A method for efficiently mixing materials with different bulk densities

Abstract

The present invention relates to the field of material mixing, and in particular to a method for efficiently and uniformly mixing materials with different bulk densities. The present invention first obtains the density and particle size of different types of materials stored in a material storage mechanism, and determines the different states of the various types of materials; then determines the mixing method for mixing the materials based on the different states of the mixed materials; finally, when using different mixing methods, the process parameters during mixing are adjusted, including adjusting the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value exerted on the stirring rod and determining whether the stirring is completed; and under preset conditions, detecting the dispersion of the bottom material contour points, adjusting the spraying force when spraying different types of materials based on the dispersion of the material contour points, and correcting the spraying force of the various types of materials based on the stacking height of the materials in the mixing bin at preset cycles; the present invention can effectively improve the material mixing effect and the material mixing uniformity.

Description

Technical Field

[0001] The invention relates to the field of material mixing, and in particular to a method for efficiently and evenly mixing materials with different bulk densities. Background Art

[0002] Material mixing involves various industries and fields. Solid materials include dusty solids and granular solids. Due to the different bulk densities of solid materials, material mixing often results in unevenness.

[0003] For example, Chinese patent publication number CN101829518A discloses a material mixer comprising a main motor, a secondary motor, a main reducer, a secondary reducer, and a cylindrical barrel. The difference lies in that a rotating shaft is mounted within the barrel, which is a spiral shaft equipped with spiral blades. The rotating shaft is divided into left and right parts, and the spiral blades on the left and right parts of the rotating shaft have opposite spiral directions. A set of bearing plates are distributed on the inner wall of the barrel. One end of the bearing plate is welded to the inner wall of the barrel, and the other end of the bearing plate points in the direction of the rotating shaft and is offset from the center of the rotating shaft by a distance. The bearing plate is also provided with a guide scraper. Because the rotating shaft is a two-section, bidirectional spiral shaft within the barrel, the material in the barrel will not be biased toward one end of the barrel during the mixing process, and the mixing is uniform and thorough.

[0004] However, the prior art still has the following problems

[0005] In the prior art, it is not considered that the different states of the materials to be mixed will affect the mixing effect, and the operating parameters of the device are adaptively adjusted to improve the mixing effect. For example, if the particle size and density of the materials to be mixed are quite different, the materials will tend to be stratified, especially in the mixing device, the proportions of the materials in each layer will be quite different, and the mixing effect will be poor. Summary of the Invention

[0006] In order to solve the problem in the prior art that the different states of the materials to be mixed will affect the mixing effect, resulting in poor mixing effect, the present invention provides a method for efficiently and uniformly mixing materials with different bulk densities, comprising:

[0007] Step S1, obtaining the density and particle size of different types of materials stored in the storage mechanism, and determining the different states of the various types of materials based on the density and particle size of the various types of materials;

[0008] Step S2, determining a mixing method for mixing the materials based on the difference states of the mixed materials, including:

[0009] After pouring different types of materials into the mixing bin, use a stirring rod to stir the materials and detect the pressure value of the stirring rod;

[0010] Alternatively, different types of materials are sprayed alternately onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin, and images of the materials scattered to the bottom of the mixing bin are detected;

[0011] Step S3, adjusting the process parameters during mixing when using different mixing methods, wherein:

[0012] adjusting the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value applied to the stirring rod and determining whether the stirring is completed;

[0013] Or, under preset conditions, the dispersion of the bottom material contour points is detected, and the spraying force when spraying different types of materials is adjusted based on the dispersion of the material contour points. Moreover, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period.

[0014] The preset condition is that after the first injection of different types of materials is completed.

[0015] Furthermore, in step S1, the differential state characterization value of the materials to be mixed is calculated according to formula (1) based on the density and particle size of each type of material.

[0016]

[0017] In formula (1), D represents the differential state characterization value of the mixed material, i is an integer greater than 1, n represents a total of n types of materials, Xi is the particle size of the i-th material, X0 represents the average particle size of the mixed material, ρi is the density of the i-th material, and ρ0 represents the average density of the mixed material.

[0018] Furthermore, in step S1, the difference state of each type of material is determined based on the difference state characterization value of the mixed material.

[0019] When the difference state representation value of the material to be mixed is less than the preset difference state representation value of the material to be mixed, determining that the difference state of the material to be mixed is the first difference state;

[0020] When the difference state representation value of the material to be mixed is greater than or equal to a preset difference state representation value of the material to be mixed, it is determined that the difference state of the material to be mixed is the second difference state.

[0021] Furthermore, in step S2, a mixing method for mixing the materials is determined based on the difference state of the mixed materials, wherein:

[0022] When the difference state of the materials to be mixed is the first difference state, a mixing method is adopted in which different types of materials are poured into the mixing bin and then stirred with a stirring rod;

[0023] When the difference state of the materials to be mixed is the second difference state, a mixing method is adopted in which different types of materials are alternately sprayed onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin.

[0024] Furthermore, in step S3, the fluctuation amplitude of the pressure value on the stirring rod is calculated according to formula (2):

[0025]

[0026] In formula (2), B represents the fluctuation amplitude, F i represents the average pressure on the stirring rod during the i-th stirring cycle, F i+1 It represents the average pressure of the stirring rod during the i+1th stirring cycle, and m represents the number of stirring cycles.

[0027] Furthermore, in step S3, whether the stirring is completed is determined based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein:

[0028] When the fluctuation amplitude of the pressure value on the stirring rod is less than the preset fluctuation amplitude, it is determined that the stirring is completed.

[0029] Furthermore, in step S3, the stirring rate of the stirring rod is adjusted based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein there are several adjustment methods for adjusting the stirring rate of the stirring rod according to the fluctuation amplitude of the pressure value applied to the stirring rod.

[0030] Among them, each adjustment method has a different adjustment effect on the stirring rate of the stirring rod.

[0031] Furthermore, in step S3, the spraying force when spraying different types of materials is adjusted based on the dispersion of the material contour points, wherein there are several adjustment methods for setting the spraying force according to the dispersion of the material contour points.

[0032] Among them, each adjustment method has a different adjustment effect on the spray force.

[0033] Furthermore, in step S3, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period, wherein there are several correction methods for adjusting the spraying force according to the accumulation height.

[0034] Among them, each correction method has a different correction size for the injection force.

[0035] Furthermore, a device for efficiently mixing materials with different bulk densities is provided.

[0036] The material storage mechanism includes a plurality of storage bins for storing different types of materials;

[0037] A detection mechanism, comprising a density detection unit provided in each storage bin for obtaining the density of the material in the storage bin and a particle size detection unit for obtaining the particle size of the material in the storage bin;

[0038] The first mixing bin includes a bin body and a stirring rod disposed in the bin body. The bin body is provided with a plurality of feeding units, each of which is connected to a corresponding storage bin so as to transport the material in each storage bin into the bin body. The stirring rod is provided with a pressure sensor for detecting a pressure value.

[0039] The second mixing bin includes a bin body, a plurality of spraying units arranged in the bin body, and a rotating disk arranged on the top of the bin body. Each spraying unit is connected to a corresponding storage bin and is used to alternately spray the material in the storage bin toward the rotating disk so that the material hits the rotating disk and is dispersed into the bin body. In addition, the bin body is also provided with a distance measuring unit for detecting the stacking height of the material in the bin body and an image detection unit for obtaining the dispersion of the material contour points at the bottom of the bin body.

[0040] A controller is connected to the detection mechanism, the stirring rod, the spraying unit and the rotating disk respectively, and includes a data processing unit, a first control unit and a second control unit.

[0041] The data processing unit is used to obtain the data detected by the detection mechanism, determine the difference state of the materials to be mixed based on the density and particle size of the materials to be mixed, and determine the mixing bin to be activated based on the difference state of the materials to be mixed;

[0042] The first control unit is configured to control each of the feeding units to transport the material in the storage bin to the first mixing bin when the data processing unit determines that the first mixing bin needs to be activated, and to adjust the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value detected by the pressure sensor and to determine whether the stirring is completed;

[0043] The second control unit is configured to control the spraying units to alternately spray the materials in the respective storage bins toward the rotating disk when the data processing unit determines that the second mixing bin needs to be activated, and, under preset conditions, to obtain an image detected by the image detection unit, set the spraying force of each spraying unit based on the dispersion of the material contour points in the image, and, at every preset period, to correct the spraying force of each spraying unit based on the stacking height detected by the distance measurement unit;

[0044] The preset condition is that each spraying unit sprays material for the first time.

[0045] Compared with the prior art, the present invention first obtains the density and particle size of different types of materials stored in the storage mechanism to determine the different states of various types of materials; then determines the mixing method for mixing the materials based on the different states of the mixed materials; finally, when using different mixing methods, adjusts the process parameters during mixing, including adjusting the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value of the stirring rod and determining whether the stirring is completed; and under preset conditions, detects the dispersion of the bottom material contour points, adjusts the spraying force when spraying different types of materials based on the dispersion of the material contour points, and corrects the spraying force of various types of materials based on the stacking height of the materials in the mixing bin at preset cycles; the present invention can effectively improve the material mixing effect and the material mixing uniformity.

[0046] In particular, the present invention can distinguish material mixing methods by calculating the difference state characterization value of the materials to be mixed according to the density of the materials to be mixed and the particle size of the materials; in actual situations, the particle size and density of the materials to be mixed are quite different, and the materials will tend to be stratified, especially in the mixing device, the proportions of the materials in each layer will vary greatly, which will lead to uneven mixing, poor mixing effect, and low material mixing effect; by calculating the difference state characterization value of the materials to be mixed, the materials with small differences in state are directly mixed by stirring, and the materials with large differences in state are mixed by spraying the materials, thereby improving the material mixing effect and material mixing uniformity.

[0047] In particular, the present invention adjusts the stirring rate of the stirring rod by the fluctuation amplitude of the pressure value exerted on the stirring rod. When the fluctuation amplitude is small, it indicates that the material mixing is more uniform, and the stirring rod can be stirred at a lower rate at this time. When the fluctuation amplitude is large, it indicates that the material mixing is less uniform, and the stirring rod can be stirred at a higher rate at this time. By calculating the fluctuation amplitude to change the stirring rate, the material mixing effect can be improved.

[0048] In particular, the present invention adjusts the spraying force when spraying different types of materials based on the dispersion of the material contour points and corrects the spraying force of various types of materials based on the stacking height of the materials in the mixing bin at preset intervals. When the dispersion of the material contour points is poor, the spraying force is adjusted so that the material falls to the bottom of the bin through the rotating disk more dispersed and evenly, thereby improving the uniformity of material mixing. When the material stacking height changes, the material falling distance changes, and the position after falling changes. The spraying force of the material should be adjusted accordingly so that the material can be evenly scattered to the current material stacking height, thereby improving the uniformity of material mixing. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 A diagram showing the steps of a method for efficiently and uniformly mixing materials of different bulk densities according to an embodiment of the invention;

[0050] Figure 2 This is a schematic structural diagram of the first mixing chamber of an embodiment of the invention;

[0051] Figure 3 This is a schematic structural diagram of the second mixing bin according to an embodiment of the invention;

[0052] The components in the accompanying drawings are marked as follows: 1. First mixing chamber; 2. Stirring rod; 3. Feeding unit; 4. Second mixing chamber; 5. Spraying unit; 6. Rotating disk. DETAILED DESCRIPTION

[0053] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0054] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0055] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside", and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0056] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0057] See also Figure 1-Figure 3 As shown, Figure 1 This is a step diagram of a method for efficiently and evenly mixing materials of different bulk densities according to an embodiment of the present invention; Figure 2 This is a schematic structural diagram of the first mixing chamber of an embodiment of the invention; Figure 3 This is a schematic diagram of the structure of the second mixing bin of an embodiment of the invention. A method for efficiently mixing materials with different bulk densities of the present invention comprises:

[0058] Step S1, obtaining the density and particle size of different types of materials stored in the storage mechanism, and determining the different states of the various types of materials based on the density and particle size of the various types of materials;

[0059] Step S2, determining a mixing method for mixing the materials based on the difference states of the mixed materials, including:

[0060] After pouring different types of materials into the mixing bin, use a stirring rod to stir the materials and detect the pressure value of the stirring rod;

[0061] Alternatively, different types of materials are sprayed alternately onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin, and images of the materials scattered to the bottom of the mixing bin are detected;

[0062] Step S3, adjusting the process parameters during mixing when using different mixing methods, wherein:

[0063] adjusting the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value applied to the stirring rod and determining whether the stirring is completed;

[0064] Or, under preset conditions, the dispersion of the bottom material contour points is detected, and the spraying force when spraying different types of materials is adjusted based on the dispersion of the material contour points. Moreover, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period.

[0065] The preset condition is that after the first injection of different types of materials is completed.

[0066] Specifically, in this embodiment, the dispersion of the bottom material contour points can be detected by obtaining the coordinates of each material contour point of the bottom material through a predetermined algorithm, and the dispersion of the material contour points in the image can be calculated according to formula (3):

[0067]

[0068] In formula (3), E represents the dispersion of the material contour points, G i It represents the distance between the i-th material contour point and the nearest material contour point, G0 represents the average distance between all material contour points and the nearest material contour point, and n represents the value of the material contour point.

[0069] Specifically, in this embodiment, the preset period is 1 minute.

[0070] Specifically, in step S1, the difference state characterization value of the materials to be mixed is calculated according to formula (1) based on the density and particle size of each type of material.

[0071]

[0072] In formula (1), D represents the differential state characterization value of the mixed material, i is an integer greater than 1, n represents a total of n types of materials, Xi is the particle size of the i-th material, X0 represents the average particle size of the mixed material, ρi is the density of the i-th material, and ρ0 represents the average density of the mixed material.

[0073] Specifically, by calculating the difference state characterization value of the materials to be mixed according to the density of the materials to be mixed and the particle size of the materials, the material mixing methods can be distinguished; in actual situations, the particle size and density of the materials to be mixed are quite different, and the materials will tend to be stratified, especially in the mixing device, the proportions of the materials in each layer will vary greatly, which will lead to uneven mixing, poor mixing effect, and low material mixing effect; by calculating the difference state characterization value of the materials to be mixed, the materials with small differences in state can be directly mixed by stirring, and the materials with large differences in state can be mixed by spraying materials, thereby improving the material mixing effect and material mixing uniformity.

[0074] Specifically, in step S1, the difference state of each type of material is determined based on the difference state representation value of the mixed material.

[0075] When the difference state representation value of the material to be mixed is less than the preset difference state representation value of the material to be mixed, determining that the difference state of the material to be mixed is the first difference state;

[0076] When the difference state representation value of the material to be mixed is greater than or equal to a preset difference state representation value of the material to be mixed, it is determined that the difference state of the material to be mixed is the second difference state.

[0077] Specifically, in step S2, the mixing method of the materials is determined based on the difference state of the mixed materials, wherein:

[0078] When the difference state of the materials to be mixed is the first difference state, a mixing method is adopted in which different types of materials are poured into the mixing bin and then stirred with a stirring rod;

[0079] When the difference state of the materials to be mixed is the second difference state, a mixing method is adopted in which different types of materials are alternately sprayed onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin.

[0080] Specifically, in step S3, the fluctuation amplitude of the pressure value on the stirring rod is calculated according to formula (2):

[0081]

[0082] In formula (2), B represents the fluctuation amplitude, F i Indicates the pressure value of the stirring rod for the i-th time, F i+1It represents the pressure value of the stirring rod for the i+1th time, and m represents the number of stirring cycles.

[0083] Specifically, in step S3, whether the stirring is completed is determined based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein:

[0084] When the fluctuation amplitude of the pressure value on the stirring rod is less than the preset fluctuation amplitude, it is determined that the stirring is completed.

[0085] In this embodiment, the preset fluctuation amplitude is determined based on the uniformity of material mixing. In this embodiment, the fluctuation amplitude of the uniformly mixed material is measured multiple times, and the average value B0 of the multiple measurements is taken, and the preset fluctuation amplitude is set as B0.

[0086] Specifically, in step S3, the stirring rate of the stirring rod is adjusted based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein there are several adjustment methods for adjusting the stirring rate of the stirring rod according to the fluctuation amplitude of the pressure value applied to the stirring rod.

[0087] Among them, each adjustment method has different adjustment effects on the stirring rate of the stirring rod;

[0088] Specifically, in this embodiment, there are three adjustment methods for adjusting the stirring rate according to the fluctuation amplitude, among which:

[0089] The first stirring rate adjustment method is to adjust the stirring rate to the first stirring rate using a preset first stirring rate adjustment coefficient under a preset first fluctuation amplitude condition;

[0090] The second stirring rate adjustment method is to adjust the stirring rate to the second stirring rate using a preset second stirring rate adjustment coefficient under a preset second fluctuation amplitude condition;

[0091] The third method for adjusting the stirring rate is to adjust the stirring rate to a third stirring rate using a preset third stirring rate adjustment coefficient under a preset third fluctuation amplitude condition;

[0092] in,

[0093] The preset first fluctuation amplitude condition is that the fluctuation amplitude is less than or equal to the preset first fluctuation amplitude;

[0094] The preset second fluctuation amplitude condition is that the fluctuation amplitude is greater than the preset first fluctuation amplitude and less than or equal to the preset second fluctuation amplitude;

[0095] The preset third fluctuation amplitude condition is that the fluctuation amplitude is greater than the preset second fluctuation amplitude;

[0096] The preset first fluctuation amplitude is smaller than the preset second fluctuation amplitude; the preset first stirring rate adjustment coefficient is smaller than the preset second stirring rate adjustment coefficient, which is smaller than the preset third stirring rate adjustment coefficient.

[0097] Specifically, the preset first fluctuation amplitude is recorded as B1, the preset second fluctuation amplitude is recorded as B2, the preset first stirring rate adjustment coefficient is recorded as β1, the preset second stirring rate adjustment coefficient is recorded as β2, and the preset third stirring rate adjustment coefficient is recorded as β3, wherein,

[0098] B1<B2, 1<β1<β2<β3<1.6, the jth stirring rate after adjustment is recorded as vj', set vj'=v×βj, v represents the standard stirring rate, 30r / min<v<100r / min, βj is the jth stirring rate adjustment coefficient, j=1, 2, 3.

[0099] In this embodiment, B1 is obtained by pre-detection, wherein the fluctuation amplitude of the material stirred at v during the material mixing process is recorded several times, and the average value of the fluctuation amplitude is solved according to the recorded fluctuation amplitude, and the average value of the fluctuation amplitude is determined as B1. B2 is determined based on B1, and B2=2×B1 is set.

[0100] Specifically, the present invention adjusts the stirring rate of the stirring rod by the fluctuation amplitude of the pressure value exerted on the stirring rod. When the fluctuation amplitude is small, it means that the material mixing is more uniform, and the stirring rod can be stirred at a lower rate at this time. When the fluctuation amplitude is large, it means that the material mixing is less uniform, and the stirring rod can be stirred at a higher rate at this time. By calculating the fluctuation amplitude to change the stirring rate, the material mixing effect can be improved.

[0101] Specifically, in step S3, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period.

[0102] Among them, there are several correction methods to adjust the spray force according to the stacking height.

[0103] Among them, each adjustment method has a different adjustment effect on the spray force.

[0104] Specifically, there are three adjustment methods for adjusting the injection force according to the dispersion of the material contour points, among which:

[0105] The first method for adjusting the spray intensity is to adjust the spray intensity to a first spray intensity using a preset first spray intensity adjustment coefficient under a preset first dispersion condition;

[0106] The second method for adjusting the spray intensity is to adjust the spray intensity to a second spray intensity using a preset second spray intensity adjustment coefficient under a preset second dispersion condition;

[0107] The third method for adjusting the spray intensity is to adjust the spray intensity to a third spray intensity using a preset third spray intensity adjustment coefficient under a preset third dispersion condition;

[0108] in,

[0109] The preset first dispersion condition is that the dispersion is less than or equal to the preset first dispersion;

[0110] The preset second dispersion condition is that the dispersion is greater than the preset first dispersion and less than or equal to the preset second dispersion;

[0111] The preset third dispersion condition is that the dispersion is greater than the preset second dispersion;

[0112] The preset first dispersion is smaller than the preset second dispersion; the preset first spray force adjustment coefficient is smaller than the preset second spray force adjustment coefficient, which is smaller than the preset third spray force adjustment coefficient.

[0113] Specifically, the preset first dispersion is recorded as E1, the preset second dispersion is recorded as E2, the preset first injection force adjustment coefficient is recorded as α1, the preset second injection force adjustment coefficient is recorded as α2, and the preset third injection force adjustment coefficient is recorded as α3, wherein,

[0114] 1<E1<E2, 1<α1<α2<α3<1.5, the j-th injection force after adjustment is recorded as Fj', and F'=F×αj is set, where F represents the initial injection force, αj is the j-th injection force adjustment coefficient, and j=1, 2, 3.

[0115] In order to ensure a better spreading effect of the ejected material, F>30N is set in this embodiment.

[0116] Specifically, the spraying force of various types of materials is corrected based on the accumulation height of the materials in the mixing bin at every preset period, wherein there are several correction methods for adjusting the spraying force according to the accumulation height.

[0117] Among them, each correction method has a different correction size for the injection force.

[0118] Specifically, there are three correction methods for adjusting the injection force according to the stacking height, among which:

[0119] The first method for correcting the spray force is to correct the spray force to a first corrected spray force using a preset first spray force correction coefficient under a preset first stacking height condition;

[0120] The second method for correcting the spray force is to correct the spray force to a second corrected spray force using a preset second spray force correction coefficient under a preset second stacking height condition;

[0121] The third method for correcting the spray force is to correct the spray force to a third corrected spray force using a preset third spray force correction coefficient under a preset third stacking height condition;

[0122] in,

[0123] The preset first stacking height condition is that the stacking height is less than or equal to the preset first stacking height;

[0124] The preset second stacking height condition is that the stacking height is greater than the preset first stacking height and less than or equal to the preset second stacking height;

[0125] The preset third stacking height condition is that the stacking height is greater than the preset second stacking height;

[0126] The preset first stacking height is smaller than the preset second stacking height; the preset first injection force correction coefficient is smaller than the preset second injection force correction coefficient, which is smaller than the preset third injection force correction coefficient.

[0127] Specifically, the preset first stacking height is recorded as H1, the preset second stacking height is recorded as H2, the preset first injection force correction coefficient is recorded as γ1, the preset second injection force correction coefficient is recorded as γ2, and the preset third injection force correction coefficient is recorded as γ3, wherein,

[0128] H1<H2, 1<γ1<γ2<γ3<1.3, the corrected injection force is recorded as F0j', set F0j'=Fj'×γj, γj is the jth injection force correction coefficient, j=1, 2, 3, set H1=H0 / 3, H2=2H0 / 3, H0 represents the height of the second mixing bin.

[0129] Specifically, the present invention adjusts the spraying force when spraying different types of materials based on the dispersion of the material contour points, and corrects the spraying force of various types of materials based on the stacking height of the materials in the mixing bin at preset intervals. When the dispersion of the material contour points is poor, the spraying force is adjusted so that the material falls to the bottom of the bin through the rotating disk more dispersed and evenly, thereby improving the uniformity of material mixing. When the material stacking height changes, the material falling distance changes, and the position after falling changes. The material spraying force should be adjusted accordingly so that the material can be evenly scattered to the current material stacking height, thereby improving the uniformity of material mixing.

[0130] Specifically, a device for efficiently mixing materials of different bulk densities comprises:

[0131] The material storage mechanism includes a plurality of storage bins for storing different types of materials;

[0132] A detection mechanism, comprising a density detection unit provided in each storage bin for obtaining the density of the material in the storage bin and a particle size detection unit for obtaining the particle size of the material in the storage bin;

[0133] The first mixing bin 1 includes a bin body and a stirring rod 2 disposed in the bin body. The bin body is provided with a plurality of feeding units 3. Each feeding unit 3 is connected to a corresponding storage bin so that the material in each storage bin is transported to the bin body. The stirring rod 2 is provided with a pressure sensor for detecting a pressure value.

[0134] The second mixing bin 4 includes a bin body, a plurality of spraying units 5 arranged in the bin body, and a rotating disk 6 arranged on the top of the bin body. Each spraying unit 5 is connected to a corresponding storage bin and is used to alternately spray the material in the storage bin toward the rotating disk 6 so that the material hits the rotating disk and is dispersed into the bin body. In addition, the bin body is also provided with a distance measuring unit for detecting the stacking height of the material in the bin body and an image detection unit for obtaining the dispersion of the material contour points at the bottom of the bin body.

[0135] The controller is connected to the detection mechanism, the stirring rod 2, the spraying unit 5 and the rotating disk 6 respectively, and includes a data processing unit, a first control unit and a second control unit.

[0136] The data processing unit is used to obtain the data detected by the detection mechanism, determine the difference state of the materials to be mixed based on the density and particle size of the materials to be mixed, and determine the mixing bin to be activated based on the difference state of the materials to be mixed;

[0137] The first control unit is configured to control each of the feeding units to transport the material in the storage bin to the first mixing bin 1 when the data processing unit determines that the first mixing bin 1 needs to be activated, and to adjust the stirring rate of the stirring rod 2 based on the fluctuation amplitude of the pressure value detected by the pressure sensor and to determine whether the stirring is completed;

[0138] The second control unit is configured to control the spraying units 5 to alternately spray the materials in each storage bin toward the rotating disk 6 when the data processing unit determines that the second mixing bin 4 needs to be activated, and, under preset conditions, to obtain an image detected by the image detection unit, set the spraying force of each spraying unit 5 based on the dispersion of the material contour points in the image, and, at every preset period, to correct the spraying force of each spraying unit 5 based on the stacking height detected by the distance measurement unit;

[0139] The preset condition is that each spraying unit 5 sprays material for the first time.

[0140] Specifically, the present invention does not limit the specific structure of the density detection unit, which can obtain the density of the stacked material. This is a prior art and will not be described in detail.

[0141] Specifically, the present invention does not limit the specific structure of the particle size detection unit. It can obtain the particle size of the material. This is a prior art and will not be described in detail.

[0142] Specifically, the present invention does not limit the specific structure of the image detection unit. It can be a combination of a camera and an image processing module to capture images of a predetermined area and analyze the images. This is existing technology and will not be repeated here.

[0143] Specifically, the present invention does not limit the specific structure of the spraying unit 5. It can be a material ejector, and it only needs to be able to extract and eject the material through a power pump, which will not be described in detail here.

[0144] Specifically, the present invention does not limit the specific structure of the pressure sensor. Preferably, in this embodiment, the pressure sensor is in the form of a combination of a sensor and a signal sending device, so that the controller receives data sent by the pressure sensor. This is a prior art and will not be repeated here.

[0145] Specifically, the present invention does not limit the specific structure of the distance measuring unit, which can obtain the distance between the material in the bin and the bottom of the bin, for example, a laser rangefinder, an ultrasonic rangefinder, etc. This is existing technology and will not be repeated.

[0146] Specifically, the present invention does not limit the specific structure of the controller. The controller and each unit therein can be composed of logic components. The logic components can be field programmable components, computers, and microprocessors in computers, etc., which will not be repeated here.

[0147] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. A method for efficiently mixing materials of different bulk densities, characterized in that: include: Step S1, obtaining the density and particle size of different types of materials stored in the storage mechanism, and determining the different states of the various types of materials based on the density and particle size of the various types of materials; Step S2, determining a mixing method for mixing the materials based on the difference states of the mixed materials, including: After pouring different types of materials into the mixing bin, use a stirring rod to stir the materials and detect the pressure value of the stirring rod; Alternatively, different types of materials are sprayed alternately onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin, and images of the materials scattered to the bottom of the mixing bin are detected; Step S3, adjusting the process parameters during mixing when using different mixing methods, wherein: adjusting the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value applied to the stirring rod and determining whether the stirring is completed; Or, under preset conditions, the dispersion of the bottom material contour points is detected, and the spraying force when spraying different types of materials is adjusted based on the dispersion of the material contour points. Moreover, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period. The preset condition is that after the first injection of different types of materials is completed; In step S1, the difference state characterization value of the materials to be mixed is calculated according to formula (1) based on the density and particle size of each type of material. In formula (1), D represents the differential state characterization value of the mixed material, i is an integer greater than 1, n represents a total of n materials, Xi is the particle size of the i-th material, X0 represents the average particle size of the mixed material, ρi is the density of the i-th material, and ρ0 represents the average density of the mixed material; In the step S1, the difference state of each type of material is determined based on the difference state characterization value of the mixed material. When the difference state representation value of the material to be mixed is less than the preset difference state representation value of the material to be mixed, determining that the difference state of the material to be mixed is the first difference state; When the difference state representation value of the material to be mixed is greater than or equal to a preset difference state representation value of the material to be mixed, it is determined that the difference state of the material to be mixed is the second difference state.

2. The method for efficiently mixing materials of different bulk densities according to claim 1, characterized in that: In the step S2, the mixing method of the materials is determined based on the difference state of the mixed materials, wherein: When the difference state of the materials to be mixed is the first difference state, a mixing method is adopted in which different types of materials are poured into the mixing bin and then stirred with a stirring rod; When the difference state of the materials to be mixed is the second difference state, a mixing method is adopted in which different types of materials are alternately sprayed onto the rotating disk so that the materials are dispersed after hitting the rotating disk and fall into the mixing bin.

3. The method for efficiently mixing materials of different bulk densities according to claim 1, wherein: In step S3, the fluctuation amplitude of the pressure value on the stirring rod is calculated according to formula (2): In formula (2), B represents the fluctuation amplitude, F i represents the average pressure on the stirring rod during the i-th stirring cycle, F i+1 It represents the average pressure of the stirring rod during the i+1th stirring cycle, and m represents the number of stirring cycles.

4. The method for efficiently mixing materials of different bulk densities according to claim 3, characterized in that: In step S3, whether the stirring is completed is determined based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein: When the fluctuation amplitude of the pressure value applied to the stirring rod is less than the preset fluctuation amplitude, it is determined that the stirring is completed.

5. The method for efficiently mixing materials of different bulk densities according to claim 3, characterized in that: In step S3, the stirring rate of the stirring rod is adjusted based on the fluctuation amplitude of the pressure value applied to the stirring rod, wherein there are several adjustment methods for adjusting the stirring rate of the stirring rod according to the fluctuation amplitude of the pressure value applied to the stirring rod. Among them, each adjustment method has a different adjustment effect on the stirring rate of the stirring rod.

6. The method for efficiently mixing materials of different bulk densities according to claim 1, characterized in that: In step S3, the spraying force when spraying different types of materials is adjusted based on the dispersion of the material contour points, wherein: There are several adjustment methods for setting the injection force according to the dispersion of the material contour points, and each adjustment method has a different adjustment effect on the injection force.

7. The method for efficiently mixing materials of different bulk densities according to claim 1, characterized in that: In step S3, the spraying force of each type of material is corrected based on the accumulation height of the material in the mixing bin at every preset period, wherein there are several correction methods for adjusting the spraying force according to the accumulation height. Among them, each correction method has a different correction size for the injection force.

8. A device using the method for efficiently mixing materials of different bulk densities according to any one of claims 1 to 7, characterized in that: include: The material storage mechanism includes a plurality of storage bins for storing different types of materials; A detection mechanism, comprising a density detection unit provided in each storage bin for obtaining the density of the material in the storage bin and a particle size detection unit for obtaining the particle size of the material in the storage bin; The first mixing bin includes a bin body and a stirring rod disposed in the bin body. The bin body is provided with a plurality of feeding units, each of which is connected to a corresponding storage bin so as to transport the material in each storage bin into the bin body. The stirring rod is provided with a pressure sensor for detecting a pressure value. The second mixing bin includes a bin body, a plurality of spraying units arranged in the bin body, and a rotating disk arranged on the top of the bin body. Each spraying unit is connected to a corresponding storage bin and is used to alternately spray the material in the storage bin toward the rotating disk so that the material hits the rotating disk and is dispersed into the bin body. In addition, the bin body is also provided with a distance measuring unit for detecting the stacking height of the material in the bin body and an image detection unit for obtaining the dispersion of the material contour points at the bottom of the bin body. A controller is connected to the detection mechanism, the stirring rod, the spraying unit and the rotating disk respectively, and includes a data processing unit, a first control unit and a second control unit. The data processing unit is used to obtain the data detected by the detection mechanism, determine the difference state of the materials to be mixed based on the density and particle size of the materials to be mixed, and determine the mixing bin to be activated based on the difference state of the materials to be mixed; The first control unit is configured to control each of the feeding units to transport the material in the storage bin to the first mixing bin when the data processing unit determines that the first mixing bin needs to be activated, and to adjust the stirring rate of the stirring rod based on the fluctuation amplitude of the pressure value detected by the pressure sensor and to determine whether the stirring is completed; The second control unit is configured to control the spraying units to alternately spray the materials in the respective storage bins toward the rotating disk when the data processing unit determines that the second mixing bin needs to be activated, and, under preset conditions, to obtain an image detected by the image detection unit, set the spraying force of each spraying unit based on the dispersion of the material contour points in the image, and, at every preset period, to correct the spraying force of each spraying unit based on the stacking height detected by the distance measurement unit; The preset condition is that each spraying unit sprays material for the first time.

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