A method and system for determining material distribution and material mixing during silo unloading

Abstract

The present application provides a method and system for determining the material distribution and material mixing during silo unloading. First, a simulation model generated in advance or in real time is obtained, and then the simulation model is used to perform numerical calculations on the material flow in the silo during silo unloading to obtain the material flow line time information; finally, according to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated. The present application predicts the distribution of each batch of materials in the silo and the mixing state at the outlet during the silo unloading process, and realizes the refined tracking of the material composition, quality, weight and time information entering the blast furnace, which can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, the present application has the characteristics of high computational efficiency and strong stability, and can meet the requirements of long-term online operation.

Description

Technical Field

[0001] The present application relates to the technical field of steel smelting, and in particular to a method and system for determining material distribution and material mixing during silo unloading. Background Art

[0002] As a container for bulk materials, the silo plays a role in mixing, homogenizing and storing materials during material transportation. In steel mills, the silo batching process is an important part of the blast furnace ironmaking process. The raw materials required for blast furnace smelting are transported from sintering machines, coke ovens and raw material yards. Sintered ore, coke and ore are transported to the silo on the trough by conveyor belts for mixing and redistribution, and finally sent to the blast furnace for production and smelting. In order to better ensure the efficient and stable production of blast furnaces, it is very necessary to track the composition, quality, weight and time of materials entering the blast furnace in a refined manner, so as to prompt and warn managers.

[0003] During the batching process in the silo, different silo structural types and different unloading operations will lead to complex changes in the material distribution in the silo and the material information at the outlet, and this information is difficult to obtain directly, which brings great difficulties to batching management and material information tracking. Therefore, it is necessary to monitor the material information during the batching process. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, the purpose of the present application is to provide a method and system for determining material distribution and material mixing during silo unloading, so as to solve the technical problems existing in the prior art.

[0005] To achieve the above objectives and other related objectives, the present application provides a method for determining material distribution and material mixing during silo unloading, the method comprising the following steps:

[0006] Access to pre- or real-time generated simulation models;

[0007] The simulation model is used to numerically calculate the material flow in the silo when the silo is unloading, and obtain the material flow line time information;

[0008] According to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated.

[0009] Optionally, the generation process of the simulation model includes:

[0010] Acquire silo unloading operation data, and establish a silo geometric model based on the silo unloading operation data;

[0011] Meshing the silo geometric model to identify silo unloading operation boundary data;

[0012] The simulation boundary conditions are loaded according to the silo unloading operation boundary data and the silo unloading material information to generate the simulation model.

[0013] Optionally, the process of acquiring the silo unloading operation data and establishing the silo geometric model based on the silo unloading operation data includes:

[0014] Acquire silo unloading operation data, wherein the silo unloading operation data includes silo feeding data and silo unloading data;

[0015] Screening the silo unloading operation data, performing a first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing into a database; wherein the first type of processing includes interpolation, padding and average processing;

[0016] The first layer material surface data is extracted from the database, and the first layer material surface is fitted based on the extracted first layer material surface data to establish the silo geometric model.

[0017] Optionally, the process of fitting the first layer material surface based on the extracted first layer material surface data includes:

[0018] If the extracted first-layer material surface data is the complete material surface position coordinates, the first-layer material surface is fitted according to the real first-layer material surface data;

[0019] If the extracted first-layer material surface data is the height of the first number of material surface measurement points, a spline curve is used to interpolate and fit the first-layer material surface;

[0020] If the extracted first-layer material surface data is the height of the second number of material surface measurement points, the first-layer material surface is fitted according to the first-layer material surface being horizontal or at a certain stacking angle; wherein the first number is much larger than the second number.

[0021] Optionally, the silo feeding data includes at least one of the following: current feeding time, material batch number, material type, material density, and first-layer material surface data at the current feeding moment;

[0022] The silo unloading data includes at least one of the following: unloading status of the silo discharge port and unloading flow rate of the silo discharge port.

[0023] Optionally, the process of using the simulation model to numerically calculate the material flow in the silo when the silo is unloading and obtaining the material flow line time information includes:

[0024] The simulation model is used to numerically calculate the material flow in the silo when the silo is unloading, and obtain material flow parameters;

[0025] Determining material flow line time information according to the material flow parameters;

[0026] Wherein, the material flow parameters include at least one of the following: material flow line number, material attribute, material speed, and material position coordinates.

[0027] Optionally, after calculating the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet, the method further includes:

[0028] Transmitting the position distribution of each batch of materials in the silo and the mixing state of each batch of materials at the silo outlet to the display for display; and,

[0029] Receive and respond to control instructions issued by the management object, and adjust the silo unloading operation data.

[0030] The present application also provides a system for determining material distribution and material mixing during silo unloading, the system comprising:

[0031] A simulation model acquisition module is used to acquire a simulation model generated in advance or in real time;

[0032] A discharge flow numerical calculation module is used to use the simulation model to perform numerical calculations on the material flow in the silo when the silo is discharged, and obtain material flow line time information;

[0033] Material surface line coordinate loading module, used to map and load the material surface line position coordinates;

[0034] The material distribution and material mixing calculation module is used to calculate the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet according to the material flow line time information and the mapped loaded material surface line position coordinates.

[0035] Optionally, the system further comprises:

[0036] Data receiving and preprocessing module, used to obtain silo unloading operation data;

[0037] A silo geometry model module, used to establish a silo geometry model according to the silo unloading operation data;

[0038] A meshing module, used to mesh the silo geometric model and identify silo unloading operation boundary data;

[0039] The simulation model generation module loads the simulation boundary conditions according to the silo unloading operation boundary data and the silo unloading material information to generate the simulation model.

[0040] Optionally, the process of the silo geometric model module establishing the silo geometric model according to the silo unloading operation data includes:

[0041] Acquire silo unloading operation data, wherein the silo unloading operation data includes silo feeding data and silo unloading data;

[0042] Screening the silo unloading operation data, performing a first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing into a database; wherein the first type of processing includes interpolation, padding and average processing;

[0043] The first layer material surface data is extracted from the database, and the first layer material surface is fitted based on the extracted first layer material surface data to establish the silo geometric model.

[0044] As described above, the present application provides a method and system for determining material distribution and material mixing during silo unloading, which has the following beneficial effects:

[0045] This application first obtains a simulation model generated in advance or in real time, and then uses the simulation model to perform numerical calculations on the material flow in the silo during silo unloading, and obtains the material flow line time information; finally, according to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated. It can be seen from this that this application predicts the distribution of each batch of materials in the silo during the silo unloading process and the mixing state at the outlet, and realizes the refined tracking of information such as the composition, quality, weight and time of the materials entering the blast furnace, which can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, this application has the characteristics of high computational efficiency and strong stability, and can meet the requirements of long-term online operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 A schematic flow chart of a method for determining material distribution and material mixing during silo unloading provided in an embodiment of the present application;

[0047] Figure 2 A schematic diagram of material distribution in a silo at the first moment provided in an embodiment of the present application;

[0048] Figure 3 A schematic diagram of material distribution in a silo at a second moment provided in an embodiment of the present application;

[0049] Figure 4 A schematic diagram of material distribution in a silo at the third moment provided in an embodiment of the present application;

[0050] Figure 5 A schematic diagram of material distribution in a silo at the fourth moment provided in an embodiment of the present application;

[0051] Figure 6A schematic diagram of material distribution in a silo at the fifth moment provided in an embodiment of the present application;

[0052] Figure 7 A schematic diagram of material distribution in a silo at the sixth moment provided in an embodiment of the present application;

[0053] Figure 8 A schematic diagram of material mixing in a silo at different times provided in an embodiment of the present application;

[0054] Fig. 9 A schematic flow chart of a method for determining material distribution and material mixing during silo unloading provided in another embodiment of the present application;

[0055] Fig.10 A schematic diagram of the hardware structure of a system for determining material distribution and material mixing during silo unloading provided in an embodiment of the present application;

[0056] Fig.11 A schematic diagram of the hardware structure of a system for determining material distribution and material mixing during silo unloading provided in another embodiment of the present application. DETAILED DESCRIPTION

[0057] The following describes the embodiments of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. The present application 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 application. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0058] It should be noted that the illustrations provided in this embodiment only illustrate the basic concept of the present application in a schematic manner, and therefore the drawings only show components related to the present application rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0059] See also Figure 1 As shown, this embodiment provides a method for determining material distribution and material mixing when a silo is unloaded, comprising the following steps:

[0060] S110, obtaining a simulation model generated in advance or in real time;

[0061] S120, using the simulation model to perform numerical calculation on the material flow in the silo when the silo is unloading, and obtaining material flow line time information;

[0062] S130, calculating the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet according to the material flow line time information and the mapped material surface line position coordinates.

[0063] It can be seen that this embodiment predicts the distribution of each batch of materials in the silo during the unloading process and the mixing at the outlet, so as to achieve refined tracking of information such as the composition, quality, weight and time of materials entering the blast furnace. It can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, this embodiment has the characteristics of high computing efficiency and strong stability, and can meet the requirements of long-term online operation. As an example, in this embodiment, the material distribution when the silo is unloaded at different times is as follows Figures 2 to 7 As shown in the figure, the material mixing state when the silo is unloaded at different times is as follows Figure 8 As shown. Among them, Figure 2 The material distribution state of the silo unloading process at t = 960s is shown. Figure 3 The material distribution status of the silo unloading process at t = 2160s is shown. Figure 4 The material distribution state of the silo unloading process at t = 3360s is shown. Figure 5 The material distribution status of the silo unloading process at t = 4560s is shown. Figure 6 The material distribution status of the silo unloading process at t = 5760s is shown. Figure 7 The material distribution state of the silo unloading process at t = 6960s is shown. Figures 2 to 7 In , character A1 represents material A1, character A2 represents material A2, character A3 represents material A3, and character A4 represents material A4; the order of adding material A1, material A2, material A3, and material A4 is material A1, material A2, material A3, and material A4. Figure 8 In the table, character a represents material a, character b represents material b, character c represents material c, character d represents material d, character e represents material e, character f represents material f, and character g represents material g.

[0064] According to the above records, in an exemplary embodiment, the generation process of the simulation model includes: obtaining the silo unloading operation data, and establishing the silo geometric model based on the silo unloading operation data; meshing the silo geometric model to identify the silo unloading operation boundary data; loading the simulation boundary conditions according to the silo unloading operation boundary data and the silo unloading material information to generate the simulation model. As an example, the process of obtaining the silo unloading operation data and establishing the silo geometric model based on the silo unloading operation data in this embodiment includes: obtaining the silo unloading operation data, screening the silo unloading operation data, and performing the first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing to a database; extracting the first layer material surface data from the database, and fitting the first layer material surface based on the extracted first layer material surface data to establish the silo geometric model. Among them, the first type of processing includes interpolation, padding and average processing, and the silo unloading operation data includes silo feeding data and silo unloading data. Specifically, in this embodiment, the silo feeding data includes but is not limited to: current feeding time, material batch number, material type, material density, and first-layer material surface data at the current feeding moment; the silo unloading data includes but is not limited to: silo unloading state and unloading flow rate at the unloading port. The unloading flow rate at the unloading port in this embodiment can be directly measured, or converted by weighing the weight of a weighing device at the bottom of the silo for a period of time, or by other reasonable methods.

[0065] According to the above records, in an exemplary embodiment, the process of fitting the first layer of material surface based on the extracted first layer of material surface data includes: if the extracted first layer of material surface data is the complete material surface position coordinates, then fitting the first layer of material surface according to the real first layer of material surface data; if the extracted first layer of material surface data is the height of a first number of material surface measurement points, then using a spline curve to interpolate and fit the first layer of material surface; if the extracted first layer of material surface data is the height of a second number of material surface measurement points, then fitting the first layer of material surface according to the first layer of material surface being horizontal or at a certain stacking angle; wherein, the first number is much larger than the second number.

[0066] In an exemplary embodiment, the simulation model is used to perform numerical calculations on the material flow in the silo when the silo is unloading, and the process of obtaining material flow line time information includes: using the simulation model to perform numerical calculations on the material flow in the silo when the silo is unloading, and obtaining material flow parameters; solving the material flow line time information based on the material flow parameters; wherein the material flow parameters include at least one of the following: material flow line number, material properties, material speed, and material position coordinates.

[0067] In an exemplary embodiment, after calculating the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet, the method further includes: transmitting the position distribution of each batch of materials in the silo and the mixing state of each batch of materials at the silo outlet to a display for display; and receiving and responding to a control instruction issued by a management object to adjust the silo unloading operation data. It can be seen that this embodiment processes the calculated material distribution coordinate data in the silo and the material mixing percentage data at the outlet and sends them to the display terminal in a corresponding format, thereby realizing continuous online prediction of the distribution of each batch of materials in the silo at different times and the mixing state at the outlet.

[0068] In another exemplary embodiment of the present application, Fig. 9 As shown, this embodiment also provides a method for determining material distribution and material mixing when a silo is unloaded, comprising the following steps:

[0069] S11, receiving and processing the on-site unloading operation data. As an example, the process of receiving and processing the on-site unloading operation data includes: selecting the required unloading operation data for receiving, including feeding data and unloading data; determining whether the data is correct and reasonable, and eliminating incorrect and unreasonable data; performing appropriate processing on the screened data, such as interpolation, padding and time-average processing, and saving it to the database. Specifically, in the present embodiment, receiving and processing the on-site unloading operation data refers to receiving the silo unloading operation data collected on-site through a receiving module. Since a lot of types of operation data are collected during on-site silo unloading, some data are required for the subsequent steps of the present invention, and some are not required; at the same time, incorrect and unreasonable data may also exist in the required data. Therefore, when receiving data, it is necessary to select the type of received data, and the received data also needs to be screened and processed. The specific process includes:

[0070] Only valid data types required for subsequent steps are received, namely, silo feeding data and unloading data, where: silo feeding data includes current feeding time, material batch number, material type, material density and first-layer material surface data at the current feeding moment; unloading data includes silo unloading status and unloading flow rate at the unloading port. The unloading flow rate at the unloading port can be measured directly, or converted by weighing the weight of the weighing device at the bottom of the silo for a period of time, or by other reasonable methods.

[0071] According to the actual measured data on site and combined with process experience, judgment rules are formulated in advance. According to the judgment rules, it is determined whether the received data is correct and reasonable, and the original data is screened and filtered to eliminate incorrect and unreasonable data.

[0072] For the filtered data, select the appropriate method for appropriate processing according to different data. For example, the first-layer material surface data may need to be interpolated and filled, and the discharge flow data may need to be processed by time-average processing. After the corresponding data is processed, it is saved to the corresponding database for calculation and solution in the subsequent steps.

[0073] S12, extracting the first-layer material surface data, fitting the first-layer material surface, and automatically establishing the silo geometric model. As an example, after completing the reception and processing of the on-site unloading operation data, this embodiment can extract the first-layer material surface data, fit the material surface according to different collection conditions of the first-layer material surface data, import the fitted first-layer material surface into the corresponding silo geometric model, and automatically build the model through the program. Furthermore, if the collected first-layer material surface data is a relatively complete material surface position coordinate, the actual first-layer material surface shape is considered during modeling, and the edge of the first-layer material surface is aligned with the silo wall; if the collected first-layer material surface data is a certain number of material surface measurement point height values, spline curves can be used for interpolation or even padding operations during modeling to fit the first-layer material surface shape curve, and the edge of the first-layer material surface is aligned with the silo wall; if the collected first-layer material surface data is a few or even a single material surface point height value, the average of all point height values ​​is taken during modeling, and it is assumed that the first-layer material surface is horizontally distributed at the average height, or is at the average height and freely stacked at a certain stacking angle, and the angle can be the natural stacking angle of the corresponding material.

[0074] S13, automatically mesh the silo geometric model and identify the corresponding boundaries. As an example, after the geometric model is automatically established, in order to perform numerical calculations on the material flow in the silo, the geometric model needs to be discretized in this embodiment. The numerical calculation of the flow can use the finite volume method, so meshing is required. In the present invention, the silo structure is relatively regular and can be divided using a structured grid. Specifically, according to the node positions of the silo geometric model, the silos with different material surface heights are automatically geometrically topologically divided into blocks, and then each block is structured meshed, and the meshes at the interface are matched to obtain the mesh of the entire silo model. When meshing, the divided grids are also identified based on the node positions to obtain the corresponding boundaries required for subsequent numerical calculations, such as the material surface inlet, the discharge outlet, and the silo wall.

[0075] S14, extracting the unloading operation boundary data and material information, automatically loading the simulation boundary conditions, and setting the simulation model. As an example, after completing the grid division, this embodiment automatically loads the corresponding boundary conditions for the identified boundaries and sets the simulation model. Specifically, for the material surface inlet, set the pressure conditions; for the unloading outlet, set the corresponding unloading flow rate according to the unloading state of each outlet; at the same time, according to the feed batch number, feed type, and feed density, automatically set the corresponding material density, material viscosity, and other model parameters in the simulation model.

[0076] S15, using the simulation model to perform numerical calculations on the material flow in the silo during the silo unloading process, obtain material flow parameters, and solve the material flow line time information. As an example, this embodiment can use a viscous flow laminar flow model to perform numerical calculations on the material flow in the silo during the silo unloading process, and obtain material flow parameters in the silo, including material flow line number, material properties, material speed, and material position coordinates. The material flow line time information, such as time contours, is solved by the material flow parameters for subsequent material flow identification and solution.

[0077] S16, loading of material surface line position coordinate data mapping. As an example, materials keep flowing during the unloading process. In addition to considering the movement of the first layer of material surface in the silo at different times, the movement of the material surface line of other materials in the silo also needs to be considered. Therefore, it is first necessary to obtain the positions of all material surface lines in the silo at each moment. Through the background grid technology, the material surface line position coordinate data of the intersection of each batch of materials at the corresponding moment can be mapped to the current moment model by querying the previous calculation results, which is used for the calculation of the new material surface line position coordinates after the material flows during the unloading process.

[0078] S17, based on the material flow line time information and the material surface line position coordinates, calculate the position distribution of each batch of materials in the bin at different times and the mixing situation at the bin outlet. As an example, in this embodiment, with the material flow line time information and all the material surface line position coordinates in the bin, the distribution position coordinates of each batch of materials in the bin at different times during the unloading process and the mixing percentage at the bin outlet can be calculated. Finally, the corresponding calculation results are sent to the display module through the data sending module, and corresponding processing is performed, so as to realize the continuous online prediction of the distribution situation of each batch of materials in the bin at different times and the mixing situation at the outlet. The prediction results can be referred to Figures 2 to 8 As shown. Among them, Figure 2 The material distribution state of the silo unloading process at t = 960s is shown. Figure 3 The material distribution status of the silo unloading process at t = 2160s is shown. Figure 4 The material distribution state of the silo unloading process at t = 3360s is shown. Figure 5 The material distribution status of the silo unloading process at t = 4560s is shown. Figure 6The material distribution status of the silo unloading process at t = 5760s is shown. Figure 7 The material distribution state of the silo unloading process at t = 6960s is shown, and the material mixing state of the silo unloading at different times is shown as follows: Figure 8 As shown. Figures 2 to 7 In , character A1 represents material A1, character A2 represents material A2, character A3 represents material A3, and character A4 represents material A4; the order of adding material A1, material A2, material A3, and material A4 is material A1, material A2, material A3, and material A4. Figure 8 In the table, character a represents material a, character b represents material b, character c represents material c, character d represents material d, character e represents material e, character f represents material f, and character g represents material g.

[0079] In summary, the present application provides a method for determining the material distribution and material mixing during the silo unloading, first obtains a simulation model generated in advance or in real time, and then uses the simulation model to perform numerical calculations on the material flow in the silo during the silo unloading, and obtains the material flow line time information; finally, according to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated. It can be seen that this method predicts the distribution of each batch of materials in the silo and the mixing at the outlet during the silo unloading process, and realizes the refined tracking of the material composition, quality, weight and time information entering the blast furnace, which can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, the present application has the characteristics of high computational efficiency and strong stability, and can meet the requirements of long-term online operation. In addition, the present method closely combines the silo unloading operation principle, process experience and actual on-site measurement data, directly receives the on-site silo unloading operation data and performs corresponding screening and processing, as the basis for geometric modeling and simulation boundary and parameter setting, which conforms to the actual production operation. At the same time, the viscous flow model and parallel computing method are used to perform numerical calculations on the material flow in the silo, which greatly improves the calculation efficiency. For silos with relatively simple structures, it can ensure that a single prediction cycle is within 10 minutes to meet on-site production needs.

[0080] like Fig.10 As shown, the present application also provides a system for determining material distribution and material mixing during silo unloading, the system comprising:

[0081] A simulation model acquisition module 1050 is used to acquire a simulation model generated in advance or in real time;

[0082] The unloading flow numerical calculation module 1060 is used to use the simulation model to perform numerical calculation on the material flow in the silo when the silo is unloading, and obtain the material flow line time information;

[0083] The material surface line coordinate loading module 1070 is used to map and load the material surface line position coordinates;

[0084] The material distribution and material mixing calculation module 1080 is used to calculate the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet according to the material flow line time information and the mapped loaded material surface line position coordinates.

[0085] It can be seen that this embodiment predicts the distribution of each batch of materials in the silo during the unloading process and the mixing at the outlet, so as to achieve refined tracking of information such as the composition, quality, weight and time of materials entering the blast furnace. It can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, this embodiment has the characteristics of high computing efficiency and strong stability, and can meet the requirements of long-term online operation. As an example, in this embodiment, the material distribution when the silo is unloaded at different times is as follows Figures 2 to 7 As shown in the figure, the material mixing state when the silo is unloaded at different times is as follows Figure 8 As shown. Among them, Figure 2 The material distribution state of the silo unloading process at t = 960s is shown. Figure 3 The material distribution status of the silo unloading process at t = 2160s is shown. Figure 4 The material distribution state of the silo unloading process at t = 3360s is shown. Figure 5 The material distribution status of the silo unloading process at t = 4560s is shown. Figure 6 The material distribution status of the silo unloading process at t = 5760s is shown. Figure 7 The material distribution state of the silo unloading process at t = 6960s is shown. Figures 2 to 7 In , character A1 represents material A1, character A2 represents material A2, character A3 represents material A3, and character A4 represents material A4; the order of adding material A1, material A2, material A3, and material A4 is material A1, material A2, material A3, and material A4. Figure 8 In the table, character a represents material a, character b represents material b, character c represents material c, character d represents material d, character e represents material e, character f represents material f, and character g represents material g.

[0086] According to the above records, in an exemplary embodiment, the system further includes:

[0087] The data receiving and preprocessing module 1010 is used to obtain the silo unloading operation data;

[0088] A silo geometry model module 1020, used to establish a silo geometry model according to the silo unloading operation data;

[0089] A meshing module 1030 is used to mesh the silo geometric model and identify silo unloading operation boundary data;

[0090] The simulation model generation module 1040 loads the simulation boundary conditions according to the silo unloading operation boundary data and the silo unloading material information to generate the simulation model.

[0091] As an example, the generation process of the simulation model of this embodiment includes: obtaining silo unloading operation data, and establishing a silo geometric model based on the silo unloading operation data; meshing the silo geometric model to identify silo unloading operation boundary data; loading simulation boundary conditions according to the silo unloading operation boundary data and silo unloading material information to generate the simulation model. In addition, the process of establishing a silo geometric model based on the silo unloading operation data of this embodiment includes: obtaining silo unloading operation data, screening the silo unloading operation data, and performing a first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing to a database; extracting the first layer material surface data from the database, and fitting the first layer material surface based on the extracted first layer material surface data to establish the silo geometric model. Among them, the first type of processing includes interpolation, padding and average processing, and the silo unloading operation data includes silo feeding data and silo unloading data. Specifically, in this embodiment, the silo feeding data includes but is not limited to: current feeding time, material batch number, material type, material density, and first-layer material surface data at the current feeding moment; the silo unloading data includes but is not limited to: silo unloading state and unloading flow rate at the unloading port. The unloading flow rate at the unloading port in this embodiment can be directly measured, or converted by weighing the weight of a weighing device at the bottom of the silo for a period of time, or by other reasonable methods.

[0092] According to the above records, in an exemplary embodiment, the process of fitting the first layer of material surface based on the extracted first layer of material surface data includes: if the extracted first layer of material surface data is the complete material surface position coordinates, then fitting the first layer of material surface according to the real first layer of material surface data; if the extracted first layer of material surface data is the height of a first number of material surface measurement points, then using a spline curve to interpolate and fit the first layer of material surface; if the extracted first layer of material surface data is the height of a second number of material surface measurement points, then fitting the first layer of material surface according to the first layer of material surface being horizontal or at a certain stacking angle; wherein, the first number is much larger than the second number.

[0093] In an exemplary embodiment, the simulation model is used to perform numerical calculations on the material flow in the silo when the silo is unloading, and the process of obtaining material flow line time information includes: using the simulation model to perform numerical calculations on the material flow in the silo when the silo is unloading, and obtaining material flow parameters; solving the material flow line time information based on the material flow parameters; wherein the material flow parameters include at least one of the following: material flow line number, material properties, material speed, and material position coordinates.

[0094] In an exemplary embodiment, after calculating the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet, the method further includes: transmitting the position distribution of each batch of materials in the silo and the mixing state of each batch of materials at the silo outlet to a display for display; and receiving and responding to a control instruction issued by a management object to adjust the silo unloading operation data. It can be seen that this embodiment processes the calculated material distribution coordinate data in the silo and the material mixing percentage data at the outlet and sends them to the display terminal in a corresponding format, thereby realizing continuous online prediction of the distribution of each batch of materials in the silo at different times and the mixing state at the outlet.

[0095] In another exemplary embodiment of the present application, Fig.11 As shown, this embodiment also provides a system for determining material distribution and material mixing during silo unloading, comprising:

[0096] The data receiving and processing module 1 is used to select and receive the on-site unloading operation data required for calculation, including feeding data and unloading data, and perform corresponding screening and processing on the received data, and then save it to the database. As an example, the process of receiving and processing the on-site unloading operation data includes: selecting the required unloading operation data for reception, including feeding data and unloading data; determining whether the data is correct and reasonable, and eliminating incorrect and unreasonable data; performing appropriate processing on the screened data, such as interpolation, padding and time-average processing, and saving it to the database. Specifically, in this embodiment, the on-site unloading operation data reception and processing refers to receiving the silo unloading operation data collected on-site through the receiving module. Since a lot of operation data types are collected when the on-site silo is unloading, some data are required for the subsequent steps of the present invention, and some are not required; at the same time, incorrect and unreasonable data may also exist in the required data. Therefore, when receiving data, it is necessary to select the received data type, and the received data also needs to be screened and processed. The specific process includes:

[0097] Only valid data types required for subsequent steps are received, namely, silo feeding data and unloading data, where: silo feeding data includes current feeding time, material batch number, material type, material density and first-layer material surface data at the current feeding moment; unloading data includes silo unloading status and unloading flow rate at the unloading port. The unloading flow rate at the unloading port can be measured directly, or converted by weighing the weight of the weighing device at the bottom of the silo for a period of time, or by other reasonable methods.

[0098] According to the actual measured data on site and combined with process experience, judgment rules are formulated in advance. According to the judgment rules, it is determined whether the received data is correct and reasonable, and the original data is screened and filtered to eliminate incorrect and unreasonable data.

[0099] For the filtered data, select the appropriate method for appropriate processing according to different data. For example, the first-layer material surface data may need to be interpolated and filled, and the discharge flow data may need to be processed by time-average processing. After the corresponding data is processed, it is saved to the corresponding database for calculation and solution in the subsequent steps.

[0100] The first-layer material surface recognition and geometric model automatic establishment module 2 is used to extract the first-layer material surface data, fit the first-layer material surface, and automatically establish the silo geometric model. As an example, after completing the reception and processing of the on-site unloading operation data, this embodiment can extract the first-layer material surface data, fit the material surface according to different collection conditions of the first-layer material surface data, import the fitted first-layer material surface into the corresponding silo geometric model, and automatically model it through the program. Furthermore, if the collected first-layer material surface data is a relatively complete material surface position coordinate, the actual first-layer material surface shape is considered during modeling, and the edge of the first-layer material surface is aligned with the silo wall; if the collected first-layer material surface data is a certain number of material surface measurement point height values, spline curves can be used for interpolation or even padding operations during modeling to fit the first-layer material surface shape curve, and the edge of the first-layer material surface is aligned with the silo wall; if the collected first-layer material surface data is a few or even a single material surface point height value, the average of all point height values ​​is taken during modeling, and it is assumed that the first-layer material surface is horizontally distributed at the average height, or is at the average height and freely stacked at a certain stacking angle, and the angle can be the natural stacking angle of the corresponding material.

[0101] The automatic grid division module 3 is used to automatically grid the silo geometric model and identify the corresponding boundaries. As an example, after the geometric model is automatically established, in order to perform numerical calculations on the material flow in the silo, the geometric model needs to be discretized in this embodiment. The numerical calculation of the flow can use the finite volume method, so grid division is required. In the present invention, the silo structure is relatively regular and can be divided using a structured grid. Specifically, according to the node positions of the silo geometric model, the silo with different material surface heights is automatically divided into geometric topological blocks, and then each block is structured grid divided, and the grids at the interface are matched to obtain the grid of the entire silo model. When performing grid division, the divided grids are also identified based on the node positions to obtain the corresponding boundaries required for subsequent numerical calculations, such as the material surface inlet, the discharge outlet, and the silo wall.

[0102] The unloading boundary automatic loading and model setting module 4 is used to extract the unloading operation boundary data and material information, automatically load the simulation boundary conditions, and set the simulation model. As an example, after completing the grid division, this embodiment automatically loads the corresponding boundary conditions for the identified boundaries and sets the simulation model. Specifically, the pressure conditions are set for the material surface inlet; for the unloading outlet, the corresponding unloading flow rate is set according to the unloading state of each outlet; at the same time, according to the feed batch number, feed type, and feed density, the corresponding material density, material viscosity, and other model parameters are automatically set in the simulation model.

[0103] The unloading flow numerical calculation module 5 is used to perform numerical calculations on the material flow in the silo during the unloading process of the silo, obtain the corresponding material flow parameters, and solve the material flow line time information. As an example, this embodiment can use a viscous flow laminar flow model to perform numerical calculations on the material flow in the silo during the unloading process of the silo, and obtain the material flow parameters in the silo, including the material flow line number, material properties, material speed, and material position coordinates. The material flow line time information, such as time contours, is solved by the material flow parameters for subsequent material flow identification and solution.

[0104] The material surface line coordinate data loading module 6 is used to map and load the material surface line position coordinate data of the intersection of each batch of materials calculated before in the current calculation through the background grid technology (the time corresponds to the current time), which is used to calculate the new material surface line position coordinates after the material flows during the unloading process. As an example, the material keeps flowing during the unloading process. In addition to considering the movement of the first layer of material surface in the silo at different times, the movement of the material surface line of other materials in the silo also needs to be considered. Therefore, it is first necessary to obtain all the material surface line positions in the silo at each moment. Through the background grid technology, the material surface line position coordinate data of the intersection of each batch of materials at the corresponding moment can be mapped to the current moment model by querying the previous calculation results, which is used to calculate the new material surface line position coordinates after the material flows during the unloading process.

[0105] The material distribution in the bin and outlet mixing calculation module 7 is used to calculate the position coordinates of each batch of materials in the bin at different times of the current unloading process and the mixing percentage at the bin outlet according to the solved material flow line time information and the loaded material surface line position coordinates. As an example, in this embodiment, with the material flow line time information and all the material surface line position coordinates in the bin, the distribution position coordinates of each batch of materials in the bin at different times of the unloading process and the mixing percentage at the bin outlet can be calculated. Finally, the corresponding calculation results are sent to the display module through the data sending module, and corresponding processing is performed, so as to realize the continuous online prediction of the distribution of each batch of materials in the bin at different times and the mixing at the outlet.

[0106] The data processing and sending module 8 processes the calculated material distribution coordinate data in the warehouse and the material mixing percentage data at the outlet, and sends them to the display terminal in the corresponding format, so as to realize the continuous online prediction of the distribution of each batch of materials in the warehouse and the mixing situation at the outlet at different times. The prediction display results can be referred to Figures 2 to 8 As shown. Among them, Figure 2 The material distribution state of the silo unloading process at t = 960s is shown. Figure 3 The material distribution status of the silo unloading process at t = 2160s is shown. Figure 4 The material distribution state of the silo unloading process at t = 3360s is shown. Figure 5 The material distribution status of the silo unloading process at t = 4560s is shown. Figure 6 The material distribution status of the silo unloading process at t = 5760s is shown. Figure 7 The material distribution state of the silo unloading process at t = 6960s is shown, and the material mixing state of the silo unloading at different times is shown as follows: Figure 8 As shown. Figures 2 to 7 In , character A1 represents material A1, character A2 represents material A2, character A3 represents material A3, and character A4 represents material A4; the order of adding material A1, material A2, material A3, and material A4 is material A1, material A2, material A3, and material A4. Figure 8 In the table, character a represents material a, character b represents material b, character c represents material c, character d represents material d, character e represents material e, character f represents material f, and character g represents material g.

[0107] In summary, the present application provides a system for determining the material distribution and material mixing during the silo unloading. First, a simulation model generated in advance or in real time is obtained, and then the simulation model is used to perform numerical calculations on the material flow in the silo during the silo unloading to obtain the material flow line time information; finally, according to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated. It can be seen that the system predicts the distribution of each batch of materials in the silo and the mixing at the outlet during the silo unloading process, and realizes the refined tracking of the material composition, quality, weight and time information entering the blast furnace, which can not only prompt and warn managers in time for abnormal materials, but also better ensure the efficient and stable production of the blast furnace. At the same time, the present application has the characteristics of high computational efficiency and strong stability, and can meet the requirements of long-term online operation. In addition, the system closely combines the silo unloading operation principle, process experience and actual on-site measurement data, directly receives the on-site silo unloading operation data and performs corresponding screening and processing, as the basis for geometric modeling and simulation boundary and parameter setting, which conforms to the actual production operation. At the same time, the viscous flow model and parallel computing method are used to perform numerical calculations on the material flow in the silo, which greatly improves the calculation efficiency. For silos with relatively simple structures, it can ensure that a single prediction cycle is within 10 minutes to meet on-site production needs.

[0108] It should be noted that the system for determining material distribution and material mixing when a silo is unloaded provided in the above embodiment and the method for determining material distribution and material mixing when a silo is unloaded provided in the above embodiment belong to the same concept, wherein the specific manner in which each module and unit performs operations has been described in detail in the method embodiment and will not be repeated here. In actual applications, the system for determining material distribution and material mixing when a silo is unloaded provided in the above embodiment can distribute the above functions to different functional modules as needed, that is, divide the internal structure of the system into different functional modules to complete all or part of the functions described above, and this is not limited here. Therefore, the present application effectively overcomes various shortcomings in the prior art and has a high industrial utilization value.

[0109] The above embodiments are only illustrative of the principles and effects of the present application, and are not intended to limit the present application. Anyone familiar with this technology can modify or change the above embodiments without violating the spirit and scope of the present application. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the relevant technical field without departing from the spirit and technical ideas disclosed in the present application should still be covered by the claims of the present application. The structures, proportions, sizes, etc. illustrated in the drawings in this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions that can be implemented in the present application, so they have no technical substantive significance. Any structural modification, change in the proportional relationship or adjustment of the size, without affecting the effects that can be produced by the present application and the purposes that can be achieved, should still fall within the scope of the technical content disclosed in the present application. It should be understood that although the terms first, second, third, etc. may be used in the embodiments of the present application to describe the preset range, etc., these preset ranges should not be limited to these terms. These terms are only used to distinguish the preset ranges from each other. For example, without departing from the scope of the embodiments of the present application, the first preset range may also be referred to as the second preset range, and similarly, the second preset range may also be referred to as the first preset range.

Claims

1. A method for determining material distribution and material mixing during silo unloading, characterized in that: The method comprises the following steps: Acquire a simulation model generated in advance or in real time; the generation process of the simulation model includes: acquiring silo unloading operation data, and establishing a silo geometric model based on the silo unloading operation data; meshing the silo geometric model to identify silo unloading operation boundary data; loading simulation boundary conditions according to the silo unloading operation boundary data and silo unloading material information to generate the simulation model; The simulation model is used to numerically calculate the material flow in the silo when the silo is unloading, and obtain the material flow line time information; According to the material flow line time information and the mapped material surface line position coordinates, the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet are calculated; Among them, the process of obtaining silo unloading operation data and establishing a silo geometric model based on the silo unloading operation data includes: obtaining silo unloading operation data, the silo unloading operation data includes silo feeding data and silo unloading data; screening the silo unloading operation data, and performing a first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing into a database; wherein the first type of processing includes interpolation, padding and average processing; extracting the first layer material surface data from the database, and fitting the first layer material surface based on the extracted first layer material surface data to establish the silo geometric model; The process of fitting the first layer of material surface based on the extracted first layer of material surface data includes: if the extracted first layer of material surface data is the complete material surface position coordinates, then fitting the first layer of material surface according to the real first layer of material surface data; if the extracted first layer of material surface data is the height of the first number of material surface measurement points, then using a spline curve to interpolate and fit the first layer of material surface; if the extracted first layer of material surface data is the height of the second number of material surface measurement points, then fitting the first layer of material surface according to the first layer of material surface being horizontal or at a certain stacking angle; wherein the first number is greater than the second number.

2. The method for determining material distribution and material mixing during silo unloading according to claim 1, characterized in that: The silo feeding data includes at least one of the following: current feeding time, material batch number, material type, material density, and first layer material surface data at the current feeding moment; The silo unloading data includes at least one of the following: unloading status of the silo discharge port and unloading flow rate of the silo discharge port.

3. The method for determining material distribution and material mixing during silo unloading according to claim 1, characterized in that: The process of numerically calculating the material flow in the silo during silo unloading by using the simulation model and obtaining the material flow line time information includes: The simulation model is used to numerically calculate the material flow in the silo when the silo is unloading, and obtain material flow parameters; Determining material flow line time information according to the material flow parameters; Wherein, the material flow parameters include at least one of the following: material flow line number, material attribute, material speed, and material position coordinates.

4. The method for determining material distribution and material mixing during silo unloading according to claim 1, characterized in that: After calculating the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet, the method further includes: Transmitting the position distribution of each batch of materials in the silo and the mixing state of each batch of materials at the silo outlet to the display for display; and, Receive and respond to control instructions issued by the management object, and adjust the silo unloading operation data.

5. A system for determining material distribution and material mixing during silo unloading, characterized in that: The system comprises: A data receiving and preprocessing module is used to obtain silo unloading operation data; wherein the silo unloading operation data includes silo feeding data and silo unloading data; A silo geometry model module is used to establish a silo geometry model according to the silo unloading operation data; including: screening the silo unloading operation data, performing a first type of processing on the screened silo unloading operation data, and saving the silo unloading operation data after the first type of processing into a database; wherein the first type of processing includes interpolation, padding and average processing; extracting the first layer material surface data from the database, and fitting the first layer material surface based on the extracted first layer material surface data to establish the silo geometry model; A meshing module, used to mesh the silo geometric model and identify silo unloading operation boundary data; A simulation model generation module, used to load simulation boundary conditions according to the silo unloading operation boundary data and silo unloading material information to generate the simulation model; A simulation model acquisition module is used to acquire a simulation model generated in advance or in real time; A discharge flow numerical calculation module is used to use the simulation model to perform numerical calculations on the material flow in the silo when the silo is discharged, and obtain material flow line time information; Material surface line coordinate loading module, used to map and load the material surface line position coordinates; The material distribution and material mixing calculation module is used to calculate the position distribution of each batch of materials in the silo at different times and the mixing state of each batch of materials at the silo outlet according to the material flow line time information and the mapped loaded material surface line position coordinates.

Images