A ceramic plate breakage alarm system for a ceramic filter machine

Abstract

This invention discloses a ceramic plate breakage alarm system for a ceramic filter, relating to the field of dewatering equipment technology. It includes a data reading unit, a shutdown execution unit, a machine alarm unit, and a control unit. These units are electrically connected to a drive circuit board within the alarm device and to an electrical cabinet used to control the operation of each ceramic filter. In this alarm system, once a ceramic plate breaks, causing the vacuum level to drop to the alarm value, the system immediately stops and issues an audible and visual alarm. This prevents avalanche effects, preventing collisions with other intact ceramic plates that could cause breakage, reducing ceramic plate wear, minimizing maintenance, and shortening repair time. Furthermore, it avoids the risk of deteriorated dewatering efficiency and increased concentrate moisture content after ceramic plate breakage.

Description

Technical Field

[0001] This invention relates to the field of dehydration equipment technology, and in particular to an alarm system for ceramic plate breakage in a ceramic filter. Background Technology

[0002] The dewatering workshop uses ceramic filters (a type of dewatering equipment mainly composed of ceramic filter plates, roller system, stirring system, ore feeding and discharging system, vacuum system, filtrate discharge system, scraping system, backwashing system, combined cleaning system, fully automatic control system, tank, and frame) to separate concentrate slurry materials. The dewatering effect and automation level are much better than the previous plate and frame filter press. In order to improve the dewatering efficiency, the dewatering workshop usually sets up multiple ceramic filters to carry out dewatering operations at the same time.

[0003] As a key component of ceramic filters, the quality of ceramic plates determines the dewatering efficiency of materials. Once broken, the entire dewatering system is disrupted, as the poor adsorption capacity of the ceramic plates leads to a significant increase in the moisture content of the dry material. During operation, ceramic filter breakage frequently occurs, causing the concentrate slurry to be drawn into the filter water pipeline, contaminating the pipeline and water tank. Furthermore, broken ceramic plates accumulate in the tank, colliding with other intact plates and causing widespread breakage, increasing maintenance difficulty and downtime, and reducing hourly efficiency. When ceramic plates break, the vacuum system of the ceramic filter rapidly decreases. Based on this characteristic, this application provides a ceramic plate breakage alarm system for ceramic filters to meet this need. Summary of the Invention

[0004] The purpose of this application is to provide a ceramic plate breakage alarm system for a ceramic filter. Once a ceramic plate breaks and the vacuum level drops to the alarm value, the system will immediately stop the machine and issue an audible and visual alarm to avoid the avalanche effect, prevent collisions with other intact ceramic plates that could cause breakage, reduce ceramic plate wear, reduce maintenance workload and shorten maintenance time, and also avoid the risk of poor dehydration effect and increased concentrate moisture after the ceramic plate breaks.

[0005] To achieve the above objectives, this application provides the following technical solution: a ceramic plate breakage alarm system for a ceramic filter, comprising a data reading unit, a stop execution unit, a machine alarm unit, and a control unit. The data reading unit, the stop execution unit, the machine alarm unit, and the control unit are all electrically connected to a drive circuit board inside the alarm device and are connected to an electrical cabinet for controlling the operation of each of the ceramic filters.

[0006] Data reading unit: Reads the vacuum data values ​​of each ceramic filter's vacuum gauge in various states such as when the machine is working, when it malfunctions, and when it stops, and stores them in the vacuum degree memory corresponding to each individual ceramic filter. Selects an appropriate vacuum data value as the body vacuum alarm value when the ceramic plate is broken and stores it in the alarm value memory set for each ceramic filter.

[0007] Shutdown execution unit: When each ceramic filter is working normally, the control unit compares the detected vacuum data value of each ceramic filter with the corresponding vacuum alarm value in real time. When an abnormal vacuum drop to the corresponding vacuum alarm value is detected, such as ceramic plate breakage, the control unit controls the ceramic filter to stop working through the electrical cabinet.

[0008] Machine alarm unit: When a ceramic plate breaks during normal operation of a single ceramic filter, the control unit will activate the alarm light corresponding to that ceramic filter to provide an alarm reminder.

[0009] Control unit: Used to control the orderly operation of each unit.

[0010] Preferably, a timer is also included as a 3-second delay switch, after which the ceramic filter pauses after the control unit alarm light is maintained for 3 seconds.

[0011] Preferably, it also includes a radio frequency module for information exchange. The radio frequency module includes a radio frequency chip and a radio frequency antenna. The radio frequency chip is provided on the circuit board of a single vacuum gauge, the circuit board of a single alarm light, the single electrical cabinet, and the drive circuit board. The drive circuit board is provided with a plurality of radio frequency chips, which are arranged one-to-one with a plurality of vacuum gauges, a plurality of alarm lights, and a plurality of electrical cabinets. The radio frequency antenna is respectively arranged on the vacuum gauge, the alarm light, the electrical cabinet, and the alarm device.

[0012] Preferably, the alarm device is equipped with a display screen for displaying the vacuum level data of each ceramic filter and the geographical location of each vacuum gauge. The alarm device is located in the monitoring room. Each ceramic filter has two sets of alarm lights, namely alarm light I and alarm light II. Alarm light I is located in the control room, and alarm light II is located at the vacuum gauge opposite to the ceramic filter. Both alarm lights and the opposite ceramic filter are equipped with the same numerical label.

[0013] Preferably, it also includes a dual-frequency GPS module for locating the geographical location of the vacuum gauge. The dual-frequency GPS module is provided on the circuit boards of several vacuum gauges. The dual-frequency GPS module communicates with the data reading unit and the personnel's mobile phone through the radio frequency module.

[0014] Preferably, it also includes a microcontroller. When the vacuum level of the ceramic filter drops to the alarm value, the control unit activates the GSM module through the microcontroller to send information to the personnel's mobile phone. The information includes the geographical location, numerical label, and vacuum level value of the vacuum gauge that triggered the alarm.

[0015] Preferably, an RF drive amplifier is provided on the circuit board of a single vacuum gauge, the circuit board of a single alarm light, and the drive circuit board. The wireless signal output interface of the RF module is connected to the RFIN interface of the RF drive amplifier, and the RFOUT interface of the RF drive amplifier is connected to the input interface of the RF antenna.

[0016] Preferably, it further includes a low-noise amplifier, the RFOUT interface of which is connected to the wireless signal input interface of the radio frequency module, and the RFIN interface of which is connected to the output interface of the radio frequency antenna.

[0017] In summary, the technical effects and advantages of this invention are as follows:

[0018] 1. The present invention has a reasonable structure. Once the ceramic plate breaks and the vacuum level drops to the alarm value, the alarm system will immediately stop and issue an audible and visual alarm to avoid the avalanche effect and prevent collision with other intact ceramic plates that may cause breakage. This reduces ceramic plate wear, reduces maintenance workload and shortens maintenance time. In addition, it avoids the risk of dehydration effect deterioration and increased concentrate moisture after the ceramic plate breaks.

[0019] 2. In this invention, different vacuum alarm values ​​are set for a single ceramic filter based on actual data collection, so that the set vacuum alarm values ​​conform to the actual working conditions of the ceramic filter and improve the accuracy of fault diagnosis.

[0020] 3. In this invention, a timer is set as a 3-second delay switch. The ceramic filter stops after the alarm light lasts for 3 seconds to prevent the instrument signal from being malfunctioned due to interference from the field conditions.

[0021] 4. In this invention, the alarm lights of a single ceramic filter are provided in two sets, which are respectively set in the control room and at the vacuum gauge opposite the ceramic filter. The alarm in the control room is used to remind the monitoring personnel, while the alarm set at the vacuum gauge not only reminds the personnel, but also helps the personnel to find the fault point in time and repair it by means of the sound and light emitted by the alarm.

[0022] 5. In this invention, a dual-frequency GPS module is also provided, preferably a dual-frequency RTK positioning module, which can simultaneously receive satellite signals from two frequency bands. By utilizing the difference in ionospheric delay between the two frequencies, the influence of the ionosphere on the delay of electromagnetic wave signals can be eliminated. The dual-frequency GPS module can also accelerate the resolution of integer channel ambiguity by observing at two frequencies, while maintaining high positioning accuracy.

[0023] 6. This invention also includes a microcontroller. The microcontroller activates the GSM module to send information to the personnel's mobile phone. The information includes the geographical location, digital label, and vacuum degree value of the vacuum gauge that triggered the alarm, so that the personnel can understand the status of the filter in a timely manner and avoid being unable to understand the on-site situation when the personnel are not at the ceramic filter working site.

[0024] 7. The present invention is equipped with a radio frequency drive amplifier and a low noise amplifier to form bidirectional amplification, which greatly improves the signal transmission distance, avoids the generation of signal dead zones, and improves the signal transmission quality. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a flowchart of the alarm system of the present invention;

[0027] Figure 2 This is a block diagram of the control structure of the alarm device of the present invention;

[0028] Figure 3 For the present invention Figure 2 Block diagram of the data reading unit structure;

[0029] Figure 4 This is a schematic diagram of the radio frequency chip signal amplification structure of the present invention;

[0030] Figure 5 This is a block diagram of the circuit board structure of the vacuum meter of the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Example: Reference Figure 1 The ceramic plate breakage alarm system for a ceramic filter shown includes a data reading unit, a stop execution unit, a machine body alarm unit, and a control unit. The data reading unit, the stop execution unit, the machine body alarm unit, and the control unit are all electrically connected to the drive circuit board inside the alarm device and are connected to the electrical cabinet used to control the operation of each ceramic filter.

[0033] Data reading unit: Reads the vacuum data values ​​of each ceramic filter's vacuum gauge in various states such as when the machine is working, when it malfunctions, and when it stops, and stores them in the vacuum degree memory corresponding to each individual ceramic filter. Selects an appropriate vacuum data value as the body vacuum alarm value when the ceramic plate is broken and stores it in the alarm value memory set for each ceramic filter.

[0034] Shutdown execution unit: When each ceramic filter is working normally, the control unit compares the detected vacuum data value of each ceramic filter with the corresponding vacuum alarm value in real time. When an abnormal vacuum drop to the corresponding vacuum alarm value is detected, such as ceramic plate breakage, the control unit controls the ceramic filter to stop working through the electrical cabinet.

[0035] Machine alarm unit: When a ceramic plate breaks during normal operation of a single ceramic filter, the control unit will activate the alarm light corresponding to that ceramic filter to provide an alarm reminder.

[0036] Control unit: Used to control the orderly operation of each unit.

[0037] Due to variations in individual ceramic filter replacements, welding processes, service life, and corrosion, the vacuum alarm values ​​reached when ceramic plates break differ. Therefore, vacuum data is collected from the vacuum gauges of each ceramic filter under various conditions, including operation, malfunction, and shutdown. A suitable vacuum alarm value range is manually selected for each ceramic filter and stored in the corresponding alarm value memory. This allows for the determination of appropriate vacuum alarm value ranges for different ceramic filters, thereby improving the accuracy of fault diagnosis.

[0038] It is important to note the following: First, the vacuum gauge should be placed near the ceramic plate of the ceramic filter, and the alarm light should also be placed at the vacuum gauge. The alarm light should be an audible and visual alarm, so that people can quickly locate the fault by the sound and light emitted by the alarm. Second, a suitable vacuum data value should be manually selected as the vacuum alarm value.

[0039] As a preferred embodiment of this example, Figure 2As shown, it also includes a timer as a 3-second delay switch. The ceramic filter will pause after the alarm light lasts for 3 seconds. The timer is set to prevent the instrument signal from being malfunctioned due to interference from the field conditions.

[0040] As a preferred embodiment of this example, Figure 2 As shown, it also includes a radio frequency (RF) module for information exchange. The RF module includes an RF chip and an RF antenna. RF chips are installed on the circuit boards of a single vacuum gauge, a single alarm light, a single electrical cabinet, and a drive circuit board. The drive circuit board has several RF chips, which are configured one-to-one with several vacuum gauges, alarm lights, and electrical cabinets. RF antennas are respectively installed on the vacuum gauges, alarm lights, electrical cabinets, and alarm devices. This alarm device can remotely exchange and transmit information with the vacuum gauges, alarm lights, and electrical cabinets through the RF module. When the vacuum level of the ceramic filter reaches the alarm value, the alarm device sends a command through the RF module to the alarm light and electrical cabinet located opposite the ceramic filter, causing the alarm light to sound and controlling the electrical cabinet to stop the ceramic filter from working.

[0041] As a preferred embodiment of this example, Figure 2 As shown, the alarm device is equipped with a display screen showing the vacuum level data of each ceramic filter and the geographical location of each vacuum gauge. The alarm device is located in the monitoring room. Each ceramic filter has two sets of alarm lights, namely alarm light I and alarm light II. Alarm light I is located in the control room, and alarm light II is located at the vacuum gauge opposite to this ceramic filter. Both alarm lights and the ceramic filter opposite to them are marked with the same numerical labels. The vacuum level data measured by the vacuum gauge is received by the alarm device through the radio frequency module and displayed on the display screen in real time for monitoring personnel to view, so that the monitoring personnel can make advance judgments and stop the operation of the ceramic filter in time to avoid the breakage of the ceramic plate. When a ceramic filter malfunctions, the control unit controls the two alarm lights corresponding to this ceramic filter to sound an alarm simultaneously. The alarm in the monitoring room is used to alert the monitoring personnel, while the alarm at the vacuum gauge not only alerts the personnel but also helps them to find the fault point in time through the sound and light emitted by the alarm and repair it.

[0042] It should be noted that the alarm device is equipped with a manual button for controlling the working status of alarm light I, and the vacuum gauge of each individual ceramic filter is equipped with a manual button for controlling the working status of alarm light II, as well as a start button to control the normal operation of the ceramic filter after maintenance. After a fault is detected, in order to prevent alarm light I and alarm light II from continuously sounding the alarm, alarm light I and alarm light II can be manually stopped by using the manual button. After maintenance is completed, the ceramic filter can be started in time by using the start button.

[0043] As a preferred embodiment of this example, Figure 5 As shown, it also includes a dual-frequency GPS module for locating the geographical location of the vacuum gauge. Several vacuum gauge circuit boards are equipped with dual-frequency GPS modules. These modules communicate with the data reading unit and personnel's mobile phones via an RF module. The dual-frequency GPS module can simultaneously receive satellite signals from two frequency bands. By utilizing the difference in ionospheric delay between the two frequencies, the effect of ionospheric delay on electromagnetic wave signals can be eliminated. Furthermore, the dual-frequency GPS module can accelerate the resolution of integer ambiguity through observations at two frequencies. The preferred dual-frequency RTK positioning module achieves centimeter-level positioning accuracy, which is beneficial for accurately locating faulty vacuum gauges and enabling maintenance personnel to quickly locate the corresponding fault points.

[0044] As a preferred embodiment of this example, Figure 2 As shown, it also includes a microcontroller. When the vacuum level of the ceramic filter drops to the alarm value, the control unit activates the GSM module through the microcontroller to send information to the personnel's mobile phone. The information includes the geographical location, numerical label, and vacuum level value of the vacuum gauge that triggered the alarm, so that personnel can understand the status of the filter in a timely manner. This avoids situations where personnel are not at the ceramic filter working site and cannot understand the on-site situation, thus making it impossible to handle the fault in a timely and efficient manner. The geographical location and numerical label help personnel reach the fault location for maintenance.

[0045] It should be noted that the personnel involved are monitoring personnel and maintenance personnel.

[0046] As a preferred embodiment of this example, Figure 4 As shown, each circuit board of a single vacuum gauge, a single alarm light, a single electrical cabinet, and a drive circuit board is equipped with an RF drive amplifier. The wireless signal output interface of the RF module is connected to the RFIN interface of the RF drive amplifier, and the RFOUT interface of the RF drive amplifier is connected to the input interface of the RF antenna. The wireless signal can be amplified inside the RF drive amplifier and transmitted to the remote wireless signal receiver through the RF antenna, thereby enhancing the wireless signal power. This is beneficial for long-distance signal transmission and is suitable for use in remote mountainous areas or sparsely populated areas with poor signal coverage.

[0047] In this embodiment, as Figure 4As shown, it also includes a low-noise amplifier. The RFOUT interface of the low-noise amplifier is connected to the wireless signal input interface of the radio frequency module, and the RFIN interface of the low-noise amplifier is connected to the output interface of the radio frequency antenna. The low-noise amplifier amplifies the weak signal received by the radio frequency antenna to avoid signal dead zones. As the distance increases, the signal will become weaker and weaker due to the obstruction of houses or trees. The setting of the low-noise amplifier can further extend the signal transmission distance. In order to balance the requirements of low noise and high gain, the low-noise amplifier adopts a common emitter-common base cascaded low-noise amplifier circuit. The working principle of this system is as follows: This alarm system collects vacuum data values ​​of individual ceramic filters under different working conditions, selects appropriate vacuum values ​​as the vacuum alarm value range, and stores them in the corresponding alarm value memory. When each ceramic filter is working normally, the control unit compares the detected vacuum data values ​​of each ceramic filter with the corresponding vacuum alarm values ​​in real time. When an abnormal vacuum drop to the corresponding vacuum alarm value is detected, such as ceramic plate breakage, the control unit controls the ceramic filter to stop working through the electrical cabinet. At the same time, the control unit controls the alarm light corresponding to this ceramic filter to light up to provide an alarm reminder, avoiding the avalanche effect and preventing collisions with other intact ceramic plates that could cause breakage, thus reducing ceramic plate wear, reducing maintenance workload and shortening maintenance time. In addition, it avoids the risk of poor dehydration effect and increased concentrate moisture after ceramic plate breakage. Furthermore, different vacuum alarm values ​​are set for individual ceramic filters based on actual data collection, so that the set vacuum alarm values ​​match the actual working conditions of the ceramic filter, improving the accuracy of fault diagnosis.

[0048] A timer is set as a 3-second delay switch. The ceramic filter will stop after the alarm light lasts for 3 seconds to prevent the instrument signal from being malfunctioned due to interference from the field conditions.

[0049] Each ceramic filter has two sets of alarm lights, one in the control room and the other at the vacuum gauge opposite the ceramic filter. The alarm in the control room alerts the monitoring personnel, while the alarm at the vacuum gauge helps personnel locate the fault point and perform repairs quickly through the sound and light emitted by the alarm. A dual-frequency GPS module is also provided, preferably a dual-frequency RTK positioning module, which can simultaneously receive satellite signals from two frequency bands. By utilizing the difference in ionospheric delay between the two frequencies, the effect of ionospheric delay on electromagnetic wave signals can be eliminated. The dual-frequency GPS module can also accelerate the resolution of integer channel ambiguity by observing at two frequencies, while maintaining high positioning accuracy.

[0050] It also includes a microcontroller. The microcontroller activates the GSM module to send information to the personnel's mobile phone. The information includes the geographical location, digital label, and vacuum value of the vacuum gauge that triggered the alarm, so that the personnel can understand the status of the filter in a timely manner and avoid being unable to understand the on-site situation when the personnel are not at the ceramic filter working site.

[0051] Equipped with an RF driver amplifier and a low-noise amplifier, forming bidirectional amplification, it greatly improves the signal transmission distance, avoids signal dead zones, and enhances signal transmission quality.

[0052] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A ceramic filter ceramic sheet breakage alarm system characterized by: The alarm device comprises a data reading unit, a shutdown executing unit, a machine body alarm unit and a control unit, which are electrically connected to a driving circuit board in the alarm device and connected with an electrical cabinet for controlling the operation of each ceramic filter. The data reading unit reads the vacuum data of each ceramic filter vacuum gauge in different states such as machine body operation, fault and shutdown, and stores the data in a vacuum degree storage corresponding to a single ceramic filter, and selects appropriate vacuum data as the machine body vacuum alarm value when the ceramic plate is broken and stores the value in an alarm value storage corresponding to each ceramic filter. The shutdown executing unit controls the ceramic filter to pause operation when the vacuum data of each ceramic filter detected by the control unit is compared with the corresponding vacuum alarm value and the vacuum degree of the ceramic filter drops to the corresponding vacuum alarm value due to ceramic plate breakage. The machine body alarm unit controls the alarm lamp corresponding to the ceramic filter to light up and alarm when the ceramic plate is broken during the normal operation of the single ceramic filter. The control unit controls the orderly operation of each unit. The alarm device further comprises a timer as a 3-second delay switch, and the control unit maintains the alarm lamp for 3 seconds and then pauses the ceramic filter. The alarm device further comprises a radio frequency module for information exchange, which comprises a radio frequency chip and a radio frequency antenna. The alarm device is provided with a display screen for displaying the vacuum degree data of each ceramic filter and the geographical position of each vacuum gauge.

2. A ceramic filter ceramic sheet breakage alarm system according to claim 1, characterized in that: The alarm device further comprises a dual-frequency GPS module for positioning the geographical position of the vacuum gauge, and each vacuum gauge circuit board is provided with the dual-frequency GPS module.

3. A ceramic filter ceramic sheet breakage alarm system according to claim 2, characterized in that: The alarm device further comprises a single-chip microcomputer, which sends information to the personnel mobile terminal through the GSM module when the vacuum degree of the ceramic filter drops to the alarm value. The information includes the geographical position, digital number and vacuum degree value of the vacuum gauge triggering the alarm.

4. The ceramic filter ceramic sheet breakage alarm system of claim 1, wherein: The circuit board of the single vacuum gauge, the circuit board of the single alarm lamp, the circuit board of the single electric cabinet and the driving circuit board are all provided with a radio frequency driving amplifier, a wireless signal output interface of the radio frequency module is connected to a radio frequency driving amplifier RFIN interface, and a radio frequency driving amplifier RFOUT interface is connected to an input interface of a radio frequency antenna.

5. A ceramic filter ceramic sheet breakage alarm system according to claim 4, characterized in that: A low noise amplifier is further included, an RFOUT interface of the low noise amplifier is connected to an input interface of a wireless signal of the radio frequency module, and an RFIN interface of the low noise amplifier is connected to an output interface of the radio frequency antenna.

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