Aerated block production monitoring system

Abstract

The present invention discloses an aerated block production monitoring system, comprising: a rangefinder, a control terminal, and a mold box for making blocks; the rangefinder is connected to the control terminal, and the rangefinder is arranged above the mold box, and is used to measure a first distance from the rangefinder to the mold box plane at each moment, and transmit each first distance to the control terminal; the control terminal is used to obtain the height of the slurry in the mold box at each moment based on each first distance; calculate the difference between the slurry height at the current moment and the previous moment to obtain a first slurry height difference; calculate the first gas emission velocity of the current embryo based on the time interval between the current moment and the previous moment and the first slurry height difference; calculate the average value of the slurry height at other moments except the current moment to obtain a first average value; and issue an abnormality warning when any preset warning condition is met. By implementing the present invention, the aerated block production process can be monitored, and the quality of aerated block production can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of aerated concrete block production, and in particular to an aerated concrete block production monitoring system. Background Art

[0002] In the aerated concrete industry, the existing monitoring of the aerated block production process is generally carried out by installing cameras in the pre-curing pit. The cameras reflect the status of the aerated block body in the pre-curing pit on the central control screen. The central control operator checks the gas emission of the body and then adjusts the pouring formula. However, the existing technology can only roughly judge the height of the body and the bubbling on the body surface through the images sent back by the camera. Moreover, due to the influence of the camera shooting angle and clarity, it is difficult to accurately obtain the body condition of the aerated block during the production process. Therefore, how to accurately monitor the body condition of the aerated block during the production process is an urgent problem that needs to be solved. Summary of the Invention

[0003] The embodiment of the present invention provides an aerated block production monitoring system, which can monitor the aerated block production process and improve the quality of aerated block production.

[0004] An embodiment of the present invention provides an aerated block production monitoring system, comprising: a rangefinder, a control terminal, and a mold box for making blocks;

[0005] The distance meter is connected to the control terminal, and the distance meter is arranged above the mold box;

[0006] The distance meter is used to measure the first distance between the distance meter and the mold box plane at each moment during the embryo casting process, and transmit the measured first distances to the control terminal;

[0007] The control terminal is used to perform the following operations during the embryo casting process:

[0008] Calculate the height of the slurry in the mold box at each moment based on the measured first distances;

[0009] Calculate the difference between the height of the slurry at the current moment and the height of the slurry at the previous moment to obtain a first slurry height difference;

[0010] Calculate the first gas evolution velocity of the current embryo based on the time interval between the current moment and the previous moment and the height difference of the first slurry;

[0011] Calculate the average value of the slurry height at other times except the current time to obtain a first average value; calculate the difference between the slurry height at the current time and the first average value to obtain a first average value difference of the slurry height;

[0012] Calculate the variance according to the slurry height at each time to obtain the first variance;

[0013] When any preset warning condition is met, an abnormal warning is issued; wherein, the warning conditions include: the first average value difference of the slurry height is within the first threshold range; the first variance of the slurry height is within the second threshold range; the first gas emission rate of the current embryo is within the third threshold range.

[0014] Furthermore, the control terminal is used to calculate the height of the slurry in the mold box at each moment based on the measured first distances, including:

[0015] The difference between the first distance measured at each moment and the distance from the distance meter to the mold box plane when the mold box is in an empty state is calculated to obtain the height of the slurry in the mold box at each moment.

[0016] Furthermore, before the control terminal calculates the height of the slurry in the mold box at each moment based on each measured first distance, the control terminal is further configured to:

[0017] The distance from the distance meter to the mold box plane when the mold box is in an empty state is taken as the actual empty box distance;

[0018] Calculate the difference between the actual empty box distance and the standard distance to obtain the height deviation value of the mold box; wherein the standard distance is: the average value of the actual empty box distances corresponding to a number of mold boxes;

[0019] The height of the slurry in the mold box at each moment is calculated based on the actual empty box distance, the height deviation value of the mold box and the first distance measured at each moment.

[0020] Furthermore, before calculating the height of the slurry in the mold box at each moment, the following steps are also included:

[0021] The variance is calculated based on the distance from the rangefinder to the mold box plane when each mold box is in an empty box state to obtain a second variance. When the second variance is less than the preset variance, the control terminal starts to execute the step of calculating the height of the slurry in the mold box at each moment based on the measured distances.

[0022] Furthermore, the first gas emission speed of the current embryo is calculated based on the time interval between the current moment and the previous moment and the height difference of the first slurry, specifically:

[0023] The first gas emission speed of the current embryo is calculated using the following formula:

[0024]

[0025] Among them, F represents the first gas emission speed of the current embryo, E ′It represents the height of the slurry at the previous moment, E represents the height of the slurry at the current moment, and Δt represents the time interval between the current moment and the previous moment.

[0026] Furthermore, when any preset warning condition is met, an abnormal warning is issued, including:

[0027] When the first average value difference of the slurry height is within a first threshold range, the control terminal issues an alarm corresponding to abnormal embryo height;

[0028] When the first variance of the slurry height is within a second threshold range, the control terminal issues an alarm corresponding to abnormal fluctuation amplitude of the embryo height;

[0029] When the first gas emission speed of the embryo body is within the third threshold range, the control terminal issues an alarm corresponding to the abnormal gas emission speed of the embryo body.

[0030] Furthermore, the control terminal is further configured to perform the following operations after the embryo casting is completed:

[0031] Obtain the second distance from the rangefinder to the mold box plane at each moment;

[0032] Calculate the difference between the second distance between the distance meter and the mold box plane at each moment and the distance between the distance meter and the mold box plane when the mold box is in an empty state, and obtain the embryo height in the mold box at each moment;

[0033] Calculating the difference in embryo body height at each adjacent moment to obtain a plurality of first embryo body height differences;

[0034] Calculating the second gas emission velocity of the embryo at each moment according to the time interval between adjacent moments and the corresponding height difference of the first embryo;

[0035] Calculate the difference between the time when the embryo casting is completed and the time when the embryo height begins to drop to obtain the embryo exhaust time;

[0036] According to the second gas emission speed of the embryo body and the exhaust time of the embryo body at each moment, a curve showing the change of the second gas emission speed of the embryo body with the exhaust time is generated.

[0037] The present invention provides an aerated block production monitoring system, which includes: a rangefinder, a control terminal and a mold box for making blocks, the rangefinder is connected to the control terminal, and the rangefinder is arranged above the mold box, the rangefinder is used to measure the distance from the rangefinder to the mold box plane at each moment, and transmit the measured distances to the control terminal, the control terminal calculates the height of the slurry in the mold box at each moment according to the measured distance at each moment, calculates the slurry height at the current moment, the gas emission speed of the current embryo and the first average value difference of the slurry height, when the first average value difference of the slurry height is within a first threshold range, it indicates that the height of the embryo in the mold box is abnormal; when the first variance of the slurry height is within a second threshold range, it indicates that the height fluctuation amplitude of the embryo in the mold box is abnormal; when the gas emission speed of the current embryo is within a third threshold range, it indicates that the gas emission speed of the embryo in the mold box is abnormal; when an abnormality is detected in the above-mentioned casting process, the control terminal issues a corresponding abnormality warning, thereby realizing the monitoring of the aerated block production process and improving the quality of aerated block production. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 The figure is a schematic structural diagram of an aerated block production monitoring system provided by one embodiment of the present invention.

[0039] Figure 2 The present invention provides a schematic diagram of the position relationship between a rangefinder and a mold box in an aerated block production monitoring system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0040] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0041] like Figure 1 and Figure 2 As shown, an embodiment of the present invention provides an aerated block production monitoring system, comprising a rangefinder, a control terminal, and a mold box for making blocks;

[0042] The distance meter is connected to the control terminal; the distance meter is arranged above the mold box;

[0043] The distance meter is used to measure the first distance between the distance meter and the mold box plane at each moment during the embryo casting process, and transmit the measured first distances to the control terminal;

[0044] The control terminal is used to perform abnormal warning analysis based on each first distance during the embryo casting process. The specific steps include:

[0045] S1: Calculating the height of the slurry in the mold box at each moment based on the measured first distances;

[0046] S2: Calculate the difference between the height of the slurry at the current moment and the height of the slurry at the previous moment to obtain a first slurry height difference;

[0047] S3: Calculating a first gas evolution velocity of the current embryo based on the time interval between the current moment and the previous moment and the height difference of the first slurry;

[0048] S4: Calculating an average value of the slurry height at other times except the current time to obtain a first average value; calculating a difference between the slurry height at the current time and the first average value to obtain a first average value difference of the slurry height;

[0049] S5: Calculate the variance according to the slurry height at each time to obtain a first variance;

[0050] S6: monitoring the relationship between the first average value difference, the first variance, and the first gas emission speed and the corresponding threshold range, and issuing an abnormal warning when a preset warning condition is met.

[0051] Specifically, the rangefinder used in this application is a laser rangefinder. The data acquired by the rangefinder at each stage includes:

[0052] Before the embryo is poured, the mold box is in an empty state. The distance from each distance meter to the corresponding mold box plane in the empty state is measured. The distance is Figure 2 H shown in;

[0053] During the embryo casting process, the mold box contains the unformed embryo and the cast slurry. The distance from each distance meter to the top of the slurry in the corresponding mold box is measured. Figure 2 The L shown in the figure is the top of the slurry. Figure 2 The K plane shown in ;

[0054] After the embryo casting is completed, the mold box contains the formed embryo. The distance from each distance meter to the top of the embryo in the corresponding mold box is measured. The distance is Figure 2 As shown in Figure 1, the top of the embryo is Figure 2 The J plane shown in ;

[0055] It should be noted that the mold box plane is a dynamic change process in the above process, and the horizontal plane auxiliary lines and distance auxiliary lines in the figure are only for easier understanding.

[0056] For step S1, there are two ways to calculate the height of the slurry in the mold box at each moment in the actual process:

[0057] First, in an optional embodiment, the control terminal is configured to calculate the height of the slurry in the mold box at each moment based on each measured first distance, including: calculating the difference between the first distance measured at each moment and the distance from the distance meter to the mold box plane when the mold box is in an empty state, to obtain the height of the slurry in the mold box at each moment;

[0058] Specifically, the control terminal obtains the height of the slurry in the mold box at each moment by subtracting the distance L from each distance meter to the top of the slurry in the corresponding mold box during the embryo casting process from the distance H from each distance meter to the corresponding mold box plane in an empty state before the embryo casting at each moment.

[0059] Second, in another optional embodiment, before the control terminal calculates the height of the slurry in the mold box at each moment based on the measured first distances, the control terminal is also used to: take the distance from the rangefinder to the mold box plane when the mold box is in an empty box state as the actual empty box distance; calculate the difference between the actual empty box distance and the standard distance to obtain the height deviation value of the mold box; wherein, the standard distance is: the average value of the actual empty box distances corresponding to several mold boxes; calculate the height of the slurry in the mold box at each moment based on the actual empty box distance, the height deviation value of the mold box and the first distance measured at each moment.

[0060] Specifically, the control terminal obtains a standard distance by calculating an average value based on several distances from each distance meter to the corresponding mold box plane in an empty box state before the embryo is poured; subtracting the standard distance from the distance from each distance meter to the corresponding mold box plane in an empty box state before the embryo is poured to obtain a height deviation value of each mold box; subtracting the distance from each distance meter to the top of the slurry in the corresponding mold box during the embryo pouring process (i.e., the above-mentioned first distance) from the distance from each distance meter to the corresponding mold box plane in an empty box state before the embryo is poured, and adding the height deviation value of the corresponding mold box to obtain the height of the slurry in the mold box at each moment.

[0061] In a preferred embodiment, before calculating the height of the slurry in the mold box at each moment, the method further includes: calculating a variance based on the distance from the rangefinder to the mold box plane when each mold box is in an empty state to obtain a second variance, and when the second variance is less than a preset variance, the control terminal starts executing the step of calculating the height of the slurry in the mold box at each moment based on the measured first distances;

[0062] Specifically, before executing step S1, it also includes: calculating the variance (i.e., the above-mentioned second variance) based on the distance from the rangefinder to the mold box plane when each mold box is in an empty box state, and when the variance is less than the preset variance, the control terminal starts to execute step S1 and its subsequent steps, wherein the preset variance is a set value obtained based on long-term and multiple tests by the operator. In the specific implementation process, the operator will make corresponding adjustments according to different implementation scenarios. Through this embodiment, before pouring the embryo, it is determined whether the mold box meets the pouring standard. If not, step S1 and its subsequent steps are not executed. If so, the control terminal starts to execute step S1 and its subsequent steps.

[0063] For step S2, the difference between the current moment and the previous moment is calculated based on the slurry heights of the slurry at each moment obtained in step S1 to obtain a first slurry height difference.

[0064] In step S3, the first gas emission velocity of the embryo in the mold box is calculated based on the slurry height difference obtained in step S2 and the time interval between the current moment and the previous moment. In a preferred embodiment, the first gas emission velocity of the embryo is calculated based on the time interval between the current moment and the previous moment and the first slurry height difference, specifically:

[0065] The first gas emission speed of the current embryo is calculated using the following formula:

[0066]

[0067] Among them, F represents the first gas emission speed of the current embryo, E ′ It represents the height of the slurry at the previous moment, E represents the height of the slurry at the current moment, and Δt represents the time interval between the current moment and the previous moment.

[0068] For step S4, the following calculation is performed on the slurry height at each moment obtained according to step S1: a first average value is calculated based on the slurry height at other moments except the current moment, and the first average value difference of the slurry height is obtained by subtracting the first average value from the slurry height at the current moment.

[0069] In step S5 , a first variance of the slurry height is calculated based on the slurry heights at each moment obtained in step S1 .

[0070] Regarding step S6, in a preferred embodiment, when any preset warning condition is met, an abnormality warning is performed, including: when the first average value difference of the slurry height is within a first threshold range, the control terminal issues an alarm corresponding to an abnormal embryo height; when the first variance of the slurry height is within a second threshold range, the control terminal issues an alarm corresponding to an abnormal embryo height fluctuation amplitude; when the first gas emission speed of the embryo is within a third threshold range, the control terminal issues an alarm corresponding to an abnormal embryo gas emission speed;

[0071] Specifically, the relationship between the gas emission speed of the current embryo, the average value difference of the slurry height, and the variance of the slurry height and the corresponding threshold ranges obtained according to step S3, step S4, and step S5 includes: when the average value difference of the slurry height (i.e., the above-mentioned first average value difference) is within the first threshold range, the control terminal issues an alarm corresponding to the abnormal embryo height; when the variance of the slurry height (i.e., the above-mentioned first variance) is within the second threshold range, the control terminal issues an alarm corresponding to the abnormal embryo height fluctuation amplitude; when the gas emission speed of the current embryo (i.e., the above-mentioned first gas emission speed) is within the third threshold range, the control terminal issues an alarm corresponding to the abnormal embryo gas emission speed;

[0072] For example, after slurry pouring, the slurry height calculated from the first measurement data is 420 mm, the slurry height calculated from the second measurement data is 410 mm, the slurry height calculated from the third measurement data is 390 mm, and the slurry height calculated from the fourth measurement data is 404 mm. The embryonic body gas evolution rate calculated from the fourth measurement data is 1.5 mm / s. The first threshold range is less than -20 mm or greater than 20 mm, the second threshold range is greater than or equal to 100, and the third threshold range is less than or equal to 1 mm / s or greater than or equal to 1.4 mm / s. During the first to third measurement processes, the average difference in slurry height is calculated as: [(420 mm + 410 mm) / 2] – 390 mm = 25 mm, which is greater than 20 mm. At this time, the average difference in slurry height is within the first threshold range, and the control terminal issues an alarm corresponding to abnormal embryonic body height. During the first to fourth measurements, the variance of the four calculated slurry heights is 118mm>100mm. At this time, the variance of the slurry height is in the second threshold range, and the control terminal issues an alarm corresponding to the abnormal fluctuation amplitude of the embryo height; the embryo gas emission rate calculated from the fourth measurement data is 1.5mm / s>1.4mm / s, and the embryo gas emission rate is in the third threshold range. The control terminal issues an alarm corresponding to the abnormal embryo gas emission rate; it should be noted that the control terminal can issue corresponding alarms in the form of text display, sound prompts, etc., and is not limited to the text display and sound prompts. The first threshold range, the second threshold range and the third threshold range described in this application are set values ​​obtained based on long-term and multiple tests by the operator. During the specific implementation process, the operator will make corresponding adjustments based on different implementation scenarios.

[0073] In a preferred embodiment, the control terminal is further configured to, after the embryo casting is completed, perform the following operations: obtain the second distance from the rangefinder to the mold box plane at each moment; calculate the difference between the second distance from the rangefinder to the mold box plane at each moment and the distance from the rangefinder to the mold box plane when the mold box is in an empty box state, to obtain the embryo height in the mold box at each moment; calculate the difference between the embryo heights at adjacent moments to obtain a plurality of first embryo height differences; calculate the second gas emission velocity of the embryo at each moment based on the time interval between adjacent moments and the corresponding first embryo height difference; calculate the difference between the time when the embryo casting is completed and the time when the embryo height begins to decrease to obtain the embryo exhaust time; and generate a curve showing the change of the second gas emission velocity of the embryo with the exhaust time based on the second gas emission velocity of the embryo at each moment and the embryo exhaust time;

[0074] Specifically, the distance from the rangefinder to the mold box plane at each moment (i.e., the second distance mentioned above) is obtained. Figure 2 ; the height of the embryo in the mold box at each moment is obtained by subtracting the distance I from the distance meter to the plane of the mold box at each moment (i.e., the second distance) from the distance H from each distance meter to the corresponding plane of the mold box in the empty box state before the embryo is poured; the difference in the embryo height at each adjacent moment is calculated to obtain a number of embryo height differences (i.e., the first embryo height difference); according to the time interval of each adjacent moment and the corresponding embryo height difference (i.e., the first embryo height difference), the gas emission speed of the embryo at each moment is calculated (i.e., the second gas emission speed); the embryo height is obtained by subtracting the time when the embryo height starts to decrease from the time when the embryo pouring is completed. body exhaust time; through the gas emission speed of the embryo at each moment (that is, the above-mentioned second gas emission speed) and the embryo exhaust time, draw a curve of the embryo gas emission speed (the second gas emission speed) changing with the exhaust time; the control terminal obtains the maximum embryo height after the pouring is completed, and subtracts the maximum embryo height from the embryo height at each moment to obtain the height of the embryo exhaust and sinking at each moment; the control terminal displays the curve of the embryo gas emission speed changing with the exhaust time, the embryo height in the lower mold box at each moment, and the embryo exhaust and sinking height at each moment on the display screen of the control terminal, and the operator can view the data and curves according to the display screen.

[0075] It should be noted that the control terminal is also used to record the first distances measured by the rangefinder, the height of the slurry in the mold box at each moment, the first slurry height difference, the first gas emission speed of the current embryo, the first average value, the first average value difference, the first variance, the height deviation value of each mold box, the second variance, the time interval between each moment, the time when the embryo pouring is completed, the time when the embryo height begins to drop, the embryo height in the mold box at each moment, the first embryo height difference, the second gas emission speed of the current embryo, the embryo exhaust time, the maximum rising height of the embryo, and the height of the embryo after exhaust and sinking at each moment.

[0076] The implementation of the above embodiments of the present invention has the following beneficial effects:

[0077] 1. According to the alarm, abnormal conditions in the casting process of the embryo can be discovered in time, the production process of aerated blocks can be monitored, and the quality of aerated block production can be improved;

[0078] 2. Before production, the mold box usage standards should be judged to avoid the situation where the aerated blocks produced are unsuitable because the mold box does not meet the production standards;

[0079] 3. Record the acquired and calculated data. Operators can view historical data and adjust the pouring slurry formula or method based on the historical data to improve the quality of aerated block production.

[0080] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A production monitoring system for aerated blocks, characterized in that: include: distance measuring instruments, control terminals, and moulding boxes for making blocks; The distance meter is connected to the control terminal, and the distance meter is arranged above the mold box; The distance meter is used to measure the first distance between the distance meter and the mold box plane at each moment during the embryo casting process, and transmit the measured first distances to the control terminal; The control terminal is used to perform the following operations during the embryo casting process: Calculate the height of the slurry in the mold box at each moment based on the measured first distances; Calculate the difference between the height of the slurry at the current moment and the height of the slurry at the previous moment to obtain a first slurry height difference; Calculate the first gas evolution velocity of the current embryo based on the time interval between the current moment and the previous moment and the height difference of the first slurry; Calculate the average value of the slurry height at other times except the current time to obtain a first average value; calculate the difference between the slurry height at the current time and the first average value to obtain a first average value difference of the slurry height; Calculate the variance according to the slurry height at each time to obtain the first variance; When any preset warning condition is met, an abnormal warning is issued; wherein the warning condition includes: the first average value difference of the slurry height is within the first threshold range; the first variance of the slurry height is within the second threshold range; the first gas emission speed of the current embryo is within the third threshold range; After the embryo body is poured, do the following: Obtain the second distance from the rangefinder to the mold box plane at each moment; Calculate the difference between the second distance between the distance meter and the mold box plane at each moment and the distance between the distance meter and the mold box plane when the mold box is in an empty state, and obtain the embryo height in the mold box at each moment; Calculating the difference in embryo body height at each adjacent moment to obtain a plurality of first embryo body height differences; Calculating the second gas emission velocity of the embryo at each moment according to the time interval between adjacent moments and the corresponding height difference of the first embryo; Calculate the difference between the time when the embryo casting is completed and the time when the embryo height begins to drop to obtain the embryo exhaust time; According to the second gas emission speed of the embryo body and the exhaust time of the embryo body at each moment, a curve showing the change of the second gas emission speed of the embryo body with the exhaust time is generated.

2. The aerated block production monitoring system according to claim 1, characterized in that: The control terminal is used to calculate the height of the slurry in the mold box at each moment based on the measured first distances, including: The difference between the first distance measured at each moment and the distance from the distance meter to the mold box plane when the mold box is in an empty state is calculated to obtain the height of the slurry in the mold box at each moment.

3. The aerated block production monitoring system according to claim 1, characterized in that: Before the control terminal calculates the height of the slurry in the lower mold box at each moment based on the measured first distances, the control terminal is further used to: The distance from the distance meter to the mold box plane when the mold box is in an empty state is taken as the actual empty box distance; Calculate the difference between the actual empty box distance and the standard distance to obtain the height deviation value of the mold box; wherein the standard distance is: the average value of the actual empty box distances corresponding to a number of mold boxes; The height of the slurry in the mold box at each moment is calculated based on the actual empty box distance, the height deviation value of the mold box and the first distance measured at each moment.

4. A production monitoring system for aerated blocks according to claim 2 or 3, characterized in that: Before calculating the height of the slurry in the mold box at each moment, it also includes: The variance is calculated based on the distance from the rangefinder to the mold box plane when each mold box is in an empty box state to obtain a second variance. When the second variance is less than the preset variance, the control terminal starts to execute the step of calculating the height of the slurry in the mold box at each moment based on the measured first distances.

5. The aerated block production monitoring system according to any one of claims 1 to 3, characterized in that: The first gas emission velocity of the current embryo is calculated based on the time interval between the current moment and the previous moment and the height difference of the first slurry, specifically: The first gas emission speed of the current embryo is calculated using the following formula: Among them, F represents the first gas emission speed of the current embryo, E ′ It represents the height of the slurry at the previous moment, E represents the height of the slurry at the current moment, and Δt represents the time interval between the current moment and the previous moment.

6. The aerated block production monitoring system according to claim 1, characterized in that: When any preset warning condition is met, an abnormal warning is issued, including: When the first average value difference of the slurry height is within a first threshold range, the control terminal issues an alarm corresponding to abnormal embryo height; When the first variance of the slurry height is within a second threshold range, the control terminal issues an alarm corresponding to abnormal fluctuation amplitude of the embryo height; When the first gas emission speed of the embryo body is within the third threshold range, the control terminal issues an alarm corresponding to the abnormal gas emission speed of the embryo body.

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