Method for automatic control of a sintering process bellows

Abstract

This invention provides an automatic control method for the bellows. By accurately judging and tracking the position of the sintering machine during start-up material feeding, shutdown material discharge, and trolley replacement, and by periodically checking for jammed materials and detecting abnormalities, the method achieves automatic control of the bellows during start-up, shutdown, trolley replacement, and abnormality detection. This reduces the workload of operators, makes the bellows control more stable during start-up and shutdown, reduces fluctuations in sinter quality, and improves the sinter qualification rate.

Description

Technical Field

[0001] This invention relates to the technical field of automatic control methods, and more particularly to an automatic control method for a bellows in a sintering process. Background Technology

[0002] During the sintering start-up process, operators need to observe the material head position on-site and remotely communicate with the main control room to control the bellows during the material feeding process. This control method is not only time-consuming and requires the attention of multiple people, but also the accuracy of visually observing the material layer thickness and material head position is affected by the environment and visibility, especially at night when starting up, and the same applies when stopping and discharging material. During the sintering production process, material jamming when the bellows opening and closing plate causes the bellows to fail to close in time, which not only increases energy consumption and aggravates damage to the bellows opening plate, but also has a certain impact on the endpoint position and quality of the sinter. Summary of the Invention

[0003] Based on the technical problems mentioned in the background section, the purpose of this invention is to provide an automatic control method for the bellows. By accurately tracking the positions of the material head and tail, and troubleshooting bellows jamming, this method achieves automatic control of the bellows during start-up, shutdown, trolley replacement, and anomaly detection, solving the problem of excessively labor-intensive bellows control in these stages. The automatic bellows control method provided by this invention achieves automatic control of the bellows during start-up material feeding, shutdown material discharge, and trolley replacement, as well as periodically checking for jamming and detecting anomalies. This reduces the workload of operators, makes bellows control more stable during start-up and shutdown, reduces fluctuations in sinter quality, and improves the sinter qualification rate.

[0004] The technical means adopted in this invention are as follows: an automatic control method for a bellows, comprising:

[0005] The system controls the material feeding air box during startup. It collects real-time material layer thickness data during startup and tracks the material head. When the material head reaches the end position of the first air box, the first air box is opened to its maximum opening value. When the material head reaches the end position of the next air box, the next air box is opened to its specified opening degree, and so on. When the last air box is opened to its maximum opening value, the automatic control of the startup air box is complete, achieving automatic control of the startup air box.

[0006] Abnormal inspection and control of air boxes: During the production process, each air box is opened / closed at regular intervals, the current status of each air box is judged one by one, and an abnormal air box will trigger an audible and visual alarm and wait to enter the next cycle.

[0007] The machine is stopped and the discharge air box is controlled. During the shutdown process, the material layer thickness detection value is collected in real time to determine the position of the material tail and to track the material tail. When the material tail reaches the head position of the first air box, the No. 1 air box is closed. When the material tail reaches the head position of the next air box, the next air box is closed, and so on. When the last air box is closed, the automatic control of the shutdown air box is completed and the calculation stops.

[0008] Carriage change air box control: When a carriage malfunctions during production and needs to be changed, the position of the carriage to be replaced is accurately located according to the material thickness. The carriage is tracked, and when the carriage reaches the first air box, the first air box is closed. When it reaches the next air box, the next air box is closed, and so on. After the carriage has completely left the first air box, the first air box is opened and restored to its previous opening degree. After leaving the next air box, the next air box is restored to its previous opening degree, and so on. When the designated position for changing the carriage is reached, the user is reminded to reduce the main exhaust fan and perform the carriage change operation.

[0009] Compared with the prior art, the present invention has the following advantages:

[0010] The automatic control method for the bellows provided by this invention achieves automatic control of the bellows during start-up, shutdown, trolley replacement, and anomaly detection by accurately judging and tracking the position of the trolley during sintering start-up material feeding, shutdown material discharge, and trolley replacement, as well as periodically checking for jammed material and detecting abnormalities. This reduces the workload of operators, makes the bellows control more stable during start-up and shutdown, reduces fluctuations in sinter quality, and improves the sinter qualification rate. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] Figure 1 This is a logic diagram of the automatic control method of the bellows in the fabric feeding mode of the present invention.

[0013] Figure 2 This is a logic diagram of the automatic control method for the blower box in the shutdown discharge mode of the present invention.

[0014] Figure 3 This is the logic diagram of the automatic control method of the bellows in the shutdown and material discharge mode. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0016] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0017] like Figure 1-3 As shown, this invention provides an automatic control method for a bellows. By accurately tracking the positions of the material head and tail, and troubleshooting operations such as material jamming in the bellows, it achieves automatic control of the bellows during start-up, shutdown, trolley replacement, and anomaly troubleshooting, solving the problem of excessively manual bellows control in these stages. This includes:

[0018] The system controls the material feeding bellows during startup. During startup, the material layer thickness is collected in real-time. The material head is positioned and tracked; when the material head completes coverage and reaches the end position of the first bellows, the first bellows is opened to the specified maximum opening value. When the material head completes coverage and reaches the end position of the next bellows, the next bellows is opened to the specified opening degree, and so on. When the last bellows is opened to the specified maximum opening value, the automatic startup bellows control is complete, and the system enters the next stage to achieve automatic startup bellows control. As a preferred implementation, this application collects basic data in real-time, including the bellows opening setting Z_SPi, the actual bellows opening Z_PVi, the material layer thickness H, the sintering machine speed V, and the model deployment method (startup material feeding, shutdown material discharge, trolley replacement, abnormal inspection) flags, for preparatory calculations.

[0019] Preferably, as one implementation, the position of the material head is automatically determined during the startup process, and the position of the material head is accurately tracked at a frequency of seconds. In this application, the material head position is considered to have appeared once the value detected by the level gauge reaches the automatic determination standard for the material head.

[0020] Abnormal inspection and control of air boxes: During the production process, each air box is opened / closed at regular intervals, the current status of each air box is judged one by one, and an abnormal air box will trigger an audible and visual alarm and wait to enter the next cycle.

[0021] The machine is stopped for material discharge bellows control. During the shutdown process, the material layer thickness is collected in real time to determine the material tail position, and the material tail is tracked. When the material tail reaches the bellows head position of the first bellows, the first bellows is closed; when the material tail reaches the bellows head position of the next bellows, the next bellows is closed, and so on. When the last bellows is closed, the automatic control of the shutdown bellows is completed, and the model calculation stops. Preferably, this step automatically determines the material tail position and completes the positioning and tracking.

[0022] The system controls the air box for changing trolleys. During production, when a trolley malfunctions and requires replacement, the system precisely locates the trolley to be replaced based on the material thickness. It tracks the trolley, closing the first air box when it reaches the first one, closing the next air box when it reaches the next, and so on. Once the trolley has completely left the first air box, the first air box is reopened and restored to its previous opening position. The same process is repeated for the next air box. When the trolley reaches the designated replacement position, the system alerts the user to reduce the main exhaust fan's output and initiate the trolley replacement operation. During the trolley replacement process, the system automatically locates the malfunctioning trolley based on material thickness and negative pressure. The cycle time during production is 1.5 to 3 hours.

[0023] Parameter measurement and setting: Based on production experience, set the material head layer thickness threshold value M, the material tail layer thickness threshold value N, the material layer thickness setting value P for changing the trolley, the air box opening deviation alarm value D, the number of air boxes NUM, the horizontal distance A from the radar material tail instrument to the starting position of air box #1, the length B_i of all air boxes along the trolley's travel direction, the length L of the trolley along the travel direction, the large cycle T of abnormal air box inspection, the interval t of abnormal inspection switch air box, and the standard ST for judging the air box switch status.

[0024] Based on the current operational status, confirm the operational mode. For example, if the current operational mode is machine-on feeding, determine the material head position based on the real-time collected material layer thickness.

[0025] If the material thickness of a sintering machine is 800mm during normal production, based on production experience, the material head position can be set when the material layer thickness exceeds 500mm during startup, i.e., M=500mm.

[0026] When the material layer thickness exceeds 100mm, it indicates that the material head is about to arrive. The system then enters a second-level judgment. When three consecutive data lines show that the material layer thickness exceeds 500mm, the location of the material head is confirmed, and the system is then located and tracked.

[0027] Based on the collected sintering machine speed V (in m / min), the material head position is located. Taking the radar level gauge position as the starting position, the position reached 1 second after the material head is determined is S = V1 / 60. (V1 is the sintering machine speed in the first second, and S is the travel distance).

[0028] And so on. After 2 seconds, the feed head position reaches S = V1 / 60 + V2 / 60; after n seconds, the feed head position reaches S = V1 / 60 + V2 / 60 + ... + Vn / 60. (V2 is the sintering machine speed in the second second, and Vn is the sintering machine speed in the nth second.)

[0029] Based on the position of the material head, when the material head completely covers the No. 1 bellows (i.e., S≧A+B_1), the No. 1 bellows is opened, the time is recorded, and a notification is pushed to the operator on the interface: "The material head has reached the position of the No. 1 bellows, and the No. 1 bellows has been opened." (A is the horizontal distance from the radar material tail indicator to the starting position of the No. 1 bellows, and B_1 is the length of the No. 1 bellows along the direction of the trolley's movement.)

[0030] Continue tracking the material head position. Based on the position, when S≧A+B_1+B_2, open the #2 bellows and record and prompt the user. The subsequent bellows logic is the same.

[0031] During this process, if a bellows fails to open (i.e., the deviation between the set opening and the actual opening exceeds the deviation alarm value Z_SP - Z_PV > D), record the error and notify the operator to have relevant personnel check the cause on-site. (Z_SP: set bellows opening; Z_PV: actual bellows opening; D: bellows opening deviation alarm value)

[0032] If the machine stops during the start-up and feeding process, or if the feeding machine is put back into control by the system after a period of time, the position correction function of this system can be used. The operator can input the current position of the material head on the interface, and the system will start tracking from the current position to complete the subsequent bellows control operation.

[0033] Once all bellows have been opened, the operator will be notified that the fabric feeding bellows control is complete, and the system will automatically switch to abnormal inspection mode.

[0034] In abnormal inspection mode, a large cycle T completes one loop, starting with bellows #1. The bellows' on / off status is checked. If Z_SP1 ≥ ST, the bellows is open and needs to be closed. After t seconds, the bellows is restored to its original opening. Before restoring to the original opening, the bellows' deviation status is checked. If Z_SP1 - Z_PV1 > D, this is recorded and an alarm is triggered. (ST is the standard for determining the bellows' on / off status.)

[0035] Perform the above operations sequentially on bellows #2, #3, #4, etc., until the last bellows is operated. Mark and record all abnormal bellows, reminding operators to check them. Stop bellows control operations and start timing until the next cycle begins.

[0036] If the system detects the activation of the shutdown and material discharge mode during operation, it will stop the abnormal inspection of the bellows and determine and locate the material tail position based on the real-time material thickness data.

[0037] Set the material tail thickness threshold value N = 400mm. When the material thickness shows a decreasing trend, the material layer thickness is judged at the second level. When three consecutive data show that the material layer thickness is less than 400mm, the material tail position is confirmed, recorded and located.

[0038] Based on the real-time sintering machine speed V (in m / min), the tail position is tracked. Similar to the head position tracking, the radar level gauge position is used as the starting position. One second after the head position is determined, the head position reaches S = V1 / 60. Two seconds later, the head position reaches S = V1 / 60 + V2 / 60. After n seconds, the head position reaches S = V1 / 60 + V2 / 60 + ... + Vn / 60.

[0039] When the material tail reaches the starting position of the first wind box (i.e., S≧A), the first wind box is closed, and the data is recorded and pushed to the interface. When the material tail reaches the starting position of the next wind box (i.e., V1 / 60+V2 / 60+……Vn / 60≧A+B_1), the next wind box is closed, and so on. The logic for subsequent wind boxes is the same.

[0040] When an abnormal closure of a bellows is encountered (i.e., the deviation between the set opening and the actual opening is greater than the deviation alarm value Z_PV-Z_SP>D), the incident is recorded and the operator is prompted to have relevant personnel go to the site to check the cause.

[0041] The shutdown discharge mode also has a position correction function. The operator inputs the current material tail position on the interface, and the system starts tracking from the current position to complete the subsequent bellows control operation.

[0042] Once all bellows are closed, the operator will be notified that the shutdown and discharge bellows control is complete, the system will automatically exit, and the system will wait to be restarted.

[0043] The trolley-changing mode operates on the same principle as the start-up material feeding and stop-down material unloading tracking. Based on the set value P of the material layer thickness for the trolley change, when three consecutive material thicknesses are less than P, the trolley change position is confirmed. When the trolley reaches the starting position of the #1 air box (i.e., V1 / 60 + V2 / 60 + ... + Vn / 60 ≧ A), the #1 air box is shut down, and the data is recorded and pushed to the interface. When the material tail reaches the starting position of the #2 air box (i.e., V1 / 60 + V2 / 60 + ... + Vn / 60 ≧ A + B_1), the #2 air box is shut down, and so on. The logic for subsequent air boxes is the same.

[0044] It is important to note that when the positioning trolley's position exceeds the position of the first bellows (i.e., V1 / 60 + V2 / 60 + ... + Vn / 60 ≥ A + B_1 + L), the #1 bellows needs to be restored to its previous opening. After exceeding the position of the next bellows (i.e., V1 / 60 + V2 / 60 + ... + Vn / 60 ≥ A + B_1 + B_2 + L), the #2 bellows needs to be restored to its previous opening, and the logic for subsequent bellows is the same.

[0045] Once the designated air box position is reached on the transfer car, the designated air box is closed, the operator is reminded to perform the transfer car operation, the main extraction is reduced, and the system stops calculation.

[0046] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0047] In the above embodiments of the present invention, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic control method for a bellows, characterized in that, include: Start-up fabric air box control; During startup, the material layer thickness is collected in real time. The material head is positioned and tracked. When the material head reaches the end position of the first air box, the first air box is opened to the maximum opening value. When the material head reaches the end position of the next air box, the next air box is opened to the specified opening degree, and so on. When the last air box is opened to the maximum opening value, the automatic control of the start-up air box is completed, realizing the automatic control of the start-up air box. Abnormal inspection and control of the bellows; During the production process, each air box is opened / closed periodically, and the current status of each air box is judged one by one. If an abnormal air box is detected, an audible and visual alarm is triggered and the process waits to enter the next cycle. The machine is stopped to control the discharge air box. During the shutdown process, the material layer thickness detection value is collected in real time to determine the position of the material tail and to track the material tail. When the material tail reaches the head position of the first air box, the first air box is closed. When the material tail reaches the head position of the next air box, the next air box is closed, and so on. When the last air box is closed, the automatic control of the shutdown air box is completed and the calculation stops. Carriage replacement air box control: When a carriage malfunctions during production and requires replacement, the system accurately locates the carriage to be replaced based on the material thickness. The system tracks the carriage, closing the first air box when it reaches the first air box's starting position, closing the next air box when it reaches the next air box's starting position, and so on. Once the carriage has completely left the first air box, the first air box is opened and restored to its previous opening degree. After leaving the next air box, the next air box is restored to its previous opening degree, and so on. When the designated replacement carriage position is reached, the system alerts the user to reduce the main exhaust fan and perform the carriage replacement operation.

2. The automatic control method for a bellows according to claim 1, characterized in that, The machine automatically determines the position of the feed head during startup and accurately tracks the position of the feed head at a frequency of seconds.

3. The automatic control method for a bellows according to claim 1, characterized in that, It automatically determines the position of the material tail and completes positioning and tracking.

4. The automatic control method for a bellows according to claim 1, characterized in that, During the trolley change process, the abnormal trolley position is automatically located based on material thickness and negative pressure.

5. The automatic control method for a bellows according to claim 1, characterized in that, The production cycle is set at 1.5 to 3 hours.

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