Centralized control system for collecting and distributing equipment in aluminum oxide industry

Abstract

The utility model relates to the technical field of automatic control, in particular to an aluminum oxide industry distributed equipment centralized control system which comprises a client side, a centralized control module, a local I / O bus, a local control module, an expansion I / O bus, an expansion I / O connection module, a switching module, a distributed control module and a field metering and collecting module. The centralized monitoring and control of the production process data of the whole plant and the automatic generation of information integration platform reports can be realized. Besides, the switching module is installed on the distributed control module, so that the system can be upgraded and replaced within the shortest time, the continuous production process in the aluminum oxide industry is met, interference and fluctuation caused by upgrading and reconstruction of the distributed control system to process production are reduced to the maximum extent, all the systems can be rapidly replaced within 24 hours at 2000 points or below, and the efficiency is improved. And the practical function is high.

Description

Technical Field

[0001] The utility model relates to the technical field of automatic control, in particular to a centralized control system for distributed equipment in the alumina industry. Background Art

[0002] In major domestic alumina production processes, the industry's continuous production and overall process liquid balance control are unique, and the coexistence of multiple DCS (distributed control systems) is a significant challenge for intensive production organization. Interoperability between various system devices is hindered by differing protocols and communication interfaces. Furthermore, each brand's control system operates in different versions, with incompatible software, hardware, and communication interfaces. For example, the Modbus TCP protocol used in the alkali pump motor pre-check and prediction system, the Power System 645 protocol used by the thermal dispatch network's electricity meters, the Modbus RTU protocol used by the distribution room's electricity meters, and the Profinet protocol used by the ash silo's dust collection PLCs, are all incompatible. The inconsistent brands and models of these devices and their dispersed physical locations make the implementation of centralized control systems challenging. Currently, production data is largely distributed across process-level DCS systems, lacking connectivity. This large amount of unrelated, accumulated data is incompatible, making it difficult to access and understand. Furthermore, the inconsistent production data obtained by various departments makes it difficult to identify real problems and make quick decisions.

[0003] Due to the continuous operation characteristics of the alumina production process, the upgrade and transformation of the automatic control system must be completed without stopping production or under the conditions of short-term local production reduction. It is required that each process link upgrade the automatic control system in the shortest possible time, under the conditions of stopping or reducing production, to avoid the interruption of the continuous production process causing the liquid balance of the entire production line to be broken, resulting in deterioration of process indicators or forced shutdown of the entire line. According to the traditional method, it is necessary to first power off the system and retract all I / O cables, remove the old control cabinet, install the new control cabinet, lay the I / O cables, and then debug the wiring. For example, a system with about 2000 conventional I / O points will take more than 15 working days to replace, which will seriously affect the normal continuous production of alumina. Utility Model Content

[0004] Therefore, based on the problems of the various system protocols used in the existing alumina production process being difficult to communicate with each other, incompatible interfaces, dispersed physical locations of the systems, unrelated information data, and the long time period for unified replacement of the centralized control system, which delays production, the following technical solutions are proposed:

[0005] A centralized control system for distributed equipment in the alumina industry, specifically comprising: a client, a centralized control module, a local I / O bus, a local control module, an extended I / O bus, an extended I / O connection module, a switching module, a decentralized control module and a field measurement and acquisition module, wherein the centralized control module is connected to multiple clients, the centralized control module is connected to the local control module via the local I / O bus, the centralized control module is connected to the switching module via the extended I / O bus and the extended I / O connection module in turn, the switching module is connected to the decentralized control module via the I / O interface, and the decentralized control module is connected to the field measurement and acquisition module; wherein the centralized control module is redundantly configured and comprises two main controllers, and the I / O interface controlled by the centralized control module exceeds 1500 points; the switching module comprises an analog switching module, a relay input module, a relay output module and a communication connection module, and the switching module and the extended I / O connection module are connected via a DB communication cable, which is a dedicated communication connection cable with different numbers of cores, for example, DB37 represents 37 cores, DB9 represents 9 cores, etc.

[0006] Furthermore, the distributed control module is placed in a cabinet, and the adapter module is placed in the cabinet of the distributed control module to which it is connected.

[0007] Furthermore, the power supply circuit of the adapter module is connected to the power supply circuit of the centralized control module. The adapter module and the centralized control module are powered by the same UPS power supply line and share the same common grounding system.

[0008] Furthermore, the I / O interfaces of the adapter module are arranged in the order of AI, AO, DI, DO, and communication card.

[0009] Optimally, the adapter modules should be arranged in the order of AI, AO, DI, DO, and communication card. Alternatively, the adapter module installation can be adjusted according to the original system order to facilitate the subsequent, orderly connection of I / O signal cables. The I / O interfaces of the adapter module and the distributed control module should be arranged in the same order as the distributed control module's I / O interfaces. This ensures that when connecting cables to the adapter module, cable length deviations do not result in the need to cut cables or create joints.

[0010] The beneficial effects of the present invention are as follows: by collecting data from the local control modules, decentralized control modules and discrete on-site metering acquisition modules connected to the control network, the centralized monitoring and control of the production process data of the entire plant and the automatic generation of information integration platform reports are finally realized in the centralized control module of the centralized control center. The control part of the original old decentralized control module is deactivated, all the original boards and stored control programs are retained, and the I / O interface signal part is led out to the new adapter module, which is connected to the new centralized control module via a DB communication cable. In addition, after the adapter module is connected, a dual-system parallel mode can be adopted, which does not affect the progress of alumina production and can compare the main parameters of concern. Moreover, the adapter module is installed in the cabinet of the old decentralized control module, and the wiring is very fast, which can achieve the complete rapid replacement of all systems below 2000 points within 24 hours. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following further describes the embodiments of the present invention with reference to the accompanying drawings, wherein:

[0012] Figure 1 A partial schematic diagram of the centralized control system for distributed equipment in the alumina industry according to the present invention is shown.

[0013] Among them, 1-client, 2-main controller, 3-centralized control module, 4-local I / O bus, 5-local control module, 6-expanded I / O bus, 7-expanded I / O connection module, 8-transfer module, 9-analog transfer module, 10-relay input module, 11-relay output module, 12-communication connection module, 13-distributed control module. DETAILED DESCRIPTION

[0014] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0015] A centralized control system for distributed equipment in the alumina industry, comprising: multiple clients 1, a centralized control module 3, a local I / O bus 4, a local control module 5, an extended I / O bus 6, an extended I / O connection module 7, a switching module 8, a distributed control module 13, and a field measurement acquisition module. The centralized control module 3 is connected to the multiple clients 1, and the centralized control module 3 is connected to the local control module 5 (a system device with a matching interface) via the local I / O bus 4. The centralized control module 3 is sequentially connected to the switching module 8 via the extended I / O bus 6 and the extended I / O connection module 7. The switching module 8 is connected to the I / O interface signal portion of the distributed control module 13 (an old system device with an unmatched interface) via the I / O interface. The distributed control module 13 is connected to the field measurement acquisition module via its I / O interface. The EC700 system features a redundant configuration, including two main controllers 2. The centralized control module 3 controls approximately 2,000 I / O points. The adapter module 8 includes an analog adapter module 9, a relay input module 10, a relay output module 11, and a communication connection module 12. The adapter module 8 and the expansion I / O connection module 7 are connected via a DB37 communication cable. The distributed control modules 13 are housed in a cabinet, and the adapter module 8 is housed in the cabinet of the corresponding distributed control module 13. The DB37 communication cable, with a maximum specification of 25 meters, is selected based on the actual distance. The DB37 communication cable is a dedicated 37-core communication cable.

[0016] The power supply circuit of the adapter module 8 is connected to the power supply circuit of the centralized control module 3. The centralized control module 3's power supply follows the original dual-circuit redundant configuration, ensuring power supply from the same UPS power supply line and establishing a common grounding system for the new and old systems. The I / O interface sequence of the adapter module 8 and the distributed control module 13 should follow the original I / O interface sequence of the distributed control module 13. This facilitates the subsequent, nearby and orderly connection of the I / O signal cables. This prevents cable length deviations when connecting the cables to the adapter module 8, requiring cable cuts or joint fabrication, thus avoiding time delays. The adapter module 8 is typically arranged in the order of AI, AO, DI, DO, and communication card.

[0017] The specific operations for quick switching of the system are as follows:

[0018] 1. Prepare the cabinet of the centralized control module 3-ECS700 control system in place, assemble and power on, and ensure external communication is in place in advance. Establish an I / O point table for the distributed control module 13, and control the logic block and operation authority allocation. Statistically list the I / O point sequence of the original distributed control system 13, and arrange the type, quantity, and arrangement order of the adapter module 8 as needed. The fixing method of the adapter module 8 needs to refer to the original I / O incoming line length. Select a suitable location in the cabinet of the distributed control module 13 (old system cabinet) for arrangement. Optimize the selection in advance to avoid unnecessary trouble caused by the length of the I / O inlet and outlet lines. Usually, the side of the old cabinet is preferred. Test the DB communication cable connection in advance, and have the system debugging personnel in place. Check the lines, power supply, cabinet exhaust fan, optical cable line, back-end switch power and signal light status, system hardware and communication, network and information equipment power and signal light status of the new system (centralized control module 3, local I / O bus 4, local control module 5, extended I / O bus 6, extended I / O connection module 7) and confirm that there are no abnormalities. The new system is put into operation and meets the conditions for access to signal debugging at any time. This step must be completed before the system is switched.

[0019] 2. For units or equipment that can be fully shut down for maintenance, reasonably adjust the construction period based on the maintenance schedule and carry out control system modifications in conjunction with production maintenance. For units or equipment that cannot be fully shut down for maintenance, try to adopt a dual-system parallel model and carry out the modification in batches. That is, after switching one or more equipment to local operation, the control system signals are switched and modified between the old and new systems, and individual debugging is carried out.

[0020] 3. Remove the I / O incoming lines in the distributed control module 13 system, and connect the I / O signals to the equipment signal module in an orderly manner according to the point table or program. At the same time as the wiring, the centralized control module 3 (new ECS700 system) starts to operate, and the new system after connection starts adjustment and testing. During this process, the old control system of the distributed control module 13 is still running in parallel with the new system. During this process, process personnel can pay attention to the main parameters by comparing the data changes before and after the replacement of the old and new systems to ensure a smooth transition of the process flow.

[0021] 4. After the new system is fully operational, disconnect the power supply and grounding system of the old system of the distributed control module 13 to ensure that the new system operates completely independently.

[0022] 5. If you need to switch to the old system of the distributed control module 13, you can quickly achieve it by following the reverse operation of the above ideas.

[0023] The above describes some of the exemplary embodiments of the present invention in reality. It can be understood that the above embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention. The features in these embodiments can be recombined in an appropriate manner, and the solutions obtained thereby are still within the scope of protection required by the present invention. Based on the above embodiments, all other embodiments obtained by those skilled in the art without making creative work, that is, all modifications, equivalent substitutions and improvements made within the spirit and principles of this application, fall within the scope of protection required by the present invention.

Claims

1. A centralized control system for distributed equipment in the alumina industry, characterized in that: include: A plurality of clients (1), a centralized control module (3), a local I / O bus (4), a local control module (5), an extended I / O bus (6), an extended I / O connection module (7), a switching module (8), a distributed control module (13) and an on-site metering acquisition module, wherein the centralized control module (3) is connected to the plurality of clients (1), the centralized control module (3) is connected to the local control module (5) via the local I / O bus (4), and the centralized control module (3) is connected to the switching module (8) via the extended I / O bus (6) and the extended I / O connection module (7). The adapter module (8) is connected to the distributed control module (13) via an I / O interface, and the distributed control module (13) is connected to the on-site metering acquisition module; wherein the centralized control module (3) is redundantly configured and includes two main controllers (2), and the I / O interface controlled by the centralized control module (3) exceeds 1500 points; the adapter module (8) includes an analog adapter module (9), a relay input module (10), a relay output module (11) and a communication connection module (12), and the adapter module (8) and the extended I / O connection module (7) are connected via a DB communication cable.

2. A centralized control system for distributed equipment in the alumina industry according to claim 1, characterized in that: The distributed control module (13) is placed in a cabinet, and the switching module (8) is placed in the cabinet of the distributed control module (13) to which it is correspondingly connected.

3. A centralized control system for distributed equipment in the alumina industry according to claim 1, characterized in that: The power supply circuit of the switching module (8) is connected to the power supply circuit of the centralized control module (3); the switching module (8) and the centralized control module (3) are powered via the same UPS power supply line and share the same common grounding system.

4. A centralized control system for distributed equipment in the alumina industry according to claim 1, characterized in that: The I / O interfaces of the switching module (8) are arranged in the order of AI, AO, DI, DO, and communication card.

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