Cement fluid flow measurement system
Technical Field
The invention relates to the technical field of fluid flow measurement, in particular to a cement fluid flow measurement system.
Background
The cement fluid flow measuring system aims at realizing high-precision and high-reliability flow measurement by an intelligent optical acoustic flow calculation technology, and realizing accurate calculation and dynamic regulation and control of the volume flow of cement slurry by utilizing optical image capturing and ultrasonic data fusion.
When the existing cement fluid flow measuring system is used for treating cement slurry with high viscosity or particles, the problems of reduction of measuring precision and increase of equipment maintenance cost can be caused due to the fact that the traditional measuring equipment is easy to be subjected to physical blockage or abrasion, and therefore, the cement fluid flow measuring system is designed.
Disclosure of Invention
The invention aims to provide a cement fluid flow measuring system, which solves the problems that the conventional measuring equipment is easy to be blocked or worn physically, so that the measuring precision is reduced and the equipment maintenance cost is increased.
To achieve the above object, the present invention provides a cement fluid flow measuring system, comprising:
a flow rate regulating unit for stably supplying the cement paste to the measurement calculating unit and receiving feedback from the flow rate regulating unit to regulate the flow rate;
A condition optimizing unit for filtering the cement paste from the flow regulating unit and adjusting the temperature and pressure of the cement paste;
The measuring and calculating unit is used for collecting and integrating optical and acoustic sensor data, and measuring and calculating the integrated volume flow of the cement slurry by using an intelligent optical acoustic flow calculating technology;
The flow feedback unit is used for receiving the comprehensive volume flow from the measurement and calculation unit, analyzing the comprehensive volume flow and feeding the comprehensive volume flow back to the flow regulation unit;
And a system maintenance unit for performing periodic system inspection and maintenance.
As a further improvement of the technical scheme, the flow regulating unit comprises a feed pump control module and a flow stabilizing module;
The feeding pump control module controls the plurality of feeding pumps to pump cement slurry in the storage area and push the cement slurry to the measurement and calculation unit;
the flow stabilizing module is used for receiving feedback from the flow regulating unit to regulate the flow of the cement slurry entering the measuring and calculating unit, and installing the pressure sensor to realize real-time monitoring and automatic regulation of the flow.
As a further improvement of the technical scheme, the condition optimizing unit comprises a particle filtering module and an environment adjusting module;
the particle filtering module is used for removing large particle impurities in the cement slurry, carrying out preliminary natural sedimentation on heavier solid particles in the cement slurry in a sedimentation tank by utilizing the gravity principle, intercepting the impurity particles larger than the medium aperture by utilizing a screen, and preventing the particles from entering a subsequent measuring system so as to avoid damaging a sensor or affecting the accuracy of the sensor;
the environment adjusting module is used for adjusting the temperature and the pressure of the cement slurry, adjusting the temperature to be between 5 ℃ and 35 ℃, and controlling the pressure to be between 1 and 10Bar, so that the ideal measuring condition is ensured before the cement slurry enters the measuring unit;
The physical and chemical states of the cement slurry are finely controlled through the condition optimization unit, a stable and controllable working environment is provided for the whole cement volume flow measurement system, the measurement accuracy and reliability are improved, and the efficiency and the product quality of the whole production line are improved.
As a further improvement of the technical scheme, the measurement calculation unit comprises a fluid modeling module, an image capturing and processing module, an ultrasonic measurement module and a flow calculation module;
The fluid modeling module is used for modeling the flow characteristics of cement paste; the image capture processing module captures images of the flowing cement slurry using a high speed camera; the ultrasonic measuring module measures the volume flow of the cement slurry by using an ultrasonic sensor array; the flow calculation module uses data fusion techniques to optimize the measurement of volumetric flow in combination with optical and acoustic measurements.
As a further improvement of the technical scheme, the intelligent optical acoustic flow computing technology is realized based on advanced image processing and acoustic signal analysis and is used for accurately measuring the volume flow of the cement paste, and the specific steps involved in measuring and computing the volume flow of the cement paste by using the intelligent optical acoustic flow computing technology are as follows:
S3.1, modeling the flow characteristic of cement paste in a fluid modeling module, and changing the shear rate And measuring the corresponding shear stressFitting generalized Newtonian fluid model through nonlinear regression method to find optimal consistency indexAnd flow behavior index:;
Wherein, Is shear stress in pascals; For shear rate, the units are ;Is the fluid consistency index in units of;Is a flow behavior index;
S3.2, capturing images of the flowing cement slurry by using an image capturing and processing module through a high-speed camera, and calculating each frame of image in the process of using an image processing algorithm Sobel operator AndBrightness gradient in directionAndAnd calculating velocity vectors of particles between successive frames using an optical flow algorithmAndAnd calculate the optical flow rateAnd optical volume flow;
S3.3, measuring the acoustic flow velocity of the cement slurry fluid by using the Doppler frequency shift of the ultrasonic sensor array by using the ultrasonic measuring moduleAnd acoustic volume flow;
S3.4, fusion acoustic volume flowAnd optical volume flowCalculation of integrated volumetric flow using weighted average。
As a further improvement of the present technical solution, the optical flow rate is calculated in S3.2 by using an optical flow algorithmThe specific mathematical formula involved is as follows:
Streamer equation:
;
wherein, A brightness gradient in the x-direction for each frame image; A brightness gradient in the y direction for each frame image; And A velocity vector for each pixel; Is the total number of velocity vectors; Is the optical flow rate; is the optical volume flow; Is the cross-sectional area.
As a further improvement of the technical scheme, the method in S3.3 utilizes an ultrasonic sensor array to measure the volume flow of cement pasteThe calculation method of (1) is as follows:
wherein, Is the doppler shift, i.e., the difference between the received frequency and the transmitted frequency; Is the speed of sound in the medium; Is the emitted ultrasonic frequency; is the included angle between the ultrasonic wave propagation direction and the flow velocity direction; is the acoustic flow rate; Is the cross-sectional area.
As a further improvement of the present technical solution, the fusion acoustic volume flow rate in S3.4And optical volume flowCalculation of integrated volumetric flow using weighted averageThe mathematical model formula involved is as follows:
wherein, Is the integrated volume flow; For optically measuring the flow rate The weight of the corresponding volume flow calculation result; for flow rates based on optical measurements A calculated volumetric flow rate; For optically measuring the flow rate The weight of the corresponding volume flow calculation result; for flow rates based on optical measurements Calculated volumetric flow.
As a further improvement of the technical scheme, the flow feedback unit comprises a receiving and analyzing module and a control feedback module;
the receiving and analyzing module is used for receiving the comprehensive volume flow of the real-time cement slurry from the measuring and calculating unit and analyzing the received comprehensive volume flow by using a statistical analysis processing algorithm;
the control feedback module is used for sending an adjusting control command to the feed pump control module and the flow stabilizing module in the flow regulating and controlling unit based on the data analysis result so as to adjust the speed of the feed pump and adjust the flow stabilizing valve.
As a further improvement of the technical scheme, the system maintenance unit comprises a periodic inspection module, an automatic cleaning module and a safety monitoring system;
The periodic inspection module is used for periodically inspecting mechanical and electronic equipment in the system and comprises a sensor, a pump and a valve;
the automatic cleaning module is used for starting cleaning programs to automatically clean equipment and pipelines at regular time;
The safety monitoring system is used for monitoring the running state of the system and monitoring pressure and temperature parameters in real time.
Compared with the prior art, the invention has the beneficial effects that:
1. In the cement fluid flow measurement system, the intelligent optical acoustic flow calculation technology is used for measuring and calculating the comprehensive volume flow of cement slurry, so that the movement state of fluid can be accurately monitored in real time, the control of the production process is optimized, and the raw material waste and the production cost caused by measurement errors are reduced.
2. In the cement fluid flow measurement system, the accuracy of measurement data and the response speed of the system can be effectively improved by integrating multi-sensor data fusion and intelligent algorithm analysis, and the refinement of flow control and the efficient operation of the production process are ensured.
Drawings
Fig. 1 is an overall flow diagram of the present invention.
The meaning of each reference sign in the figure is:
1. a flow rate control unit; 2. a condition optimizing unit; 3. a measurement calculation unit; 4. a flow feedback unit; 5. and a system maintenance unit.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Examples
Referring to fig. 1, there is provided a cement fluid flow measurement system comprising:
A flow regulating unit 1 for stably supplying cement paste to the measurement calculating unit 3 and receiving feedback from the flow feedback unit 4 to regulate the flow;
the flow regulating unit 1 comprises a feed pump control module and a flow stabilizing module;
the feeding pump control module controls the plurality of feeding pumps to pump cement slurry in the storage area and push the cement slurry to the measurement and calculation unit 3;
The flow stabilizing module is used for receiving feedback from the flow feedback unit 4 to adjust the flow of the cement slurry entering the measurement and calculation unit 3, and installing a pressure sensor to realize real-time monitoring and automatic adjustment of the flow.
Further comprising a condition optimizing unit 2, the condition optimizing unit 2 being used for filtering the cement slurry from the flow regulating unit 1 and adjusting the temperature and pressure of the cement slurry;
the condition optimizing unit 2 comprises a particle filtering module and an environment adjusting module;
the particle filtering module is used for removing large particle impurities in the cement slurry, carrying out preliminary natural sedimentation on heavier solid particles in the cement slurry in a sedimentation tank by utilizing the gravity principle, intercepting the impurity particles larger than the medium aperture by utilizing a screen, and preventing the particles from entering a subsequent measuring system so as to avoid damaging a sensor or affecting the accuracy of the sensor;
the environment adjusting module is used for adjusting the temperature and the pressure of the cement slurry, adjusting the temperature to be between 5 ℃ and 35 ℃, and controlling the pressure to be between 1 and 10Bar, so that the ideal measuring condition is ensured before the cement slurry enters the measuring unit;
The physical and chemical states of the cement slurry are finely controlled through the condition optimization unit, a stable and controllable working environment is provided for the whole cement volume flow measurement system, the measurement accuracy and reliability are improved, and the efficiency and the product quality of the whole production line are improved.
The system further comprises a measurement and calculation unit 3, wherein the measurement and calculation unit 3 collects and synthesizes optical and acoustic sensor data, and uses intelligent optical acoustic flow calculation technology to measure and calculate the comprehensive volume flow of the cement slurry;
the measurement and calculation unit 3 comprises a fluid modeling module, an image capturing and processing module, an ultrasonic measurement module and a flow calculation module;
The fluid modeling module is used for modeling the flow characteristics of cement paste; the image capture processing module captures images of the flowing cement slurry using a high speed camera; the ultrasonic measuring module measures the volume flow of the cement slurry by using an ultrasonic sensor array; the flow calculation module uses data fusion techniques to optimize the measurement of volumetric flow in combination with optical and acoustic measurements.
The intelligent optical acoustic flow computing technology is realized based on advanced image processing and acoustic signal analysis and is used for accurately measuring the volume flow of the cement paste, and the specific steps involved in measuring and computing the volume flow of the cement paste by using the intelligent optical acoustic flow computing technology are as follows:
S3.1, modeling the flow characteristic of cement paste in a fluid modeling module, and changing the shear rate And measuring the corresponding shear stressFitting generalized Newtonian fluid model through nonlinear regression method to find optimal consistency indexAnd flow behavior index:;
Wherein, Is shear stress in pascals; For shear rate, the units are ;Is the fluid consistency index in units of;Is a flow behavior index;
S3.2, capturing images of the flowing cement slurry by using an image capturing and processing module through a high-speed camera, and calculating each frame of image in the process of using an image processing algorithm Sobel operator AndBrightness gradient in directionAndAnd calculating velocity vectors of particles between successive frames using an optical flow algorithmAndAnd calculate the optical flow rateAnd optical volume flow;
S3.3, measuring the acoustic flow velocity of the cement slurry fluid by using the Doppler frequency shift of the ultrasonic sensor array by using the ultrasonic measuring moduleAnd acoustic volume flow;
S3.4, fusion acoustic volume flowAnd optical volume flowCalculation of integrated volumetric flow using weighted average。
Wherein the generalized Newtonian fluid model is a mathematical model describing the behavior of fluid viscosity as a function of shear rate, applicable to fluids whose viscosity is not constant, but depends on the applied shear rate;
The optical flow algorithm is used for calculating the optical flow velocity in the S3.2 The specific mathematical formula involved is as follows:
Streamer equation:
;
wherein, A brightness gradient in the x-direction for each frame image; A brightness gradient in the y direction for each frame image; And A velocity vector for each pixel; Is the total number of velocity vectors; Is the optical flow rate; is the optical volume flow; Is a cross-sectional area;
the optical flow algorithm is a computer vision technology and is used for estimating the motion speed and direction of pixel points in an image sequence;
In S3.3, the volume flow of the cement paste is measured by using an ultrasonic sensor array The calculation method of (1) is as follows:
wherein, Is the doppler shift, i.e., the difference between the received frequency and the transmitted frequency; Is the speed of sound in the medium; Is the emitted ultrasonic frequency; is the included angle between the ultrasonic wave propagation direction and the flow velocity direction; is the acoustic flow rate; Is a cross-sectional area;
Wherein the ultrasonic sensor array is a group of ultrasonic sensors arranged in a certain geometric arrangement and is used for accurately measuring the flow velocity and the volume flow of cement slurry;
Fusion of acoustic volume flow in S3.4 And optical volume flowCalculation of integrated volumetric flow using weighted averageThe mathematical model formula involved is as follows:
wherein, Is the integrated volume flow; For optically measuring the flow rate The weight of the corresponding volume flow calculation result; for flow rates based on optical measurements A calculated volumetric flow rate; For optically measuring the flow rate The weight of the corresponding volume flow calculation result; for flow rates based on optical measurements Calculated volumetric flow.
The system further comprises a flow feedback unit 4, wherein the flow feedback unit 4 is used for receiving the comprehensive volume flow from the measurement and calculation unit 3 and analyzing the comprehensive volume flow to feed back to the flow regulation and control unit 1;
the flow feedback unit 4 comprises a receiving and analyzing module and a control feedback module;
The receiving and analyzing module is used for receiving the comprehensive volume flow of the real-time cement slurry from the measuring and calculating unit 3 and analyzing the received comprehensive volume flow by using a statistical analysis processing algorithm;
The control feedback module is used for sending an adjusting control command to the feed pump control module and the flow stabilizing module in the flow regulating unit 1 based on the data analysis result so as to adjust the feed pump speed and adjust the flow stabilizing valve.
Wherein the statistical analysis processing algorithm is used for processing and analyzing a series of mathematical and statistical methods of the integrated volume flow data from the measurement calculation unit (3), including an autoregressive model, a moving average model and an autoregressive moving average model;
A system maintenance unit 5, wherein the system maintenance unit 5 is used for performing periodic system inspection and maintenance;
The system maintenance unit 5 comprises a periodic inspection module, an automatic cleaning module and a safety monitoring system;
The periodic inspection module is used for periodically inspecting mechanical and electronic equipment in the system and comprises a sensor, a pump and a valve;
the automatic cleaning module is used for starting cleaning programs to automatically clean equipment and pipelines at regular time;
The safety monitoring system is used for monitoring the running state of the system and monitoring pressure and temperature parameters in real time.
The foregoing has shown and described the basic principles, principal features and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the above-described embodiments, and that the above-described embodiments and descriptions are only preferred embodiments of the present invention, and are not intended to limit the invention, and that various changes and modifications may be made therein without departing from the spirit and scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.