Full-automatic inspection method for coke size fraction

Abstract

The invention discloses a full-automatic coke size fraction inspection method which comprises the following steps: automatically sampling by a sampler, and calculating the sampling times and the sampling interval time according to the number of discharging vehicles, the discharging duration and the total weight of the required sample amount; a forward and reverse rotation belt is used for division treatment, a screened sample enters a secondary collection hopper through a bucket elevator during forward rotation, and a work-separated sample enters a sample collection barrel during reverse rotation; opening the secondary collection hopper to enable the samples to uniformly enter a vibrating screen for screening, enabling the samples screened by the vibrating screen to respectively enter sample collection barrels of various size fractions, arranging an electronic platform scale below each sample collection barrel, and connecting the electronic platform scales with a mass metering system; and the mass metering system automatically reads the weight data of the electronic scale, calculates the coke proportion of each particle fraction according to the total weight added by each particle fraction and the unit weight of each particle fraction, and automatically generates a quality grade according to a preset quality judgment rule. According to the invention, the accuracy and reliability of coke fraction inspection can be improved, the labor intensity is reduced, and the inspection efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of coke physical inspection, in particular to a fully automatic inspection method for coke particle size. Background Art

[0002] Coke is the primary fuel in the blast furnace process. Its particle size and quality directly impact production stability and hot metal costs. Uneven particle size can reduce ironmaking output. In particular, the coke fineness directly affects the air permeability and thermal efficiency of the blast furnace process. Excessive fineness leads to uneven airflow distribution within the blast furnace, increasing coke and energy consumption, and even affecting the furnace's lifespan. Therefore, it is necessary to test the particle size of incoming coke.

[0003] At present, the particle size inspection of coke purchased from the factory is mainly carried out by manual screening (manual screening, vibrating screen), namely: manual screening by manual screening and manual vibrating screen screening. Both screening methods require sampling, which represents the overall inspection results. The following problems exist: 1. There are some factors in manual screening (manual screening, vibrating screen). For example, when manually operating a manual screen, too much material is poured in and the number of back and forth shakes is not enough, which affects the screening rate. When manually operating a vibrating screen, the material is poured in too quickly, and the material accumulates and is screened, which affects the screening rate and causes cascade, etc. 2. There may be operational errors during manual weighing, reading and result calculation, which may affect the accuracy of the test; 3. Manual operations involve significant uncontrollable factors, which may result in data manipulation and tampering with test results. Manual screening is labor-intensive. Each particle size sample weighs 380-450 kilograms and needs to be carried back to the screening site from the sampling site. It also needs to be screened manually one basket at a time. The operation is time-consuming and labor-intensive, affecting the efficiency of coke quality inspection. Summary of the Invention

[0004] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of the present invention is to provide a fully automatic inspection method for coke particle size. The technical solution adopted by the present invention to solve the technical problem is: a fully automatic coke particle size inspection method, comprising the following steps: A sampling machine is installed at the head of the conveyor belt to automatically sample. The sampling times and sampling intervals are calculated based on the number of discharge vehicles, discharge time and the total weight of the required sample volume. The belt is rotated in both forward and reverse directions to process the sample. When rotating in forward direction, the screened sample enters the secondary collecting hopper through the bucket elevator, and when rotating in reverse direction, the screened sample enters the sample collection bucket. Open the secondary collecting hopper to allow the sample to enter the vibrating screen evenly for screening. The sample after screening by the vibrating screen enters the sample collection bucket of each particle size respectively. An electronic scale is set under each sample collection bucket, and the electronic scale is connected to the mass measurement system; The mass measurement system automatically reads the weight data from the electronic scale, calculates the proportion of coke in each particle size based on the total weight of each particle size and the unit weight of each particle size, and automatically generates the quality grade based on the preset quality judgment rules.

[0005] As a further improvement of the present invention: 50 kg of sample is selected from the particle size of >60 mm for compression and wear resistance index test, the 50 kg sample is poured into a rotary drum machine, the drum of the rotary drum machine is rotated 100 times for 4 minutes, and then the sample is released into a mechanical shaking screen, shaken back and forth 15 times, and the sample is collected and weighed separately for the particle size of >40 mm and <10 mm, and the proportion of the particle size of >40 mm and <10 mm is calculated respectively.

[0006] As a further improvement of the present invention: the sampling interval is determined as follows: According to the number of discharge vehicles N, the total discharge time T and the required sample volume W, the sampling interval time Δt = T / (N×k) is calculated, where k is the adjustment coefficient.

[0007] As a further improvement of the present invention: an industrial camera is installed at the sampling machine to collect images of the coke material on the belt in real time; Perform pre-processing and particle size analysis on the collected coke material images to identify the coke particle size and distribution area; If the coke particle size exceeds the set particle size and the distribution area ratio exceeds the set ratio, the distribution area is determined to be an abnormal area, and the sampling frequency of the distribution area is adjusted. The sampling frequency is positively correlated with the degree of abnormality of the distribution area.

[0008] As a further improvement of the present invention, the vibrating screen is connected to an intelligent control system, which automatically adjusts the screen width, frequency and tilt angle of the vibrating screen according to the real-time flow rate and particle size distribution of the coke material.

[0009] As a further improvement of the present invention: the first set portion of the work-point sample is used as a thermal performance sample to detect hot strength, and the second set portion of the work-point sample is used as an analytical sample to test the content of each element.

[0010] As a further improvement of the present invention: the automatic sampling process further comprises: a near infrared spectrometer is installed at the conveyor belt head sampling machine; The spectrum of the coke material is collected at a set time interval and pre-processed to obtain the coke spectrum data; Input the coke spectrum data into the composition analysis model and compare it with the pre-set coke composition range; If the current target component content in the coke deviates from the set standard and the target component has a high degree of influence on the subsequent test results, the sampling strategy adjustment mechanism is triggered: the current target component content is positively correlated with the sampling frequency and sample size of the area where the target component is located.

[0011] As a further improvement of the present invention: the quality measurement system encrypts and stores the inspection data in the blockchain, and uses the blockchain smart contract to realize automatic data verification and automatic execution of results.

[0012] Compared with the prior art, the present invention has the following beneficial effects: The present invention uses fully automated sampling, particle size screening, weighing, result calculation, and quality determination to reduce errors in every step from sampling to result calculation, ensuring that test results more accurately reflect the actual quality of the coke. This solves the problems of existing manual screening that affect test accuracy, increase worker labor intensity, and reduce test efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 Schematic diagram of the process of the fully automatic coke particle size inspection method of the present invention. DETAILED DESCRIPTION

[0014] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0015] In order to solve the technical problems in the prior art, the present invention is further described with reference to the accompanying drawings and embodiments: like Figure 1 As shown, the present invention discloses a fully automatic coke particle size inspection method, comprising the following steps: A sampling machine is installed at the head of the conveyor belt to automatically sample. The sampling times and sampling intervals are calculated based on the number of discharge vehicles, discharge time and the total weight of the required sample volume. The belt is rotated in both forward and reverse directions to process the sample. When rotating in forward direction, the screened sample enters the secondary collecting hopper through the bucket elevator, and when rotating in reverse direction, the screened sample enters the sample collection bucket. Open the secondary collecting hopper to allow the sample to enter the vibrating screen evenly for screening. The sample after screening by the vibrating screen enters the sample collection bucket of each particle size respectively. An electronic scale is set under each sample collection bucket, and the electronic scale is connected to the mass measurement system; The mass measurement system automatically reads the weight data from the electronic scale, calculates the proportion of coke in each particle size based on the total weight of each particle size and the unit weight of each particle size, and automatically generates the quality grade based on the preset quality judgment rules.

[0016] The inspection method of the present invention specifically includes fully automatic sampling, particle size screening, automatic weighing, result calculation, and quality determination. After unloading the coke, it enters the receiving trough. The belt head sampler is used to complete the automatic sampling work during the discharge process, and the samples are stored in the sample collection bucket. After sampling is completed, the sample collection bucket is opened and the sample is divided by a reduction belt (forward and reverse belt). The forward rotation is for screening samples to enter the secondary collection hopper, and the reverse rotation is for work-point samples to enter the sample collection bucket. After the reduction is completed, the secondary collection hopper is opened to allow the samples to enter the vibrating screen evenly for screening. After the screening is completed, the system (mass measurement system) automatically reads the electronic scale weight data and completes the result (the proportion of coke in each particle size) calculation, uploads (the results are uploaded to the corresponding batch), and grade determination (quality determination). During the entire inspection process, the only manual work is to clean the sample collection buckets (work-point sample collection bucket and each particle size sample collection bucket of the vibrating screen) before sampling. Through a fully automatic coke particle size inspection method, the problems of existing manual screening affecting detection accuracy and high labor intensity and low inspection efficiency are solved.

[0017] In some embodiments, the automatic sampling process further comprises: installing a near infrared spectrometer at the conveyor belt head sampling machine; The spectrum of the coke material is collected at a set time interval and pre-processed to obtain the coke spectrum data; Input the coke spectrum data into the composition analysis model and compare it with the pre-set coke composition range; If the current target component content in the coke deviates from the set standard and the target component has a high degree of influence on the subsequent test results, the sampling strategy adjustment mechanism is triggered: the current target component content is positively correlated with the sampling frequency and sample size of the area where the target component is located.

[0018] In some embodiments, the sampling interval is determined as follows: According to the number of discharge vehicles N, the total discharge time T and the required sample volume W, the sampling interval Δt = T / (N×k) is calculated. k is the adjustment factor used to correct the sampling frequency (usually 1.5~2.0) to avoid missed or repeated sampling due to uneven material flow. The number of sampling times is n=N×k, and the single sampling volume is W / (N×k); Sampling was carried out in stratified proportions of 20% for the upper layer, 60% for the middle layer and 20% for the lower layer.

[0019] Implicit processing of W (sample volume): control through single sampling volume n=T / Δt=N×k, W=m×n; m is the single sampling volume. W is satisfied by adjusting m rather than Δt. Keeping Δt stable is more conducive to mechanical execution. The single sampling volume m can be easily accurately controlled by the size of the sampling shovel.

[0020] The formula for Δt essentially controls the temporal distribution of sampling, rather than directly calculating the total sample volume. The role of the sample volume W is to adjust the single sampling volume or the total number of samplings, not the time interval itself. Calculating Δt directly based on W (e.g., Δt = T × (single sampling volume / W)) can result in overly dense or sparse sampling points, failing to ensure temporal representativeness.

[0021] The introduction of the adjustment factor k increases the flexibility of the formula. Different production scenarios and inspection requirements may require different sampling strategies. By adjusting the k value, the sampling interval can be fine-tuned to meet specific needs. For example, for coke product inspections with high quality requirements, the k value can be appropriately reduced, the sampling frequency can be increased, and the accuracy of the inspection results can be improved.

[0022] In some embodiments, 50 kg of sample is selected from the particle size of >60 mm for compression and wear resistance index testing, the 50 kg sample is poured into a tumbler, the drum of the tumbler is rotated 100 times for 4 minutes, and then the sample is released into a mechanical shaker and shaken 15 times back and forth. The sample is collected and weighed separately for the particle size of >40 mm and <10 mm, and the proportion of the particle size of >40 mm and <10 mm is calculated respectively.

[0023] In some embodiments, an industrial camera is installed at the sampling machine to capture images of the coke material on the belt in real time; Perform pre-processing and particle size analysis on the collected coke material images to identify the coke particle size and distribution area; If the coke particle size exceeds the set particle size and the distribution area ratio exceeds the set ratio, the distribution area is determined to be an abnormal area, and the sampling frequency of the distribution area is adjusted. The sampling frequency is positively correlated with the degree of abnormality of the distribution area.

[0024] A normal particle size range is pre-set. When image analysis results show that the coke particle size in a certain area exceeds this range (is significantly larger or smaller), the area is marked as abnormal. The normal particle size range can be determined based on statistical analysis and practical experience. For example, for common coke particle sizes, the normal range is set to 20-80mm. When the proportion of coke particle sizes in a certain area that is larger than 80mm or smaller than 20mm exceeds a certain threshold (such as 10%), the area is identified as abnormal.

[0025] When the image analysis module detects an abnormal area, the control module generates corresponding control instructions based on the location and scope of the abnormal area. The instructions include increasing the sampling frequency of the area. The specific sampling frequency increase factor can be adjusted according to the severity of the abnormality. For example, when the abnormality is mild, the sampling frequency is increased by 1.5 times; when the abnormality is severe, the sampling frequency is increased by 2 times or more.

[0026] After receiving the control command, the sampling execution module adjusts the sampling head's movement speed and sampling interval based on the command content. For example, under normal circumstances, the sampling head samples every 10 seconds. However, upon receiving the command to increase the sampling frequency, the sampling interval is shortened to 5 seconds or less, thereby achieving high-frequency sampling of abnormal areas.

[0027] In some embodiments, the vibrating screen is connected to an intelligent control system, which automatically adjusts the screen width, frequency and tilt angle of the vibrating screen according to the real-time flow rate and particle size distribution of the coke material.

[0028] In some embodiments, the first set portion of the work-point sample is used as a thermal property sample to detect hot strength, and the second set portion of the work-point sample is used as an analytical sample to test the content of each element.

[0029] The present invention solves the problems of existing manual screening affecting detection accuracy and high labor intensity for employees and low inspection efficiency, reduces employee labor intensity, improves the representativeness of coke quality inspection, and reduces employee operation error rate and disputes between supply and demand parties. Example

[0030] The embodiment of the present invention discloses a fully automatic inspection method for coke particle size, which includes fully automatic sampling, particle size screening, automatic weighing, result calculation and quality judgment. After the coke is unloaded from the truck, it enters the receiving trough. The belt head sampler is used to complete the automatic sampling work during the discharge process, and the samples are stored in the sample collection bucket. After the sampling is completed, the sample collection bucket is opened, and the belt is reversed for reduction. The forward rotation is for screening samples to enter the secondary collection bucket, and the reverse rotation is for working samples to enter the sample collection bucket. After the reduction is completed, the secondary collection bucket is opened to allow the sample to enter the vibrating screen evenly for screening. After the screening is completed, the mass counting system automatically reads the weight data of the electronic scale, and completes the calculation of the proportion of coke in each particle size, uploads the results to the corresponding batch and makes quality judgment. During the entire inspection process, manual labor only needs to clean the sample collection bucket before sampling.

[0031] The details are as follows: 1. The fully automatic mechanical inspection method for coke particle size includes: fully automatic sampling, particle size screening, automatic weighing, result calculation and quality determination; 2. After unloading the coke, it enters the receiving trough. The belt head sampling machine is used to complete automatic sampling during the discharge process. The sampling times and sampling intervals are calculated based on the number of discharge vehicles, discharge time and the total weight of the required sample quantity to ensure that the sampling points are evenly distributed in the entire batch of materials and the sampling representativeness is guaranteed. Each time a sample is taken, the sample is stored in a sample collection bucket. After sampling is completed, the sample collection bucket is opened and evenly fed. The sample is divided by the forward and reverse belts. The forward belts are used to convert the sample into a screening sample and then enter the secondary collection bucket (granularity sample collection bucket) through the bucket elevator. The reverse belts are used to convert the sample into a work-grade sample and enter the sample collection bucket. A portion of the work-grade sample is selected as a thermal performance sample to test the hot strength, and the other portion is selected as an analytical sample to test the content of each element. 4. After the reduction is completed, open the secondary hopper (granularity sample hopper) to allow the sample to enter the vibrating screen evenly for screening. The samples from the vibrating screen are respectively put into the sample collection buckets of each particle size. There is an electronic platform scale under each sample collection bucket. The electronic platform scale is connected to the mass meter system, which can automatically upload data without manual reading of the weight of each particle size coke and system entry. 5. After the screening is completed, the total weight system automatically reads the weight data of the electronic scale, and completes the calculation of the results (the proportion of coke in each particle size), uploads the results (uploads the results to the corresponding batch), and judges the grade (quality). The system sets the formula to calculate the proportion of each particle size based on the total weight of each particle size and the unit weight of each particle size, and uploads it to the system. The system judges according to the judgment rules, and classifies them as Grade 1, Grade 2, or unqualified. 6. After the screening, 50 kg of the sample is selected from the particle size of >60 mm for compression and wear resistance test. The 50 kg sample is poured into the drum machine, and the drum of the drum machine is rotated for 100 revolutions for 4 minutes. The sample is released and put into the mechanical shaking screen, shaken back and forth 15 times, and the sample is collected and weighed separately (>40 mm and <10 mm), and the proportion of 40 mm and 10 mm is calculated respectively; 7. After the work sample and wear index results are uploaded (the work sample is tested by the laboratory and the results are uploaded, and the wear index is uploaded by the quality inspection), the system completes the judgment of the entire batch of experiments according to the relevant judgment rules and automatically generates a settlement statement. The finance department settles the accounts based on the settlement statement; 8. During the entire inspection process, workers only need to clean the sample collection buckets for work-level samples and the sample collection buckets for each particle size on the vibrating screen before sampling. The rest of the work process is automatically controlled and completed by the system. Workers only need to regularly check and maintain the equipment, which greatly reduces the labor intensity of workers in screening and improves the efficiency of quality inspection of coke purchased from outside the factory. The coke particle size inspection process and fully automatic mechanical inspection method solve the problems of existing manual screening affecting inspection accuracy and high labor intensity for employees and low inspection efficiency.

[0032] In summary, after reading the present invention document, ordinary technicians in this field can make various other corresponding transformation schemes based on the technical solutions and technical concepts of the present invention without creative mental work, and all of them fall within the scope of protection of the present invention.

Claims

1. A fully automatic coke particle size inspection method, characterized in that: The following steps are involved: A sampling machine is installed at the head of the conveyor belt to automatically sample. The sampling times and sampling intervals are calculated based on the number of discharge vehicles, discharge time and the total weight of the required sample volume. The belt is rotated in both forward and reverse directions to process the sample. When rotating in forward direction, the screened sample enters the secondary collecting hopper through the bucket elevator, and when rotating in reverse direction, the screened sample enters the sample collection bucket. Open the secondary collecting hopper to allow the sample to enter the vibrating screen evenly for screening. The sample after screening by the vibrating screen enters the sample collection bucket of each particle size respectively. An electronic scale is set under each sample collection bucket, and the electronic scale is connected to the mass measurement system; The mass measurement system automatically reads the weight data from the electronic scale, calculates the proportion of coke in each particle size based on the total weight of each particle size and the unit weight of each particle size, and automatically generates the quality grade based on the preset quality judgment rules.

2. A fully automatic coke particle size inspection method according to claim 1, characterized in that: A 50 kg sample was selected from the particle size of >60 mm for compression and wear resistance index test. The 50 kg sample was poured into a rotary drum machine, and the drum of the rotary drum machine was rotated 100 times for 4 minutes. After that, the sample was released into a mechanical shaking screen and shaken 15 times back and forth. The sample was collected and weighed separately for the particle size of >40 mm and <10 mm, and the proportion of the particle size of >40 mm and <10 mm was calculated respectively.

3. A fully automatic coke particle size inspection method according to claim 1, characterized in that: The sampling interval is determined as follows: According to the number of discharge vehicles N, the total discharge time T and the required sample volume W, the sampling interval time Δt = T / (N×k) is calculated, where k is the adjustment coefficient; The number of sampling times is n=N×k, and the single sampling volume is W / (N×k); Sampling was carried out in stratified proportions of 20% for the upper layer, 60% for the middle layer and 20% for the lower layer.

4. A fully automatic coke particle size inspection method according to claim 1, characterized in that: An industrial camera is installed at the sampling machine to collect images of the coke material on the belt in real time; Perform pre-processing and particle size analysis on the collected coke material images to identify the coke particle size and distribution area; If the coke particle size exceeds the set particle size and the distribution area ratio exceeds the set ratio, the distribution area is determined to be an abnormal area, and the sampling frequency of the distribution area is adjusted. The sampling frequency is positively correlated with the degree of abnormality of the distribution area.

5. A fully automatic coke particle size inspection method according to claim 1, characterized in that: The vibrating screen is connected to an intelligent control system, which automatically adjusts the screen width, frequency and inclination angle of the vibrating screen according to the real-time flow rate and particle size distribution of the coke material.

6. A fully automatic coke particle size inspection method according to claim 1, characterized in that: The first set portion of the work-point sample is used as a thermal performance sample to detect the hot strength, and the second set portion of the work-point sample is used as an analytical sample to test the content of each element.

7. A fully automatic coke particle size inspection method according to claim 1, characterized in that: The automatic sampling process also includes: a near-infrared spectrometer is installed at the conveyor belt head sampling machine; The spectrum of the coke material is collected at a set time interval and pre-processed to obtain the coke spectrum data; Input the coke spectrum data into the composition analysis model and compare it with the pre-set coke composition range; If the current target component content in the coke deviates from the set standard and the target component has a high degree of influence on the subsequent test results, the sampling strategy adjustment mechanism is triggered: the current target component content is positively correlated with the sampling frequency and sample size of the area where the target component is located.

8. A fully automatic coke particle size inspection method according to claim 1, characterized in that: The quality control system encrypts and stores the inspection data in the blockchain, and uses blockchain smart contracts to realize automatic data verification and automatic execution of results.

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