A method for determining a state of a request for distributing material from a stock bin on a furnace roof and a material distribution system

Abstract

The present application relates to the technical field of furnace top stock bin distribution, and discloses a furnace top stock bin distribution request state determination method and a furnace top stock bin distribution system, which solve the problem of low efficiency caused by manual setting of furnace top stock bin distribution in the continuous production process, improve the accuracy of the distribution batch by automatically determining the distribution stock bin number, and predict the distribution situation that will occur; the working strength of the operator is reduced in terms of manpower load, the distribution process is unattended, compared with the prior art, the mathematical model is established on the actual layout and operation state logic control of the field equipment, which is closer to the actual demand and equipment operation posture of the process production, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of furnace top silo material distribution technology, and in particular to a method for determining the material distribution request status of furnace top silo and a material distribution system. Background Technology

[0002] The furnace top hopper mainly consists of a hopper body, chutes, and weighing sensors. It is primarily used in open calcium carbide furnaces, semi-enclosed calcium carbide furnaces, closed calcium carbide furnaces, and other submerged arc furnaces, such as ferrosilicon alloy furnaces, manganese silicon alloy furnaces, and titanium slag furnaces. Its function is to store furnace charge and coordinate the intermittent charging system with continuous furnace production. Currently, in practical applications in the metallurgical industry, electric furnaces are generally configured as a unit of two furnaces equipped with a single charging system. Each furnace uses eight furnace top hoppers to transport raw materials into the furnace for smelting. Each furnace top hopper has a unique number (i.e., hopper number). When the weight of the raw material in the furnace top hopper falls below a set value, the corresponding hopper sends a material request signal. Upon receiving the request signal, the charging system initiates the material conveying operation. Therefore, the process of real-time monitoring of the raw material weight in the 16 furnace top hoppers of the two furnaces and the cyclical conveying of raw materials via the moving belts in the charging system is called charging. The process of conveying a single batch of mixed material to the furnace top silo is called batch feeding. Each batch consists of a fixed weight of mixed material prepared from raw materials in different proportions. The number of times the mixed material needs to be fed to each furnace top silo, calculated based on the set weight limits, is called a batch. Currently, manual setting during feeding presents several problems: (1) After completing the material distribution task of the current silo, when switching silos, it is necessary to manually determine which silo to distribute the material based on the status of all silos, which wastes time during the switching process; (2) After the material hopper is switched, the target batch of fabric required needs to be calculated manually; (3) Manual setting method reduces the efficiency of continuous production, increases the error rate, and increases the workload of operators.

[0003] For example, CN115109881A discloses a method and apparatus for top material distribution in a furnace. Based on the deviation between the current parameters of the material surface and the target parameters preset according to the requirements, the material distribution parameters of the distributor are adjusted in real time until the deviation is within the allowable range. The material is then distributed according to the adjusted material distribution parameters to achieve intelligent fine-tuning, improve the adjustment accuracy, enhance the stability of the furnace condition, and reduce the intensity of manual labor. However, in actual material distribution, the distribution of different batches still needs to be done manually, which reduces the efficiency of continuous production, increases the error rate, and increases the workload of operators. Therefore, an efficient automatic batch distribution method is needed. Summary of the Invention

[0004] The purpose of this invention is to solve the problem of low efficiency caused by manual setting of the furnace top hopper in continuous production processes. It aims to automatically determine the hopper number, improve the accuracy of hopper batch setting, and predict upcoming hopper setting situations. Furthermore, it reduces the workload of operators, enabling unattended operation of the hopper setting process. To address these issues, this invention provides the following technical solution: a method for determining the hopper setting request status, comprising the following steps: S1. Define and input the parameters of the furnace top hopper equipment; S2. Create automatic position selection status words and define the high-priority and low-priority statuses of each position; S3. Create a manual position selection status word, and define the position status of each position by defining each bit of the low-order word; S4. Integrate all status words, including automatic and manual position selection status words, to obtain the total status word, high-priority low-order word value, and low-priority high-order word value; S5. Based on the obtained total status word, high priority low bit value and low priority high bit value, obtain the fabric request bin number and calculate the fabric batch. Then, according to the calculation result and the priority of the fabric bin number, the fabric is laid out sequentially.

[0005] This invention addresses the need to control the material distribution of 16 furnace top hoppers. Therefore, it designs a method for determining the material distribution priority based on the hopper's distribution priority. This involves integrating the automatic and manual hopper selection status words to obtain a total status word. Then, based on logical operations on this total status word, the high-priority low-order word value and low-priority high-order word value are used to prioritize the furnace top hopper material distribution requests. Material is then distributed sequentially according to the prioritized order, with dynamic adjustments to ensure efficient distribution. This method can be used for material distribution control of various electric furnace top hoppers, automatically outputting the status of the requested hopper number after determination. It also automatically calculates the batch demand for each hopper, automatically sorts priorities, and dynamically displays the status of all hopper requests. The main purpose of this invention is to technically solve the inefficiency problem caused by manual settings in continuous production processes. It automatically determines the material distribution hopper number, improves the accuracy of material distribution batches, and predicts upcoming material distribution situations. In terms of manpower, it reduces the workload of operators, achieving unattended operation of the material distribution process. This invention is applicable to the determination of material feeding requests in the top charge bin of electric furnaces, especially in scenarios with high requirements for production efficiency, continuous production, and labor costs.

[0006] Preferably, the parameters of the furnace charge silo equipment include input parameters, output parameters, built-in parameters, monitoring parameters, and temporary variables, and the temporary variables include the status of the corresponding silo when manually selecting the silo.

[0007] This invention designs and creates a bin selection status word based on information from various parameters, performs a series of logical operations based on the bin selection status word to obtain the priority ranking of each furnace top bin, and then distributes material to each furnace top bin according to the priority ranking.

[0008] Preferably, the specific process of step S2 includes: creating a 32-bit automatic position selection status word, wherein each bit of the low-order word is defined as the low-low-order (high priority) status of 16 positions, and each bit of the high-order word is marked as the low-order (low priority) status of 16 positions.

[0009] To accommodate the specific needs of bins 1-8 and 2-8, this invention employs a manual screen-triggered method to trigger high-priority material placement requests for these bins. Low-priority requests are inactive, but their functionality is temporarily retained. After comparing the weights of the 16 bins with preset lower and lower-lower limits, each status is assigned to the corresponding bit in the double-word VIEW1, thus identifying the bin weight status. This invention considers the actual layout of the bins on-site and performs a cyclical query of each status bit. Therefore, the bin numbers of adjacent bins are arranged continuously in the status word, avoiding the problem of low material placement efficiency caused by the subsequent material placement system's control conveyor belt constantly moving due to bin number jumps during queries.

[0010] Preferably, step S3 specifically includes: creating a 32-bit manual warehouse selection status word, wherein each bit of the low-order word is defined as 16 warehouse statuses. In manual mode, after manually setting the fabric request warehouse number through the screen, it will be reflected in the corresponding bit of the low-order word of the manual warehouse selection status word. Manual mode is a high-priority state, and in this mode, all high-order bits are set to 0.

[0011] Preferably, the specific process of step S4 includes: performing a bitwise logical OR operation on the automatic warehouse selection status word VIEW1 and the manual warehouse selection status word VIEW2 to obtain a new total status word VIEW, with the following formula: VIEW = OR_UDINT(VIEW1,VIEW2), and then performing a logical operation on the obtained total status word with 65535 and 4294901760 to obtain the high-priority low-bit word value and the low-priority high-bit word value.

[0012] Regardless of the mode, the program can easily obtain the fabric request bin number by judging the status in the total status word VIEW, the high priority low-order word value DW_L, and the low priority high-order word value DW_H. At the same time, it ensures that the query is performed in sequence, avoiding large jumps in the requested bin number.

[0013] As a preferred option, the specific calculation process of the high priority low-order word value is as follows: the total status word VIEW is logically ANDed with 65535 to obtain the high priority low-order word value DW_L, formula: DW_L=AND_UDINT(VIEW,65535); The specific calculation process of the low-priority high-order word value is as follows: The total status word VIEW is ANDed with 4294901760 to obtain the low-priority high-order word value DW_H. The formula is: DW_H = AND_UDINT(VIEW, 4294901760).

[0014] Since each batch of material is a mixture with a fixed ratio and the total weight remains constant, in order to ensure that each batch of material can be put into the silo without spillage, rounding is required when calculating the batch size.

[0015] Preferably, the specific process of step S5 is as follows: when calculating the fabric batch, a rounding operation is performed, and the specific calculation formula is as follows: BAT_S1=REAL_TO_USINT((WT_H-WT1) / BW) Where: BAT_S1 is the batch calculation result; REAL_TO_USINT(A) is the rounding operation on A; WT_H is the upper limit of the material bin weight; WT1 is the actual weight of bin 1; BW is the total weight of a single batch of material. When the calculation result is 0, it means that the material in the current bin has been completed and there is no need to continue material.

[0016] This invention incorporates a "hopper change permission signal" from the fabric distribution system. Upon receiving this signal, the system switches the hopper number requesting fabric distribution to the next available hopper. This ensures that all materials on the conveyor belts in the fabric distribution system have been delivered to the designated hoppers, preventing the fabric conveyor belts from shifting due to the switching of the hopper number requesting fabric distribution, which could lead to material spillage.

[0017] Preferably, after the calculation of the fabric batch is completed, 16 variables QUE1-QUE16 are created to store the corresponding silo numbers in the order in which the fabric request commands need to be executed. The silo number that needs to be executed first is stored in QUE1, the silo number that needs to be executed next is stored in QUE2, and so on. The fabric operation is executed in ascending order of variable number. During the entire fabric stage, the fabric request sequence is dynamically queried and updated based on the remaining material weight of all silos.

[0018] This invention dynamically queries and updates the material placement request sequence throughout the entire material placement phase based on the remaining material weight in all hoppers. Operators can visually see the hopper number to be placed on the screen. This sequence presentation also helps to anticipate or avoid emergencies or abnormal situations, thereby reducing the accident rate and improving production efficiency. This module can be used in all electric furnace material placement systems. During application, the corresponding weight detection signals should be connected to the appropriate pins based on the actual installation location of the hoppers. If the number of hoppers is less than 16, the extra input pins can be set to a number greater than the maximum weight limit to avoid triggering the material placement request status.

[0019] A furnace top hopper material distribution system, applicable to the aforementioned furnace top hopper material distribution request status determination method, includes: a first electric furnace and a second electric furnace, the first and second electric furnaces employing three-phase electrodes, the first electric furnace having eight furnace top hoppers numbered 1-1 to 1-8 around its perimeter, and the second electric furnace having eight furnace top hoppers numbered 2-1 to 2-8 around its perimeter, the furnace top hoppers being connected to a moving belt, the moving belt being equipped with a plurality of material distribution devices.

[0020] This invention's system has two control modes: manual and automatic. Each electric furnace is surrounded by top charge bins numbered 1-8, with the main number being the furnace number. During charge distribution, the manual / automatic mode control for each furnace's top charge bin can be set by clicking the manual / automatic mode switch button. In automatic mode, the required target batch is automatically calculated by detecting the existing weight. In manual mode, the target batch of the charge bin can be manually set, and the charge distribution request command can be triggered by clicking the corresponding charge bin selection button. Due to the automatic determination by the module using this invention, the display device can also show the charge bin number currently executing the charge distribution request and the request sequence of the charge bins to be distributed. The high and low limits of the charge bins can be directly assigned fixed constants during module use, and these values ​​will theoretically not change after normal use, exhibiting stability.

[0021] Preferably, the furnace top hopper material distribution system determines the weight values ​​of the 16 furnace top hoppers and issues material distribution requests for the corresponding furnace top hopper numbers according to the expected order and priority. This allows the subsequent material distribution system to automatically control the material distribution device on the moving belt to move to the furnace top hopper position corresponding to the furnace top hopper number for material distribution.

[0022] This invention distributes material to the furnace top hoppers according to the material distribution priority requests of each hopper, thereby improving material distribution efficiency and reducing labor costs.

[0023] The beneficial effects of this invention are as follows: 1. Compared with existing solutions, this invention not only solves the shortcomings of existing technologies, but also establishes a mathematical model for the actual layout and operational status logic control of on-site equipment, which is closer to the actual needs of process production and equipment operation; 2. By using this invention, the time for each material bin switching can be shortened by 30 seconds. Based on a total motor power of 250kW for one fabric production line, a factory with 5 fabric production lines, where each production line needs to switch material bins 250 times per day, can save 5*250*30 / 3600*250 = 2604 kWh of electricity per day. Therefore, the stable operation of fabric request control can save the company a considerable amount of energy costs. Attached Figure Description

[0024] Figure 1 This is a flowchart of Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the system in Embodiment 2 of the present invention; Figure 3 This is a diagram of the system operation interface in Embodiment 2 of the present invention; In the diagram: 1-First electric furnace; 2-Second electric furnace; 3-Moving belt; 4-Material feeding device. Detailed Implementation

[0025] The specific implementation of the technical solution of the present invention will be further described below through examples and in conjunction with the accompanying drawings.

[0026] Example 1: Please see Figure 1 This invention provides a method for determining the material distribution request status of a furnace top silo, comprising the following steps: S1. Define and input the parameters of the furnace top hopper equipment; S2. Create automatic position selection status words and define the high-priority and low-priority statuses of each position; S3. Create a manual position selection status word, and define the position status of each position by defining each bit of the low-order word; S4. Integrate all status words, including automatic and manual position selection status words, to obtain the total status word, high-priority low-order word value, and low-priority high-order word value; S5. Based on the obtained total status word, high priority low bit value and low priority high bit value, obtain the fabric request bin number and calculate the fabric batch. Then, according to the calculation result and the priority of the fabric bin number, the fabric is laid out sequentially.

[0027] This invention addresses the need to control the material distribution of 16 furnace top hoppers. Therefore, it designs a method for determining the material distribution priority based on the hopper's distribution priority. This involves integrating the automatic and manual hopper selection status words to obtain a total status word. Then, based on logical operations on this total status word, the high-priority low-order word value and low-priority high-order word value are used to prioritize the furnace top hopper material distribution requests. Material is then distributed sequentially according to the prioritized order, with dynamic adjustments to ensure efficient distribution. This method can be used for material distribution control of various electric furnace top hoppers, automatically outputting the status of the requested hopper number after determination. It also automatically calculates the batch demand for each hopper, automatically sorts priorities, and dynamically displays the status of all hopper requests. The main purpose of this invention is to technically solve the inefficiency problem caused by manual settings in continuous production processes. It automatically determines the material distribution hopper number, improves the accuracy of material distribution batches, and predicts upcoming material distribution situations. In terms of manpower, it reduces the workload of operators, achieving unattended operation of the material distribution process. This invention is applicable to the determination of material feeding requests in the top charge bin of electric furnaces, especially in scenarios with high requirements for production efficiency, continuous production, and labor costs.

[0028] The parameters of the furnace charge silo equipment include input parameters, output parameters, built-in parameters, monitoring parameters, and temporary variables. The temporary variables include the status of the corresponding silo when manually selecting a silo.

[0029] This invention designs and creates a bin selection status word based on information from various parameters, performs a series of logical operations based on the bin selection status word to obtain the priority ranking of each furnace top bin, and then distributes material to each furnace top bin according to the priority ranking.

[0030] The types and meanings of each parameter are shown in the table below: (1) Input parameters AUTO1 BOOL The material feeding request for electric furnace No. 1 hopper is for manual / automatic operation. AUTO2 BOOL The material feeding request for electric furnace No. 2 hopper is to be manually or automatically operated. MANSV1 USINT Request setting of material bin number in manual mode for electric furnace No. 1 MANSV2 USINT Request setting of material bin number in manual mode for electric furnace No. 2 WT1-WT8 REAL Weight values ​​of the 8 hoppers of electric furnace No. 1 WT9-WT16 REAL Weight values ​​of the 8 hoppers of electric furnace No. 2 WT_H REAL Weight limit WT_L REAL Weight limit WT_LL REAL Low weight limit BW REAL Total weight of a single batch LC_BL_EN BOOL Current material placement status in the hopper BAT_F USINT Complete batch counting LC_HC_ST BOOL Warehouse swapping allowed status C8_ST BOOL Material feeding request for #8 hopper requires manual start. C16_ST BOOL Material placement in hopper #16 requires manual activation. (2) Output parameters RQ_NO USINT Fabric request warehouse number RQ BOOL Request status RQ_1 BOOL Request status for Furnace #1 RQ_2 BOOL Request status for Furnace #2 BAT_S1-BAT_S8 USINT Target values ​​for fabric batches in warehouses 1-8 of furnace #1 BAT_S9-BAT_S16 USINT Target values ​​for fabric batches in warehouses 1-8 of furnace #2 RQ1-RQ8 BOOL Material feeding request status for No. 1 furnace, bins 1-8 RQ9-RQ16 BOOL Material feeding request status for No. 2 furnace, bins 1-8 COUNT USINT Request the quantity of fabric silos STA BOOL Request that the number of fabric bins be greater than 1 be ON MANSV1_ USINT Request setting of material bin number in manual mode for electric furnace No. 1 MANSV2_ USINT Request setting of material bin number in manual mode for electric furnace No. 2 QUE array Queue output array QUE1-QUE16 USINT Output the bin numbers corresponding to the 16 queues. Built-in parameters L1-L16 BOOL 16 hoppers corresponding to the lower weight limit indicator L17-L32 BOOL 16 hoppers corresponding to low and low weight limit indicators (4) Monitoring parameters (5) Temporary variables M1-M32 BOOL Manually select the corresponding warehouse status The specific process of step S2 includes: creating a 32-bit automatic position selection status word, wherein each bit of the low-order word is defined as the low-low (high priority) status of 16 positions, and each bit of the high-order word is marked as the low (low priority) status of 16 positions.

[0031] To accommodate the specific needs of bins 1-8 and 2-8, this invention employs a manual screen-triggered method to trigger high-priority material placement requests for these bins. Low-priority requests are inactive, but their functionality is temporarily retained. After comparing the weights of the 16 bins with preset lower and lower-lower limits, each status is assigned to the corresponding bit in the double-word VIEW1, thus identifying the bin weight status. This invention considers the actual layout of the bins on-site and performs a cyclical query of each status bit. Therefore, the bin numbers of adjacent bins are arranged continuously in the status word, avoiding the problem of low material placement efficiency caused by the subsequent material placement system's control conveyor belt constantly moving due to bin number jumps during queries.

[0032] Step S3 specifically includes: creating a 32-bit manual warehouse selection status word, where each bit of the low-order word is defined as 16 warehouse statuses. In manual mode, after manually setting the fabric request warehouse number through the screen, it will be reflected in the corresponding bit of the low-order word of the manual warehouse selection status word. Manual mode is a high-priority state, and in this mode, all high-order bits are set to 0.

[0033] The specific process of step S4 includes: performing a bitwise logical OR operation on the automatic position selection status word VIEW1 and the manual position selection status word VIEW2 to obtain a new total status word VIEW, as follows: VIEW = OR_UDINT(VIEW1,VIEW2). Then, the obtained total status word is logically operated with 65535 and 4294901760 to obtain the high priority low bit value and the low priority high bit value.

[0034] Regardless of the mode, the program can easily obtain the fabric request bin number by judging the status in the total status word VIEW, the high priority low-order word value DW_L, and the low priority high-order word value DW_H. At the same time, it ensures that the query is performed in sequence, avoiding large jumps in the requested bin number.

[0035] The specific judgment process includes: judging the value of the high-priority low-order word value DW_L; if the high-priority low-order word value DW_L is 0, then the scan pointer I is set to 16; if the high-priority low-order word value DW_L is not 0, then the scan pointer I is set to 0. When I is 16, the following operation is performed: RQ = GBIT_UDINT(DW_H, I); judging whether the request status RQ is equal to ON; if the request status RQ is equal to ON, then the next material request bin number RQ_NO_T is set to I + 1; if the request status RQ is not equal to ON, then the scan pointer I is incremented; if the value of the incremented scan pointer I is less than or equal to 31, then the operation RQ = GBIT_UDINT(DW_H, I) is returned; if the value of the incremented scan pointer I is greater than 31, then the scan pointer is reassigned to 16. This judgment path... The process of obtaining the high-priority material request bin number is as follows: When the scan pointer I is 0, the following operation is performed: RQ = GBIT_UDINT(DW_L, I), which checks if the request status RQ is equal to ON. If the request status RQ is equal to ON, the next material request bin number RQ_NO_T is set to I + 1. If the request status RQ is not equal to ON, the scan pointer I is incremented. If the incremented value of the scan pointer I is greater than 15, the scan pointer I is set to 0. If the incremented value of the scan pointer I is less than or equal to 15, the process returns: RQ = GBIT_UDINT(DW_L, I). This judgment path is the process of obtaining the low-priority material request bin number. After the two judgment paths are completed, the final RQ_NO_T is the final bin number. Where: RQ is the request status of the bit used for polling. When it is ON, there is a material request in the corresponding bin; GBIT_UDINT(A, X) is to retrieve the X bit of word A. RQ_NO_T is the final silo request number obtained.

[0036] The specific calculation process of the high priority low-order word value is as follows: The total status word VIEW is ANDed with 65535 to obtain the high priority low-order word value DW_L. The formula is: DW_L = AND_UDINT(VIEW, 65535); The specific calculation process of the low-priority high-order word value is as follows: The total status word VIEW is ANDed with 4294901760 to obtain the low-priority high-order word value DW_H. The formula is: DW_H = AND_UDINT(VIEW, 4294901760).

[0037] Since each batch of material is a mixture with a fixed ratio and the total weight remains constant, in order to ensure that each batch of material can be put into the silo without spillage, rounding is required when calculating the batch size.

[0038] The specific process of step S5 is as follows: When calculating the fabric batch, a rounding operation is performed. The specific calculation formula is as follows: BAT_S1=REAL_TO_USINT((WT_H-WT1) / BW) Where: BAT_S1 is the batch calculation result; REAL_TO_USINT(A) is the rounding operation on A; WT_H is the upper limit of the material bin weight; WT1 is the actual weight of bin 1; BW is the total weight of a single batch of material. When the calculation result is 0, it means that the material in the current bin has been completed and there is no need to continue material.

[0039] This invention incorporates a "hopper change permission signal" from the fabric distribution system. Upon receiving this signal, the system switches the hopper number requesting fabric distribution to the next available hopper. This ensures that all materials on the conveyor belts in the fabric distribution system have been delivered to the designated hoppers, preventing the fabric conveyor belts from shifting due to the switching of the hopper number requesting fabric distribution, which could lead to material spillage.

[0040] After the fabric batch calculation is completed, 16 variables QUE1-QUE16 are created to store the corresponding silo numbers in the order in which the fabric request commands need to be executed. The silo number that needs to be executed first is stored in QUE1, the silo number that needs to be executed next is stored in QUE2, and so on. The fabric operation is executed in ascending order of variable number. Throughout the fabric stage, the fabric request sequence is dynamically queried and updated based on the remaining material weight of all silos.

[0041] This invention dynamically queries and updates the material placement request sequence throughout the entire material placement phase based on the remaining material weight in all hoppers. Operators can visually see the hopper number to be placed on the screen. This sequence presentation also helps to anticipate or avoid emergencies or abnormal situations, thereby reducing the accident rate and improving production efficiency. This module can be used in all electric furnace material placement systems. During application, the corresponding weight detection signals should be connected to the appropriate pins based on the actual installation location of the hoppers. If the number of hoppers is less than 16, the extra input pins can be set to a number greater than the maximum weight limit to avoid triggering the material placement request status.

[0042] Example 2: like Figure 2As shown, Embodiment 2 of the present invention provides a furnace top hopper material distribution system, applicable to the furnace top hopper material distribution request status determination method of Embodiment 1 above, including: a first electric furnace and a second electric furnace, the first electric furnace and the second electric furnace adopt three-phase electrodes, the first electric furnace is equipped with 8 furnace top hoppers numbered 1-1 to 1-8 around its perimeter, the second electric furnace is equipped with 8 furnace top hoppers numbered 2-1 to 2-8 around its perimeter, the furnace top hoppers are connected to a moving belt, and the moving belt is equipped with a plurality of material distribution devices.

[0043] like Figure 3 As shown, the system of this invention has two control modes: manual and automatic. Each electric furnace is surrounded by top charge bins numbered 1-8, with the main number being the furnace number. During charge distribution, the manual / automatic mode control for each furnace's top charge bin can be set by clicking the manual / automatic mode switch button. In automatic mode, the required target batch is automatically calculated by detecting the existing weight. In manual mode, the target batch of the charge bin can be manually set, and the charge distribution request command can be triggered by clicking the corresponding charge bin selection button. Due to the automatic determination by the module after adopting this invention, the display device screen can also display the charge bin number currently executing the charge distribution request and the request sequence of the charge bins to be distributed. The high and low limits of the charge bins can be directly assigned fixed constants when the module is used. These values ​​will theoretically not change after normal use, exhibiting stability.

[0044] The furnace top hopper material distribution system determines the weight values ​​of the 16 furnace top hoppers and issues material distribution requests based on the expected order and priority. This causes the subsequent material distribution system to automatically control the material distribution device on the moving belt to move to the furnace top hopper position corresponding to the furnace top hopper number to carry out the material distribution operation.

[0045] This invention distributes material to the furnace top hoppers according to the material distribution priority requests of each hopper, thereby improving material distribution efficiency and reducing labor costs.

[0046] The status words involved in this invention are combined with the actual position of the material bins, making them easier to understand during actual programming and use, and also easier to port to other similar application scenarios. This invention distinguishes between high and low priority material request states, and the system can automatically process high-priority requests during operation. This invention presents the future request status of all material bins in real time, making it easier to control and predict the system's working status. Compared with existing solutions, this invention not only solves the shortcomings of existing technologies, but also establishes a mathematical model for the actual layout and operational status logic control of field equipment, which is closer to the actual needs of process production and equipment operation. Using this invention, the time for each material bin switching can be reduced by 30 seconds. Based on a total motor power of 250kW for one material feeding line, a factory with 5 material feeding production lines, where each production line needs to switch material bins 250 times per day, can save 5*250*30 / 3600*250 = 2604 kWh of electricity per day. Therefore, stable operation of material feeding request control can save the company a considerable amount of energy costs.

[0047] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A method for determining the material distribution request status of a furnace top hopper, characterized in that, Includes the following steps: S1. Define and input the parameters of the furnace top hopper equipment; S2. Create automatic position selection status words and define the high-priority and low-priority statuses of each position; S3. Create a manual position selection status word, and define the position status of each position by defining each bit of the low-order word; S4. Integrate all status words, including automatic and manual position selection status words, to obtain the total status word, high-priority low-order word value, and low-priority high-order word value; S5. Based on the obtained total status word, high priority low-order word value and low priority high-order word value, obtain the fabric request bin number and calculate the fabric batch. Then, according to the calculation result and the priority of the fabric bin number, the fabric is laid out sequentially.

2. The method for determining the material distribution request status of a furnace top silo according to claim 1, characterized in that, The parameters of the furnace top hopper equipment include input parameters, output parameters, built-in parameters, monitoring parameters, and temporary variables. The temporary variables include the status of the hopper corresponding to the manually selected hopper.

3. The method for determining the material distribution request status of a furnace top silo according to claim 1, characterized in that, The specific process of step S2 includes: creating a 32-bit automatic position selection status word, wherein each bit of the low-order word is defined as the low-low-order status of 16 positions as high priority, and each bit of the high-order word is marked as the low-order status of 16 positions as low priority.

4. The method for determining the material distribution request status of a furnace top silo according to claim 1, characterized in that, The specific process of step S3 includes: creating a 32-bit manual warehouse selection status word, wherein each bit of the low-order word is defined as 16 warehouse statuses. In manual mode, after the manual person sets the fabric request warehouse number through the screen, it will be reflected in the corresponding bit of the low-order word of the manual warehouse selection status word. Manual mode is a high-priority state. In this mode, all high-order words are set to 0.

5. The method for determining the material distribution request status of a furnace top silo according to claim 1, characterized in that, The specific process of step S4 includes: performing a bitwise logical OR operation on the automatic warehouse selection status word VIEW1 and the manual warehouse selection status word VIEW2 to obtain a new total status word VIEW, with the following formula: VIEW=OR_UDINT(VIEW1,VIEW2), and then performing a logical operation on the obtained total status word with 65535 and 4294901760 to obtain the high priority low bit value and the low priority high bit value.

6. A method for determining the material distribution request status of a furnace top silo according to claim 1 or 5, characterized in that, The specific calculation process of the high-priority low-order word value is as follows: the total status word VIEW is logically ANDed with 65535 to obtain the high-priority low-order word value DW_L, formula: DW_L=AND_UDINT(VIEW,65535); The specific calculation process of the low-priority high-order word value is as follows: The total status word VIEW is ANDed with 4294901760 to obtain the low-priority high-order word value DW_H, and the formula is: DW_H=AND_UDINT(VIEW,4294901760).

7. The method for determining the material distribution request status of a furnace top silo according to claim 1, characterized in that, The specific process of step S5 is as follows: When calculating the fabric batch, a rounding operation is performed, and the specific calculation formula is as follows: BAT_S1=REAL_TO_USINT((WT_H-WT1) / BW) Where: BAT_S1 is the batch calculation result; REAL_TO_USINT(A) is the rounding operation on A; WT_H is the upper limit of the material bin weight; WT1 is the actual weight of bin 1; BW is the total weight of a single batch of material. When the calculation result is 0, it means that the material in the current bin has been completed and there is no need to continue material.

8. A method for determining the material distribution request status of a furnace top silo according to claim 1 or 7, characterized in that, After the calculation of the fabric batch is completed, 16 variables QUE1-QUE16 are created to store the corresponding silo numbers in the order in which the fabric request commands need to be executed. The silo number that needs to be executed first is stored in QUE1, the silo number that needs to be executed next is stored in QUE2, and so on. The fabric operation is executed in ascending order of variable number. Throughout the fabric stage, the fabric request sequence is dynamically queried and updated based on the remaining material weight of all silos.

9. A furnace top hopper material distribution system, applicable to the furnace top hopper material distribution request status determination method according to any one of claims 1-8, characterized in that, include: The first electric furnace (1) and the second electric furnace (2) are equipped with three-phase electrodes. The first electric furnace is surrounded by eight furnace top material bins numbered 1-1 to 1-8, and the second electric furnace is surrounded by eight furnace top material bins numbered 2-1 to 2-8. The furnace top material bins are connected to a moving belt (3), and the moving belt (3) is equipped with several material distribution devices (4).

10. A furnace top hopper material distribution system according to claim 9, characterized in that, The furnace top silo distribution system determines the weight values ​​of the 16 furnace top silos and issues a distribution request for the furnace top silo number according to the expected order and priority. This causes the distribution system to automatically control the distribution device (4) on the moving belt (3) to move to the furnace top silo position corresponding to the furnace top silo number for distribution operations.

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