CN103605323B - The Discrete Control Method of Chemical Manufacture and device - Google Patents
The Discrete Control Method of Chemical Manufacture and device Download PDFInfo
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The present invention relates to a kind of Discrete Control Method and device of Chemical Manufacture.Discrete Control Method comprises: set up the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each technological parameter has a regression coefficient all accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Obtain multiple regression coefficient; The history value utilizing the regression coefficient of acquisition, the instantaneous value of the first parameter, the second parameter corresponding and linear regression model (LRM), obtain the technic index estimated value of current time online.The present invention can carry out real-time, significant guidance to production run, has both saved the energy, can reach again predetermined finger requirement, solves the problem of the crucial Con trolling index directly cannot measured by detecting device due to the reason such as device hardware or technological requirement.
Description
Technical field
The present invention relates to chemical field, particularly relate to a kind of Discrete Control Method and device of Chemical Manufacture.
Background technology
Below, to produce neoprene process, the Discrete Control Method of Chemical Manufacture of the prior art and device are described.
Due to reasons such as device hardware problem and techniques, cannot by the situation of change of " finished product glue fugitive constituent % " in detecting device on-line real time monitoring drying box production run (belonging to crucial technic index).Laboratory just can obtain " finished product glue fugitive constituent % " this critical technic index after needing the final products waiting for this batch or order of classes or grades at school to produce for the analysis of this technic index after sampling for final products.
But chemical examination frequency is about 2 hours once at present.Visible, directly cannot obtain any data of this index in process of production.If after waiting until that Analytical Laboratory Results out, define final products, therefore, laboratory data belongs to " knowing aftersensation afterwards ", to production run without any directive significance.
For these reasons, in order to avoid end product quality does not reach user's requirement, in operation, usually take the mode of the luxus consumption energy (drying box 1-3 section being controlled the valve wide open of steam) to guarantee product quality.But this can make " finished product glue fugitive constituent % " this technic index of the product produced in prior art too high, not only wastes the energy but also cannot meet quality requirements.
Summary of the invention
The object of this invention is to provide a kind of use simple, can carry out to target process index Discrete Control Method and the device estimated in real time to carry out the Chemical Manufacture of real-time instruction to production online.
For solving the problems of the technologies described above, as first aspect of the present invention, provide a kind of Discrete Control Method of Chemical Manufacture, comprising: set up the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each technological parameter has a regression coefficient all accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Obtain multiple regression coefficient; The history value utilizing the regression coefficient of acquisition, the instantaneous value of the first parameter, the second parameter corresponding and linear regression model (LRM), obtain the technic index estimated value of current time online.
Further, Discrete Control Method also comprises: the chemical products obtained by current time obtain the technic index measured value of the chemical products of this current time after chemically examining, correct regression coefficient according to the deviation between technic index estimated value and technic index measured value.
Further, Discrete Control Method also comprises: utilize multiple technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, correct according to the deviation between technic index estimated value and technic index mean value to regression coefficient.
Further, Discrete Control Method also comprises: judge whether technic index estimated value meets predetermined variation range, if do not met, send warning.
Further, Discrete Control Method also comprises: be each second optimum configurations retardation time, to obtain the historical data of this second parameter.
As second aspect of the present invention, provide a kind of discrete control device of Chemical Manufacture, comprising: model storage unit, for storing the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each technological parameter has a regression coefficient all accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Regression coefficient acquiring unit, for obtaining multiple regression coefficient; Computing unit, for the history value that utilizes the instantaneous value of the regression coefficient of acquisition, the first parameter, the second parameter corresponding and linear regression model (LRM), obtains the technic index estimated value of current time online.
Further, discrete control device also comprises: correcting unit, for correcting regression coefficient according to the deviation between technic index estimated value and technic index measured value, wherein, technic index measured value obtains after the chemical products obtained by current time are chemically examined.
Further, discrete control device also comprises: correcting unit, for correcting regression coefficient according to the deviation between technic index estimated value and technic index mean value, wherein, technic index mean value is the mean value of multiple technic index measured values of the chemical products of producing when production even running, in predetermined amount of time.
Further, discrete control device also comprises: judging unit, for judging whether technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
Further, discrete control device also comprises: retardation time setting unit, for being each second optimum configurations retardation time, to obtain the historical data of this second parameter.
The history value of the instantaneous value of the first parameter, the second parameter and the regression coefficient that determines are brought in predetermined linear regression model (LRM) by the present invention, so, not needing to utilize the hardware of equipment to expecting that the critical technic index obtained is measured in real time, just can estimate the technic index estimated value of current time.Therefore, solve in prior art, when the data of this technic index directly cannot be obtained in process of production in real time, when can only utilize the laboratory data with time-lag effect, problem that is real-time, significant guidance cannot be carried out to production run.Operating personnel can according to this technic index estimated value, real-time online ground regulates each technological parameter, thus make the present invention can carry out real-time, significant guidance to production run, both the energy had been saved, predetermined requirement can be reached again, solve the problem of the crucial Con trolling index directly cannot measured by detecting device due to the reason such as device hardware or technological requirement.
Accompanying drawing explanation
Fig. 1 diagrammatically illustrates the process flow diagram of the Discrete Control Method of the Chemical Manufacture in the present invention;
Fig. 2 diagrammatically illustrates the workflow diagram of CALCU module; And
Fig. 3 diagrammatically illustrates the workflow diagram of ADD module.
Embodiment
Below embodiments of the invention are described in detail, but the multitude of different ways that the present invention can be defined by the claims and cover is implemented.
In the technological parameter that the present invention is involved from production run, extract crucial technological parameter, and these technological parameters are decomposed into incoherent the first parameter without time-lag effect and there is the second parameter of time-lag effect.Then, utilize technic index measured value and the first parameter, the second parameter to carry out matching, thus obtain the linear regression model (LRM) between technic index and technological parameter.Like this, only need the first parameter according to current time, and second parameter of the historical juncture corresponding with current time, just by this linear regression model (LRM), the technic index of current time is estimated, thus obtain the technic index estimated value in moment at that time, thus provide online, real-time support for actual production.
As a first aspect of the present invention, provide a kind of Discrete Control Method of Chemical Manufacture, especially, this Discrete Control Method can be applicable in DCS device, and the corresponding module in DCS device (such as PVI module, LAG module, DLAY module, CALCU module and ADD module etc.) can be utilized to realize.Especially, this Discrete Control Method can be applicable to produce neoprene process.
This Discrete Control Method comprises: set up the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each technological parameter has a regression coefficient all accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Obtain multiple regression coefficient, especially, manually can be inputted by artificial mode, also automatically can be inputted by system; The history value utilizing the regression coefficient of acquisition, the instantaneous value of the first parameter, the second parameter corresponding and linear regression model (LRM), obtain the technic index estimated value of current time online.Especially, the sampling interval to each technological parameter can be set, to improve the precision of estimation.Further, also the technic index estimated value of current time can be shown in real time.
The history value of the instantaneous value of the first parameter, the second parameter and the regression coefficient that determines are brought in predetermined linear regression model (LRM) by the present invention, so, not needing to utilize the hardware of equipment to expecting that the critical technic index obtained is measured in real time, just can estimate the technic index estimated value of current time.Therefore, solve in prior art, when the data of this technic index directly cannot be obtained in process of production in real time, when can only utilize the laboratory data with time-lag effect, problem that is real-time, significant guidance cannot be carried out to production run.Operating personnel can according to this technic index estimated value, real-time online ground regulates each technological parameter, thus make the present invention can carry out real-time, significant guidance to production run, both the energy had been saved, predetermined finger requirement can be reached again, solve the problem of the critical process index directly cannot measured by detecting device due to the reason such as device hardware or technological requirement.
After linear regression model (LRM) uses a period of time, its regression coefficient etc. can change according to production actual conditions, therefore, in order to adapt to new change, need to correct regression coefficient etc.For this reason, in one embodiment, Discrete Control Method also comprises: the chemical products obtained by current time obtain the technic index measured value of the chemical products of this current time after chemically examining, correct regression coefficient according to the deviation between technic index estimated value and technic index measured value.In another embodiment, preferably, Discrete Control Method also comprises: utilize multiple technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, correct according to the deviation between technic index estimated value and technic index mean value to regression coefficient.
Preferably, Discrete Control Method also comprises: judge whether technic index estimated value meets predetermined variation range, if do not met, send warning.
Preferably, Discrete Control Method also comprises: be each second optimum configurations retardation time, to obtain the historical data of this second parameter.In fact, the retardation time of each second parameter may be different, therefore, needs to be respectively each second optimum configurations different retardation time.
As a second aspect of the present invention, please refer to Fig. 2 and Fig. 3, provide a kind of discrete control device of Chemical Manufacture, comprising: model storage unit, for storing the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each technological parameter has a regression coefficient all accordingly, technological parameter comprises at least one first parameter and at least one second parameter, first parameter is real time data, second parameter is the historical data with time-lag effect, especially, the PVI module in DCS system can be adopted to obtain technological parameter in real time; Regression coefficient acquiring unit, for obtaining multiple regression coefficient, especially, regression coefficient acquiring unit can use the LAG module in DCS system to realize; Computing unit, for the history value that utilizes the instantaneous value of the regression coefficient of acquisition, the first parameter, the second parameter corresponding and linear regression model (LRM), obtains the technic index estimated value of current time online.Especially, computing unit can adopt the CALCU module in DCS system to realize.
In one embodiment, discrete control device also comprises: correcting unit, for correcting regression coefficient according to the deviation between technic index estimated value and technic index measured value, wherein, technic index measured value obtains after the chemical products obtained by current time are chemically examined.Especially, correcting unit can use the ADD module in DCS to realize.
In another embodiment, discrete control device also comprises: correcting unit, for correcting regression coefficient according to the deviation between technic index estimated value and technic index mean value, wherein, technic index mean value is the mean value of multiple technic index measured values of the chemical products of producing when production even running, in predetermined amount of time.Especially, correcting unit can use the ADD module in DCS to realize.
Preferably, please refer to Fig. 3, discrete control device also comprises: judging unit, for judging whether technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
Preferably, discrete control device also comprises: retardation time setting unit, for being each second optimum configurations retardation time, to obtain the historical data of this second parameter.Especially, retardation time, setting unit can adopt the DLAY module in DCS system to realize.
Below for DCS and module thereof, the Discrete Control Method with hard measurement function in the present invention and device are described in detail.
First, after determining linear regression model (LRM), be made up of real time data and the historical data with hysteresis characteristic that determines due to production technology for the technological parameter that calculates crucial technic index, in order to ensure versatility of the present invention, all can adopt the configuration of More General Form in dcs, comprise PVI module, LAG module and DLAY module etc., by being the different parameter of above-mentioned each block configuration, realizing selecting real time data or historical data to enter in model and participating in calculating.
(1) PVI module: for the input signal from input/output module and other functional block is shown as measured value (PV).In addition, this measured value can also be exported.Herein, PVI module can be used for the real time data obtaining each technological parameter, and it can be used as output to send into following LAG module (not considering the hysteresis requirements of data herein).
(2) LAG module: be mainly used in obtaining the regression coefficient in linear regression model (LRM) corresponding to each technological parameter.Such as, these regression coefficients are inputted by man-machine interface.
(3) DLAY module: for realize technological parameter in linear regression model (LRM) carry out cross-correlation analysis with controlled device respectively after determined retardation time, retardation time is different, then in module, parameter configuration is different.
Secondly, the CALCU module in DCS can be used to complete the calculating of the technic index based on linear regression model (LRM), comprise the summation of constant and each technological parameter acquired in linear regression model (LRM).
3rd, the ADD module in DCS can be utilized to complete the function of data deviation correction.It should be noted that, be closely connected because the actual result of laboratory test of sampling also exists with equipment operating condition at that time, limit by the sampling frequency, sample for Modling model can not comprise whole operating condition, therefore can drift about after linear regression model (LRM) on-line running a period of time, measuring accuracy also can decline to a great extent thereupon.In order to solve the problem, need to realize the offset correction function for model in the present invention.
In production neoprene process, the critical technic index that cannot directly obtain is " finished product glue fugitive constituent % ".Below, the measured data received for mountain, in conjunction with the embody rule of Yokogawa CS3000DCS, further illustrates the present invention.
First, following linear regression model (LRM) is obtained:
Finished product glue fugitive constituent %=53.5-0.0394HIC-727206.MV (%)
-0.204TR-727225.PV-3.15TR-727219.PV_4
-0.138TIC-727226.PV-0.124TRC727203.PV_1
-0.0198TIC-727206.PV_1+0.0883TIC-727205.PV
Wherein, seven technological parameters participating in calculating are comprised altogether, i.e. HIC-727206.MV, TR-727225.PV, TR-727219.PV_4, TIC-727226.PV, TRC727203.PV_1, TIC-727206.PV_1 and TIC-727205.PV.Especially, the variable with hysteresis characteristic is: TR-727219.PV_4, TRC727203.PV_1 and 727206.PV_1.The retardation time that can obtain three variablees according to delayed zone bit is respectively 20 minutes, 5 minutes and 5 minutes.But in order to ensure the versatility of linear regression model (LRM), all adopting the configuration of More General Form in dcs, realizing delayed or real time data by the parameter different for block configuration and entering in model and participate in calculating.
Input signal from input/output module and other functional block shows as measured value by PVI module.In addition, can outputting measurement value.Herein, PVI module for obtaining the real time data of above-mentioned seven technological parameters, and it can be used as output to send into LAG module (not considering the hysteresis requirements of data herein).It is to be noted that the content of " Input " → " ProcessVariableRange " → " Highlimitvalue " and " Lowlimitvalue " etc. should be arranged according to technological parameter different in kind (with reference to the current existing relevant configuration information in dcs of this variable) accordingly when configuring on this module backstage.
The effect of LAG module realizes regression coefficient before being positioned at each technological parameter in linear regression model (LRM), that obtained by recurrence.
The effect of DLAY module be realize technological parameter TR-727219.PV_4, TRC727203.PV_1 and TIC-727206.PV_1 in linear regression model (LRM) carry out cross-correlation analysis with controlled device respectively after determined retardation time, such as, 20 minutes, 5 minutes and 5 minutes are respectively the retardation time of three.
According to the principle of work of DLAY module, in order to realize the retardation time (being respectively 20 minutes, 5 minutes and 5 minutes) of technological parameter TR-727219.PV_4, TRC727203.PV_1 and TIC-727206.PV_1 in linear regression model (LRM) and all the other are without the need to delayed technological parameter, concrete configuration is divided into three steps:
Step1: number of sampling points is set as 60 in Function Block Configuration, i.e. m=60.Can intuitivism apprehension be establish in DLAY module in " houses of 60 store data ", according to the scan period (this example is 1 second) of DCS, often through the single pass cycle, data will be filled up " 1 house ", and 60 therefore set up houses will be filled after 60 seconds.
Step2: according to the requirement of different retardation time, sampling interval (SMPL) is arranged accordingly in front console.For technological parameter TR-727219.PV_4, want to pass through set up linear regression model (LRM) and calculate current process index estimated value, the value that this technological parameter participates in calculating should be the measured value before 20 minutes, namely dead time L=20 minute=1200 seconds.According to this requirement, extrapolate SMPL=L/m=1200/60=20.According to above-mentioned computing method, the retardation time due to TRC727203.PV_1 and TIC-727206.PV_1 is 5 minutes, and therefore the input value of the sampling interval of these two technological parameters is set as 5.
Step3: except the variable with hysteresis characteristic, HIC-727206.MV (%), TR-727225.PV, TIC-727226.PV and TIC-727205.PV all need to obtain instantaneous value in model computation process, therefore, sampling interval can be set to 0.1 by it.
ADD module is used for model drift correction, wherein, should be noted that following problem:
(1) without the need to frequent operation, once correct after linear regression model (LRM) runs a period of time (such as, 1 week etc.);
(2) best practices herein operated should be completed by DCS slip-stick artist, avoids operative employee frequently to correct (considering to be completed by priority assignation).
In prior art, in chemical process, ubiquity is due to the reason such as device hardware or technological requirement, directly cannot be measured or the problem of not easily certain critical process index of Quick Measurement by detecting device.Usual needs carry out assay to the above-mentioned technic index that cannot directly measure again after producing final products, like this, also cannot adjust, thus can cause significant loss even if off quality.Based on the technological parameter that the present invention is crucial in production run, based in real time and historical data foundation, in DCS system real time execution, On-Line Dynamic Monitoring linear regression model (LRM), can Real-time Obtaining display can not directly be measured or certain critical process index of not easily Quick Measurement, thus very first time Instructing manufacture.
The present invention can realize in DCS system automatic acquisition linear regression model (LRM) calculate required for, without the performance variable real time data of retardation time, also can realize in DCS system required for the calculating of automatic acquisition linear regression model (LRM), when having influence on historical data when controlled device has certain retardation time after performance variable changes.Thus the automatic calculating realized in DCS system based on the real time data of linear regression model (LRM), technological parameter and the critical process index of historical data and Dynamic Announce.Further, the zero point drift automatic calibration of linear regression model (LRM) also can be realized in DCS system, like this, after the technological parameter of linear regression model (LRM) or regression coefficient change according to production actual conditions, in DCS system, consistent adjustment can be made based on new model.
The foregoing is only the preferred embodiments of the present invention, be not limited to the present invention, for a person skilled in the art, the present invention can have various modifications and variations.Within the spirit and principles in the present invention all, any amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.
Claims (10)
1. a Discrete Control Method for Chemical Manufacture, is characterized in that, comprising:
Set up the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each described technological parameter has a regression coefficient all accordingly, and described technological parameter comprises at least one first parameter and at least one second parameter, and described first parameter is real time data, and described second parameter is the historical data with time-lag effect;
Obtain multiple described regression coefficient;
The history value utilizing the described regression coefficient of acquisition, the instantaneous value of described first parameter, described second parameter corresponding and described linear regression model (LRM), obtain the technic index estimated value of current time online.
2. Discrete Control Method according to claim 1, it is characterized in that, described Discrete Control Method also comprises: the technic index measured value obtaining the chemical products of current time described in this after the chemical products that described current time obtains being chemically examined, and corrects described regression coefficient according to the deviation between described technic index estimated value and described technic index measured value.
3. Discrete Control Method according to claim 1, it is characterized in that, described Discrete Control Method also comprises: utilize multiple technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, correct according to the deviation between described technic index estimated value and described technic index mean value to described regression coefficient.
4. the Discrete Control Method according to Claims 2 or 3, is characterized in that, described Discrete Control Method also comprises: judge whether described technic index estimated value meets predetermined variation range, if do not met, sends warning.
5. the Discrete Control Method according to Claims 2 or 3, is characterized in that, described Discrete Control Method also comprises: be each described second optimum configurations retardation time, to obtain the historical data of this second parameter.
6. a discrete control device for Chemical Manufacture, is characterized in that, comprising:
Model storage unit, for storing the linear regression model (LRM) between the technic index of chemical products to be produced and the multiple technological parameters affecting this technic index; Each described technological parameter has a regression coefficient all accordingly, and described technological parameter comprises at least one first parameter and at least one second parameter, and described first parameter is real time data, and described second parameter is the historical data with time-lag effect;
Regression coefficient acquiring unit, for obtaining multiple described regression coefficient;
Computing unit, for the history value that utilizes the instantaneous value of the described regression coefficient of acquisition, described first parameter, described second parameter corresponding and described linear regression model (LRM), obtains the technic index estimated value of current time online.
7. discrete control device according to claim 6, is characterized in that, described discrete control device also comprises:
Correcting unit, for correcting described regression coefficient according to the deviation between described technic index estimated value and technic index measured value, wherein, described technic index measured value obtains after the chemical products that described current time obtains being chemically examined.
8. discrete control device according to claim 6, is characterized in that, described discrete control device also comprises:
Correcting unit, for correcting described regression coefficient according to the deviation between described technic index estimated value and technic index mean value, wherein, described technic index mean value is the mean value of multiple technic index measured values of the chemical products of producing when production even running, in predetermined amount of time.
9. the discrete control device according to claim 7 or 8, it is characterized in that, described discrete control device also comprises: judging unit, for judging whether described technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
10. the discrete control device according to claim 7 or 8, is characterized in that, described discrete control device also comprises: retardation time setting unit, for being each described second optimum configurations retardation time, to obtain the historical data of this second parameter.
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| CN109694422B (en) * | 2018-12-25 | 2021-09-17 | 重庆化医长寿化工集团有限公司 | Automatic control method for chloroprene rubber polymerization |
| CN109885869B (en) * | 2019-01-09 | 2023-01-20 | 石化盈科信息技术有限责任公司 | Online user-defined process calculation method |
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