CN-121578735-B - Gypsum-based flame-retardant board production line control system and method based on PLC

CN121578735BCN 121578735 BCN121578735 BCN 121578735BCN-121578735-B

Abstract

The invention relates to the technical field of automatic production control and industrial data processing, in particular to a control system and a control method for a gypsum-based flame-retardant board production line based on a PLC, wherein the control system comprises a data acquisition module for acquiring sensor data in real time; the ideal state construction module is used for constructing a pure ideal state vector; the disturbance simulation module generates a theoretical damaged state vector corresponding to the specific fault mode; the invention effectively solves the difficult problem that physical faults and sensor clutter are difficult to distinguish under a high-noise environment, and avoids missing report.

Inventors

SHI KUN
WANG CHAO
HAN PANPAN
ZHOU CHANGKUI
LIU TIANCHENG
LI ZHIHUI

Assignees

泰山石膏(东营)有限公司

Dates

Publication Date: 20260508
Application Date: 20260127

Claims (9)

1. A gypsum-based flame retardant board production line control system based on PLC, characterized by comprising: The data acquisition module is configured to acquire raw material purity data, environment temperature and humidity parameters and PLC real-time sensor data of each station of the production line of the gypsum-based flame-retardant board in real time through an analog input interface of the PLC; the ideal state construction module is configured to substitute the raw material purity data and the environmental temperature and humidity parameters into a preset gypsum hydration reaction kinetic equation, and deduce and calculate a theoretical value sequence of each sensor changing along with time in a fault-free state so as to construct a pure ideal state vector; The disturbance simulation module is configured to call a preset fault mechanism model from a fault parameter database, inject quantized fault factor parameters into the gypsum hydration reaction kinetic equation and generate a theoretical damaged state vector corresponding to a specific fault mode; a difference calculation module configured to perform a vector subtraction on the PLC real-time sensor data and the pure ideal state vector to generate a real deviation vector, and perform a vector subtraction on the theoretical damaged state vector and the pure ideal state vector to generate a theoretical deviation vector; The coupling verification control module is configured to calculate a similarity value between the actual deviation vector and the theoretical deviation vector, judge that a real physical fault exists currently if the similarity value is larger than a preset judging threshold value, generate a PLC accurate compensation instruction and send the PLC accurate compensation instruction to a production line executing mechanism, judge that non-physical noise exists currently if the similarity value is smaller than or equal to the preset judging threshold value, keep the control parameters of the production line unchanged and start a dynamic filtering program.
2. The PLC based gypsum-based flame retardant board production line control system of claim 1, wherein the ideal state construction module performs the construction of the pure ideal state vector, specifically comprising: Reading the current raw material semi-hydrated gypsum content percentage, an ambient temperature value, an ambient humidity value and a water-paste ratio set value of a production line through a sensor; Substituting the read data as boundary conditions into a preset gypsum hydration reaction kinetic equation and a thermodynamic heat transfer equation; And deducing the ideal running state of the production line in a set time window through numerical integration, and generating a pure ideal state vector containing the temperature, pressure and flow dimensions.
3. The PLC-based gypsum-based flame retardant board production line control system of claim 1, wherein the disturbance simulation module performs the generation of the theoretical damaged state vector, and specifically comprises: extracting a mechanism model of a specific fault type from a preset fault parameter database, and converting the mechanism model into a quantized disturbance operator acting on equation coefficients; The disturbance operator is added to a reaction rate constant or a heat transfer coefficient of the gypsum hydration reaction kinetic equation, and band loss simulation calculation is executed; A theoretical fault state vector is output for each sensor value over time for that particular fault type.
4. The PLC-based fire retardant board production line control system of claim 1, wherein the differential calculation module specifically performs the following operations: Performing element-by-element vector subtraction operation on the PLC real-time sensor data and the pure ideal state vector to obtain a real deviation vector containing a noise component and a potential fault signal component; And carrying out element-by-element vector subtraction operation on the theoretical damaged state vector and the pure ideal state vector to obtain a theoretical deviation vector representing a specific fault numerical characteristic mode.
5. The PLC-based fire retardant board production line control system of claim 1, wherein the coupling verification control module calculates a similarity value comprising: mapping the actual deviation vector and the theoretical deviation vector to a multidimensional Euclidean space formed by sensor data dimensions; The cosine value of the included angle between the actual deviation vector and the theoretical deviation vector is calculated, and the cosine value is used as the similarity value; When the cosine value is strictly greater than the judging threshold value, generating a real physical fault confirmation signal to trigger PLC accurate compensation operation; And when the cosine value is less than or equal to the decision threshold, generating a non-physical noise confirmation signal to trigger a dynamic filtering operation.
6. The PLC based gypsum-based flame retardant board production line control system of claim 3, wherein the failure mechanism model comprises a spray head blockage model, a stirring shaft wear model, and a flame retardant uneven distribution model; The stirring shaft abrasion model is defined as a specific frequency harmonic function superimposed on a motor torque output signal and used for representing periodic vibration caused by mechanical eccentricity; the flame retardant uneven distribution model is defined as a discretized variance increasing function of the thermal conductivity parameters of the local area of the plate, and represents the randomness dispersion of the material distribution.
7. The PLC-based fire retardant board production line control system of claim 5, wherein the coupling verification control module performs PLC accurate compensation operations, comprising: identifying a fault type corresponding to the theoretical damaged state vector, and calling a PID parameter correction table pre-bound with the fault type from a strategy library; And generating a reverse control instruction according to the amplitude of the actual deviation vector, and adjusting the operation parameters of the production line executing mechanism to offset the deviation caused by the actual physical fault.
8. The PLC based fire retardant board production line control system of claim 5, wherein the coupling verification control module performs a dynamic filtering operation comprising: the actual deviation vector is identified as random noise, and the control parameters of the PLC are not adjusted; And smoothing the subsequently acquired sensor data by applying a moving average filtering algorithm or a Kalman filtering algorithm to remove data fluctuation.
9. A control method of a gypsum-based flame-retardant board production line based on a PLC (programmable logic controller) is characterized by comprising the following steps: The data acquisition step is that raw material purity data, environment temperature and humidity parameters and PLC real-time sensor data of each station of the production line of the gypsum-based flame-retardant board are acquired in real time through an analog input interface of the PLC; the ideal state construction step is that the raw material purity data and the environmental temperature and humidity parameters are used as dynamic boundary conditions, and are substituted into a gypsum hydration reaction kinetic equation and an associated physical field equation which are preset in a PLC storage area, and a theoretical value sequence of each sensor changing along with time in a fault-free state is deduced and calculated, so that a pure ideal state vector is constructed; A disturbance simulation step, namely calling a preset fault mechanism model from a fault parameter database, injecting quantized fault factor parameters into the gypsum hydration reaction kinetic equation and the related physical field equation, and carrying out loss operation deduction in a virtual environment to generate a theoretical damaged state vector corresponding to a specific fault mode; A differential calculation step of performing a vector subtraction operation on the PLC real-time sensor data and the pure ideal state vector to generate a real deviation vector, and performing a vector subtraction operation on the theoretical damaged state vector and the pure ideal state vector to generate a theoretical deviation vector; And a coupling verification control step of calculating a similarity value between the actual deviation vector and the theoretical deviation vector, and executing the following judgment logic: If the similarity value is larger than a preset judging threshold value, judging that a real physical fault exists currently, generating a PLC accurate compensation instruction and sending the PLC accurate compensation instruction to a production line executing mechanism; And if the similarity value is smaller than or equal to the preset judging threshold value, judging that non-physical noise exists currently, keeping the control parameters of the production line unchanged and starting a dynamic filtering program.

Description

Gypsum-based flame-retardant board production line control system and method based on PLC Technical Field The invention relates to the technical field of automatic production control and industrial data processing, in particular to a control system and a control method for a gypsum-based flame-retardant board production line based on a PLC. Background In the current automatic production process of the gypsum-based flame-retardant board, a PLC control system needs to periodically process a large amount of real-time sensor data from stations such as a stirring system, a forming station, a drying kiln and the like, and the data are subjected to coupling influence of multiple factors such as raw material purity fluctuation, environment temperature and humidity change, random noise caused by electromagnetic environment of a production line and the like, and present high nonlinearity and uncertainty; In order to maintain stable production, the existing control scheme generally adopts a logic based on out-of-tolerance alarm, namely, parameters such as temperature, pressure or current are monitored by setting a fixed threshold value, although the scheme has a certain monitoring capability when the scheme is used for coping with obvious equipment faults, the sensor random noise and weak early physical faults are difficult to distinguish effectively due to lack of deep understanding of a physical mechanism, the limitation causes that a system is extremely easy to misinformation under a high noise background or the optimal maintenance time is missed due to incapability of identifying physical abnormality of a sprouting period, so that the control parameters frequently and invalidity fluctuation is caused, and the high-precision self-adaptive production requirement is difficult to support. Disclosure of Invention The invention aims to provide a control system and a control method for a gypsum-based flame-retardant board production line based on a PLC (programmable logic controller), which aim to solve the problems that weak physical faults are difficult to identify and environmental fluctuation is easy to cause false alarm of a control system under a strong noise background, and realize accurate decoupling of real physical faults and non-physical noise by a digital twin model and double-track differential pair technology driven by a physical mechanism, so that the accuracy and the operation stability of self-adaptive control of the production line are improved, and specifically, the technical scheme of the invention is as follows: a PLC based gypsum based flame retardant board production line control system comprising: The data acquisition module is configured to acquire raw material purity data, environment temperature and humidity parameters and PLC real-time sensor data of each station of the production line of the gypsum-based flame-retardant board in real time through an analog input interface of the PLC; the ideal state construction module is configured to substitute the raw material purity data and the environmental temperature and humidity parameters into a preset gypsum hydration reaction kinetic equation, and deduce and calculate a theoretical value sequence of each sensor changing along with time in a fault-free state so as to construct a pure ideal state vector; The disturbance simulation module is configured to call a preset fault mechanism model from a fault parameter database, inject quantized fault factor parameters into the gypsum hydration reaction kinetic equation and generate a theoretical damaged state vector corresponding to a specific fault mode; a difference calculation module configured to perform a vector subtraction on the PLC real-time sensor data and the pure ideal state vector to generate a real deviation vector, and perform a vector subtraction on the theoretical damaged state vector and the pure ideal state vector to generate a theoretical deviation vector; The coupling verification control module is configured to calculate a similarity value between the actual deviation vector and the theoretical deviation vector, judge that a real physical fault exists currently if the similarity value is larger than a preset judging threshold value, generate a PLC accurate compensation instruction and send the PLC accurate compensation instruction to a production line executing mechanism, judge that non-physical noise exists currently if the similarity value is smaller than or equal to the preset judging threshold value, keep the control parameters of the production line unchanged and start a dynamic filtering program. Preferably, the ideal state construction module performs construction of the pure ideal state vector, and specifically includes: Reading the current raw material semi-hydrated gypsum content percentage, an ambient temperature value, an ambient humidity value and a water-paste ratio set value of a production line through a sensor; Substituting the read data as boundary conditions into a