基于软测量技术的流体粘度在线测量系统的研究与开发
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摘要
粘度是流体的重要物理性质之一,是食品业、油漆业、聚合涂层业、石油工业及其它工业的一个重要的标准特征。测量流体的粘度在工业生产和基础学科研究中都非常有意义。但是国内生产的在线粘度计在功能、精度和稳定性上都不尽如人意,而国外生产的粘度计虽然性能优越,但其昂贵的价格让人望而却步。因此,对于流体粘度在线测量方法的研究至关重要。
本文将可编程序控制器、组态软件与工业控制计算机相结合,开发设计了流体粘度在线测量系统,其主要任务是提高测量精度,降低测量成本,实现在线测量。
本文从理论基础,硬件构成及软件设计等方面详细地论述了流体粘度在线测量系统设计的基本原理和总体方案。提出了将软测量技术应用于粘度在线测量,首先解决了传统粘度测量设备应用于在线测量性能差的问题;其次大大地降低了粘度测量的成本;最后,由于软测量模型的参数易于更改,维护保养非常方便。为保证模型的精确性,采用统计判别法和滤波的方法对数据进行预处理,并在模型估测值偏差超限时及时校正模型。
针对系统实时性的要求,利用可编程控制器与上位机进行串口通信,并设计数据采集程序,同时实现模拟量数据滤波及A/D转换功能。为便于工作人员实时监控注聚液粘度,采用MCGS组态软件设计上位机监控画面,将整个监控软件分成四个功能模块,使系统变得可视化、系统化。
应用DDE技术实现了组态软件与MATLAB之间的通信,有效地解决了组态软件处理数据功能薄弱的问题;同时利用SQL技术将数据从组态软件中转存入Access数据库,解决了大量采集数据的存储问题,为日后读取和管理提供了方便。
Viscosity is one of the most important physical properties of liquid, and also is an important standard character in the industry of foodstuff, oil paint, polymerization coating, petroleum and other industry. It is very significative to measure liquid viscosity in industrial production and basic study. The domestic on-line viscometer is not satisfying all in function, precision and stability, while the viscometer overseas has good capability, but also is very expensive. Therefore, research on on-line measuring of liquid viscosity is quit important.
We combined PLC, Configure software and industrial control computer to develop an on-line measuring system of liquid viscosity, main tasks of which are enhancing measuring precision, reducing measuring cost and realizing measuring on-line.
In this paper, we detailedly discuss the fundament and whole scheme of on-line measuring of liquid viscosity from basic theory, hardware composing and software designing. Applying soft-sensing technology to measure viscosity is advanced, and it has three main merits. Firstly, the problem of traditional viscosity measuring instruments perform badly when they are used to measure on-line is solved, secondly, measuring cost is reduced consumedly, finally, maintenance is convenient for the parameters of model are easy to be modified. In order to ensure the accuracy of the model, we apply the statistic discriminance and method of filter to do data pretreatment, and modify the model in time when the model output error beyond limits.
To the request of real-time measuring, the communication between PLC and PC is established, and we design data acquisition programmatic which the analog data filter and A/D conversion is realized. Convenient for monitoring liquid viscosity, we design monitoring interface with MCGS and divide it into four function modules, which makes the whole system visual and systematize.
Communication between MCGS and MATLAB was realized through DDE technology, and the unsubstantial function of data processing of MCGS is solved availably. Meanwhile, we storage large numbers of collecting data in Access database with SQL technology convenient for reading and management.
本文将可编程序控制器、组态软件与工业控制计算机相结合,开发设计了流体粘度在线测量系统,其主要任务是提高测量精度,降低测量成本,实现在线测量。
本文从理论基础,硬件构成及软件设计等方面详细地论述了流体粘度在线测量系统设计的基本原理和总体方案。提出了将软测量技术应用于粘度在线测量,首先解决了传统粘度测量设备应用于在线测量性能差的问题;其次大大地降低了粘度测量的成本;最后,由于软测量模型的参数易于更改,维护保养非常方便。为保证模型的精确性,采用统计判别法和滤波的方法对数据进行预处理,并在模型估测值偏差超限时及时校正模型。
针对系统实时性的要求,利用可编程控制器与上位机进行串口通信,并设计数据采集程序,同时实现模拟量数据滤波及A/D转换功能。为便于工作人员实时监控注聚液粘度,采用MCGS组态软件设计上位机监控画面,将整个监控软件分成四个功能模块,使系统变得可视化、系统化。
应用DDE技术实现了组态软件与MATLAB之间的通信,有效地解决了组态软件处理数据功能薄弱的问题;同时利用SQL技术将数据从组态软件中转存入Access数据库,解决了大量采集数据的存储问题,为日后读取和管理提供了方便。
Viscosity is one of the most important physical properties of liquid, and also is an important standard character in the industry of foodstuff, oil paint, polymerization coating, petroleum and other industry. It is very significative to measure liquid viscosity in industrial production and basic study. The domestic on-line viscometer is not satisfying all in function, precision and stability, while the viscometer overseas has good capability, but also is very expensive. Therefore, research on on-line measuring of liquid viscosity is quit important.
We combined PLC, Configure software and industrial control computer to develop an on-line measuring system of liquid viscosity, main tasks of which are enhancing measuring precision, reducing measuring cost and realizing measuring on-line.
In this paper, we detailedly discuss the fundament and whole scheme of on-line measuring of liquid viscosity from basic theory, hardware composing and software designing. Applying soft-sensing technology to measure viscosity is advanced, and it has three main merits. Firstly, the problem of traditional viscosity measuring instruments perform badly when they are used to measure on-line is solved, secondly, measuring cost is reduced consumedly, finally, maintenance is convenient for the parameters of model are easy to be modified. In order to ensure the accuracy of the model, we apply the statistic discriminance and method of filter to do data pretreatment, and modify the model in time when the model output error beyond limits.
To the request of real-time measuring, the communication between PLC and PC is established, and we design data acquisition programmatic which the analog data filter and A/D conversion is realized. Convenient for monitoring liquid viscosity, we design monitoring interface with MCGS and divide it into four function modules, which makes the whole system visual and systematize.
Communication between MCGS and MATLAB was realized through DDE technology, and the unsubstantial function of data processing of MCGS is solved availably. Meanwhile, we storage large numbers of collecting data in Access database with SQL technology convenient for reading and management.
引文
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[7]周超,影响落球法测液体粘度的主要因素的研究[J],西安建筑科技大学(自然科学版),2002,34(2):198-200
[8]杜方迅,许呈栋,董兴法,超声波固体粘度计的设计[J],传感器技术,2005,24(5):45-46
[9]刘晓辉,红外油液粘度测试仪的研制[J],中国煤炭,2003,29(4):36-39
[10]李鹏,徐立军,董峰,非牛顿液体粘度的在线测量方法[J],天津大学学报,2003,36(2):169-173
[11]俞金寿,软测量技术在石油化工中的应用[J],石油化工,2000(29):21-226
[12] Arthur Kordon.Robust soft sensors on integration of genetic programming analytical neural networks and support vector machines Evolutionary Computation [J].Proceedings of the 2002 Congress on, Volume: 1,12-17,May 2002 Page(s):896-901
[13] Thor Mejdell,Sigurd, Skogesatd.Output Estimation Using Multiple Secondary Meas urements:High-Purity Distillation[J].AIChEJ,1993,39(10):1641-1653
[14] Ming-Syan Chen, etal. Data Mining: An Overview from a Database Perspective[J].IEEE Transon Knowledge and Data Engineering,1996,8(6):866-883
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[18] Tong H,Crowe C M.Detecting persistent gross errors by sequential analysis of principal components[J].AIChE,1997,43(5):1242-1249
[19] Albuquerque J S,Biegler L T.Data reconciliation and gross-error detection for dynamic systems[J].AIChE,1996,42(10):2841-2856
[20]孙涛,曹广益,软测量建模方法分析[J],机床与液压,2005(2):67-68
[21]朱学峰,软测量技术及其应用[J],华南理工大学学报(自然科学版),2002,30(11):61-67
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[23] Heenan W.A.,Serth R.W Detecting errors in process data[J].Chem.Eng.1986,10:99 -106
[24] Kao Chen Shan, Tamhane Ajit C.,Mah Richard S.H. Gross error detection in serially correlated process data[J].2 Dynamics ystems. Ind Eng.Chem.Res.,1992,310):254-262
[25]易灵芝,朱建林,张林亭等,软测量的工程化设计[J],自动检测技术,2002,21(6):25-28
[26]王子延,许新,邱平,具有线性输出的靶式流量传感器[J],仪器仪表学报,1995,12(2):191-193
[27]石贤良,吴成富,基于MATLAB的最小二乘法参数辨识与仿真[J],微处理机,2005,12(6):44-46
[28]赵静,但琦,数学建模与数学实验[M],北京:高等教育出版社,2000.10。199-208
[29]王新和,程世洲,曲线拟合的最小二乘法[J],新疆职业大学学报,2004,6(12):84-86
[30] William T.Thomson, Theory of Vibration with Applications [M], Fifth Edition.96-101
[31]李鹏,徐立军等.非牛顿液体粘度的在线测量方法[J].天津大学学报,2003,2(36):169-173
[32] Kevin M.Passino,Linear Least Squares Methods,Biomimicry for Optimization, Control, and Automation,PartIII,2005
[33] N.V. Swindale. Orientation tuning curves: empirical description and estimation of parameters, Biological Cybernetics,1998,78(1):45-56
[34]吴晓光,徐精彩,李树刚等,基于MATLAB实验数据的几种处理方法[J],模式识别与仿真技术,2005,24(1):25-27
[35]王可,毛志伋，基于MATLAB实现最小二乘曲线拟合[J],北京广播学院学报,2005,12(2):52-56
[36]李桢,丁苯橡胶门尼粘度的软测量建模,[硕士学位论文]华南理工大学,2004.11
[37]许伟,软测量技术及其应用中应注意的问题[J],炼油技术与工程,2005,35(10):40-43
[38] Y.C.Fung A First Course in continuum Mechanics [M], Third Edition.121-124
[39] GLP-SBL型数显靶式流量计选型样本,北京格乐普高新技术有限公司,2006
[40] HYDC型电磁流量计说明书,北京格乐普高新技术有限公司,2006
[41] SIMATIC S7-200可编程控制器系统手册,西门子公司,2000.3
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[43]袁任光,可编程序控制器应用技术与实例[M],广州:华南理工大学出版社,1997.6。156-158
[44]荣大龙,顾启民等,工控机IPC-PLC电气控制技术[M],南京:东南大学出版社,2003.4
[45] STEP7-Micro/WIN32编程手册,西门子公司,2000.5
[46]王天文,天然气流量检测与控制智能系统的研究,[硕士学位论文]四川大学,2004.4
[47]吴勤勤,控制仪表与装置[M],北京化学工业出版社,2002.8。78-85
[48]王永华,现代电气及可编程控制技术[M],北京:北京航天航空大学出版社,2002.9。112-116
[49] MCGS6.0电子手册,北京亚控科技发展有限公司,2001
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[2]骆晨钟,邵惠鹤,软仪表技术及其工业应用[J],仪表技术与传感器,1999(1):32-34
[3]秦毅,胡鑑安,旋转式粘度计的工作原理及其主要部件设计[J],同济大学学报,1994,22(3):390-394
[4]朱震钧,王明时,新型全自动毛细管式粘度测量系统的设计[J],化工自动化及仪表,2001,28(3):54-57
[5]梁明湖,曲君乐,吴承璇等,单筒旋转式在线粘度计[J],山东科学,2002,5(2):50-53
[6]王永洪,冯正鸣,张春瑞,单音片振动式液体粘度测量仪的研究,计量学报,1995,16(3):186-189
[7]周超,影响落球法测液体粘度的主要因素的研究[J],西安建筑科技大学(自然科学版),2002,34(2):198-200
[8]杜方迅,许呈栋,董兴法,超声波固体粘度计的设计[J],传感器技术,2005,24(5):45-46
[9]刘晓辉,红外油液粘度测试仪的研制[J],中国煤炭,2003,29(4):36-39
[10]李鹏,徐立军,董峰,非牛顿液体粘度的在线测量方法[J],天津大学学报,2003,36(2):169-173
[11]俞金寿,软测量技术在石油化工中的应用[J],石油化工,2000(29):21-226
[12] Arthur Kordon.Robust soft sensors on integration of genetic programming analytical neural networks and support vector machines Evolutionary Computation [J].Proceedings of the 2002 Congress on, Volume: 1,12-17,May 2002 Page(s):896-901
[13] Thor Mejdell,Sigurd, Skogesatd.Output Estimation Using Multiple Secondary Meas urements:High-Purity Distillation[J].AIChEJ,1993,39(10):1641-1653
[14] Ming-Syan Chen, etal. Data Mining: An Overview from a Database Perspective[J].IEEE Transon Knowledge and Data Engineering,1996,8(6):866-883
[15] Lorena J.S, Biegler T. Data reconciliation and gross error detection for dynamic systems [J].AIChE J, 1996, 42(10):2841-2856
[16]李红军,秦永胜,徐用懋,化工过程中的数据协调及显著误差检测[J],化工自动化及仪表,1997(2):25-32
[17] Tong H,Crowe C M.Detection of gross errors in data reconciliation by principalcomponent analysis[J].AIChE,1995,41(7):1712-1722
[18] Tong H,Crowe C M.Detecting persistent gross errors by sequential analysis of principal components[J].AIChE,1997,43(5):1242-1249
[19] Albuquerque J S,Biegler L T.Data reconciliation and gross-error detection for dynamic systems[J].AIChE,1996,42(10):2841-2856
[20]孙涛,曹广益,软测量建模方法分析[J],机床与液压,2005(2):67-68
[21]朱学峰,软测量技术及其应用[J],华南理工大学学报(自然科学版),2002,30(11):61-67
[22] TamhaneA.C.,MahR.S.H,Data reconciliation and gross error detection in chemical process networks Technometrics[J],1985,27(4):409-422
[23] Heenan W.A.,Serth R.W Detecting errors in process data[J].Chem.Eng.1986,10:99 -106
[24] Kao Chen Shan, Tamhane Ajit C.,Mah Richard S.H. Gross error detection in serially correlated process data[J].2 Dynamics ystems. Ind Eng.Chem.Res.,1992,310):254-262
[25]易灵芝,朱建林,张林亭等,软测量的工程化设计[J],自动检测技术,2002,21(6):25-28
[26]王子延,许新,邱平,具有线性输出的靶式流量传感器[J],仪器仪表学报,1995,12(2):191-193
[27]石贤良,吴成富,基于MATLAB的最小二乘法参数辨识与仿真[J],微处理机,2005,12(6):44-46
[28]赵静,但琦,数学建模与数学实验[M],北京:高等教育出版社,2000.10。199-208
[29]王新和,程世洲,曲线拟合的最小二乘法[J],新疆职业大学学报,2004,6(12):84-86
[30] William T.Thomson, Theory of Vibration with Applications [M], Fifth Edition.96-101
[31]李鹏,徐立军等.非牛顿液体粘度的在线测量方法[J].天津大学学报,2003,2(36):169-173
[32] Kevin M.Passino,Linear Least Squares Methods,Biomimicry for Optimization, Control, and Automation,PartIII,2005
[33] N.V. Swindale. Orientation tuning curves: empirical description and estimation of parameters, Biological Cybernetics,1998,78(1):45-56
[34]吴晓光,徐精彩,李树刚等,基于MATLAB实验数据的几种处理方法[J],模式识别与仿真技术,2005,24(1):25-27
[35]王可,毛志伋，基于MATLAB实现最小二乘曲线拟合[J],北京广播学院学报,2005,12(2):52-56
[36]李桢,丁苯橡胶门尼粘度的软测量建模,[硕士学位论文]华南理工大学,2004.11
[37]许伟,软测量技术及其应用中应注意的问题[J],炼油技术与工程,2005,35(10):40-43
[38] Y.C.Fung A First Course in continuum Mechanics [M], Third Edition.121-124
[39] GLP-SBL型数显靶式流量计选型样本,北京格乐普高新技术有限公司,2006
[40] HYDC型电磁流量计说明书,北京格乐普高新技术有限公司,2006
[41] SIMATIC S7-200可编程控制器系统手册,西门子公司,2000.3
[42]殷洪义,可编程序控制器选择、设计与维护[M],北京:机械工业出版社,2002.11。23-43
[43]袁任光,可编程序控制器应用技术与实例[M],广州:华南理工大学出版社,1997.6。156-158
[44]荣大龙,顾启民等,工控机IPC-PLC电气控制技术[M],南京:东南大学出版社,2003.4
[45] STEP7-Micro/WIN32编程手册,西门子公司,2000.5
[46]王天文,天然气流量检测与控制智能系统的研究,[硕士学位论文]四川大学,2004.4
[47]吴勤勤,控制仪表与装置[M],北京化学工业出版社,2002.8。78-85
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