A detection device and detection method for a calciner tank level

Abstract

This application relates to the field of carbon product manufacturing technology, specifically to a detection device and method for the material level of a calcining furnace feed hopper. The detection device includes: a material level detection sensor, a rotating gimbal, a rotation angle detection module, and a data processing module. The rotating gimbal can be controlled to rotate, and the material level detection sensor acquires at least one distance data point to the target calcining furnace feed hopper. The rotation angle detection module acquires the rotation angle displacement data of the rotating gimbal. Based on the rotation angle displacement data and the various distance data, the data processing module determines the material level information of the calcining furnace feed hopper. The technical solution provided by this application can simultaneously detect the material level of multiple calcining furnace feed hoppers, achieving unmanned operation and thus improving work efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carbon product production, in particular to a calcination furnace stock tank level detection device and method. BACKGROUND

[0002] In the production and manufacturing process of carbon blocks for aluminum, calcination is an important process in the production process. During calcination, the raw materials are added to the stock tank by the top charging device and are subjected to high-temperature preheating treatment under air isolation conditions. The purpose is to remove volatile matter and moisture from the raw materials to obtain better electrical conductivity and thermal conductivity, as well as oxidation and corrosion resistance. Due to different factors such as volatile content and moisture content of the raw materials, there is a large difference in the discharge speed of different stock tanks. When the stock level is too low or the discharge is not smooth, the raw materials will be directly exposed to the air, which will seriously affect the physical properties of the raw materials.

[0003] Therefore, there is an urgent need in the art for a calcination furnace stock tank level detection device and method that can simultaneously detect the levels of multiple calcination furnace stock tanks and achieve unmanned operation to improve work efficiency. SUMMARY

[0004] The embodiments of the present application provide a calcination furnace stock tank level detection device and method that can simultaneously detect the levels of multiple calcination furnace stock tanks and achieve unmanned operation to improve work efficiency.

[0005] Other characteristics and advantages of the present application will become apparent from the following detailed description, or will be learned by practice of the present application.

[0006] According to one aspect of the embodiments of the present application, a calcination furnace stock tank level detection device is provided, which comprises: a stock level detection sensor for detecting distance data between a stock level surface of at least one calcination furnace stock tank and the stock level detection sensor; a rotating holder for rotating the stock level detection sensor; a rotating angle detection module for obtaining rotating angle displacement data of the rotating holder; and a data processing module for processing the distance data and the rotating angle displacement data to determine stock level information of each calcination furnace stock tank.

[0007] In some embodiments of the present application, the stock level detection sensor and the rotating holder are arranged above the calcination furnace stock tank.

[0008] According to an aspect of some embodiments of the present application, a method for detecting a charge level of a calcination furnace is provided. The method is implemented based on the detection device described above. The method comprises: controlling the rotating holder to rotate, obtaining at least one distance data of a target calcination furnace by the charge level detection sensor; obtaining rotation angle displacement data of the rotating holder by the rotation angle detection module; and determining the charge level information of the target calcination furnace by the data processing module based on the rotation angle displacement data and the distance data.

[0009] In some embodiments of the present application, based on the foregoing scheme, the step of obtaining at least one distance data by the charge level detection sensor comprises: obtaining first distance data of the target calcination furnace by the charge level detection sensor; keeping the rotating holder static; and obtaining second distance data of the target calcination furnace by the charge level detection sensor after a first preset time.

[0010] In some embodiments of the present application, based on the foregoing scheme, the step of obtaining rotation angle displacement data of the rotating holder by the rotation angle detection module, and determining the charge level information of the target calcination furnace by the data processing module based on the rotation angle displacement data and the distance data comprises: obtaining rotation angle displacement data of the rotating holder by the rotation angle detection module; and determining the charge level information of the target calcination furnace by the data processing module based on the rotation angle displacement data, the first distance data and the second distance data.

[0011] In some embodiments of the present application, the step of obtaining at least one distance data by the charge level detection sensor comprises: obtaining third distance data of the target calcination furnace by the charge level detection sensor; keeping the rotating holder rotating; and obtaining fourth distance data of the target calcination furnace by the charge level detection sensor after a second preset time.

[0012] In some embodiments of the present application, based on the foregoing scheme, the step of obtaining rotation angle displacement data of the rotating holder by the rotation angle detection module, and determining the charge level information of the target calcination furnace by the data processing module based on the rotation angle displacement data and the distance data comprises: obtaining first rotation angle displacement data of the rotating holder at the same time when the third distance data is obtained; obtaining second rotation angle displacement data of the rotating holder at the same time when the fourth distance data is obtained; and determining the charge level information of the target calcination furnace by the data processing module based on the first rotation angle displacement data, the second rotation angle displacement data, the third distance data and the fourth distance data.

[0013] In some embodiments of this application, after determining the material level information of each calcining furnace hopper, the method further includes: drawing a material level curve or material level chart for each calcining furnace hopper based on the material level information; and determining whether there is an abnormality in the feeding of each calcining furnace hopper based on each material level curve or material level chart.

[0014] Based on the above solution, this application has at least the following advantages or advancements:

[0015] In some embodiments of this application, a detection device and method for the material level in a calcining furnace hopper are provided. The detection device includes a material level detection sensor, a rotating gimbal, a rotation angle detection module, and a data processing module. The rotating gimbal can be controlled to rotate, and at least one distance data of the target calcining furnace hopper is acquired through the material level detection sensor. The rotation angle detection module acquires the rotation angle displacement data of the rotating gimbal. Based on the rotation angle displacement data and the various distance data, the data processing module determines the material level information of the calcining furnace hopper. The technical solution provided in this application can simultaneously detect the material level of multiple calcining furnace hoppers, achieving unmanned operation and thus improving work efficiency.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0018] Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort.

[0019] In the attached diagram:

[0020] Figure 1 A simplified structural diagram of a calcining furnace feed tank level detection device according to one embodiment of this application is shown.

[0021] Figure 2 A simplified flowchart of a method for detecting the material level in a calcining furnace feed hopper according to one embodiment of this application is shown.

[0022] Figure 3 A simplified diagram illustrating the working principle of a detection device according to one embodiment of this application is shown.

[0023] Figure 4 A simplified diagram illustrating the working principle of a detection device according to one embodiment of this application is shown. Detailed Implementation

[0024] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art.

[0025] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0026] It should be noted that "multiple" in this article refers to two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0027] Please see Figure 1 , Figure 1 A simplified structural diagram of a calcining furnace feed tank level detection device according to one embodiment of this application is shown. The detection device may include: a feed level detection sensor 101, which is used to detect the distance data between the feed level surface of at least one calcining furnace feed tank and the feed level detection sensor 101; a rotating gimbal 102, which is used to drive the feed level detection sensor to rotate; a rotation angle detection module 103, which is used to acquire the rotation angle displacement data of the rotating gimbal 102; and a data processing module 104, which is used to process the distance data and the rotation angle displacement data to determine the feed level information of each calcining furnace feed tank.

[0028] In one embodiment of this application, the material level detection sensor and the rotating platform can be disposed above the calcining furnace material tank. Preferably, the installation height of the material level detection sensor and the rotating platform is greater than 1 / 2 of the length of the calcining furnace and less than the length of the calcining furnace.

[0029] In one embodiment of this application, the material level detection sensor is capable of detecting material information. The sensor can be any type of sensor, such as infrared, laser, or ultrasonic, and its output is in the format of an analog signal.

[0030] In one embodiment of this application, the rotating gimbal can be driven by any type of motor, such as a stepper motor, a servo motor, or a frequency converter motor, and the rotation angle detection module can be an encoder or an angular displacement sensor.

[0031] In one embodiment of this application, a 64-tank calcining furnace can be configured, with the tanks arranged in a 16*4 side-by-side layout. Based on the existing plant height and tank layout, each rotating platform can detect a group of 16 calcining furnace tanks. Therefore, four sets of rotating platforms are needed to achieve 64-tank level detection. The rotating platform can rotate back and forth between 0-180-0 degrees from the laser scanning position point. During rotation, the platform drives the level detection sensor to read data in real time, realizing online level detection. The number of tanks detected within the 0-180 degree range is divided to obtain the corresponding angle value for each calcining furnace tank. Within this angle range, the level detection sensor can detect the level data of the corresponding tank, and the level height value is calculated using trigonometric functions.

[0032] Please see Figure 2 , Figure 2 A simplified flowchart of a method for detecting the material level in a calcining furnace feed hopper according to one embodiment of this application is shown. The method is implemented based on the detection device described above and may include steps S201-S202:

[0033] Step S201: Control the rotating gimbal to rotate, and obtain at least one distance data of the target calcining furnace material tank through the material level detection sensor.

[0034] Step S202: Obtain the rotation angle displacement data of the rotating gimbal through the rotation angle detection module, and determine the material level information of the calcining furnace hopper through the data processing module based on the rotation angle displacement data and various distance data.

[0035] Please see Figure 3 , Figure 3A simplified diagram illustrating the working principle of a detection device according to an embodiment of this application is shown. The method for acquiring at least one distance data through the material level detection sensor may include: acquiring a first distance data L1 of the target calcining furnace hopper through the material level detection sensor; keeping the rotating gimbal stationary; and after a first preset time, acquiring a second distance data L2 of the target calcining furnace hopper through the material level detection sensor. Then, the method for acquiring the rotational angular displacement data of the rotating gimbal through the rotational angle detection module, and determining the material level information of the target calcining furnace hopper based on the rotational angular displacement data and the various distance data through the data processing module may include: acquiring the rotational angular displacement data A of the rotating gimbal through the rotational angle detection module. Finally, the material level information of the target calcining furnace hopper can be determined by the data processing module based on the rotational angular displacement data A, the first distance data L1, and the second distance data L2. The specific calculation method is as follows: H1 = L1 × sin A, where H1 represents a vertical distance between the material level plane and the material level detection sensor; H2 = L2 × sin A, where H2 represents a vertical distance between the material level plane and the material level detection sensor after a first preset time. Therefore, it is not difficult to calculate the drop height of the material level within the first preset time, and thus calculate the feeding speed. Since the installation height of the material level detection sensor is fixed, H1 and H2, after data processing, can also represent the real-time material level at two different moments.

[0036] Please see Figure 4 , Figure 4A simplified diagram illustrating the working principle of a detection device according to an embodiment of this application is shown. The method for acquiring at least one distance data through the material level detection sensor may include: acquiring a third distance data L3 of the target calcining furnace hopper through the material level detection sensor; maintaining the rotation of the rotating platform; and after a second preset time, acquiring a fourth distance data L4 of the target calcining furnace hopper through the material level detection sensor. Then, the method for acquiring the rotational angular displacement data of the rotating platform through the rotational angle detection module, and determining the material level information of the target calcining furnace hopper through the data processing module based on the rotational angular displacement data and the various distance data may include: acquiring a first rotational angular displacement data B1 of the rotating platform while acquiring the third distance data L3; acquiring a second rotational angular displacement data B2 of the rotating platform while acquiring the fourth distance data; and determining the material level information of the target calcining furnace hopper through the data processing module based on the first rotational angular displacement data B1, the second rotational angular displacement data B2, the third distance data L3, and the fourth distance data L4. The specific calculation method is as follows: H3 = L3 × sin B1, where H3 represents a vertical distance between the material level plane and the material level detection sensor; H4 = L4 × sin B2, where H4 represents a vertical distance between the material level plane and the material level detection sensor after a first preset time. Therefore, it is not difficult to calculate the drop height of the material level within the first preset time, and thus calculate the feeding speed. Since the installation height of the material level detection sensor is fixed, H3 and H4, after data processing, can also represent the real-time material level at two different moments.

[0037] In one embodiment of this application, after determining the material level information of each calcining furnace hopper, the method further includes: drawing a material level curve or material level chart for each calcining furnace hopper based on the material level information; and determining whether there is an abnormality in the material discharge of each calcining furnace hopper based on each material level curve or material level chart.

[0038] To enable those skilled in the art to gain a deeper understanding of this application, a specific embodiment will be described below.

[0039] Taking a 64-tank calcining furnace as an example, the furnace is arranged in a 16*4 side-by-side layout. Based on the existing plant height and tank layout, each rotating platform can detect a group of 16 tanks, requiring the installation of 4 sets of rotating platforms to achieve 64-tank material level detection. The rotating platform can rotate back and forth between "0-180-0" degrees from the laser scanning position point. During the rotation, the rotating platform drives the material level detection sensor to read data in real time, realizing the function of online material level detection. Taking the No. 1 material tank of the calcining furnace as an example, the encoder records the rotational angular displacement data A1 of the rotating gimbal, and the material level detection sensor records the corresponding material level information L1. Then, the data processing module calculates the material level height H1 of this material tank using trigonometric functions = L1 * SinA1. When the rotating gimbal rotates to position A2, the laser material level record records the corresponding material level information L2. Then, the material level height H2 of the material tank at this time = L2 * SinA2. During the rotation of the rotating gimbal from A1 to A2, N angle and material level data will be generated, and N material level data will be calculated accordingly. After abnormal data filtering, the data processing module can calculate and give the highest value, lowest value, and average value of the material level of the No. 1 material tank, and generate corresponding curves, reports, material level, and information such as whether the data is abnormal.

[0040] This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary technical means in the art that are not disclosed in this application.

[0041] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A device for detecting the material level in a calcining furnace feed hopper, characterized in that, The detection device includes: A material level detection sensor is used to detect the distance data between the material level surface of at least one calcining furnace material tank and the material level detection sensor; A rotating gimbal, used to drive the material level detection sensor to rotate; A rotation angle detection module is used to acquire the rotation angle displacement data of the rotating gimbal; The data processing module processes the distance data and the rotational angular displacement data to determine the material level information of each calcining furnace hopper; wherein, The material level detection sensor and the rotating gimbal are positioned above the calcining furnace material tank; The rotating gimbal rotates back and forth between 0 and 180 degrees to cover multiple calcining furnace material tanks arranged side by side; The data processing module is also used to, after determining the material level information of each calcining furnace hopper, draw the material level curve or material level chart of each calcining furnace hopper based on the material level information; and determine whether there is an abnormality in the feeding of each calcining furnace hopper based on each material level curve or material level chart.

2. A method for detecting the material level in a calcining furnace feed hopper, characterized in that, The method is implemented based on the detection device of claim 1, and the method includes: The rotating gimbal is controlled to rotate, and at least one distance data of the target calcining furnace hopper is obtained through the material level detection sensor; The rotation angle detection module acquires the rotation angle displacement data of the rotating gimbal, and the data processing module determines the material level information of the calcining furnace hopper based on the rotation angle displacement data and various distance data.

3. The method according to claim 2, characterized in that, The acquisition of at least one distance data through the material level detection sensor includes: The first distance data of the target calcining furnace hopper is obtained by the material level detection sensor. The rotating gimbal is kept stationary. After a first preset time, the second distance data of the target calcining furnace hopper is obtained by the material level detection sensor.

4. The method according to claim 3, characterized in that, The process involves acquiring the rotational angular displacement data of the rotating gimbal through the rotational angle detection module, and determining the material level information of the target calcining furnace hopper through the data processing module based on the rotational angular displacement data and various distance data, including: The rotation angle displacement data of the rotating gimbal is obtained through the rotation angle detection module; Based on the rotational angular displacement data, the first distance data, and the second distance data, the data processing module determines the material level information of the target calcining furnace hopper.

5. The method according to claim 2, characterized in that, The acquisition of at least one distance data through the material level detection sensor includes: The third distance data of the target calcining furnace hopper is obtained by the material level detection sensor. The rotating gimbal is kept rotating. After a second preset time, the fourth distance data of the target calcining furnace hopper is obtained by the material level detection sensor.

6. The method according to claim 5, characterized in that, The process involves acquiring the rotational angular displacement data of the rotating gimbal through the rotational angle detection module, and determining the material level information of the target calcining furnace hopper through the data processing module based on the rotational angular displacement data and various distance data, including: When acquiring the third distance data, the first rotational angular displacement data of the rotating gimbal is also acquired. While acquiring the fourth distance data, the second rotational angular displacement data of the rotating gimbal is also acquired. Based on the first rotational angular displacement data, the second rotational angular displacement data, the third distance data, and the fourth distance data, the data processing module determines the material level information of the target calcining furnace hopper.

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