A method for managing the life of mixer blades

Abstract

The present invention relates to a method for managing the life of a mixer blade, belonging to the field of automation. The method comprises the following steps: S1: inputting the theoretical service life T0 and theoretical material processing volume M0 of the blade designed at the factory, which are defined as the initial values ​​of the blade theoretical life index 1 and index 2 respectively; S2: recording the initial external dimensions V0 of the blade; S3: establishing a basic attribute library of blade quality; S4: recording the cumulative operating time T0 of the blade; i , cumulative processing volume M i and the external dimensions V measured during the intermediate repair i S5: Synchronously collect mixer operating status parameters and label blades from the same batch; S6: Compile a historical database and expert knowledge base of blade lifespans and perform statistical analysis on these historical values; S7: Create a visual dashboard for dynamic presentation. This invention enables automatic prediction and refined management of rotary hearth furnace mixer blade lifespans, reducing mixer maintenance costs while ensuring stable operation.

Description

Technical Field

[0001] The invention belongs to the field of automation and relates to a method for managing the life of mixer blades. Background Art

[0002] The rotary hearth furnace process is primarily used for the environmentally friendly treatment of iron- and zinc-containing dust and sludge in steel plants, producing metallized pellets and secondary zinc oxide powder. This process has gradually gained domestic recognition and acceptance. However, as production practices progress, new challenges have emerged. For example, the raw material processed by the rotary hearth furnace is iron-containing dust and sludge with varying physical properties. To facilitate subsequent processing, it must be thoroughly mixed in a mixer. However, due to the highly abrasive nature of the raw material and the complex and harsh operating conditions, the mixer blades wear rapidly, requiring regular replacement.

[0003] Because rotary hearth furnace production operates continuously around the clock, severe blade wear can directly impact raw material mixing, impacting the stability and quality of downstream production, and even necessitating production suspension. To ensure production, blade lifespans are currently estimated based on manual experience and replaced regularly. However, due to the high cost of blades and the inaccuracy of manual judgment, premature replacement can easily lead to wasteful or untimely replacement, compromising production and failing to meet the demands of refined management. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a method for managing the life of mixer blades,

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] A method for managing the life of mixer blades, the method comprising the following steps:

[0007] S1: Input the theoretical service life T0 and theoretical material processing volume M0 of the blade designed at the factory, which are defined as the initial values ​​of the blade theoretical life index 1 and index 2 respectively;

[0008] S2: Record the initial dimensions of the leaf, V0, including length, width, and height, which are defined as the initial values ​​of the leaf health characteristic values;

[0009] S3: Synchronously record the material characteristics of this batch of blades, including material, hardness, processing technology and supplier information, and establish a basic attribute library for blade quality;

[0010] S4: Record the cumulative running time of the blade T i , cumulative processing volume M i and the external dimensions V measured during the intermediate repair i, obtain the life index and health characteristic value of the intermediate process state. The life index refers to the theoretical use time T0, and the health characteristic value refers to the theoretical processing material volume M0. Calculate and compare their change rates. The change rates include the theoretical use time change rate K T =T i / T0, processing material quantity change rate K M =M i / M0 and blade size change rate K V =V i / V0 is calculated and compared; if the blade size change rate K V The change rate of theoretical usage time K T Or the change rate of processed material K M If they are not synchronized, the blade size change rate K V Correct the two life indicators of theoretical service time T0 and theoretical processing material volume M0, that is, T0 = T i *K v , M0=M i *K v ; When any remaining life t i or m i When the preset level 1 threshold, i.e. 10% of the corrected theoretical life span, is reached, an early warning is issued. When the level 2 threshold, i.e. 0, is reached, the life span is reset to zero.

[0011] S5: Synchronously collect the operating status parameters of the mixer process, including current, speed, vibration, and temperature, and classify them into normal and abnormal operating conditions, as follows. The operating time and material processing volume under different rules are counted separately, and then the blades in the same batch are marked;

[0012] S6: Accumulate and form a historical database and expert knowledge base of blade life, conduct statistical analysis on its historical life values, and take the average value as feedback to revise the theoretical service time T0 and theoretical processing amount M0 of a new batch of blades;

[0013] S7: Establish a visual dashboard to dynamically present the real-time lifespan, health status, and operating parameters of the blades, and provide risk warnings, maintenance recommendations, data interaction, and report display functions.

[0014] Optionally, the normal operating condition is no greater than the maximum operating value allowed by the factory design of the equipment;

[0015] Abnormal operating conditions: exceeding the maximum operating value allowed by the equipment's factory design and unplanned shutdown, are divided into three levels: mild, moderate and severe according to the extent of the excess, as follows:

[0016] Mild: The excess is less than or equal to 1.1 times the maximum operating value;

[0017] Moderate: The excess is 1.1 to 1.2 times the maximum operating value;

[0018] Severe: The excess is greater than or equal to 1.2 times the maximum operating value;

[0019] Unplanned downtime: equipment stops operating.

[0020] Optionally, the historical database includes the theoretical service life and theoretical material usage of each batch of blades designed for delivery, as well as the actual service life and theoretical material usage when scrapped, and is synchronized with the blade quality basic attribute library recorded in S3;

[0021] The expert knowledge base is based on the statistical data of blade life under different attribute conditions, forming a classification evaluation according to the actual length of use, and at the same time establishing the statistical laws between it and the material, hardness and processing technology, as follows:

[0022] Excellent: actual service life ≥ design service life × 110%;

[0023] Good: Design service life value < actual service life ≤ design service life value × 110%;

[0024] Qualified: Design service life value = actual service life;

[0025] Unqualified: Design service life value ≤ actual service life;

[0026] According to the classification of excellent, well qualified and unqualified, we accumulate and establish the corresponding usage effects under the basic quality attribute library of blades from different suppliers, materials, hardness and processing technology. Before a new batch of blades is put into use, they are matched according to the basic attributes and their design life is replaced by the average value of the corresponding historical statistical life.

[0027] Optionally, the risk warning includes:

[0028] The system backend matches the basic properties of the blades and issues a warning when the statistical mean of their historical lifespan is unqualified.

[0029] During use, when the remaining life reaches the level 1 threshold, a reminder will be displayed that the life is about to return to zero;

[0030] The maintenance suggestions include Case 1 and Case 2:

[0031] Case 1: Based on changes in status parameters such as operating current, speed, amplitude, or temperature, maintenance strategies are pushed, including:

[0032] (a) When there is a slight abnormality, push reminders to operators to reduce production load;

[0033] (b) When the device is in a moderate abnormality, in addition to the operations in (a), a reminder is sent to the equipment maintenance personnel to conduct on-site observation and inspection;

[0034] (c) When a serious abnormality occurs, in addition to the operations in (b), reminders and spare parts inventory status are pushed to management personnel, and timely spare parts replacement is recommended;

[0035] Case 2: Based on the historical classification evaluation of the actual service life of the blades, provide selection suggestions for spare parts procurement, including:

[0036] (a) When the number of times the historical evaluation is "qualified" or above is greater than 80%, the supplier's name and material, hardness and processing technology requirements;

[0037] (b) 70% < When the number of times the historical evaluation is "qualified" or above is ≤ 80%, the supplier's name and material, hardness and processing technology requirements;

[0038] (c) 60% ≤ When the number of “qualified” and above ratings in historical evaluations is ≤ 70%, the supplier’s name and material, hardness, and processing technology requirements;

[0039] The data interaction and report display is to graphically display risk warnings and maintenance suggestions on the computer side and interact with humans to facilitate monitoring by production management personnel.

[0040] The beneficial effect of the present invention is that the present invention is completely different from the traditional manual management mode. The present invention can realize the automatic prediction and refined management of the blade life of the rotary hearth furnace mixer, reduce the maintenance cost of the mixer and ensure stable operation.

[0041] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0043] Figure 1 This is a diagram showing the architecture of the rotary hearth furnace mixer blade life management system according to the present invention;

[0044] Figure 2 The diagram is a life status diagram of the blade life management of a rotary mixer according to the present invention. DETAILED DESCRIPTION

[0045] The following describes the embodiments of the present invention by means of specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0046] Among them, the accompanying drawings are only for illustrative purposes and represent only schematic diagrams rather than actual pictures, and should not be understood as limiting the present invention. In order to better illustrate the embodiments of the present invention, some parts of the accompanying drawings may be omitted, enlarged or reduced, and do not represent the dimensions of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted in the accompanying drawings.

[0047] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "front", "back", etc. indicating directions or positional relationships, they are based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0048] See also Figure 1 and Figure 2 There is a method and system for managing the life of blades of a rotary hearth furnace mixer. The implementation steps are as follows:

[0049] 1) Input the theoretical service life T0 and theoretical material processing volume M0 of the blade designed at the factory, which are defined as the initial values ​​of the blade theoretical life index 1 and index 2 respectively.

[0050] 2) Record the initial external dimensions V0 of the leaf (including length, width, and height), which are defined as the initial values ​​of the leaf health characteristic values.

[0051] 3) Simultaneously record the material characteristics of the batch of blades, such as material, hardness, processing technology, etc., as well as supplier details, and establish a basic attribute library for blade quality.

[0052] 4) Record the cumulative running time of the blade T i , cumulative processing volume M i and the external dimensions V measured during the intermediate repair i, obtain the life index and health characteristic value of the intermediate process state, and calculate its change rate K T , K M , K V Calculate and compare, then use the blade size change rate K V Correction time and processing material quantity are two life indicators; when the remaining life indicator t i or m i An early warning is issued when the preset level 1 threshold is reached, and the life span is reset to zero when the level 2 threshold is reached.

[0053] 5) Synchronously collect operating status parameters of the mixer process, such as current, speed, vibration, temperature, etc., and classify them according to two expert rules: normal operating conditions and abnormal operating conditions. The operating time and material processing volume under different rules are counted separately, and then the blades in the same batch are marked.

[0054] 6) Accumulate a historical database and expert knowledge base of blade life, conduct statistical analysis on its historical life values, and take the average value as feedback to revise the theoretical life indicators of a new batch of blades.

[0055] 7) Establish a visual dashboard to dynamically present the real-time life, health status and operating parameters of the blades, and provide risk warnings, maintenance recommendations, data interaction, report display and other functions.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for managing the life of mixer blades, characterized by: The method comprises the following steps: S1: Input the theoretical service life T0 and theoretical material processing volume M0 of the blade designed at the factory, which are defined as the initial values ​​of the blade theoretical life index 1 and index 2 respectively; S2: Record the initial dimensions of the leaf, V0, including length, width, and height, which are defined as the initial values ​​of the leaf health characteristic values; S3: Synchronously record the material characteristics of this batch of blades, including material, hardness, processing technology and supplier information, and establish a basic attribute library for blade quality; S4: Record the cumulative running time of the blade T i , cumulative processing volume M i and the external dimensions V measured during the intermediate repair i , obtain the life index and health characteristic value of the intermediate process state. The life index refers to the theoretical use time T0, and the health characteristic value refers to the theoretical processing material volume M0. Calculate and compare their change rates. The change rates include the theoretical use time change rate K T =T i / T0, processing material quantity change rate K M =M i / M0 and blade size change rate K V =V i / V0 is calculated and compared; if the blade size change rate K V The change rate of theoretical usage time K T Or the change rate of processed material K M If they are not synchronized, the blade size change rate K V Correct the two life indicators of theoretical service time T0 and theoretical processing material volume M0, that is, T0 = T i *K v , M0=M i *K v ; When any remaining life t i or m i When the preset level 1 threshold, i.e. 10% of the corrected theoretical life span, is reached, an early warning is issued. When the level 2 threshold, i.e. 0, is reached, the life span is reset to zero. S5: Synchronously collect the operating status parameters of the mixer process, including current, speed, vibration, and temperature, and classify them into normal and abnormal operating conditions, as follows. The operating time and material processing volume under different rules are counted separately, and then the blades in the same batch are marked; S6: Accumulate and form a historical database and expert knowledge base of blade life, conduct statistical analysis on its historical life values, and take the average value as feedback to revise the theoretical service time T0 and theoretical processing amount M0 of a new batch of blades; S7: Establish a visual dashboard to dynamically present the real-time lifespan, health status, and operating parameters of the blades, and provide risk warnings, maintenance recommendations, data interaction, and report display functions.

2. The method for managing the life of a mixer blade according to claim 1, characterized in that: The normal operating condition is no greater than the maximum operating value allowed by the factory design of the equipment; Abnormal operating conditions: exceeding the maximum operating value allowed by the equipment's factory design and unplanned shutdown, are divided into three levels: mild, moderate and severe according to the extent of the excess, as follows: Mild: The excess is less than or equal to 1.1 times the maximum operating value; Moderate: The excess is 1.1 to 1.2 times the maximum operating value; Severe: The excess is greater than or equal to 1.2 times the maximum operating value; Unplanned downtime: equipment stops operating.

3. The method for managing the life of a mixer blade according to claim 1, characterized in that: The historical database contains the theoretical service life and theoretical material usage of each batch of blades designed for delivery, as well as the actual service life and theoretical material usage when scrapped, and is synchronized with the blade quality basic attribute library recorded in S3; The expert knowledge base is based on the statistical data of blade life under different attribute conditions, forming a classification evaluation according to the actual length of use, and at the same time establishing the statistical laws between it and the material, hardness and processing technology, as follows: Excellent: actual service life ≥ design service life × 110%; Good: Design service life value < actual service life ≤ design service life value × 110%; Qualified: Design service life value = actual service life; Unqualified: Design service life value ≤ actual service life; According to the classification of excellent, good, qualified and unqualified, we accumulate and establish the corresponding usage effects under the basic quality attribute library of blades from different suppliers, materials, hardness and processing technology. Before a new batch of blades is put into use, they are matched according to the basic attributes and their design life is replaced by the average value of the corresponding historical statistical life.

4. The method for managing the life of a mixer blade according to claim 1, characterized in that: The risk warning includes: The system backend matches the basic properties of the blades and issues a warning when the statistical mean of their historical lifespan is unqualified. During use, when the remaining life reaches the level 1 threshold, a reminder will be displayed that the life is about to return to zero; The maintenance suggestions include Case 1 and Case 2: Case 1: Based on changes in status parameters such as operating current, speed, amplitude, or temperature, maintenance strategies are pushed, including: (a) When there is a slight abnormality, push reminders to operators to reduce production load; (b) When the device is in a moderate abnormality, in addition to the operations in (a), a reminder is sent to the equipment maintenance personnel to conduct on-site observation and inspection; (c) When a serious abnormality occurs, in addition to the operations in (b), reminders and spare parts inventory status are pushed to management personnel, and timely spare parts replacement is recommended; Case 2: Based on the historical classification evaluation of the actual service life of the blades, provide selection suggestions for spare parts procurement, including: (a) When the number of times the historical evaluation is "qualified" or above is greater than 80%, the supplier's name and material, hardness and processing technology requirements; (b) 70% < When the number of "qualified" and above in historical evaluations is ≤ 80%, the supplier's name and material, hardness and processing technology requirements; (c) 60% ≤ When the number of "qualified" and above historical evaluations is ≤ 70%, the supplier's name and material, hardness and processing technology requirements; The data interaction and report display is to graphically display risk warnings and maintenance suggestions on the computer side and interact with humans to facilitate monitoring by production management personnel.

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