选厂石灰添加自动控制系统研究
摘要
浮选实践和理论研究均已表明,调节矿浆的pH值对浮选工艺至关重要。对于特定的矿石及其相应的浮选工艺,只有在适宜的矿浆pH值条件下,才有可能获得较为满意的浮选效果。石灰是浮选作业中常用的pH值调整剂和铜、硫分离的重要抑制剂。在某些选矿过程中,石灰添加量的多少对浮选指标有重要的影响,石灰供给的均衡与稳定直接影响到精矿品位和回收率。
某选矿厂选用石灰作为pH调整剂,通过石灰添加机将干石灰给入球磨机,从而调整矿浆pH值。现场工人用pH试纸,测粗选矿浆的pn值,再调节石灰添加量。现场要求十分钟测量一次,并相应的调整石灰添加量。测量及调整非常繁琐,而且由于人工调节受条件、责任心、劳动强度等外界条件影响,使pH值在一个比较大的范围内波动,控制精度远远不能满足浮选工艺要求。因此研究一套石灰添加自动控制系统具有很重要的意义。
针对系统的要求和特点,研究了Smith预估控制算法、模糊控制算法和采样PI控制算法。通过比较研究,Smith预估控制算法不能用于数学模型不确定的过程。而模糊控制虽然不需要建立数学模型,但由于模糊控制器的规则和参数无法实时修改,控制效果并不理想。所以最终确定采用采样PI控制算法,该算法不需要建立精确的数学模型,编程实现容易,控制效果较好。
利用Protel 99 SE电路设计软件,对下位机控制器的信号调理板、人机交互电路(按键面板、显示面板)以及控制器主板进行了设计。选用AT89S51单片机作为下位机控制器的核心器件;选用BPHM-I矿浆专用pH传感器检测矿浆的pH值;A/D转换选用ADC0809芯片;D/A转换选用DAC0832芯片。
在上述硬件电路及控制算法的基础上,利用C语言,开发了pH控制器的控制软件。系统在软件上采用模块化的程序结构,包括算法控制程序、显示程序、参数设置程序及一些辅助的子程序等,并从硬件和软件两方面对系统的抗干扰性能进行了设计。
为了便于整个选厂自动化的实现,利用pH控制器的串口实现与上位机的实时通讯。上位机实时监控pH值的变化,并进行报表打印、实时和趋势曲线以及报警窗口显示等。
The practice of flotation process and the fundamental research have proven that the adjustment of pulp's pH value is very important.Regarding specific ore and corresponding flotation process craft,it is possible to obtain more satisfactory effect of flotation process under the suitable condition of pulp's pH value.The lime is the commonly used as the regulator of pH value and the important inhibitor of the separation of the copper and the sulfur in the practice of flotation process.The amount of adding lime has the important influence to the target of flotation process.The balance and stabilitation of supply lime directly affect the status of ore concentrate personal and the returns-ratio.
The lime is used as the pH regulator in some concentrators.The machine of lime add the lime into the ball mill in order to adjust the pulp's pH value.The pH indicator paper is used to measure the rough end's pH value,then adjust the amount of adding lime by manual labour. The concentrators requests measuring every ten minutes,and corresponding adjustment the adding of lime.Because the measurement and the adjustment is extremely tedious and the manual regulation is influenced by worker's responsibility and labor's intensity,the pH value is fluctuated in a so larger scope that the precision of controlment cannot satisfy the requirement of the flotation process.Therefore it is very important to design the automatic control system of adding the lime.
Considering the request and characteristic of the system,we have studied the control algorithm of Smith estimate,the fuzzy control algorithm and the sampling PI control algorithm.Through the comparison research study,we have found that the control algorithm of Smith estimated cannot be used in the process of indefinite mathematical model.Although the fuzzy control algorithm does not need to establish the mathematical model,the rule and the parameter of fuzzy controller are unable to be repaired in the real-time.So the control effect is not ideal.Therefore we finally determine to use the sampling PI control algorithm. The algorithm does not need to establish the precise mathematical model,the programming realization is simple and the control effect is good.
Using the software of Protel 99 SE,we have designed the board of signal recuperation and the motherboard of controller.AT89S51 is used as the core component.The sensor of the BPHM-I pulp is used to examine the pulp's pH value.We selects the ADC0809 chip as A/D switch and the DAC0832 chip as the D/A switch.
Using the language of the C,we have designed the control software of the pH control software.The system uses the modular of procedure structure,including the procedure of controlment algorithm,the demonstration procedure,the parameter establishment procedure and some assistant procedures.We have carried on the design of system anti-jamming from both the hardware and the software.
In order to realize the automation of entire factory,we use the serial port of the pH controller realizing the real-time communication with computer that monitor the changement of pH value,print the report form、the real-time curve and trendline and show the window of the alarm and so on.
某选矿厂选用石灰作为pH调整剂,通过石灰添加机将干石灰给入球磨机,从而调整矿浆pH值。现场工人用pH试纸,测粗选矿浆的pn值,再调节石灰添加量。现场要求十分钟测量一次,并相应的调整石灰添加量。测量及调整非常繁琐,而且由于人工调节受条件、责任心、劳动强度等外界条件影响,使pH值在一个比较大的范围内波动,控制精度远远不能满足浮选工艺要求。因此研究一套石灰添加自动控制系统具有很重要的意义。
针对系统的要求和特点,研究了Smith预估控制算法、模糊控制算法和采样PI控制算法。通过比较研究,Smith预估控制算法不能用于数学模型不确定的过程。而模糊控制虽然不需要建立数学模型,但由于模糊控制器的规则和参数无法实时修改,控制效果并不理想。所以最终确定采用采样PI控制算法,该算法不需要建立精确的数学模型,编程实现容易,控制效果较好。
利用Protel 99 SE电路设计软件,对下位机控制器的信号调理板、人机交互电路(按键面板、显示面板)以及控制器主板进行了设计。选用AT89S51单片机作为下位机控制器的核心器件;选用BPHM-I矿浆专用pH传感器检测矿浆的pH值;A/D转换选用ADC0809芯片;D/A转换选用DAC0832芯片。
在上述硬件电路及控制算法的基础上,利用C语言,开发了pH控制器的控制软件。系统在软件上采用模块化的程序结构,包括算法控制程序、显示程序、参数设置程序及一些辅助的子程序等,并从硬件和软件两方面对系统的抗干扰性能进行了设计。
为了便于整个选厂自动化的实现,利用pH控制器的串口实现与上位机的实时通讯。上位机实时监控pH值的变化,并进行报表打印、实时和趋势曲线以及报警窗口显示等。
The practice of flotation process and the fundamental research have proven that the adjustment of pulp's pH value is very important.Regarding specific ore and corresponding flotation process craft,it is possible to obtain more satisfactory effect of flotation process under the suitable condition of pulp's pH value.The lime is the commonly used as the regulator of pH value and the important inhibitor of the separation of the copper and the sulfur in the practice of flotation process.The amount of adding lime has the important influence to the target of flotation process.The balance and stabilitation of supply lime directly affect the status of ore concentrate personal and the returns-ratio.
The lime is used as the pH regulator in some concentrators.The machine of lime add the lime into the ball mill in order to adjust the pulp's pH value.The pH indicator paper is used to measure the rough end's pH value,then adjust the amount of adding lime by manual labour. The concentrators requests measuring every ten minutes,and corresponding adjustment the adding of lime.Because the measurement and the adjustment is extremely tedious and the manual regulation is influenced by worker's responsibility and labor's intensity,the pH value is fluctuated in a so larger scope that the precision of controlment cannot satisfy the requirement of the flotation process.Therefore it is very important to design the automatic control system of adding the lime.
Considering the request and characteristic of the system,we have studied the control algorithm of Smith estimate,the fuzzy control algorithm and the sampling PI control algorithm.Through the comparison research study,we have found that the control algorithm of Smith estimated cannot be used in the process of indefinite mathematical model.Although the fuzzy control algorithm does not need to establish the mathematical model,the rule and the parameter of fuzzy controller are unable to be repaired in the real-time.So the control effect is not ideal.Therefore we finally determine to use the sampling PI control algorithm. The algorithm does not need to establish the precise mathematical model,the programming realization is simple and the control effect is good.
Using the software of Protel 99 SE,we have designed the board of signal recuperation and the motherboard of controller.AT89S51 is used as the core component.The sensor of the BPHM-I pulp is used to examine the pulp's pH value.We selects the ADC0809 chip as A/D switch and the DAC0832 chip as the D/A switch.
Using the language of the C,we have designed the control software of the pH control software.The system uses the modular of procedure structure,including the procedure of controlment algorithm,the demonstration procedure,the parameter establishment procedure and some assistant procedures.We have carried on the design of system anti-jamming from both the hardware and the software.
In order to realize the automation of entire factory,we use the serial port of the pH controller realizing the real-time communication with computer that monitor the changement of pH value,print the report form、the real-time curve and trendline and show the window of the alarm and so on.
引文
[1]胡熙庚.浮选理论与工艺[M].中南工业大学出版社 1991.
[2]高清林,温华容,张学良.厂坝铅锌矿磨浮过程中药剂的添加控制及矿浆pH值和浓度的测控[J].甘肃冶金 2005,(4):31.
[3]王丰雨,张覃,黄宋魏.我国选矿自动化评述[J].国外金属矿选矿.2006,(8):18.
[4]陈旭俊,余玮,赖卫东.大山选矿厂石灰乳系统的不断改进和完善[J].有色冶金(选矿部分).2002,(6):30.
[5]薛华,李隆弟等.分析化学(第二版)[M].北京.清华大学出版社.1994.
[6]黄君礼.水分析化学(第二版)[M].北京.中国建筑工业出版社.1997.
[7]薛华,李隆弟等.分析化学(第二版)[M].北京.清华大学出版社.1994.
[8]山东大学.硕士论文.工业酸碱度的测量及中和反应中pH值的预测控制.
[9]段晓良,李茂林.铜矿选矿厂矿浆pH值检测中电极的选择[J].矿业工程.1999,(9).
[10]张艳伟,李世厚等.选厂石灰添加控制系统的研究[J].矿业快报,2007,(11):40-42.
[11]选矿手册编辑委员会.选矿手册[M].第四卷.北京.冶金工业出版社.
[12]邵裕森,戴先中.过程控制工程(第二版)[M].机械工业出版社.
[13]洪镇南,王旭东.Smith预估补偿器及其应用[J].控制工程.2002.(5):69-71.
[14]Ingimundarson,A.and Hagghund,T.Robust tuning procedures of dead-time compensatingcontrollers.Control Engineering Practice.2001.9(11):1195-1208.
[15]Crowe.J.,B.L.Ranmker.Dynamic matrix control-a computer control algorithm.Proc,Joint Automat,Control.Theory Appl 2002.149(1):26-31.
[16]C.C.Hang et al.A Performance Study of Control System with Dead Time.IEEE.IECI.1980.27(3):234-241.
[17]傅燕,周琼,杨建刚.改进型Smith预估控制系统的仿真.计算机仿真.1998,15(4):39-41.
[18]N.Shanmugathasan and R.D.Johnston.Exploitation of Time Delays for Improved Process Control.Int.J.Control.1988,48(3):1137-1162.
[19]孙增圻.智能控制理论与技术[M].清华大学出版社.1997.
[20]King P J,Mamdani E H.The Application of Fuzzy Control Systems to Industrial Process.Automatic,1997,3:235-242
[21]Ying H.General Analytical Structure of Typical Fuzzy Controllers and Their Limiting Structure Theorems.Automation,1993,29:1139-1143
[22]Petrov M.,Ganchev I..Taneva A.Fuzzy PID control of nonlinear plants.Intdligent Systems,2002.Proceedings,2002 First International IEEE Symposium,2002,1(9):30-35.
[23]李丹,谢植,程杰.模糊控制在温度控制中的应用与发展[J].黄金学报.2002.(4):294-269.
[24]郑恩让,张玲.采样控制及其在定量控制中的应用[J].自动化与仪器仪.2002.(5):29-30.
[25]何离庆,张寿明,朱文嘉.过程控制系统与装置[M].重庆大学出版社.2003.7.
[26]李辉.控制大纯滞后工业过程[J].电气传动.2003.(6):20-22.
[27]孙绍凯,管心盼,张棣.采样周期对控制系统性能的影响[J].信息技术.1998.(6):25-26
[28]黄晶,阙沛文,唐景肃.论微机控制系统的采样周期[J].计算机测量与控制.2003.(8):588-590.
[29]张大明,彭旭昀,尚静基.单片微机控制应用技术[M].北京.机械工业出版社.2006.
[30]李华.MCS-51系列单片机实用接口技术[M].北京.北京航空航天大学出版社.1993.
[31]韩志军,沈晋源,王振波.单片机应用系统设计[M].北京.机械工业出版社.2005.
[32]李刚.51系列单片机系统设计与应用技巧[M].北京.北京航空航天大学出版社.2004.
[33]曹龙汉,刘安才,高占国.MCS-51单片机原理及应用[M].重庆.重庆出版社.2004.
[34]贾金玲.单片机原理及应用[M].成都.电子科技出版社.2004.
[35]雷思效、冯育长.单片机系统设计及工程应用[M].西安.西安电子科技大学出版社.2005.
[36]苏家键,曹柏容,汪志峰.单片机原理及应用技术[M].北京.高等教育出版社.2004.
[37]韩全立.单片机控制技术及应用[M].北京.电子工业出版社.2004.
[38]郑富昭.填充率对球磨机动态重量的影响研究:[硕士学位论文].昆明.2007.
[39]程勇.用单片机变频器控制电动机调速实验的探索[J].实验室研究与探索.2004. (10):69-71.
[40]刘和平,刘跃,鲁顺昌.单片机原理及应用[M].重庆.重庆大学出版社.
[41]马忠梅,籍顺心,张凯,马岩.单片机的C语言应用程序设计(第四版)[M].北京.北京航空航天大学出版社.
[42]组态王6.5使用手册.北京亚控科技有限公司.2003.2.
[2]高清林,温华容,张学良.厂坝铅锌矿磨浮过程中药剂的添加控制及矿浆pH值和浓度的测控[J].甘肃冶金 2005,(4):31.
[3]王丰雨,张覃,黄宋魏.我国选矿自动化评述[J].国外金属矿选矿.2006,(8):18.
[4]陈旭俊,余玮,赖卫东.大山选矿厂石灰乳系统的不断改进和完善[J].有色冶金(选矿部分).2002,(6):30.
[5]薛华,李隆弟等.分析化学(第二版)[M].北京.清华大学出版社.1994.
[6]黄君礼.水分析化学(第二版)[M].北京.中国建筑工业出版社.1997.
[7]薛华,李隆弟等.分析化学(第二版)[M].北京.清华大学出版社.1994.
[8]山东大学.硕士论文.工业酸碱度的测量及中和反应中pH值的预测控制.
[9]段晓良,李茂林.铜矿选矿厂矿浆pH值检测中电极的选择[J].矿业工程.1999,(9).
[10]张艳伟,李世厚等.选厂石灰添加控制系统的研究[J].矿业快报,2007,(11):40-42.
[11]选矿手册编辑委员会.选矿手册[M].第四卷.北京.冶金工业出版社.
[12]邵裕森,戴先中.过程控制工程(第二版)[M].机械工业出版社.
[13]洪镇南,王旭东.Smith预估补偿器及其应用[J].控制工程.2002.(5):69-71.
[14]Ingimundarson,A.and Hagghund,T.Robust tuning procedures of dead-time compensatingcontrollers.Control Engineering Practice.2001.9(11):1195-1208.
[15]Crowe.J.,B.L.Ranmker.Dynamic matrix control-a computer control algorithm.Proc,Joint Automat,Control.Theory Appl 2002.149(1):26-31.
[16]C.C.Hang et al.A Performance Study of Control System with Dead Time.IEEE.IECI.1980.27(3):234-241.
[17]傅燕,周琼,杨建刚.改进型Smith预估控制系统的仿真.计算机仿真.1998,15(4):39-41.
[18]N.Shanmugathasan and R.D.Johnston.Exploitation of Time Delays for Improved Process Control.Int.J.Control.1988,48(3):1137-1162.
[19]孙增圻.智能控制理论与技术[M].清华大学出版社.1997.
[20]King P J,Mamdani E H.The Application of Fuzzy Control Systems to Industrial Process.Automatic,1997,3:235-242
[21]Ying H.General Analytical Structure of Typical Fuzzy Controllers and Their Limiting Structure Theorems.Automation,1993,29:1139-1143
[22]Petrov M.,Ganchev I..Taneva A.Fuzzy PID control of nonlinear plants.Intdligent Systems,2002.Proceedings,2002 First International IEEE Symposium,2002,1(9):30-35.
[23]李丹,谢植,程杰.模糊控制在温度控制中的应用与发展[J].黄金学报.2002.(4):294-269.
[24]郑恩让,张玲.采样控制及其在定量控制中的应用[J].自动化与仪器仪.2002.(5):29-30.
[25]何离庆,张寿明,朱文嘉.过程控制系统与装置[M].重庆大学出版社.2003.7.
[26]李辉.控制大纯滞后工业过程[J].电气传动.2003.(6):20-22.
[27]孙绍凯,管心盼,张棣.采样周期对控制系统性能的影响[J].信息技术.1998.(6):25-26
[28]黄晶,阙沛文,唐景肃.论微机控制系统的采样周期[J].计算机测量与控制.2003.(8):588-590.
[29]张大明,彭旭昀,尚静基.单片微机控制应用技术[M].北京.机械工业出版社.2006.
[30]李华.MCS-51系列单片机实用接口技术[M].北京.北京航空航天大学出版社.1993.
[31]韩志军,沈晋源,王振波.单片机应用系统设计[M].北京.机械工业出版社.2005.
[32]李刚.51系列单片机系统设计与应用技巧[M].北京.北京航空航天大学出版社.2004.
[33]曹龙汉,刘安才,高占国.MCS-51单片机原理及应用[M].重庆.重庆出版社.2004.
[34]贾金玲.单片机原理及应用[M].成都.电子科技出版社.2004.
[35]雷思效、冯育长.单片机系统设计及工程应用[M].西安.西安电子科技大学出版社.2005.
[36]苏家键,曹柏容,汪志峰.单片机原理及应用技术[M].北京.高等教育出版社.2004.
[37]韩全立.单片机控制技术及应用[M].北京.电子工业出版社.2004.
[38]郑富昭.填充率对球磨机动态重量的影响研究:[硕士学位论文].昆明.2007.
[39]程勇.用单片机变频器控制电动机调速实验的探索[J].实验室研究与探索.2004. (10):69-71.
[40]刘和平,刘跃,鲁顺昌.单片机原理及应用[M].重庆.重庆大学出版社.
[41]马忠梅,籍顺心,张凯,马岩.单片机的C语言应用程序设计(第四版)[M].北京.北京航空航天大学出版社.
[42]组态王6.5使用手册.北京亚控科技有限公司.2003.2.