Method and system for controlling the charging of a roller kiln

Abstract

This invention relates to the field of roller kiln technology and discloses a method and system for controlling the feeding of saggers in a roller kiln. The method involves acquiring a first control time and a second control time in a first roller kiln, and a third control time and a fourth control time in a second roller kiln; calculating the difference between the first and third control times; obtaining first priority information by following a first control method when the difference is less than or equal to a preset threshold; obtaining second priority information by following a second control method when the difference is greater than the preset threshold; determining the priority of the first and second roller kilns based on the first or second priority information; and controlling the order in which saggers enter the first and second roller kilns based on their priorities. This invention solves the problem that existing roller kiln sagger feeding control methods cannot promptly adjust the feeding control strategy according to the actual speed of the roller kiln and the feeding device.

Description

Technical Field

[0001] This invention relates to the field of roller kiln technology, and in particular to a method and system for controlling the feeding of kilns in a roller kiln. Background Technology

[0002] A roller kiln, also known as an archless kiln, is a tunnel kiln with a narrow, elongated cross-section. It consists of a roller track composed of parallel rollers that traverse the working channel. Products are placed in saggers, which are then placed on the roller track and conveyed into the kiln as the rollers rotate, thus completing the firing process within the kiln. Because saggers are quite heavy when filled with material, a feeding device is typically installed upstream of the kiln feeder to facilitate operation. To reduce production costs, one feeding device can feed saggers from two roller kilns. However, depending on production conditions, the roller kiln may experience speed increases while the feeding device speed decreases; that is, the saggers enter the roller kiln at a faster rate, while the feeding device's loading speed decreases. If the sagger feeding control cannot be adjusted accordingly, it can easily cause a break in the sagger supply in the roller kiln, resulting in dry firing. However, current control methods are mostly based on preset values ​​for production conditions, with both the sagger feeding speed and method pre-set. When the roller kiln speeds up or the sagger feeding device speeds down, the feeding strategy cannot be adjusted in time, leading to excessive dry firing time and wasted energy. Therefore, existing roller kiln sagger feeding control methods suffer from the problem of failing to adapt the feeding control strategy to the actual speeds of the roller kiln and the sagger feeding device in a timely manner. Summary of the Invention

[0003] This invention provides a method and system for controlling the feeding of bowls in a roller kiln, in order to solve the problem that existing methods for controlling the feeding of bowls in roller kilns cannot promptly adjust the feeding control strategy according to the actual speed of the roller kiln and the feeding device.

[0004] To achieve the above objectives, the present invention employs the following technical solution:

[0005] In a first aspect, the present invention provides a method for controlling the feeding of bowls in a roller kiln, the method comprising: The time taken for the current sagger to move from the waiting area to the sagger detection area in the first roller kiln is used as the first control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the second control time. The time taken for the current sagger to move from the waiting area to the sagger detection area in the second roller kiln is used as the third control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the fourth control time. Calculate the difference between the first control time and the third control time. When the difference is less than or equal to a preset threshold, determine the priority of the first roller kiln and the second roller kiln according to the first control method to obtain the first priority information. When the difference is greater than the preset threshold, the priority of the first roller kiln and the second roller kiln is determined by the second control method to obtain the second priority information. The priorities of the first roller kiln and the second roller kiln are determined based on the first priority information or the second priority information, and the order in which the saggers enter the first roller kiln and the second roller kiln is controlled based on the priorities of the first roller kiln and the second roller kiln.

[0006] Optionally, the first control method includes: Calculate the first difference between the first control time and the second control time, and the second difference between the third control time and the fourth control time; Subtracting the second difference from the first difference yields a first judgment value. When the first judgment value is less than or equal to 0, priority information is obtained that the second roller kiln has a higher priority than the first roller kiln, and this priority information is used as the first priority information. When the first judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is used as the first priority information.

[0007] Optionally, the second control method includes: The first control time is subtracted from the third control time to obtain the second judgment value. When the second judgment value is less than 0, the priority information that the second roller kiln has a higher priority than the first roller kiln is obtained, and this priority information is used as the second priority information. When the second judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is used as the second priority information.

[0008] Optionally, the priority control of the order in which the saggers enter the first and second roller kilns based on the first and second roller kilns includes: When the priority of the first roller kiln is higher than that of the second roller kiln, the sagger is controlled to enter the first roller kiln first and then the second roller kiln. When the priority of the second roller kiln is higher than that of the first roller kiln, the control sagger is given priority to enter the second roller kiln before entering the first roller kiln.

[0009] Optionally, the process of controlling the saggers entering the roller kiln includes: After determining the priority between the first roller kiln and the second roller kiln at the current moment, control four consecutive saggers to enter the roller kiln with the higher priority, and then control four consecutive saggers to enter the roller kiln with the lower priority.

[0010] Optionally, the method further includes: During the operation of the target roller kiln, the time from when the sagger in the target roller kiln moves from the waiting area to when it enters the sagger detection area is taken as the first detection time, and the time from when the sagger in the target roller kiln normally enters the sagger detection area from the kiln opening is taken as the second detection time. The critical value of the dry burning time is determined based on the difference between the first detection time and the second detection time; The first detection time is compared with the empty-fire time threshold. When the first detection time is greater than the empty-fire time threshold, the target roller kiln enters the empty-fire state and starts the empty-fire state timing. When the first detection time is less than or equal to the empty-fire time threshold, the target roller kiln exits the empty-fire state and stops the empty-fire state timing. The time value obtained from the no-burn state is recorded as the no-burn duration.

[0011] Optionally, determining the critical value for dry burning time based on the difference between the first detection time and the second detection time includes: The time difference is obtained by subtracting the value of the second detection time from the value of the first detection time, and 3% of this time difference is taken as the critical value of the no-burn time. The calculation formula is shown below: ; in, This indicates the critical value for no-fire time. Indicates the first detection time. This indicates the second testing time.

[0012] Optionally, the step of entering the dry-firing state and timing the dry-firing state when the first detection time is greater than the dry-firing time threshold includes: When the first detection time is greater than the critical value of the empty firing time, the upstream loading equipment of the target roller kiln is controlled to stop transporting loading saggers to the target roller kiln, and the upstream loading equipment of the target roller kiln is controlled to transport empty firing saggers to the target roller kiln. When the upstream loading equipment of the target roller kiln transports the empty-fired sagger to the target roller kiln, the target roller kiln enters the empty-fired state and the empty-fired state timer is started.

[0013] Optionally, the step of exiting the dry-firing state and stopping the dry-firing state timing when the first detection time is less than or equal to the dry-firing time threshold includes: When the upstream loading equipment of the target roller kiln switches from transporting empty-fired saggers to transporting loading saggers, and the first detection time is less than or equal to the critical value of the empty-fired time, the target roller kiln exits the empty-fired state and stops the empty-fired state timing.

[0014] Secondly, embodiments of this application provide a bowl-feeding control system for a roller kiln, including a processor and a memory; Memory, used to store computer programs; A processor, when executing a program stored in memory, implements the steps of any of the control methods described in the first aspect.

[0015] Beneficial effects: The present invention provides a method for controlling the feeding of saggers in a roller kiln. By acquiring the first and second control times in the first roller kiln and the third and fourth control times in the second roller kiln, the difference between the first and third control times can be calculated. When this difference is less than or equal to a preset threshold, a first priority information is obtained by following a first control method. When the difference is greater than the preset threshold, a second priority information is obtained by following a second control method. Finally, the priority of the first and second roller kilns can be determined based on the first or second priority information, and the order in which the saggers enter the first and second roller kilns can be controlled based on their priorities. This allows the feeding control strategy to be adjusted in a timely manner according to the actual speed of the roller kiln and the feeding device, thereby reducing the dry-firing time of the roller kiln and avoiding excessive energy waste during production. Attached Figure Description

[0016] Figure 1 This is a flowchart of a preferred embodiment of the roller kiln feeding control method of the present invention; Figure 2 This is a schematic diagram of the roller kiln feeder structure according to a preferred embodiment of the present invention; Figure 3 This is a schematic diagram of the bowl-feeding device according to a preferred embodiment of the present invention; Among them, 1. Kiln body; 2. Roller bar; 3. Baffle; 4. First saggar inspection area; 5. Second saggar inspection area; 6. Kiln inlet chamber; 7. Saggar; 8. Inlet motor; 9. First main kiln motor; 10. Second main kiln motor; 11. Third main kiln motor; 12. Fourth main kiln motor; 13. Fifth main kiln motor. Detailed Implementation

[0017] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms "an" or "a" and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "connected" or "linked" and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. "Up," "down," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship also changes accordingly.

[0019] Please see Figure 1-3 This application provides a method for controlling the feeding of food bowls in a roller kiln, the method comprising: The time taken for the current sagger to move from the waiting area to the sagger detection area in the first roller kiln is used as the first control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the second control time. The time taken for the current sagger to move from the waiting area to the sagger detection area in the second roller kiln is used as the third control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the fourth control time. Calculate the difference between the first control time and the third control time. When the difference is less than or equal to a preset threshold, determine the priority of the first roller kiln and the second roller kiln according to the first control method to obtain the first priority information. When the difference is greater than the preset threshold, the priority of the first roller kiln and the second roller kiln is determined by the second control method to obtain the second priority information. The priorities of the first roller kiln and the second roller kiln are determined based on the first priority information or the second priority information, and the order in which the saggers enter the first roller kiln and the second roller kiln is controlled based on the priorities of the first roller kiln and the second roller kiln.

[0020] like Figure 2As shown, when the roller kiln is working, the first main kiln motor 9, the second main kiln motor 10, the third main kiln motor 11, the fourth main kiln motor 12, and the fifth main kiln motor 13 drive the roller 2 to rotate. At this time, the conveyor belt on the roller 2 moves into the kiln body 1 along with the rotation of the roller 2. At this time, the sagger 7 is placed on the conveyor belt near the kiln inlet 6 through the sagger feeding device. The sagger 7 is sent into the interior of the roller kiln by the conveyor belt. When the sagger 7 enters the interior of the kiln body 1, it will be detected by the first sagger detection area 4 and the second sagger detection area 5. The first sagger detection area 4 and the second sagger detection area 5 are separated by a baffle 3. The baffle 3 is movably connected to the kiln body 1 and can separate the first sagger detection area 4 and the second sagger detection area 5 without affecting the normal entry of the sagger 7 into the kiln body 1.

[0021] In the above embodiments, by acquiring the first control time and the second control time in the first roller kiln, and the third control time and the fourth control time in the second roller kiln, the difference between the first control time and the third control time can be calculated. When the difference is less than or equal to a preset threshold, the first control method is followed to obtain the first priority information. When the difference is greater than the preset threshold, the second control method is followed to obtain the second priority information. Finally, the priority of the first roller kiln and the second roller kiln can be determined based on the first priority information or the second priority information, and the order in which the saggers enter the first roller kiln and the second roller kiln can be controlled based on the priority of the first roller kiln and the second roller kiln. This allows the sagger feeding control strategy to be changed in a timely manner according to the actual speed of the roller kiln and the sagger feeding device, thereby reducing the dry firing time of the roller kiln and avoiding excessive energy waste during the production process.

[0022] Meanwhile, in the embodiments, only time periods can be used for calculations such as size comparison and difference. When time points or moments appear, it will cause problems for the calculation. Therefore, the time appearing in the embodiments are all time periods and not time points or moments. In addition, for convenience, the time will be converted to seconds before calculation or size comparison. For example, when the first control time is 6 minutes and the third control time is 4 minutes, 6 minutes is first converted to 360 seconds, then 4 minutes is converted to 240 seconds, and then 240 seconds is subtracted from 360 seconds to obtain the difference between the first control time and the third control time. The above conversion can reduce the calculation difficulty when the time appears in the form of minutes plus seconds.

[0023] The examples above are for illustrative purposes only and are not intended to limit the scope of the discussion.

[0024] Optionally, the first control method includes: Calculate the first difference between the first control time and the second control time, and the second difference between the third control time and the fourth control time; Subtracting the second difference from the first difference yields a first judgment value. When the first judgment value is less than or equal to 0, priority information is obtained that the second roller kiln has a higher priority than the first roller kiln, and this priority information is used as the first priority information. When the first judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is used as the first priority information.

[0025] Optionally, the second control method includes: The first control time is subtracted from the third control time to obtain the second judgment value. When the second judgment value is less than 0, the priority information that the second roller kiln has a higher priority than the first roller kiln is obtained, and this priority information is used as the second priority information. When the second judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is used as the second priority information.

[0026] Optionally, the priority control of the order in which the saggers enter the first and second roller kilns based on the first and second roller kilns includes: When the priority of the first roller kiln is higher than that of the second roller kiln, the sagger is controlled to enter the first roller kiln first and then the second roller kiln. When the priority of the second roller kiln is higher than that of the first roller kiln, the control sagger is given priority to enter the second roller kiln before entering the first roller kiln.

[0027] In the above embodiment, the current waiting time for the sagger to enter the sagger detection area in the roller kiln 1 is T. 1i1 The current waiting time for the sagger to enter the sagger detection area in roller kiln 2 is T. 2i1， The time T is the time for a sagger to enter the sagger detection area on roller kiln 1. 1i0 The time for a sagger to enter the sagger detection area on roller kiln 2 is T. 2i0 .

[0028] When | T 1i1 – T 2i1 If | ≤1, then determine T. 1i1 – T 1i0 = T 1Δ With T 2i1 – T 2i0 = T 2Δ The difference T Δ ; The first control method includes: T Δ = T 1Δ – T 2Δ When T ΔWhen T2 is ≤0, it indicates that the waiting time for the sagger to enter the sagger detection area is increasing, and the roller kiln 2 has a higher priority. Δ When T1 is greater than 0, it indicates that the waiting time for the sagger to enter the sagger detection area is increasing, and the priority of roller kiln 1 is high. The first control method includes: when |T 1i1 – T 2i1 When | > 1, if T 1i1 – T 2i1 When T < 0, then roller kiln 2 has a higher priority. 1i1 – T 2i1 When the value is greater than 0, roller kiln 1 has a higher priority.

[0029] Optionally, the process of controlling the saggers entering the roller kiln includes: After determining the priority between the first roller kiln and the second roller kiln at the current moment, control four consecutive saggers to enter the roller kiln with the higher priority, and then control four consecutive saggers to enter the roller kiln with the lower priority.

[0030] In the above embodiment, when the automatic line detects a sagger, it determines the priority of the roller kiln at the current moment. If four consecutive saggers enter the kiln with a higher priority, then four consecutive saggers enter the kiln with a lower priority.

[0031] Specifically, specific kilns can be designated for loading and unloading into specific kilns, and the priority is sorted among the designated kilns. If more than two kilns need to load kilns, or more than two kilns need to load and unload kilns, the kilns are loaded from high priority to low priority according to the loading strategy.

[0032] Optionally, the method further includes: During the operation of the target roller kiln, the time from when the sagger in the target roller kiln moves from the waiting area to when it enters the sagger detection area is taken as the first detection time, and the time from when the sagger in the target roller kiln normally enters the sagger detection area from the kiln opening is taken as the second detection time. The critical value of the dry burning time is determined based on the difference between the first detection time and the second detection time; The first detection time is compared with the empty-fire time threshold. When the first detection time is greater than the empty-fire time threshold, the target roller kiln enters the empty-fire state and starts the empty-fire state timing. When the first detection time is less than or equal to the empty-fire time threshold, the target roller kiln exits the empty-fire state and stops the empty-fire state timing. The time value obtained from the no-burn state is recorded as the no-burn duration.

[0033] Optionally, determining the critical value for dry burning time based on the difference between the first detection time and the second detection time includes: The time difference is obtained by subtracting the value of the second detection time from the value of the first detection time, and 3% of this time difference is taken as the critical value of the no-burn time. The calculation formula is shown below: ; in, This indicates the critical value for no-fire time. Indicates the first detection time. This indicates the second testing time.

[0034] Optionally, the step of entering the dry-firing state and timing the dry-firing state when the first detection time is greater than the dry-firing time threshold includes: When the first detection time is greater than the critical value of the empty firing time, the upstream loading equipment of the target roller kiln is controlled to stop transporting loading saggers to the target roller kiln, and the upstream loading equipment of the target roller kiln is controlled to transport empty firing saggers to the target roller kiln. When the upstream loading equipment of the target roller kiln transports the empty-fired sagger to the target roller kiln, the target roller kiln enters the empty-fired state and the empty-fired state timer is started.

[0035] Optionally, the step of exiting the dry-firing state and stopping the dry-firing state timing when the first detection time is less than or equal to the dry-firing time threshold includes: When the upstream loading equipment of the target roller kiln switches from transporting empty-fired saggers to transporting loading saggers, and the first detection time is less than or equal to the critical value of the empty-fired time, the target roller kiln exits the empty-fired state and stops the empty-fired state timing.

[0036] In the above embodiment, when the roller kiln is running, if the waiting time T1 for the sagger to enter the sagger detection area exceeds the critical value T1e for empty firing, the roller kiln begins empty firing and issues an audible and visual alarm to notify the operator to immediately send the empty sagger into the roller kiln. Typically, at this time, the upstream sagger loading equipment stops normal sagger loading and switches to empty sagger loading operation to send the sagger into the roller kiln. Therefore, when the roller kiln is running and the upstream sagger loading equipment stops normal sagger loading, the empty firing duration T1a begins to be counted.

[0037] When the roller kiln is running and the upstream sagger loading equipment resumes normal sagger loading operation from a standstill to a standstill operation, and the time T1 for waiting for the sagger to enter the sagger detection area is less than or equal to the critical value T1e for dry firing, the dry firing statistical duration T1a is stopped, the dry firing duration is obtained, and a record is triggered to generate a report. At the same time, the time when the roller kiln starts dry firing when the time T1 for waiting for the sagger to enter the sagger detection area is greater than the critical value T1e for dry firing is also recorded in the report as the response time for determining this dry firing.

[0038] This application provides a bowl-feeding control system for a roller kiln, including a processor and a memory; Memory, used to store computer programs; The processor, when executing a program stored in memory, implements any step in the method for controlling the feeding of the kiln bowl in a roller kiln.

[0039] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A method for controlling the feeding of bowls in a roller kiln, characterized in that, The method includes: The time taken for the current sagger to move from the waiting area to the sagger detection area in the first roller kiln is used as the first control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the second control time. The time taken for the current sagger to move from the waiting area to the sagger detection area in the second roller kiln is used as the third control time, and the time taken for the previous sagger to move from the waiting area to the sagger detection area is used as the fourth control time. Calculate the difference between the first control time and the third control time. When the difference is less than or equal to a preset threshold, determine the priority of the first roller kiln and the second roller kiln according to the first control method to obtain the first priority information. The first control method includes: Calculate the first difference between the first control time and the second control time, and the second difference between the third control time and the fourth control time; Subtracting the second difference from the first difference yields a first judgment value. When the first judgment value is less than or equal to 0, priority information is obtained that the second roller kiln has a higher priority than the first roller kiln, and this priority information is used as the first priority information. When the first judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is taken as the first priority information. When the difference is greater than the preset threshold, the priority of the first roller kiln and the second roller kiln is determined by the second control method to obtain the second priority information. The second control method includes: The first control time is subtracted from the third control time to obtain the second judgment value. When the second judgment value is less than 0, the priority information that the second roller kiln has a higher priority than the first roller kiln is obtained, and this priority information is used as the second priority information. When the second judgment value is greater than 0, the priority information that the first roller kiln has a higher priority than the second roller kiln is obtained, and this priority information is used as the second priority information. The priorities of the first roller kiln and the second roller kiln are determined based on the first priority information or the second priority information, and the order in which the saggers enter the first roller kiln and the second roller kiln is controlled based on the priorities of the first roller kiln and the second roller kiln. The priority control of the order in which saggers enter the first and second roller kilns based on the first and second roller kilns includes: When the priority of the first roller kiln is higher than that of the second roller kiln, the sagger is controlled to enter the first roller kiln first and then the second roller kiln. When the priority of the second roller kiln is higher than that of the first roller kiln, the sagger is controlled to enter the second roller kiln first and then the first roller kiln. The process of controlling the saggers entering the roller kiln includes: After determining the priority between the first roller kiln and the second roller kiln at the current moment, control four consecutive saggers to enter the roller kiln with the higher priority, and then control four consecutive saggers to enter the roller kiln with the lower priority.

2. The method for controlling the feeding of bowls in a roller kiln according to claim 1, characterized in that, The method further includes: During the operation of the target roller kiln, the time from when the sagger in the target roller kiln moves from the waiting area to when it enters the sagger detection area is taken as the first detection time, and the time from when the sagger in the target roller kiln normally enters the sagger detection area from the kiln opening is taken as the second detection time. The critical value of the dry burning time is determined based on the difference between the first detection time and the second detection time; The first detection time is compared with the empty-fire time threshold. When the first detection time is greater than the empty-fire time threshold, the target roller kiln enters the empty-fire state and starts the empty-fire state timing. When the first detection time is less than or equal to the empty-fire time threshold, the target roller kiln exits the empty-fire state and stops the empty-fire state timing. The time value obtained from the no-burn state is recorded as the no-burn duration.

3. The method for controlling the feeding of the kiln bowl in a roller kiln according to claim 2, characterized in that, The determination of the dry-burning time threshold based on the difference between the first detection time and the second detection time includes: The time difference is obtained by subtracting the value of the second detection time from the value of the first detection time, and 3% of this time difference is taken as the critical value of the no-burn time. The calculation formula is shown below: ； in, This indicates the critical value for no-fire time. Indicates the first detection time. This indicates the second testing time.

4. The method for controlling the feeding of bowls in a roller kiln according to claim 2, characterized in that, When the first detection time exceeds the critical value for the empty-firing time, the target roller kiln enters the empty-firing state and the empty-firing state time is started, including: When the first detection time is greater than the critical value of the empty firing time, the upstream loading equipment of the target roller kiln is controlled to stop transporting loading saggers to the target roller kiln, and the upstream loading equipment of the target roller kiln is controlled to transport empty firing saggers to the target roller kiln. When the upstream loading equipment of the target roller kiln transports the empty-fired sagger to the target roller kiln, the target roller kiln enters the empty-fired state and the empty-fired state timer is started.

5. The method for controlling the feeding of bowls in a roller kiln according to claim 4, characterized in that, When the first detection time is less than or equal to the critical value of the empty-firing time, the target roller kiln exits the empty-firing state and stops the empty-firing state timing, including: When the upstream loading equipment of the target roller kiln switches from transporting empty-fired saggers to transporting loading saggers, and the first detection time is less than or equal to the critical value of the empty-fired time, the target roller kiln exits the empty-fired state and stops the empty-fired state timing.

6. A bowl-feeding control system for a roller kiln, characterized in that, Including processor and memory; Memory, used to store computer programs; A processor, when executing a program stored in memory, implements the steps of the control method according to any one of claims 1-5.

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