Iron removal detection control system for ore crushing based on sensor technology

Abstract

The invention belongs to the technical field of ore crushing processing, and relates to a sensor technology-based iron removal detection control system for ore crushing, which is characterized in that the magnetic field intensity and the rotating speed of an electromagnetic roller are set according to a magnetic intensity distribution field of a target batch of materials collected by a metal detector; the ferromagnetic adsorption load is detected in real time through the pressure sensor array in the ferromagnetic crushed material adsorption process of the electromagnetic roller, when the electromagnetic roller is fully loaded, the scraper iron unloading mechanism is started to clean the ferromagnetic crushed materials adsorbed on the inner wall, and the guide rail grate sieve is triggered to filter out the ferromagnetic crushed materials after cleaning is completed; in the filtering process, the vibration amplitude and the inclination angle of the guide rail grate screen are dynamically adjusted according to the relative material output ratio of the guide rail grate screen, the material separation state of the grate screen is monitored through a visual recognition device, and when qualified ore and ferromagnetic crushed aggregates are recognized to be in a complete separation state, an iron removal stop signal is fed back to a control unit; and the ore iron removal precision and efficiency are improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of ore crushing processing, and relates to an iron removal detection control system for ore crushing based on sensor technology. BACKGROUND

[0002] In the field of ore crushing processing, efficient separation of ferromagnetic impurities is a core link to ensure the safe operation of equipment and the quality of products. If ferromagnetic fragments are mixed into the crushing process, it is easy to cause serious wear and even jamming failure of the crusher, conveying equipment and other equipment, resulting in equipment damage, production interruption and safety accidents. Therefore, it is urgent to improve the precision and efficiency of ore iron removal, reduce energy consumption and equipment maintenance cost, and ensure the safety of production process.

[0003] In the prior art, there are also some related solutions for ore iron removal, for example, a coal mine iron removal method and system based on reflection gray scale disclosed in Chinese Patent No. CN114155192A, which determines the method of ferromagnetic fragments by using gray scale contrast, improves the recognition accuracy of ferromagnetic fragments, and adjusts and controls the power of electromagnet according to the size of ferromagnetic fragment volume, thereby avoiding resource waste while ensuring the efficiency of iron removal.

[0004] Another new method for removing iron from ore containing strong magnetic minerals disclosed in Chinese Patent No. CN101099942B adjusts the parameters of electromagnet by computer to separate the ore, and absorbs the ferromagnetic fragments by the last electromagnet, thereby improving the separation efficiency of ore iron removal.

[0005] The above-mentioned solutions propose some solutions for ore iron removal, but the prior art still has the following limitations, specifically:

[0006] (1) The prior art only analyzes the optical and geometric characteristics of the ore, without considering the influence of the adsorption capacity of the electromagnet and the actual magnetic intensity distribution of the ore, which cannot dynamically adjust according to the actual magnetic needs of the ore, may cause insufficient adsorption in the area with weak magnetism, or excessive adsorption in the area with strong magnetism, affecting the efficiency and accuracy of iron removal.

[0007] (2) The prior art focuses more on the control and adjustment of the iron removal process, but lacks a comprehensive evaluation process of the iron removal effect, and does not set up an effective monitoring and feedback mechanism to evaluate the separation state of qualified ore and ferromagnetic fragments in real time, which leads to the inability to accurately judge whether the iron removal operation achieves the expected effect, and thus it is difficult to continuously optimize and improve the iron removal process, affecting the overall efficiency and quality of the iron removal operation. SUMMARY

[0008] To solve the problems raised in the background art, an iron removal detection control system for ore crushing based on sensor technology is proposed.

[0009] The technical scheme adopted by the present application to solve its technical problems is: the present application provides an iron removal detection control system for ore crushing based on sensor technology, comprising: an electromagnetic metal detection module, an electromagnetic roller adsorption module, an electromagnetic roller cleaning module, a guide rail grizzly filter module and a visual separation feedback module.

[0010] The electromagnetic metal detection module is connected with the electromagnetic roller adsorption module, the electromagnetic roller adsorption module is connected with the electromagnetic roller cleaning module, the electromagnetic roller cleaning module is connected with the guide rail grizzly filter module, and the guide rail grizzly filter module is connected with the visual separation feedback module.

[0011] The electromagnetic metal detection module collects the magnetic intensity distribution field of the target batch of materials according to the built-in metal detector in the feed bin, sets the magnetic field intensity and rotating speed of the downstream electromagnetic roller, and triggers the ferromagnetic fragment adsorption operation of the electromagnetic roller.

[0012] The electromagnetic roller adsorption module detects the ferromagnetic adsorption load in real time through the pressure sensor array arranged on the inner wall of the electromagnetic roller, and when the detected load is higher than the preset full load threshold, the scraper iron unloading mechanism is automatically started to clean the ferromagnetic fragments adsorbed on the inner wall.

[0013] When the detected load is lower than the preset empty load threshold, the electromagnetic roller cleaning module controls the electromagnetic roller to deliver the internal fragments to the guide rail grizzly, and triggers the guide rail grizzly ferromagnetic fragment filtering operation.

[0014] The guide rail grizzly filter module collects the relative material output ratio of the qualified ore discharge port and the ferromagnetic fragment discharge port of the guide rail grizzly in real time, and dynamically adjusts the vibration amplitude and inclination angle of the guide rail grizzly.

[0015] The visual separation feedback module monitors the grizzly material separation state through the visual recognition device arranged above the guide rail grizzly, and when it is identified that the qualified ore and the ferromagnetic fragments are completely separated, it feeds back a stop signal to the control unit.

[0016] Compared with the prior art, the present application has the following beneficial effects:

[0017] (1) The present application collects the magnetic distribution field of the material in real time through the electromagnetic metal detection module, and monitors the roller adsorption load through the pressure sensor array, realizes the dynamic perception of the small ferromagnetic fragment adsorption process, effectively deals with the fluctuation of ore flow and the change of material distribution, improves the adsorption efficiency of ferromagnetic fragments and reduces energy consumption.

[0018] (2) The present application relies on the guide rail grizzly filter module to calculate the output ratio of the qualified ore and the ferromagnetic fragments, dynamically adjusts the vibration amplitude and inclination angle of the guide rail grizzly, realizes the screening of large ferromagnetic fragments, avoids the problems of clogging and leakage caused by the solidification of screen parameters, and improves the iron removal precision and efficiency of the equipment.

[0019] (3)The application combines the guide rail grizzly filter module and the visual separation feedback module, monitors the separation state of qualified ore and ferromagnetic fragments while adjusting the vibration amplitude and inclination angle of the guide rail grizzly, feeds a stop signal to the control unit when the two are completely separated, realizes closed-loop control of the iron removal equipment, and improves the iron removal accuracy and the robustness of the control system. BRIEF DESCRIPTION OF DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0021] Figure 1 It is a schematic diagram of the module connection of the present application.

[0022] Figure 2 It is a logic flow chart for setting the magnetic field strength of the downstream electromagnetic roller in the electromagnetic metal detection module of the present application.

[0023] Figure 3 It is a logic flow chart for obtaining the separation state of the grizzly material in the visual separation feedback module of the present application. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the present application will be described clearly and completely in the following with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0025] Please refer to Figure 1 As shown in the drawings, the iron removal detection control system for ore crushing based on sensor technology provided by the present application comprises an electromagnetic metal detection module, an electromagnetic roller adsorption module, an electromagnetic roller cleaning module, a guide rail grizzly filter module and a visual separation feedback module.

[0026] The electromagnetic metal detection module is connected with the electromagnetic roller adsorption module, the electromagnetic roller adsorption module is connected with the electromagnetic roller cleaning module, the electromagnetic roller cleaning module is connected with the guide rail grizzly filter module, and the guide rail grizzly filter module is connected with the visual separation feedback module.

[0027] The electromagnetic metal detection module collects the magnetic intensity distribution field of the target batch of materials according to the built-in metal detector in the feed bin, sets the magnetic field strength and rotating speed of the downstream electromagnetic roller, and triggers the electromagnetic roller ferromagnetic fragment adsorption operation.

[0028] As a preferred, the magnetic intensity distribution field of the target batch material is obtained by moving the magnetic induction probe of the metal detector along the preset gridded sampling track in the feed bin, and synchronously recording the spatial coordinate parameters and the magnetic intensity values of each sampling point during the movement of the probe.

[0029] Based on the physical arrangement order of the spatial coordinate parameters, the magnetic intensity values are mapped into a two-dimensional discrete intensity distribution matrix with the detection plane of the feed bin as the reference, wherein the matrix rows and columns correspond to the horizontal and vertical coordinates of the sampling points respectively, and the matrix element values correspond to the magnetic intensity values of the sampling points. The two-dimensional discrete intensity distribution matrix is taken as the magnetic intensity distribution field of the target batch material.

[0030] It should be noted that the spatial coordinate parameters are obtained by selecting the geometric center of the detection plane of the feed bin as the origin, taking the horizontal axis parallel to the conveying direction of the conveying belt as the positive direction, and taking the vertical axis perpendicular to the conveying direction of the conveying belt as the positive direction.

[0031] Referring to Figure 2 As a preferred, the process of setting the magnetic field strength of the downstream electromagnetic roller includes: obtaining the mean value of the magnetic intensity of the sampling points in the magnetic intensity distribution field by truncated mean calculation, and taking it as the standard magnetic intensity of the target batch material.

[0032] The preset unit field strength coefficient and the electromagnetic roller calibration magnetic field strength value corresponding to the reference magnetic intensity material are called from the cloud database.

[0033] The difference between the quantized standard magnetic intensity and the calibration magnetic field strength value is obtained, and the preset unit field strength coefficient is combined to obtain the magnetic field strength compensation value of the target batch material relative to the reference magnetic intensity material.

[0034] The magnetic field strength compensation value and the calibration magnetic field strength value are superimposed to obtain the set magnetic field strength of the downstream electromagnetic roller.

[0035] It should be noted that the electromagnetic roller calibration magnetic field strength value is obtained by performing electromagnetic roller adsorption experiments on the material doped with small ferromagnetic fragments under the reference magnetic intensity under different magnetic field strength conditions, recording the adsorption amount and adsorption time of the small ferromagnetic fragments under different magnetic field strength conditions, obtaining the adsorption effect index under different magnetic field strength conditions, and taking the magnetic field strength parameter corresponding to the maximum value as the electromagnetic roller calibration magnetic field strength value corresponding to the reference magnetic intensity material.

[0036] On this basis, the material doped with small ferromagnetic fragments under different magnetic strengths of each group can be subjected to electromagnetic drum adsorption experiment to obtain the magnetic field strength corresponding to the maximum value of the adsorption effect index of each group of materials with different magnetic strengths. The magnetic strength difference between each group of magnetic strength materials and the reference magnetic strength material is calculated, and the magnetic field strength difference between the maximum value of the adsorption effect index corresponding to each group of magnetic strength materials and the reference magnetic strength material is calculated to obtain the magnetic field strength adjustment amount. The linear relationship between the magnetic strength difference and the corresponding magnetic field strength adjustment amount is fitted by the least square method, and the magnetic field strength adjustment amount adapted to the unit magnetic strength change of the material is calculated, which is defined as the unit field strength coefficient.

[0037] It should be noted that the ferromagnetic fragments with a volume less than or equal to 50mm 3 are defined as small ferromagnetic fragments, and the ferromagnetic fragments with a volume greater than 50mm 3 are defined as large ferromagnetic fragments.

[0038] As a preferred, the process of setting the rotation speed of the downstream electromagnetic drum includes: taking the vertical distance of each sampling point in the magnetic strength distribution field from the relative horizontal central axis as the vertical distance, and counting the total vertical distance of each sampling point from the relative horizontal central axis.

[0039] The magnetic strength standard dispersion parameter is obtained by fusing the magnetic strength standard deviation of each sampling point and the total vertical distance.

[0040] It should be noted that the discrete feature fusion is a product operation of the magnetic strength standard deviation of each sampling point and the total vertical distance.

[0041] The absolute difference between the magnetic strength of each sampling point and the standard magnetic strength is calculated, and the vertical distance of each sampling point is taken as a weight factor to linearly weight and fuse the absolute difference value of each sampling point to obtain the magnetic strength weighted dispersion parameter.

[0042] The ratio of the magnetic strength weighted dispersion parameter and the magnetic strength standard dispersion parameter is taken as the magnetic strength distribution dispersion U of the target batch of materials based on the horizontal axis.

[0043] The rotation speed of the electromagnetic drum is calculated by the formula n=n0+k×(1-U)×n0, wherein n0 is a preset rated speed, and k is a preset speed adjustment coefficient.

[0044] It should be noted that the above-mentioned preset rated speed can refer to the corresponding labeled value in the product specification provided by the manufacturer of the electromagnetic drum.

[0045] It should be noted that the preset rotating speed adjustment coefficient is obtained by randomly distributing materials with the same magnetic strength, adjusting the rotating speed of the electromagnetic drum under the condition of the same magnetic field strength, performing adsorption experiments on each group of materials, obtaining the rotating speed corresponding to the maximum value of the adsorption effect index of each group of materials, and fitting the rotating speed adjustment coefficient based on the electromagnetic drum rotating speed calculation formula through the least square method.

[0046] The electromagnetic drum adsorption module detects the ferromagnetic adsorption load in real time through the pressure sensor array arranged on the inner wall of the electromagnetic drum, and automatically starts the scraper iron unloading mechanism to clean the ferromagnetic fragments adsorbed on the inner wall when the detected load is higher than the preset full load threshold.

[0047] It should be noted that because the magnetic adsorption force of the ferromagnetic fragments is proportional to the volume and mass thereof, the ferromagnetic fragments with small volume and weight are more easily adsorbed by the magnetic field, while the large ferromagnetic fragments need higher magnetic field strength and longer adsorption time to be effectively adsorbed. Therefore, under the same magnetic field environment in the electromagnetic drum, small ferromagnetic fragments have higher adsorption efficiency and faster response speed than large ferromagnetic fragments, and their motion trajectory is more easily constrained by the magnetic force line to adhere to the inner wall of the drum and migrate in the rotating direction. When the electromagnetic drum detects that the load reaches the empty load, it indicates that the small ferromagnetic fragments are filtered out.

[0048] As a preferred, the pressure sensor array arranged on the inner wall of the electromagnetic drum detects the ferromagnetic adsorption load in real time, and the specific acquisition process includes: compensating the pressure data detected by each pressure sensor based on a preset centrifugal force compensation formula to obtain the compensated pressure data of the ferromagnetic fragments on each pressure sensor.

[0049] The ratio of the compensated pressure data to the preset sensing area of the pressure sensor is taken as the adsorption pressure, so as to obtain the adsorption pressure of each partition of the inner wall of the electromagnetic drum, and the detection load of the electromagnetic drum is obtained by accumulation.

[0050] It should be noted that the preset sensing area of the pressure sensor can refer to the corresponding labeled value in the product specification provided by the sensor manufacturer.

[0051] As a preferred, the centrifugal force compensation formula is: F1=F0-α×r×ω 2 calculates the compensated pressure data of the ferromagnetic fragments, wherein F0 is the pressure data detected by the pressure sensor, α is a preset pressure sensor adjustment coefficient, ω and r are the angular velocity of the electromagnetic drum and the preset radius of the electromagnetic drum, respectively.

[0052] It should be noted that the preset pressure sensor adjustment coefficient is obtained by uniformly laying the ferromagnetic fragments of a known weight on the inner wall of the drum in a stationary state, recording the readings of each pressure sensor at this time as the measured pressure data, adjusting the rotational speed of the electromagnetic drum, recording the pressure readings of each pressure sensor at different rotational speeds as the monitoring pressure data, and fitting the pressure sensor adjustment coefficient based on the centrifugal force compensation formula through the least square method.

[0053] It should be noted that the angular velocity of the electromagnetic drum is obtained by substituting the rotational speed of the electromagnetic drum into the existing standard rotational speed-angular velocity conversion formula.

[0054] It should be noted that the preset radius of the electromagnetic drum can refer to the corresponding labeled value in the product specification provided by the manufacturer of the electromagnetic drum.

[0055] The embodiment of the present application realizes dynamic perception of the adsorption process of small ferromagnetic fragments by real-time acquisition of the magnetic distribution field of the material by the electromagnetic metal detection module and linkage of the pressure sensor array to monitor the adsorption load of the drum, effectively deals with the fluctuation of ore flow and the change of material distribution, improves the adsorption efficiency of ferromagnetic fragments and reduces energy consumption.

[0056] The electromagnetic drum cleaning module controls the electromagnetic drum to transport the internal fragments to the guide rail grizzly screen when the detected load is lower than the preset empty load threshold, and triggers the ferromagnetic fragment filtering operation of the guide rail grizzly screen.

[0057] The guide rail grizzly screen filtering module real-time acquires the relative material output ratio of the qualified ore discharge port and the unqualified ferromagnetic fragment discharge port of the guide rail grizzly screen, and dynamically adjusts the vibration amplitude and inclination angle of the guide rail grizzly screen.

[0058] It should be noted that because the volume and mass of the remaining ferromagnetic fragments in the target material are large after the small ferromagnetic fragments are adsorbed by the electromagnetic drum, the remaining ferromagnetic fragments cannot pass through the screen holes of the guide rail grizzly screen, and by dynamically adjusting the vibration amplitude and inclination angle of the guide rail grizzly screen, the efficiency of qualified ore passing through the screen holes is improved, and the sliding speed of large ferromagnetic fragments is accelerated, thereby ensuring the accuracy and efficiency of ore iron removal.

[0059] As a preferred, the dynamic adjustment of the vibration amplitude and inclination angle of the guide rail grizzly screen is specifically as follows: according to the preset time interval, the operation process of the guide rail grizzly screen is divided to generate each sampling period.

[0060] The mass ratio of the qualified ore discharge port to the ferromagnetic fragment discharge port in the unit sampling period is taken as the relative material output ratio.

[0061] The relative material output ratios of the preceding sampling periods are statistically analyzed to obtain the ideal relative material output ratio.

[0062] The difference between the relative material output ratio of the current sampling period and the ideal relative material output ratio is calculated, and the difference is compared with a preset deviation threshold after being absolute. If the comparison relationship is greater than, it is determined that the guide grate screen needs adjustment.

[0063] When the difference is greater than 0 and the absolute value of the mass change rate of the ferromagnetic scrap discharge port in the current sampling period relative to the previous adjacent sampling period is greater than the absolute value of the mass change rate of the qualified ore discharge port at the same period, the adjustment object of the current sampling period is determined as the vibration amplitude of the guide grate screen.

[0064] When the difference is less than 0 and the absolute value of the mass change rate of the ferromagnetic scrap discharge port in the current sampling period relative to the previous adjacent sampling period is less than the absolute value of the mass change rate of the qualified ore discharge port at the same period, the adjustment object of the current sampling period is determined as the inclination angle of the guide grate screen.

[0065] It should be noted that the process of obtaining the ideal material output ratio includes: statistically analyzing the mean, median and mode of the relative material output ratio of each previous sampling period, taking them as reference values in turn, calculating the absolute cumulative error of the relative material output ratio of each sampling period and each reference value, and selecting the relative material output ratio corresponding to the minimum value as the ideal material output ratio.

[0066] As a preferred, if the adjustment object of the current sampling period is the vibration amplitude of the guide grate screen, the following is performed: the difference between the relative material output ratios of the sampling period and the previous sampling period is recorded as the relative material deviation.

[0067] The mass change rate of the qualified ore discharge port is taken as the discharge deviation, and the discharge deviation of each previous sampling period is integrated and summed to obtain the cumulative discharge deviation.

[0068] The relative material deviation and the instantaneous unit response coefficient, the cumulative discharge deviation and the cumulative unit response coefficient are multiplied respectively to generate instantaneous adjustment amount and cumulative adjustment amount, and the vibration amplitude total adjustment amount is obtained by linear superposition, so as to positively adjust the vibration amplitude of the guide grate screen.

[0069] It should be noted that the guide grate screen will cause instantaneous fluctuations in the relative material output ratio due to the uniformity and uneven particle size distribution of the material during operation, and will cause persistent deviations in the discharge port mass change rate due to mechanical aging and increasing average particle size of the material.

[0070] The relative material deviation and the cumulative discharge deviation respectively reflect instantaneous fluctuation and persistent deviation of the system in a short term, the instantaneous fluctuation is compensated by calculating the instantaneous adjustment amount, the dynamic response performance and anti-interference ability of the system are improved, the persistent deviation is compensated by calculating the cumulative adjustment amount, the qualified ore output rate is ensured, the precision and stability of the control are improved, and the vibration amplitude of the guide rail grizzly is dynamically adjusted by calculating the total adjustment amount of the vibration amplitude.

[0071] As a preferred, if the adjustment object of the current sampling time period is the inclination angle of the guide rail grizzly, the following is performed: calculating the ferromagnetic material discharge port current sampling time period quality time domain variation parameter.

[0072] The preset guide rail grizzly inclination angle adjustment table stored in the cloud database is called, the variation trend level is determined according to the quality time domain variation parameter, and the inclination angle adjustment amount corresponding to the level is matched, so that the inclination angle of the guide rail grizzly is positively adjusted.

[0073] It should be noted that the time domain variation parameter is obtained by drawing the node diagram of the ferromagnetic material discharge port quality changing with time in the current sampling time period and the previous sampling time period, and the slope of the quality trend line corresponding to each quality node is obtained by linear fitting.

[0074] It should be noted that the preset guide rail grizzly inclination angle adjustment table contains the value range of the quality time domain variation parameter corresponding to different variation trend levels and the corresponding inclination angle adjustment amount adapted.

[0075] The embodiment of the application relies on the guide rail grizzly filtering module to calculate the output ratio of qualified ore and ferromagnetic material, dynamically adjust the vibration amplitude and inclination angle of the guide rail grizzly, realize the screening of large ferromagnetic material, avoid the problems of clogging and screening leakage caused by fixed screening parameters, and improve the iron removal precision and efficiency of the equipment.

[0076] The visual separation feedback module monitors the separation state of the grizzly material through the visual recognition device arranged above the guide rail grizzly, and feeds back a stop signal to the control unit when it is identified that the qualified ore and the ferromagnetic material are in a completely separated state.

[0077] Please refer to Figure 3 As a preferred, the process of monitoring the separation state of the grizzly material through the visual recognition device arranged above the guide rail grizzly includes: converting the image collected by the visual recognition device into a gray image, and calculating the contrast of each pixel point.

[0078] Based on the preset contrast threshold range of the qualified ore and the ferromagnetic material pixel points, each pixel point is classified into a qualified ore pixel point, a ferromagnetic material pixel point and a background pixel point.

[0079] The classified pixel points are labeled with a connected domain, qualified ore connected regions and ferromagnetic debris connected regions are identified, the minimum circumscribed rectangle of adjacent qualified ore connected regions and ferromagnetic debris connected regions is constructed, and overlapping pixel points are obtained therefrom.

[0080] The number of overlapping pixels, the total number of qualified ore pixels and the total number of ferromagnetic debris pixels are counted, and the sum of the total number of qualified ore pixels and the total number of ferromagnetic debris pixels is recorded as the ore material pixel number.

[0081] The ratio of the number of overlapping pixels, the total number of qualified ore pixels and the ore material pixel number is calculated respectively, and the ore overlap degree and the ore separation degree are obtained.

[0082] When the ore overlap degree is less than a preset overlap threshold, and the ore separation degree is greater than a preset separation threshold, it is determined that the qualified ore and the ferromagnetic debris are in a completely separated state.

[0083] It should be noted that, since the value range of the ore overlap degree and the ore separation degree is [0, 1], the preset overlap threshold and the preset separation threshold can be exemplarily set to 0.1 and 0.8 respectively.

[0084] The embodiment of the present application combines the guide rail grate screen filtering module and the visual separation feedback module, monitors the separation state of the qualified ore and the ferromagnetic debris while adjusting the vibration amplitude and the inclination angle of the guide rail grate screen, feeds back a de-ironing stop signal to the control unit when they are in a completely separated state, realizes closed-loop control of the de-ironing equipment, and improves the de-ironing precision and the robustness of the control system.

[0085] The cloud database is used in the system during execution, and is used to store the preset unit field coefficient, the electromagnetic drum calibration magnetic field strength value corresponding to the reference magnetic intensity material, and the preset guide rail grate screen inclination angle adjustment table.

[0086] All parameters in the cloud database are derived from the initial implantation of the system.

[0087] The above formulas are dimensionless numerical calculations, the formulas are obtained by software simulation of a large amount of data to obtain a formula of the nearest real situation, and the preset parameters in the formula are set by a person skilled in the art according to the actual situation.

[0088] The above embodiments can be realized by software, hardware, firmware or any combination thereof, in whole or in part. When realized by software, the above embodiments can be realized in the form of a computer program product in whole or in part.

[0089] Those skilled in the art can understand that the modules and algorithm steps of each example described in combination with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0090] In addition, each functional module in each embodiment of the present application can be integrated in one processing module, or each module can exist physically alone, or two or more modules can be integrated in one module.

[0091] The above description is merely specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any modification or replacement within the technical scope disclosed by the present application can be easily thought by those skilled in the art, and should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

[0092] Finally, the above description is only the preferred embodiments of the present application, and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A sensor-based iron removal detection and control system for ore crushing, characterized in that, include: The electromagnetic metal detection module sets the magnetic field strength and rotation speed of the downstream electromagnetic roller based on the magnetic intensity distribution field of the target batch of materials collected by the metal detector built into the feed hopper, and triggers the electromagnetic roller to adsorb ferromagnetic fragments. The electromagnetic roller adsorption module uses an array of pressure sensors installed on the inner wall of the electromagnetic roller to detect the ferromagnetic adsorption load in real time. When the detected load is higher than the preset full load threshold, the scraper unloading mechanism is automatically activated to clean the ferromagnetic debris adsorbed on the inner wall. The electromagnetic drum cleaning module controls the electromagnetic drum to transport internal debris to the guide rail grate screen when the detected load is lower than the preset no-load threshold, and triggers the ferromagnetic debris filtering operation of the guide rail grate screen. The guide rail grate screen filtration module collects the relative material output ratio between the qualified ore outlet and the ferromagnetic crushed material outlet of the guide rail grate screen in real time, and dynamically adjusts the vibration amplitude and tilt angle of the guide rail grate screen. The visual separation feedback module monitors the material separation status of the grate screen through a visual recognition device installed above the guide rail grate screen. When it recognizes that the qualified ore and ferromagnetic fragments are completely separated, it sends a feedback iron removal stop signal to the control unit.

2. The iron removal detection and control system for ore crushing based on sensor technology according to claim 1, characterized in that, The specific process for obtaining the magnetic intensity distribution field of the target batch of materials includes: The magnetic induction probe of the metal detector is moved along the preset gridded sampling trajectory in the feed bin, and the spatial coordinate parameters and magnetic intensity values ​​of each sampling point are recorded simultaneously during the movement of the probe. Based on the physical arrangement order of the spatial coordinate parameters, the magnetic intensity value is mapped to a two-dimensional discrete intensity distribution matrix with the detection plane of the feed hopper as the reference. The matrix rows and columns correspond to the horizontal and vertical coordinates of the sampling points, respectively, and the matrix element values ​​correspond to the magnetic intensity values ​​of the sampling points. The two-dimensional discrete intensity distribution matrix is ​​used as the magnetic intensity distribution field of the target batch of materials.

3. The iron removal detection and control system for ore crushing based on sensor technology according to claim 2, characterized in that, The process of setting the magnetic field strength of the downstream electromagnetic drum includes: The mean magnetic intensity of the sampling points in the magnetic intensity distribution field is obtained by truncating the mean, and it is used as the standard magnetic intensity of the target batch of materials. Retrieve the preset unit field strength coefficient and the electromagnetic roller calibration magnetic field strength value corresponding to the reference magnetic strength material from the cloud database; The difference between the quantified standard magnetic strength and the calibrated magnetic field strength value is used to obtain the magnetic field strength compensation value of the target batch of materials relative to the reference magnetic strength material, combined with the preset unit field strength coefficient. The magnetic field strength compensation value is superimposed with the calibrated magnetic field strength value to obtain the set downstream electromagnetic drum magnetic field strength.

4. The iron removal detection and control system for ore crushing based on sensor technology according to claim 3, characterized in that, The process of setting the speed of the downstream electromagnetic drum includes: The vertical coordinate values ​​of each sampling point in the magnetic intensity distribution field are taken as their vertical distance relative to the horizontal central axis, and the total vertical distance of each sampling point relative to the horizontal central axis is calculated. By fusing the discrete features of the standard deviation of magnetic intensity at each sampling point with the total vertical distance, the standard discrete parameters of magnetic intensity are obtained. Calculate the absolute difference between the magnetic intensity of each sampling point and the standard magnetic intensity, and use the vertical distance of each sampling point as a weighting factor to perform linear weighted fusion on the absolute difference of each sampling point to obtain the magnetic intensity weighted discrete parameters. The ratio of the weighted magnetic intensity discrete parameter to the standard magnetic intensity discrete parameter is used as the magnetic intensity distribution dispersion U of the target batch of materials based on the horizontal axis. The rotational speed of the electromagnetic drum is calculated using the formula n = n0 + k × (1 - U) × n0, where n0 is the preset rated speed and k is the preset speed adjustment coefficient.

5. The iron removal detection and control system for ore crushing based on sensor technology according to claim 1, characterized in that, The real-time detection of the ferromagnetically adsorbed load via a pressure sensor array deployed on the inner wall of the electromagnetic drum includes the following specific acquisition process: Based on the preset centrifugal force compensation formula, the pressure data detected by each pressure sensor is compensated to obtain the compensation pressure data of the ferromagnetic debris on each pressure sensor. The ratio of the compensated pressure data to the preset sensing area of ​​the pressure sensor is used as the adsorption pressure. The adsorption pressure of each zone on the inner wall of the electromagnetic roller is obtained in this way, and the sum is used to obtain the detection load of the electromagnetic roller.

6. The iron removal detection and control system for ore crushing based on sensor technology according to claim 5, characterized in that, The centrifugal force compensation formula is as follows: Through F1=F0-α×r×ω 2 Calculate the compensation pressure data for the ferromagnetic scrap, where F0 is the pressure data detected by the pressure sensor, α is the preset pressure sensor adjustment coefficient, and ω and r are the angular velocity and preset radius of the electromagnetic drum, respectively.

7. The iron removal detection and control system for ore crushing based on sensor technology according to claim 1, characterized in that, The specific process for dynamically adjusting the vibration amplitude and tilt angle of the guide rail grate is as follows: The operation process of the guide rail grate is divided according to a preset time interval to generate each sampling period. The ratio of the mass of qualified ore at the discharge port to the mass of ferromagnetic crushed material at the discharge port within a unit sampling period is taken as the relative material output ratio. Statistical analysis was performed on the relative material output ratios of each preceding sampling period to obtain the ideal relative material output ratio; Calculate the difference between the relative material output ratio and the ideal relative material output ratio during the current sampling period. After absolutizing the difference, compare it with a preset deviation threshold. If the difference is greater than the comparison threshold, it is confirmed that the guide rail grate screen needs adjustment. When the difference is greater than 0 and the absolute value of the mass change rate of the current sampling period at the ferromagnetic crushed material outlet relative to the previous adjacent sampling period is greater than the absolute value of the mass change rate of the qualified ore outlet during the same period, the adjustment object of the current sampling period is determined to be the vibration amplitude of the guide rail grate screen. When the difference is less than 0 and the absolute value of the mass change rate of the current sampling period at the ferromagnetic crushed material outlet relative to the previous adjacent sampling period is less than the absolute value of the mass change rate of the qualified ore outlet during the same period, the adjustment object of the current sampling period is determined to be the tilt angle of the guide rail grate.

8. The iron removal detection and control system for ore crushing based on sensor technology according to claim 7, characterized in that, If the adjustment target for the current sampling time period is the vibration amplitude of the guide rail grate, then the following actions will be performed: The difference between the relative material output ratio of the sampling period and the previous sampling period is recorded as the relative material deviation. The rate of change in the quality of qualified ore at the discharge port is taken as the discharge deviation. The discharge deviations of each previous sampling period are integrated and summed to obtain the cumulative discharge deviation. The relative material deviation and instantaneous unit response coefficient, and the cumulative discharge deviation and cumulative unit response coefficient are multiplied respectively to generate the instantaneous adjustment amount and the cumulative adjustment amount. These are then linearly superimposed to obtain the total vibration amplitude adjustment amount, which is used to positively adjust the vibration amplitude of the guide rail grate screen.

9. The iron removal detection and control system for ore crushing based on sensor technology according to claim 7, characterized in that, If the adjustment target for the current sampling time period is the tilt angle of the guide rail grate, then the following actions will be performed: Calculate the time-domain variation index of the mass of ferromagnetic scrap at the discharge port during the current sampling period; The preset tilt angle adjustment table of the guide rail grate stored in the cloud database is called. The change trend level is determined according to the quality time domain change index, and the corresponding tilt angle adjustment amount is matched to adjust the tilt angle of the guide rail grate in a positive direction.

10. The iron removal detection and control system for ore crushing based on sensor technology according to claim 1, characterized in that, The process of monitoring the material separation status of the grate screen through a visual recognition device installed above the guide rail grate screen includes: The image captured by the visual recognition device is converted into a grayscale image, and the contrast of each pixel is calculated. Based on the preset contrast threshold range of qualified ore and ferromagnetic debris pixels, each pixel is classified into qualified ore pixels, ferromagnetic debris pixels, and background pixels. Connectivity components are marked on the classified pixels to identify the connected regions of qualified ore and ferromagnetic debris. The minimum bounding rectangle of adjacent connected regions of qualified ore and ferromagnetic debris is constructed to obtain overlapping pixels. The number of overlapping pixels, the total number of pixels of qualified ore, and the total number of pixels of ferromagnetic fragments are counted, and the sum of the number of pixels of qualified ore and the total number of pixels of ferromagnetic fragments is recorded as the number of pixels of ore material; The ore overlap and ore separation degree are obtained by calculating the ratio of the number of overlapping pixels and the total number of pixels of qualified ore to the number of pixels of ore material, respectively. When the ore overlap is less than a preset overlap threshold and the ore separation is greater than a preset separation threshold, it is determined that the qualified ore and the ferromagnetic fragments are in a completely separated state.

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