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Control method, system and process for automatic proportioning of emulsion


source:[Gravimetric blender]   release time:2021-04-09 16:18:19




As a working medium, emulsion is widely used in hydraulic support equipment such as coal mine hydraulic supports and single hydraulic props. The concentration of the emulsion is an important indicator that affects the performance of the emulsion. Whether its concentration is appropriate or not directly affects the working life and production cost of hydraulic supports and hydraulic props. Too low a concentration will greatly reduce the lubricity, rust resistance and stability of hydraulic components, and at the same time affect equipment life and safety production. Too high a concentration will increase the amount of emulsified oil and increase production costs. Therefore, in order to extend the service life of hydraulic support equipment and reduce production costs, the concentration of the emulsion must be strictly controlled. my country's "Coal Mine Safety Regulations" stipulates that the concentration of mine emulsion is generally between 3% and 5%. Therefore, an accurate, stable, fast and efficient emulsion automatic proportioning system is particularly important.

There are two main types of existing emulsion automatic proportioning systems: one is automatic proportioning based on fluid mechanics or volume characteristics, that is, proportioning by mechanical devices. The structure is simple and the cost is low. But its proportioning control principle is open-loop control, the proportioning accuracy is not high, and the concentration of the emulsion fluctuates greatly; the other type is completely controlled by the controller to control the valve or the liquid supply pump motor to feed water and oil, and the concentration and level sensors are used. Monitor, analyze and process by the controller, adjust the speed of the water supply or oil supply pump to correct the emulsion concentration. However, due to the large interference from the liquid pump and precipitation tank during the use of the emulsion, the concentration of the emulsion fluctuates, which leads to frequent start and stop of the proportioning pump, continuous changes in speed, which reduces the service life and stability of the entire system , And its control process is more complicated, and the overall system cost is higher. Therefore, the study of a closed-loop system with accurate proportioning concentration, simple proportioning principle, and low-cost automatic proportioning of emulsions is of great significance to increase equipment life and improve production efficiency.
Technical realization elements:
Purpose of the invention: In view of the above-mentioned prior art, a method and system for controlling the automatic proportioning of emulsions is proposed, which can realize automatic and accurate proportioning of emulsions and improve the service life of the system.

Technical solution: A control method for automatic emulsion proportioning, including the following steps: measuring the emulsion concentration and liquid level in the emulsion tank through a concentration sensor and a liquid level sensor; if the concentration is not within the specified range, control The device calculates the volume of water and oil in the emulsion tank according to the detected liquid level and concentration, and then calculates and determines the volume of water and oil that needs to be added to the standard concentration; then turn on the corresponding water supply solenoid valve or oil supply emulsified oil pump , Through the corresponding flowmeter to detect and control the corresponding volume of water and oil; if the liquid level in the emulsion tank is lower than the preset value H2 at this time, control the water supply solenoid valve or the oil supply emulsified oil pump, and add the standard concentration configuration The corresponding proportion of water and oil until the liquid level in the emulsion tank reaches the preset value H3.

Further, the water supply solenoid valve or the oil supply emulsified oil pump is automatically controlled by the controller according to the volume of water and oil to be added.

Further, the specified concentration range is 3 to 5%, and the standard concentration is 4%.

Further, the outputs of the water supply solenoid valve and the oil supply emulsified oil pump are mixed through the mixer and then enter the emulsion tank.

Further, the oil supply emulsified oil pump is controlled to take oil from the oil tank, and the operation of the oil supply pump is automatically controlled by the controller to maintain the oil volume in the oil tank within the preset range H0-H1.

An emulsion automatic proportioning control system, including a pressure reducing valve, a water supply solenoid valve, a flow meter, an oil supply pump, an oil tank, an emulsified oil pump, a mixer, and a controller; the water source is connected to the pressure reducing valve and the water supply solenoid valve in sequence through a pipeline , Flow meter, the outlet of the flow meter is connected to the first inlet of the mixer; the oil source is connected to the inlet of the oil tank through the oil supply pump, and the outlet of the oil tank is connected to the emulsified oil pump and the flow meter through the pipeline, and then connected to the second inlet of the mixer The outlet of the mixer is connected to the inlet of the emulsion tank; the emulsion tank is provided with an emulsion concentration sensor and a liquid level sensor, and its signal output terminal is connected to the controller, which is connected to the water supply solenoid valve, The control end of the oil supply pump and the emulsified oil pump.
Further, a filter is provided in the management between the water source and the pressure reducing valve.
Beneficial effects: Compared with the traditional mechanical proportioning method, the present invention adopts closed-loop control. Through the detection of the liquid level and concentration of the emulsion in the liquid tank, the corresponding liquid volume can be accurately filled, which can reach the standard of 4%. concentration.

The existing method of using a frequency converter to adjust the rotation speed of the water supply and oil supply pump to correct the concentration of the emulsion is susceptible to interference from the liquid pump and related internal sedimentation tanks, and is easy to overshoot. As a result, the correction process takes a long time. In theory, the present invention is "one-time calibration" without overshoot, and the calibration process is short.
The invention theoretically only needs to start and stop the corresponding water supply solenoid valve or emulsified oil pump once in a calibration process. Avoid frequent start and stop of the motor, prolong the life of the equipment, and improve the stability of the entire system.
The invention realizes accurate liquid dispensing and omits a complicated frequency conversion speed regulating device, avoids complicated system control and adjustment, saves manufacturing costs, and increases system reliability.
It is the structure of emulsion automatic proportioning system;
Among them: 1. Filter, 2. Pressure reducing valve, 3. Water supply solenoid valve, 4. Flow meter, 5. Oil supply pump, 6. Oil tank, 7. Emulsified oil pump, 8. Mixer, 9. Emulsion tank;
Detailed ways

In the following, the present invention will be further explained in combination.

As shown in Figure 1, an emulsion automatic proportioning control system includes a filter, a pressure reducing valve, a water supply solenoid valve, a flow meter, an oil supply pump, an oil tank, an emulsified oil pump, a mixer, and a controller. The water source is connected to the filter, the pressure reducing valve, the water supply solenoid valve, and the flow meter in sequence through the pipeline, and the outlet of the flow meter is connected to the first inlet of the mixer. The oil source is connected to the inlet of the oil tank through the oil supply pump, and the outlet of the oil tank is connected to the emulsified oil pump and the flow meter through the pipeline, and then connected to the second inlet of the mixer. The outlet of the mixer is connected to the inlet of the emulsion tank. The emulsion tank is provided with an emulsion concentration sensor and a liquid level sensor, the signal output end of which is connected to the controller, and the controller is connected to the water supply solenoid valve, the oil supply pump and the control end of the emulsified oil pump.

In this system, the water supply solenoid valve, the oil supply pump, and the emulsified oil pump act as actuators. The oil supply pump keeps the oil level in the oil tank within the set range. Emulsion concentration sensor, liquid level sensor, and flow meter are used as detection mechanisms to detect the concentration, liquid level, water intake, and oil intake in the emulsion tank, respectively. The controller adopts Siemens 200 PLC, and the emulsion tank is equipped with a sedimentation tank and an overflow tank.
An automatic emulsification control method. After the system is turned on, the controller cooperates with the fuel supply pump to ensure that the oil level in the fuel supply tank is within the preset range H0~H1. As shown in Figure 2, it can be sent to the emulsified fuel tank at any time through the emulsified oil pump. Fuel supply. At the same time, the concentration and liquid level of the emulsion in the emulsion tank are measured by the concentration sensor and the liquid level sensor. Judged by the controller, if the concentration is not within the specified range of 3 to 5%, the controller calculates the volume of water and oil in the emulsion tank according to the detected liquid level and concentration, and then calculates and determines the compensation required to calibrate to the standard concentration. The volume of incoming water and oil, and the relationship between the liquid level in the emulsion tank and the volume have been determined in advance. Then turn on the corresponding water supply solenoid valve or oil supply emulsified oil pump, and detect and control the corresponding volume of water and oil flowing in through the corresponding flowmeter, so as to accurately correct the concentration of the emulsion in the liquid tank, as shown in Figure 3. If the liquid level in the emulsion tank is lower than the preset value H2 at this time, the controller will automatically control the water supply solenoid valve or the oil supply emulsified oil pump, and add water and oil corresponding to the standard concentration configuration until the water in the emulsion tank is The liquid level reaches the preset value H3. Among them, the output of the water supply solenoid valve and the oil supply emulsified oil pump is mixed through the mixer and then enters the emulsion tank.

In this process, the concentration of the emulsion in the tank is only calibrated once. After the calibration, the concentration of the emulsion in theory should be 4% of the standard concentration. Since the entire liquid supply system is a closed structure, liquid leakage will generally not occur during normal work, and the emulsion will be more and more uniform as the work progresses. Unless the entire system is switched to manual proportioning, under normal circumstances, the emulsion concentration will be constant at 4%. Unless the concentration deviates from the specified range of 3 to 5%, it will not be corrected. Normally, it only needs to calibrate its concentration once in a working mode of automatic proportioning.

The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and modifications can be made, and these improvements and modifications are also It should be regarded as the protection scope of the present invention.

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