阅读说明：本技术 一种粒子发泡工艺中阀门自动调节的系统和方法 (System and method for automatically adjusting valve in particle foaming process ) 是由 顾鹏程 陶庭 于 2020-05-28 设计创作，主要内容包括：本发明涉及一种粒子发泡工艺中阀门自动调节的系统,包括数据采集模块,用于采集各个反应釜子端必要参数,并将采集到的反应釜子端必要参数上传；数据处理器,用于分析数据采集模块上传的反应釜子端必要参数,并进行处理和分析；阀门控制模块,为数据处理器下游的执行单元,用于接收数据处理器下发的指令信息和获取流量控制阀门的状态,并根据指令信息控制流量控制阀门；服务器,用于存储数据处理器的实时数据、通过服务器的显示装置进行界面展示以及指令下达。本发明的目的是克服现有技术存在的缺陷,提供一种自动化程度高、阀门控制精准度高的粒子发泡工艺中阀门自动调节的系统和方法。(The invention relates to a system for automatically adjusting a valve in a particle foaming process, which comprises a data acquisition module, a data processing module and a control module, wherein the data acquisition module is used for acquiring necessary parameters of each reactor sub-end and uploading the acquired necessary parameters of the reactor sub-ends; the data processor is used for analyzing the necessary parameters of the reactor sub-end uploaded by the data acquisition module, and processing and analyzing the parameters; the valve control module is an execution unit at the downstream of the data processor and is used for receiving instruction information sent by the data processor, acquiring the state of the flow control valve and controlling the flow control valve according to the instruction information; and the server is used for storing the real-time data of the data processor, and performing interface display and instruction issuing through a display device of the server. The invention aims to overcome the defects in the prior art and provide a system and a method for automatically adjusting a valve in a particle foaming process, which have high automation degree and high valve control accuracy.)

1. A system for automatically adjusting a valve in a particle foaming process is characterized in that: the system comprises a data acquisition module (1) for acquiring the necessary parameters of each reactor sub-end and uploading the acquired necessary parameters of the reactor sub-ends;

the data processor (2) is used for analyzing the necessary parameters of the reactor sub-end uploaded by the data acquisition module (1), and processing and analyzing the parameters;

the valve control module (3) is an execution unit at the downstream of the data processor (2) and is used for receiving instruction information sent by the data processor (2), acquiring the state of the flow control valve and controlling the flow control valve according to the instruction information;

and the server (4) is used for storing the real-time data of the data processor (2), and performing interface display and instruction issuing through a display device of the server (4).

2. The system for automatic valve adjustment in particle foaming process according to claim 1, wherein: the necessary parameters of the reactor sub-end comprise real-time parameters of a reactor internal temperature sensor (5) and real-time parameters of a reactor internal pressure sensor (6).

3. The system for automatic valve adjustment in particle foaming process according to claim 1, wherein: the data acquisition module (1) is communicated with the data processor (2) through wireless or wired communication.

4. A system for automatic valve adjustment in a particle foaming process according to any of claims 1 to 3, wherein: the data processor (2) analyzes the acquired necessary parameters of the reactor sub-end by using a PID algorithm and issues instructions in combination with the existing state of the flow control valve.

5. A method for automatically adjusting a valve in a particle foaming process is characterized by comprising the following steps: the method comprises the following steps:

a, initializing system parameters, namely initializing and setting parameters of a flow control valve, a temperature sensor (5) in a kettle and a pressure sensor (6) in the kettle;

b, acquiring necessary parameters of each reaction kettle sub-end by a data acquisition module (1), and uploading data through wireless or wired communication, wherein the data acquisition period is T;

c, uploading the data obtained in the step b to a data processor (2);

d, analyzing the data by the data processor (2), judging whether the obtained parameters are in the parameter range set by the system, if so, carrying out a step e, and if not, carrying out a step f;

e, keeping the existing state of the valve when the parameters obtained in each reaction kettle are within the parameter range set by the system, and then entering the step b;

f, calculating the current position of the valve when the parameters obtained in each reaction kettle are not in the parameter range set by the system;

step g, acquiring a target valve position according to a PID algorithm of the data processor (2);

h, calculating the required stroke according to the current valve position and the target valve position;

step i, judging whether the required travel is in the minimum travel, entering a step j if yes, and entering a step j if no

Step j, the valve control module (3) controls the valve to adjust at the minimum speed, and simultaneously adjusts the acquisition period of the data acquisition module 1 to T1, and then the step b is carried out;

and step k, entering an acceleration stage, calculating an acceleration curve and controlling the valve control module (3) to act and execute by the data processor (2) according to the deduction of a PID algorithm, and then entering step b.

6. The method according to claim 5, wherein the valve is automatically adjusted in the particle foaming process, and the method comprises the following steps: the acquisition period T1 is 1/2 of the original data acquisition period T.

Technical Field

The invention relates to the field of valve control in a particle foaming process, in particular to a system and a method for automatically adjusting a valve in the particle foaming process.

Background

The foaming technology is utilized to form a large amount of bubbles in the polymer material to form the polymer foam material with a porous structure, and the method is an effective means for realizing light weight and saving materials. The existence of a large number of foam holes endows the material with the characteristics of excellent heat insulation and preservation, damping and buffering, noise reduction and sound absorption and the like.

Generally, the higher the expansion ratio of the polymer foam, the lighter the product weight, the more material saving, and the more excellent the heat insulation and cushioning properties. Common high-rate foamed products often have complex appearance structures, however, no effective technical means for obtaining products with high-rate complex structures through one-step foaming is available in the industry at present. The two-step forming method of firstly foaming the solid polymer particles to obtain the foamed beads and then leading steam into the mold to weld the surfaces of the foamed beads is an effective way for preparing foamed products with large-magnification complex structures, can realize the high-efficiency production of the foamed products with large-magnification complex structures, and is widely applied to the production and manufacture of foamed products such as Polystyrene (PS), polypropylene (PP), Polyethylene (PE), Thermoplastic Polyurethane (TPU) and the like.

In the particle foaming process, the control of the valve flow is of great importance, the existing valve is manually closed or opened according to experience after being displayed by an instrument, the automation degree is low, and the flow control is unstable.

Disclosure of Invention

The invention aims to overcome the defects in the prior art and provide a system and a method for automatically adjusting a valve in a particle foaming process, which have high automation degree and high valve control accuracy.

The technical scheme for realizing the purpose of the invention is as follows: a system for automatically adjusting a valve in a particle foaming process comprises a data acquisition module, a data processing module and a control module, wherein the data acquisition module is used for acquiring necessary parameters of each reactor sub-end and uploading the acquired necessary parameters of the reactor sub-ends;

the data processor is used for analyzing the necessary parameters of the reactor sub-end uploaded by the data acquisition module, and processing and analyzing the parameters;

the valve control module is an execution unit at the downstream of the data processor and is used for receiving instruction information sent by the data processor, acquiring the state of the flow control valve and controlling the flow control valve according to the instruction information;

and the server is used for storing the real-time data of the data processor, and performing interface display and instruction issuing through a display device of the server.

Further, the necessary parameters of the reactor sub-end comprise real-time parameters of a temperature sensor in the reactor and real-time parameters of a pressure sensor in the reactor.

Further, the data acquisition module analyzes the acquired necessary parameters of the reactor sub-end by using a PID algorithm through wireless or wired communication and a data processor, and issues an instruction in combination with the existing state of the flow control valve.

A method for automatically adjusting a valve in a particle foaming process is characterized by comprising the following steps: the method comprises the following steps:

a, setting system initialization parameters, namely initializing and setting parameters of a flow control valve, parameters of a temperature sensor in a kettle and parameters of a pressure sensor in the kettle;

b, acquiring necessary parameters of each reactor sub-end by a data acquisition module, and uploading data through wireless or wired communication, wherein the data acquisition period is T;

c, uploading the data obtained in the step b to a data processor;

d, analyzing the data by the data processor, judging whether the obtained parameters are in the parameter range set by the system, if so, carrying out a step e, and if not, carrying out a step f;

e, keeping the existing state of the valve when the parameters obtained in each reaction kettle are within the parameter range set by the system, and then entering the step b;

f, calculating the current position of the valve when the parameters obtained in each reaction kettle are not in the parameter range set by the system;

step g, acquiring a target valve position according to a PID algorithm of the data processor;

h, calculating the required stroke according to the current valve position and the target valve position;

step i, judging whether the required travel is in the minimum travel, entering a step j if yes, and entering a step j if no

Step j, the valve control module controls the valve to adjust at the minimum speed, and simultaneously adjusts the acquisition period of the data acquisition module 1 to T1, and then the step b is carried out;

and step k, entering an acceleration stage, calculating an acceleration curve and controlling the valve control module to act according to PID algorithm deduction by the data processor, and then entering step b.

Further, the acquisition period T1 is 1/2 of the original data acquisition period T.

After the technical scheme is adopted, the invention has the following positive effects: the automatic valve adjusting system in the particle foaming process has high automation degree, and avoids the problem of time node difference caused by the fact that an operator observes firstly and then adjusts manually; in addition, during valve control, when the difference between the opening degree of the valve and the target valve position is small, data are collected more finely and more densely by shortening the data collection period and are adjusted in time according to the data, so that the valve flow control precision under the monitoring of the whole system is higher, and the problem of foaming failure caused by unstable flow is avoided.

Drawings

In order that the present disclosure may be more readily and clearly understood, reference is now made to the following detailed description of the present disclosure taken in conjunction with the accompanying drawings, in which

FIG. 1 is a block diagram of the system architecture of the present invention;

FIG. 2 is a flow chart of the present invention;

FIG. 3 is experimental comparison data of the present invention.

The reference numbers in the drawings are as follows: the system comprises a data acquisition module 1, a data processor 2, a valve control module 3, a server 4, a kettle internal temperature sensor 5 and a kettle internal pressure sensor 6.

Detailed Description

(example 1)

Referring to fig. 1, the invention provides a system for automatically adjusting a valve in a particle foaming process, which comprises a data acquisition module 1, a data processing module and a data processing module, wherein the data acquisition module is used for acquiring necessary parameters of each reactor sub-end and uploading the acquired necessary parameters of the reactor sub-end;

the data processor 2 is used for analyzing the necessary parameters of the reactor sub-end uploaded by the data acquisition module 1, and processing and analyzing the parameters;

the valve control module 3 is an execution unit at the downstream of the data processor 2 and is used for receiving the instruction information sent by the data processor 2, acquiring the state of the flow control valve and controlling the flow control valve according to the instruction information;

and the server 4 is used for storing the real-time data of the data processor 2, and performing interface display and instruction issuing through a display device of the server 4.

(example 2)

The invention provides a system for automatically adjusting a valve in a particle foaming process, which comprises a data acquisition module 1, wherein the data acquisition module is used for acquiring necessary parameters of each reactor sub-end and uploading the acquired necessary parameters of the reactor sub-ends. The necessary parameters of the reactor sub-end comprise real-time parameters of the temperature sensor 5 in the reactor and real-time parameters of the pressure sensor 6 in the reactor, wherein the real-time parameters of the temperature sensor 5 in the reactor are specifically that the temperature in the reactor is uploaded to the data acquisition module 1 by the thermistor through the transmitter.

And the data processor 2 is used for analyzing the necessary parameters of the reactor sub-end uploaded by the data acquisition module 1, and processing and analyzing the parameters. The data acquisition module 1 communicates with the data processor 2 through wireless or wired communication, the wireless communication mode can be LORA wireless communication, the wired communication adopts RS485 communication, and the wireless or wired communication is equipped with corresponding interfaces.

The valve control module 3 is an execution unit at the downstream of the data processor 2, and is configured to receive instruction information sent by the data processor 2, obtain a state of the flow control valve, and control the flow control valve according to the instruction information. The instruction information of the data processor 2 is obtained by the data processor 2 analyzing necessary parameters of the reactor sub-end by using a PID algorithm, and calculating and deducing, and the instruction information is an execution action performed after referring to the existing state and position information of the flow control valve.

And the server 4 is used for storing the real-time data of the data processor 2, and performing interface display and instruction issuing through a display device of the server 4. Besides the control of the valve control module 3, the operator can also directly and manually operate the control valve, and the operation can be carried out through the server 4.

(example 3)

Referring to fig. 2, a method for automatically adjusting a valve in a particle foaming process includes the following steps:

a, setting system initialization parameters, namely performing initialization setting on parameters of a flow control valve, parameters of a temperature sensor and parameters of a pressure sensor;

b, the data acquisition module 1 acquires the necessary parameters of each sub-end of the reaction kettle, and uploads the data through wireless or wired communication, the data acquisition period is T, the wireless communication mode can be LORA wireless communication, the wired communication adopts RS485 communication, and the wireless or wired communication is provided with corresponding interfaces;

c, uploading the data obtained in the step b to a data processor 2;

d, the data processor 2 analyzes the data, compares the received data with the temperature sensor parameter and the pressure sensor parameter set during the system initialization, and judges whether the obtained parameters are in the parameter range set by the system, if yes, step e is carried out, and if not, step f is carried out;

e, if the parameters obtained in each reaction kettle are within the parameter range set by the system, the temperature and the pressure in the reaction kettle are normal, and the existing valve state meets the particle foaming condition, so the existing state of the valve is maintained, and then the step b is carried out;

f, calculating the current position of the valve according to the valve state obtained by the valve control module from the front end when the parameters obtained in each reaction kettle are not in the parameter range set by the system;

step g, calculating according to the PID algorithm of the data processor 2 by combining the read temperature sensor parameters and the read pressure sensor parameters so as to obtain a target valve position;

h, calculating the required stroke according to the current valve position and the target valve position;

step i, judging whether the required travel is in the minimum travel, entering a step j if yes, entering a step k if no, wherein the minimum travel can be set in the initial state of the system;

step j, the valve control module 3 controls the valve to adjust at the minimum speed, and simultaneously adjusts the acquisition period of the data acquisition module 1 to T1, the acquisition period T1 is 1/2 of the original data acquisition period T, and the acquisition period is shortened to T1, so that the data acquisition frequency is improved, and the adjustment is carried out in real time according to the acquired data, so that the accuracy of valve control is improved, and the particle foaming is facilitated. After the acquisition period is adjusted, then entering the step b;

and step k, entering an acceleration stage, calculating an acceleration curve and controlling the valve control module 3 to act according to the deduction of a PID algorithm by the data processor 2, and then entering step b.

The step b is repeatedly carried out in the steps, so that the influence of adjusting the temperature and the pressure in the multi-reaction kettle can be monitored in real time, namely whether the valve is in place or not is detected in a real-time phase-change mode, and when the temperature sensor parameter and the pressure sensor parameter are detected to be in the specified range of the system, the position of the valve at the moment is required to correspond to the position of a target valve calculated by the system through a PID algorithm.

Fig. 3 shows comparative experimental data between the automatic scheme and the conventional manual scheme, which indicates that the upper and lower fluctuation ranges of the conventional manual scheme are large when the temperature and pressure in the reaction kettle are controlled, and the result is that the qualified rate of the particle foaming product is only 83.1%, while the automatic scheme has the advantages of higher precision, shorter response time, high foaming success rate and high popularization value in the aspects of temperature and pressure control in the experiment.

The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are only exemplary embodiments of the present invention, and are not intended to limit the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.