CN1348122A - Controller with embedded advanced process control (APC) model software - Google Patents
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- CN1348122A CN1348122A CN 00129789 CN00129789A CN1348122A CN 1348122 A CN1348122 A CN 1348122A CN 00129789 CN00129789 CN 00129789 CN 00129789 A CN00129789 A CN 00129789A CN 1348122 A CN1348122 A CN 1348122A
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Abstract
The controller with embedded advanced process control (APC) model software consists of CPU, electronic hard disk, static ram memory, dynamic ram memory, the first buffer, the second buffer, special ICs, interface and operation state display, Ethernet interface and RS232 interface and RS422/485 interface for transmitting industrial data. The present invention is based on PC, has high reliability for real-time control, and can call and run APC program easily as to common control module in fast response speed and high reliability.
Description
The present invention relates to technical field of industrial automatic control, but particularly reach the controller (APCC) of embedded advanced process control system (APC) prototype software based on the required high reliability of the real-time control of having of PC.
Earth-shaking variation has taken place current in field of personal computers, makes computer technology obtain unprecedented success in the office field.Begin to enter industrial control field now again gradually, and factory automation as main target.
Through the course of long-term alternative conventional instrument, the development of control will step to a new level automatically, and that is exactly energy-saving and cost-reducing, produces economic benefit.This will use Advanced process control method and technology.Advanced process control is meant to be inferred by series of mathematical the immeasurablel amount in the process, and its next step variation estimated, thereby the control corresponding amount is predicted,, reached the purpose of optimal control to reduce the fluctuation in the process control.With regard to the realization of Advanced process control (APC), PC also has stronger advantage.But PC disturbs etc. aspect the commercial Application not mature enoughly framed structure, dustproof, anti-opening, and reliability is made us not enough conviction, these weakness limited its industrial especially in the extensive application aspect the bottom robotization.
Along with development of semiconductor, the embedded hardware system uses in every respect, has developed into the third generation based on the real time operating system of field control, for having laid sufficient basis based on the control system of PC.But for various reasons, this change does not make a breakthrough always, exactly owing to when these two kinds of new systems improve to some extent, all exist the defective of self in original system.Also have some to utilize classical control theory and the insurmountable problem of modern control theory, as some complicated process control, these complicated processes do not have clear and definite physics law to follow, even make various hypothesis, it also is very difficult carrying out traditional quantitative analysis, even can't realize.Their control is often finished based on operator's experience, in this case, is that the control of controlled process or operator's experience all can't be described with analytical expression, and this just brings difficulty for our system design and analysis.
The objective of the invention is deficiency at existing control technology, design a kind of both based on PC, the controller that has the required reliability of real-time control again.It also has the function that realizes APC method and technology except the function of the controller module that possesses conventional DCS and PLC and SCADA.And, the user can work out the APC program fully voluntarily, set up as the prediction of non-linear time series modeling the nonlinear adaptive prediction of wavelet neural network, nerve fuzzy control, constrained forecast control, the tandem fuzzy control, spectrum analysis, and based on the chaos system of neuron and fuzzy control etc., perhaps utilize standard feature piece such as the modules such as PID, feedforward of APCC to work out the APC program, and pass through the embedded configuration software of APCC
The APC program generates a new APC functional block, under install in the controller, make the APC program arbitrarily to call in controller inside as the general control functional block, operation, no longer need the support of host computer, can accelerate process response and the reliability of APC like this, up to the present some all can't deal with problems with classical control theory and modern control theory to reach solution.
Purpose of the present invention can realize by following technical scheme, but the controller of this embedded advanced process control system (APC) prototype software comprises:
1, handles the management of computing and system, the CPU of the Pentium type of working procedure in mainly finishing real-time image data.
2, in the storage system watchdog routine, user program, initialize routine, the electronic hard disc of operating system and ethernet driver and APC functional block.
3, be used for the operational system program the dynamic random memory.
4, be used to store dynamic data, the static random memory of intermediate variable.
5, be used to connect each interface unit and store the special IC that each interface data plays buffer action.
6, be used to transmit the I/O interface unit of industrial control data;
7, be used to transmit the RS232 interface and the RS485/RS422 communication interface of industrial control data;
8, be used for the data communication between each remote controllers unit and the Ethernet interface of exchange;
9, be used for temporary electronic hard disc data, increase the first-level buffer device of CPU processing speed, and the level 2 buffering device.
The present invention compared with prior art is based on PC, and controller with the required high reliability of real-time control, it is except possessing conventional PCS, PLC, and outside the function of the controller module of SCADA, also has the function that realizes APC method and technology, and the user can compile the APC program fully voluntarily, can utilize standard feature piece such as the PID of APCC, modules such as feedforward are worked out the APC program, and the embedded configuration software that passes through APCC generates a new APC functional block with the APC program, under install in the controller, make the APC program arbitrarily to call in controller inside as the general control functional block, operation, no longer need some classical controls and modern control theory up to the present, insurmountable problem, and greatly reduce cost.
Figure l is a theory diagram of the present invention:
Fig. 2 is an embodiments of the invention grinding process optimal control system construction drawing:
Fig. 3 gives ore deposit process control structure figure for embodiments of the invention;
Fig. 4 gives ore deposit process working control curve map for embodiments of the invention;
Fig. 5 is embodiments of the invention overflow concentration in classifier control curve map;
Fig. 6 is embodiments of the invention ore mill load control chart.
Details are as follows to the present invention below in conjunction with accompanying drawing: but the controller (APCC) of embedded advanced process control system (APC) prototype software is by RS232 interface 9 and RS422/485 interface 10, Ethernet interface 11 and the I/O interface unit 12 of CPU1, electronic hard disc 2, static random memory 3, dynamic random memory 4, first-level buffer device 6, level 2 buffering device 5, special IC 7, interface and running status display 8, transmission industrial data.
The CPU of system normally moves, drive display unit by special IC, by the RS232 interface, RS422/RS485 interface and Ethernet interface contact and extraneous communication, exchange by the I/O interface unit of TCS tank circuit bus with the external world, electronic hard disc by three-bus structure and internal system, DRAM, SRAM connects, line data calculation process and the system peripherals of going forward side by side control uses the firsts and seconds buffer memory to accelerate the speed of system's calculation process greatly, makes it the control of some complexity is responded fast, this also is its more senior than the controller of other type, more advanced place.Carry out the APC program, then the performance requirement of the CPU of Cai Yonging must be much higher than common controller, the PC that it is a reduction of having removed some peripherals on the benefit, but the core function that its keeps is very powerful, the floating-point operation ability that comprises it, logical process ability etc.Here we have selected Pentium type CPU for use, and it can satisfy this requirement fully.In addition, we adopt the electronic hard disc of 128M, but the embedded OS that support function can be two, and the 32M that system provides dynamically stores coffee, the static storage of 256KB and one-level and level 2 buffering the device more high speed processing of system provide guarantee.Equally, it provides RS232, and RS422/RS485 and Ethernet interface and the external world keep in communication, and is better than general controller greatly.
Enforcement of the present invention is the application of APCC in grinding process optimal control system shown in Fig. 2,3,4,5,6, and detailed process is as follows:
One, purpose background
To leach or floatation extraction mineral in order utilizing, mineral powder must to be ground to certain fineness.Therefore, from practical operation and extraction efficiency two aspects, the mog of seeking a best is vital.Traditional grinding circuit is carried out the operation of grinding process by experienced operators with the method for a kind of " touch--listening---smell " of instinct seemingly.To the use of the needs of efficient grinding operation, reliable instrument, owing to operator's replacing causes skilled labor's minimizing, utilizing automatic control system to produce required ore milling product and optimizing grinding efficiency has become possible and usually has been necessary.
Two, controlled target
Usually controlling the operation that improves grinding circuit with ore grinding is based in the following operation and reason economically:
In the practical operation:
1, fixed operation reduces fluctuation so that produce more standard compliant product;
2, enough avoid the wasteful shutdown phenomenon that breaks down and cause because of grinding machine;
3, a good Monitoring and Controlling process helps to make correct management decision;
4, the operator can concentrate one's energy to carry out process optimization rather than keep system stability.
Economically:
1, increases treatment capacity;
2, the product granularity can be controlled in the optimal granularity scope, and valuable mineral is reclaimed effectively;
3, improve grinding efficiency.
Three, system architecture
Systemic-function
(a) technic index:
Mine-supplying quantity: maximum 85 tons/hour in the ore deposit of giving, minimum 50 tons/hour in the ore deposit of giving;
Ore milling concentration: 70-75%;
The spiral classifier overflow granularity :-200 orders (75 μ m) account for 65%;
(b) control loop
Control one section mill by regulating rock feeder frequency converter frequency output control rock feeder speed
The ore deposit mine-supplying quantity;
Add discharge by adjusting grinding machine inlet and control primary grinding concentration;
Add discharge (variable valve) to control the overflow of primary grinding dense by regulating the grinding machine outlet
Degree;
By regulating one section ball mill load of mine-supplying quantity control, keep maximum processing capability;
Four, the application of advanced control technology (APC)
1, gives the ore deposit process control
High efficiency ore grinding is to proposing high requirement to the ore deposit: assurance enters the ore deposit of grinding machine and measures tracing preset value quickly and accurately; Ensure to the ore deposit and continue, stablize, reduce the interference that ore grinding is caused as far as possible.
Measuring instrument has long distance apart from feed port, makes to the ore deposit process to have bigger pure hysteresis characteristic, and conventional PID regulator response speed is very slow, can not follow the tracks of setting value apace.It is very effective when the PREDICTIVE CONTROL functional block that is integrated in APCC controller inside is handled this type of problem.The control system structure as shown in the figure.
Fig. 3 gives the ore control curve for rock feeder, and when changing to setting value, actual mine-supplying quantity can be followed the tracks of set point fast and accurately.
2, ore milling concentration control
Ore milling concentration mainly is to influence the friction force of milling medium and material, the effective weight of medium (absolute weight of medium deducts ore pulp buoyancy), the flowability of ore pulp and the movement capacity of ore mill etc.Thereby influence the throughput rate of ore mill.Ore milling concentration should have a suitable scope, and is excessive too small all bad.
The inner pulp density of control grinding machine is realized by control grinding machine inlet pulp density.As long as guarantee to add water by a certain percentage, just can guarantee the stable of grinding machine inlet pulp density.In the control of ore mill concentration, considered of the influence of grader sand return water to ore milling concentration.
Cascade control method is adopted in ore milling concentration control, and external loop adopts ratio controller to determine that the grinding machine inlet adds the water yield, and inner looping suppresses the disturbance that variation in water pressure etc. causes by the PID controller, guarantees that the quick floating of actual confluent follows the tracks of setting value.
3, effluent concentration control
The control of effluent concentration is regulated by changing the spiral classifier amount of water.Adopt the PI tandem to control the controller that designs effluent concentration.External loop is set the grader amount of water by the PI controller, the quick disturbance that inner looping is caused by variations such as PI control inhibition hydraulic pressure, stable feedwater.The actual motion effect shows that control is effective.Fig. 4 follows the tracks of the response curve of set point change for overflow concentration in classifier.
4, grinding machine optimal control
Improving the treatment capacity of grinding machine, give full play to the operating efficiency of grinding circuit, is the important productive target of grinding operation.The operational means of realizing this goal is exactly by regulating mine-supplying quantity, keeping the charging capacity of grinding machine to be in optimum condition.
According to the variation of ore character, in time adjust grinding machine and go into the ore deposit amount, make material appropriateness in the mill, what prevent the self-reproduction phenomenon is the key of optimizing grinding efficiency.
According to operating experience, bowl mill under normal operating load, grinding machine electric current kept stable.And when the grinding machine overload, the grinding machine electric current can descend gradually, and fall strengthens along with the aggravation of grinding machine overload degree, finally causes the generation of grinding machine " tripe expands " accident.
Therefore, the grinding machine electric current can reflect the situation of change of grinding machine internal loading, can regulate the mill internal loading effectively by the control to the grinding machine electric current, thereby realizes increasing the grinding machine treatment capacity, and the maximum processing capability of performance grinding machine improves grinding efficiency.
According to the variation relation of grinding machine electric current and mill load, set up mill load Based Intelligent Control (GSISC):
Wherein, e is grinding machine steady-state current I
0Poor with grinding machine momentary current I: e=I
0-I, c are that sand return is than (circulating load/new mine-supplying quantity), c
0Sand return ratio for grinding machine during than high work load.e
0＞0, e
1＞0, be respectively the current deviation thresholding of indicating grinding machine different operating state, Δ u is the increment of grinding machine treatment capacity, Δ D
ApBe overflow concentration in classifier setting value increment, f
1(c), f
2(e, c), f
3(e c) is fuzzy controller.K
1, K
2, K
3, K
4Be fuzzy controller amplification coefficient, K
3＜K
2＜0, K
1＞0, K
4＞0.
This control algolithm utilizes the inner fuzzy control model that embeds of APCC controller to be achieved realization.Fig. 5 is the working control curve of ore mill load control.
The operation result of the reality of grinding operation shows, mill load control can be by adjusting the grinding machine mine-supplying quantity, realization has been avoided having given full play to the processing power of grinding machine simultaneously because the variation of ore characteristic causes the generation of grinding machine " tripe expands " accident to effective control of mill load.Since this control system operation, be subjected to the consistent of field staff and affirmed.
Claims (2)
- But the controller of 1 embedded advanced process control system (APC) prototype software is characterized in that described controller comprises:A, be used for mainly finishing real-time image data and handle the CPU of computing and system management;B, be used for the storage system watchdog routine, user program, initialize routine, the electronic hard disc of operating system and ethernet driver and APC functional block;C, be used for the dynamic random memory of operational system program;D, be used to store dynamic data, the static random memory of intermediate variable;E, be used to connect each interface unit and store each interface data and play the special IC of buffer action;F, be used to transmit the I/O interface unit of industrial control data;G, be used to transmit the RS232 interface and the RS485/RS422 communication interface of industrial control data;H, be used for the data communication between each remote controllers unit and the Ethernet interface of exchange;
- But 2, the controller of embedded advanced process control system according to claim 1 (APC) prototype software is characterized in that described controller comprises:Be used for temporary electronic hard disc data, increase the first-level buffer device and the level 2 buffering device of CPU processing speed.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100359515C (en) * | 2003-12-26 | 2008-01-02 | 上海自动化仪表股份有限公司 | Multifunctional communication capture card and distributed control system and capture method thereof |
| CN100558054C (en) * | 2006-07-31 | 2009-11-04 | 深圳达实智能股份有限公司 | Building controller based on Ethernet |
| CN100582977C (en) * | 2003-05-30 | 2010-01-20 | 东京毅力科创株式会社 | Data pre-population method |
| CN101617504B (en) * | 2005-11-15 | 2012-10-10 | 洛克威尔自动控制技术股份有限公司 | Integrated programmer reference for industrial control device data |
-
2000
- 2000-10-12 CN CN 00129789 patent/CN1348122A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100582977C (en) * | 2003-05-30 | 2010-01-20 | 东京毅力科创株式会社 | Data pre-population method |
| CN100359515C (en) * | 2003-12-26 | 2008-01-02 | 上海自动化仪表股份有限公司 | Multifunctional communication capture card and distributed control system and capture method thereof |
| CN101617504B (en) * | 2005-11-15 | 2012-10-10 | 洛克威尔自动控制技术股份有限公司 | Integrated programmer reference for industrial control device data |
| CN100558054C (en) * | 2006-07-31 | 2009-11-04 | 深圳达实智能股份有限公司 | Building controller based on Ethernet |
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