Method to control a process variable

• US 10,407,328 B2
• Filed: 12/14/2015
• Issued: 09/10/2019
• Est. Priority Date: 12/15/2014
• Status: Active Grant

• Current Assignee: Endress+Hauser Conducta GmbH+Company KG (Endress+Hauser AG)
• Original Assignee: Endress+Hauser Conducta GmbH+Company KG (Endress+Hauser AG)
• Inventors: Alber, Thomas, Herb, Christoph
• Primary Examiner(s): Lee, Thomas C
• Assistant Examiner(s): Chu, Alan
• Application Number:
  US14/968,115
• Publication Number:
  US 20160167992A1
• Time in Patent Office: 1,366 Days
• Field of Search: 700 11
• CPC Class Codes: C02F 2209/005 Processes using a programmable logic controller [PLC]
• CPC Class Codes: C02F 2209/14 NH3-N
• CPC Class Codes: C02F 2209/22 O2
• CPC Class Codes: C02F 2209/38 Gas flow rate
• CPC Class Codes: C02F 2209/40 Liquid flow rate
• CPC Class Codes: C02F 3/006 Regulation methods for biological treatment
• CPC Class Codes: C02F 3/12 Activated sludge processes
• CPC Class Codes: C02F 3/302 Nitrification and denitrification treatment C02F3/308 takes precedence
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05D 7/0617 specially adapted for fluid materials

Abstract

A method to control a process variable in a process by means of a control unit comprises: sequential determination of values of a reference variable to be supplied to the first control unit based on the values of a first measurand; sequential determination of values of a regulating variable using both values for the reference variable and sequentially determined values for the process variable; with a current value for the reference variable being determined: by sequentially saving values of the first measurand, or values derived therefrom, in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest of the values saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=k); and by using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater or equal 1.

Claims

1. A method to control a process variable representing an air volume to be fed into a liquid volume inside a container including a fluid intake and a fluid discharge in a process for treating the liquid, said process being conducted in the container and said method being performed using an air-mass flow controller and comprising the steps:

measuring values of a first measurand representing a load of one or more substances to be degraded in the process and found in a settable volume unit of the liquid in the fluid intake;

sequentially determining values of a reference variable to be supplied to the air-mass flow controller based on the values of the first measurand, said reference variable representing a nominal value of the air volume to be fed into the liquid volume;

sequentially determining values of a regulating variable using both values for the reference variable and sequentially determined values of the process variable, said regulating variable being a variable for an aerator that serves to supply air into the liquid volume in the container and said variable influencing the air volume fed into the liquid volume using the aerator; and

determining a current value for the reference variable by;

sequentially saving values of the first measurand, or values derived therefrom, in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest value saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=k);

using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater than or equal to 1; and

adjusting the aerator using the air-mass flow controller using the values of the regulating variable;

wherein the values of the first measurand or air requirement values derived from at least one value of the first measurand using a proportionality factor are saved sequentially in the first FIFO memory, and each air requirement value represents an air volume to be fed into the liquid to degrade the substance load represented by the at least one value of the first measurand.

2. The method according to claim 1, wherein:

sequentially determining values of the reference variable to be provided to the air-mass flow controller further comprises measuring values of a second measurand that differs from the first measurand, said values being used to determine the reference variable.

3. The method according to claim 2, further comprising:

determining the current value for the reference variable by sequentially saving values for the second measurand, or values derived therefrom, in a second FIFO memory having a number N of memory locations for saving one value respectively, namely a memory featuring a number N of logically consecutive memory locations (h=I), and by using all the values saved in the second FIFO memory to determine the current value for the reference variable, with N being a number of values that is equal to the number n of the values saved in the first FIFO memory and used for determining the current value of the reference variable.

4. The method according to claim 1, wherein:

the regulating variable is a pump capacity or a rotational speed.

5. The method according to claim 4, further comprising:

sequentially measuring values of a third measurand, which represent the remaining quantity of the substance to be degraded in the process and discharged from the container via the fluid discharge, or a dissolved oxygen content found in the liquid in the container.

6. The method according to claim 5, further comprising:

using the values of the third measurand for determining the values of the reference variable.

7. The method according to claim 1, wherein:

several values for the first measurand and a throughput of the liquid are measured sequentially to determine each air requirement value;

with the sequentially measured values for the first measurand or values derived therefrom being accumulated until the throughput reaches a settable throughput threshold value; and

the air requirement value is determined by the accumulation value resulting from the accumulation of values of the first measurand using the proportionality factor.

8. The method according to claim 7, wherein:

with the respective air requirement value determined most recently being saved to a memory location in the first FIFO memory, the oldest air requirement value saved in the first FIFO memory is simultaneously deleted or overwritten.

9. The method according to claim 7, wherein:

the values of the first measurand are measured at a measuring point arranged in the fluid intake, and wherein the settable throughput threshold value equals the quotient of the volume taken up by the liquid found between the measuring point and the fluid discharge, and the number K of the memory locations of the first FIFO memory, so that each memory location corresponds to a liquid volume unit flowing into the container by the way of the fluid intake, and the air requirement value saved in that memory location represents the air volume to be supplied into the liquid in order to degrade the load contained in this liquid volume unit.

10. The method according to claim 9, wherein:

to obtain the current value of the reference variable to be supplied to the air-mass flow controller, the n oldest requirement values saved in the first FIFO memory are added to obtain a total air requirement value; and

the number n of the air requirement values being used for the total air requirement value is selected in such a way that the sum of the liquid volume units corresponding to the respective memory locations is equal to the volume of the container comprising the liquid.

11. The method according to claim 7, wherein:

the second measurand represents an air volume introduced into the liquid in the container using the aerator; and

the method further comprises determining air introduction values from several sequentially captured values of the second measurand by accumulating the sequentially captured values of the second measurand or values derived therefrom until the liquid throughput detected for the simultaneous determination of an air requirement value has reached the settable throughput threshold values, and the air introduction values are determined by accumulation values obtained by the accumulation of the values of the second measurand or the values derived therefrom.

12. The method according to claim 11, wherein:

at the same time that a newly determined air requirement value is saved, and the oldest air requirement value in the first FIFO memory is deleted, the air introduction value saved in the second FIFO memory at a first memory location according to the logical sequence of the memory locations (h=1) is deleted as well.

13. The method according to claim 12, wherein:

to obtain the current value of the reference variable to be supplied to the air-mass flow controller, all air introduction values saved in the second FIFO memory are added to obtain a total air introduction value.

14. The method according to claim 13, wherein:

in order to determine the current value for the reference variable, a deviation value representing the deviation of the total air requirement value from the total air introduction value is determined.

15. A method to control a process variable representing an air volume to be fed into a liquid volume inside a container including a fluid intake and a fluid discharge in a process for treating the liquid, said process being conducted in the container and said method being performed using an air-mass flow controller and comprising the steps:

measuring values of a first measurand representing a load of one or more substances to be degraded in the process and found in a settable volume unit of the liquid in the fluid intake;

sequentially determining values of a reference variable to be supplied to the air-mass flow controller based on the values of the first measurand, said reference variable representing a nominal value of the air volume to be fed into the liquid volume;

sequentially determining values of a regulating variable using both values for the reference variable and sequentially determined values of the process variable, said regulating variable being a variable for an aerator that serves to supply air into the liquid volume in the container and said variable influencing the air volume fed into the liquid volume using the aerator, wherein the regulating variable is a pump capacity or a rotational speed;

determining a current value for the reference variable by;

sequentially saving values of the first measurand, or values derived therefrom,

in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest value saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=k); and

using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater than or equal to 1;

sequentially measuring values of a third measurand, which represent the remaining quantity of the substance to be degraded in the process and discharged from the container via the fluid discharge, or a dissolved oxygen content found in the liquid in the container;

using the values of the third measurand for determining the values of the reference variable;

deriving from the values of the third measurand nominal values by means of a second control unit and using the nominal values in the step of sequentially determining values of the reference variable to be supplied to the air-mass flow controller;

adjusting the aerator using the air-mass flow controller using the values of the regulating variable.

16. The method according to claim 15, wherein:

the second control unit is an output control that is supplied with the values of the third measurand measured downstream from the liquid discharge as a process variable to be controlled by the second control unit, and said second control unit determines values of a variable representing an air volume to be introduced into the container and serving as the regulating variable of the second control unit, said second control unit determining the values of said regulating variable based on a comparison of the process variable with a fixed reference variable; and

wherein the values of the regulating variable of the second control unit are used in the step of sequentially determining values of the reference variable to be supplied to the air-mass flow controller.

17. A method to control a process variable representing an air volume to be fed into a liquid volume inside a container including a fluid intake and a fluid discharge in a process for treating the liquid, said process being conducted in the container and said method being performed using an air-mass flow controller and comprising the steps:

measuring values of a first measurand representing a load of one or more substances to be degraded in the process and found in a settable volume unit of the liquid in the fluid intake;

sequentially determining values of a reference variable to be supplied to the air-mass flow controller based on the values of the first measurand, said reference variable representing a nominal value of the air volume to be fed into the liquid volume;

sequentially determining values of a regulating variable using both values for the reference variable and sequentially determined values of the process variable, said regulating variable being a variable for an aerator that serves to supply air into the liquid volume in the container and said variable influencing the air volume fed into the liquid volume using the aerator;

determining a current value for the reference variable by;

sequentially saving values of the first measurand, or values derived therefrom, in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest value saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=k); and

using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater than or equal to 1;

adjusting the aerator using the air-mass flow controller using the values of the regulating variable;

deriving air requirement values from at least one value of the first measurand using a proportionality factor, and sequentially saving the air requirement values into the first FIFO memory;

measuring at least one value of a third measurand in the discharge or downstream of the discharge; and

adapting the proportionality factor based on said at least one value of the third measurand;

wherein the regulating variable is a pump capacity or a rotational speed.

18. The method according to claim 17, wherein:

the adapting of the proportionality factor includes;

measuring values of the first measurand at the intake or upstream from the intake during a given time period;

determining from said values of the first measurand a load of substances to be degraded that has been added to the process during the given time period;

measuring values of the third measurand at the discharge during the given time period, determining from said values of the third measurand a load of substances to be degraded that leaves the process by the discharge in this time period from said measuring values of the third measurand;

determining deviation values which represent a deviation from the load of substances to be degraded added to the process from the load of substances to be degraded that leave the process at the discharge; and

using the deviation values and values for the air volume introduced into the container in the given time period for adapting the proportionality factor.

19. A device comprising:

an aerator configured to supply air into a liquid volume in a container, said container having a fluid inlet and a fluid discharge;

an air mass flow controller configured to control the aerator;

a first measuring unit serving to measure values of a first measurand representing a load of one or several substances to be degraded in the process and found in a settable volume unit of the liquid in the fluid intake, said first measuring unit being arranged in the fluid intake or upstream from the fluid intake; and

an electronic control unit connected with the first measuring unit to receive the measuring values from the first measuring unit, which comprises an operating software configured to;

sequentially determine values of a reference variable to be supplied to the first measuring unit based on the values of the first measurand, said reference variable representing a nominal value of the air volume to be fed into the liquid volume;

sequentially determine values of a regulating variable using both values for the reference variable and sequentially determined values of a process variable, said regulating variable being a variable for the aerator influencing the air volume fed into the liquid volume by means of the aerator, said process variable represents an air volume to be fed into a liquid volume inside a container including a fluid intake and a fluid discharge in a process for treating the liquid;

with a current value for the reference variable being determined by sequentially saving values of the first measurand, or values derived therefrom, in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest value saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=1); and

by using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater or equal 1, and adjusting the aerator by means of the air-mass flow controller;

the values of the first measurand or air requirement values derived from at least one value of the first measurand using a proportionality factor are saved sequentially in the first FIFO memory; and

each air requirement value represents an air volume to be fed into the liquid to degrade the substance load represented by the at least one value of the first measurand.

20. A method to control a process variable in a process using a control unit, the process being conducted in a container, the method comprising the steps of:

measuring values of a first measurand, wherein the values of the first measurand represent a load of one or more substances to be degraded in the process and found in a settable volume unit of liquid in a fluid intake of the container;

sequentially determining values of a reference variable to be supplied to the control unit based on the values of the first measurand;

sequentially determining values of a regulating variable using both values for the reference variable and sequentially determined values of the process variable, wherein the regulating variable represents a variable for an aerator that serves to supply air into the liquid volume of the container and said variable influencing the air volume fed into the liquid volume using the aerator, wherein the process variable represents an air volume to be fed into a liquid volume inside a container including a fluid intake and a fluid discharge in a process for treating the liquid;

determining of a current value for the reference variable by;

sequentially saving values of the first measurand, or values derived therefrom, in a first FIFO memory having a number K of memory locations for saving one value respectively, namely a memory featuring a number K of logically consecutive memory locations (j=i) in such a way that the oldest value saved in the first FIFO memory is saved in a first memory location (j=1) and the value saved last in the first FIFO memory is saved in a final memory location (j=k);

using only the n oldest values saved in the first FIFO memory to determine the current value for the reference variable, with n being a number of values that is smaller than the number K of the values saved in the memory locations of the first FIFO memory and greater than or equal to 1; and

sequentially saving values of a second measurand, or values derived therefrom, in a second FIFO memory having a number N of memory locations for saving one value respectively, namely a memory featuring a number N of logically consecutive memory locations (h=1);

using all the values saved in the second FIFO memory to determine the current value for the reference variable, with N being a number of values that is equal to the number n of the values saved in the first FIFO memory and used for determining the current value of the reference variable; and

adjusting the aerator using the air-mass flow controller using the values of the regulating variable.