Intelligent water pump system on-line operation monitor
Technical field
The utility model relates to a kind of intelligent water pump system on-line operation monitor in fields such as metallurgy, petrochemical industry, papermaking, power plant, machinery, mine, stove, building, urban water supply and sewerage, heating plant, oil field, large-scale agricultural irrigation, central air conditioning.
Background technique
The universal machine that water pump is a wide application, amount is big.Water pump uses and spreads all over each production of national economy, life department, like metallurgy, petrochemical industry, papermaking, power plant, machinery, mine, stove, building, urban water supply and sewerage, heating plant, oil field, large-scale agricultural irrigation, steamer ...
Present water pump system operational efficiency is low, power consumption is huge, level falls behind.Show according to authoritative data; China's electric system power consumption accounts for 60% of national power consumption at present; Wherein the power consumption of water pump, blower fan, compressor and air conditioner refrigerating device accounts for 20.9%, 10.4%, 9.4% and 6% of national power consumption respectively; " three machines, one pump (blower fan, compressor, refrigerator and water pump) " total power consumption accounts for 46.9% of national electricity consumption total amount, be close to and account for the half the of the total power consumption of country, and single water pump just consumes 20.9% of total electric weight.Past is because China Higher education professional module is divided too thin; Performance study to water pump only limits to this professional content; Water pump is held performance after the system, and that the systematic science principle understanding of basic change will take place is unclear; Pump performance and pipe-line system characteristic and operation control strategy do not match; Add that the design office design and calculation method falls behind, the water pump capacity of selection is 1.7 times of actual demand at least, water pump generally in big flow, the little temperature difference, low load with strong power is inefficient and how be unable to explain clearly in the system matches situation, move under the state of feeling about in the dark that the road is not clear.The operational efficiency of China's pump type systematic is about 30% according to statistics, than abroad approximately low 20%; China's per GDP energy consumption is 3 times of the U.S., is more than 10 times of Japan, and water pump fallback " merit " can not have.Therefore solving the problem of water pump operation highly energy-consuming, poor efficiency and backwardness level from theory and practice, should be China 12 planning unit GDP one of contents of 16% challenge that lower consumption.
Summary of the invention
It is a kind of simple in structure that the purpose of the utility model is to provide; Installation, debugging make things convenient for, energy-saving effect is remarkable; The operator under the guide of operation displayed tutorial message on the monitor touch screen, can the control system water pump constantly at the intelligent water pump system on-line operation monitor of best efficiency point work.
In order to overcome the deficiency of existing technology, the technological scheme of the utility model is to solve like this: this monitor comprises the Expert Controller that touch screen, programmable controller constitute; The water pump operation parameter measurement instrument that pressure difference transmitter, flow transmitter constitute; The water pump electric weight remote sensing instrument that power transducer, frequency transmitter, electric parameters transducer, wireless data transfer module constitute; The actuator that manual modulation valve and operator take on; Frequency variator, pump motor, water pump, pipe-line system constitute links such as controlled device, and monitor is the open loop expert control system that is made up of above-mentioned several links.The special way of the utility model is near the said Expert Controller that is made up of touch screen TS and programmable controller PLC of water pump, installing; Pressure difference transmitter Δ P is installed on the import and export pipeline of said water pump P 1, flow transmitter F is installed on outlet conduit constitutes the water pump operation parameter measurement instrument; The water pump electric weight remote sensing instrument that connects pump power transmitter W, frequency transmitter f, electric parameters transducer TEQ, wireless data transfer module GPRS formation on the said electric control cubicle of pump variable frequency in the distance respectively; Manual modulation valve HV1 and operator are installed on the exit of pump pipeline take on actuator together; Said frequency variator VFD, pump motor M, water pump P 1 and pipe-line system constitute controlled device; The real-time electric quantity signal of said water pump is transported among touch screen TS and the programmable controller PLC through remote sensing instrument; Said pressure difference transmitter Δ P, flow transmitter F lift, the flux signal that water pump is real-time are transported among touch screen TS and the programmable controller PLC through A/D converter; Said Expert Controller is made up of water pump system knowledge base, comparing element, data processing system, message handler, inference machine, rule set; Said Expert Controller, actuator, system's water pump and sensor groups four processes have constituted the open loop expert control system.
When load changes or disturbing factor such as water pump operation platform number takes place; When water pump departs from best efficiency point; Sensor groups is delivered to water pump real time execution parameter in the Expert Controller; Through expert control system and specified optimum value comparison, must deviate and variance ratio, again through each link computing, on touch screen TS, demonstrate water pump real-time characteristic curve, real-time working condition point, real time execution parameter and real time operation tutorial message.The operator is under the real time operation tutorial message guides, and control manually operated valve HV1 can make water pump constantly in the best efficiency point operation, thereby reach absolutely clear to the water pump operation operating mode and purpose pump energy saving.Because the control signal of the output of Expert Controller; Can not directly control manual modulation valve HV1; And the process that needs the operator to participate in controlling so monitor essence is the open loop expert control system, its objective is in order to save expensive heavy caliber electric control valve.
Compared with prior art; The utility model proposes according to " energy saving of system " theoretical integration water pump system Energy saving theory, Computer Control Technology, computer graphics techniques, computer networking technology, computer radio networking technology; Have that simple in structure, Installation and Debugging are convenient, the energy-saving effect distinguishing feature; Water pump online in real time operation information image clearly shows on touch screen; Guide down in water pump real time operation information that monitor provides, the operator can control of pump constantly in best efficiency point work, overcome traditional water pump feel about in the dark operation and not energy-conservation shortcoming.In the example that provides, the efficient of water pump improves more than 7%, and air horsepower reduces more than the 6kW, energy-conservation electric energy 12.2%.
Intelligent water pump system on-line operation monitor has following distinguishing feature in sum:
1). the graphic display of water pump real time execution parameter acquisition: real-time inlet outlet pressure differential (lift), flow, useful energy output, power input to machine, frequency, the pump efficiency of water pump is presented on the touch screen; The user can absolutely clearly know the running situation that water pump, frequency variator, pipeline form, the cost that needs flower or the like information, consumes as clear as noondayly, eliminated traditional water pump feel about in the dark blindly use, feel unsure of, the application situation of poor efficiency, expense ability.
2). water pump capacity coupling diagnosis: add the collection of cold machine out temperature or cooling tower out temperature and ambient temperature, can carry out the calculating and the diagnosis of water pump capacity coupling of system's maximum load demand;
3). provide the Operating Guideline that water pump system is tending towards the best efficiency point operation.Thoroughly changed the situation that traditional water pump, system matches situation are felt about in the dark, can make water pump system energy-conservation to greatest extent;
4). online water pump feature measurement: after installing the operation monitoring appearance first, can obtain online water pump actual characteristic through method for scanning, so that the user knows what's what to the water pump actual characteristic, the propaganda of exempting some water pump manufacturers misleads.
5). combine with complete similar frequency conversion or velocity fluctuation pump control technique; Can make water pump system reach the boundary of " configuration rationally; operation is coordinated "; The minimum cost of can spending water pump system realizes the control of real-time tracking load variations, can reach the water pump dissipative system that people dream of clever, IQ is arranged, with can state with having sagacity, simplified the work of pump energy saving operation management greatly.
6). intelligent water pump system on-line operation monitor, can be used as the water pump quality inspection detector of the State Bureau of Quality Supervision, selective examination be manufacturer or online water pump product performance;
7). water pump vane fault diagnosis, warning: water pump descends pump efficiency because of the cavitation erosion impeller surface produces pit, can be through detecting the decline degree of water pump peak efficiency, the degree that the knot dirt is stained with on the cavitation erosion degree of estimation water pump or water pump blade surface.
8). intelligent water pump system on-line operation monitor is open; Can incorporate any kind control system: it is optional that device has various standard communication modules, and device can be held in the building control system or plant control system of DCS, BAS, any type of PLC.
This utility model can be widely used in the energy-saving design and reducing energy consumption of steel mill, chemical plant, large-scale central air-conditioner water pump system.
Description of drawings
Fig. 1 is the structural representation skeleton diagram of the utility model;
Fig. 2 is the expert control system theory structure schematic block diagram of Fig. 1;
Fig. 3 is the characteristic curve of pump figure in Fig. 1 example.
Embodiment
Accompanying drawing is the embodiment of the utility model.
Below in conjunction with accompanying drawing summary of the invention is described further:
With reference to Fig. 1, shown in Figure 2, a kind of intelligent water pump system on-line operation monitor, this monitor comprises the Expert Controller that touch screen, programmable controller and control software constitute; Pressure difference transmitter, flow transmitter constitute the water pump operation parameter measurement instrument; Electric parameters transducers such as power transducer, frequency transmitter, electric current and voltage, wireless data transfer module constitute water pump electric weight remote sensing instrument; Manual modulation valve and operator take on actuator; The controlled device that frequency variator, pump motor, water pump and pipe-line system constitute.Said touch screen TS, programmable controller PLC (1) and control software constitute Expert Controller; Pressure difference transmitter Δ P 11 is installed on the import and export pipeline of said water pump P 1 10, flow transmitter F 2 formation water pump operation parameter measurement instruments are installed on outlet conduit; Pump power transmitter W 6, frequency transmitter f 8, electric parameters transducer TEQ 5, wireless data transfer module GPRS 4 formation water pump electric weight remote sensing instruments are installed respectively on the said electric control cubicle of pump variable frequency in the distance; Manual modulation valve HV1 3 is installed on the exit of pump pipeline takes on actuator together with the operator; Said frequency variator VFD 7, pump motor M 9, water pump P 1 10 and pipe-line system constitute controlled device; Said Expert Controller 21 is made up of system's water pump knowledge base 12, comparing element 20, data processing system 18, message handler 19, inference machine 17, rule set 16; Said Expert Controller 21, actuator 15, system's water pump 14 and sensor groups 15 four processes have been formed the open loop expert control system.Said water pump operation parameter measurement instrument is transported to the real-time lift of water pump, flux signal among touch screen TS and the programmable controller PLC 1 through A/D converter; The real-time electric quantity signal of said water pump is transported among touch screen TS and the programmable controller PLC 1 through the electric weight remote sensing instrument; Relatively must deviate through expert control system and optimum value; Again through each link computing; On touch screen TS, demonstrate water pump real-time characteristic curve, real-time working condition point, real time execution parameter and real time operation tutorial message, the operator controls manual modulation valve HV1 3 under the real time operation tutorial message guides; Can make the system water pump constantly in the best efficiency point operation, thereby reach every absolutely clear and purpose of energy saving of water pump operation operating mode.
Water pump is the multi-parameter complex system that is mutually related.Monitor is attached with the expert control system that is made up of touch screen, programmable controller (TS+PLC) at water pump; Pressure difference transmitter Δ P 11 is installed between water pump P 1 10 is imported and exported, flow transmitter F 2 formation water pump operation parameter measurement instruments is installed at exit of pump; The water pump electric weight remote sensing instrument of pump power transmitter W 6, frequency transmitter f 8, electric parameters transducer TEQ 5, wireless data transfer module GPRS 4 formations is installed at pump variable frequency electricity system cabinet place; Manual modulation valve HV1 3 and operator take on actuator; Frequency variator VFD 7, pump motor M 9, water pump P 1 10 and pipe-line system constitute controlled device.The real-time electrical parameter of water pump is sent among the PLC through the electric weight remote sensing instrument; The water pump operation parameter is sent among the PLC through A/D converter; Carry out data processing, reasoning computing through expert system control software; Indicate online water pump system roadability, and feed water pump is tending towards peak efficiency operating point operation and provides operation guidance information, utilize computer graphics techniques that water pump on-line operation real-time parameter and operating point are shown on the screen of touch screen (TS) visually simultaneously.Consider that the dried up pump of water pump high-voltage frequency-changing electricity system cabinet is far away, technological with GPRS wireless networking technology or ISM wireless networking technology or power carrier communication, with the spread of the rumours of water pump electric weight to (TS+PLC) 1.So intelligent water pump system on-line operation monitor is the target of moving at best efficiency point constantly according to water pump, multi-door modern technologies innovations such as integration system water pump principle, computer graphics techniques, radio network technique are come out under " energy saving of system " theoretical direction.
It is that God is to our severe and just Energy saving theory examination that pump energy saving is used actual; The situation that water pump is long-time, fallback appears in large size; Explain that we fail in the Energy saving theory examination; We also do not have to grasp the water pump system Energy saving theory that meets objective law, not too are familiar with essence, moving law property and the characteristics of water pump dissipative system.The modern theory of knowledge is thought, observes and is permeating theory, and the Chairman Mao also says: " sensation only solves the phenomenon problem, the theoretical essential problem that just solves." the theory decision world, change not problem of energy saving of water pump, at first to solve the theoretical question that water pump is used in system.
Fig. 2 is the control principle structural representation block diagram of Fig. 1.Expert Controller (21) is made up of system's water pump knowledge base 12, comparing element 20, data processing system 18, message handler 19, inference machine 17, rule set 16; Expert Controller 21, actuator 15, system's water pump 14 and sensor groups 15 four processes have been formed the open loop expert control system.
Water pump online in real time Operational Limits is sent in the Expert Controller 21 of touch screen TS and programmable controller PLC 1 formation; The real-time electrical parameter of water pump is delivered in the Expert Controller through water pump electric weight remote sensing instrument; Expert Controller 21 is according to water pump real time execution parameter, electrical parameter; Through each link data processing; On touch screen TS, demonstrate real-time characteristic curve, real-time working condition point, the real time execution parameter of water pump and the operation guidance information that is tending towards best efficiency point visually, the operator just can be under the guide of operation guidance information, is seeing that operating point on the touch screen TS is tending towards best efficiency point and operates.
Because costing an arm and a leg of heavy caliber electric control valve just replaces mortor operated valve with manually operated valve HV1, the online coupling of the water pump system expert that actual on-line expert control system is open loop instructs control system.The software of data processing system is programmed by the thought of block diagram.Water pump system receive the variation of load variations, valve regulated, water pump operation platform number or the like disturbing factor (
F) influence, make water pump depart from best efficiency point work, the pump sensor group has measured the variation of real-time parameters such as the flow, pressure, electric weight of water pump and has been input to the data processing system of expert data processing system, calculates the actual efficient of online water pump
η t With calculate the peak efficiency setting value according to actual measurement parameter and system's water pump knowledge base
η 0Compare and draw deviation delta
η, deliver to the information process unit of expert system and export signal through computing
SBe sent to reasoning element, through the reasoning computing output information of reasoning element
IGo computing in the rule set select and on the TS screen output satisfied be tending towards the best efficiency point operation guidance information; The operator is according to the information that provides on the TS screen; Keeping watch on the variation control manual modulation valve of TS screen charging pump operating point, regulating being input to the regulated quantity in the water pump system
R, overcome interference
FThe interior operation of scope that best efficiency point allows fluctuation is got back in the influence that causes, the system water pump of making again.So go round and begin again, system's water pump is moved at best efficiency point constantly.
The formation process of intelligent water pump system on-line operation monitor is such: according to the model characteristic of actual water system water pump; Pressure difference transmitter Δ P, flow transmitter F, electric parameters transducer TEQ, GPRS data transmission module and PLC and the touch screen TS of selected suitable range, type; Constitute the online matching control apparatus of intelligent water pump like accompanying drawing 1; According to accompanying drawing 2 establishment expert data processing system softwares; Examination is transferred, and is delivered for use, and just constitutes and intelligent water pump system on-line operation monitor that water pump system combines together.
Shown in Figure 3 is Wilo-NP150/315V 1450rpm φ 356 type characteristic curve of pump 22.With the calculated examples of this water pump system as the utility model.The design conditions point of water pump for (
L, Δ
P,
η p ,
W p )=(350,38,85%, 43).
Wherein:
L---pump capacity, m
3/ h;
Δ
P---pump head, mH
2O;
η p ---water pump spindle efficient, %;
W p ---pump shaft power, kW.
Intelligent water pump system on-line operation monitor actual measurement pump capacity is 460 m
3/ h is 1.31 times of design discharge.Actual conditions point for (
L, Δ
P,
η p ,
W p )=(460,32,79%, 49).If the water pump design discharge is selected correct, if the water pump of leaving in big flow, the little temperature difference, low usefulness state operation, 31% what do is idle work in the declared working condition pump capacity.If be equipped with intelligent water pump system on-line operation monitor, supervise and guide water pump constantly in best efficiency point work, the efficient of water pump can improve 7%, and air horsepower can reduce 6kW, and energy-conservation 12.2%.
Because intelligent water pump system on-line operation monitor proposes according to " energy saving of system " principle, if combine, just constituted complete, perfect pump energy saving theory and technology system with the other technologies of " energy saving of system " principle proposition.
As combining with water pump capacity diagnostic techniques, it is big by 31% that monitor detects water pump Capacity Ratio actual demand, matches a water pump that is complementary with the water system characteristic again, then reaches flow 350 m that system needs
3The water pump that/h and water system characteristic are complementary calculates only needs lift 18.5mH
2O.Select Wilo-NP125/250V 1470rpm φ 267.5 type pump performances can satisfy such requirement.Looking into the Wilo-NP125/250V pump characteristic, need air horsepower 19.8 kW, only is 40% of raw water pump actual motion power consumption, energy-conservationly surpasses 50%.
As add the technology of " spending minimum cost to realize the process of real-time tracking load variations "; Then theoretical calculation is at full similar operating condition; The water pump power consumption be merely coupling new water pump power consumption 21.6%; At this moment water pump be in clever, IQ is arranged, with can state with having sagacity, can obtain best energy-saving effect.