基于密度测量的丝光机碱液浓度在线监控系统开发与应用

针对棉织物丝光工艺处理过程中对碱液浓度在线监控与碱回收的需求，首先根据碱液密度-浓度之间的关系特性，设计开发了一种具有ZigBee无线网络通讯功能的智能压差式碱液浓度计。该浓度计测量范围为10~770g/L，可解决车间内多点测量浓度时信号长距离传输过程中的抗干扰问题，并可降低控制系统复杂度与开发成本；通过将该浓度计应用于开发的丝光机碱液浓度在线控制系统中，实现了一定浓度碱液的在线自动配比、混合与输送功能，并达到了碱回收和降低浓碱消耗量的目的。系统在半年期间现场运行结果表明其控制误差可达±5g/L，单位织物丝光浓碱消耗量降低15%以上。

Design and development of alkali consistency online monitoring system for mercerizing machine based on measurement of alkali density

Aiming at the need of online monitoring of alkali consistency and alkali recovery in domestic dyeing and printing industry, an intelligent differential pressure type alkali consistency meter with wireless communication function is developed according to the alkali’s density-consistency characteristics. With this meter, signal interference problems during long distance transmission in multi-point measurement mode can be effectively resolved, and the cost and complexity for developing a relevant control system can be reduced. Then an online alkali consistency monitoring system for mercerizing machine is developed by adopting the mentioned meter. With this system, a certain concentration alkali can be proportioned, mixed and transported to the target automatically, and alkali recovery and the requirement for reducing the consumption of concentrated alkali can be achieved. According to the experimental results, the measurement range of the system is between 0~770g/L while the consistency control accuracy is ±5g/L, and a half-year field operation of the system approves that the concentrated alkali for processing unit fabric can be reduced by more than 15%.