I. Overview
Automatic drying equipment heating technology. Each temperature zone is controlled by the AI ​​program type regulator PID to control the far-infrared radiating element, and the heating of the furnace is started after the power is turned on. The use of shifting adjustment can not only prolong the use time of the far-infrared radiating element, but also keep the temperature of the heating furnace constant.
In recent years, it has been widely applied to various production fields. The energy used is gas and electricity. Taking far infrared heating as an example, the heat energy is directly transmitted from the radiation source to the object to be heated in the form of rays, and the heat energy utilization rate is high. Use far infrared heating technology to dry thin technology widely used to dry grain, tea, wood, grass sludge, distiller's grains, bone meal, biological fertilizer organic fertilizer, salt, / blood meal, wet materials, food, oil, food, red dates, peppers, vegetables Quick drying machine for organic raw materials such as buckwheat and bean food.
1. Structure of the furnace body
The far-infrared heater used is mainly for drying various materials, so the rectangular furnace structure is adopted, and the whole furnace body is divided into three small heating zones (see Fig. 1). From the direction of the feed inlet: the first section is the preheating low temperature zone, the main function is to preheat the drying tunnel; then enter the second section of the high temperature zone, which is the main drying zone of the material; after the material is dry, enter the first The three-stage heat preservation low temperature zone is then sent out from the discharge port.
It can be seen from the above scheme that the two heating zones of the heating furnace near the inlet and the outlet are lower in temperature, and the far-infrared radiating elements used can be less and the power can be smaller. The middle section of the heating furnace is the main drying zone of the heating furnace, and the temperature is required to be high, and the far-infrared radiation elements used are large and the power is large.
2. Working principle
Infrared heat furnace In order to ensure the drying quality, the temperature control of the entire far infrared furnace uses an automatic temperature control method. Three far-infrared radiating elements are respectively arranged in each of the three temperature zones of the furnace. Each temperature zone is controlled by the AI ​​program type regulator PID to control the far-infrared radiating element, and the heating of the furnace is started after the power is turned on. The use of shifting adjustment can not only prolong the use time of the far-infrared radiating element, but also keep the temperature of the heating furnace constant.
Second, the choice of control equipment:
The choice of advanced instruments: We use advanced AI artificial intelligence regulators in the system. The AI ​​regulator is the core part of the temperature control system. The AI ​​instrument is the first to adopt the platform concept. It converts the very professional digital adjustment instrument into the platform design product. The AI ​​artificial intelligence adjustment algorithm is based on fuzzy rules. A new algorithm for PID adjustment uses fuzzy algorithm to adjust the phenomenon of PID saturation integration when the error is large. When the error is small, the improved PID algorithm is used for adjustment, and the automatic learning and memory can be controlled in the adjustment. Part of the characteristics of the object to optimize the effect.
The self-tuning method is simple and convenient to apply: since the self-tuning is performed by positional adjustment, after 2~3 oscillations, the internal microprocessor of the instrument automatically calculates the period, amplitude and waveform according to the oscillation generated by the position control. M 5, P, t and other control parameters. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects.
In the process of use, AI regulator combines PID adjustment, self-learning and fuzzy control technology to realize self-tuning/adaptive function and precise adjustment without under-adjustment. The performance is far superior to traditional PID regulator.
Control system We use Yudian AI-808PAI5X3L2L2S4 temperature control table: AI-808P program type instrument is used for occasions that need to automatically change the given value for control according to a certain time rule. It has powerful programming and operation capabilities to further increase the automation of the control device. It has a 30-segment programming function, which can set the rising/falling slope of a given value of any size; with programmable/operable commands such as jump, run, pause and stop, the program can be modified during program control operation; Event output function. The alarm output can be used to control the interlocking action of other devices to further improve the automation capability of the device; the operation of the program can be executed by running an external switch to suspend or synchronize the operation or convenient operation; Start function and prepare function to make program execution more efficient and complete.
1, function and concept:
Block: The segment number can be from 1-30, and the current segment (STEP) indicates the segment currently being executed.
Set time: refers to the total time of the block setting operation, the unit is min, the valid value is from 1-9999.
Running time: refers to the running time of the current segment. When the running time reaches the set time, the program automatically skips a running period.
Jump: The program block can be programmed to automatically jump to any of the 1-30 segments for loop control. Jumps can also be achieved by modifying the value of STEP.
Run/HoLd: When the program is running, it is timed and the setpoint changes according to the pre-programmed program curve. When the program is in the pause state, the timer is stopped and the set value remains unchanged. The meter can be programmed to pause in the block, or it can be paused/runned at any time. The meter still maintains the adjustment function during the pause state.
Stop (stoP): Executing a stop operation will stop the program. At this time, the run time is cleared to 0, the event output switch is reset, and the control output is stopped. When the running operation is executed in the stop state, the instrument will start the running program from the segment number set by STEP. The function of automatic stop can be programmed in the block and the STEP value of the running segment number can be set at the same time. It is also possible to perform a stop operation at any time (STEP is set to 1 after execution, but the user can modify it).
Event output: Occurs by program orchestration. The 2-way alarm switch can be controlled during program operation to facilitate synchronization or interlocking of various external devices.
Power outage/power-on event: refers to the instrument is connected to the power supply or unexpected power failure during operation, and can provide a variety of processing options for the user to choose. The user can set the meter's parameter (run) to set the running status of the meter after power-on.
Preparation (rdy) / measured value start function: When the start running program has a deviation between the temperature of the furnace body and the initial temperature set by the meter, and the difference is greater than the positive (or negative) deviation alarm value (dHAL and dLAL), The meter does not immediately perform a positive (or negative) deviation alarm, but first adjusts the measured value to a value less than the deviation alarm value. At this time, the program also pauses the timing and does not output the deviation alarm signal until the positive and negative deviations meet the requirements. Only start the program again. The Ready/Measured Value Start function is also useful for setting up segments that cannot predict the rise/lower time. To allow or cancel the preparation/measurement value start function, set it in the run parameter. The preparation/measurement value start function ensures the integrity of the entire program curve. The preparation/measurement value start function is used to solve the uncertainty caused by the inconsistency between the measured value and the set value at the start-up operation. Efficiency, completeness and compliance with user requirements.
Setting of program curve: Program table adjuster can be used to automatically change the given value for control according to a certain time rule. The program is programmed in the format of [temperature-time-temperature], with 50-segment programming function, which can set the rising and falling slope of the given value of any size; with jump (the target segment is limited to the first 30 segments), running Programmable/operable commands such as pause, stop, etc., can be modified during program control operation; have two-way event output function. The alarm output can be used to control other equipment interlocking actions such as: warning lights, fans, and alarms to further improve the equipment automation capability; with power-off processing mode, measured value start-up function and preparation function, the program execution is more efficient and complete.
The program instrument self-tuning sets the first program to the normal temperature or the highest temperature to start the auto-tuning, and the time stops running.
2, parameter settings:
According to the requirements of the system, we can choose various instrument types such as AI-808PAI5X3L1L1S4+AIJK3, use the main output of AI-808P as the control signal of AIJK6 to control the heating output, and the AI-808P intelligent regulator adds 30 time program control function. The first 30 segments can be programmed as automatic jump execution, realize loop control, adopt advanced modular design, and have 5 function module sockets: auxiliary input, main output, alarm, auxiliary output and communication.
The input mode of the meter can be freely set to thermocouple, thermal resistance and linear current (voltage). The specific module functions are as follows;
I5: external switch input, control the start and stop of the instrument program;
X3: Photoelectric isolation high precision linear current output;
S4: Photoelectric isolation RS485 communication interface module with isolated power supply;
L2: relay contact switch output module;
AIJK6 series is an intelligent three-phase phase shift trigger and cycle zero-crossing trigger using single-chip technology. It is powerful and reliable. It can adapt to various resistance wires, silicon carbon rods and transformers. Rods, tungsten wires, etc. can be used in various types of industrial electric furnaces, and can also be used for the control of motor soft start. The main features include:
0-20mA (0-5V) / 4-20mA (1-5V) signal compatible input;
Phase loss detection, overcurrent detection and alarm function; AIJK6 also has thyristor breakdown and load open circuit detection function;
Automatic synchronization function, the phase sequence is not required when connecting the thyristor trigger line; AIJK6 does not even need polarity;
The use of photoelectric isolation and "burning not bad" technology, the reliability is very high, causing little interference to the input;
Soft start/soft stop function with adjustable current feedback or delay time, which can adapt to silicon molybdenum rod, tungsten wire, motor and inductive load;
It includes a switching power supply, which can be directly powered by 220VAC power supply, and has two sets of DC power output of 5V and 24V;
The instrument's adjustment function uses an advanced AI artificial intelligence PID adjustment algorithm. The AI ​​artificial intelligence adjustment algorithm is a new algorithm that uses fuzzy rules for PID adjustment. When the error is large, the fuzzy algorithm is used to adjust to eliminate the PID saturation integral phenomenon. When the error is small, the improved PID algorithm is used to adjust. And can automatically learn and memorize some features of the controlled object in the adjustment to optimize the effect. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects. The improved PID parameters are represented by U-specific M 5, P, t and other control parameters.
Debugging mode: electric blast drying oven control instrument AI-808PX3L1L1S4 enhanced intelligent regulator, three-phase zero-crossing trigger control.
Module X3 three-phase shift item trigger, module L1 switch quantity alarm output, module S4 communication RS485 communication parameter
3, debugging method:
After the parameter is set, it must first be self-tuned. The AI ​​artificial intelligence adjustment algorithm is a new algorithm that uses fuzzy rules for PID adjustment. When the error is large, the fuzzy algorithm is used to adjust to eliminate the PID saturation integral phenomenon. When the error is small, the improved PID algorithm is used to adjust. And can automatically learn and memorize some features of the controlled object in the adjustment to optimize the effect. It has the characteristics of no overshoot, high precision, simple parameter determination, and good control effect on complex objects.
The AI ​​series adjustment instrument also has a parameter self-tuning function. When the AI ​​artificial intelligence adjustment mode is used for the first time, the self-tuning function can be activated to assist in determining the control parameters such as M 5, P, and t. When the auto-tuning is started for the first time, the meter can be switched to the display state. In the state where the PV measurement value SV is given, press and hold the semi-circular arc button for about 2 seconds. At this time, the display under the meter will flash to display “At "The words indicate that the meter has entered the self-tuning state. Self-tuning, the instrument performs position adjustment. After 2~3 oscillations, the internal microprocessor of the instrument automatically calculates M 5, P, t, etc. according to the oscillation generated by the position control, analyzing its period, amplitude and waveform. control parameter. If you want to abandon the auto-tuning in advance during the auto-tuning process, you can press and hold the semi-circular arc button for about 2 seconds to stop the display under the instrument from flashing “Atâ€. Depending on the system, the time required for self-tuning can vary from a few seconds to several hours. After the self-tuning of the instrument is completed successfully, the parameter CtrL will be set to 3 (1 at the factory) or 4, so that the auto-tuning cannot be started from the panel by pressing the button again in the future, and the self-tuning can be avoided again by human error. A meter that has started a self-tuning function. If you want to start auto-tuning in the future, you can start it by setting the parameter CtrL to 2. The specific operation should refer to the instruction manual.
The parameter values ​​obtained by the system under different set values ​​are not exactly the same. Before executing the auto-tuning function, the set value should be set to the most common value or intermediate value (for the AI-708P/808P program type instrument, The set value can be changed to meet the requirement by modifying the current block value. If the system is an electric furnace with good insulation performance, the set value should be set at the maximum value used by the system, and then the operation function of starting the auto-tuning should be performed. The setting of parameters CtI (control cycle) and dF (hysteresis) also have an effect on the self-tuning process. Generally speaking, the smaller the set values ​​of these two parameters, the higher the accuracy of the theoretical self-tuning parameters. However, if the dF value is too small, the meter may cause a misalignment of the position adjustment near the given value due to the input fluctuation, which may instead set a completely wrong parameter. It is recommended that CtI = 0-2 and dF = 2.0. In addition, based on the reason for learning, the first time after the end of auto-tuning, the control effect may not be optimal, and it takes a period of time (usually the same time as auto-tuning) to get the best results.
In the process of use, AI regulator combines PID adjustment, self-learning and fuzzy control technology to realize self-tuning/adaptive function and precise adjustment without under-adjustment. The performance is far superior to traditional PID regulator.
4, the layout of the program curve:
The schedule adjuster can be used to automatically change the given value for control according to a certain time rule. With 50-segment programming function, it can set the rising and falling slope of the given value of any size; with programmable/operable commands such as jump (the target segment is limited to the first 30 segments), running, pause and stop, it can be controlled in the program. Modify the program during operation; has two-way event output function. The alarm output can be used to control other equipment interlocking actions to further improve the equipment automation capability; the power failure processing mode, the measured value start function and the preparation function are enabled, so that the program execution is more efficient and complete.
The program layout uniformly adopts the temperature-time-temperature format, which is defined as the temperature set from the current segment and the time set by the segment reaches the next temperature. The unit of temperature setting is °C, and the unit of time value is minutes.
The following example is an example of a 6-segment program that includes linear warming, constant temperature, linear cooling, jump loop, preparation, pause, and event output.
The first paragraph C 01=100 t 01=30; starting linear temperature rise from 100 ° C, the heating time is 30 minutes
The second stage C 02 = 400 t 02 = 60; the temperature was raised to 400 ° C, and the temperature rising slope was 10 ° C / min. The constant temperature time is 60 minutes
The third paragraph C 03=400 t 03=120; in the cooling section, the cooling time is 120 minutes, and the cooling slope is 2 ° C / min.
Paragraph 4 C 04=160 t 04=-35 ; After cooling down to 160 °C, turn on the alarm switch 1, and jump to the fifth stage to execute.
The fifth paragraph C 05=160 t 05=0; enter the pause state, the operator needs to perform the operation to continue to the sixth paragraph.
Paragraph 6 C 06=160 t 06=-151 ; Turn off alarm switch 1, and jump to the first segment to execute and cycle from the beginning.
The advantage of using the temperature-time programming method is that the range of temperature rise and temperature ramp settings is very wide. The heating and constant temperature sections have a uniform setting format for easy learning. The setting curve is more flexible, and it can be set to continuously set the temperature rising section (for example, the temperature rising section with different slopes is approximated to achieve the function temperature rise), or the continuous constant temperature section.
Third, the split paperless recorder function
Far-infrared automatic drying equipment In the application, the AI-2070C split paperless recorder will be used to record data. The main functions are: rich display screen; powerful setting function; perfect flow processing; practical U disk recording function; convenient data statistics function; flexible alarm function; reliable communication function;
The data recording function has developed rapidly, from paper recording to paperless recording; paperless recording analog input to digital paperless recorder; since the automatic drying equipment is a digital adjustment instrument using communication function to control the electric furnace thyristor, real time Record the temperature control curve of the automatic drying equipment.
The digital AI-2070 paperless recorder is installed in the control cabinet. It can be easily used with the AI ​​intelligent program type PID temperature regulator through the RS485 communication interface and the upper and lower position.
The program curve can be set on the touch screen when the far infrared automatic drying device controls the temperature. Display hyperbolic running chart, can be set, read, and upload temperature, constant temperature, cooling program formula.
Control the operating program instrument on the screen [Start] [Stop] [Pause], switch the [Manual/Automatic] status in the running state, manually control the output; modify the [Segment No.] in real time.
Fixed operating segment
The data in the U disk record is visually displayed in the form of a multi-curve, showing the measured relationship between the relevant channels during the time period. According to the channel order, the channel combinations of 1, 2, 3, and 4 are fixedly combined. For the channel that needs to compare key parameters, the instrument address can be arranged in the same group to display the trend curve, so that the object variation of the process parameters can be better compared and analyzed. . You can choose to enable single or four curves to display trend changes; query historical data to set the start time and time span; set the data range so that the curve is displayed in the center of the chart, and different data ranges enable a single query. Click the [Query] in the lower right corner of the function screen of the history screen. The touch screen display is the current start time: year/month/day/hour/minute/second; modify the time span: hour/minute/second setting; click the [confirm] button, The system immediately displays historical curves, data reports, and alarm reports.
In the data logger, you can set the data sampling time, storage interval and whether to save the record, whether to save the data to the U disk and other functions according to the actual needs of the customer to meet different needs. (1) The sampling time defaults to 6 seconds. The user can set the range from 6 seconds to 3600 seconds. (2) The memory to U disk storage interval defaults to 60 minutes. The user can set the range: 60 minutes to 300. (3) If the user needs to immediately take away the data stored in the recorder's memory, click the "Save Now" button, and the collected data will be stored in the CF immediately.
The data record is an external USB flash drive to save data; the 2G electronic hard disk is standard. The data alarm report of the U disk save data can be directly opened on the PC to open the data file in CSV format using Excel spreadsheet, or print the report with a micro printer. ,
The AI-2070C split paperless recorder is equipped with a temperature curve data recorded by a micro printer. Printing of data reports. Click on the print button directly on the touch screen to print historical data and curves. Print the data curve query.
Fourth, the conclusion
The far-infrared heating furnace was installed and commissioned and put into operation. From the perspective of usage, the application of the AI ​​program type regulator has a good control effect. Since the far-infrared radiating element is controlled by the shifting item, the use time of the far-infrared radiating element is prolonged, and the operation is simple, and the data recording of the paperless recorder is completely managed conveniently.
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