelope surface, predict control trajectory to enter condensation risk side when triggering refrigeration dehumidification and heating compensation, environmental state point is back to safety side after cutting off heating instruction, reduce operating power consumption and avoid refrigeration and reheating energy consumption superposition.

Description

Technical Field

[0001] This invention relates to the field of warehouse environment control technology, specifically a warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system. Background Technology

[0002] The storage space is divided into multiple zones for independent temperature and humidity control. Current control methods adjust each storage zone individually, ignoring energy differences between adjacent zones. When a storage zone requires cooling or dehumidification, the control equipment directly activates the inverter compressor within that zone to output cooling. This approach fails to utilize the low-enthalpy air present in adjacent storage zones, foregoing the potential for this low-enthalpy air to neutralize the heat in the target storage zone. This results in an increased cooling load on the inverter compressor, leading to higher power consumption for cooling during equipment operation.

[0003] In terms of cross-zone airflow control, monitoring the intensity of cross-zone air exchange relies on installing physical differential pressure sensors and flow sensors at the partitions in the warehouse area. The addition of physical sensors increases the hardware construction cost of the warehouse environmental control system and increases subsequent maintenance investment.

[0004] In existing temperature and humidity control processes, when faced with changes in environmental conditions or the introduction of air from other zones, the control logic is set to operate the inverter compressor for cooling and dehumidification and the independent reheater for heating and compensation simultaneously to avoid condensation on the inner walls of the storage unit caused by a drop in dew point. However, due to the lack of quantitative monitoring of enthalpy disturbances caused by the introduction of air from other zones, the control equipment cannot track the predictive control trajectory from the current environmental state to the target state in real time, making it difficult to accurately determine the dew point critical boundary. This results in the independent reheater function operating for an excessively long time, leading to a problem where the inverter air conditioning unit relies solely on the internal inverter compressor and independent reheater to cope with the combined cooling and reheating energy consumption caused by environmental changes.

[0005] Therefore, this invention proposes a warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system to address the shortcomings of existing technologies. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system. It solves the problems of superimposed cooling energy consumption and reheating energy consumption caused by variable frequency air conditioning units relying solely on internal variable frequency compressors and independent reheaters to cope with changes in environmental conditions during warehouse temperature and humidity adjustment, as well as the problem of increased hardware costs caused by cross-zone air volume monitoring relying on physical differential pressure sensors or flow sensors.

[0007] To achieve the above objectives, the present invention provides the following technical solution: This invention provides a warehouse temperature and humidity zone synchronous adjustment and energy consumption optimization control system, including an industrial controller, a temperature and humidity transmitter, a variable frequency air conditioning unit, and a proportional-integral electric guide valve. The storage space is divided into multiple storage zones, which are separated by partitions. Temperature and humidity transmitters are distributed within each storage zone, with their signal outputs connected to the input of an industrial controller. These transmitters detect the dry-bulb temperature and relative humidity within each storage zone. Each storage zone is equipped with a variable frequency air conditioning unit, which contains a variable frequency compressor and an independent reheater. The frequency control of the variable frequency compressor and the power control of the independent reheater are both connected to the output of the industrial controller. Proportional-integral (PI) electric air deflectors are installed at the partitions between the storage zones. These valves connect to the storage zones at both ends of the partition and are equipped with valve opening position feedback mechanisms. The control signal receiver of the PI electric air deflector is connected to the command output of the industrial controller, and the position signal transmitter is connected to the data receiver of the industrial controller. The industrial controller reads the ambient dry-bulb temperature and ambient relative humidity based on the detection signals from the temperature and humidity transmitter, calls the built-in empirical equation to map the ambient dry-bulb temperature and ambient relative humidity into air specific enthalpy and absolute humidity, and constructs the target state polygonal region in the system's internal coordinate system. The industrial controller establishes a spatial heat and humidity exchange coupling matrix and calculates and generates the enthalpy difference gradient between adjacent storage zones. When the environmental state of a storage zone deviates from the target state polygonal region and meets the enthalpy reduction condition, the industrial controller retrieves the spatial heat and humidity exchange coupling matrix, compares it with the equivalent heat and enthalpy threshold, and generates a cross-zone synchronization request command. The industrial controller reads the operating frequency of the indoor circulating fan, the air volume level, the feedback frequency of the variable frequency compressor, and the feedback opening value of the proportional-integral electric diverter valve of the variable frequency air conditioning unit. After the cross-zone synchronization request command is generated, it first generates the candidate target opening of the proportional-integral electric diverter valve, and obtains the return air mass flow rate estimate and the candidate cross-zone supply air mass flow rate estimate based on the return air mass flow rate mapping table and the cross-zone mass flow rate mapping table. The industrial controller calculates and generates virtual air specific enthalpy and virtual absolute humidity by combining the estimated return air mass flow rate and the estimated candidate cross-zone supply air mass flow rate, and projects them into the system's internal coordinate system. When the industrial controller determines that the coordinates of the virtual air specific enthalpy and virtual absolute humidity are on the condensation risk side of the dew point critical boundary line, it cancels the cross-zone synchronization request command. When the industrial controller determines that the coordinates of the virtual air specific enthalpy and virtual absolute humidity are on the safe side of the dew point critical boundary line, it releases the cross-zone synchronization request command and outputs an open command to drive the proportional-integral electric guide valve to operate. The industrial controller calculates the enthalpy disturbance caused by the cross-regional air parameter introduction, and combines the enthalpy disturbance with the static safety dew point margin to generate the dynamic safety dew point margin. Based on the dynamic safety dew point margin, the dew point critical boundary line is translated to generate the dynamic safety envelope surface. The industrial controller generates a predictive control trajectory from the current environmental state point to the target state polygon region. When the predictive control trajectory crosses the dynamic safety envelope and enters the condensation risk side, the industrial controller synchronously sends a cooling command to the variable frequency compressor and a heating compensation command to the independent reheater. When the real-time state point fed back by the temperature and humidity transmitter returns from the condensation risk side of the dynamic safety envelope to the safety side and continuously meets the preset hysteresis criterion, the industrial controller cuts off the heating compensation command transmitted to the independent reheater and controls the variable frequency compressor to operate independently under normal cooling and dehumidification conditions.

[0008] The industrial controller maps ambient dry-bulb temperature and relative humidity to air specific enthalpy and absolute humidity, and completes target state determination in the system's internal coordinate system. When there is low-enthalpy air in an adjacent storage zone that meets the call conditions, the industrial controller opens the proportional-integral electric guide valve to reduce the cooling output of the variable frequency compressor, provided that the net enthalpy gain is greater than the equivalent heat enthalpy threshold and the virtual mixing state meets the dew point safety criterion. When cross-zone air exchange causes condensation risk, the industrial controller triggers cooling dehumidification and reheat compensation based on the dynamic safety envelope surface, and shuts down the independent reheater after the condensation risk is eliminated, reducing the superposition of cooling energy consumption and reheat energy consumption. There is no need to install an additional physical flow sensor to complete the cross-zone air exchange intensity control.

[0009] This invention provides a warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system. It has the following beneficial effects: 1. This invention uses an industrial controller to map ambient dry-bulb temperature and relative humidity into air specific enthalpy and absolute humidity. It establishes a spatial heat and humidity exchange coupling matrix to generate an enthalpy gradient between adjacent storage zones. When the enthalpy reduction condition is met and the net enthalpy gain is greater than the equivalent enthalpy threshold, a command is output to drive a proportional-integral electric guide valve. This utilizes the low-enthalpy air within adjacent storage zones that meets the call conditions to neutralize the heat within the target storage zone, reducing the cooling output of the variable frequency compressor and lowering the cooling power consumption during equipment operation.

[0010] 2. This invention uses an industrial controller to read the operating frequency, airflow level, and feedback opening value of the proportional-integral electric guide valve of the indoor circulating fan of the variable frequency air conditioning unit. Based on the return air mass flow rate mapping table and the cross-zone mass flow rate mapping table, it directly obtains the estimated return air mass flow rate and the estimated value of the candidate cross-zone supply air mass flow rate. The industrial controller combines the estimated values ​​to calculate the virtual air specific enthalpy and virtual absolute humidity to complete the dew point safety determination and valve opening control. This eliminates the need to install physical differential pressure sensors and flow sensors on the warehouse site, saving system hardware construction costs and subsequent maintenance investment.

[0011] 3. This invention calculates the enthalpy disturbance caused by cross-regional air parameter import through an industrial controller, generates a dynamic safety dew point margin, and translates the dew point critical boundary line to generate a dynamic safety envelope surface. It also monitors the predictive control trajectory from the current environmental state point to the target state polygonal region in real time. When a condensation risk is detected, the inverter compressor cooling and independent reheater heating compensation are simultaneously activated. Once the environmental state point returns to the safe side, the independent reheater heating function is promptly cut off to prevent condensation. This also avoids the problem of cumulative cooling and reheating energy consumption caused by the inverter air conditioning unit solely responding to environmental changes. Attached Figure Description

[0012] Figure 1 This is a system block diagram of the present invention.

[0013] Figure 2 This is a flowchart of the method of the present invention.

[0014] Figure 3 This is a comparison chart showing the environmental dry-bulb temperature verification of the present invention.

[0015] Figure 4 This is a comparison chart showing the environmental relative humidity verification of the present invention.

[0016] Figure 5 This is a diagram showing the trajectory of air specific enthalpy change according to the present invention.

[0017] Figure 6 This is the adaptive adjustment diagram for the dynamic safety dew point margin of the present invention.

[0018] Figure 7 This is a comparison chart of power suppression for the independent reheater of the present invention.

[0019] Figure 8 This is a cumulative energy consumption diagram for the overall operation of warehousing according to the present invention. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] See attached document Figure 1 This invention provides a warehouse temperature and humidity zone synchronous adjustment and energy consumption optimization control system, including an industrial controller, a temperature and humidity transmitter, a variable frequency air conditioning unit, and a proportional-integral electric guide valve.

[0022] The storage space is divided into multiple storage zones, which are separated by partitions. Temperature and humidity transmitters are distributed within each storage zone. The signal output of the temperature and humidity transmitters is connected to the input of the industrial controller. The temperature and humidity transmitters detect the dry-bulb temperature and relative humidity of the environment inside the storage zone. The industrial controller reads the dry-bulb temperature and relative humidity based on the detection signals from the temperature and humidity transmitters.

[0023] The storage area is equipped with variable frequency air conditioning units. The variable frequency air conditioning units are equipped with variable frequency compressors and independent reheaters. The frequency control terminal of the variable frequency compressor is connected to the output terminal of the industrial controller, and the power control terminal of the independent reheater is connected to the output terminal of the industrial controller. The industrial controller calculates and generates compressor frequency adjustment commands and transmits them to the variable frequency compressor. The industrial controller also calculates and generates heating compensation commands and transmits them to the independent reheater.

[0024] Proportional-integral (PI) electric guide valves are installed at the partitions between the storage areas. The two ends of the PI electric guide valves are connected to the storage areas at both ends of the partitions. The PI electric guide valves are equipped with valve opening position feedback mechanisms. The control signal receiving end of the PI electric guide valves is connected to the command output end of the industrial controller, and the position signal sending end of the PI electric guide valves is connected to the data receiving end of the industrial controller. The industrial controller generates valve opening adjustment commands and transmits them to the PI electric guide valves. The industrial controller receives the opening percentage feedback value returned by the PI electric guide valves.

[0025] The cross-zone air exchange between adjacent storage areas is driven by the supply and return air pressure difference generated during the operation of the variable frequency air conditioning unit, the static pressure difference between adjacent storage areas, or the pressure difference generated by the existing circulating fans within the storage area. A proportional-integral (PI) electric deflector is used to adjust the air exchange channel area between adjacent storage areas. The industrial controller determines the cross-zone air exchange intensity based on the target opening, feedback opening, and pressure difference calibration value on both sides of the valve.

[0026] When no real-time differential pressure sensor is installed at the storage site, the industrial controller uses a pre-calibrated mapping table of air valve opening, differential pressure and mass flow rate to estimate the mass flow rate of cross-zone air supply; the mapping table is obtained by testing under different air conditioning operating levels and different air valve openings during the commissioning phase of the storage system.

[0027] See attached document Figure 2 Based on the aforementioned warehouse temperature and humidity zone synchronous adjustment and energy consumption optimization control system, this invention also provides a warehouse temperature and humidity zone synchronous adjustment and energy consumption optimization control method, which includes the following steps: S10, the industrial controller reads the ambient dry-bulb temperature and ambient relative humidity collected by the temperature and humidity transmitter. The industrial controller calls the built-in empirical equation to map the ambient dry-bulb temperature and ambient relative humidity into air specific enthalpy and absolute humidity. The industrial controller extracts the air specific enthalpy and absolute humidity and constructs the target state polygon region in the system's internal coordinate system. S20, the industrial controller establishes a spatial heat and humidity exchange coupling matrix, calculates and generates the enthalpy difference gradient between adjacent storage zones, when the environmental state of the storage zone deviates from the target state polygonal area and meets the enthalpy reduction condition, the industrial controller retrieves the spatial heat and humidity exchange coupling matrix and compares it with the equivalent heat and enthalpy threshold, and the industrial controller generates a cross-zone synchronization request command. S30, the industrial controller reads the operating frequency of the indoor circulating fan, the air volume level, the feedback frequency of the variable frequency compressor, and the feedback opening value of the proportional-integral electric guide valve of the variable frequency air conditioning unit. After the cross-zone synchronization request command is generated, the industrial controller first generates the candidate target opening of the proportional-integral electric guide valve, and obtains the return air mass flow rate estimate and the candidate cross-zone supply air mass flow rate estimate based on the return air mass flow rate mapping table and the cross-zone mass flow rate mapping table. The industrial controller calculates and generates virtual air specific enthalpy and virtual absolute humidity by combining the estimated return air mass flow rate and the estimated candidate cross-zone supply air mass flow rate, and projects them into the coordinate system. When the industrial controller determines that the coordinate position of the virtual air specific enthalpy and virtual absolute humidity is on the condensation risk side of the dew point critical boundary line, it cancels the cross-zone synchronization request command. When the industrial controller determines that the coordinate position is on the safe side of the dew point critical boundary line, it releases the cross-zone synchronization request command and outputs an opening command to drive the proportional-integral electric diverter valve to operate. After the proportional-integral electric diverter valve operates, the industrial controller then corrects the estimated cross-zone supply air mass flow rate based on the feedback opening degree. S40, the industrial controller calculates the enthalpy disturbance caused by the cross-regional air parameter introduction. The industrial controller combines the enthalpy disturbance and the static safety dew point margin to generate the dynamic safety dew point margin. The industrial controller translates the dew point critical boundary line according to the dynamic safety dew point margin to generate the dynamic safety envelope surface. S50, the industrial controller generates a predictive control trajectory from the current environmental state point to the target state polygon area. When the predictive control trajectory crosses the dynamic safety envelope and enters the condensation risk side, the industrial controller synchronously sends a cooling command to the variable frequency compressor and a heating compensation command to the independent reheater. When the real-time state point fed back by the temperature and humidity transmitter returns from the condensation risk side of the dynamic safety envelope to the safety side and continuously meets the preset hysteresis criterion, the industrial controller cuts off the heating compensation command transmitted to the independent reheater and controls the variable frequency compressor to operate independently according to the normal cooling and dehumidification conditions.

[0028] The technical solution will be described in detail below.

[0029] Step S10 includes the following sub-steps: S101, the industrial controller communicates with temperature and humidity transmitters distributed within the storage area according to a preset sampling period. The industrial controller reads the ambient dry-bulb temperature and ambient relative humidity collected by the temperature and humidity transmitters. The unit for the ambient dry-bulb temperature is set to ℃. The unit for the ambient relative humidity is set to %. The industrial controller stores the read ambient dry-bulb temperature and ambient relative humidity in its internal registers as basic calculation parameters.

[0030] S102, the industrial controller uses built-in empirical equations to map ambient dry-bulb temperature and relative humidity into air specific enthalpy and absolute humidity. The industrial controller has internal floating-point arithmetic space. Ambient dry-bulb temperature and relative humidity are independent control variables that influence each other and can lead to control execution deviations. The industrial controller calculates the water vapor saturation partial pressure and moisture content using built-in empirical equations. The industrial controller then calculates the real-time air specific enthalpy and absolute humidity parameters.

[0031] For the specific calculation process of converting air specific enthalpy and absolute humidity using the built-in empirical equation, those skilled in the art can refer to the HVAC property calculation manual. The derivation steps of converting water vapor partial pressure using the Antoine equation are well-known techniques in the field and will not be elaborated here.

[0032] To ensure that the industrial controller can directly perform the conversion, the industrial controller calculates the absolute humidity and specific enthalpy of the air in storage zone i according to the following relationship:

[0033] In the formula, Indicates warehouse partitions Ambient dry-bulb temperature; Indicates warehouse partitions The relative humidity of the environment; Indicates ambient dry bulb temperature The saturated partial pressure of water vapor at that point; Indicates the partial pressure of water vapor; Indicates the atmospheric pressure within the storage zone; Indicates absolute humidity; This indicates the specific enthalpy of air. Industrial controllers will display absolute humidity. enthalpy of air It serves as a unified state parameter for subsequent coordinate determination, cross-regional hybrid simulation, and energy consumption optimization calculation.

[0034] S103, the industrial controller extracts the specific enthalpy and absolute humidity of the air and constructs a polygonal region representing the target state within the system's internal coordinate system. The industrial controller establishes a two-dimensional coordinate system in memory. The horizontal axis of the two-dimensional coordinate system is defined as absolute humidity. The vertical axis of the two-dimensional coordinate system is defined as the specific enthalpy of the air. The industrial controller receives the upper and lower limits of the target temperature and humidity from external input.

[0035] Industrial controllers set lower temperature limit Upper temperature limit Lower limit of relative humidity and upper limit of relative humidity Multiple temperature and humidity boundary points are combined and then substituted into the built-in empirical equation to convert them into the coordinates of the target boundary vertex.

[0036] When constructing the target state polygon region using a four-vertex method, the target boundary vertices include:

[0037] In the formula, This represents a mapping function that converts ambient dry-bulb temperature and relative humidity into air enthalpy and absolute humidity coordinates. The industrial controller connects sequentially according to the adjacency relationship of the boundary vertices in the two-dimensional coordinate system. and This generates a closed target state polygon region.

[0038] Step S20 includes the following sub-steps: S201, the industrial controller allocates a two-dimensional array space in its internal running memory to establish a spatial thermal and moisture exchange coupling matrix. The row and column dimensions of the spatial thermal and moisture exchange coupling matrix are equal to the total number of storage partitions. The spatial thermal and moisture exchange coupling matrix is ​​used to record the numerical state of the energy potential difference between different storage partitions.

[0039] S202, the industrial controller reads the current air specific enthalpy of each storage zone in real time. The industrial controller calculates the enthalpy difference gradient between adjacent storage zones i and j. The calculation formula is as follows:

[0040] In the formula, This represents the enthalpy gradient between storage partition i and storage partition j; This represents the specific enthalpy of air in storage zone i; This represents the air enthalpy of storage zone j.

[0041] when When the value is greater than 0, it indicates that the specific enthalpy of air in storage zone j is lower than that in storage zone i, and storage zone j has the potential to provide low-enthalpy air to storage zone i.

[0042] S203, the industrial controller compares the real-time environmental status point coordinates of storage partition i with the positional relationship of the target state polygonal region. When the environmental status point coordinates of storage partition i are outside the boundary of the target state polygonal region, and the specific enthalpy of air in storage partition i is higher than the allowable enthalpy range corresponding to the target state polygonal region, the industrial controller determines that storage partition i has a need for enthalpy reduction. The industrial controller then searches for storage partition j adjacent to storage partition i, and determines whether storage partition j meets the low enthalpy air request conditions based on the enthalpy difference gradient and equivalent thermal enthalpy threshold between adjacent storage partitions; when the low enthalpy air request conditions are met, the industrial controller initiates the cross-regional scheduling retrieval process.

[0043] For the execution process of the logic for determining whether the environmental state point deviates from the target area, those skilled in the art can consult the manual of automatic control algorithms. The rules for comparing and determining the coordinates of the environmental state point are well-known technologies in this field and will not be elaborated here.

[0044] S204, the industrial controller retrieves the enthalpy difference gradient data associated with storage zone i from the spatial heat and humidity exchange coupling matrix. The industrial controller extracts the air specific enthalpy of storage zone j. The equivalent enthalpy threshold between storage zones i and j Perform numerical comparison.

[0045] Equivalent enthalpy threshold This represents the enthalpy compensation benchmark value for the additional energy consumption required for cross-zone air diversion, converted to a unit mass of air. The industrial controller reads this value through a preset calibration table, or calculates it according to the following relationship:

[0046] In the formula, This represents the energy consumption conversion factor; This indicates the additional fan power consumption or equivalent additional power consumption caused by opening the air exchange channel between storage zone i and storage zone j. This represents the estimated mass flow rate of cross-zone air supply when air is introduced from storage zone j to storage zone i.

[0047] The industrial controller determines that there is available redundant low-enthalpy air in adjacent storage zones when the following conditions are met:

[0048] The industrial controller further calculates the net enthalpy gain of storage zone j relative to storage zone i:

[0049] When multiple adjacent storage zones meet the low enthalpy air call conditions, the industrial controller prioritizes net enthalpy gain. The largest adjacent storage partition is selected as the candidate synchronization partition. When multiple storage partitions request the same candidate synchronization partition at the same time, the industrial controller sorts them from largest to smallest according to the distance of the environmental state point of each requesting storage partition from the target state polygon area, and executes the cross-region synchronization request in sequence.

[0050] The industrial controller generates a cross-zone synchronization request instruction in system memory. This instruction records the proportional-integral (PI) motorized diverter valves to be opened between storage zone i and storage zone j, the candidate target opening degree, and the corresponding candidate cross-zone airflow mass flow rate. The industrial controller suspends the cross-zone synchronization request instruction in its internal control stack and does not output an opening instruction to the PPI motorized diverter valves until the dew point safety check is completed.

[0051] Step S30 includes the following sub-steps: S301, the industrial controller performs mass flow status mapping. The industrial controller reads the operating frequency, air volume level, and variable frequency compressor feedback frequency of the indoor circulating fan of the variable frequency air conditioning unit through the communication bus, and simultaneously reads the feedback opening value of the proportional-integral electric guide valve.

[0052] The industrial controller has pre-set return air mass flow rate mapping tables and cross-zone mass flow rate mapping tables. The return air mass flow rate mapping table records the correspondence between the operating frequency and air volume level of the indoor circulating fan and the return air mass flow rate; the cross-zone mass flow rate mapping table records the correspondence between the opening degree of the proportional-integral electric guide valve, the pressure difference calibration value on both sides of the valve, and the cross-zone supply air mass flow rate.

[0053] Before the proportional-integral electric guide valve opens, the industrial controller determines the target opening degree based on the candidate target opening degree in the cross-regional synchronization request command. Pressure difference calibration value on both sides of the air valve Obtain the estimated mass flow rate of candidate cross-regional air supply by looking up a table or interpolation:

[0054] The industrial controller is based on the operating frequency of the indoor circulating fan. Airflow settings Obtain the estimated return air mass flow rate for storage zone i by looking up a table or interpolation:

[0055] After the proportional-integral (PI) electric flow deflector actuates, the industrial controller determines the opening degree based on the feedback from the PI electric flow deflector. Revised inter-regional air supply mass flow rate estimate:

[0056] In the formula, This represents the cross-regional mass flow rate mapping function; This represents the return air mass flow rate mapping function. The industrial controller uses this mapping relationship to estimate mass flow rate parameters without adding physical flow sensors.

[0057] The pressure difference calibration value on both sides of the above-mentioned air valve The static differential pressure constant is estimated and extracted by the industrial controller based on the real-time operating frequency combination of the indoor circulating fans of the variable frequency air conditioning units in the two zones, or by using the static differential pressure constant preset during the system commissioning phase.

[0058] S302, the industrial controller performs virtual hybrid simulation calculations based on the estimated return air mass flow rate and the estimated mass flow rate of candidate cross-zone supply air. The industrial controller combines the absolute humidity of storage zone i and storage zone j, and generates a virtual absolute humidity based on mass conservation logic. The calculation formula is as follows:

[0059] In the formula, This represents the virtual absolute humidity after air is introduced from storage zone j into storage zone i; This represents the estimated return air mass flow rate for storage zone i. Indicates the absolute humidity of storage zone i; This represents the estimated mass flow rate of candidate cross-regional air supply. This indicates the absolute humidity of storage zone j.

[0060] when At that time, the industrial controller determines that the current cross-regional hybrid simulation conditions are invalid and cancels the corresponding cross-regional synchronization request command.

[0061] The S303 industrial controller synchronously calculates and generates the virtual air specific enthalpy after cross-zone air mixing based on energy conservation logic. The calculation formula is as follows:

[0062] In the formula, This represents the virtual air enthalpy after air is introduced from storage zone j into storage zone i; This represents the estimated return air mass flow rate for storage zone i. This represents the specific enthalpy of air in storage zone i; This represents the estimated mass flow rate of candidate cross-regional air supply. This represents the air enthalpy of storage zone j.

[0063] S304, the industrial controller will use virtual air enthalpy. and virtual absolute humidity The virtual coordinate points are combined and then projected onto the system's internal coordinate system.

[0064] The industrial controller pre-stores the minimum allowable surface temperature of storage zone i in memory. and static dew point safety temperature difference Minimum permissible surface temperature This refers to the minimum permissible temperature on the surfaces of goods, walls, shelves, metal surfaces of air vents, or other surfaces prone to condensation within storage zone i. The industrial controller is based on virtual absolute humidity. Calculate virtual dew point temperature The following criteria are used to determine whether the virtual coordinate point is located on the condensation risk side:

[0065] When the above criteria are met, the industrial controller determines that the virtual coordinate point is located on the condensation risk side of the dew point critical boundary line. When the above criteria are not met, the industrial controller determines that the virtual coordinate point is located on the safe side of the dew point critical boundary line.

[0066] The dew point critical boundary line is the projection boundary of an air state point in the system's internal coordinate system that satisfies the following conditions:

[0067] When the virtual coordinate point is located on the condensation risk side, the industrial controller immediately cancels the cross-zone synchronization request instruction in the internal control stack and blocks the opening operation of the proportional-integral electric guide valve.

[0068] When the virtual coordinate point is located on the safe side, the industrial controller releases the cross-zone synchronization request command in its internal control stack and outputs the candidate target opening to the proportional-integral electric guide valve. This drives the valve's mechanical mechanism to reach the target opening position.

[0069] The S40 step includes the following sub-steps: The S401 industrial controller quantifies and extracts parameter fluctuations caused by cross-regional air import. The industrial controller extracts virtual air enthalpy in memory. Enthalpy of air in storage zone i Industrial controller calculates virtual air specific enthalpy. air enthalpy relative to storage zone i The absolute value of the difference between them generates the enthalpy perturbation. The calculation formula is as follows:

[0070] In the formula, This indicates the amount of enthalpy disturbance caused by the introduction of air from other regions; Indicates virtual air enthalpy; This represents the air enthalpy of storage zone i.

[0071] The S402 industrial controller calculates the dynamic safety dew point margin for anti-condensation protection based on enthalpy disturbances. The industrial controller also has a pre-stored static safety dew point margin in its memory. and spatial coupling deformation coefficient Static safety dew point margin The basic translational distance of the dew point critical boundary line in the direction of absolute humidity or the boundary normal direction; spatial coupling deformation coefficient. This is a conversion factor obtained through cross-regional wind-guiding tests during the commissioning phase. It is used to convert the unit enthalpy disturbance into the additional translation distance of the dew point critical boundary line.

[0072] The industrial controller generates the dynamic safety dew point margin according to the following relationship:

[0073] In the formula, This represents the dynamic safety dew point margin when warehouse partition i and warehouse partition j are synchronized across partitions. Indicates the static safety dew point margin; Indicates the spatial coupling deformation coefficient; This represents the amount of enthalpy disturbance.

[0074] S403, the industrial controller performs a boundary update process in the system's internal coordinate system. The industrial controller extracts the dynamic safety dew point margin. And according to the dynamic safety dew point margin A limited translation distance is used to shift the critical dew point boundary line toward the direction of low dew point risk, thereby generating a dynamic safety envelope.

[0075] The dynamic safety envelope divides the system's internal coordinate system into a condensation risk side and a safe side. Compared to the original dew point critical boundary line, the dynamic safety envelope expands the judgment range of the condensation risk side, enabling the industrial controller to trigger anti-condensation control earlier when there is significant cross-zone airflow disturbance.

[0076] When the industrial controller uses absolute humidity directional translation, the critical absolute humidity corresponding to the dynamic safety envelope is determined according to the following relationship:

[0077] In the formula, This represents the original critical absolute humidity determined by the minimum permissible surface temperature and the static dew point safety temperature difference; This represents the critical absolute humidity corresponding to the dynamic safety envelope.

[0078] When the industrial controller uses boundary normal translation, the industrial controller uses The normal translation distance of the dew point critical boundary line generates a dynamic safety envelope surface.

[0079] The S50 step includes the following sub-steps: S501, the industrial controller locates the current environmental state point of storage partition i in the system's internal coordinate system. When the current environmental state point is outside the target state polygon area, the industrial controller calculates the shortest distance from the current environmental state point to the boundary of the target state polygon area, and selects the nearest target boundary point or a preset target point as the control target point.

[0080] The industrial controller connects the current environmental state point and the control target point to generate a predictive control trajectory. The industrial controller performs cross-validation between the predictive control trajectory and the dynamic safety envelope to determine whether the predictive control trajectory crosses the dynamic safety envelope and enters the condensation risk side.

[0081] S502 When the predictive control trajectory crosses the dynamic safety envelope and enters the condensation risk side, the industrial controller confirms the existence of condensation risk, and synchronously sends a cooling command to the variable frequency compressor of the variable frequency air conditioning unit through the communication bus, and sends a heating compensation command to the independent reheater of the variable frequency air conditioning unit.

[0082] The cooling command is used to drive the variable frequency compressor to increase the cooling output, causing the moisture in the air to condense and precipitate, thus reducing the absolute humidity value; the heating compensation command is used to regulate the heat output of the independent reheater to compensate for the drop in ambient dry-bulb temperature during the cooling and dehumidification process.

[0083] The industrial controller maintains the ambient dry-bulb temperature of storage zone i within the allowable deviation range of the target temperature through synchronous control of variable frequency compressor refrigeration and dehumidification and independent reheater heating compensation, and reduces the absolute humidity to the humidity range corresponding to the target state polygon area.

[0084] S503, the industrial controller updates the environmental status point of storage zone i in real time based on the data received from the temperature and humidity transmitter. When the environmental status point returns from the condensation risk side of the dynamic safety envelope to the safety side, and the safety side criteria are continuously met for a preset number of samplings or a preset hysteresis time, the industrial controller determines that the condensation danger has been eliminated, disconnects the heating compensation command sent to the independent reheater, and shuts down the heating function of the independent reheater.

[0085] After the independent reheater is shut down, the industrial controller keeps the variable frequency compressor running under normal cooling and dehumidification conditions, causing the current environmental state point to move along the direction of enthalpy and dehumidification, and continuously corrects the position of the environmental state point based on the real-time collected environmental dry-bulb temperature and relative humidity, until the environmental state point is stably constrained within the target state polygon area.

[0086] S504, the industrial controller performs control debouncing and anomaly handling. When determining whether to release, cancel, open, or close a cross-zone synchronization request, the industrial controller sets a preset hysteresis threshold or a preset number of consecutive samples.

[0087] When the temperature and humidity transmitter data is missing, the data exceeds the physical reasonable range, or the jump variable exceeds the preset jump threshold in adjacent sampling periods, the industrial controller determines that the temperature and humidity data of the corresponding storage zone is invalid and temporarily uses the environmental state point of the previous stable sampling period to participate in the control calculation; when the invalid data continues for more than the preset time, the industrial controller cancels the cross-zone synchronization request of the corresponding storage zone and controls the proportional integral electric guide valve to return to the closed or safe opening position.

[0088] When the deviation between the target opening and the feedback opening of the proportional-integral electric deflector exceeds the preset deviation threshold and continues for more than the preset time, the industrial controller determines that the proportional-integral electric deflector is malfunctioning, stops the corresponding cross-zone synchronous control, and keeps the variable frequency air conditioning unit operating in the single-zone conventional temperature and humidity control mode.

[0089] Through the above control process, the industrial controller does not output control commands solely based on the ambient dry-bulb temperature or ambient relative humidity. Instead, it maps the ambient dry-bulb temperature and ambient relative humidity to air specific enthalpy and absolute humidity, and completes target state determination, cross-regional low-enthalpy air retrieval, dew point risk verification, and reheat compensation exit judgment in the air specific enthalpy and absolute humidity coordinate system.

[0090] When there is available low-enthalpy air in adjacent storage zones, the industrial controller will open the proportional-integral electric deflector valve only when the net enthalpy gain is greater than the equivalent enthalpy threshold and the virtual mixing state meets the dew point safety criterion, thereby reducing the ineffective cooling output of the variable frequency compressor. When cross-zone deflection causes condensation risk, the industrial controller will trigger cooling dehumidification and reheat compensation in advance through the dynamic safety envelope surface, and shut down the independent reheater after the condensation risk is eliminated.

[0091] Therefore, this invention can achieve synchronous allocation of low-enthalpy air between storage zones, anti-condensation protection, and reheat energy consumption suppression without adding additional physical flow sensors, thereby reducing the overall energy consumption during the temperature and humidity regulation process in storage.

[0092] Specific application examples: The experimental scenario and initial parameter settings are as follows: This embodiment is set in a large pharmaceutical warehousing center, where the storage space is divided into storage area A (corresponding to storage area i in the instruction manual) and storage area B (corresponding to storage area j in the instruction manual). The atmospheric pressure inside the storage area is kept constant at P = 101325 Pa.

[0093] Control target polygonal area: dry bulb temperature 22°C to 24°C, relative humidity 45% to 55%.

[0094] Initial state (when thermal and humidity disturbance occurs): Storage Zone i (A batch of ambient temperature and high humidity medicinal materials just received): The ambient dry-bulb temperature is measured by a temperature and humidity transmitter. =26℃, ambient relative humidity =65%.

[0095] Storage zone j (already in a stable storage state): ambient dry-bulb temperature measured by a temperature and humidity transmitter. =20℃, ambient relative humidity =40%.

[0096] The process of substituting the core formula and logical deduction is as follows: The industrial controller communicates with the temperature and humidity transmitter according to the preset sampling cycle and executes step S102: According to the Antoine equation, the saturated partial pressures of water vapor at 26℃ and 20℃ are respectively... (26℃)≈3363Pa, (20℃)≈2339Pa.

[0097] For storage zone i, the industrial controller calculates the absolute humidity and specific enthalpy of air:

[0098]

[0099] Similarly, substitute the values ​​into the formula to calculate the state of storage partition j:

[0100] Execution steps S202 and S204 (cross-regional synchronous analysis): Enthalpy gradient between adjacent storage zones:

[0101] Preset damper opening equivalent enthalpy threshold

[0102] Net enthalpy return The industrial controller determines that a low-enthalpy air requirement exists and generates a cross-regional synchronization request command.

[0103] Execution steps S30 and S40 (Virtual Hybrid and Dynamic Security Envelope): Assuming the return air mass flow rate is estimated using a mapping table of airflow level and damper opening, the estimated value is... =2.0kg / s, estimated mass flow rate of candidate cross-regional air supply =1.0kg / s.

[0104] Virtual absolute humidity .

[0105] Virtual air enthalpy .

[0106] enthalpy disturbance .

[0107] Industrial controllers based on The dynamic safety envelope is calculated and translated to generate it. At this point, the dew point temperature calculated by the virtual absolute humidity has not yet reached the condensation risk side of the dynamic safety envelope. The industrial controller releases the cross-regional synchronization request command and outputs an opening command to the proportional-integral electric guide valve.

[0108] Execution step S50 (Synchronization and Reheat Suppression): As the air valve opens, the environmental state point moves toward the target polygonal region. During the brief penetration of the dynamic safety envelope, the industrial controller synchronously sends a cooling command to the variable frequency compressor and a heating compensation command to the independent reheater. Five minutes later, the environmental state point returns to the safe side, and the industrial controller cuts off the heating compensation command sent to the independent reheater, continuing to operate independently using the low-enthalpy dry air introduced into zone j and the conventional cooling and dehumidification conditions.

[0109] The experimental verification and effect comparison are as follows: To verify the actual engineering effect of the above logic, it was compared with a single-zone conventional temperature and humidity control mode (without opening the cross-zone air valve, relying solely on the local compressor for dehumidification and the reheater for constant temperature) within 60 minutes of the control logic's operation, with a sampling period of 1 minute.

[0110] Reference Appendix Figure 3 , attached Figure 3 The paper shows that under initial thermal and humidity disturbances, the conventional mode blindly increases the cooling capacity of the inverter compressor, causing the dry-bulb temperature to drop below the lower limit of 22°C, resulting in overcooling. However, when using the solution of this invention, the industrial controller introduces air from storage zone j in advance based on the position of the environmental state point in the system's internal coordinate system. The dry-bulb temperature drops steadily and converges within the safe range enclosed by the coordinates of the target boundary vertex.

[0111] Reference Appendix Figure 4 , attached Figure 4The results show that due to the introduction of air from other zones, the relative humidity in storage zone i decreased at a faster rate than in the conventional mode. Because the industrial controller continuously determines the projection positions of the virtual air specific enthalpy and virtual absolute humidity, severe oscillations are avoided in the initial stage of dehumidification, and it takes only about 12 minutes to stabilize within the target state polygonal area of ​​45%-55%.

[0112] Reference Appendix Figure 5 , attached Figure 5 This demonstrates that after the industrial controller retrieves the spatial heat and humidity exchange coupling matrix and executes the cross-zone synchronization request command, the specific enthalpy of the air in storage zone i is rapidly reduced. Compared to the conventional mode that relies on its own cooling to withstand the load, the specific enthalpy decrease curve of this scheme has a steeper initial slope, verifying the system response advantage brought by utilizing the net enthalpy value.

[0113] Reference Appendix Figure 6 , attached Figure 6 The data indicates that during the initial opening of the proportional-integral electric deflector valve (approximately 0-8 minutes), the enthalpy disturbance caused by the cross-zone air introduction is instantly raised by the industrial controller from the base value (2.0) of the static safety dew point margin to a maximum of 4.5 based on this disturbance. This anti-shake operation of shifting the dew point critical boundary line prevents any false alarms in the initial condensation risk assessment.

[0114] Reference Appendix Figure 7 In conventional mode, to combat severe overcooling caused by dehumidification of the variable frequency compressor, the output power of the independent reheater surges to 5.5kW at the 8th minute. In contrast, this invention only sends a slight heating compensation command during the 2-6 minute period when the predicted control trajectory briefly crosses the dynamic safety envelope, and then quickly cuts off the heating compensation command transmitted to the independent reheater, thus achieving deep suppression of reheat power.

[0115] Reference Appendix Figure 8 , attached Figure 8 This reflects the macroscopic engineering benefits brought about by the invention after 60 minutes of operation. By reducing the operating time of the independent reheater inside the variable frequency air conditioning unit and reusing the low enthalpy air from adjacent zones, the total power consumption of the system is only about 40% of that of the conventional temperature and humidity control mode, perfectly demonstrating the technical effects mentioned in the manual of achieving synchronous use of low enthalpy air between storage zones, anti-condensation protection, and reheat energy consumption suppression.

Claims

1. A warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system, characterized in that, Applied to multiple warehouse zones, including: Temperature and humidity transmitters are used to detect ambient dry-bulb temperature and ambient relative humidity. Variable frequency air conditioning units, including variable frequency compressors and independent reheaters; A proportional-integral electric air deflector is installed between adjacent storage zones; An industrial controller is used to execute the following control logic: The ambient dry-bulb temperature and ambient relative humidity are converted into air specific enthalpy and absolute humidity to generate environmental state points, construct a target state polygon region, and pre-define the dew point critical boundary line with the safe side and the condensation risk side. When the environmental state point deviates from the target state polygon area, a cross-regional synchronization request command is generated based on the air specific enthalpy difference between adjacent storage zones. By combining the estimated return air mass flow rate and the estimated candidate cross-zone supply air mass flow rate, a virtual coordinate point containing virtual air specific enthalpy and virtual absolute humidity is generated; if the virtual coordinate point is determined to be on the safe side, the proportional-integral electric guide valve is activated. The absolute value of the difference between the virtual air enthalpy and the air enthalpy of the storage zone is calculated to generate an enthalpy disturbance. The dew point critical boundary line is translated according to the enthalpy disturbance to generate a dynamic safety envelope. When the predicted control trajectory of the environmental state point crosses the dynamic safety envelope to the condensation risk side, a cooling command is simultaneously sent to the variable frequency compressor and a heating compensation command is sent to the independent reheater.

2. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, The industrial controller combines the lower temperature limit, upper temperature limit, lower relative humidity limit, and upper relative humidity limit into temperature and humidity boundary points, converts them into target boundary vertex coordinates, and connects them according to the adjacency relationship of the target boundary vertex coordinates to generate a closed target state polygon region.

3. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, The industrial controller establishes a spatial heat and humidity exchange coupling matrix; when the environmental state point deviates from the target state polygon region, the industrial controller retrieves the spatial heat and humidity exchange coupling matrix and compares it with the equivalent enthalpy threshold to generate the cross-regional synchronization request instruction.

4. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 3, characterized in that, The equivalent enthalpy threshold represents the enthalpy compensation benchmark value after converting the additional energy consumption required for cross-zone air diversion to a unit mass of air; when multiple storage zones meet the low enthalpy air call conditions, the industrial controller preferentially selects the adjacent storage zone with the largest net enthalpy benefit as the candidate synchronization zone.

5. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, The industrial controller obtains the estimated value of the candidate cross-zone supply air mass flow rate through the cross-zone mass flow rate mapping table based on the candidate target opening degree and the pressure difference calibration value on both sides of the air valve; and obtains the estimated value of the return air mass flow rate through the return air mass flow rate mapping table based on the operating frequency and air volume level of the indoor circulating fan.

6. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, When the virtual coordinate point is determined to be on the condensation risk side, the industrial controller internally cancels the cross-regional synchronization request command and blocks the opening operation of the proportional-integral electric guide valve.

7. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, The industrial controller calculates and generates a dynamic safe dew point margin by combining the enthalpy disturbance and the static safe dew point margin; and performs a translation of the dew point critical boundary line according to the dynamic safe dew point margin to generate the dynamic safe envelope surface.

8. The warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, The industrial controller calculates the shortest distance from the current environmental state point to the boundary of the target state polygon region, selects the nearest target boundary point or a preset target point as the control target point, and connects the environmental state point and the control target point to generate the predicted control trajectory.

9. A warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, When the environmental status point fed back in real time returns from the condensation risk side to the safety side, and the safety side criteria are continuously met for a preset number of samplings or a preset hysteresis time, the industrial controller cuts off the heating compensation command transmitted to the independent reheater and controls the variable frequency compressor to operate independently under normal cooling and dehumidification conditions.

10. A warehouse temperature and humidity zoned synchronous adjustment and energy consumption optimization control system according to claim 1, characterized in that, When the deviation between the target opening and the feedback opening of the proportional-integral electric guide valve exceeds a preset deviation threshold and continues for a preset time during the operation process, the industrial controller stops the corresponding cross-zone synchronous control and keeps the variable frequency air conditioning unit operating in the single-zone conventional temperature and humidity control mode.

Images