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火电厂凝汽器清洗机器人的控制系统研究
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摘要
凝汽器是火电厂的关键设备之一,在大型汽轮机装置的热力循环中起冷源的作用,能降低汽轮机排汽压力和温度,提高汽轮发电机组的循环热效率。凝汽器运行时,由于冷却水不洁净、热交换时伴随化学反应等原因,致使冷凝管内壁积聚了不利于传热的污垢,冷凝管的污垢将产生一系列危害:严重削弱凝汽器的换热能力,引起真空度降低、能耗增加,还可能导致冷凝管堵塞甚至造成管壁腐蚀穿孔而引发事故。论文依托湖南省产业研发项目和湖南省科技攻关项目,结合国家安全高效生产、节能降耗的需求,分析了现有污垢清洗方法的优点与不足,针对凝汽器在线清洗的具体要求,提出了一种火电厂凝汽器在线清洗的新方案,设计了凝汽器清洗机器人的体系结构,重点研究了该机器人的控制系统。
     根据凝汽器的水室结构及管束布局,论文首先介绍了清洗机器人的体系结构,设计了一具有两关节机器臂、履带式移动车体的新型清洗机器人,重点研究了机器人控制系统。然后,详细开发了清洗机器人控制系统的软硬件,该控制系统由工控机、PLC和触摸屏等组成。工控机作为上位机通过RS-485串行接口总线监控清洗机器人的运行状态;PLC作为下位机主控制器控制清洗机器人的机电设备;触摸屏作为现场的人机交互窗口实现现场设备的操作和状态信息的显示。最后,针对高压水射流的压力控制,设计了PID控制器,实验结果表明,该控制器能够使高压水压力自动调节,并稳定在设定值附近;针对清洗机器人的化学药剂投加量、电液伺服阀和两关节机器臂清洗喷枪精确定位等控制问题,分别设计了相应的自适应模糊PID控制器,实验结果表明,所设计的控制器均能满足清洗机器人的控制要求。
     论文的研究成果解决了火电厂凝汽器污垢在线自动化清洗的问题,改善了凝汽器传热效果,提高了汽轮机组的运行效率,为火电厂凝汽器的安全高效运行提供了保障。
Condenser is one of the key equipments in thermal power plant. It is the cold source of the thermodynamic cycle of the large steam turbine, and it can decrease the exaust pressure and temperature of the steam turbine, and enhance the cycle thermal efficiency of the turbogenerator. Due to the unpure cooling water and chemical reactions during heat exchange when the condenser is running, the fouling not favorable for heat tranfer is accumulated in the inner wall of condenser tube. These fouling has subsequent of harms: severely decreases the heat exchange capacity of the condenser; lowers the vacuum degree; increases energy consumption; and probably leads to accidence due to the occulation of condenser tube and followed by erosion and perforation. According to industry R&D projects in Hunan Province and Hunan scientific and technological project, and the high-efficiently safe production and energy saving requirment of the nation, we analyzed the advantages and disadvantages of the current fouling-cleaning methods, and desined a new scheme for condenser fouling cleaning in power plants by a robot, whose system structure and control system were well designed and explainated.
     According to the water chamber instructure and tube bundle layout of the condenser, first of all, this thesis introduced the system insructure of the robot: the two-joint manipulator arm, and the track mobile robot body. The contol system of the robot was well studied. Then, the software and hardware of the robot control system was well developed. The control system consists of industrial computer, PLC and touch screen. As host computer, the industrial computer monitors robot’s operation process through RS-485 serial interface bus. As the key control device of slave computer, PLC controls the electromechanical equipment of the robot through serial interface bus. As the field window of human-computer interface, touch screen realizes the operation of the field devices and indication of the status information. Finally, controller of PID was designed accroding to the pressure control requirment of the high pressure water jet. Studies showed that such controller could make pressure of high pressure water self-regulating and steady in the scheduled value; and the self-adaptive fuzzy PID controller was designed and verified by the study to satisfy the control requirment of the cleaning robot, such as adding chemical drug dosages, accurate location for electro-hydraulic servo valve and two-joint arm cleaning spray gun, and so on.
     The results of the study resolved the problem of the automaticlly cleaning of condenser fouling in power plant; improved the effect of heat transfer of condenser; increased the operation efficiency of steam turbine unit; and secured the safe and efficient operation of condenser in power plant.
引文
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