WO2018134451A1 - Control device for water processing installations - Google Patents

Abstract

Control device for water processing installations with a microcontroller core with a specific software adapted to each particular installation and a user interface, with signal input and output modules which receive the signals from various control elements for flow, volumetric consumption, chemical product consumption, operation of the metering systems, physicochemical parameters, and/or device status, and regulate the metering pumps for chemical products and various actuators. The main advantage is that the device is optimized for monitoring and controlling water distribution and purification systems, especially those for metering products added to the water and for measuring the parameters of the water, especially processes that have a limited number of signals to manage.

Description

 CONTROL DEVICE FOR PROCESSING FACILITIES OF

 WATER

The present specification refers, as its title indicates, to a control device for water processing facilities in which water distribution systems are involved.

Field of the Invention

The invention relates to the field of monitoring and control equipment for water distribution and purification systems, especially those dedicated to the dosing of products added to the water and tailored to the water parameters,

Current state of the art

Currently, multiple devices for dosing products in the water are known, such as ios included in patents ES2212592 consisting of an "apparatus for dosing a powder or granulate additive in hydraulic installations, especially swimming pools" and ES2402135 consisting of a "automatic dispenser of chemical products in the form of dry grains, for example for the chlorination of water in a pool", but they are manual equipment, with a fixed dosage adjustable by the user, without measurement of water parameters.

Other facilities, such as the one described in ES2109874 consisting of a "facility for the dosing of foams or additives to a water vein" allow a rudimentary regulation of the product depending on the flow rate, but without greater flexibility. In other cases, as for example in the installation described in WO02076625 consisting of a "method and dosing system for direct injection of active materials for applicators of phytosanitary products" an electronic control center is included, being able to work adapting the dosage of matter activates the reading of a flowmeter and a speed sensor, but without major measurement possibilities, or adjustments by the user, and without providing a remote control.

This lack of flexibility is also found in the system described in patent ES23101 10 consisting of a "system and procedure for control and dosing of anti-fouling and / or dispersant products for desalination plants", with the added drawback of its exclusive application for desalination plants.

Also known are complex systems such as those described in patent ES1096233 consisting of a "water treatment system" and in patent ES1 171510 consisting of a "control unit, modular device and water volume treatment system", but have a great complexity, to foresee too many types of processing, such as electrolysis, dosing, ultraviolet, etc ... which greatly increases its use.

Finally, plants controlled by PLC programmable industrial logic controllers are also known, as for example found in patent ES2397635 consisting of a "compact plant for wastewater treatment", but the high cost of commercial equipment available (PLC) it makes its installation difficult to assume. It is necessary to take into account that these teams are normally oriented to manage a large number of signals with a high capacity for autonomy when controlling processes and consequently making decisions, which does not make them especially suitable for this specific type of process. .

Description of the invention

In order to solve the current problem in the regulation of processes related to water purification and processing, the control device for water processing facilities object of the present invention has been devised, which comprises a microcontroller core with specific software and an interface with the user, with input and output modules of signals through ios which receive the signals from different flow control elements, volumetric consumption, chemical consumption, operation of the systems of dosage, physical-chemical parameters, and / or state of devices, and perform the regulation of the dosing pumps of chemical products and of different actuators, such as valves, motors, pumps and other equipment. It is also equipped with ID identity identifiers that allow you to read labels associated with the products used in the process, allowing you to identify a container with the type of chemical contained, the expiration date of the packaged product, the format of the package and the quantity contained and the batch number, among other parameters.

It is also equipped with communication means, both wired and wireless, enabling remote access for monitoring, control and programming, as well as the connection of external user interfaces. The control device for water processing facilities is a device whose fundamental objective is to monitor and control processes that have a limited number of signals to manage since the number of equipment involved capable of generating and receiving signals is reduced. This control device for water processing facilities is provided so that, in a generic way, it serves to perform the control work in any water processing facility, being provided with a plurality of input and output modules, allowing adapt to the particularities of each installation. The operation of this control device, as already mentioned above, is based on the regulation of metering pumps of chemical products and of different actuators, such as valves, motors, pumps and other equipment, depending on various signals coming from different elements of flow control, volumetric consumption, chemical consumption, operation of the dosing systems, physical-chemical parameters, and / or device status.

The specific operation of the interaction between the different elements that make up the control device will be defined in each particular case of water processing installation by means of the specific software and the particular parameters of each installation. The basis of its operation is that:

- It is capable of operating autonomously based on a first level programming that takes into account the status of the different input signals.

- You can establish communication with other equipment to transmit the data received and stored from the input signals, as well as the effects of first level programming that have generated a modification of the output signals.

- The transmitted data is analyzed by a second level programming, or human operators, who can transmit specific orders to the control device and activate output signals or make changes to the first level programming.

Advantages of the invention

This control device for water processing facilities presented provides multiple advantages over the equipment currently available, the most important being optimized for monitoring and control functions for water distribution and purification systems, especially those dedicated to the dosing of products added to the water and to the measure of the water parameters, especially processes that have a limited number of signals to manage since the number of equipment involved capable of generating and receiving signals is reduced.

Another important advantage is that it has a significantly lower economic cost compared to the equipment currently available in the market that could offer the same benefits, thanks to the fact that the actuators modulate in their possible configurations and do not include more components than necessary for each type of application.

It is important to note that the specific operation procedure of this control device increases the level of control of the facilities by means of monitoring of its status and the possibility of acting based on a program defined on several levels in order to modulate its operation and achieve the required levels of effectiveness. The equipment present in the processes that are intended to be monitored and controlled, normally have a certain degree of automatism to prevent malfunctions and it is quite common to assume a degree of drift in the systems because they do not consider their operation to be critical. To avoid drift in the process equipment it is necessary to carry out a periodic check that is normally necessary to be carried out by specialized personnel. In our case this task is greatly facilitated.

Another advantage of the present invention is that it greatly improves the operating effectiveness of the dosing equipment. The control of the dosage in the current equipment is carried out by means of the direct control and monitoring of the equipment, as well as by measuring the concentration of the chemical more or less periodically. There are also equipment that uses measuring probes to know exactly the concentration of chemicals in the environment. These devices are usually relatively expensive, so in simple installations they are not usually installed due to their cost and the complexity involved in their installation.

We must also highlight that the control device does not need to make modifications to the facilities to be monitored and can be used for any pre-existing dosing equipment without determining the manufacturer, model or characteristics thereof. The control device performs an indirect control of the dosage of the chemical by taking into account the established dosing parameters, the regulation of the dosing equipment and the consumption of the chemical. The real-time control of these parameters guarantees a control of the effectiveness of the dosage. It can be used in conjunction with any previously installed control or monitoring element, thus complementing the level of monitoring and control of the installation.

It is also another advantage to highlight the possibility of connecting the control device with other remote control elements, which allows programming adjustments when necessary without the need to move personnel to perform these operations. It also allows the generation of alarms so that in If necessary, personnel move and carry out the necessary maintenance operations, thus facilitating the remote control of the installation and reducing the necessary personnel for its monitoring. On the other hand it is important to note that this control device guarantees the safety of The dosage of the chemical products, since it has two levels of programming: a basic level takes control in real time of the different input and output signals, based on these signals verifies the proper functioning of the installation and through the module Remote communication can warn of installation failures to be corrected. The second level of programming analyzes trends, historical data, relationship between the data monitored by the control device and ios that other equipment can generate, etc. The second level complements the basic level of security provided by the control device. It must be taken into account that the operation of the control device is completely autonomous, so it would not be strictly necessary for the operation of the equipment in the presence of the second level of programming.

Another important advantage is that a module of recognition of the chemical products used has been implemented to ensure that the specific products of each application are used and at the determined doses. Once the product to be used and the doses have been determined, the control device automatically adjusts the dosing parameters, controls the use of that product, preventing other unspecified products from being used by mistake. It is also important to highlight that this control device has a large plurality of input and output modules, providing a universal application to any type of water processing facilities using the same device, defining the interaction between the modules and the operating parameters specific to each installation using the specific custom software of each installation.

Finally, it should be noted that this control device reduces the operating cost of the facilities, since the control of the effectiveness of the dosage, (that is the minimum amount necessary), and the safety of the dosage, (avoiding events of overdosing, lack of dosing and / or dosing of products unauthorized,) allows to reduce the cost of managing the facilities. Thus, greater control means greater savings, since complex and expensive equipment is not necessary since the control device object of the invention allows it to be carried out in a simple and economical way.

Description of the figures

To better understand the object of the present invention, a preferred practical embodiment has been shown in the attached drawing! of a control device for water processing facilities. In said plane, Figure 1 shows a generic block diagram of the invention.

Preferred Embodiment of the Invention

The control device for water processing facilities object of the present invention basically comprises, as can be seen in the attached drawing, a microcontroller core (1), provided with specific software (2), a user interface module (3), one or more signal input modules (4) associated with control elements (5), one or more signal output modules (6) associated with actuators (7), one or more ID reader modules (8), at least one communications module (10), which is associated with a wireless communications interface (1 1) and a wired communications interface (12), and a power supply (16).

The microcontroller core (1) is based on programmable logic programmer structures, either through microcontroller structures in embedded systems or through industrial PLCs, with proprietary or free systems. Said microcontroller core (1) stores the specific software (2) that manages the input (4) and signal output (6), serves as support and control of the communications module (10) and supports the user interface (3) .

This control device for water processing facilities is intended so that, in a generic way, it serves to perform the control tasks in any water processing facility, being provided with a plurality of input and output modules, allowing to adapt to the particularities of each installation. The operation of this control device, as already mentioned above, is based on the regulation of metering pumps of chemical products and of different actuators, such as valves, motors, pumps and other equipment, depending on various signals coming from different elements of flow control, volumetric consumption, chemical consumption, operation of the dosing systems, physical-chemical parameters, and / or device status. The specific operation of the interaction between the different elements that make up the control device will be defined in each particular case of water processing installation by means of the specific software (2) of the microcontroller core (1) and the particular parameters of each installation included in said specific software (2).

For programming the microcontroller core (1), in the case of microcontrollers in embedded systems, high-level languages such as C, Assembler, Basic, with or without visual programming environment can be used. In the case of PLCs, each manufacturer's own programming software based on Ladder (L) diagrams, function block diagrams (FBD) or sequential function chart (SFC) -GRAFCET or OPEN source SW will be used in case of using PLCs based on OPEN Hardware technologies.

 The programming recorded in the microcontroller core (1) may be modified at any time in person or remotely. The specific software (2) will have a graphical interface in which it will be possible to make the necessary adjustments to manage the different signals in the most intuitive way possible.

The input (4) and signal output (6) modules are the electronic components that provide a link between the microcontroller core (1) and the existing external devices in e! process. Through these modules the acquisition of process data takes place or the command or control signals of the external process equipment are generated.

These modules have on the one hand the mission of facilitating the connection operations of the different elements and additionally protecting and isolating the control device from the external elements to which it is connected. The signal input module (s) (4) accept analog and / or digital input signals, and are connected to control elements (5), which can be flow control or volumetric consumption elements, control elements for chemical product, control elements of the operation of the dosing systems, physical-chemical parameter measurement probes, and / or device status sensors using discrete variables.

Flow control or volumetric consumption elements normally generate signals of the following type: pulse emitter type reed (potential free contact), electric opto emitter or inductive type pulses. They can also emit analog or digital signals. In both cases the signals generated are proportional to the volume of water that has circulated through the equipment.

The chemical consumption control elements can be level buoys, differential pressure control elements, capacitive type meters, ultrasonic systems or conductive / resistive type levels. Mass control systems can also be used through the use of scales that record pressure variations due to the chemical content. All of the above elements can generate discontinuous or continuous signals that can be used to evaluate the consumption of chemical over time.

The control elements of the operation of the dosing equipment can be used to monitor the effectiveness of the process, since the dosing equipment can generate signals directly or by other types of coupled sensors, such as injection detectors.

With regard to physical-chemical parameter measurement probes, they usually require control elements that decode the electrical signals generated by the probe and relate it to the value of a specific physical-chemical parameter such as: temperature, pH , conductivity, 02 dissolved, redox potential, Ion Ci, Ion Ca, Ion Mg, Ion N03, hardness, turbidity, residual of biocidal products or any other chemical compound or physical quantity for which there is a specific probe. There are probes that generate standardized analog signals that can be connected directly to the control device, but others need an additional element to decode the signal. These decoders / controllers have the possibility of generating standardized analog signals proportional to the measured physical-chemical parameter, so it would be possible to connect the control device easily to said devices.

The status sensors of devices by means of discrete variables can be: level sensors, valves, motors, pushbuttons ... in short, any element for which it is possible to define its status digitally as on or off, 0 - 1, etc. .

The output modules or modules (6) provide analog and / or digital signals and are connected to actuators (7), which can be:

As for the chemical dosing pumps, there are different ways of regulating the dosing pumps, from the most basic ones that can be controlled by a digital power regulation system, to more complex equipment that work with pulse signals, signals digital, etc The control device, based on the basic programming established and the orders by remote access that can be received from an operator or from the second level programming, will adjust the control values of the dosing pumps to ensure an effective dosage of the chemical products .

Referring to the system actuators, an actuator is able to act on different components of the system mainly using digital outputs to establish redundant safety systems. The operation of different actuators {hydraulic or pneumatic cylinders, pneumatic rotary actuators, electric actuators, solenoid-based electromagnetic actuators, piezoelectric actuators), motors, or the opening and closing of all types of valves can be controlled.

Both the input signals (5) and the output signals (6) can be indistinctly of any of the following types of signals: one

The ID reader module (8) accept labels (9) associated with the products used in the process. This feature can be activated independently of the normal operation of the control device to be used with a series of restricted products from certain manufacturers.

The identification of the products used by the control device is done through the use of labels (9) with specific codes that are uniquely associated with each type of product. These codes of the labels (9) will allow to identify a container with:

The type of chemical contained,

 - the expiration date of the packaged product,

 the format of the container and the quantity contained,

 the number of ote.

In this way the control device can perform the following functions:

Adjust the dosage automatically to the selected product. Perform the dosage monitoring based on those specifications,

- Control the use of unauthorized products that do not meet the approved quality standards.

 Avoid the use of non-compliant, expired product or fill containers with products from other manufacturers.

These codes can be presented in various ways on the labels (9) of the product packages: - By alphanumeric codes that can be entered into the control device manually by means of the integrated user interface (3) or an interface device external user (14).

 Through an optical reader of QR codes or barcodes.

 - Through an Auto ID system such as an RFID reader.

Once the product code has been introduced to the control device, it processes it to validate its use. If the validation is negative, it will not authorize its use, it will block the system and generate an alarm. The wireless communications interface (1 1) can be of the type GSM, GPRS, EDGE, SMS, WiFi, Biuetootb, WLAN, or a combination of them. The wired communications interface (12) can be Ethernet, RJ45, RS-232, RS-485, USB or a combination of them. The wireless communications interface (1 1) and the wired communications interface (12) allow connection with a remote access device for maintenance and control (13), and / or with an external user interface device (14).

The user interface module (3) and the external user interface equipment (14) comprise data entry and reading elements, chosen from the group consisting of keyboard, roulette, regulator, rotary encoders, screens and touch screens.

It is also provided that the control device for water processing facilities has extension means (19), which will favor the incorporation of new modules or inérerces, or the modification of existing ones, to adapt it to its operation with other types of analogue and digital signals, communication protocols, and ID protocols or interfaces. The power supply (16) allows the connection of an AC adapter for the mains (17), a rechargeable battery module (18), or a combination of both.

This control device for water processing facilities uses a characteristic operating procedure comprising:

A first stage of autonomous operation based on a first level programming that takes into account the status of the different input signals,

 - a second stage of communication with other equipment to transmit the data received and stored from the input signals, as well as the effects of first level programming that have generated a modification of the output signals, and

 a third stage of analysis of the data transmitted by a second-level programming or by human operators, which may, where appropriate, transmit specific orders to the control device and activate output signals or make changes in the first-level programming.

This control device is of special use in those processes in which water distribution facilities with at least one chemical dosing equipment consisting of a dosing pump and a container containing said product are involved, such as may exist in Different sectors: industrial, human consumption, food industry, livestock, agriculture, energy sector, and managers of large-scale storage and distribution systems.

The person skilled in the art will readily understand that he can combine characteristics of different embodiments with characteristics of other possible embodiments, provided that such combination is technically possible. All information referring to examples or embodiments is part of the description of the invention.

Claims

1 - Control device for water processing facilities comprising: - a user interface module (3),  - one or more signal input modules (4) associated with control elements (5),  - one or more signal output modules (6) associated with actuators (7),  - at least one communication module (10), which is associated with a wireless communications interface (1 1) and a wired communications interface (1 2), and  - a power supply (16), wherein the control device is characterized in that it comprises: - a microcontroller core (1), equipped with specific software (2) to manage the one or several signal input modules (4) and the one or several signal output modules (6), and which serves as support and control of the communications module (10) and supports the user interface (3), and - one or more ID reader modules (8) suitable for labels (9) associated with the products used in the process, these labels (9) being chosen from the group consisting of FID, QR code, bar code or a combination of they. 2 - Control device for water processing facilities, according to claim 1, characterized in that the labels (9) comprise specific codes uniquely associated with each type of product, wherein these specific codes allow identifying a product with: type of chemical content, the expiration date of the packaged product, the format of! container and quantity contained, and  - the lot number. 3 - Control device for water processing facilities, according to the preceding claim, characterized in that the signal input module (s) (4) are suitable for analog and / or digital input signals, and are connected to control elements (5), chosen from the group consisting of: - control elements of cauda! or volumetric consumption, chosen from! subgroup consisting of: reed type pulse emitters, opto electric emitters or inductive type pulses,  chemical consumption control elements, chosen from the subgroup consisting of scales, level buoys, differential pressure sensors, capacitive type meters, ultrasonic devices or conductive / resistive type levels,  - control elements of the operation of the dosing equipment, chosen from the subgroup formed by directly generated signals or injection detectors, - physical-chemical parameter measurement probes, chosen from the subgroup formed by temperature, pH, conductivity, 02 dissolved, redox potential, Ion C !, Ion Ca, Ion Mg, Ion N0 ₃ , hardness, turbidity and residual biocidal products, - device status sensors using discrete variables, chosen from the subgroup consisting of level sensors, valves, motors and pushbuttons. 4 - Control device for water processing facilities, according to the preceding claims, characterized in that the output signal module (s) (6) are suitable for generating analog and / or digital signals and are connected to actuators ( 7), chosen from the group consisting of chemical dosing pumps, hydraulic or pneumatic cylinders, pneumatic rotary actuators, electric actuators, electromagnetic solenoid-based actuators, piezoelectric actuators, motors and electro-valves. 5 - Control device for water processing facilities, according to the preceding claims, characterized in that the input signals (5) and the Output signals (6) are chosen, in the case of analog signals, from the group consisting of: 0--2G mA current, 4-20 mA, +10 mA, +20 mA, or voltage 0-10 V, 0 -5 V, 0-2 V, +10 V, or, in the case of digital signals, of the group consisting of: relay type, TRIAC type, transistor, discrete, 5 V DC voltage output, 10 V, 12 V or 24 V, alternating voltage output 120 V or 230 V. 6 - Control device for water processing facilities, according to the preceding claims, characterized in that the wireless communications interface (1 1) is chosen from the group consisting of GSM, GPRS, EDGE, SMS, WiFi, Bluetooth, WLAN, or A combination of them. 7 - Control device for water processing facilities, according to the preceding claims, characterized in that the wired communications interface (12) is chosen from the group consisting of Ethernet, RJ45, RS-232, RS-485, USB or a combination from them. 8 - Control device for water processing facilities, according to the preceding claims, characterized in that the wireless communications interface (1 1) and the wired communications interface (12) are suitable for connection with a remote access equipment for maintenance and control (13), and / or with an external user interface equipment (14). 9 - Control device for water processing facilities, according to the preceding claims, characterized in that the power supply (16) is suitable for the connection of an AC adapter for the power grid (17), of a power module rechargeable battery (18), or a combination of both. 10 - Control device for water processing facilities, according to the preceding claims, characterized in that the user interface module (3) and the external user interface equipment (14) comprise elements for entering and reading data, chosen from the group consisting of keyboard, roulette, regulator, rotary encoders, screens and touch screens.