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Display Control Instruments: A Key Link in Industrial Process Automation

Display control instruments, as important components of detection and control products in industrial process automation systems, have left a profound mark and played an irreplaceable role in many industries, including national defense, steel, power, petrochemicals, machinery, pharmaceuticals, textiles, metallurgy, and printing and dyeing. They are like the intelligent eyes and dexterous hands in industrial production, capable of sensitively perceiving changes in various physical quantities and quickly and accurately regulating relevant equipment.

The core functions of display control instruments include comprehensive processing of various signals such as temperature, pressure, liquid level, and speed on – site. First, they accurately collect these signals to ensure the acquisition of the most real and accurate data. Then, they display the data in a clear and intuitive manner. Whether it is through pointer, recording pen, printing, or display screen, operators can clearly understand the current operating status of the system at a glance. In terms of control, they precisely control relevant equipment based on preset parameters and algorithms, ensuring that the entire production process runs stably in accordance with established technological requirements. They also have a remote transmission function, which can transmit the collected data to a remote monitoring center, facilitating managers to grasp the production situation anytime and anywhere. The communication function enables display control instruments to conduct efficient data interaction with other devices, constructing a large – scale and intelligent industrial automation network. The printing function provides convenience for data preservation and analysis, facilitating subsequent traceability and optimization of the production process.

To meet the diverse needs of different industries and scenarios, display control instruments exhibit many remarkable features in technology and design. In terms of anti – interference ability and reliability, they adopt IC chips with higher integration, advanced SMT surface – mount technology, and unique circuit shielding technology. The comprehensive application of these technologies makes display control instruments seem to wear a solid “protective armor,” enabling them to work stably for a long time in an electromagnetic – interference environment and ensuring the accuracy of data and the reliability of control. Their universal input jumper settings are highly innovative. Each instrument can easily achieve input of various indexing numbers, standard signals, remote – transmission pressure signals, and millivolt signals through simple and quick parameter settings, greatly improving the instrument’s versatility and enabling it to adapt to complex and changeable industrial environments. The modular universal circuit structure is also a major highlight. Through simple module combinations, various functions of the instrument can be transformed, from basic measurement and display functions to complex control and communication functions, which can be flexibly adjusted according to actual needs, significantly enhancing the instrument’s versatility and flexibility.

In terms of calibration, display control instruments adopt a microcomputer – controlled full – automatic digital calibration system, abandoning the traditional potentiometer adjustment method. This advanced calibration system not only improves the accuracy and efficiency of calibration but also reduces errors and instability factors caused by manual adjustment. Their appearance design also fully considers aesthetics and practicality, with a variety of appearance structures and sizes available, enabling perfect integration with different industrial devices and operating environments. Both the entire machine and the movement assembly adopt a snap – in structure. This ingenious design makes maintenance and disassembly extremely convenient, greatly reducing equipment maintenance costs and downtime. In terms of power supply selection, display control instruments are also very flexible. They can choose conventional AC 220V, 50/60HZ power supply, 90 – 265V switching power supply, or DC 24V power supply to meet the power supply requirements of different occasions. In addition, they can be equipped with RS – 232/RS – 485 or RS – 422 communication interfaces, facilitating connection with the host computer to form a more powerful control system and achieving a higher level of automated control and management.

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A Comprehensive Analysis of Control Instruments

In modern industrial production and numerous technological application scenarios, control instruments play an extremely crucial role. They are like precise commanders, regulating various complex systems in an orderly manner. Essentially, a control instrument is a device that automatically controls the controlled variables. It accurately compares the measured signals with the set values, calculates based on specific control laws for the deviation signals, and finally outputs the calculation results as specified signals to achieve precise control over the entire process.

Control instruments come in a wide variety of classifications. In terms of energy sources, there are electric, pneumatic, and hydraulic control instruments. Electric control instruments are widely used in the industrial field due to their high efficiency, precision, and ease of integration with modern electrical systems. Pneumatic control instruments, on the other hand, hold a certain market share because of their safety in environments with high explosion – proof requirements and their adaptability to certain special processes. Hydraulic control instruments play an important role in situations where high torque and high – power output are required. Structurally, they can be divided into base – mounted and unit – combined types. All components of base – mounted control instruments are closely connected through an inseparable mechanical structure and are installed in a single enclosure. Just one instrument can handle a series of tasks such as measurement, recording, and control in simple automation systems. Common examples include temperature controllers and pressure controllers. They are compact in structure and concentrated in function, suitable for relatively independent small – scale systems with less complex control requirements. Unit – combined controllers, however, consist of multiple units such as 变送 (transmitter), regulation, operation, display, and execution. Standard signals are used for communication between these units. This modular design allows for flexible combination of various units according to different needs, enabling the construction of control systems of different complexities. As a result, it greatly improves the versatility and flexibility of control instruments, and is widely applied in large – scale industrial automation production lines and complex industrial process control systems.

There are various sophisticated control laws embedded within control instruments, which are the core of achieving precise control. In the field of chemical automation, common basic control laws include proportional action (P), integral action (I), and derivative action (D). In proportional action, the change in the controller’s output is in strict proportion to the change in the deviation. The larger the deviation, the stronger the control action.

In situations such as liquid – level control where strict elimination of residual deviation is not required, proportional action alone can achieve good control results. In integral action, the rate of change of the controller’s output is proportional to the deviation. The longer the deviation exists, the stronger the control action. It is mainly used in situations where high requirements for eliminating residual deviation are imposed. However, it is rarely used alone in the chemical industry. In derivative action, the controller’s output is proportional to the rate of change of the deviation. It can excel in situations where accelerating the regulation process is necessary, and is also seldom used alone in the chemical industry. In practical applications, control laws are often a clever combination of proportional action and other actions. For example, for the control of general parameters such as flow rate, proportional – integral action (PI) is commonly used. It combines the advantages of proportional action’s rapid response to deviation and integral action’s elimination of residual deviation. For objects with large inertia, such as temperature and composition control, proportional – integral – derivative action (PID) is usually adopted. This combination can more comprehensively deal with complex control situations and achieve more accurate and efficient control.

Control instruments are widely applied in industrial production and many other industries. They can cooperate seamlessly with various sensors and transmitters to achieve accurate measurement and clear display of physical quantities such as temperature, pressure, liquid level, volume, and force. Moreover, they can coordinate with various actuators to perform PID regulation and control on electric heating equipment, electromagnetic, and electric valves. They also have alarm control and data acquisition functions. In the petrochemical industry, the precise control of key parameters such as reaction temperature and pressure by control instruments is directly related to product quality and the safety and stability of the production process. In the pharmaceutical industry, they ensure the accuracy of raw material ratios during drug production and the precision of finished product packaging dosages, safeguarding drug quality and patient safety. In the food processing industry, they are used for accurate metering of ingredients and finished products, ensuring strict compliance with food quality and safety standards. From large – scale industrial production to fine – scale pharmaceutical and food processing, control instruments are everywhere, providing solid support for the efficient and stable operation of various industries.

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Dust removal equipment controller industry development trend and prospect

In the context of the increasing global environmental awareness and the continuous expansion of industrial production scale, the market demand for dust removal equipment is growing. As the core control component of dust removal equipment, the dust removal equipment controller industry has also ushered in new development opportunities and challenges. In-depth analysis of the development trend of this industry is of great significance for relevant enterprises to grasp the market dynamics and formulate reasonable development strategies.

Technological innovation promotes product upgrading
Deep integration of intelligent control technology

With the rapid development of cutting-edge technologies such as the Internet of Things, big data and artificial intelligence, intelligence has become an important development trend in the dust removal equipment controller industry. In the future, the dust removal equipment controller will be more intelligent, able to collect and analyze a large number of data related to the operation of the dust removal system in real time, such as dust concentration, equipment pressure, temperature, valve switching status, etc. Through the deep mining and analysis of these data, the controller can use artificial intelligence algorithms to automatically optimize the cleaning strategy and achieve accurate control of the dust removal equipment. For example, according to the generation law and change trend of dust under different working conditions, the pulse width, pulse interval and cleaning cycle are intelligently adjusted, so that the dust removal equipment is always maintained in the best operating state, which not only improves the dust removal efficiency, but also effectively reduces energy consumption and equipment wear. At the same time, the intelligent controller can also achieve remote monitoring and fault diagnosis functions, operators can check the operating status of the equipment anytime and anywhere through mobile phones, computers and other terminal equipment, when the equipment is abnormal, the controller can quickly issue an alarm, and through data analysis to locate the cause of the fault, to provide accurate maintenance suggestions for maintenance personnel. Greatly improve the timeliness and convenience of equipment maintenance.

Application of high precision sensor technology

The application of high precision sensor will further improve the performance of dust removal equipment controller. In the dust removal system, the accurate measurement of dust concentration, pressure, temperature and other parameters is very important for the controller to achieve accurate control. The new high-precision dust concentration sensor can more accurately detect the content of fine dust particles in the air, provide more accurate dust concentration data for the controller, so that it can adjust the cleaning force and frequency according to the actual dust pollution situation. At the same time, the high-precision pressure sensor and temperature sensor can monitor the pressure and temperature changes inside the dust removal equipment in real time, and help the controller to timely find abnormal conditions during the operation of the equipment, such as pressure rise caused by the blockage of the filter bag, equipment overheating and other problems, and take appropriate measures to adjust and warn, to ensure the safe and stable operation of the dust removal equipment.

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Timer controller：Cleaning Control Function

Main Functions

Cleaning Control Function

Cleaning control is one of the core functions of the dust removal equipment controller. By accurately setting parameters such as pulse width, pulse interval, and cycle interval, the controller can achieve efficient cleaning of filter bags. For example, the pulse width determines the duration of each blow of the electromagnetic pulse valve. An appropriate pulse width ensures that the compressed air effectively removes dust from the surface of the filter bags without causing excessive impact on the filter bags. The pulse interval controls the time interval between adjacent blows. A reasonable pulse interval allows the filter bags to restore their filtering performance sufficiently between two blows, thus ensuring the stable operation of the dust collector.

Adjustable Output Channel Function

Dust removal equipment of different scales has different requirements for the number of output channels of the controller. The dust removal equipment controller has the function of adjustable output channels. Operators can use the “+” and “-” buttons of the universal dial switch to set the number of output channels of the controller according to actual needs. This function enables the controller to adapt to various dust removal equipment of different specifications, greatly improving its versatility and flexibility. For instance, a small dust collector may only require a small number of output channels to control a small number of electromagnetic pulse valves, while a large dust removal system may need a large number of output channels to achieve precise control of a large number of pulse valves.

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Dust Removal Equipment Controller: Principles, Functions and Technical Indicators

In modern industrial production, the widespread application of dust removal equipment is crucial for reducing environmental pollution, ensuring the safety of the production environment, and improving production efficiency. As the core component of the dust removal system, the performance of the dust removal equipment controller directly affects the operation of dust removal equipment. This article will delve into the working principles, main functions, and key technical indicators of the dust removal equipment controller.

Working Principles

The dust removal equipment controller uses an industrial-grade chip as its control core and coordinates the operation of various components through precise logical operations. Its working process mainly revolves around the control of electromagnetic pulse valves. There are clear setting marks on the printed circuit board, facilitating operators to set the parameters of the controller according to actual needs. After the controller is started, electrical signals are output from each output terminal, which are used to control the opening of electromagnetic pulse valves. Once the electromagnetic pulse valves open, compressed air is blown to clean the filter bags. Meanwhile, the controller is equipped with manual operation buttons. During equipment debugging and the initial operation stage, operators can use these buttons for convenient operation to ensure the normal operation of the equipment.

Take the pulse bag dust collector as an example. While filtering dust-laden gas, the dust collector conducts blow cleaning simultaneously. The dust removal controller outputs electrical signals in sequence to control the pulse valves to blow and clean one by one according to the preset pulse width and pulse interval. During this process, the controller monitors the working status of each output point in real time and displays it through the working indication device, enabling operators to quickly judge the equipment operation status.

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Smart Sensors Empower Electromagnetic Pulse Valves, Driving Digital Upgrades in Dust Removal Systems
Advancing industrial intelligence is transforming traditional dust removal equipment through technological innovation. Take the ASCO 353 series pulse valve as an example – its integration with digital sensors provides real-time monitoring and intelligent control solutions for dust systems.

Intelligent Monitoring Architecture
This system combines dust concentration meters, differential pressure transmitters, and air tank pressure sensors to collect critical data like filter bag resistance, jetting pressure, and air flow. For instance, differential pressure sensors trigger automatic jetting when resistance thresholds are exceeded, while air tank sensors ensure stable jetting pressure to prevent cleaning failures.

Digital Management Advantages

Predictive Maintenance: Analyzing diaphragm cycle frequency and response times predicts component wear and blockages, minimizing downtime.

Energy Optimization: Dynamic parameter adjustments based on real-time pressure reduce compressed air waste while maintaining cleaning effectiveness.

Remote Control: Cloud-based platforms enable remote status monitoring and cycle adjustments for cross-regional management.

Case Study
A steel plant deploying smart pulse valves in its sintering machine dust system achieved:

30% reduction in collector resistance fluctuations

25% decrease in jetting frequency

Annual energy cost savings of ¥180,000
Stable dust emissions below 10mg/m³ were also maintained, supported by automated operational reports for process optimization.

Looking ahead, IoT integration will drive pulse valves toward “adaptive cleaning” through AI algorithms dynamically matching changing operating conditions, propelling industrial dust removal toward higher efficiency, lower carbon footprint, and unmanned operation.
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Performance Comparison and Selection Guide for Submerged vs. Right-Angle Pulse Valves
Submerged and right-angle electromagnetic pulse valves represent two primary designs in pulse bag dust collectors, with structural differences directly affecting cleaning efficiency and energy consumption.

Structural & Operational Characteristics
Submerged valves feature a fully integrated design flush with the air tank interior. Their dual-section diaphragm uses pressure differentials to control opening/closing, enabling direct airflow to filter bags with faster response and stronger jetting. Right-angle valves use perpendicular inlet/outlet configurations with standalone mounting, offering simplicity and ease of maintenance but slightly higher resistance due to 90° airflow turns.

Performance Benchmarks

Jetting Efficiency: Submerged valves deliver 20% higher airflow than equivalent right-angle models, maintaining stability even at low pressures (0.3MPa).

Energy Savings: Their rapid actuation reduces jetting time, achieving 15%+ compressed air savings through optimized diaphragm design.

Installation Flexibility: Right-angle valves support threaded/flanged connections for versatile layouts, while submerged valves require custom air tank interfaces ideal for new installations or large-scale retrofits.

Selection Recommendations

Unstable Pressure Environments: Prioritize submerged valves with their 0.3-0.8MPa pressure tolerance.

Space Constraints: Right-angle valves’ compact design suits small systems or renovation projects.

Long-Term 经济性: Submerged valves’ energy efficiency and extended diaphragm life (2+ million cycles) make them ideal for continuous industrial operations.
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Core Principles and Key Role of Dust Removal Electromagnetic Pulse Valves

In modern industrial dust removal systems, electromagnetic pulse valves serve as the “heart components” of pulse bag filters. Their performance directly impacts equipment efficiency and service life. As intelligent switches for compressed air, these valves precisely control filter bag cleaning cycles through commands from pulse controllers, ensuring stable system resistance and optimal operation.

The working principle relies on differential pressure control: when energized, the electromagnetic force moves the spool to open the pressure relief port. This rapidly drops the pressure in the rear chamber, lifting the diaphragm via compressed air for instantaneous jetting. After power-off, the spring resets the spool to close the port, restoring rear chamber pressure and reclosing the diaphragm. This process demands precise diaphragm design and airflow engineering to achieve sub-100ms response times and stable jetting pressure.

Typical technical specifications include aluminum alloy bodies for -10°C to 55°C environments, 0.4-0.7MPa operating pressure, and compatibility with AC220V/DC24V power supplies. The diaphragm must resist wear and corrosion, with high-quality models offering over 1 million jetting cycles.

Selection criteria depend on dust collector size, air source conditions, and cleaning frequency. Right-angle valves (90° inlet/outlet) suit small-to-medium systems with vertical installations, while submerged valves (integrated into air tanks) provide lower resistance and higher efficiency for fluctuating air pressure scenarios.

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Structural Classification and Filtration Modes of Dust Removal Filter Bags
The structural design of dust removal filter bags directly impacts their filtration efficiency and applicability. Based on cross-sectional shape, they can be categorized as:

Round filter bags: The most common type, cylindrical in shape, specified by diameter × length (D×L). Their simple structure ensures uniform airflow distribution, suitable for most standard dust collectors.

Flat filter bags: Including rectangular and trapezoidal shapes, specified by perimeter × length (P×L). Flat bags maximize filtration area in limited spaces, improving efficiency in compact dust removal systems.

Special-shaped filter bags: Unconventional forms like star or polygonal shapes, designed for unique operational needs, with specifications based on specific structural parameters.

In terms of filtration modes, filter bags can be internally filtered or externally filtered:

Internally filtered bags: Dusty gas enters from the inside, and dust is trapped on the inner surface. This design facilitates cleaning but requires regular maintenance to prevent internal dust accumulation.

Externally filtered bags: Dusty gas enters from the outside, with dust adhering to the outer surface. Often paired with pulse-jet cleaning systems, external filtration offers more thorough dust removal, ideal for high-concentration dust environments.

Moreover, material and structural design must work in tandem. For instance, needle-punched felt or flocked filter fabrics, with their dense pore structures, can initiate sieving early in the filtration process without relying solely on dust layer formation. This design enhances efficiency, particularly for capturing fine, dry, non-fibrous dust.

Each structural type and filtration mode has its advantages and limitations. Selection should consider factors such as dust characteristics, equipment space, and cleaning methods to ensure the efficient and stable operation of dust removal systems.
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Classification and Innovative Application Trends of Dust Filter Bags

Dust filter bags can be classified in various ways, with different types differing in structure and function to adapt to complex industrial demands.

In terms of shape, filter bags are mainly divided into three categories: circular, flat, and irregular. Circular filter bags have a simple structure and wide application, specified by diameter × length. Flat filter bags (e.g., rectangular, trapezoidal) maximize filtration area within limited space, enhancing dust removal efficiency. Irregular filter bags are custom-designed to meet specialized requirements.

By filtration method, filter bags can be categorized into internal and external filtration types. In internal filtration, dusty gas is filtered from the inside, with dust adhering to the inner surface of the bag, suitable for low-viscosity dust. In external filtration, gas is filtered from the outside, with dust accumulating on the outer surface, facilitating ash cleaning and commonly used in high-concentration dust environments.

With technological advancements, innovative applications of filter bags continue to emerge. For example, membrane-coated filter bags enhance the capture of fine particles by combining a PTFE microporous membrane with a base material while maintaining good permeability, becoming a new choice for high-efficiency dust removal. Additionally, “three-proof” (waterproof, oil-proof, anti-static) filter bags perform exceptionally in handling oily, humid, or flammable dust, widely used in steel, power, and other industries.

In the future, dust filter bags will evolve toward higher efficiency, longer lifespan, and 智能化 (intelligentization). Through material innovation and structural optimization, they will continue to drive the green transformation of industrial sectors.

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Material Selection and Industrial Applications of Dust Filter Bags

The performance of dust filter bags is closely related to their materials. Different materials exhibit significant differences in temperature resistance, corrosion resistance, and filtration efficiency, requiring careful selection based on specific working conditions.

Polyester fiber filter bags are among the most widely used materials. They offer excellent acid and alkali resistance and wear resistance, making them suitable for normal-temperature dust removal in industries such as cement, ceramics, and chemicals. Post-treatment processes (e.g., oil and water repellency, anti-static treatment) can further expand their application range.

For high-temperature environments, glass fiber filter bags excel. They can withstand temperatures up to 260°C and exhibit outstanding alkali resistance, commonly used in fields like carbon black production and ore smelting. However, glass fiber bags have poor flexibility and require care to avoid damage from frequent folding.

In complex chemical environments, PPS (polyphenylene sulfide) filter bags are ideal. They operate stably at 190°C and tolerate sulfur oxides and wet flue gas, making them particularly suitable for power plant boilers and waste incineration. Additionally, P84 filter bags stand out in industries like chemicals and cement due to their high-temperature resistance (below 260°C) and chemical corrosion resistance.

Fumei Si filter bags integrate multiple advantages, including high-temperature resistance (80–230°C), acid and alkali resistance, wear resistance, folding resistance, and easy ash cleaning. They are capable of capturing high-concentration dust and are widely applied in metallurgy, building materials, and other sectors.

Through targeted design, different materials of filter bags can meet the diverse needs of various industries, not only improving dust removal efficiency but also extending equipment lifespan and providing strong support for environmental upgrades in industrial production.

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Core Filtration Mechanisms of Dust Filter Bags

As the core component of bag dust collectors, the efficiency of dust filter bags relies on the synergistic effect of multiple filtration mechanisms. When dusty gas passes through the filter material, dust particles are captured through the following processes:

First is the sieving effect. When the diameter of dust particles exceeds the pores between filter material fibers or the gaps in the dust layer, the particles are directly intercepted on the surface of the filter bag. New filter bags have larger fiber gaps, resulting in insignificant sieving effects initially. However, as the dust layer gradually forms, this effect becomes increasingly prominent, evolving into one of the primary filtration mechanisms.

Next is the inertial impaction effect. For dust particles larger than 1 micron in diameter, high-speed airflow causes them to deviate from the streamline due to inertia, directly colliding with the filter bag fibers and being trapped. This effect is more pronounced at higher gas velocities, but excessive velocity may damage the filter bag and reduce dust removal efficiency.

The diffusion effect primarily targets tiny dust particles (smaller than 0.2 microns). These particles undergo Brownian motion due to collisions with gas molecules, increasing their chance of contacting fibers and being adsorbed. Unlike inertial impaction, the diffusion effect is more significant at lower gas velocities, and finer fibers enhance the trapping efficiency.

Additionally, gravitational sedimentation and electrostatic effects play auxiliary roles. Large, high-density dust particles settle naturally under gravity. When dust and filter bag materials carry opposite charges, the adsorption force increases, improving dust removal efficiency but potentially complicating ash cleaning. Conversely, identical charges reduce adsorption but facilitate dust detachment.

The combined action of these mechanisms enables dust filter bags to efficiently purify air, meeting the environmental protection requirements of various industrial scenarios. Optimizing the material, structure, and gas velocity of filter bags can further enhance their performance, achieving more stable dust removal results.

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