Ore pulp multi-working condition particle size on-line self-adaptive detection system and method

Abstract

The present application relates to the technical field of industrial automatic control system device manufacturing, and discloses a kind of ore pulp multi-working condition granularity online self-adapting detection system and method, comprising: state observation module, control topology switching module, first linear feedback module, second variable structure gain module and bus convergence module;State observation module is used to generate residual envelope characteristic value;Control topology switching module is used to freeze the state of integrator in first linear feedback module when residual envelope characteristic value breaks through steady-state determination boundary, and activates second variable structure gain module;Second variable structure gain module is used to output phase feedforward compensation gain;Bus convergence module is used to superimpose phase feedforward compensation gain with proportional output instruction algebra, generates composite control regulation instruction and sends to downstream regulation module, and the present application eliminates phase change transition period loop response lag and control instruction oscillation.

Description

Technical Field

[0001] This invention belongs to the field of industrial automatic control system device manufacturing technology, and particularly relates to an online adaptive detection system and method for particle size of mineral slurry under multiple working conditions. Background Technology

[0002] The current distributed control architecture for scheduling variable frequency drives and regulating valves is a common solution for maintaining flow stability. Conventional control strategies rely on calibrated loop transfer functions, using proportional-integral-derivative (PID) controllers to calculate and output control commands to suppress unknown disturbances in the closed loop and ensure continuous system operation. However, when the slurry inside the pipeline undergoes hard switching between multiple operating conditions or flow phase changes, the time-varying and hysteresis characteristics of the controlled object cause frequent shifts in the loop's zeros and poles. Traditional solutions use online searches of fixed parameter tables to alternate loop parameters. Due to gain gaps between adjacent operating points, transient switching can easily trigger integral saturation divergence in the controller. This sudden change in feedback energy is transmitted along the digital bus to the downstream drive, inducing high-frequency overshoot in the commands. When the transient response exceeds 50ms and the control deviation crosses the 0.4 boundary, loop divergence and oscillation occur, causing downstream regulating mechanisms to trigger shutdown protection due to transient overload or current surges, increasing the potential risk of pipeline blockage and equipment damage.

[0003] To address feedback instability caused by abrupt changes in flow regime, relying on linear paths such as increasing valve power or adding filter branches often introduces new dynamic phase shift obstacles, compressing the loop phase margin. Existing technologies, including adjusting physical components, increasing the power of regulating mechanisms, and improving control channels at the control strategy algorithm level, exhibit limitations in the face of drastic phase change and multi-task environments. For example, Chinese invention patent application CN122018418A discloses a PLC control method and system for stabilizing mineral processing slurry, which uses a combination strategy of dynamic median-arithmetic mean filtering and incomplete derivative PID to suppress impulse noise. This method fundamentally relies on... The mathematical and statistical characteristics of slurry flow rate under relatively stable operating conditions, such as standard deviation and adjacent sampling difference, cannot cope with the frequent and large-scale shifts of zeros and poles in the closed loop of the system when facing extreme sudden changes such as hard switching of multi-task operating conditions or phase transition of solid-liquid two-phase flow. This is because mathematical filtering based on the difference between historical and current sampling values ​​and conventional PID limiting framework cannot handle the situation. They cannot reconstruct the control bus topology in situ, which leads to channel response lag and control command oscillation caused by time-varying logic such as integral separation. They cannot take into account the smoothness and stability margin of transient control during operating condition alternation. When facing the requirements of operating condition alternation, related technologies are generally constrained by the fundamental conflict between the smoothness of parameter switching and the stability margin of the closed loop.

[0004] Therefore, the technical problem to be solved by this invention is how to cut off the integral divergence path at the moment of hard switching of operating conditions through dynamic topology reconstruction of digital bus nodes in control loop, and to construct a variable structure phase feedforward counteracting channel with advanced phase compensation function to suppress transient oscillations in situ. Summary of the Invention

[0005] This invention aims to solve the problems of control command bounce and nonlinear oscillation caused by integral divergence during hard switching of multi-task operating conditions in the control loop.

[0006] In this technical solution, a multi-condition online adaptive particle size detection system for slurry includes: The status observation module is used to collect loop deviation data and feedback current signals, and to perform sliding window accumulation calculations based on the loop deviation data to generate residual envelope characteristic values. The control topology switching module is used to activate the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and to trigger an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. The first linear feedback module is used to output the main control adjustment command, which includes proportional output command and integral output command. The second variable structure gain module is used to calculate the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. The bus convergence module is connected to the first linear feedback module and the second variable structure gain module respectively. It is used to algebraically superimpose the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and send it to the downstream adjustment module.

[0007] Preferably, the system further includes a state hysteresis loop control module; the state hysteresis loop control module is connected to the control topology switching module, and is used to lock the trigger threshold as a high trigger boundary when the residual envelope characteristic value crosses the steady-state determination boundary from small to large, and to lock the switching threshold as a low switching boundary when the residual envelope characteristic value falls back from large to small, wherein the difference between the high trigger boundary and the low switching boundary is a preset discrete state lock-up step size, which is used to smooth out the control command bounce at the bus convergence module.

[0008] Preferably, the state observation module includes a state observer module and a residual envelope calculation module; the state observer module consists of multiple sub-observation modules configured in parallel for different flow conditions, used to capture the multidimensional time-varying characteristics of multiphase fluid in slurry in real time and output residual sequences; the residual envelope calculation module is used to perform square integration and sliding window smoothing on the residual sequences to generate residual envelope feature values.

[0009] Preferably, the system further includes a saturation suppression module; the saturation suppression module is used to calculate the first-order time derivative of the feedback current signal in real time during the process of the bus convergence module outputting the composite control adjustment command, and to dynamically link the first-order time derivative with the loop deviation data; when the absolute value of the feedback current signal reaches the set safety trigger threshold, the saturation suppression module adaptively limits and reduces the amplitude of the composite control adjustment command, wherein the safety trigger threshold is configured to be 0.95 times the set safety rated current value of the downstream adjustment module.

[0010] Preferably, the value of the steady-state determination boundary registered in the control topology switching module is 0.4; when the residual envelope characteristic value exceeds 0.4, an internal interrupt is enabled.

[0011] Preferably, the system further includes a low-pass rate limiting module, which is located on the front-end input side of the bus convergence module. Within the discrete state lock-up step locked by the state hysteresis loop control module, the low-pass rate limiting module is used to perform first-order low-pass filtering on the variable structure phase feedforward compensation gain output by the second variable structure gain module to limit the rate of change of the variable structure phase feedforward compensation gain during the topology network switching instant.

[0012] Preferably, the second variable structure gain module includes a sign discrimination module; the sign discrimination module is used to perform discrete state combination judgment on the sign of the loop deviation data and the sign of the feedback current signal, outputting the first phase feedforward gain when the two have the same sign, and outputting the second phase feedforward gain when the two have opposite signs, so as to construct a variable structure phase feedforward compensation gain with nonlinear characteristics.

[0013] Preferably, the first linear feedback module includes an integral clock control module; the integral clock control module is used to receive a clock disconnect command issued by the control topology switching module, and freeze the current accumulation state of the integral output command by turning off the clock input line of the integrator inside the first linear feedback module.

[0014] Preferably, the bus convergence module includes a hardware algebraic adder module located at the convergence node of the main control bus. This hardware algebraic adder module has a first input terminal, a second input terminal, and a composite output terminal. The first input terminal is connected to a first linear feedback module via a signal line to receive the proportional output command retained before freezing. The second input terminal is connected to a second variable structure gain module via a signal line to receive the variable structure phase feedforward compensation gain. The composite output terminal is connected to the downstream adjustment module via a control port. The system also includes a safety isolation protection module, which is connected in series between the bus convergence module and the downstream adjustment module. The safety isolation protection module monitors the amplitude of the composite control adjustment command in real time and disconnects the signal path between the control port and the downstream adjustment module when the amplitude continuously exceeds a set physical safety limit for 10ms.

[0015] A method for online adaptive particle size detection of mineral slurry under multiple operating conditions, used to operate an online adaptive particle size detection system for mineral slurry under multiple operating conditions, includes the following steps: Step S101: The state observation module collects loop deviation data and feedback current signal, and performs sliding window accumulation calculation based on the loop deviation data to generate residual envelope feature values. In step S102, the control topology switching module activates the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and triggers an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. Step S103: The first linear feedback module outputs a main control adjustment command that includes a proportional output command and an integral output command; Step S104: The second variable structure gain module calculates the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. In step S105, the bus convergence module algebraically superimposes the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and sends it to the downstream adjustment module.

[0016] Compared with existing technologies, the online adaptive particle size detection system for slurry under multiple working conditions of the present invention has the following advantages: 1. In the online adaptive detection of particle size under multiple working conditions of slurry, the discrete deviation flow signal in the feedback loop is captured by the error feature dynamic decoupling unit. The residual envelope energy characteristic value reflecting the disturbance intensity of the loop is calculated by using a digital sliding register window. Based on the comparison result between the characteristic value and the steady-state judgment boundary, the control topology switching finite state machine sends a topology arbitration command to the main control bus to activate the first linear feedback channel, or simultaneously loads the second variable structure damping channel with a leading phase compensation transfer function. The control gain is then superimposed in situ at the convergence node of the main control bus. This adjustment method directly changes the overall transfer function structure of the controlled system and realizes the dynamic adjustment of the zero-pole space.

[0017] 2. When the residual envelope energy characteristic value crosses the steady-state judgment boundary, the control topology switching finite state machine immediately triggers the internal interrupt logic, disconnects the clock enable of the integrator inside the first linear feedback channel, hard freezes the current accumulation state, cuts off the integral divergence path caused by the sudden change in flow state, synchronously activates the second variable structure damping channel and collects the deviation flow signal and the action current feedback signal, and produces the variable structure phase feedforward offset gain based on the discrete sign discrimination operator. At the convergence node, the gain is recombined with the proportional output command retained before freezing to produce the final composite control adjustment command. This avoids the inherent control command bounce and high-frequency oscillation during the hard switching of multiple models and ensures smooth system adjustment.

[0018] 3. A state hysteresis loop controller is introduced on the trigger path of the second variable structure damping channel. By setting a directional discrete event state machine hysteresis locking mechanism, when the residual envelope energy characteristic value goes out of bounds from small to large or falls back from large to small, the switching threshold is locked in different discrete state lock-up step ranges. In conjunction with the low-pass speed limiting link in front of the convergence node, the rate of change of compensation gain is limited. This blocks the transmission of high-frequency random noise and pipeline fluid pulses to the topology network, eliminates the high-frequency bouncing of control commands at the parallel bus convergence node, and prevents the actuator from being damaged by resonance while ensuring that the control bus topology arbitration delay is within a reasonable range. Attached Figure Description

[0019] Figure 1 This is a topology diagram of the control loop of the system of the present invention; Figure 2 This is a hardware topology diagram of the system of the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0021] A multi-condition online adaptive particle size detection system for mineral slurry includes: The status observation module is used to collect loop deviation data and feedback current signals, and to perform sliding window accumulation calculations based on the loop deviation data to generate residual envelope characteristic values. The control topology switching module is used to activate the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and to trigger an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. The first linear feedback module is used to output the main control adjustment command, which includes proportional output command and integral output command. The second variable structure gain module is used to calculate the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. The bus convergence module is connected to the first linear feedback module and the second variable structure gain module respectively. It is used to algebraically superimpose the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and send it to the downstream adjustment module.

[0022] Preferably, the system further includes a state hysteresis loop control module; the state hysteresis loop control module is connected to the control topology switching module, and is used to lock the trigger threshold as a high trigger boundary when the residual envelope characteristic value crosses the steady-state determination boundary from small to large, and to lock the switching threshold as a low switching boundary when the residual envelope characteristic value falls back from large to small, wherein the difference between the high trigger boundary and the low switching boundary is a preset discrete state lock-up step size, which is used to smooth out the control command bounce at the bus convergence module.

[0023] Preferably, the state observation module includes a state observer module and a residual envelope calculation module; the state observer module consists of multiple sub-observation modules configured in parallel for different flow conditions, used to capture the multidimensional time-varying characteristics of multiphase fluid in slurry in real time and output residual sequences; the residual envelope calculation module is used to perform square integration and sliding window smoothing on the residual sequences to generate residual envelope feature values.

[0024] Preferably, the system further includes a saturation suppression module; the saturation suppression module is used to calculate the first-order time derivative of the feedback current signal in real time during the process of the bus convergence module outputting the composite control adjustment command, and to dynamically link the first-order time derivative with the loop deviation data; when the absolute value of the feedback current signal reaches the set safety trigger threshold, the saturation suppression module adaptively limits and reduces the amplitude of the composite control adjustment command, wherein the safety trigger threshold is configured to be 0.95 times the set safety rated current value of the downstream adjustment module.

[0025] Preferably, the value of the steady-state determination boundary registered in the control topology switching module is 0.4; when the residual envelope characteristic value exceeds 0.4, an internal interrupt is enabled.

[0026] Preferably, the system further includes a low-pass rate limiting module, which is located on the front-end input side of the bus convergence module. Within the discrete state lock-up step locked by the state hysteresis loop control module, the low-pass rate limiting module is used to perform first-order low-pass filtering on the variable structure phase feedforward compensation gain output by the second variable structure gain module to limit the rate of change of the variable structure phase feedforward compensation gain during the topology network switching instant.

[0027] Preferably, the second variable structure gain module includes a sign discrimination module; the sign discrimination module is used to perform discrete state combination judgment on the sign of the loop deviation data and the sign of the feedback current signal, outputting the first phase feedforward gain when the two have the same sign, and outputting the second phase feedforward gain when the two have opposite signs, so as to construct a variable structure phase feedforward compensation gain with nonlinear characteristics.

[0028] Preferably, the first linear feedback module includes an integral clock control module; the integral clock control module is used to receive a clock disconnect command issued by the control topology switching module, and freeze the current accumulation state of the integral output command by turning off the clock input line of the integrator inside the first linear feedback module.

[0029] Preferably, the bus convergence module includes a hardware algebraic adder module located at the convergence node of the main control bus. This hardware algebraic adder module has a first input terminal, a second input terminal, and a composite output terminal. The first input terminal is connected to a first linear feedback module via a signal line to receive the proportional output command retained before freezing. The second input terminal is connected to a second variable structure gain module via a signal line to receive the variable structure phase feedforward compensation gain. The composite output terminal is connected to the downstream adjustment module via a control port. The system also includes a safety isolation protection module, which is connected in series between the bus convergence module and the downstream adjustment module. The safety isolation protection module monitors the amplitude of the composite control adjustment command in real time and disconnects the signal path between the control port and the downstream adjustment module when the amplitude continuously exceeds a set physical safety limit for 10ms.

[0030] A method for online adaptive particle size detection of mineral slurry under multiple operating conditions, used to operate an online adaptive particle size detection system for mineral slurry under multiple operating conditions, includes the following steps: Step S101: The state observation module collects loop deviation data and feedback current signal, and performs sliding window accumulation calculation based on the loop deviation data to generate residual envelope feature values. In step S102, the control topology switching module activates the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and triggers an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. Step S103: The first linear feedback module outputs a main control adjustment command that includes a proportional output command and an integral output command; Step S104: The second variable structure gain module calculates the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. In step S105, the bus convergence module algebraically superimposes the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and sends it to the downstream adjustment module.

[0031] Example 1: In the field of industrial automatic control system device manufacturing, a multi-condition online adaptive particle size detection system for slurry operates in a continuous fluid regulation environment. Due to abrupt phase transitions in the solid-liquid two-phase flow of the controlled object and step changes in mineral phase hardness, the transfer function poles of the closed-loop regulation system frequently shift. This causes the internal regulation channel of the control device to experience continuous integral saturation divergence due to regulation lag under phase transition disturbances. Consequently, during the transition period of multi-task condition switching, the control loop experiences loop divergence oscillation due to phase margin collapse, inducing high-frequency overshoot in the output command of the downstream drive device. The residual envelope eigenvalue... The calculation is expressed by the following formula: ,in, The residual envelope eigenvalue represents the average deviation envelope energy of the closed-loop circuit within the sliding window. Sampling time Digital deviation of the closed loop at the location. The length of the digital sliding register window is fixed at 10, representing 10 consecutive sampling periods.

[0032] To address the technical problem of model mismatch in multi-task operation conditions mentioned above, the industrial automatic control system device periodically collects loop deviation data and feedback current signals through a state observation module, and continuously accumulates the time-domain absolute value of the loop deviation data in an internal digital sliding register window to generate a residual envelope characteristic value reflecting the intensity of loop disturbance. The aforementioned state observation module contains three sub-observation modules configured in parallel for different flow conditions, corresponding to laminar flow, transitional flow, and turbulent flow conditions, respectively. Each sub-observation module pre-constructs a first-order autoregressive state estimation model for the multiphase fluid dynamics of the slurry under the corresponding flow condition. By receiving the deviation data of the parallel receiving loop and the feedback current signal, it recursively calculates the estimated output under the current flow condition in real time. The estimated output of each sub-observation module is subtracted from the actual acquired raw signal, thereby outputting an independent discrete residual sequence in its respective channel. These are then combined to form the aforementioned residual sequence, thereby achieving parallel capture of the multidimensional time-varying characteristics of the multiphase fluid. The control topology switching module transmits the real-time residual envelope feature values. Comparison with the internally registered steady-state decision boundary cascade, when the residual envelope eigenvalue When the steady-state judgment boundary of 0.4 is not exceeded, the control topology switching module sends a first bus scheduling instruction to uniquely activate the first linear feedback module. The first linear feedback module then outputs a main control adjustment instruction containing proportional and integral output instructions to the bus convergence module to meet the normal adjustment requirements under standard steady-state conditions.

[0033] When the phase change of the material flow state of the controlled object leads to the residual envelope characteristic value When the discrete event of exceeding 0.4 occurs, the control topology switching module immediately triggers an internal interrupt to send a clock cutoff signal to the first linear feedback module. This hardens the current accumulation state of the integrator within the first linear feedback module by shutting down its clock input line, thus cutting off the integration divergence path caused by physical lag. Based on this, the control topology switching module synchronously activates the second variable structure gain module. The second variable structure gain module has an internal lead phase compensation transfer function, which, based on the collected loop deviation data... With feedback current signal The internal sign discrimination module is used to determine the loop deviation data. The symbol and feedback current signal The signs of the two signals are used to calculate and output the first phase feedforward gain when they are the same, and the second phase feedforward gain when they are opposite. This calculates the output variable structure phase feedforward compensation gain with nonlinear characteristics. The bus convergence module, through a hardware algebraic addition module located at the main control bus convergence node, algebraically superimposes the variable structure phase feedforward compensation gain output by the second variable structure gain module with the proportional output command retained by the first linear feedback module before freezing, to generate a composite control adjustment command and send it to the downstream adjustment module to drive the downstream adjustment mechanism to perform a counter-acting action. Simultaneously, the state hysteresis loop control module connected to the trigger path of the second variable structure gain module also takes effect, when the residual envelope characteristic value... When the threshold exceeds the steady-state determination boundary from smallest to largest, the trigger threshold is locked as a high trigger boundary, while the residual envelope eigenvalues... When the signal decreases from large to small, the switching threshold is locked at a low switching boundary. A hysteresis locking mechanism that locks the step size interval in discrete states is introduced to smooth out control command bounce at the bus convergence module. In addition, a low-pass speed limiting module located at the input of the bus convergence module performs first-order low-pass filtering on the variable structure phase feedforward compensation gain to limit the instantaneous rate of change of the network switching. As a result, the adaptive transition time of the control system when facing phase transitions in multi-task conditions is controlled within 2.2 seconds, and the feedback error signal falls back to within 0.08. The existing processor in the system completes the offsetting and smoothing of the variable condition disturbance. Specifically, the high trigger boundary locked by the aforementioned state hysteresis loop control module... The quantization value is determined by the linear algebraic addition of the basic steady-state threshold constant and the discrete state lock-up step size. Under the current parameter configuration, since the basic steady-state threshold constant is fixed at 0.40 and the discrete state lock-up step size is fixed at 0.05, the calculated value of the high trigger boundary is determined to be 0.45. When the residual envelope eigenvalue increases from small to large and reaches or exceeds 0.45 for the first time, the system control topology switching finite state machine immediately locks the trigger threshold, hard limiting the switching state of the bus network until the eigenvalue subsequently falls back and breaks the low switching boundary before the lock is released. In this way, the asymmetric nonlinear hysteresis window is used to eliminate the bidirectional frequent switching bounce that occurs instantaneously during topology reconstruction.

[0034] Example 2: In the field of industrial automatic control system device manufacturing, a multi-condition online adaptive particle size detection system for slurry is placed in a test environment of fluid closed-loop regulation. The environment is constructed through a semi-physical simulation test method to create a measurement and control channel with phase transition disturbance characteristics of the solid-liquid two-phase flow state of the material to generate loop deviation data and feedback current signals. The computing unit adopts a central processing unit with partitioned independent computing units, and the connected sensor unit has a sampling frequency of 100Hz and a measurement resolution of 0.01mV. In order to simulate the electromagnetic interference in the power distribution network environment of the ore dressing plant, a Gaussian white noise with a signal-to-noise ratio of 20dB is superimposed on the test signal source, and a power frequency interference harmonic with a frequency of 50Hz is introduced. The length of the digital sliding register window used for sliding window accumulation calculation inside the adaptive detection system is considered. This parameter directly affects the temporal smoothness of feature extraction and the timeliness of the control loop's response to phase transitions. When the signal noise power increases and the spectral bandwidth of the interference harmonics is in the range of 5Hz to 15Hz, the length of the digital sliding register window is crucial to avoid signal aliasing under the Nyquist sampling theorem and to maintain the smoothness of residual extraction. The length of the digital sliding register window is inversely proportional to the interference frequency, thus determining the length for the current test conditions. The set value is 10, and the residual envelope eigenvalue is... The calculation expression is as follows: ,in, The residual envelope eigenvalue represents the average deviation envelope energy of the closed-loop circuit within the sliding window. Sampling time Digital deviation of the closed loop at the location. The length of the digital sliding register window is fixed at 10, representing 10 consecutive sampling periods.

[0035] To test the dynamic topology reconfiguration function of the control loop digital bus node in cutting off the integral divergence path and smoothing nonlinear oscillations during hard switching of operating conditions, the test program configured the sample group of this invention consisting of the complete technical solution. It also configured a first control group that maintained the clock enable input during phase transition but lacked the state lock-up characteristic of the integral accumulator, and a second control group lacking the lead-phase feedforward gain compensation channel. In the external parameter calibration, a lower limit out-of-range control group with a steady-state judgment boundary of 0.1 and an upper limit out-of-range control group with a steady-state judgment boundary of 1.2 were set respectively. The test uniformly applied three problem intensity gradient levels to the above groups, including low-degree flow regime fluctuations, medium-degree hardness steps, and severe two-phase flow regime abrupt changes. Under the test condition of severe two-phase flow regime abrupt changes, each group... The raw loop deviation data collected by the sensors all contained the aforementioned Gaussian white noise and power frequency interference harmonics. Test data showed that when the physical state of the controlled object crossed the range boundary, its parameter response exhibited a nonlinear performance inflection point. In the upper limit out-of-range control group with a steady-state judgment boundary set at 1.2, the set trigger threshold caused the control topology switching module to delay capturing discrete events during the transition period, extending its adaptive transition time to 8.45s. The control loop produced adjustment lag and path saturation. In the lower limit out-of-range control group with a steady-state judgment boundary set at 0.1, the trigger threshold caused high-frequency background noise to frequently trigger the internal interrupt logic, thereby causing the bus scheduling command to generate high-frequency bounce and causing the loop to diverge and oscillate. The above test results determined that the numerical range was the working window for maintaining a smooth transition of phase margin.

[0036] During the transient process of severe two-phase flow abrupt change in the test program, the state observation module continuously accumulates loop deviation data. To output intermediate feature data, the residual envelope feature values ​​in the sample group of this invention The steady-state reference value changes from 0.11 to 0.56. Upon exceeding the steady-state threshold of 0.4, the internal interrupt hardware of the control topology switching module is instantly activated. Its output bus scheduling command cuts off the clock input line of the integrator within the first linear feedback module, freezing the digital state of the accumulator register at its current value to prevent secondary divergence. In contrast, in the first control group lacking the integrator freezing characteristic, the internal register continues to accumulate values ​​during the adjustment lag period because the clock line is not turned off when a discrete event is triggered. This leads to an increase in the intermediate characteristic value to 1.54, inducing a 45.2% transient overshoot in the downstream drive device's output command and triggering a 12.65s-long nonlinear divergent oscillation. In the second control group lacking a phase-forward gain compensation channel, the loop's ability to counteract pole drift is reduced due to the lack of adjustment of the leading phase compensation transfer function, resulting in a feedback error convergence time of 7.82s. The present invention's sample group evaluates loop deviation data using a combination of sign discrimination modules within the variable structure gain module. The positive and negative polarities and feedback current signals The flow direction is determined, and the first phase feedforward gain is used when the two signs are the same, and the second phase feedforward gain is used when the signs are opposite. The variable structure phase feedforward compensation gain is superimposed on the aforementioned frozen proportional output command in situ by the hardware algebraic addition module located at the main control bus convergence node. This ensures that the adaptive transition time of the control system when facing the phase change switching of the flow condition is kept within 2.15s, and the feedback error signal falls back to within 0.075 after experiencing noise fluctuations. The existing processor in the system completes the offsetting and smoothing of the variable condition disturbance.

[0037] Example 3: This example combines Figures 1 to 2 This paper describes the online adaptive particle size detection system and method for slurry under multiple working conditions, such as... Figure 1 As shown, the state observation module collects feedback current signals and loop deviation data, and generates residual envelope characteristic values ​​by performing sliding window accumulation calculations, which are then output to the control topology switching module. The control topology switching module executes topology reconstruction and interruption logic based on the steady-state determination boundary. When the residual envelope characteristic value does not exceed the steady-state determination boundary, the first linear feedback module is activated. The first linear feedback module outputs a main control adjustment command containing proportional output and integral output commands, and outputs the retained proportional output command to the bus convergence module. When the residual envelope characteristic value exceeds the steady-state determination boundary, the control topology switching module sends a clock cutoff signal and freezes the integrator state to the first linear feedback module. At the same time, the second variable structure gain module is activated. The loop deviation data and feedback current signals are transmitted to the second variable structure gain module, which calculates and outputs the variable structure phase feedforward compensation gain and outputs it to the bus convergence module. The bus convergence module generates a composite control adjustment command by algebraically superimposing the gain and command, and finally outputs the composite control adjustment command to the downstream adjustment module.

[0038] like Figure 2 As shown, the sensor unit sends the raw deviation voltage signal to the central processing unit (CPU) via a transmission wire. The CPU has a partitioned independent processing unit, which is internally configured with a state observation module, a control topology switching module, a first linear feedback module, a second variable structure gain module, and a low-pass speed limiting module. The state observation module outputs the residual envelope characteristic value to the control topology switching module. The control topology switching module outputs a clock cutoff signal to the first linear feedback module and an activation signal to the second variable structure gain module. The first linear feedback module sends the proportional output command to the first input terminal and then to the main control bus convergence node. The second variable structure gain module outputs the variable structure phase feedforward compensation gain to the low-pass speed limiting module. The low-pass speed limiting module sends the speed limiting filter gain to the second input terminal and then to the main control bus convergence node. The main control bus convergence node sends the composite control adjustment command from the composite output terminal to the safety isolation protection module. The safety isolation protection module is connected to and outputs to the downstream regulating valve through the control port signal path.

[0039] Example 4: In the field of industrial automatic control system device manufacturing, when a multi-condition online adaptive particle size detection system for slurry operates in a multi-phase fluid multi-task working environment in a mineral processing plant's classification loop, high-frequency transient stress impacts are caused by the high-velocity mass transfer resistance of the pipeline material, and high-power background random noise is applied by the workshop power distribution network. This causes small and frequent fluctuations in the residual envelope characteristic value output by the state observation module, resulting in frequent mismatch topology decisions and causing continuous high-frequency disordered switching of the control topology switching module between different control loops. This not only exacerbates the control command bounce and bus scheduling conflict at the main control bus convergence node, but also causes parasitic heat loss in the adjustment channel due to the high-frequency operation of the high-power electromagnetic mechanism. In addition, the dynamic displacement deviation caused by the physical transmission gap of the mechanical actuator causes the feedback error signal of the loop to oscillate, resulting in a downward trend in the gain margin and phase margin of the controlled system.

[0040] To mitigate the interference of high-frequency background random noise on topology decision-making, the control topology switching module constructs a dynamic steady-state decision boundary by linearly superimposing the standard deviation compensation of the feedback current signal onto the threshold constant. Dynamic steady-state determination boundary The calculation formula is as follows: ,in, The dynamic steady-state determination boundary refers to the decision threshold used by the control topology switching module to identify discrete events of flow phase transition. The basic steady-state threshold constant is fixed at 0.4. This is the noise suppression adjustment factor, set to a value of 1.5. This represents the real-time time-domain standard deviation of the loop deviation data over 10 consecutive sampling periods.

[0041] In the aforementioned measurement and control topology control loop, the state observation module continuously collects loop deviation data under severe two-phase flow state abrupt change conditions. And calculate the real-time time domain standard deviation. This makes the calculated dynamic steady-state decision boundary... The residual envelope eigenvalues ​​obtained by the sliding window accumulation calculation of the state observation module exhibit a monotonically increasing trend. It rapidly climbs from the steady-state benchmark value of 0.11 and exceeds the dynamic steady-state determination boundary. At this time, the control topology switching module triggers its internal interrupt logic in real time through its internal interrupt hardwire, disconnecting the clock input line of the integrator in the first linear feedback module to lock the current register accumulation state and interrupt the integration divergence path. Simultaneously, it outputs an enable control command to the second variable structure gain module, which then determines the enable control based on the loop deviation data. The positive and negative polarities and feedback current signals The flow direction is determined, and the output has a variable structure phase feedforward compensation gain with advanced phase feedforward characteristics. The bus convergence module uses a hardware algebraic addition circuit located at the main control bus convergence node to algebraically superimpose the gain and the retained proportional output command in place. In addition, the first-order low-pass digital filter operator in the front-end low-pass speed limiting module limits the time domain change during bus switching. As a result, the adaptive transition time of the control system during phase transition switching in multi-task conditions is kept within 2.15 seconds, and the feedback error signal falls back to within 0.075. The central processing unit in the system completes the offsetting of the phase transition switching disturbance.

[0042] Example 5: When the system faces the initial physical calibration condition before the deployment of a new channel on site, the measurement and control channel continuously collects the initial electrical signal for 120 seconds in a zero-flow, zero-bias state without fluid injection through the state observation module. The processor calculates the average value of the initial electrical signal to measure the inherent zero-point bias voltage of the hardware. Its calibration formula is expressed as follows: ,in, For the calibrated loop deviation data, The original deviation voltage signal was acquired. The inherent zero-point bias voltage of the hardware eliminates the static polarization voltage drift caused by the distributed impedance of the transmission lines and the mechanical stress of the sensor installation in situ at the measurement and control link layer, keeping the initial zero-point error of the entire control loop within 0.01mV.

[0043] During the initial flow commissioning of the fluid regulation closed-loop circuit, the monitoring and control channel operates continuously for 30 minutes under steady-state material flow to inject slurry to regulate disturbances. During this period, the status observation module synchronously reads the loop deviation data at a sampling frequency of 100Hz. With feedback current signal The loop deviation data is calculated using a periodic sliding window with a length of 10 within the internal digital sliding register window. Real-time time domain standard deviation The central processing unit verifies the fundamental steady-state threshold constants in real time based on the lossless algebraic mapping equation. The time-domain stability of the loop when the residual envelope eigenvalue is under no phase transition perturbation When the maximum fluctuation ripple is within 0.15, the control topology switching module will dynamically determine the steady-state boundary. The calibration trigger reference is locked at 0.48. Under the drive of the composite control regulation command, the downstream regulating mechanism maintains the relative fluctuation of the valve opening to less than 0.5%, ultimately correcting the overall phase margin of the automatic control loop to... above.

[0044] Example 6: Under the conditions of two-phase flow change and high-frequency stray electromagnetic interference in the automated control production line for grinding and classification, the system determines the operating parameters of the control device through pre-parameter calibration and loop closed-loop verification. The system includes a central processing unit with independent partitioned computing units as the control component, constructs a digital signal channel with a fixed sampling frequency of 50Hz, and configures a hardware algebraic addition module at the convergence node of the system's main control bus. The parameter adjustment and topology reconstruction of the control device under different operating conditions are discretized by the three-point support method of supporting the lower limit, median, and upper limit.

[0045] In the lower limit test condition corresponding to the first support point, the mine water supply regulation loop is in a low-flow process rest period. The original deviation voltage signal output by the field transmitter transmission link is mixed with Gaussian white noise with a standard deviation of 0.02mV. The status observation module continuously collects electrical signals for 120s. The processor calculates the time-domain mean of the electrical signal through the built-in microcontroller register to measure the hardware zero-point bias voltage of the current detection link. The voltage is 0.15mV. The calibration unit injects the hardware zero-point bias voltage into the initial acquisition terminal of the error characteristic dynamic decoupling unit. The static polarization bias is eliminated through algebraic subtraction. The calibrated loop deviation data is then obtained. The calculation formula is configured as follows: ,in, For the calibrated loop deviation data, This refers to the hardware zero-point bias voltage. To acquire the raw deviation voltage signal, under the lower limit operating condition, the residual envelope calculation module within the state observation module processes data from 10 consecutive sampling periods within a sliding window, and calculates the residual envelope characteristic value. Random white noise fluctuations are generated between 0.04 and 0.08. The control topology switching module compares the real-time feature value with the basic steady-state threshold constant stored in the internal register. When the feature value does not exceed the steady-state judgment boundary of 0.40, the control topology switching module outputs the first bus scheduling command to activate the first linear feedback module. The first linear feedback module outputs the proportional adjustment command and the integral adjustment command to prevent the controlled bus node from performing a topology switching action.

[0046] In the median test condition corresponding to the second support point, the grinding and classification loop experiences a fluid flow phase change due to the step hardness of the feed ore phase, causing the closed-loop loop deviation to increase. The state observation module captures the discrete deviation flow signal in the loop and sends it to the envelope energy integral arbitrator. The envelope energy integral arbitrator uses its internal digital sliding register window to calculate the absolute value of the deviation flow signal and accumulates the integral. The calculation formula is configured as follows: ,in, The residual envelope eigenvalue represents the average deviation envelope energy of the closed-loop circuit within the sliding window. Sampling time The absolute value of the digital deviation of the closed-loop circuit at the location. The length of the digital sliding register window is fixed at 10; when a phase transition causes When the value climbs to 0.56 and breaks through the steady-state threshold of 0.40, the internal hard-wired interrupt logic of the topology switching module is triggered. The topology switching module sends a clock cut-off signal to the integral clock control module within the first linear feedback module to shut off the clock input line of the internal integrator. This freezes the current accumulator register state of the integrator at its current value, cutting off the divergence path of the integral term. Simultaneously, the topology switching module activates the second variable structure gain module, and the sign discrimination module compares the current loop deviation data sign with the inverter main drive feedback current signal. The flow direction sign completes the discrete state combination judgment. When the two signs are the same, the second variable structure gain module outputs the first phase feedforward gain in a stepped manner. The single-step adjustment amount is fixed at 5% of the basic control output. The hardware algebraic addition module at the convergence point of the main control bus node algebraically superimposes the variable structure phase feedforward compensation and the proportional output command retained before freezing in situ to generate a composite control adjustment command and send it to the downstream regulating valve. The state lag loop control module locks the switching threshold at the low switching boundary. The value of the low switching boundary is determined by the following formula: ,in, Returning to the boundary as the lower bound, The basic steady-state threshold constant is fixed at 0.40. The discrete-state lock-in step size is fixed at 0.05. Under this parameter configuration, a first-order low-pass digital filter with a time constant of 10ms is introduced into the low-pass speed limiting module at the front-end input of the bus convergence module to limit the abrupt change rate of control commands at the bus nodes. The composite command drives the regulating valve to correct the phase margin of the loop to above 46°, and as the valve opening is adjusted, the residual envelope eigenvalue... The value dropped from 0.56 to 0.38. Due to the directional hysteresis lockout boundary of 0.35, the state machine did not switch or bounce when the eigenvalue fell below 0.40. Once the eigenvalue fell below 0.35, the internal interrupt was unlocked, and the control topology switching module returned control to the first linear feedback module. In actual operation, when the aforementioned sign discrimination module determines that the sign of the loop deviation data is opposite to the sign of the variable frequency drive feedback current signal, it indicates that the current controlled object's action direction is opposite to the deviation adjustment trend. At this time, the second variable structure gain module is activated and outputs a targeted second phase feedforward gain. The second phase feedforward gain also adopts a discrete step-by-step form, but its single-step adjustment is fixed at 3% of the basic control output amplitude, and its output... The algebraic direction is configured to be absolutely opposite in sign to the current loop deviation data. Thus, by introducing a reverse damping hedging mechanism, excess kinetic energy generated during the transition period of the opposite sign loop can be promptly offset, preventing excessive superposition of the system's feedback energy at the bus convergence node. Together with the first phase feedforward gain, a variable structure phase feedforward compensation gain with nonlinear characteristics is constructed. In the upper limit test condition corresponding to the third support point, a large piece of material mechanically jams in the feed pipe of the ore dressing plant's grading loop, and harmonic interference with a power frequency of 50Hz is mixed into the measurement and control channel. To avoid topology decision mismatch caused by random noise, the control topology switching module constructs a dynamic steady-state decision boundary by linearly superimposing the dynamic compensation amount of the time-domain standard deviation of the feedback current signal to the threshold constant. The calculation formula is configured as follows: ,in, The dynamic steady-state determination boundary refers to the decision threshold for identifying discrete events of phase transition in the flow regime. The basic steady-state threshold constant is fixed at 0.40. The noise suppression adjustment coefficient is set to 1.5. The standard deviation of the loop deviation data in the real-time time domain over 10 consecutive sampling periods is used as the basis. The aforementioned basic steady-state threshold constant is set to 0.40, and the noise suppression adjustment coefficient is set to 1.5. This is based on prior data statistics and closed-loop robustness limit calculations before the industrial automation system is deployed at the mineral processing site. Field experiments show that when the pipeline material is in a standard steady-state flow state, the maximum residual envelope characteristic value of the background random noise fluctuation caused by high-power, high-frequency stray electromagnetic interference in the workshop is between 0.15 and 0.28. Setting the basic steady-state threshold constant to 0.40 ensures the system... A safety threshold margin of at least 30% is reserved to avoid erroneous switching of the control network caused by background random white noise. Simultaneously, through spectral analysis of power frequency harmonic interference in the distribution network, it is determined that the real-time time-domain standard deviation of the loop deviation data will experience a non-physical blind zone amplification of 1.2 to 1.4 times when subjected to pulsed electromagnetic shocks. Setting the noise suppression adjustment coefficient to 1.5 ensures that the calculated dynamic steady-state judgment boundary exactly covers the transient pseudo-out-of-bounds peak caused by high-power electromagnetic pulses, guaranteeing the absolute accuracy of topology decision-making under multi-task conditions. In the event of mechanical jamming, the feedback current signal... The absolute value reached 143A, triggering the 95% safety trigger threshold of the rated current of 150A. The saturation suppression module calculated the first-order time derivative of the current signal and determined that the control loop was in a mechanically jammed saturated state. It activated the closed-loop amplitude and speed limiting protection across the signal, causing the saturation suppression module to hard lock the integral accumulator of the main circuit controller to stop the continued superposition of the integral term in the delay stage. It also hard limited the amplitude change rate of the composite control regulation command output by the hardware algebraic addition module to no more than 1% of the total output amplitude per microsecond. At the same time, the safety isolation protection module monitored the signal path of the control port in series. When the amplitude continuously exceeded the physical safety limit for 10ms, it automatically disconnected the signal to block the overload divergence. Through the offsetting effect of the variable structure orthogonal topology and the amplitude and speed limiting module, the regulation response action converged within 2.15s, and the feedback deviation returned to the steady-state range within 0.075mV. The relative fluctuation amplitude of the valve opening of the downstream regulating valve remained below 0.5%. The aforementioned hard limit function for amplitude change rate of no more than 1% of the total output amplitude per microsecond is not executed by the central processing unit with a sampling frequency of 50 Hz through software algorithm, but is independently implemented by the analog hardware speed limiting circuit integrated at the output of the hardware algebraic adder module. The analog hardware speed limiting circuit consists of a low-pass damping filter network composed of a high-speed operational amplifier and peripheral resistor and capacitor components. Its inherent slew rate and dynamic response time constant hard lock the transient transition slope of the output analog voltage at the microsecond level. Thus, when the central processing unit updates and outputs discrete digital main control adjustment commands at a period of 20 milliseconds, the analog hardware speed limiting circuit automatically performs continuous physical smoothing decoupling on the step signal after algebraic superposition at the main control bus convergence node. This fundamentally ensures the continuous evolution of the final composite control adjustment command on the micro time scale and avoids the fundamental defect that the digital processor cannot implement microsecond-level amplitude limiting within the 20-millisecond control blind zone.

[0047] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit of this application and the scope of protection of this invention, and all of these forms are within the protection scope of this application.

Claims

1. A multi-condition online adaptive particle size detection system for slurry, characterized in that, include: The status observation module is used to collect loop deviation data and feedback current signals, and to perform sliding window accumulation calculations based on the loop deviation data to generate residual envelope characteristic values. The control topology switching module is used to activate the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and to trigger an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. The first linear feedback module is used to output the main control adjustment command, which includes proportional output command and integral output command. The second variable structure gain module is used to calculate the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. The bus convergence module is connected to the first linear feedback module and the second variable structure gain module respectively. It is used to algebraically superimpose the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and send it to the downstream adjustment module.

2. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The system also includes a state hysteresis loop control module; the state hysteresis loop control module is connected to the control topology switching module, and is used to lock the trigger threshold as a high trigger boundary when the residual envelope characteristic value crosses the steady-state determination boundary from small to large, and lock the switching threshold as a low switching boundary when the residual envelope characteristic value falls back from large to small. The difference between the high trigger boundary and the low switching boundary is a preset discrete state lock-up step size, which is used to smooth out the control command bounce at the bus convergence module.

3. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The state observation module includes a state observer module and a residual envelope calculation module. The state observer module consists of multiple sub-observation modules configured in parallel for different flow conditions. It is used to capture the multidimensional time-varying characteristics of multiphase fluid in slurry in real time and output the residual sequence. The residual envelope calculation module is used to perform square integration and sliding window smoothing on the residual sequence to generate residual envelope feature values.

4. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The system also includes a saturation suppression module; the saturation suppression module is used to calculate the first-order time derivative of the feedback current signal in real time during the process of the bus convergence module outputting the composite control regulation command, and to dynamically link the first-order time derivative with the loop deviation data; when the absolute value of the feedback current signal reaches the set safety trigger threshold, the saturation suppression module adaptively limits and clips the amplitude of the composite control regulation command, wherein the safety trigger threshold is configured to be 0.95 times the set safety rated current value of the downstream regulation module.

5. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The steady-state determination boundary value stored in the control topology switching module is 0.4; an internal interrupt is enabled when the residual envelope eigenvalue exceeds 0.

4.

6. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 2, characterized in that, The system also includes a low-pass rate limiting module, which is located on the front-end input side of the bus convergence module. Within the discrete state lock-up step size locked by the state hysteresis loop control module, the low-pass rate limiting module is used to perform first-order low-pass filtering on the variable structure phase feedforward compensation gain output by the second variable structure gain module to limit the rate of change of the variable structure phase feedforward compensation gain during the instant of topology network switching.

7. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The second variable structure gain module includes a sign discrimination module. The sign discrimination module is used to perform discrete state combination judgment on the sign of the loop deviation data and the sign of the feedback current signal. When the two have the same sign, it outputs the first phase feedforward gain, and when the two have different signs, it outputs the second phase feedforward gain, so as to construct a variable structure phase feedforward compensation gain with nonlinear characteristics.

8. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The first linear feedback module includes an integral clock control module; The integral clock control module is used to receive the clock disconnect command issued by the control topology switching module, and freeze the current accumulation state of the integral output command by turning off the clock input line of the integrator inside the first linear feedback module.

9. The online adaptive particle size detection system for slurry under multiple working conditions according to claim 1, characterized in that, The bus convergence module includes a hardware algebraic adder module located at the convergence node of the main control bus. This module has a first input terminal, a second input terminal, and a composite output terminal. The first input terminal is connected to a first linear feedback module via a signal line to receive the proportional output command retained before freezing. The second input terminal is connected to a second variable structure gain module via a signal line to receive the variable structure phase feedforward compensation gain. The composite output terminal is connected to the downstream regulation module via a control port. The system also includes a safety isolation protection module, which is connected in series between the bus convergence module and the downstream regulation module. The safety isolation protection module monitors the amplitude of the composite control regulation command in real time and disconnects the signal path between the control port and the downstream regulation module when the amplitude continuously exceeds the set physical safety limit for 10ms.

10. A method for online adaptive particle size detection of slurry under multiple working conditions, used to operate the online adaptive particle size detection system for slurry under multiple working conditions as described in claim 1, characterized in that, Includes the following steps: Step S101: The state observation module collects loop deviation data and feedback current signal, and performs sliding window accumulation calculation based on the loop deviation data to generate residual envelope feature values. In step S102, the control topology switching module activates the first linear feedback module when the residual envelope eigenvalue does not exceed the steady-state determination boundary, and triggers an internal interrupt when the residual envelope eigenvalue exceeds the steady-state determination boundary to send a clock cut-off signal to the first linear feedback module to freeze the current accumulation state of the internal integrator, while activating the second variable structure gain module. Step S103: The first linear feedback module outputs a main control adjustment command that includes a proportional output command and an integral output command; Step S104: The second variable structure gain module calculates the output variable structure phase feedforward compensation gain based on the loop deviation data and the feedback current signal. In step S105, the bus convergence module algebraically superimposes the variable structure phase feedforward compensation gain and the frozen proportional output command to generate a composite control adjustment command and sends it to the downstream adjustment module.

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