A method for predicting the service life of a high-temperature discharge screw blade

Abstract

The present application relates to a kind of high temperature discharge screw blade life prediction method, belong to the field of automation.The method includes the following steps:S1: obtaining screw blade initial theoretical life;S2: take the greater value in K T And K H Corresponding blade health coefficient K i Of this scan is assigned;S3: the mean of health coefficient in time period is recorded as α and β respectively;S4: get the remaining processing material quantity R i It is the remaining life of screw blade;S5: according to the degree of change of initial size W0 to obtain wear degree γ, the remaining life R i Of blade is corrected;S6: when the remaining life R i Reach the 1st threshold value of preset, reach the 2nd threshold value of life zero;S7: correct screw blade theoretical life value M0.The present application can realize the automatic prediction and fine management of rotary hearth furnace discharge screw blade life, reduce the maintenance cost of discharge screw while ensuring stable operation.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of automation, and relates to a method for predicting the service life of high-temperature discharge screw blade. BACKGROUND

[0002] The rotary hearth furnace process is mainly used for environmental protection treatment of dust and mud containing iron and zinc in steel enterprises, and produces metallized pellets and secondary zinc oxide powder. The process is gradually recognized and accepted in China. With the production practice, new problems of the new process are exposed, for example, the rotary hearth furnace discharge screw is used to discharge the high-temperature metallized pellets completed by roasting in the furnace, but due to the strong grinding and chipping property of the metallized pellets and the high-temperature environment, the discharge screw blade is quickly worn and needs to be replaced regularly.

[0003] The rotary hearth furnace production is a 24-hour uninterrupted continuous operation. Once the screw blade is worn too seriously, the furnace bottom will rise, causing abnormal work of the screw, seriously affecting the production stability, and even forcing the production to stop in severe cases. In order to ensure production, the blade life is currently estimated according to manual experience, and then replaced regularly. Due to the high cost of the screw blade and the poor accuracy of manual judgment, it is often easy to replace too early and cause waste or not in time, which leads to unsustainable production and cannot support the requirement of fine management. SUMMARY

[0004] Therefore, the purpose of the present application is to provide a method for predicting the service life of high-temperature discharge screw blade.

[0005] In order to achieve the above purpose, the present application provides the following technical scheme:

[0006] A method for predicting the service life of high-temperature discharge screw blade, the method comprising the following steps:

[0007] S1: recording the theoretical treatment material amount M0 of the screw blade design, obtaining the initial theoretical service life of the screw blade;

[0008] S2: using an endoscopic infrared imaging device to perform regular scanning detection on the axial temperature distribution of the surface of the screw blade and the distribution state of the furnace bottom material surface in the running process, identifying and analyzing the collected radiation spectrum and image, extracting the blade surface temperature distribution value and the furnace bottom material surface distribution value, and then comparing and calculating the two with the theoretical value respectively, so as to obtain the blade surface temperature difference change rate K T =T 实测 / T 理论 and the furnace bottom material surface difference change rate K H =H 实测 / H 理论 , taking the larger value of K T and K H as the blade health coefficient K i, K T =Max(K T , K H ); The theoretical value refers to the factory theoretical design value of the blade surface temperature and the furnace bottom material surface;

[0009] S3: Synchronously collect the state parameters of current, speed, displacement and duration during the operation of the discharge screw, and classify them into normal working conditions and abnormal working conditions. Abnormal working conditions do not include downtime. Then, according to the number of scans n within the corresponding operating time, calculate the average health coefficient within the period. The health coefficient during normal working conditions is α = ∑K i / n1, the health factor during abnormal working hours is β=∑K i / n2;

[0010] Among them, normal operating conditions are those that are not greater than the maximum operating value allowed by the equipment's factory design; abnormal operating conditions are those that exceed the maximum operating value allowed by the equipment's factory design;

[0011] S4: Use the calculated health coefficients α and β to correct the theoretical processing volume M0 of the spiral blade, and then deduct the accumulated processed volume M i , get the remaining processing material amount R i =(1-α-β)*M0-M i , which is the remaining life of the spiral blade;

[0012] S5: Synchronously record the spiral blade size change data W obtained during the scheduled maintenance i , and the wear degree γ=W is obtained according to the degree of change from the initial size W0 i / W0, the remaining life of the blade R i Make corrections, that is, R i =γ*R i ;

[0013] S6: When the remaining life R i When the preset level 1 threshold, i.e. 10% of the theoretical life span M0, is reached, an early warning is issued; when the level 2 threshold, i.e. 0, is reached, the life span is reset to zero;

[0014] S7: accumulating and forming a statistical database of spiral blade life data, classifying and calculating the historical life average according to normal working conditions and abnormal working conditions, and using this as feedback to correct the spiral blade theoretical life value M0.

[0015] Optionally, the historical life average values ​​are classified and counted according to normal working conditions and abnormal working conditions, and used as feedback to correct the theoretical life value M0 of the spiral blade, specifically:

[0016] 1) Level I: When the normal operating time is 80% < ≤ 100%, the average blade life is recorded as M0-I;

[0017] 2) Grade II: 60% < normal operating time ratio < 80%, the average blade life is recorded as M0-II;

[0018] 3) Grade III: < 60% of normal operating time ratio, the average blade life is recorded as M0-III.

[0019] The beneficial effects of the present application are that the present application is completely different from the traditional manual prediction mode, and the automatic prediction and fine management of the screw blade life of the rotary hearth furnace discharge screw can be realized by using the present application, thereby reducing the maintenance cost of the discharge screw while ensuring stable operation.

[0020] Other advantages, objects, and features of the present application will be set forth in part in the following specification taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art from a consideration of the following specification and from the practice of the present application. The objects and other advantages of the present application will be realized and attained by means of the instrumentalities and combinations pointed out in the following specification. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to make the objects, technical solutions and advantages of the present application clearer, the preferred detailed description of the present application will be made below in conjunction with the drawings, in which:

[0022] Figure 1 The figure is suitable for the architecture of the rotary hearth furnace high-temperature discharge screw blade life prediction of the present application;

[0023] Figure 2 The figure is suitable for the flow chart of the rotary hearth furnace high-temperature discharge screw blade life prediction of the present application. DETAILED DESCRIPTION

[0024] The embodiments of the present application will be described below through specific specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in the specification. The present application can also be implemented or applied by different specific embodiments, and the details in the specification can be modified or changed based on different views and applications without departing from the spirit of the present application. It should be noted that the figures provided in the following examples only illustrate the basic concept of the present application in a schematic manner, and the following examples and features in the examples can be combined with each other without conflict.

[0025] The figures are only used for illustrative explanation, and the representation is only a schematic diagram, not a physical diagram, and cannot be understood as a limitation of the present application; in order to better illustrate the embodiments of the present application, some components in the drawings are omitted, enlarged or reduced, and do not represent the size of the actual product; it is understandable for those skilled in the art that some known structures and their descriptions in the drawings can be omitted.

[0026] The same or similar reference numerals in the drawings of the embodiments of the present application correspond to the same or similar components; in the description of the present application, it is understood that if the orientations or positional relationships indicated by the terms "upper", "lower", "left", "right", "front", "back", etc. are based on the orientations or positional relationships shown in the drawings, they are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore the terms describing the positional relationship in the drawings are only used for exemplary illustration, and cannot be understood as a limitation on the present application, for those skilled in the art, the specific meanings of the above terms can be understood according to the specific circumstances.

[0027] Referring to Figure 1 and Figure 2 , there is a method for predicting the service life of the screw blade of the high-temperature discharge screw of the rotary hearth furnace, which is implemented as follows:

[0028] 1) Record the theoretical treatment amount M0 of the screw blade design to obtain the initial theoretical service life of the screw blade.

[0029] 2) Use an endoscopic infrared integrated imaging device to perform timed scanning detection on the axial temperature distribution of the screw blade surface and the distribution state of the furnace bottom material surface during operation, identify and analyze the collected radiation spectrum and image, extract the blade surface temperature distribution value and the furnace bottom material surface distribution value, and then compare and calculate the two values with the theoretical values respectively, so as to obtain the blade surface temperature difference change rate K T and the furnace bottom material surface difference change rate K H , take the larger value of K T and K H as the blade health coefficient K i of the corresponding scanning.

[0030] 3) Synchronously collect the key state parameters such as current, speed, displacement and time length during the operation of the discharge screw, classify them according to normal and abnormal working conditions according to expert knowledge, and then calculate the average health coefficient in the scanning times n within the corresponding operation time, which are respectively denoted as alpha and beta.

[0031] 4) Use the calculated health coefficients alpha and beta to correct the theoretical treatment amount M0 of the screw blade, and then deduct the accumulated treatment amount M i , so as to obtain the remaining treatment amount R i , which is the remaining service life of the screw blade.

[0032] 5) Synchronously record the size change data W i of the screw blade obtained by measuring and mapping at the time of repair, obtain the wear degree gamma according to the change degree of W i and the initial size W0, and correct the remaining service life R i of the blade according to the judgment of expert knowledge.

[0033] 6) When the remaining life R reaches the preset 1st level threshold, a pre-warning is issued, and when the 2nd level threshold is reached, the life is zeroed. i

[0034] 7) Accumulate the statistical library of the life data of the spiral blade, then analyze and screen it in combination with the expert knowledge, and feed back the historical mean value to correct the theoretical life value M0 of the spiral blade.

[0035] Finally, it is to be explained that the above embodiments are only used to illustrate the technical solutions of the present application but not to limit the present application. Although the present application 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 application can be modified or replaced equivalently without departing from the purpose and scope of the present application, and all should be covered in the scope of the claims of the present application.​

Claims

1. A method for high temperature discharge auger flight life prediction, the method comprising: The method comprises the following steps: S1: record the theoretical handling amount M0 of the spiral blade design, and obtain the initial theoretical service life of the spiral blade; S2: Adopting endoscopic infrared imaging device to detect the axial temperature distribution of the screw blade surface and the distribution state of the furnace bottom material surface in the running process, identifying and analyzing the collected radiation spectrum and image, extracting the blade surface temperature distribution value and the furnace bottom material surface distribution value, then comparing and calculating the two with the theoretical value respectively, so as to obtain the blade surface temperature difference change rate K T = T 实测 / T 理论 and the furnace bottom material surface difference change rate K H = H 实测 / H 理论 , taking the larger value of K T and K H as the health coefficient K i of the corresponding blade of this scan, K T = Max(K T , K H ); wherein the theoretical value refers to the factory theoretical design value of the blade surface temperature and the furnace bottom material surface. S3: synchronously collect the state parameters of current, rotation speed, displacement and time length in the running process of the discharging screw, classify according to normal working condition and abnormal working condition, the abnormal working condition does not contain downtime, then calculate the health coefficient mean in the time period according to the scanning number n in the corresponding running time length, the health coefficient in the normal working condition time is α = ∑K i / n1, and the health coefficient in the abnormal working condition time is β = ∑K i / n2; Wherein, the normal working condition is not more than the maximum value allowed by the design of the equipment out of the factory; the abnormal working condition is beyond the maximum value allowed by the design of the equipment out of the factory; S4: using the calculated health coefficients a and b to correct the theoretical processing amount M0 of the spiral blade, and then deducting the accumulated processed material amount M i , to obtain the remaining processing material amount R i = (1 - a - b) * M0 - M i , which is the remaining life of the spiral blade; S5: synchronously recording the size change data W of the spiral blade obtained by the mapping at the repair time i , and obtaining the wear degree γ = W i / W0 according to the change degree thereof from the initial size W0, correcting the remaining life R i of the blade, i.e. R i = γ * R i ; S6: when the remaining life R reaches a pre-set level 1 threshold, i.e. 10% of the theoretical life M0, a warning is issued, and when it reaches a level 2 threshold, i.e. 0, the life is zeroed. i S6: when the remaining life R reaches a pre-set level 1 threshold, i.e. 10% of the theoretical life M0, a warning is issued, and when it reaches a level 2 threshold, i.e. S7: accumulate the statistical library of the spiral blade service life data, classify and statistically calculate the historical service life average according to the normal working condition and the abnormal working condition, and use it to feedback and correct the theoretical service life value M0 of the spiral blade.

2. A method of life prediction of high temperature discharge auger flight as claimed in claim 1 wherein: The classification and statistical calculation of the historical service life average according to the normal working condition and the abnormal working condition, and the feedback and correction of the theoretical service life value M0 of the spiral blade are specifically as follows: 1) I level: 80% < normal working condition running time ratio ≤ 100%, blade service life average is recorded as M0-I; 2) II level: 60% < normal working condition running time ratio ≤ 80%, blade service life average is recorded as M0-II; 3) III level: normal working condition running time ratio ≤ 60%, blade service life average is recorded as M0-III.

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