Keywords: automatic control regulator ultrasonic
In the Yongping Copper Mine Concentrator of Jiangxi Copper Company, the original four sand pump pools used automatic liquid level control. Because the E27 series imported regulators used in the control system are expensive, with the gradual aging of the internal components of the regulator, The failure rate has increased significantly. The use of domestic instruments to replace imported regulators has become a top priority. In January 2001, after the analysis and comparison, the concentrator first tried the domestic AI-808 artificial intelligence regulator on the tailing pump pump liquid level control, with VEGASON52K liquid level gauge, DFD-1000 handheld actuator and ZKJ-210 actuator. Together, the 3# pump pool liquid level automatic control system of No. 2 pumping station was formed. After the on-site parameter setting and system parameter adjustment and setting, the automatic control of the pumping tank liquid level was successfully achieved and good results were obtained.
Introduction to AI-808 regulatorThe AI-808 regulator is a domestically advanced instrument. It uses a high-performance ASIC chip and modular hardware design. It uses digital correction technology on both input and output signals to eliminate unstable resistors. The error caused by the automatic zero adjustment technology can be used for a long time without zero drift, and the measurement digital is accurate and stable; it has various input and output specifications and alarm mode settings. It not only has manual/automatic bumpless switching operation, but also has manual auto-tuning and display output values, and is used as a proportional output for the servo amplifier to directly control the valve position. The power supply can fluctuate within a wide range of 85-264VAC (50-60HZ). In the strong interference environment, the measurement accuracy and the stability of the work can be guaranteed.
Pump tank liquid level automatic control and wiring principlePump tank liquid level automatic control and wiring principle are shown in Figure 1, Figure 2
The realization of the automatic control function of the pump pool liquid level is converted into a 4-40 mA current output signal by the VEGASON 52K level gauge, which is sent to the regulator through the resistor, and the regulator performs data analysis and processing, according to Control function parameter setting requirements, drive the intermediate relay 1ZJ or 2ZJ, control the positive and backward rotation of the ZKJ-210 actuator, adjust the oil quantity of the sand pump hydraulic coupler, so as to increase or decrease the sand pump output power, stabilize the pump The purpose of the pool level.
Table 1 AI-808 regulator parameter function table parameter code parameter meaning setting value
HIAL upper limit alarm 85 (see Note 1)
LOAL lower limit alarm 50 (see Note 2)
DF backlash 0.3
CTRL control mode 5 (see Note 3)
M5 maintains parameter 2.0
P rate parameter 2
T lag time 3 seconds
CTL output cycle 4 seconds
SN output specification 33 (see Note 4)
DIP decimal point position 1
DIL input lower limit display value 0
DIH input upper limit display value 100
SC main input translation correction 0
OPI output mode 5 (see Note 5)
OPL output lower limit 0
OPH output limit 100
ALP Alarm Output Setting 15 (see Note 6)
CF system function selection 15
ADDR communication address 0
BAUD communication baud rate 9600
DL input digital filter 1
RUN operation status and power-on display processing 1 (see Note 7)
LOC parameter modification level 1 (see note 8)
EP1—EP8 field parameter definition (see Note 9)
2 The lower limit alarm value is set to prevent the pump or air from entering the pump and to signal the alarm in advance.
3 CTRL=5, indicating that the AI-808 regulator acts as a servo amplifier, and the meter outputs the measured value directly as an output value.
4 Input specification Sn=33, indicating that the input is a 1-5VDC signal.
5 OPI=5, indicating the position proportional output without valve feedback signal. The main output and alarm 1 control relay directly drive the ZKJ-210 actuator forward and reverse.
6 ALP=15, indicating that the upper and lower limit alarms are all output by AL2, and the alarm symbol (high HIAL, low LOAL) is displayed alternately on the lower display, so that the operator can quickly understand the cause of the instrument alarm.
7 RUN=1, indicating that the instrument works in the automatic state 8 parameter modification level, LOC=1, indicating that the field parameters can be displayed, no modification is allowed, but the set value is allowed to be set, and the unrelated person is prevented by the parameter lock function setting. The turmoil affects the normal operation of the meter.
9 When the parameters of the instrument are set, most parameters will no longer need to be set by the field workers, and the field operator does not understand many parameters. It may cause misoperation and change the parameters to the wrong value, which affects the normal operation of the instrument. . Therefore, the operator can understand that the parameters that need to be changed are defined by EP1-EP8 to 1-8 field parameters for the operator. Installation and commissioning of the instrument VEGASON52K ultrasonic level gauge firstly checks the instrument for power-on, and sets the program parameters according to the actual liquid level change at the pump pool site, such as the type, range and output mode of the measured medium, and according to the technical requirements. The analog adjustment before the installation makes the level of the liquid level and the output signal change linearly. Since the tailings pump pool is an open container, it is necessary to maintain a certain distance between the meter and the container wall when manufacturing the probe position frame, that is, to avoid the blind pressure of the detection; and to keep the central axis of the sensor perpendicular to the surface of the medium. At the same time, there should be no other debris in the cone-shaped emission angle of the ultrasonic sensor to avoid false echoes and affect the accuracy of the measurement. DFD Communicator and ZKJ-210 Actuator Debugging The DFD-1000 electric operator adopts the principle of “switching operation system†for hand/automatic switching and operation. When the diverter switch is in the manual position, 1, 2 input The terminals are open to the output terminals of (11) and (12) respectively, and the (11) and (12) terminals are controlled by the operation switch, and the length of the power-on time is controlled according to the magnitude of the position feedback signal; when the switch is in the automatic position, 1 and (11) are connected, 2 Connected with (12). The AI-808 regulator controls the actuator ZJK-210, so that the AI-808 regulator controls the ZKJ-210 angular stroke according to the liquid level change, adjusts the sand pump output power, and stabilizes the pump pool level.
After the instrument is connected to the control line as required, the consistency of the change of the angular stroke and position feedback signal of the ZKJ-210 actuator is adjusted, and the full scale of the actuator angular stroke zero is adjusted by the coarse adjustment and the potentiometer fine adjustment. Corresponding to 4-20m linear change output (indicated on the DFD meter head), and manual operation with the operator to test, and check whether the 1XC and 2XC travel limit switches meet the specified technical limit requirements.
System Debugging Dynamic system debugging is the most important step in achieving automatic level control. First check whether the AI-808 regulator can realize manual control adjustment through the intermediate relay, and the consistency of the positive and negative control directions of the actuator, and then check the liquid level high and low alarm function, the stroke control switch limit and the protection function are normal. Is the measurement of the bit correct? After the manual linkage test is completed, the pump pool level is stabilized by manual control within the range required by the process. The DFD-1000 hand-held device is firstly directed to the automatic control, and then the AI-808 is put into the automatic viewing automatic control system. The dynamic change of the liquid level is adjusted accordingly, and then the self-tuning function is started to obtain the optimal system control parameters. After the self-tuning is finished, record the system control parameters and perform the necessary password lock on the parameters. Effect After more than 2 months of actual operation and tracking assessment, the liquid level automatic control fully meets the specified technical requirements, and because of the addition of the low alarm function, it can also play a role in preventing the sand pump from pumping the pump. Conclusion
The original pump tank liquid level automatic control system due to the aging of E27 series regulator equipment, more control links, not only equipment (import) investment (1 set of regulators 14,000 yuan), and the use of servo amplifier (valued at 1,000 yuan) The actuator has a high failure rate. With the domestic AI-808 regulator, the investment cost is only 2,000 yuan (including the application function module), which is only one-seventh of the imported regulator. It can also save a servo amplifier. The digital display is intuitive and easy to operate. High and low alarm output improves the function and stability of automatic control.
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