Process automation factory practical training device

Abstract

The utility model discloses a process automation factory practical training device, and aims to provide a teaching platform closer to an industrial site so as to comprehensively improve practical ability and comprehensive skills of students. The device comprises a rack with a four-layer structure, a raw material and product combined tank, a plurality of raw material pumps and conveying pipelines, a mixing tank, a mixing buffer tank, an industrial plate heat exchanger, a boiler and other key components. Multi-loop control and various interlocking protections are realized through a coil pipe for simulating lag time, a snakelike reaction coil pipe, a heating rod, a liquid level sensor, a pressure transmitter, a temperature transmitter and the like. In addition, the device further provides a three-stage heat exchange system, raw material preheating, mixture reaction heating and product heat dissipation cooling are achieved, and the stability and reliability of a temperature experiment are ensured. The overall design considers the safety and the comprehensiveness of automatic control, and is suitable for teaching and practical training of various process control courses.

Description

Technical Field

[0001] This utility model relates to the technical field of experimental equipment for teaching, and more specifically, to a process automation factory training device. Background Technology

[0002] In modern industrial automation education, process automation factory training devices have become an important teaching tool. These devices are experimental equipment used in undergraduate or associate degree programs for courses such as "Sensor Detection and Conversion Technology," "Chemical Instrumentation and Automation," "Thermal Instrumentation and Automatic Devices," "Process Control and Automation Instruments," "Process Control Instruments and Devices," "Automation Device Installation and Maintenance," and "Distributed Control Systems." This equipment not only helps students deepen their understanding of theoretical knowledge but also improves their practical operational skills.

[0003] The existing process control training devices mainly consist of a jacketed boiler, three vertically stacked circular water tanks of varying sizes, two power branches, and a small storage tank. There are also some smaller process control training devices with even simpler structures. These existing devices lack complex control systems and a realistic industrial environment. While they can perform basic single-loop, cascade, and ratio experiments, they cannot simulate factory-level start-up and shutdown process timing control, the control of multiple loops interacting with each other, and various interlocking protection controls. Furthermore, the existing devices use a jacketed boiler without efficient heat exchangers and radiators, resulting in poor temperature experiment performance and excessively high system temperatures during prolonged experiments, failing to meet long-term stability requirements. The tank outlets are manually operated, leading to significant siphon effects; the small outlet diameter and cross-sectional area result in insufficient characteristic time and poor control performance. The storage tank is too small and lacks a radiator, causing the entire system to heat up rapidly during temperature experiments, making it impossible to complete the experiments. The tanks can only be connected in series vertically, not in a horizontal double-tank structure. Furthermore, it lacks a transparent transmission structure, preventing the two tanks from independently controlling the liquid level.

[0004] Furthermore, existing devices lack comprehensive interlocking protection mechanisms, including water shortage protection, water replenishment solenoid valve control, overflow alarms, and over-temperature and over-pressure interlocking protection. This deficiency not only affects the safety of experiments but also prevents students from fully understanding and mastering the design and application of safety instrumented systems in industrial automation. Therefore, developing a more realistic and comprehensive process automation factory training device is of paramount importance. Utility Model Content

[0005] This utility model provides a process automation factory training device to overcome the technical problems existing in the prior art.

[0006] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows:

[0007] A process automation factory training device includes a frame, on which are mounted a mixing tank, a mixing buffer tank, a boiler, a radiator, a raw material pump P01, a raw material pump P02, a boiler heat circulation pump P04, a heat exchanger, a serpentine reaction coil, a regulating ball valve FV02, and a solenoid valve XV02, wherein:

[0008] The raw material pumps P01 and P02 are respectively connected to the inlet of the mixing tank via a first pipe, and are used to supply raw material A and raw material B to the mixing tank respectively; the mixing tank is used to mix raw material A and raw material B to obtain a mixture.

[0009] The inlet of the mixing buffer tank is connected to the mixing tank, allowing the mixed liquid to flow into the mixing buffer tank by gravity. The mixing buffer tank is also equipped with a discharge pump P05 and a frequency converter. The discharge pump P05 is connected to the cold water inlet of the heat exchanger through a second pipe. The discharge pump P05 is used to discharge the mixed liquid to the heat exchanger for preheating. The frequency converter is used to control the flow rate of the discharge pump P05 to maintain the liquid level in the mixing buffer tank. The hot water inlet of the heat exchanger is connected to the boiler heat circulation pump P04 through a third pipe. The boiler heat circulation pump P04 is used to draw hot water from the boiler to the hot water inlet of the heat exchanger.

[0010] The boiler contains hot water, and the serpentine reaction coil is installed inside the boiler to heat the bath water; the outlet of the heat exchanger is connected to the serpentine reaction coil, and the mixed liquid undergoes a chemical reaction through the serpentine reaction coil;

[0011] The boiler is connected in sequence to the solenoid valve XV02 and the regulating ball valve FV02. The regulating ball valve FV02 is connected to the radiator. The reacted mixture enters the radiator for water-gas heat exchange to reduce the product temperature.

[0012] Furthermore, the rack has a four-layer structure, specifically:

[0013] The first layer is equipped with horizontal semi-finished product tanks;

[0014] The second layer includes the boiler and the mixing tank, which is used to mix two raw materials.

[0015] The third layer includes the mixing buffer tank, the radiator, and the regulating ball valve FV02.

[0016] The fourth layer is equipped with a combination tank, which is equipped with a liquid level switch LS03, a liquid level switch LS04 and a solenoid valve XV03 for water replenishment.

[0017] Furthermore, the heat exchanger, the serpentine reaction coil, and the radiator constitute a three-stage heat exchange system, wherein:

[0018] The heat exchanger is used for preheating the raw material and is connected to the raw material inlet and outlet pipelines.

[0019] The serpentine reaction coil is located inside the boiler and is used for heating and reacting the mixture, and is heated by heating rods in the boiler.

[0020] The radiator is used to dissipate heat and cool the raw materials.

[0021] Furthermore, the boiler is equipped with an upper limit liquid level switch LS01 and a lower limit liquid level switch LS02 for anti-dry burning interlock protection.

[0022] Furthermore, the outlets of the mixing tank and the mixing buffer tank are gate-type outlets to prevent siphoning.

[0023] Furthermore, the mixing tank, the mixing buffer tank, and the horizontal semi-finished product tank are made of plexiglass and are all divided into a main storage area and a drainage area by partitions. The main storage area and the drainage area are connected by a gate.

[0024] The mixing tank has two drainage pipes in the drainage area: one is a transparent pipe, and the other is a vertical double-containment pipe. The transparent pipe is configured to form a vertical double-containment structure with the mixing buffer tank when it is blocked by a rubber stopper.

[0025] Furthermore, the boiler is equipped with an overflow pipe, the top of which is lower than the top surface of the boiler, to ensure that water does not overflow when the boiler is replenished and to prevent boiling water from splashing.

[0026] Furthermore, the boiler is equipped with a temperature pointer meter, which includes temperature switches TS01 and TS02, for constructing overheat interlock protection.

[0027] Furthermore, the mixing buffer tank includes a main storage area, a drainage area, and a buffer tank transmission area.

[0028] Furthermore, the process automation factory training device also includes an auxiliary raw material pump PO3, which is used to transport auxiliary raw materials before the mixture enters the serpentine reaction coil.

[0029] Compared with the prior art, the beneficial effects of this utility model's technical solution are:

[0030] This invention provides a process automation factory training device that not only meets the basic requirements of single-loop and cascade experiments, but also enables factory-level start-up and shutdown process timing control, control of multiple loop interactions, and various interlocking protection controls, making it more closely resemble an industrial setting. By designing large-section mixing and buffer tanks, and a siphon-free gate-type outlet, a wider controllable range of fluid characteristics over time is ensured, improving control effectiveness. The three-stage heat exchange system achieves the effects of raw material preheating, mixture reaction heating, and product cooling, making temperature experiments more convenient and stable. Furthermore, level switches, temperature switches, and pressure switches form a comprehensive interlocking protection mechanism, providing safety guarantees for equipment and personnel, enabling students to conduct complex process control experiments in a safe environment. The overall design considers both comprehensive teaching and safety, making it highly suitable for process control courses in undergraduate and vocational education. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a front view of a process automation factory training device provided in one embodiment of this application;

[0033] Figure 2 This is a left view of a process automation factory training device provided in one embodiment of this application;

[0034] Figure 3 This is a right view of a process automation factory training device provided in one embodiment of this application;

[0035] Figure 4 This is a three-dimensional structural schematic diagram of a process automation factory training device provided in one embodiment of this application;

[0036] Figure 5 This is an instrument layout diagram of a process automation factory training device provided in one embodiment of this application;

[0037] Figure 6 This is a process flow diagram of a process automation factory training device provided in one embodiment of this application;

[0038] Explanation of markings in the diagram:

[0039] 1. Frame; 2. Horizontal semi-finished product tank; 3. Mixing tank; 4. Mixing buffer tank; 5. Boiler; 6. Lag coil; 7. Radiator; 8. Raw material pump P01; 9. Raw material pump P02; 10. Discharge pump P05; 11. Boiler heat circulation pump P04; 12. Auxiliary raw material pump P03; 13. Combined tank;

[0040] 15. Heat exchanger; 17. Serpentine reaction coil; 18. Heating rod; 19. Overflow pipe;

[0041] 21. Liquid level sensor LT01; 22. Liquid level sensor LT02; 23. Liquid level sensor LT03; 24. Liquid level sensor LT04; 25. Pressure transmitter PT01; 26. Pressure transmitter PT02; 27. Flow transmitter FT01; 28. Flow transmitter FT02; 29. ​​Flow transmitter FT03;

[0042] 31. Temperature transmitter TE01; 32. Temperature transmitter TE02; 33. Temperature transmitter TE03; 34. Temperature transmitter TE04; 35. Temperature transmitter TE05; 36. Temperature transmitter TE06; 37. Upper limit level switch LS01; 38. Lower limit level switch LS02; 39. Level switch LS03; 40. Level switch LS04; 41. Control ball valve FV01; 42. Control ball valve FV02; ​​43. Solenoid valve XV01; 44. Solenoid valve XV02; 45. Solenoid valve XV03;

[0043] 47. Leakage detection sensor LW01; 48. Temperature switch TS01; 49. Temperature switch TS02; 50. Pressure switch PS01; 51. Pressure switch PS02. Detailed Implementation

[0044] The following description provides numerous specific details to offer a more thorough understanding of this application. However, it will be apparent to those skilled in the art that this application can be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described to avoid confusion with this application.

[0045] It should be understood that this application can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, providing these embodiments will make the disclosure thorough and complete, and will fully convey the scope of this application to those skilled in the art. In the drawings, for clarity, the dimensions and relative dimensions of layers and regions may be exaggerated. The same reference numerals denote the same elements throughout.

[0046] In the description of this utility model, it should be understood that the terms "left side," "right side," "upper part," "lower part," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. The specific dimensions used in the embodiments are only for illustrating the technical solution and do not limit the protection scope of this utility model. It is understandable that some well-known structures and their descriptions may be omitted in the drawings for those skilled in the art.

[0047] Unless otherwise expressly specified and limited, the terms "installation," "setting," "connection," and "fixation" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0048] To fully understand this application, a detailed structure will be presented in the following description to illustrate the technical solutions proposed in this application. Preferred embodiments of this application are described in detail below; however, in addition to these detailed descriptions, this application may have other implementation methods.

[0049] Example 1:

[0050] like Figure 1-4 As shown, this utility model provides a technical solution:

[0051] A process automation factory training device includes a frame 1, on which are mounted a mixing tank 3, a mixing buffer tank 4, a boiler 5, a radiator 7, a raw material pump P01, a raw material pump P02, a boiler heat circulation pump P04, a heat exchanger 15, a serpentine reaction coil 17, a regulating ball valve FV02, and a solenoid valve XV02, wherein:

[0052] The raw material pump PO1 and the raw material pump PO2 are respectively connected to the inlet of the mixing tank 3 through the first pipe, and are used to supply raw material A and raw material B to the mixing tank 3 respectively; the mixing tank 3 is used to mix raw material A and raw material B to obtain a mixture.

[0053] The inlet of the mixing buffer tank 4 is connected to the mixing tank 3, allowing the mixed liquid to flow into the mixing buffer tank 4 by gravity. The mixing buffer tank 4 is also equipped with a discharge pump P05 and a frequency converter. The discharge pump P05 is connected to the cold water inlet of the heat exchanger 15 through a second pipe. The discharge pump P05 is used to discharge the mixed liquid to the heat exchanger 15 for preheating. The frequency converter is used to control the flow rate of the discharge pump P05 to maintain the liquid level in the mixing buffer tank 4. The hot water inlet of the heat exchanger 15 is connected to the boiler heat circulation pump P04 through a third pipe. The boiler heat circulation pump P04 is used to draw hot water from the boiler 5 to the hot water inlet of the heat exchanger 15.

[0054] The boiler 5 contains hot water, and the serpentine reaction coil 17 is installed inside the boiler 5 to heat the bath water; the outlet of the heat exchanger 15 is connected to the serpentine reaction coil 17, and the mixed liquid undergoes a chemical reaction through the serpentine reaction coil 17.

[0055] The boiler 5 is connected in sequence to the solenoid valve XV02 and the regulating ball valve FV02. The regulating ball valve FV02 is connected to the radiator 7. The reacted mixture enters the radiator 7 for water-gas heat exchange to reduce the product temperature.

[0056] like Figure 6 As shown, the process automation factory training device provided in this embodiment includes a four-layer frame, a raw material and output simulation combination tank, raw material pump P01 and conveying pipeline, raw material pump P02 and conveying pipeline, auxiliary raw material pump P03 and conveying pipeline. The pipeline of raw material pump P01 includes a coil simulating lag time, a mixing tank, a mixing buffer tank, a horizontal externally sourced semi-finished product tank, an industrial plate heat exchanger for preheating the mixture, a serpentine reaction coil, and a heating and reaction boiler with an external protective sleeve. Raw materials A and B, and auxiliary raw material pump P03 pump, draw the main raw material and auxiliary raw material, mix them in the mixing tank, and then enter the mixing buffer tank. After passing through discharge pump P05, they enter the plate heat exchanger for preheating, and then enter the heating and reaction boiler, where they undergo a chemical reaction through the serpentine reaction coil. Finally, at the outlet, the reaction pressure is controlled by a regulating ball valve, while the pressure regulating module and the frequency converter of the mixing pump work together to control the reaction temperature. A solenoid valve discharges waste products, and a regulating ball valve discharges good products. The good products then pass through a radiator to lower the product temperature.

[0057] Example 2:

[0058] Based on Example 1, and referring to Figure 1-4 The frame 1 has a four-layer structure, specifically:

[0059] The first layer is equipped with horizontal semi-finished product tanks 2;

[0060] The second layer includes the boiler 5 and the mixing tank 3, which is used to mix two raw materials.

[0061] The third layer includes the mixing buffer tank 4, the radiator 7, and the regulating ball valve FV02.

[0062] The fourth layer is equipped with a combination tank 13, which is equipped with a liquid level switch LS03, a liquid level switch LS04 and a solenoid valve XV03 for water replenishment.

[0063] Furthermore, the heat exchanger 15, the serpentine reaction coil 17, and the radiator 7 constitute a three-stage heat exchange system, achieving the effects of preheating the mixture, heating the chemical reaction, and cooling the raw materials with air cooling.

[0064] The heat exchanger 15 is used for preheating the raw material and is connected to the raw material inlet and outlet pipelines.

[0065] The serpentine reaction coil 17 is located inside the boiler 5. The serpentine reaction coil 17 is used for heating and reacting the mixture and is heated by the heating rod 18 in the boiler 5.

[0066] The radiator 7 is used to dissipate heat and cool the raw materials.

[0067] Specifically, the three-stage heat exchange system realizes the process of raw material preheating, mixture reaction heating, and product heat dissipation and cooling. Discharge pump P05 draws the mixture and sends it to the cold water inlet of plate heat exchanger 15, while pump P04 draws boiler hot water and sends it to the hot water inlet of the plate heat exchanger. This achieves water-to-water heat exchange, raising the temperature of the mixed raw materials. The mixture then enters the serpentine coil 17 for bath heat exchange, where a chemical reaction takes place. Finally, it exits from below the boiler and enters radiator 7 for water-to-gas heat exchange, rapidly reducing the product temperature. This three-stage heat exchange system makes temperature experiments more convenient and effective. It also provides experimental capabilities for more heat exchangers, including plate heat exchangers, coil heat exchangers, and water-to-air heat exchangers.

[0068] Furthermore, the instruments include level switches LS01, LS02, LS03, and LS04; temperature switches TS01 and TS02; pressure switches PS01 and PS02; LW01 leakage detection sensor; water supply solenoid valve; heating switches on the power distribution system; water pump relays; and frequency converter switches. Through the system's safety monitoring module, safety interlock protection for equipment and personnel is achieved.

[0069] Furthermore, the boiler 5 is equipped with an upper limit liquid level switch LS01 and a lower limit liquid level switch LS02 for anti-dry burning interlock protection.

[0070] Furthermore, the outlets of the mixing tank 3 and the mixing buffer tank 4 are gate-type outlets to prevent siphoning.

[0071] Furthermore, the mixing tank 3, the mixing buffer tank 4, and the horizontal semi-finished product tank 2 are all made of plexiglass and are divided into a main storage area and a drainage area by partitions. The main storage area and the drainage area are connected by a gate, which can form a horizontal double-capacity structure or a variable-capacity structure. The mixing tank 3 has two drainage pipes in the drainage area, one is a through-flow pipe and the other is used for the vertical double-capacity pipe. By blocking the through-flow pipe with a rubber stopper, it can form a vertical double-capacity structure with the mixing buffer tank. By blocking the through-flow pipe, it forms a single-capacity structure with the mixing buffer tank that does not affect each other.

[0072] Furthermore, the mixing buffer tank 4 includes a main storage area, a drainage area, and a buffer tank transmission area. When the mixing buffer tank passes through the drainage pipe above the transmission area, they do not affect each other, forming a single-capacity structure that does not affect each other.

[0073] Specifically, mixing tank 3 and mixing buffer tank 4 have large cross-sectional areas and large outlet diameters, resulting in a wider controllable flow range. The use of a gate outlet ensures fast water flow, preventing the tank from filling quickly and eliminating siphon effects, thus guaranteeing a controllable inlet flow range from 0% to 100%. A weir-type baffle prevents water from overflowing the tank even when the outlet gate is closed and the inlet flow reaches 100%. The water storage area of ​​mixing tank 3 is divided into a left and right storage area by a baffle, with an intermediate gate between them. A rear gate connects the right storage area and the outlet area of ​​the mixing tank. The outlet area of ​​the mixing tank has a through-flow outlet pipe and cascaded outlet pipes. This design allows for simultaneous vertical multi-capacity and horizontal dual-capacity experiments, and also enables variable-capacity experiments. Together with mixing buffer tank 4, they can form two independent single-capacity water tanks.

[0074] The specific adjustment method is as follows:

[0075] 1. By setting the middle gate opening to be small and the rear gate opening to be small, a horizontal double-capacity design is achieved, thus realizing a double-capacity design where the left and right sides influence each other.

[0076] 2. If the middle gate is fully open and the rear gate is partially open, it becomes a single-containment water tank with a full cross-sectional area.

[0077] 3. By setting the middle gate to a small opening and the rear gate to be fully open, it becomes a single-capacity water tank with half the cross-sectional area; thus achieving variable capacity. In the cascade design of a double-capacity system, a water tank with half the cross-sectional area is used to speed up the response time of the secondary loop.

[0078] 4. If a transparent water outlet pipe is used, it can directly penetrate the mixing buffer tank 4, thus realizing two independent single-tank water tanks.

[0079] Furthermore, the mixing buffer tank 4 is divided into a transmission zone, an outlet zone, a monitoring zone, and a storage zone by partitions. The outlet gate can adjust the outlet size, and there is no siphon effect. It has a large controllable range and good experimental control effect.

[0080] Furthermore, the boiler 5 is provided with an overflow pipe 19 inside, the top of which is lower than the top surface of the boiler 5, to ensure that water will not overflow when water is added to the boiler 5 and to ensure that boiling water will not splash when it boils.

[0081] Furthermore, the boiler 5 is equipped with a temperature pointer meter, which includes temperature switches TS01 and TS02, for constructing overheat interlock protection.

[0082] Specifically, the heating and reaction boiler is located on the left side of the second layer of frame 1. Inside, there is a serpentine reaction coil 17 and heating rods 18. The water in the serpentine reaction coil is isolated from the water being heated inside the boiler. Heat is obtained through bath water heat exchange to simulate a chemical reaction. An external protective sleeve prevents scalding. An internal large overflow pipe 19 ensures that water will not overflow when replenishing the boiler and also prevents boiling water from splashing. The heating and reaction boiler has two upper and lower limit level switches, which can form an anti-dry-burning interlock protection system. There is also a temperature gauge with high-limit and ultra-high-limit switches, which can be used to construct an overheat interlock protection system.

[0083] Furthermore, the process automation factory training device also includes an auxiliary raw material pump P03, which is used to transport auxiliary raw materials before the mixture enters the serpentine reaction coil 17.

[0084] Furthermore, the process automation factory training device has five water pumps: main raw material pump P01, main raw material pump P02, auxiliary raw material pump P03, mixing and discharge pump P05, and boiler heat circulation pump P04; among which pump P03 is not mandatory.

[0085] Furthermore, such as Figure 5 As shown, the overall instrumentation system of the process automation factory training device includes LT01, LT02, LT03, and LT04 level sensors; PT01 and PT02 pressure transmitters; FT01, FT02, and FT03 flow transmitters; TE01, TE02, TE03, TE04, TE05, and TE06 temperature transmitters; XV01, XV02, and XV03 solenoid valve actuators; FV01 regulating valve; and FV02 regulating ball valve. The distribution cabinet also includes U01 to U03 frequency converters; GZ01 regulating valve; LS01, LS02, LS03, and LS04 level switches; TS01 and TS02 temperature switches; PS01 and PS02 pressure switches; and LW01 leakage detection sensor.

[0086] Furthermore, the special structures of the mixing tank and the mixing buffer tank include the horizontal double-capacity structure of the mixing tank 3, the through-transmission pipeline and the vertical double-capacity pipeline structure; the buffer tank through-transmission zone structure of the mixing buffer tank 14; the gate and dam-type baffle structure; and the 38mm large outlet pipe structure without siphon.

[0087] Furthermore, the reaction boiler, along with the level switch and pressure regulating module, forms a structure to prevent dry burning, and together with the temperature switch, it forms a water shortage and over-temperature interlock protection system.

[0088] Furthermore, the water storage tank is equipped with high and low limit level switches and a water replenishment solenoid valve. Through the monitoring system, automatic water replenishment can be achieved; it can also perform water shortage and overflow interlock protection and alarm notification.

[0089] The process automation factory training device in this embodiment simulates a process automation factory process, as follows:

[0090] Raw materials are extracted by main raw material pumps P01 and P02. Pump A controls the flow rate according to the yield through a frequency converter, and pump B controls the proportion according to the formula through a regulating valve.

[0091] The mixture is mixed in a mixing tank and then flows by gravity into a mixing buffer tank for buffering. The purpose of buffering is to maintain the liquid level in the mixing tank and then discharge the liquid through a discharge pump PO4. The flow rate of the discharge pump PO4 is controlled by a frequency converter to maintain a certain liquid level in the mixing buffer tank.

[0092] Pump P05 delivers auxiliary materials, such as catalysts, into the mixed feedstock before entering the serpentine coil;

[0093] Pump P04 draws hot water from the boiler to form a hot water circulation system;

[0094] The mixed liquid pumped by the discharge pump P04 is preheated in the heat exchanger and then enters the serpentine coil in the boiler hot water; the serpentine coil is heated in the boiler hot water through the front pump P05 and the rear regulating ball valve.

[0095] At the beginning of the reaction, the system has not yet fully met the reaction regulation requirements, so all the products are waste and are discharged through the solenoid valve. Then, after a certain period of time, when the temperature meets the requirements, the solenoid valve 44 is closed and the regulating ball valve 42 is opened. The pressure is then adjusted and the product is obtained.

[0096] In summary, the complete system of this application simulates a process automation processing plant in the process industry, realizing processes such as mixing two main raw materials, adding auxiliary raw materials, raw material mixing, discharge of the mixture, bath reaction, and boiler heat circulation. It provides four level switches, interlocking protection and alarms for water shortage and overflow, automatic water replenishment control for water shortage, and interlocking protection and alarms for over-temperature and over-pressure. The plant system is constructed using five water pumps, multiple mixing tanks, combined tanks, and a boiler, and provides level switches, temperature switches, and pressure switches to establish interlocking protection and alarms. A three-stage heat exchange system is provided to realize the processes of raw material preheating, mixture reaction heating, and product heat dissipation and cooling. More complex mixing tank designs are provided, including two-stage mixing tanks, simultaneously realizing horizontal double-capacity, vertical double-capacity structures, and single-capacity structures that do not interfere with each other.

[0097] Compared to existing technologies, this automated factory training device goes beyond traditional training experiments. It can provide multi-path simultaneous control during factory startup, shutdown, and operation, as well as fault interlock protection and hazardous shutdown training projects. It is much closer to the industrial environment.

[0098] This automated factory training device features a large cross-sectional area for both the mixing tank and the secondary mixing tank, along with a large outlet diameter, resulting in a wider controllable flow range. The gate-type outlet ensures rapid water flow, preventing the tank from filling quickly and eliminating siphon effects, thus guaranteeing a controllable inlet flow rate from 0% to 100%. Furthermore, its weir-type overflow structure prevents water from overflowing the tank even when the gate-type outlet is closed and the inlet flow rate reaches 100%.

[0099] This automated factory training device provides a three-stage heat exchange system to realize the processes of raw material preheating, mixture reaction heating, and product heat dissipation and cooling. Temperature experiments are more convenient and effective; it provides heat-cold heat exchange, heat-to-heat heat exchange, and water-air heat exchange, thus enabling more heat exchanger experiments.

[0100] This process automation factory training device provides level switches, temperature switches, and pressure switches to build interlocking protection and alarms; it provides experimental conditions for the SIS safety instrumented system in process automation, and provides equipment and personal safety protection through the power distribution system.

[0101] All devices selected in this application (parts whose specific structures are not described) are general standard parts or parts known to those skilled in the art, and their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods. Furthermore, all software programs involved in this application are prior art, and this application does not involve any improvements to the software programs.

[0102] Although exemplary embodiments have been described herein with reference to the accompanying drawings, it should be understood that the above exemplary embodiments are merely illustrative and are not intended to limit the scope of this application. Various changes and modifications can be made therein by those skilled in the art without departing from the scope and spirit of this application. All such changes and modifications are intended to be included within the scope of this application as claimed in the appended claims.

[0103] Similarly, it should be understood that, in order to simplify this application and aid in understanding one or more aspects of the application, various features of this application may sometimes be grouped together in a single embodiment, figure, or description thereof in the description of exemplary embodiments of this application. However, this approach should not be construed as reflecting an intention that the claimed application requires more features than are expressly recited in each claim. Rather, as reflected in the corresponding claims, the point of application is that the corresponding technical problem can be solved with fewer features than all of a single disclosed embodiment. Therefore, the claims following the detailed description are hereby expressly incorporated into that detailed description, wherein each claim itself is a separate embodiment of this application.

[0104] Furthermore, those skilled in the art will understand that although some embodiments described herein include certain features but not others included in other embodiments, combinations of features from different embodiments are intended to be within the scope of this application and form different embodiments. For example, in the claims, any one of the claimed embodiments can be used in any combination.

[0105] It should be noted that the above embodiments are illustrative of this application and not limiting of it, and that those skilled in the art can devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses should not be construed as limiting the claims. The use of the words first, second, and third, etc., does not indicate any order. These words can be interpreted as names.

Claims

1. A process automation factory training device, characterized in that: The equipment includes a frame (1), on which are mounted a mixing tank (3), a mixing buffer tank (4), a boiler (5), a radiator (7), a raw material pump P01 (8), a raw material pump P02 (9), a boiler heat circulation pump P04 (11), a heat exchanger (15), a serpentine reaction coil (17), a regulating ball valve FV02 (42), and a solenoid valve XV02 (44), wherein: The raw material pump P01 (8) and the raw material pump P02 (9) are respectively connected to the inlet of the mixing tank (3) through the first pipe, and are used to supply raw material A and raw material B to the mixing tank (3) respectively; the mixing tank (3) is used to mix raw material A and raw material B to obtain a mixture; The inlet of the mixing buffer tank (4) is connected to the mixing tank (3) to allow the mixed liquid to flow into the mixing buffer tank (4) by gravity. The mixing buffer tank (4) is also equipped with a discharge pump P05 (10) and a frequency converter. The discharge pump P05 (10) is connected to the cold water inlet of the heat exchanger (15) through a second pipe. The discharge pump P05 (10) is used to discharge the mixed liquid to the heat exchanger (15) for preheating. The frequency converter is used to control the flow rate of the discharge pump P05 (10) to maintain the liquid level of the mixing buffer tank (4). The hot water inlet of the heat exchanger (15) is connected to the boiler heat circulation pump P04 (11) through a third pipe. The boiler heat circulation pump P04 (11) is used to draw hot water from the boiler (5) to the hot water inlet of the heat exchanger (15). The boiler (5) contains hot water, and the serpentine reaction coil (17) is installed inside the boiler (5) to heat the bath water; the outlet of the heat exchanger (15) is connected to the serpentine reaction coil (17), and the mixture undergoes a chemical reaction through the serpentine reaction coil (17); The boiler (5) is connected in sequence to the solenoid valve XV02 (44) and the regulating ball valve FV02 (42). The regulating ball valve FV02 (42) is connected to the radiator (7). The mixed liquid after the reaction enters the radiator (7) for water-gas heat exchange to reduce the product temperature.

2. The process automation factory training device according to claim 1, characterized in that, The rack (1) has a four-layer structure, specifically: The first layer is equipped with horizontal semi-finished product tanks (2); The second layer includes the boiler (5) and the mixing tank (3), which is used to mix two raw materials; The third layer includes the mixing buffer tank (4), the radiator (7), and the regulating ball valve FV02 (42); The fourth layer is equipped with a combination tank (13), which is equipped with a liquid level switch LS03 (39), a liquid level switch LS04 (40) and a solenoid valve XV03 (45) for water replenishment.

3. The process automation factory training device according to claim 1, characterized in that, The heat exchanger (15), the serpentine reaction coil (17), and the radiator (7) constitute a three-stage heat exchange system, wherein: The heat exchanger (15) is used for preheating the raw material and is connected to the raw material inlet and outlet pipelines; The serpentine reaction coil (17) is located inside the boiler (5). The serpentine reaction coil (17) is used for heating and reacting the mixture and is heated by the heating rod (18) in the boiler (5). The radiator (7) is used to dissipate heat and cool the raw materials.

4. The process automation factory training device according to claim 1, characterized in that, The boiler (5) is equipped with an upper limit liquid level switch LS01 (37) and a lower limit liquid level switch LS02 (38) for anti-dry burning interlock protection.

5. The process automation factory training device according to claim 1, characterized in that, The outlets of the mixing tank (3) and the mixing buffer tank (4) are gate-type outlets to prevent siphoning.

6. The process automation factory training device according to claim 2, characterized in that, The mixing tank (3), the mixing buffer tank (4), and the horizontal semi-finished product tank (2) are made of plexiglass and are all divided into a main storage area and a drainage area by partitions. The main storage area and the drainage area are connected by a gate. The mixing tank (3) has two drainage pipes in the drainage area, one is a through pipe and the other is a vertical double-containment pipe; the through pipe is configured to form a vertical double-containment structure with the mixing buffer tank (4) when it is blocked by a rubber stopper.

7. The process automation factory training device according to claim 1, characterized in that, The boiler (5) is equipped with an overflow pipe (19) inside. The top of the overflow pipe (19) is lower than the top surface of the boiler (5) to ensure that water will not overflow when water is added to the boiler (5) and to ensure that boiling water will not splash.

8. The process automation factory training device according to claim 1, characterized in that, The boiler (5) is equipped with a temperature pointer meter, which includes temperature switch TS01 (48) and temperature switch TS02 (49) for constructing overheat interlock protection.

9. The process automation factory training device according to claim 1, characterized in that, The mixing buffer tank (4) includes a main storage area, a drainage area, and a buffer tank transmission area.

10. The process automation factory training device according to claim 1, characterized in that, The process automation factory training device also includes an auxiliary raw material pump P03 (12), which is used to transport auxiliary raw materials before the mixture enters the serpentine reaction coil (17).

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