CN103605323A - Discrete control method and device for chemical industry production - Google Patents
Discrete control method and device for chemical industry production Download PDFInfo
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Abstract
The invention relates to a discrete control method and a device for chemical industry production. The discrete control method comprises establishing a technological index of a chemical product to be produced and a linear regression model that influences a plurality of technological parameters of the technological index; each technical parameter correspondingly having a regression coefficient, the technological parameter including at least a first parameter and at least a second parameter, the first parameter being real-time data, and the second parameter being historical data with time delay; obtaining a plurality of regression coefficients; and obtaining an estimated value of the technological index on line at the current time by using the obtained regression coefficients, the real-time value of the first parameter, the historical value of the second parameter, and the linear regression model. The discrete control method and the device for chemical industry production can provide real-time and significant guidance for a production process, saves energy, can achieve a predetermined quality requirement, and solves the problem that a key control index cannot be directly measured through a detector due to equipment hardware or technological requirements and the like.
Description
Technical field
The present invention relates to chemical field, particularly relate to a kind of Discrete Control Method and device of Chemical Manufacture.
Background technology
Below, take and produce neoprene process as example, the Discrete Control Method of Chemical Manufacture of the prior art and device are described.
Due to reasons such as device hardware problem and techniques, cannot be by the situation of change of " finished product glue fugitive constituent % " (belonging to crucial technic index) in detecting device on-line real time monitoring drying box production run.Laboratory just can obtain " finished product glue fugitive constituent % " this critical technic index after need to waiting for that for the analysis of this technic index the final products of this batch or order of classes or grades at school are produced by after sampling for final products.
Yet, chemically examine at present frequency and be about 2 hours once.Visible, cannot directly obtain in process of production any data of this index.If by the time lab analysis result out after, formed final products, therefore, laboratory data belongs to " knowing afterwards aftersensation ", to production run without any directive significance.
For these reasons, for fear of end product quality, do not reach customer requirements, in operating process, conventionally take the mode of the luxus consumption energy (drying box 1-3 section being controlled to the valve wide open of steam) to guarantee product quality.Yet this can make " finished product glue fugitive constituent % " this technic index of the product produced in prior art too high, has not only wasted the energy but also cannot meet quality requirements.
Summary of the invention
The object of this invention is to provide a kind of use simple, can to target process index, carry out estimating in real time production to be carried out to Discrete Control Method and the device of the Chemical Manufacture of real-time instruction online.
For solving the problems of the technologies described above, as first aspect of the present invention, the Discrete Control Method that a kind of Chemical Manufacture is provided, comprising: set up the technic index of chemical products to be produced and affect the linear regression model (LRM) between a plurality of technological parameters of this technic index; Each technological parameter all has a regression coefficient accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Obtain a plurality of regression coefficients; The instantaneous value of the regression coefficient that utilization is obtained, the first parameter, corresponding history value and the linear regression model (LRM) of the second parameter, obtain the technic index estimated value of current time online.
Further, Discrete Control Method also comprises: the chemical products that current time is obtained obtain the technic index measured value of the chemical products of this current time after chemically examining, and according to the deviation between technic index estimated value and technic index measured value, regression coefficient is proofreaied and correct.
Further, Discrete Control Method also comprises: utilize a plurality of technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, according to the deviation between technic index estimated value and technic index mean value, regression coefficient is proofreaied and correct.
Further, Discrete Control Method also comprises: judge that whether technic index estimated value meets predetermined variation range, if do not met, sends warning.
Further, Discrete Control Method also comprises: for each second parameter arranges retardation time, to obtain the historical data of this second parameter.
As second aspect of the present invention, a kind of discrete control device of Chemical Manufacture is provided, comprising: model storage unit, for storing the technic index of chemical products to be produced and affecting the linear regression model (LRM) between a plurality of technological parameters of this technic index; Each technological parameter all has a regression coefficient accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Regression coefficient acquiring unit, for obtaining a plurality of regression coefficients; Computing unit, for utilizing regression coefficient, the instantaneous value of the first parameter, corresponding history value and the linear regression model (LRM) of the second parameter obtaining, obtains the technic index estimated value of current time online.
Further, discrete control device also comprises: correcting unit, for regression coefficient being proofreaied and correct according to the deviation between technic index estimated value and technic index measured value, wherein, technic index measured value is to obtain after chemical products that current time is obtained are chemically examined.
Further, discrete control device also comprises: correcting unit, for regression coefficient being proofreaied and correct according to the deviation between technic index estimated value and technic index mean value, wherein, technic index mean value is the mean value of a plurality of technic index measured values of the chemical products of producing the in the situation that of production even running, in predetermined amount of time.
Further, discrete control device also comprises: judging unit for judging whether technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
Further, discrete control device also comprises: retardation time setting unit, be used to each second parameter that is set retardation time, to obtain the historical data of this second parameter.
The present invention brings the history value of the instantaneous value of the first parameter, the second parameter and the regression coefficient that determines in predetermined linear regression model (LRM) into, so, do not need to utilize the hardware of equipment to measure in real time the critical technic index of expectation acquisition, just can estimate the technic index estimated value of current time.Therefore, solved in prior art, in the time cannot directly obtaining in real time the data of this technic index in process of production, in the time of can only utilizing the laboratory data with time-lag effect, cannot carry out problem real-time, significant guidance to production run.Operating personnel can be according to this technic index estimated value, real-time online ground regulates each technological parameter, thereby make the present invention to carry out real-time, significant guidance to production run, both saved the energy, can reach again predetermined finger requirement, solve the problem of the pass key control index that cannot directly measure by detecting device due to reasons such as device hardware or technological requirements.
Accompanying drawing explanation
Fig. 1 has schematically shown the process flow diagram of the Discrete Control Method of the Chemical Manufacture in the present invention;
Fig. 2 has schematically shown the workflow diagram of CALCU module; And
Fig. 3 has schematically shown the workflow diagram of ADD module.
Embodiment
Below embodiments of the invention are elaborated, but the multitude of different ways that the present invention can be defined by the claims and cover is implemented.
The present invention in related technological parameter, extracts crucial technological parameter from production run, and the second parameter that these technological parameters are decomposed into incoherent the first parameter without time-lag effect and have time-lag effect.Then, utilize technic index measured value and the first parameter, the second parameter to carry out matching, thus the linear regression model (LRM) between the technic index of obtaining and technological parameter.Like this, only need to be according to the first parameter of current time, and the second parameter of the historical juncture corresponding with current time, just can pass through this linear regression model (LRM), technic index to current time is estimated, thereby obtain at that time technic index estimated value constantly, thereby provide online, real-time support for actual production.
As a first aspect of the present invention, a kind of Discrete Control Method of Chemical Manufacture is provided, especially, this Discrete Control Method can be applicable in DCS device, and can utilize the corresponding module (such as PVI module, LAG module, DLAY module, CALCU module and ADD module etc.) in DCS device to realize.Especially, this Discrete Control Method can be applicable to produce neoprene process.
This Discrete Control Method comprises: set up the technic index of chemical products to be produced and affect the linear regression model (LRM) between a plurality of technological parameters of this technic index; Each technological parameter all has a regression coefficient accordingly, and technological parameter comprises at least one first parameter and at least one second parameter, and the first parameter is real time data, and the second parameter is the historical data with time-lag effect; Obtain a plurality of regression coefficients, especially, can manually be inputted by artificial mode, also can automatically be inputted by system; The instantaneous value of the regression coefficient that utilization is obtained, the first parameter, corresponding history value and the linear regression model (LRM) of the second parameter, obtain the technic index estimated value of current time online.Especially, the sampling interval to each technological parameter can be set, to improve the precision of estimation.Further, also the technic index estimated value of current time can be shown in real time.
The present invention brings the history value of the instantaneous value of the first parameter, the second parameter and the regression coefficient that determines in predetermined linear regression model (LRM) into, so, do not need to utilize the hardware of equipment to measure in real time the critical technic index of expectation acquisition, just can estimate the technic index estimated value of current time.Therefore, solved in prior art, in the time cannot directly obtaining in real time the data of this technic index in process of production, in the time of can only utilizing the laboratory data with time-lag effect, cannot carry out problem real-time, significant guidance to production run.Operating personnel can be according to this technic index estimated value, real-time online ground regulates each technological parameter, thereby make the present invention to carry out real-time, significant guidance to production run, both saved the energy, can reach again predetermined finger requirement, solve the problem of the critical process index that cannot directly measure by detecting device due to reasons such as device hardware or technological requirements.
After linear regression model (LRM) is used a period of time, the meetings such as its regression coefficient change according to production actual conditions, therefore, in order to adapt to new variation, need to proofread and correct regression coefficient etc.For this reason, in one embodiment, Discrete Control Method also comprises: the chemical products that current time is obtained obtain the technic index measured value of the chemical products of this current time after chemically examining, and according to the deviation between technic index estimated value and technic index measured value, regression coefficient is proofreaied and correct.In another embodiment, preferably, Discrete Control Method also comprises: utilize a plurality of technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, according to the deviation between technic index estimated value and technic index mean value, regression coefficient is proofreaied and correct.
Preferably, Discrete Control Method also comprises: judge that whether technic index estimated value meets predetermined variation range, if do not met, sends warning.
Preferably, Discrete Control Method also comprises: for each second parameter arranges retardation time, to obtain the historical data of this second parameter.In fact, may be different the retardation time of each the second parameter, therefore, need to be respectively each second parameter is set different retardation time.
As a second aspect of the present invention, please refer to Fig. 2 and Fig. 3, the discrete control device that a kind of Chemical Manufacture is provided, comprising: model storage unit, for storing the technic index of chemical products to be produced and affecting the linear regression model (LRM) between a plurality of technological parameters of this technic index; Each technological parameter all has a regression coefficient accordingly, technological parameter comprises at least one first parameter and at least one second parameter, the first parameter is real time data, the second parameter is the historical data with time-lag effect, especially, can adopt the PVI module in DCS system to obtain in real time technological parameter; Regression coefficient acquiring unit, for obtaining a plurality of regression coefficients, especially, regression coefficient acquiring unit can be used the LAG module in DCS system to realize; Computing unit, for utilizing regression coefficient, the instantaneous value of the first parameter, corresponding history value and the linear regression model (LRM) of the second parameter obtaining, obtains the technic index estimated value of current time online.Especially, computing unit can adopt the CALCU module in DCS system to realize.
In one embodiment, discrete control device also comprises: correcting unit, for regression coefficient being proofreaied and correct according to the deviation between technic index estimated value and technic index measured value, wherein, technic index measured value is to obtain after chemical products that current time is obtained are chemically examined.Especially, correcting unit can be used the ADD module in DCS to realize.
In another embodiment, discrete control device also comprises: correcting unit, for regression coefficient being proofreaied and correct (preferably according to the deviation between technic index estimated value and technic index mean value, regression model constant is revised), wherein, technic index mean value is the mean value of a plurality of technic index measured values of the chemical products of producing the in the situation that of production even running, in predetermined amount of time.For example, can all above steps be tried again by new sample.Especially, correcting unit can be used the ADD module in DCS to realize.
Preferably, please refer to Fig. 3, discrete control device also comprises: judging unit for judging whether technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
Preferably, discrete control device also comprises: retardation time setting unit, be used to each second parameter that is set retardation time, to obtain the historical data of this second parameter.Especially, retardation time, setting unit can adopt the DLAY module in DCS system to realize.
DCS and module thereof take below as example, the Discrete Control Method with soft measurement function and device in the present invention are elaborated.
First, after determining linear regression model (LRM), for the technological parameter that calculates crucial technic index, by real time data and the historical data with hysteresis characteristic that determines due to production technology, formed, in order to guarantee versatility of the present invention, can in DCS, all adopt the configuration of More General Form, comprise PVI module, LAG module and DLAY module etc., by being the different parameter of above-mentioned each block configuration, realize and select real time data or historical data to enter participation calculating in model.
(1) PVI module: for (PV) shows using the input signal from input/output module and other functional block as measured value.In addition, can also export this measured value.Herein, PVI module can be used for obtaining the real time data of each technological parameter, and using it as output, sends into following LAG module (not considering the hysteresis requirements of data herein).
(2) LAG module: be mainly used in obtaining the corresponding regression coefficient of each technological parameter in linear regression model (LRM).For example, can input these regression coefficients by man-machine interface.
(3) DLAY module: carry out determined retardation time after cross-correlation analysis with controlled device respectively for realizing linear regression model (LRM) technological parameter, retardation time is different, and in module, parameter configuration is different.
Secondly, can use CALCU module in DCS to complete the calculating of the technic index based on linear regression model (LRM), comprise the summation of constant and obtained each technological parameter in linear regression model (LRM).
The 3rd, can utilize the ADD module in DCS to complete the function that data deviation is proofreaied and correct.It should be noted that, because the actual result of laboratory test of sampling exists and is closely connected with equipment operating condition at that time, being sampled the frequency limits, for setting up the sample of model, can not comprise whole operating conditions, therefore after linear regression model (LRM) on-line running a period of time, can drift about, measuring accuracy also can decline to a great extent thereupon.In order to address the above problem, need to realize in the present invention the offset correction function for model.
Producing neoprene process, the critical technic index that cannot directly obtain is " finished product glue fugitive constituent % ".Below, the measured data that mountain receives of take is example, the concrete application in conjunction with Yokogawa CS3000DCS, further illustrates the present invention.
First, obtain following linear regression model (LRM):
Finished product glue fugitive constituent %=53.5-0.0394HIC-727206.MV (%)
-0.204TR-727225.PV-3.15TR-727219.PV_4
-0.138TIC-727226.PV-0.124TRC727203.PV_1
-0.0198TIC-727206.PV_1+0.0883TIC-727205.PV
Wherein, comprise altogether seven and participate in the technological parameter calculating, i.e. HIC-727206.MV, TR-727225.PV, TR-727219.PV_4, TIC-727226.PV, TRC727203.PV_1, TIC-727206.PV_1 and TIC-727205.PV.Especially, the variable that has a hysteresis characteristic is: TR-727219.PV_4, TRC727203.PV_1 and 727206.PV_1.Be respectively 20 minutes, 5 minutes and 5 minutes the retardation time that can obtain three variablees according to hysteresis zone bit.But in order to guarantee the versatility of linear regression model (LRM), in DCS, all adopt the configuration of More General Form, by realize hysteresis or real time data for the different parameter of block configuration, enter participation calculating in model.
PVI module shows the input signal from input/output module and other functional block as measured value.In addition, can outputting measurement value.Herein, PVI module is used for obtaining the real time data of above-mentioned seven technological parameters, and using it as output, sends into LAG module (not considering the hysteresis requirements of data herein).It should be noted that: when the configuration of this module backstage, the content of " Input " → " Process Variable Range " → " High limit value " and " Low limit value " etc. should arrange accordingly according to technological parameter different in kind (with reference to this variable existing relevant configuration information in DCS at present).
The effect of LAG module is to realize in linear regression model (LRM), being positioned at regression coefficient before each technological parameter, that obtained by recurrence.
The effect of DLAY module is to realize in linear regression model (LRM) technological parameter TR-727219.PV_4, TRC727203.PV_1 and TIC-727206.PV_1 to carry out determined retardation time after cross-correlation analysis with controlled device respectively, for example, be respectively 20 minutes, 5 minutes and 5 minutes three's retardation time.
According to the principle of work of DLAY module, in order to realize the retardation time (being respectively 20 minutes, 5 minutes and 5 minutes) of technological parameter TR-727219.PV_4, TRC727203.PV_1 and TIC-727206.PV_1 in linear regression model (LRM) and all the other without the technological parameter lagging behind, concrete configuration is divided into three steps:
Step1: number of sampling points is set as to 60 in Function Block Configuration, i.e. m=60.Can intuitivism apprehension be in DLAY module, to have set up " houses of 60 store data ", according to the scan period of DCS (this example is 1 second), every through the single pass cycle, data will be filled up " 1 house ", and 60 houses therefore setting up will be filled after 60 seconds.
Step2: the requirement according to different retardation times arranges sampling interval (SMPL) accordingly in front console.Take technological parameter TR-727219.PV_4 as example, want to pass through set up linear regression model (LRM) and calculate current technic index estimated value, it should be the measured value before 20 minutes, dead time L=20 minute=1200 seconds that this technological parameter participates in the value calculated.According to this requirement, extrapolate SMPL=L/m=1200/60=20.According to above-mentioned computing method, owing to retardation time of TRC727203.PV_1 and TIC-727206.PV_1 being 5 minutes, so the input value of the sampling interval of these two technological parameters is set as 5.
Step3: except having the variable of hysteresis characteristic, HIC-727206.MV (%), TR-727225.PV, TIC-727226.PV and TIC-727205.PV all need to obtain instantaneous value in model computation process, therefore, its sampling interval can be set to 0.1.
ADD module, for model drift correction, wherein, should be noted that following problem:
(1), without frequent operation, for example, after linear regression model (LRM) operation a period of time (, 1 week etc.), once proofread and correct;
(2) best practices of operation should be completed by DCS slip-stick artist herein, avoids operative employee frequently to proofread and correct (considering to complete by authority setting).
In prior art, in chemical process, the problem of certain critical process index of Quick Measurement cannot directly be measured or be difficult for by detecting device to ubiquity, due to reasons such as device hardware or technological requirements.Conventionally need to after producing final products, to the above-mentioned technic index that cannot directly measure, carry out assay again, like this, even off quality, also cannot adjust, thereby can cause significant loss.It is basis that crucial technological parameter in production run is take in the present invention, based in real time and historical data foundation, in DCS system real time execution, On-Line Dynamic Monitoring linear regression model (LRM), can also show certain critical process index that can not directly measure or be difficult for Quick Measurement by Real-time Obtaining, thereby the very first time is instructed production.
The present invention can in DCS system, realize automatic acquisition linear regression model (LRM) calculate needed, without the performance variable real time data of retardation time, also can in DCS system, realize automatic acquisition linear regression model (LRM) and calculate historical data needed, when having influence on controlled device thering is certain retardation time after performance variable changes.Thereby in DCS system, realize real time data based on linear regression model (LRM), technological parameter and historical data critical process index automatic calculating with dynamically show.Further, also can in DCS system, realize the zero point drift automatic calibration of linear regression model (LRM), like this, after the technological parameter of linear regression model (LRM) or regression coefficient change according to production actual conditions, can in DCS system, make consistent adjustment by the model based on new.
The foregoing is only the preferred embodiments of the present invention, be not limited to the present invention, for a person skilled in the art, the present invention can have various modifications and variations.Within the spirit and principles in the present invention all, any modification of doing, be equal to replacement, improvement etc., within all should being included in protection scope of the present invention.
Claims (10)
1. a Discrete Control Method for Chemical Manufacture, is characterized in that, comprising:
Set up the technic index of chemical products to be produced and affect the linear regression model (LRM) between a plurality of technological parameters of this technic index; Described in each, technological parameter all has a regression coefficient accordingly, and described technological parameter comprises at least one first parameter and at least one second parameter, and described the first parameter is real time data, and described the second parameter is the historical data with time-lag effect;
Obtain a plurality of described regression coefficients;
The described regression coefficient that utilization is obtained, the instantaneous value of described the first parameter, corresponding history value and the described linear regression model (LRM) of described the second parameter, obtain the technic index estimated value of current time online.
2. Discrete Control Method according to claim 1, it is characterized in that, described Discrete Control Method also comprises: the chemical products that described current time is obtained obtain the technic index measured value of the chemical products of current time described in this after chemically examining, according to the deviation between described technic index estimated value and described technic index measured value, described regression coefficient is proofreaied and correct.
3. Discrete Control Method according to claim 1, it is characterized in that, described Discrete Control Method also comprises: utilize a plurality of technic index measured values of the chemical products of producing in predetermined amount of time in production even running situation to obtain technic index mean value, according to the deviation between described technic index estimated value and described technic index mean value, described regression coefficient is proofreaied and correct.
4. according to the Discrete Control Method described in claim 2 or 3, it is characterized in that, described Discrete Control Method also comprises: judge that whether described technic index estimated value meets predetermined variation range, if do not met, sends warning.
5. according to the Discrete Control Method described in claim 2 or 3, it is characterized in that, described Discrete Control Method also comprises: for the second parameter described in each arranges retardation time, to obtain the historical data of this second parameter.
6. a discrete control device for Chemical Manufacture, is characterized in that, comprising:
Model storage unit, for storing the technic index of chemical products to be produced and affecting the linear regression model (LRM) between a plurality of technological parameters of this technic index; Described in each, technological parameter all has a regression coefficient accordingly, and described technological parameter comprises at least one first parameter and at least one second parameter, and described the first parameter is real time data, and described the second parameter is the historical data with time-lag effect;
Regression coefficient acquiring unit, for obtaining a plurality of described regression coefficients;
Computing unit, for utilizing the instantaneous value of the described regression coefficient of obtaining, described the first parameter, corresponding history value and the described linear regression model (LRM) of described the second parameter, obtains the technic index estimated value of current time online.
7. discrete control device according to claim 6, is characterized in that, described discrete control device also comprises:
Correcting unit, for described regression coefficient being proofreaied and correct according to the deviation between described technic index estimated value and technic index measured value, wherein, described technic index measured value is to obtain after chemical products that described current time is obtained are chemically examined.
8. discrete control device according to claim 6, is characterized in that, described discrete control device also comprises:
Correcting unit, for described regression coefficient being proofreaied and correct according to the deviation between described technic index estimated value and technic index mean value, wherein, described technic index mean value is the mean value of a plurality of technic index measured values of the chemical products of producing the in the situation that of production even running, in predetermined amount of time.
9. according to the discrete control device described in claim 7 or 8, it is characterized in that, described discrete control device also comprises: judging unit for judging whether described technic index estimated value meets predetermined variation range, and sends warning message in incongruent situation.
10. according to the discrete control device described in claim 7 or 8, it is characterized in that, described discrete control device also comprises: retardation time setting unit, be used to the second parameter described in each that is set retardation time, to obtain the historical data of this second parameter.
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| CN104133437B (en) * | 2014-07-07 | 2017-05-17 | 蓝星（北京）技术中心有限公司 | Continuous-type chemical-engineering device and performance indicator real-time evaluation method and device thereof |
| CN109694422A (en) * | 2018-12-25 | 2019-04-30 | 重庆化医长寿化工集团有限公司 | Neoprene polymerize autocontrol method |
| CN109694422B (en) * | 2018-12-25 | 2021-09-17 | 重庆化医长寿化工集团有限公司 | Automatic control method for chloroprene rubber polymerization |
| CN109885869A (en) * | 2019-01-09 | 2019-06-14 | 石化盈科信息技术有限责任公司 | A kind of online customized Technology Calculation |
| CN109885869B (en) * | 2019-01-09 | 2023-01-20 | 石化盈科信息技术有限责任公司 | Online user-defined process calculation method |
| CN109813782A (en) * | 2019-02-01 | 2019-05-28 | 杭州原创软件有限公司 | A kind of self diagnosis PH on-line monitoring system and method |
| CN109813782B (en) * | 2019-02-01 | 2020-12-29 | 杭州原创软件有限公司 | Self-diagnosis PH on-line monitoring system and method |
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