A method for predicting the service life of a ball press roller sleeve

Abstract

The present application relates to a kind of ball press roller sleeve life prediction method, belong to metallurgical dust and mud solid waste rotary hearth furnace field.The method includes the following steps: S1: obtaining roller sleeve initial life state;S2: using machine vision analysis technology to the green ball granularity made is on-line real-time monitoring and image recognition, continuously obtain the green ball granularity distribution characteristics of intermediate process state;S3: the green ball granularity data greater than classification limit is counted;S4: the residual life value of roller sleeve is obtained;S5: when residual life value reaches the 1st threshold 10%, send early warning, reaches 2nd threshold, life is zero;S6: the historical statistical mean is fed back to correct roller sleeve theoretical processing amount.The present application is completely different from traditional manual prediction mode, using the present application can realize rotary hearth furnace ball press roller sleeve life automatic prediction, can help reduce maintenance cost while guaranteeing operation stability, support the fine management of production maintenance.

Description

Technical Field

[0001] This invention belongs to the field of rotary hearth furnace for metallurgical dust and solid waste, and relates to a method for predicting the lifespan of roller sleeves in briquetting machines. Background Technology

[0002] Rotary hearth furnace technology is mainly used for the environmentally friendly treatment of iron- and zinc-containing dust and sludge in steel enterprises, producing metallized pellets and zinc oxide powder. This technology has gradually gained recognition and acceptance in China. However, with the advancement of production practice, new problems have also emerged. For example, the raw materials processed by the rotary hearth furnace are iron-containing dust and sludge with varying physical properties. To facilitate subsequent processing, the materials must be batched and mixed evenly before being manually briquetteed using a forming machine to obtain uniformly shaped green pellets. The equipment used for manual briquetting mainly includes disc pelletizers and briquetting machines, with the briquetting machine being the most widely used.

[0003] A briquetting machine mainly consists of a feeder, a drive unit, a pair of working rollers, and an extrusion device. Its working principle is that the drive unit rotates the working rollers, the feeder evenly feeds the raw material into the gap between the working rollers, and the extrusion device acts on the working rollers, causing the raw material to be squeezed into green balls of a regular shape and size by the roller sleeves surrounding the working rollers. The size of the notches on the surface of the roller sleeves directly determines the shape of the produced green balls. Due to the high abrasiveness of the raw material and the long-term exposure to high pressure, the working conditions are complex and harsh, leading to rapid wear of the briquetting machine's roller sleeves and a gradual change in the size of the green balls. Therefore, regular inspection and replacement of the roller sleeves are necessary.

[0004] Because rotary hearth furnaces operate continuously 24 hours a day, excessive wear of the roller sleeves makes it difficult to obtain green pellets of the required size, failing to meet downstream production requirements and potentially forcing a production shutdown. To ensure production, experienced operators currently estimate the remaining lifespan of the roller sleeves based on the amount of material already processed and then periodically request replacements in advance. However, due to the high cost of the roller sleeves and the poor accuracy of manual judgment, premature replacement often leads to waste, while untimely replacement disrupts production and fails to meet the requirements of refined management. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a method for predicting the life of roller sleeves in a briquetting machine.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for predicting the lifespan of a briquetting machine roller sleeve, the method comprising the following steps:

[0008] S1: Record the initial green ball design particle size P0 and theoretical processing capacity M0 of the roller sleeve design to obtain the initial life state of the roller sleeve;

[0009] S2: The machine vision analysis technology is used to monitor and recognize the particle size of the green pellets in real time online. The image recognition is used to identify and automatically count the size of the green pellets so as to continuously obtain the particle size distribution characteristics of the green pellets in the intermediate process.

[0010] S3: According to the preset grading limits, collect the data on green pellet size larger than the grading limits and take the statistical mean P. i The wear coefficient K of the roller sleeve ball socket is calculated by comparing it with the initial green ball size P0. P K P =P0 / P i ;K P ∈[0.7,1], the lower limit value is preset and adjustable;

[0011] S4: Using the calculated wear coefficient K P Correct the theoretical processing capacity M0 of the roller sleeve, and then subtract the accumulated processed capacity M. i The remaining life value R of the roller sleeve is obtained by performing dimensionless processing. i That is, R i =[1-M i / (K P *M0)]×100%;

[0012] S5: When the remaining lifetime value R i An alert is issued when the preset Level 1 threshold of 10% is reached, and the lifespan is reset to zero when the Level 2 threshold is reached.

[0013] S6: Accumulate a historical database of roller sleeve life, and then use its historical statistical average. Feedback correction roller sleeve theoretical material handling capacity M0.

[0014] Optionally, the equivalent diameter of the initial green pellets is 8mm to 16mm; if the initial green pellets are irregular spherical, they are converted into spherical particles of equal volume, and the resulting diameter is the equivalent diameter; the theoretical processing capacity is 80,000 tons to 120,000 tons, and the initial life state of the roller sleeve is obtained.

[0015] Optionally, the grading limit is 8mm. When the roller sleeve wears, the size of the resulting green balls will increase, i.e., the volume will increase. The statistical average P of particles larger than 8mm is calculated. i ,8mm≤P i ≤16mm.

[0016] The beneficial effects of this invention are as follows: This invention is completely different from the traditional manual prediction mode. Using this invention, the life of the roller sleeve of the rotary hearth furnace briquetting machine can be automatically predicted, which can help reduce maintenance costs while ensuring stable operation and supporting the refined management of production maintenance.

[0017] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0018] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein:

[0019] Figure 1 This is a flowchart illustrating the application of the present invention to predict the lifespan of roller sleeves in rotary hearth furnace briquetting machines;

[0020] Figure 2 This is a schematic diagram illustrating the application of the present invention to the image recognition of green pellet size in a rotary hearth furnace briquetting machine. Detailed Implementation

[0021] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed 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 representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0022] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0023] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship 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 orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0024] See Figure 1 , Figure 2 A method for predicting the lifespan of roller sleeves in a rotary hearth furnace briquetting machine is available. The implementation steps are as follows:

[0025] 1) Record the initial green ball design particle size P0 and theoretical processing capacity M0 of the roller sleeve design to obtain the initial life state of the roller sleeve.

[0026] 2) such as Figure 2 As shown, machine vision analysis technology is used to monitor and recognize the particle size of the produced green pellets online in real time, so as to continuously obtain the particle size distribution characteristics of green pellets in the intermediate process state.

[0027] 3) Based on the preset grading threshold (adjustable as needed), only collect data on green pellet size larger than the grading threshold, and take the statistical mean P. i The wear coefficient K of the roller sleeve ball socket is calculated by comparing it with the initial green ball size P0. P (K P ∈[0, 1], lower limit value is preset and adjustable), that is, K P =P0 / P i ;

[0028] 4) Using the calculated wear coefficient K P Correct the theoretical processing capacity M0 of the roller sleeve, and then subtract the accumulated processed capacity M. i The remaining life value R of the roller sleeve is obtained by performing dimensionless processing. i That is, R i =[1-M i / (K P *M0)]×100%;

[0029] 5) When the remaining lifetime value R i When the preset Level 1 threshold of 10% is reached (the preset threshold is adjustable), an early warning is issued; when the Level 2 threshold (i.e., 0%) is reached, the lifespan is reset to zero.

[0030] 6) Accumulate a historical database of roller sleeve life, and then calculate its historical average. Feedback correction roller sleeve theoretical material handling capacity M0.

[0031] Remaining lifetime value R i The following is an example of the calculation:

[0032] 1) Assuming the initial green ball design of the roller sleeve has an equivalent diameter of 12mm (the green ball size may be an irregular sphere, which is converted into spherical particles with equal volume, and the resulting diameter is the equivalent diameter), and the theoretical processing capacity is assumed to be 100,000 tons, this is the initial life state value of the roller sleeve.

[0033] 2) Statistical data on the actual production green pellet particle size distribution are automatically obtained through image recognition. 8mm (adjustable as needed) is selected because the green pellet size obtained from pelletizing is relatively uniform, but some broken particles are present. In production, 8mm (adjustable as needed) is often used as the grading boundary. As the roller sleeve wears, the size of the resulting green pellets will gradually increase, i.e., the volume will gradually increase. The statistical mean P of particles 8mm (inclusive) and above is calculated. i (8mm≤P i (≤16mm). Assuming the average of the above statistical data is 15mm, then the wear coefficient K... p =12 / 15=0.8;

[0034] 3) If the cumulative material throughput is 40,000 tons, then the remaining lifespan value R is... i = [1 - 40000 / (0.8 * 100000)] × 100% = 50%.

[0035] 4) Repeat the iterative detection process until the alarm threshold is triggered, at which point the lifetime is reduced to zero.

[0036] 5) Record the life data of each batch of roller sleeves, calculate the average value, and then correct the theoretical material handling capacity of the next batch of roller sleeves.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for predicting the lifespan of a briquetting machine roller sleeve, characterized in that: The method includes the following steps: S1: Record the initial green pellet size P0 and theoretical processing capacity M0 of the roller sleeve design to obtain the initial life state of the roller sleeve; S2: The machine vision analysis technology is used to monitor and recognize the particle size of the green pellets in real time online. The image recognition is used to identify and automatically count the size of the green pellets so as to continuously obtain the particle size distribution characteristics of the green pellets in the intermediate process. S3: According to the preset grading limits, collect the data on green pellet size larger than the grading limits and take the statistical mean P. i The wear coefficient K of the roller sleeve ball socket is calculated by comparing it with the initial green ball size P0. P K P = P0 / P i ;K P ∈[0.7,1], the lower limit value is preset and adjustable; S4: Using the calculated wear coefficient K P Correct the theoretical processing capacity M0 of the roller sleeve, and then subtract the accumulated processed capacity M. i The remaining life value R of the roller sleeve is obtained by performing dimensionless processing. i That is, R i =[1-M i / (K P M0)]×100%; S5: When the remaining lifetime value R i An alert is issued when the preset Level 1 threshold of 10% is reached, and the lifespan is reset to zero when the Level 2 threshold is reached. S6: Accumulate and form a historical database of roller sleeve life, and then calculate the historical statistical average of roller sleeve life. Feedback correction roller sleeve theoretical material handling capacity .

2. The method for predicting the lifespan of a briquetting machine roller sleeve according to claim 1, characterized in that: The equivalent diameter of the initial green pellets is 8mm to 16mm; if the initial green pellets are irregular spherical, they are converted into spherical particles of equal volume, and the resulting diameter is the equivalent diameter; the theoretical processing capacity is 80,000 tons to 120,000 tons, and the initial life state of the roller sleeve is obtained.

3. The method for predicting the lifespan of a briquetting machine roller sleeve according to claim 2, characterized in that: The grading limit is 8mm. When the roller sleeve wears down, the size of the resulting green balls will increase, i.e., the volume will increase. The statistical average value P of particles larger than 8mm is calculated. i ,8mm≤P i ≤16mm.

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