Intelligent heat exchange capacity analysis system

Abstract

The utility model provides an intelligent heat exchange capability analysis system, which is characterized in that a core board module in the device is connected with a central control room master station system through a first Ethernet, is in data connection with a sensor collector through a second Ethernet and is used for reading sensor data; and the core board module is connected with a water pump controller and a valve controller of the circulating water system. The core board module is connected with the industrial control all-in-one machine module through an RS-232 serial port. The core board module is connected with the cloud platform system through 4G wireless communication. The central control room master station system is connected with the industrial control all-in-one machine module through a fourth Ethernet, the central control room master station system is connected with the PLC module through a third Ethernet, the PLC module is connected with a sensor, a water pump controller and a valve controller in a main pipe of the circulating water system, and the cloud platform is further in signal connection with the central control room master station system. The device can automatically collect running parameters of a circulating water path and analyze the heat exchange capacity of a heat exchanger, and intelligent group control is conducted on circulating water system valves and water pumps according to analysis results.

Description

Technical Field

[0001] The utility model belongs to the technical field of automatic control of circulating water systems in chemical enterprises, and specifically relates to an intelligent heat exchange capacity analysis system. Background Art

[0002] Circulating cooling water is required for cooling in the production processes of coal coking and ethylene glycol. Since coal coking enterprises are located in the western region, the temperature difference between seasons and between morning and evening is large, resulting in unstable heat exchange capacity, which affects the heat exchange capacity. Circulating cooling water is also affected by changes in temperature. The above changes interact with heat exchange devices and process devices, making the temperature quality and heat exchange capacity of circulating cooling water a systematic problem, affecting the process flow indicators and thus affecting the benefits of the enterprise.

[0003] Systematic problems require systematic solutions. High energy consumption and unstable heat exchange efficiency are major problems in circulating cooling water systems. Through the analysis of various influencing factors, correlations, and related processes in the circulating cooling water system of coal coking, ethylene glycol circulating cooling water system, and air separation circulating cooling water system, it is recommended to focus on the heat exchange capacity of the heat exchanger, use intelligent group control for water pumps and valves, and systematically solve the quality problems of circulating cooling water to improve cooling quality and production efficiency. The automated control systems of production processes such as coal coking and ethylene glycol have high requirements for operational stability. Once the automated control system fails, it will cause unplanned shutdowns in the production process, thus affecting production. Utility Model Content

[0004] In view of the deficiencies in the prior art, the utility model provides an intelligent heat exchange capacity analysis system, which can automatically collect circulating water circuit operating parameters and perform heat exchange capacity analysis of the heat exchanger, and intelligently group control the valves and water pumps of the circulating water system according to the heat exchange efficiency of the heat exchanger; further, when the main station system or core board module in the central control room fails, it can still ensure the effectiveness of operation data collection and operation control, and ensure the safe and stable operation of the entire circulating water circuit system.

[0005] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0006] An intelligent heat exchange capacity analysis system, comprising: a core board module, an industrial control all-in-one machine module, a central control room master station system and a cloud platform system;

[0007] The core board module is connected to the industrial control integrated machine module, the industrial control integrated machine module is used to receive the data output by the core board module and to exchange signal data with the core board module, and the industrial control integrated machine module is used to send control signals of water pumps and valves in the circulating water system to the core board module when the main station system in the central control room fails;

[0008] The core board module is connected to the sensor collector of the circulating water system to collect operating parameter data of the circulating water system;

[0009] The core board module is connected to the central control room master station system, which is used to receive the data output by the core board module and calculate the heat exchange capacity of the heat exchanger according to the inlet and outlet operating parameter data of the heat exchanger in the circulating water system. The heartbeat data is established between the core board module and the central control room master station system for fault judgment of the central control room master station system or the core board module;

[0010] The core board module is connected to the water pump controller and valve controller of the circulating water system, and the core board module is used to control the working state of the water pump and valve in the circulating water system according to the control signal of the master station system in the central control room;

[0011] The core board module is wirelessly connected to the cloud platform system, and the cloud platform system is used to receive data output by the core board module; heartbeat data is established between the cloud platform system and the core board module for core board module fault determination;

[0012] The cloud platform system is connected to the central control room main station system, and is used to verify the circulating water system operation parameter data received by the cloud platform system with the circulating water system operation parameter data received by the central control room main station system. Heartbeat data is established between the cloud platform system and the central control room main station system for fault judgment of the central control room main station system.

[0013] Preferably, the 12V switching power supply module is used to provide a DC working voltage for the water pump controller signal interface, the valve controller signal interface, the industrial control all-in-one machine module, and the core board module.

[0014] Preferably, the core board module includes an LPC2468 chip.

[0015] Preferably, the central control room master station system is connected to the pressure sensor, temperature sensor and flow sensor arranged in the main pipe of the circulating water system through the PLC module, and the central control room master station system is also connected to the water pump controller and valve controller that control the main pipe of the circulating water system through the PLC module.

[0016] Preferably, the industrial control integrated machine module is connected to the central control room master station system, and the industrial control integrated machine module is used to upload local warning information and system operation logs to the central control room master station system.

[0017] Preferably, the core board module is provided with a dual-loop Ethernet wired communication interface module, wherein the first Ethernet path is used for data connection between the core board module and the central control room master station system, and the second Ethernet path is used for data connection between the core board module and the sensor collector.

[0018] Preferably, the central control room master station system is connected to the factory switch, the factory switch is connected to the core board module through a first Ethernet path, the factory switch is connected to the industrial control all-in-one machine module through a fourth Ethernet path, and the factory switch is connected to the PLC module through a third Ethernet path.

[0019] Preferably, the core board module is connected to the cloud platform system via 4G wireless communication, and the core board module is provided with a 4G wireless communication interface module, and the 4G wireless communication interface module adopts a SIM7100CE module.

[0020] Preferably, the core board module is connected to the industrial control integrated machine module via an RS-232 serial port.

[0021] Preferably, the core board module is connected to the water pump controller and the valve controller of the circulating water system through an I / O interface.

[0022] Furthermore, the 12V switching power supply module is also used to provide DC working voltage for the dual-circuit Ethernet wired communication interface module and the 4G wireless communication interface module.

[0023] Furthermore, the core board module adopts a modular system board with LPC2468 chip as the core, including 5V power supply circuit, reset circuit, program and data storage circuit, standard JTAG debugging interface, debugging indicator light, etc.

[0024] Furthermore, the core board module is connected to the sensor signals arranged on each branch waterway in the circulating waterway through the sensor collector, and cyclically reads the data of the sensor acquisition module, including temperature sensors, pressure sensors, flow sensors, etc., including sensor data on the inlet and outlet waterways of the heat exchanger. The core board module transmits the collected sensor data to the main station system, and uses existing analysis methods to analyze and compare the inlet and outlet sensor data of the heat exchanger to calculate the heat exchange capacity of the heat exchanger.

[0025] Furthermore, under normal operation, the industrial control integrated machine module and the core board module do not control the water pumps and valves, but only respond to the control commands of the central control room master station system. The core board module communicates with the central control room master station system through the first Ethernet line, exchanges data in real time, and establishes heartbeat data as the first judgment condition for determining the failure of the central control room master station system. The heartbeat data established between the cloud platform server and the central control room master station system serves as the second judgment condition for the failure of the central control room master station system. When the central control room master station system has no data exchange with the core board module and the cloud platform server for more than the agreed time range, the core board module can determine that the central control room master station system has a failure.

[0026] When the main station system in the central control room fails, the cloud platform server notifies the core board module, takes over the local water pumps and valves, and enters the pre-set local plan control mode. The local plan control mode can effectively solve the problem of controllable and adjustable equipment running in the set safety mode when the main station control system fails. The core board module judges the current operating status of the water pump and valve according to the local plan control mode and issues the plan control command. The control result is further confirmed through the collected state data to ensure that the water pump and valve are in safe and stable operation. The execution result is also notified to the cloud platform, waiting for the operation and maintenance personnel to check and handle it on site.

[0027] The industrial control all-in-one module is equipped with an operation mode switch, which has two gears and is used to change the working modes of the core board module and the industrial control all-in-one module, including remote control mode and local control mode. When the main station system in the central control room fails, the on-site operation and maintenance personnel will set the knob to the local control mode and actively exit the local plan-making mode and remote control mode. The on-site operation and maintenance personnel can use the industrial control all-in-one module to issue control instructions to the core board module through manual interaction, control the working status of the water pump and valve, and adjust important parameters. When the failure of the main station system in the central control room is resolved, it will switch back to the remote control mode to respond to the optimization control command of the main station system in the central control room.

[0028] Furthermore, the core board module establishes communication with the cloud platform server through the 4G wireless communication interface module, exchanges data in real time, responds to the command of the cloud platform, and sends heartbeat data to the cloud platform at regular intervals as the first judgment condition for the failure of the core board module. The core board module communicates with the central control room master station system, and the established heartbeat data is used as the second judgment condition for judging the failure of the core board module. When the core board module has no data exchange with the central control room master station system and the cloud platform server within the agreed time range, the central control room master station system can judge that the core board module has a fault.

[0029] When the core board module fails, the main station system in the central control room can also collect important process data through the PLC module, including the pressure data, temperature data, and flow data of the circulating water system trunk pipe, and control the water pump and valve of the circulating water system trunk pipe to ensure the stable operation of the circulating water trunk pipe process equipment.

[0030] Furthermore, when both the core board module and the central control room main station system fail, the cloud platform system will promptly issue an alarm to notify the operation and maintenance personnel to handle it on site.

[0031] Furthermore, the I / O interface of the core board module connected to the water pump controller and valve controller of the circulating water system includes a water pump power frequency start signal interface module and a valve controller signal interface module. The water pump power frequency start signal interface module is connected to the power frequency start signal port of the frequency converter and is used for the power frequency operation of the water pump under the plan mode. The valve controller interface signal module is connected to the valve controller and is used for adjusting the opening of the valve under the plan mode.

[0032] Furthermore, due to the communication relationship between the cloud platform system and the central control room master station system, after the cloud platform system receives the data sent by the core board module, it compares the data collected by the local central control room master station system. The data is verified at the structural level to ensure the reliability of the data.

[0033] The beneficial effects of the utility model are as follows: first, the intelligent heat exchange capacity analysis device can realize the collection, transmission, storage of operating parameter data of the circulating water system of the chemical plant, the analysis and processing of the heat exchange capacity of the heat exchanger, and the output of control instructions in one, and is an important part of the intelligent control of the circulating water system of the chemical plant; second, by setting up a cloud platform system, the heartbeat data established between the cloud platform system, the core board module and the main station system of the central control room can be used to realize the fault judgment of the core board module and the main station system of the central control room; third, when the main station system of the central control room fails, the industrial control all-in-one machine can be used to realize the parameter collection and display of the circulating water system of the chemical plant and the control of the water pump and valve. When the core board module fails, the main station system of the central control room can use the PLC module to directly collect the important main pipe operating parameters in the circulating water system and control the main pipe water pump and valve, ensuring the stable operation of the circulating water system equipment under the fault state; fourth, by configuring a variety of operation modes, local intelligent management of controllable and adjustable equipment is realized, effectively solving the fault exit and manual safety takeover problems of the local main station control system in a certain application scenario. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a functional module schematic diagram of an intelligent heat exchange capacity analysis system of the utility model;

[0035] Figure 2 The utility model is a structural schematic diagram of an intelligent heat exchange capacity analysis system. DETAILED DESCRIPTION

[0036] The utility model is described in detail below with reference to the accompanying drawings.

[0037] In the production process of coal coking, ethylene glycol, etc., a circulating cooling water system is needed, which has high requirements for operation stability. At the same time, due to the continuous production of chemical enterprises, unplanned shutdown of the circulating cooling water system is not allowed. In order to solve the above problems, this embodiment provides an intelligent heat exchange capacity analysis system applied in the circulating water system of a chemical plant, such as Figure 1 As shown, it includes a 12V switching power supply module, a core board module, an industrial control all-in-one machine module, a PLC module, a central control room master station system and a cloud platform system.

[0038] In this embodiment, the core board module adopts a modular system board with LPC2468 as the core, which includes the most basic 5V power supply circuit, reset circuit, program and data storage circuit, standard JTAG debugging interface, debugging indicator light, etc.

[0039] The core board module is also provided with a dual-loop Ethernet wired communication interface module, wherein the core board module is connected to the central control room master station system through the first Ethernet road and the plant switch, and the core board module is connected to the sensor collector data through the second Ethernet road, and the data of the sensor acquisition module is cyclically read, including the temperature sensor, pressure sensor, flow sensor, etc. of the circulating water system. The core board module is connected to the water pump controller and valve controller of the circulating water system through the I / O interface. The core board module is connected to the industrial control integrated machine module through RS-232 serial port communication. The core board module is also provided with a 4G wireless communication interface module. In this embodiment, the 4G wireless communication interface module adopts the SIM7100CE module, and the core board module is connected to the cloud platform system through 4G wireless communication.

[0040] In this embodiment, the main station system of the central control room is connected to the industrial control all-in-one machine module through the factory switch and the fourth Ethernet line, and the main station system of the central control room is connected to the PLC module through the factory switch and the third Ethernet line. The PLC module is connected to the pressure sensor, temperature sensor and flow sensor arranged in the main pipe of the circulating water system. The PLC module is also connected to the water pump controller and valve controller that control the main pipe of the circulating water system.

[0041] In this embodiment, the cloud platform is also connected to the central control room master station system signal.

[0042] In this embodiment, the 12V switching power supply module is used to provide DC working voltage for the water pump industrial frequency starting signal interface module, valve controller signal interface module, industrial control all-in-one machine module, core board module, 4G wireless communication interface module, and dual-loop Ethernet communication interface module.

[0043] In this embodiment, the core board module communicates with the central control room master station system through the first Ethernet, exchanges data in real time, and establishes heartbeat data as the first judgment condition for judging the failure of the central control room master station system. The heartbeat data established between the cloud platform server and the central control room master station system is used as the second judgment condition for the failure of the central control room master station system. When the central control room master station system has no data exchange with the core board module and the cloud platform server within the agreed time range, the core board module can judge that the central control room master station system has a failure.

[0044] In the present embodiment, the core board module establishes communication with the cloud platform server through the 4G wireless communication interface module, exchanges data in real time, responds to the command of the cloud platform, and sends heartbeat data to the cloud platform regularly as the first judgment condition of the core board module failure. The core board module communicates with the central control room master station system, and the established heartbeat data is used as the second judgment condition for judging the core board module failure. When the core board module has no data exchange with the central control room master station system and the cloud platform server within the agreed time range, the central control room master station system can judge that the core board module is faulty.

[0045] In this embodiment, when the core board module and the central control room master station system are working normally, the core board module is connected to the sensor signals set on each branch waterway in the circulating waterway through the sensor collector, and the data of the sensor acquisition module is read cyclically, including temperature sensors, pressure sensors, flow sensors, etc., including sensor data on the inlet and outlet waterways of the heat exchanger. The core board module transmits the collected sensor data to the central control room master station system, and uses the existing analysis method to analyze and compare the inlet and outlet sensor data of the heat exchanger to calculate the heat exchange capacity of the heat exchanger. At the same time, the core board module transmits the sensor data collected locally to the industrial control integrated machine for human-computer interaction of the controlled equipment.

[0046] The central control room master station system issues group control instructions to the core board module based on the analysis results. The core board module performs group control on the water pumps and valves in each waterway of the circulating water system according to the control instructions, completes intelligent control, and ensures the efficient and stable operation of the circulating water system. At this time, the industrial control all-in-one module and the core board module do not control the water pumps and valves, but only respond to the control commands of the central control room master station system.

[0047] In this embodiment, when it is determined that the main station system in the central control room fails, the cloud platform server notifies the core board module, takes over the local water pumps and valves, and enters the pre-set local plan control mode. The local plan control mode can effectively solve the problem that the controllable and adjustable equipment operates in the set safety mode when the main station control system fails. The core board module issues a plan control command after judging the current operating status of the water pump and valve according to the local plan control mode, and further confirms the control result through the collected state quantity data to ensure that the water pump and valve are in safe and stable operation. The execution result is also notified to the cloud platform, waiting for the operation and maintenance personnel to check and handle it on site.

[0048] The industrial control all-in-one machine module is equipped with an operation mode switch, which has two gears and is used to change the working modes of the core board module and the industrial control all-in-one machine module, including remote control mode and local control mode. When the main station system in the central control room fails, the on-site operation and maintenance personnel will set the knob to the local control mode and actively exit the local plan-making mode and remote control mode. The on-site operation and maintenance personnel can use the industrial control all-in-one machine module to issue control instructions to the core board module through manual interaction, control the working status of water pumps and valves, and adjust important parameters. Ensure that the on-site manual operation control level is the highest during the production process of chemical enterprises. When the fault of the main station system in the central control room is resolved, switch back to the remote control mode to respond to the optimization control command of the main station system in the central control room.

[0049] In this embodiment, when it is determined that the core board module fails, the central control room master station system can collect important process link data through the PLC module, including the pressure data, temperature data, and flow data of the circulating water system trunk pipe, and control the circulating water system trunk pipe water pump and valve to ensure the stable operation of the circulating water trunk pipe process equipment.

[0050] In this embodiment, when both the core board module and the central control room master station system fail, the cloud platform system promptly issues an alarm to notify the operation and maintenance personnel to handle it on site.

[0051] In this embodiment, the I / O interface of the core board module connected to the water pump controller and valve controller of the circulating water system includes a water pump power frequency start signal interface module and a valve controller signal interface module. The water pump power frequency start signal interface module is connected to the power frequency start signal port of the frequency converter and is used for the power frequency operation of the water pump under the plan mode. The valve controller interface signal module is connected to the valve controller and is used for adjusting the opening of the valve under the plan mode.

[0052] In this embodiment, the control interface circuit controls the water pump controller and the valve controller by controlling the magnetic latching relay to close. The magnetic latching control circuit does not affect the control result even when the device is powered off or fails. Furthermore, the intelligent heat exchange capacity analysis system also comprehensively determines whether the control result is normal through the collected sensor data and state quantity data.

[0053] Due to the harsh working conditions in chemical plants, the core board module, industrial control all-in-one machine module, PLC module and various interface modules need to work in an explosion-proof environment. In this embodiment, an explosion-proof box with an explosion-proof grade of CT6 is selected, and the core board module, industrial control all-in-one machine module, PLC module and various interface modules are installed and deployed in the explosion-proof box to ensure the safe and reliable operation of the equipment on site.

[0054] In summary, this technical solution discloses an intelligent heat exchange capacity analysis system, which can realize the collection, transmission, storage of operating parameter data of the chemical plant's circulating water system, as well as the analysis and processing of the heat exchange capacity of the heat exchanger and the output of control instructions in one during normal operation, so as to ensure the intelligent operation of the chemical plant's circulating water system. At the same time, heartbeat data is established between the core board module, the central control room master station system and the cloud platform, which can monitor the core board module and the central control room master station system for faults, and ensure the smooth and normal operation of the circulating water system through preset devices according to the fault location. Furthermore, the core board module and the industrial control all-in-one machine module can be configured with multiple operating modes to realize local intelligent management of controllable and adjustable equipment. It effectively solves the problem of fault exit and manual safety takeover of the local master station control system in a certain application scenario, and ensures the highest level of on-site manual operation control in the production process of chemical enterprises.

Claims

1. An intelligent heat exchange capacity analysis system, characterized in that: include: Core board module, industrial control integrated machine module, central control room master station system and cloud platform system; The core board module is connected to the industrial control integrated machine module, the industrial control integrated machine module is used to receive the data output by the core board module and to exchange signal data with the core board module, and the industrial control integrated machine module is used to send control signals of water pumps and valves in the circulating water system to the core board module when the main station system in the central control room fails; The core board module is connected to the sensor collector of the circulating water system to collect operating parameter data of the circulating water system; The core board module is connected to the central control room master station system, which is used to receive the data output by the core board module and calculate the heat exchange capacity of the heat exchanger according to the inlet and outlet operating parameter data of the heat exchanger in the circulating water system. The heartbeat data is established between the core board module and the central control room master station system for fault judgment of the central control room master station system or the core board module; The core board module is connected to the water pump controller and valve controller of the circulating water system, and the core board module is used to control the working state of the water pump and valve in the circulating water system according to the control signal of the master station system in the central control room; The core board module is wirelessly connected to the cloud platform system, and the cloud platform system is used to receive data output by the core board module; heartbeat data is established between the cloud platform system and the core board module for core board module fault determination; The cloud platform system is connected to the central control room main station system, and is used to verify the circulating water system operation parameter data received by the cloud platform system with the circulating water system operation parameter data received by the central control room main station system. Heartbeat data is established between the cloud platform system and the central control room main station system for fault judgment of the central control room main station system.

2. An intelligent heat exchange capacity analysis system according to claim 1, characterized in that: It also includes a 12V switching power supply module, which is used to provide DC working voltage for the water pump controller signal interface, valve controller signal interface, industrial control all-in-one machine module, and core board module.

3. The intelligent heat exchange capacity analysis system according to claim 1, characterized in that: The core board module includes an LPC2468 chip.

4. The intelligent heat exchange capacity analysis system according to claim 1, characterized in that: The central control room master station system is connected to the pressure sensor, temperature sensor and flow sensor arranged in the main pipe of the circulating water system through the PLC module. The central control room master station system is also connected to the water pump controller and valve controller that control the main pipe of the circulating water system through the PLC module.

5. The intelligent heat exchange capacity analysis system according to claim 4, characterized in that: The industrial control integrated machine module is connected to the central control room master station system, and the industrial control integrated machine module is used to upload local warning information and system operation logs to the central control room master station system.

6. An intelligent heat exchange capacity analysis system according to claim 5, characterized in that: The core board module is provided with a dual-loop Ethernet wired communication interface module, wherein the first Ethernet path is used for data connection between the core board module and the central control room master station system, and the second Ethernet path is used for data connection between the core board module and the sensor collector.

7. An intelligent heat exchange capacity analysis system according to claim 6, characterized in that: The central control room master station system is connected to the factory switch, the factory switch is connected to the core board module through the first Ethernet path, the factory switch is connected to the industrial control all-in-one machine module through the fourth Ethernet path, and the factory switch is connected to the PLC module through the third Ethernet path.

8. The intelligent heat exchange capacity analysis system according to claim 1, characterized in that: The core board module is connected to the cloud platform system via 4G wireless communication. The core board module is provided with a 4G wireless communication interface module. The 4G wireless communication interface module adopts a SIM7100CE module.

9. The intelligent heat exchange capacity analysis system according to claim 1, characterized in that: The core board module is connected to the industrial control integrated machine module via the RS-232 serial port.

10. The intelligent heat exchange capacity analysis system according to claim 1, characterized in that: The core board module is connected to the water pump controller and the valve controller of the circulating water system through the I / O interface.

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