An online monitoring ceramic powder automatic bin changing system and automatic feeding method thereof

Abstract

The present invention relates to the technical field of ceramic tile production, and in particular to an online monitored automatic bin-changing system for ceramic powder, comprising a press hopper, a main conveyor belt and a plurality of powder conveying groups; each powder conveying group comprises a main feeding belt and a plurality of storage bins, and a sub-feeding belt is provided at the discharge port of each storage bin; the automatic bin-changing system also comprises a main control device, a powder detection probe, a bin valve, and a high limit probe and a low limit probe; the main control device is respectively connected to a wireless signal transceiver, a prompt alarm, a fault alarm and a control panel for communication. The present invention has a high degree of automation, and plays the functions of automatic monitoring and automatic bin-changing, and does not require manual calculation of the time when the powder is used up, thus avoiding manual errors, reducing the workload and labor intensity of the staff, saving time and effort, and improving the economic benefits of production.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic tile production, and in particular to an online monitored automatic warehouse changing system for ceramic powder and an automatic feeding method thereof. Background Art

[0002] In the production process of ceramic tiles, the transportation and storage of raw materials is a very important process, and the raw material powder feeding and the production line press hopper need to be carried out simultaneously. The general requirement is that the above process must be produced continuously without interruption.

[0003] At present, in the powder material distribution process of ceramic and other industries, the processes of powder material feeding, finishing warehouse and adding warehouse are generally done by manual squatting, closing warehouse after finishing warehouse and opening warehouse in advance. The powder delivery workers must often run back and forth to the top of the silo to check the changes in the amount of materials used in the powder silo. This will have some disadvantages and shortcomings: 1. If the manual calculation of the time of finishing the silo is inaccurate, there will be a shortage of materials in the silo, and the flow rate and weight of the powder delivered to the press hopper will decrease, resulting in insufficient feeding, causing the press hopper to stop due to lack of materials, affecting the continuity of the press hopper and the production line; 2. When the silo is short of materials, the moisture and particles of the powder delivered to the press hopper will change greatly, affecting the quality control of pressed bricks and products, and causing product instability; 3. A powder delivery worker needs to deliver powder to 3-4 production lines, the workload and labor intensity are very large, and the manual error rate is high. It is not only time-consuming and labor-intensive, but also increases labor costs, affecting production economic benefits. Summary of the invention

[0004] In view of the problems in the prior art, the present invention provides an online monitored automatic bin-changing system for ceramic powder and an automatic feeding method thereof.

[0005] In order to solve the above technical problems, the present invention adopts the following technical scheme: an online monitored automatic bin changing system for ceramic powder, comprising a press hopper, a main conveyor belt and several powder conveying groups, the discharge end of each powder conveying group is connected to the feed end of the press hopper through the main conveyor belt; each powder conveying group comprises a main feeding belt and several storage bins, and the discharge port of each storage bin is provided with a sub-feeding belt; the automatic bin changing system also comprises a main control device, a powder detection probe arranged in the storage bin, a bin mouth valve arranged at the discharge port of the storage bin, and a high limit probe and a low limit probe both arranged in the press hopper; the powder detection probe, the high limit probe and the low limit probe are all connected to the input end of the main control device, the bin mouth valve is connected to the output end of the main control device, and the main control device is respectively communicated with a wireless signal transceiver, a prompt alarm, a fault alarm and a control panel.

[0006] Furthermore, the number of the powder conveying groups is at least two.

[0007] Furthermore, the number of press hoppers is at least two, and one end of the main conveyor belt close to the press hopper is connected to a distribution conveyor belt, and the end of the distribution conveyor belt away from the main conveyor belt is provided with two distribution ports, and one distribution port is connected to the feeding end of a press hopper.

[0008] Furthermore, the main control device is a PLC controller.

[0009] Furthermore, the main control device is provided with a digital-to-analog conversion module, and the main control device is communicatively connected with the wireless signal transceiver via the digital-to-analog conversion module.

[0010] Furthermore, the length of the main feeding belt is greater than the length of the sub-feeding belt.

[0011] An automatic feeding method includes a press hopper, a powder detection probe, a main conveyor belt, a main feeding belt, a storage bin, a sub-feeding belt, a main control device, a bin valve, a high limit probe, a low limit probe, a wireless signal transceiver, a prompt alarm and a control panel; and also includes the following steps:

[0012] Step 1: Fill each storage bin with powder and set the order of discharging the materials in batches through the control panel;

[0013] Step 2: After setting the order of discharging, if the powder in the press hopper is low enough to trigger the low limit probe, the low limit probe outputs a signal of insufficient powder in the press hopper to the main control device, and the main control device controls the opening valves of the first batch of storage bins in sequence, and at the same time controls the main conveyor belt, the main feeding belt and the sub-feeding belt corresponding to the above storage bins to start working, so that the powder is discharged from the discharge port of the storage bin, and is sequentially conveyed into the press hopper through the sub-feeding belt, the main feeding belt and the main conveyor belt for pressing;

[0014] Step 3: During the process of the storage bin outputting powder, if the powder detection probe in the storage bin detects that the powder inside is insufficient, the powder detection probe outputs a powder shortage signal to the main control device, and the main control device controls the corresponding bin valve to close and the corresponding sub-feeding belt to stop working. At the same time, the main control device controls the bin valve of the next batch of storage bins to open and the corresponding sub-feeding belt to start working according to the sequence set in step 1; at the same time, the main control device controls the reminder alarm to send out a powder replenishment alarm to remind the staff to replenish the powder in time, and sends the powder replenishment alarm to the mobile terminal through the wireless signal transceiver;

[0015] Step 4: During the process of the storage bin outputting powder, if the powder in the press hopper is high enough to trigger the high limit probe, the high limit probe outputs a signal to the main control device that the press hopper is full of powder. The main control device controls the corresponding storage bin's hopper valve to close, and at the same time controls the main conveyor belt, the main feed belt and the sub-feed belt corresponding to the above storage bin to stop working. At the same time, the main control device sends a powder full alarm to the mobile terminal through the wireless signal transceiver.

[0016] Furthermore, step 2 is specifically as follows: each batch of at least 3-4 storage bins discharge materials simultaneously.

[0017] Furthermore, step two is specifically as follows: Step two is specifically as follows: for each batch, ensure that no two or more storage bins at the head position or at the tail position discharge materials at the same time.

[0018] Beneficial effects of the present invention: The present invention has a high degree of automation. The discharging order of each batch of storage bins can be set in advance through the control panel. The powder detection probe of the storage bin and the low limit probe and high limit probe of the press hopper can be used to automatically monitor and automatically change bins. There is no need to manually calculate the time when the powder is used up, which avoids manual errors, reduces the workload and labor intensity of the staff, saves time and effort, and improves the economic benefits of production.

[0019] The start and stop control of the three-layer feeding belt is realized through the main feeding belt, the sub-feeding belt and the main conveyor belt, which improves the effect of accurate feeding and accurate stopping;

[0020] Through the wireless signal transceiver, the powder remaining information of each storage bin and the powder status information of the press hopper are sent to the existing cloud server. The staff can log in to the cloud server through a mobile terminal such as a mobile phone to view the information and perform remote monitoring, thereby achieving the effect of remote monitoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of the present invention.

[0022] Figure 2 It is a schematic structural diagram of the powder conveying group of the present invention.

[0023] Figure 3 It is a module block diagram of the present invention.

[0024] Reference numerals:

[0025] 1- press hopper; 2- main conveyor belt; 3- main feeder belt; 4- storage bin; 5- sub-feeder belt; 6- main control equipment; 7- powder conveying group; 8- mobile phone; 9- material distribution conveyor belt; 10- bin valve. DETAILED DESCRIPTION

[0026] To facilitate understanding by those skilled in the art, the present invention is further described below in conjunction with embodiments and drawings.

[0027] See also Figures 1 to 3 As shown, an online monitored automatic bin-changing system for ceramic powder includes a press hopper 1, a main conveyor belt 2 and a plurality of powder conveyor groups 7, wherein the discharge end of each powder conveyor group 7 is connected to the feed end of the press hopper 1 through the main conveyor belt 2;

[0028] Each powder conveying group 7 includes a main feeding belt 3 and a plurality of storage bins 4. The outlet of each storage bin 4 is provided with a sub-feeding belt 5. Every two sub-feeding belts 5 are symmetrically arranged at the two ends of the main feeding belt 3 and are connected to the main feeding belt 3.

[0029] The automatic bin changing system also includes a main control device 6, a powder detection probe arranged in the storage bin 4, a bin mouth valve 10 arranged at the discharge port of the storage bin 4, and a high limit probe and a low limit probe both arranged in the press hopper 1; the powder detection probe, the high limit probe and the low limit probe are all connected to the input end of the main control device 6, the bin mouth valve 10 is connected to the output end of the main control device 6, and the main control device 6 is respectively communicated with a wireless signal transceiver, a prompt alarm, a fault alarm and a control panel.

[0030] The present invention has a high degree of automation. The discharge sequence of each batch of storage bins 4 is set in advance through the control panel, and the closing or opening of the bin valve 10 is controlled by the main control device 6. The powder detection probe of the storage bin 4 and the low limit probe and the high limit probe of the press hopper 1 play the functions of automatic monitoring and automatic bin changing. There is no need to manually calculate the time when the powder is used up, which avoids manual errors, reduces the workload and labor intensity of the staff, saves time and effort, and improves the economic benefits of production.

[0031] Specifically, the start and stop control of the three-layer feeding belt is realized by conveying through the main feeding belt 3, the sub-feeding belt 5 and the main conveying belt 2, thereby improving the effect of accurate feeding and accurate stopping;

[0032] Through the wireless signal transceiver, the powder remaining information of each storage bin 4 and the powder condition information of the press hopper 1 are sent to the existing cloud server. The staff can log in to the cloud server through a mobile terminal such as a mobile phone 8 to view information and perform remote control functions, thereby achieving the effect of remote monitoring.

[0033] The specific effect of remote monitoring is as follows: if there is insufficient remaining material in the storage bin 4, the powder detection probe sends a signal of insufficient remaining material to the main control device 6, and the main control device 6 controls the prompt alarm to issue an alarm for replenishing powder, reminding the staff to replenish powder in time, and at the same time sends the alarm for replenishing powder to the staff's mobile phone 8 through the wireless signal transceiver, such as an alarm reminder on the corresponding APP; if an abnormal fault occurs in the press hopper 1, the main control device 6 controls the fault alarm to issue a fault alarm, reminding the staff to check and eliminate the fault in time, and at the same time sends the fault alarm to the staff's mobile phone 8 through the wireless signal transceiver, such as an alarm reminder on the corresponding APP, the staff can use the mobile phone 8 to remotely start and stop the bin valve 10, the main feed belt 3, the sub-feed belt 5 and the main conveyor belt 2, thereby realizing the function of remote monitoring of the staff;

[0034] In this embodiment, the number of powder material conveying groups 7 is at least two. This arrangement reduces the number of times that staff members manually replenish powder materials, increases the amount of material supplied, and improves automation efficiency.

[0035] In this embodiment, there are at least two press hoppers 1, and one end of the main conveyor belt 2 close to the press hopper 1 is connected to a material distribution conveyor belt 9, and one end of the material distribution conveyor belt 9 away from the main conveyor belt 2 is provided with two material distribution ports, and one material distribution port is connected to the feeding end of one press hopper 1. In this way, powder can be discharged to two press hoppers 1 at the same time for pressing, thereby improving work efficiency.

[0036] In this embodiment, the main control device 6 is a PLC controller, which improves the accuracy of control and is automatic and efficient.

[0037] In this embodiment, the main control device 6 is provided with a digital-to-analog conversion module, and the main control device 6 is connected to the wireless signal transceiver through the digital-to-analog conversion module to ensure that the transmitted signal will not be distorted and avoid signal errors.

[0038] In this embodiment, the sub-feeding belt 5 is an automatic start-stop PVC feeding belt. The automatic start-stop PVC feeding belt has the function of weight sensing start-stop. Specifically, when the corresponding storage bin 4 has no discharge, the automatic start-stop PVC feeding belt will have a weight sensing time of 3-5 seconds. When no powder is sensed to come out, it is judged that the storage bin 4 is empty, and the automatic start-stop PVC feeding belt automatically stops running, thereby improving the reaction sensitivity of the sub-feeding belt 5, improving the efficiency of accurate material stopping, and improving the degree of automation.

[0039] In this embodiment, the length of the main feeding belt 3 is greater than the length of the sub-feeding belt 5. In this way, the length of the sub-feeding belt 5 can be reduced, saving costs.

[0040] An automatic feeding method includes a press hopper 1, a powder detection probe, a main conveyor belt 2, a main feeding belt 3, a storage bin 4, a sub-feeding belt 5, a main control device 6, a bin valve 10, a high limit probe, a low limit probe, a wireless signal transceiver, a prompt alarm and a control panel; and further includes the following steps:

[0041] Step 1: Fill each storage bin 4 with powder and set the order of discharging the materials in batches through the control panel;

[0042] Step 2: After setting the order of discharging, if the powder in the press hopper 1 is low enough to trigger the low limit probe, the low limit probe outputs a powder shortage signal of the press hopper 1 to the main control device 6, and the main control device 6 controls the opening valves 10 of the first batch of storage bins 4 in sequence, and at the same time controls the main conveyor belt 2, the main feeding belt 3 and the sub-feeding belt 5 corresponding to the above storage bins 4 to start working through the main control device 6, so that the powder is discharged from the discharge port of the storage bin 4, and the powder is transported into the press hopper 1 through the sub-feeding belt 5, the main feeding belt 3 and the main conveyor belt 2 in sequence for pressing;

[0043] Step 3: During the process of the storage bin 4 outputting powder, if the powder detection probe in the storage bin 4 detects that the powder inside is insufficient,

[0044] The powder detection probe outputs a powder shortage signal to the main control device 6, and the main control device 6 controls the corresponding port valve 10 to close and the corresponding sub-feeding belt 5 to stop working. At the same time, the main control device 6 controls the port valve 10 of the next batch of storage bins 4 to open and the corresponding sub-feeding belt 5 to start working according to the sequence set in step 1; at the same time, the main control device 6 controls the reminder alarm to issue a powder replenishment alarm to remind the staff to replenish the powder in time, and at the same time sends the powder replenishment alarm to the mobile terminal through the wireless signal transceiver;

[0045] Step 4: During the process of the storage bin 4 outputting powder, if the powder in the press hopper 1 is high enough to trigger the high limit probe, the high limit probe outputs a signal to the main control device 6 that the press hopper 1 is full of powder. The main control device 6 controls the corresponding bin valve 10 of the storage bin 4 to close, and at the same time controls the main conveyor belt 2, the main feed belt 3 and the sub-feed belt 5 corresponding to the above-mentioned storage bin 4 to stop working through the main control device 6; at the same time, the main control device 6 sends a powder full alarm to the mobile terminal through the wireless signal transceiver.

[0046] In this embodiment, step 2 specifically includes: at least 3-4 storage bins 4 discharge materials simultaneously in each batch.

[0047] In this embodiment, step 2 is specifically as follows: for each batch, ensure that no two or more storage bins 4 at the head position or at the tail position discharge materials at the same time.

[0048] It is required that 3-4 raw material bins are fed at the same time, and the material storage in each bin is in a stepped manner to ensure that 2 or more bin tail materials and bin head materials cannot be used at the same time. This can ensure the quality of the size and thickness of the pressed bricks.

[0049] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention is disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with the profession can make some changes or modifications to equivalent embodiments of equivalent changes by using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent changes and modifications made to the above embodiments according to the technology of the present invention are within the scope of the technical solution of the present invention without departing from the content of the technical solution of the present invention.

Claims

1. An automatic feeding method, characterized in that: The invention comprises a press hopper (1), a powder detection probe, a main conveyor belt (2), a main feed belt (3), a storage bin (4), a sub-feed belt (5), a main control device (6), a bin valve (10), a high limit probe, a low limit probe, a wireless signal transceiver, a prompt alarm and a control panel; and further comprises the following steps: Step 1: Fill each storage bin (4) with powder and set the order of discharging the powder from the storage bin (4) in batches through the control panel; Step 2: After setting the order of discharge, if the powder in the press hopper (1) is low enough to trigger the low limit probe, the low limit probe outputs a signal to the main control device (6) indicating that the press hopper (1) is short of powder, and the main control device (6) sequentially controls the opening valves (10) of the first batch of storage bins (4). At the same time, the main control device (6) controls the main conveyor belt (2), the main feed belt (3) and the sub-feed belt (5) corresponding to the above storage bins (4) to start working, so that the powder is discharged from the discharge port of the storage bin (4), and the powder is sequentially conveyed into the press hopper (1) through the sub-feed belt (5), the main feed belt (3) and the main conveyor belt (2) for pressing; Step 3: During the process of the storage bin (4) outputting powder, if the powder detection probe in the storage bin (4) detects that the powder inside is insufficient, The powder detection probe outputs a powder shortage signal to the main control device (6), and the main control device (6) controls the corresponding port valve (10) to close and the corresponding sub-feeding belt (5) to stop working. At the same time, the main control device (6) controls the port valve (10) of the next batch of storage bins (4) to open and the corresponding sub-feeding belt (5) to start working according to the sequence set in step 1; at the same time, the main control device (6) controls the reminder alarm to issue a powder replenishment alarm to remind the staff to replenish the powder in time, and at the same time sends the powder replenishment alarm to the mobile terminal through the wireless signal transceiver; Step 4: During the process of the storage bin (4) outputting powder, if the powder in the press hopper (1) is high enough to trigger the high limit probe, the high limit probe outputs a signal to the main control device (6) indicating that the press hopper (1) is full of powder, and the main control device (6) controls the corresponding bin valve (10) of the storage bin (4) to close, and at the same time controls the main conveyor belt (2), the main feed belt (3) and the sub-feed belt (5) corresponding to the storage bin (4) to stop working through the main control device (6); at the same time, the main control device (6) sends a powder full alarm to the mobile terminal through the wireless signal transceiver; Step 2 specifically includes: each batch of at least 3-4 storage bins (4) discharge materials simultaneously; Step 2 specifically includes: for each batch, ensure that no two or more storage bins (4) at the head or tail of the bin can discharge materials at the same time.

2. An online monitoring ceramic powder automatic bin changing system based on the automatic feeding method according to claim 1, characterized in that: It comprises a press hopper (1), a main conveyor belt (2) and a plurality of powder conveying groups (7), wherein the discharge end of each powder conveying group (7) is connected to the feed end of the press hopper (1) via the main conveyor belt (2); Each powder material conveying group (7) comprises a main feeding belt (3) and a plurality of storage bins (4), and a sub-feeding belt (5) is provided at the discharge port of each storage bin (4); The automatic bin-changing system further comprises a main control device (6), a powder detection probe arranged on the storage bin (4), a bin port valve (10) arranged on the discharge port of the storage bin (4), and a high limit probe and a low limit probe both arranged on the press hopper (1); the powder detection probe, the high limit probe and the low limit probe are all connected to the input end of the main control device (6), the bin port valve (10) is connected to the output end of the main control device (6), and the main control device (6) is respectively connected to a wireless signal transceiver, a prompt alarm, a fault alarm and a control panel; The discharging sequence of each batch of storage bins (4) is set through the control panel, and the closing or opening of the bin valve (10) is controlled through the main control device (6), and the powder detection probe of the storage bin (4) and the low limit probe and the high limit probe of the press hopper (1) are used for automatic monitoring and automatic bin change; The remaining powder information of each storage bin (4) and the powder condition information of the press hopper (1) are sent to an existing cloud server via a wireless signal transceiver, and the cloud server is logged in via a mobile terminal (8) to view the information and perform remote control; If the material storage bin (4) is insufficient, the powder detection probe sends a signal of insufficient material to the main control device (6), and the main control device (6) controls the reminder alarm to issue a powder replenishment alarm, reminding the staff to replenish the powder in time, and at the same time sends the powder replenishment alarm to the staff's mobile phone (8) through the wireless signal transceiver, and an alarm reminder appears on the corresponding APP; If an abnormal fault occurs in the press hopper (1), the main control device (6) controls the fault alarm to issue a fault alarm, reminding the staff to promptly check and eliminate the fault, and at the same time sends the fault alarm to the staff's mobile phone (8) through a wireless signal transceiver; The number of press hoppers (1) is at least two, one end of the main conveyor belt (2) close to the press hopper (1) is connected to a material distribution conveyor belt (9), and the end of the material distribution conveyor belt (9) away from the main conveyor belt (2) is provided with two material distribution openings, one of which is connected to the feeding end of a press hopper (1).

3. The online monitoring automatic storage system for ceramic powder according to claim 2 is characterized in that: The number of the powder material conveying groups (7) is at least two.

4. The online monitoring automatic storage system for ceramic powder according to claim 2 is characterized in that: The main control device (6) is a PLC controller.

5. The online monitoring automatic storage system for ceramic powder according to claim 2 is characterized in that: The main control device (6) is provided with a digital-to-analog conversion module, and the main control device (6) is communicatively connected with the wireless signal transceiver via the digital-to-analog conversion module.

6. The online monitoring automatic storage system for ceramic powder according to claim 2 is characterized in that: The length of the main feeding belt (3) is greater than the length of the sub-feeding belt (5).

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