A residual ash amount monitoring system and method for a cement ash bin

Abstract

The application discloses a residual cement mortar amount monitoring system and method for a cement mortar tank, which comprises a signal detection device arranged on a guide rail of the outer wall of a cement mortar tank to be monitored, and used for collecting a characteristic signal for representing the interface position of the residual cement mortar amount of the current cement mortar tank; and an information processing device used for quantitatively analyzing the residual cement mortar amount of the current cement mortar tank to be monitored by processing the received characteristic signal. The application can realize automatic real-time detection of the residual cement mortar amount of the cement mortar tank in the cementing construction process, and guide the operation of replacing the cement mortar tank in the cementing construction process.

Description

Technical Field

[0001] This invention relates to the field of cement silo residual quantity monitoring technology, and in particular to a system and method for monitoring the residual ash quantity in cement ash silos. Background Technology

[0002] In recent years, petroleum engineering technology has developed rapidly, and many engineering design problems can be solved using computer software. Utilizing computer software is an indispensable means of reducing the workload of engineering design. Therefore, the petroleum engineering field has begun to develop from informatization to automation, and cementing engineering, as a subfield of petroleum engineering, is no exception.

[0003] Cementing engineering is gradually moving towards automation and intelligence throughout the entire process, from design and construction to evaluation. Simultaneously, against the backdrop of oil companies striving to reduce costs and increase efficiency, the development of automated cementing equipment is an inevitable trend. Compared to conventional cementing equipment, automated cementing equipment boasts superior performance, a higher degree of automation, and better meets the requirements of future cementing operations, aligning with the strategic goals of cost reduction and efficiency improvement in shale gas extraction. Therefore, developing domestically produced automated cementing equipment can not only fill the current gap in this field in China but also holds significant economic benefits. The research and application of automated cementing equipment is conducive to achieving large-scale, economical development of shale gas. Mastering the core technologies of high-end cementing equipment has a very positive and far-reaching significance for exploring new markets and enhancing the company's international capabilities.

[0004] Cement is one of the essential raw materials in cementing operations. During cementing, to easily determine the remaining amount of cement in the tank, workers typically tap the outer wall of the tank and listen to the sound to determine if cement is present at the tapped point, thus determining the amount of cement remaining in the tank. However, due to the height of the cement storage tank and the significant pressure generated during cementing operations (which poses safety risks to workers), measuring the remaining amount of cement is time-consuming, labor-intensive, and lacks accuracy, posing safety hazards during construction.

[0005] Furthermore, in cementing operations, the amount of cement often needs to be stored in two or even more cement tanks. To ensure the continuity of cementing operations, workers determine the remaining cement level by tapping the outer wall of the cement tank. When the cement in the tank used for cementing is about to run out, another cement tank is opened, and the cement in that tank is used to continue the work. The tank is then closed once the cement in the first tank is used up. This process usually requires workers to determine the tank-changing time based on experience and to complete the operation. In addition, due to the high-pressure pipelines involved in cementing operations, there are certain safety hazards. Summary of the Invention

[0006] The purpose of this invention is to provide a solution that can accurately measure the remaining amount of cement in a cement silo, thereby enabling automatic replacement of the cement silo by monitoring the amount of cement residue in the silo.

[0007] To address the aforementioned technical problems, this invention provides a residual ash monitoring system for cement ash silos, comprising: a signal detection device disposed on a guide rail on the outer wall of the cement ash silo to be monitored, for real-time acquisition of characteristic signals characterizing the current residual ash content interface position of the cement ash silo; and an information processing device for quantitatively analyzing the current residual ash content of the cement ash silo to be monitored by processing the received characteristic signals.

[0008] Preferably, the guide rail is arranged along the axial direction of the cement ash hopper, wherein the signal detection device includes: an electric support rod adapted to the guide rail for moving on the guide rail; an impact member disposed on the electric support rod for continuously striking the outer wall of the cement ash hopper at preset time intervals during the movement of the support rod; a sound wave receiving module disposed on the electric support rod for receiving sound wave signals from the surrounding environment during the movement of the support rod; and a first wireless transceiver for transmitting the sound wave signals to the information processing device, wherein the information processing device is further used to identify the interface height of the remaining cement ash based on the sound wave signals.

[0009] Preferably, the residual ash monitoring system further includes: an automatic valve device disposed on the outer wall of the discharge port pipeline of the cement ash silo to be monitored, wherein the automatic valve device includes: a second data transceiver device communicating with the information processing device; a discharge port valve disposed inside the discharge port for adjusting its opening degree under the action of a first command, thereby controlling the current discharge flow rate of the cement ash silo to be monitored; and a discharge switch connected to the discharge port valve for receiving the discharge control command sent from the information processing device through the second data transceiver device and converting it into the first command for controlling the discharge port valve to close or open.

[0010] Preferably, the information processing device is further configured to determine the valve closing type of the corresponding cement ash hopper to be monitored based on the height of the real-time remaining ash content and generate the corresponding discharge control command, wherein when the height of the remaining ash content is less than 0.5 meters, the current valve closing type is gradual closing; when the height of the remaining ash content is 0, the current valve closing type is complete closing.

[0011] Preferably, the information processing device is further configured to send the discharge control command to the discharge switch to instruct the discharge port valve to gradually open or fully open.

[0012] Preferably, the information processing device is further configured to identify the interface height of the remaining cement ash based on the acoustic signal using an interface recognition model. The interface recognition model is constructed based on artificial intelligence and machine learning methods. The process of constructing the interface recognition model includes: establishing a basic neural network model; then extracting signal features from acoustic signals with and without cement ash and acoustic signals with cement ash as training input data; and using the identification results marked with or without cement ash as training output data to train the basic neural network model, thereby constructing the interface recognition model.

[0013] Preferably, the information processing device further calculates the volume of the remaining ash using the following expression:

[0014] v = hS

[0015] M = ρv

[0016] V = yM

[0017] Where h represents the height of the remaining cement ash in the cement ash hopper, v represents the volume of the cement ash, S represents the bottom area inside the cement ash hopper, M represents the real-time weight of the remaining cement ash in the cement ash hopper, ρ represents the density of the cement ash, y represents the slurry preparation rate, and V represents the volume of the remaining cement slurry.

[0018] Preferably, the information processing device includes: a third data transceiver device, a data control module, a data processing module, and a display module that communicate with the signal detection device.

[0019] Preferably, the information processing device communicates with the signal detection device and the automatic valve device located on multiple cement ash silos, wherein the information processing device is further configured to send a discharge control command to one of the cement ash silos, indicating that the discharge port valve is gradually closed or completely closed, and simultaneously send a discharge control command to another cement ash silo, indicating that the discharge port valve is gradually opened or completely opened.

[0020] On the other hand, a method for monitoring the residual ash content of cement ash silos is provided. The residual ash content monitoring method is implemented by the residual ash content monitoring system described above. The residual ash content monitoring method includes the following steps: acquiring characteristic signals in real time to characterize the current residual ash content interface position of the cement ash silo by means of a signal detection device installed on a guide rail on the outer wall of the cement ash silo to be monitored; and the information processing device quantitatively analyzing the current residual ash content of the cement ash silo to be monitored by processing the received characteristic signals.

[0021] Compared with the prior art, one or more embodiments of the above solutions may have the following advantages or beneficial effects:

[0022] This invention proposes a system and method for monitoring the remaining cement content in cement silos. This system and method enable automated, real-time monitoring of the remaining cement content in cement silos during cementing operations, providing guidance for cement silo replacement procedures.

[0023] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the description, claims, and drawings. Attached Figure Description

[0024] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0025] Figure 1 This is a schematic diagram of the overall structure of the residual ash monitoring system for cement ash silos according to an embodiment of this application.

[0026] Figure 2 This is a schematic diagram of the specific structure of the residual ash monitoring system for cement ash silos according to an embodiment of this application.

[0027] Figure 3 This is a schematic diagram of the specific structure of the signal detection device in the residual ash monitoring system for cement ash silos according to an embodiment of this application.

[0028] Figure 4 This is a schematic diagram of the automatic valve device in the residual ash monitoring system for cement ash silos according to an embodiment of this application.

[0029] Figure 5 This is a step diagram of the method for monitoring the residual ash content in a cement ash silo, which is an embodiment of this application. Detailed Implementation

[0030] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings and examples, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. It should be noted that, as long as there is no conflict, the various embodiments and features in the various embodiments of the present invention can be combined with each other, and the resulting technical solutions are all within the protection scope of the present invention.

[0031] Furthermore, the steps illustrated in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Also, although a logical order is shown in the flowcharts, in some cases the steps shown or described may be performed in a different order than that shown here.

[0032] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments. Unless the context clearly indicates otherwise, the singular forms “a” and “an” as used herein are also intended to include the plural. It should also be understood that the terms “comprising” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, without excluding the presence or addition of one or more other features, integers, steps, operations, units, components, and / or combinations thereof.

[0033] In recent years, petroleum engineering technology has developed rapidly, and many engineering design problems can be solved using computer software. Utilizing computer software is an indispensable means of reducing the workload of engineering design. Therefore, the petroleum engineering field has begun to develop from informatization to automation, and cementing engineering, as a subfield of petroleum engineering, is no exception.

[0034] Cementing engineering is gradually moving towards automation and intelligence throughout the entire process, from design and construction to evaluation. Simultaneously, against the backdrop of oil companies striving to reduce costs and increase efficiency, the development of automated cementing equipment is an inevitable trend. Compared to conventional cementing equipment, automated cementing equipment boasts superior performance, a higher degree of automation, and better meets the requirements of future cementing operations, aligning with the strategic goals of cost reduction and efficiency improvement in shale gas extraction. Therefore, developing domestically produced automated cementing equipment can not only fill the current gap in this field in China but also holds significant economic benefits. The research and application of automated cementing equipment is conducive to achieving large-scale, economical development of shale gas. Mastering the core technologies of high-end cementing equipment has a very positive and far-reaching significance for exploring new markets and enhancing the company's international capabilities.

[0035] Cement is one of the essential raw materials in cementing operations. During cementing, to easily determine the remaining amount of cement in the tank, workers typically tap the outer wall of the tank and listen to the sound to determine if cement is present at the tapped point, thus determining the amount of cement remaining in the tank. However, due to the height of the cement storage tank and the significant pressure generated during cementing operations (which poses safety risks to workers), measuring the remaining amount of cement is time-consuming, labor-intensive, and lacks accuracy, posing safety hazards during construction.

[0036] Furthermore, in cementing operations, the amount of cement often needs to be stored in two or even more cement tanks. To ensure the continuity of cementing operations, workers determine the remaining cement level by tapping the outer wall of the cement tank. When the cement in the tank used for cementing is about to run out, another cement tank is opened, and the cement in that tank is used to continue the work. The tank is then closed once the cement in the first tank is used up. This process usually requires workers to determine the tank-changing time based on experience and to complete the operation. In addition, due to the high-pressure pipelines involved in cementing operations, there are certain safety hazards.

[0037] To address the aforementioned technical problems, this application proposes a cement ash hopper residual ash monitoring system and method based on automated cementing. The method and system include a cement hopper, an electric guide rail, a signal detection device, a discharge port, an automatic valve module, a wireless transceiver module, a data control module, a data processing module, and a display module. This invention, by providing a residual ash ash monitoring system for cement ash hoppers, can accurately measure the residual cement ash in the cement hopper, reduce safety hazards during cementing operations, and enhance the automation level of cementing operations.

[0038] Figure 1 This is a schematic diagram of the overall structure of a residual ash monitoring system for cement ash silos, according to an embodiment of this application. Figure 1 As shown, the residual ash volume monitoring system of this embodiment includes: a signal detection device 100 and an information processing device 101.

[0039] A signal detection device 100 is mounted on a guide rail 2 on the outer wall of the cement ash silo 1 to be monitored. The guide rail 2 is an electric track and is arranged along the axial direction of the cement ash silo 1. The signal detection device 100 is used to acquire characteristic signals in real time to characterize the interface position of the current remaining ash amount in the cement ash silo. An information processing device 101 communicates with the signal detection device 100. The information processing device 101 is used to quantitatively analyze the current remaining ash amount in the cement ash silo 1 to be monitored by processing the received characteristic signals.

[0040] Figure 2 This is a schematic diagram of the specific structure of a residual ash monitoring system for cement ash silos according to an embodiment of this application. The following refers to... Figure 2 The specific structure and function of the residual ash monitoring system described in the embodiments of the present invention will be explained.

[0041] The signal detection device 100 is installed on the electric track 2 on the outer wall of the cement ash hopper 1, and can move back and forth in a direction perpendicular to the ground under the drive of the electric track 2.

[0042] Figure 3 This is a schematic diagram illustrating the specific structure of the signal detection device in a residual ash monitoring system for cement ash silos, according to an embodiment of this application. Figure 3 As shown, the signal detection device 100 (i.e. Figure 3Component 3) includes: an electric support rod 7, an impactor 4, an acoustic wave receiving module 5, and a first wireless transceiver 6. In this embodiment, the electric support rod 7 is adapted to be connected to the guide rail 2. The electric support rod 7 is used to move on the guide rail 2. The impactor 4, the acoustic wave receiving module 5, and the first wireless transceiver 6 are all connected to the electric support rod 7 by welding. The output end of the acoustic wave receiving module 5 is connected to the input end of the first wireless transceiver 6. The impactor 4 is disposed on the electric support rod 7 and is used to continuously strike the outer wall of the cement ash tank 1 at preset time intervals during the movement of the support rod. The acoustic wave receiving module 5 is disposed on the electric support rod 7 and is used to receive acoustic wave signals from the surrounding environment during the movement of the support rod. Further, the acoustic wave receiving module 5 is used to continuously detect the acoustic wave signals generated by the striking action of the impactor 4. The first wireless transceiver 6 is used to transmit the acoustic wave signals collected by the acoustic wave receiving module 5 to the information processing device 101. At this time, the information processing device 101 is also used to identify the interface height of the remaining cement ash in the cement ash hopper 1 to be monitored based on the acoustic signal transmitted by the signal detection device 3.

[0043] In this embodiment of the invention, the working principle of the signal detection device 3 is as follows: the sound wave receiving module 5 collects the sound waves generated by the impactor 4 striking the outer wall of the cement ash jar 1 while moving on the track of the electric guide rail 2, and transmits the collected sound wave signal to the information processing device 101 through the first wireless transceiver device 6.

[0044] Furthermore, such as Figure 2 As shown, the information processing device 101 includes: a third data transceiver 13 communicating with the first data transceiver 6 within the signal detection device 100, a data control module 14, a data processing module 15, and a display module 16. The third data transceiver 13 is wirelessly connected to the first data transceiver 6. The output of the data control module 14 is connected to the input of the data processing module 15, and the output of the data processing module 15 is connected to the input of the display module 16. The data control module 14 is used to locally store the current characteristic data and forward it to the data processing module 15 after receiving the characteristic signal (acoustic signal) from the signal detection device 3 through the third data transceiver 13. The data processing module 15 is used to determine the interface position of the remaining cement ash in the cement ash hopper based on the current (acoustic signal), and calculate the cement slurry volume used to characterize the remaining ash in the cement ash hopper based on the height inside the cement hopper corresponding to the interface position. The display module 12 is used to display the remaining data such as the cement slurry volume calculated by the data processing module 11, as well as the current usage status of the cement ash hopper 1 to be monitored.

[0045] Specifically, the data processing module 11 within the information processing device 101 is also used to identify the interface height of remaining cement ash based on the real-time acquired acoustic signals using an interface recognition model. The interface recognition model is constructed using artificial intelligence and machine learning methods. In constructing the interface recognition model, the first step is to establish a basic neural network model and a training dataset. When establishing the training dataset, multiple sound segments generated by striking the outer wall of an empty cement hopper with an impactor are first collected, and these sound segments are labeled as having no cement ash. Then, multiple sound segments generated by striking the outer wall of a cement hopper containing cement ash with an impactor are collected, and these sound segments are labeled as having cement ash. These labeled multiple sound segments are used as the training dataset. The second step involves extracting signal features from the sound wave (segment) signals with and without cement ash, using them as training input data, and using the identification results of those with and without cement ash as training output data to train the aforementioned basic neural network model, thereby constructing the interface recognition model.

[0046] Thus, since the sound waves produced when the cement hopper is struck with a part without cement ash are different from those produced when the part with cement ash is struck, the data processing module 15, through the model constructed by artificial intelligence and machine learning methods, can distinguish whether there is cement ash inside the striking position of the striking part 4, thereby determining the remaining height h of cement ash in the cement ash hopper.

[0047] Next, the data processing module 11 is also used to calculate the volume of cement slurry, which represents the amount of cement ash remaining in the cement ash hopper, based on the interface height of the remaining cement ash identified in real time, using the following expression:

[0048] v = hS (1)

[0049] M=ρv (2)

[0050] V=yM (3)

[0051] Where h represents the height of the remaining cement ash in the cement ash hopper as measured by the signal detection device 100, v represents the volume of the cement ash, S represents the bottom area inside the cement ash hopper, M represents the real-time weight of the remaining cement ash in the cement ash hopper, ρ represents the density of the cement ash, y represents the slurry production rate, and V represents the volume of the remaining cement slurry.

[0052] Based on the characteristic that the signal detection device 100 can detect changes in the remaining amount of cement ash in the tank in real time, during cementing operations, the amount of cement ash used often needs to be stored in two or more cement ash tanks, and in order to ensure the continuity of the construction process, the supply of cement ash to the cement ash tanks needs to be stable and continuous. Therefore, this invention uses an automatic valve device 9 to control the automatic emptying operation of the cement ash tanks.

[0053] In this embodiment of the invention, the cement ash silo 1 to be monitored is connected to the high-pressure pipeline of the cement pump truck used for pumping cement ash. An automatic valve device 9 is installed on the outer wall of the discharge port pipeline 8 of the cement ash silo 1 to be monitored.

[0054] Figure 4 This is a schematic diagram of the automatic valve device in the residual ash monitoring system for cement ash silos, according to an embodiment of this application. Figure 4 As shown, the automatic valve device 9 includes: a second data transceiver 12, a discharge port valve 10, and a discharge switch 11.

[0055] The second data transceiver 12 is wirelessly connected to the third data transceiver 13 within the information processing device 101. The output of the second data transceiver 12 is connected to the input of the discharge switch 11. The discharge valve 10 is located inside the discharge pipeline 8. The discharge switch 11 is connected to the discharge valve 10. The discharge switch 11 is connected to the information processing device 101 via the second data transceiver 12. The discharge switch 11 is an automated switching device. Specifically, the discharge valve 10 is used to adjust its opening degree under the action of a first command, thereby controlling the discharge flow rate of the cement ash silo 1 currently being monitored; the discharge switch 11 is used to receive the discharge control command sent from the data control module 14 in the information processing device 101 via the second data transceiver 12, and convert the discharge control command into a first command for controlling the discharge valve 10 to close or open.

[0056] Furthermore, the data control module 14 within the information processing device 101 is also used to determine the valve closing type of the corresponding cement ash hopper to be monitored based on the real-time height of the remaining ash, and generate a discharge control command corresponding to the current valve closing type. This discharge control command is then sent to the discharge switch 11 of the cement ash hopper 1 to be monitored via the data control module 14. Valve closing types include, but are not limited to, gradual closing and complete closing. The data processing module 15 within the information processing device 101 is also used to calculate the real-time height of the remaining ash based on the volume V of the cement ash and the bottom area S inside the cement hopper, and forwards the real-time height data of the remaining cement ash to the data control module 14, enabling the data control module 14 to dynamically control the discharge flow rate based on the real-time height data.

[0057] In one embodiment, when the remaining ash height is less than 0.5 meters, the current valve closing type is gradual closing.

[0058] In another embodiment, when the remaining ash height is 0, the current valve closure type is fully closed.

[0059] In addition, the data control module 14 in the information processing device 101 is also used to send a discharge control command to the discharge switch 11 to instruct the discharge valve 10 to gradually open or fully open.

[0060] In this embodiment of the invention, the information processing device 101 also communicates with a first data transceiver 6 and a second data transceiver 12 located on multiple cement ash silos. In this embodiment, the information processing device 101 is used to control the remaining ash quantity and discharge flow rate of the multiple cement silos required for the current automatic backfilling operation. The information processing device 101 is communicatively connected to a signal detection device 100(3) and an automatic valve device 9 on each cement silo participating in the current automatic backfilling operation.

[0061] The information processing device 101 is also used to send a discharge control command to another unused water-lime tank 1, while sending a discharge control command to one of the water-lime tanks 1 to indicate that the discharge outlet valve is gradually closed or completely closed, to indicate that the discharge outlet valve is gradually opened or completely opened.

[0062] In practical applications, when the data processing module 15 calculates that the remaining cement ash in the cement ash silo being supplied is less than 0.5 cubic meters, the data control module 14 sends a discharge control command to the automatic valve module 9 via the wireless data transceiver module 13. After receiving the command, the automatic valve device 9 gradually reduces and closes the opening of the discharge port valve 10 through the discharge switch module 11. Furthermore, the data control module 14 sends a command to another standby (unused) cement ash silo 1 to automatically close the discharge port valve under the control of the discharge switch 11 of the other cement ash silo 1. Door 10 opens gradually; when the cement ash remaining in the cement ash hopper being supplied is 0, the data control module 14 sends a discharge control command to the automatic valve module 9 through the wireless data transceiver module 13. After receiving the command, the automatic valve device 9 controls the discharge port valve 10 to be completely closed through the discharge switch module 11, and the data control module 14 sends a command to another spare (unused) cement ash hopper 1 to automatically open the discharge port valve 10 under the control of the discharge switch 11 of the other cement ash hopper 1, thereby completing the automatic hopper transfer operation.

[0063] Example 1

[0064] During construction, the discharge valve of cement ash silo A is opened to supply ash to the cement pump truck, while the discharge valves of the other cement ash silos are closed.

[0065] As construction progresses, the cement ash residue interface in cement ash silo A gradually decreases. The signal detection device 3 sends the acquired data to the data processing module 15 for processing. By using different sound wave waveforms, the remaining amount of cement ash in the silo is determined, thereby calculating the remaining data such as the cement slurry volume, and displaying it through the display module 12.

[0066] As construction progresses, the cement ash residue interface in cement ash silo A gradually decreases. When the cement ash residue height in cement ash silo A is less than 0.5 meters, the automatic valve device 9 of cement ash silo A will receive an instruction, and the discharge valve 10 will gradually close. At the same time, the automatic valve device 9 of the standby cement ash silo B will receive an instruction, and the discharge valve 10 will gradually open.

[0067] When the remaining cement ash in cement ash silo A is 0, the discharge valve 10 of cement ash silo A is completely closed, and the discharge valve 10 of the standby cement ash silo B is fully opened, thereby completing the automated cement ash silo switching operation in the cementing process, making the cementing process stable and continuous.

[0068] On the other hand, based on the aforementioned residual ash monitoring system, this embodiment of the invention also provides a method for monitoring the residual ash content of cement ash silos. This method is implemented using the residual ash monitoring system described above.

[0069] Figure 5 This is a step diagram illustrating the method for monitoring the residual ash content in a cement ash silo, as described in this embodiment of the present application. Figure 5 As shown, the residual ash monitoring method according to the embodiments of the present invention includes the following steps:

[0070] Step S601: The signal detection device 100 installed on the guide rail on the outer wall of the cement ash hopper 1 to be monitored collects characteristic signals in real time to detect the interface position of the remaining ash in the cement ash hopper. Step S602: The information processing device 101 processes the received characteristic data to quantitatively analyze the remaining ash in the cement ash hopper to be monitored.

[0071] This invention discloses a system and method for monitoring the remaining cement content in cement silos. This system and method enable automated real-time monitoring of the remaining cement content in cement silos during cementing operations, providing guidance for cement silo replacement procedures during cementing.

[0072] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0073] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0074] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0075] It should be understood that the embodiments disclosed herein are not limited to the specific structures, processing steps, or materials disclosed herein, but should be extended to equivalent substitutions of these features as understood by those skilled in the art. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0076] The phrase "an embodiment" or "an embodiment" used in this specification means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Therefore, the phrase "an embodiment" or "an embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment.

[0077] While the embodiments disclosed in this invention are as described above, the content is merely for the purpose of facilitating understanding of the invention and is not intended to limit the invention. Any person skilled in the art to which this invention pertains may make any modifications and changes in form and detail of the implementation without departing from the spirit and scope disclosed herein; however, the scope of patent protection of this invention shall still be determined by the scope defined in the appended claims.

Claims

1. A residual ash monitoring system for cement ash silos, characterized in that, include: The signal detection device is set on the guide rail on the outer wall of the cement ash hopper to be monitored, and is used to collect characteristic signals in real time to characterize the interface position of the current remaining ash in the cement ash hopper. An information processing device is used to quantitatively analyze the remaining ash content of the cement ash silo currently being monitored by processing the received characteristic signals, wherein... The information processing device is also used to identify the interface height of the remaining cement ash based on the acoustic signal and the interface recognition model. Then, based on the interface height of the remaining cement ash identified in real time, the volume of cement slurry and its corresponding height data used to characterize the amount of remaining cement ash in the cement ash hopper are calculated and recorded as the real-time height data of the remaining cement ash. The interface recognition model is constructed based on artificial intelligence and machine learning methods. The information processing device also uses the following expression to calculate the volume of cement slurry with remaining ash content: in, h This indicates the height of the remaining cement ash in the cement ash container. v This indicates the volume of cement ash. S This indicates the bottom area inside the cement ash silo. M This indicates the real-time weight of the remaining cement ash in the cement ash hopper. ρ This indicates the density of cement ash. y Indicates pulping rate, V Indicates the volume of remaining cement paste; The information processing device also communicates with the signal detection device located on multiple cement ash silos, wherein it determines the valve closing type of the corresponding cement ash silo to be monitored based on the real-time height data of the remaining cement ash and generates corresponding discharge control commands, including: When the real-time height of the remaining cement ash in one of the water-cement hoppers is less than 0.5 meters, a discharge control command indicating that the valve closing type is gradual is sent to the current water-cement hopper, and at the same time, a discharge control command indicating that the discharge port valve is gradually opened is sent to the other water-cement hopper. When the real-time height data of the remaining cement ash in the current water-cement hopper is 0, a discharge control command indicating that the valve closure type is fully closed is sent to the current water-cement hopper, and at the same time, a discharge control command indicating that the discharge port valve is fully open is sent to the other water-cement hopper.

2. The residual ash monitoring system according to claim 1, characterized in that, The guide rail is arranged along the axial direction of the cement ash hopper, wherein the signal detection device includes: An electric support rod, adapted to the guide rail, for movement on the guide rail; The impact component is mounted on the electric support rod and is used to continuously strike the outer wall of the cement ash hopper at preset time intervals during the movement of the support rod. An acoustic wave receiving module is installed on the electric support rod to receive acoustic wave signals from the surrounding environment during the movement of the support rod. A first wireless transceiver device is used to transmit the acoustic signal to the information processing device, wherein... The information processing device is also used to identify the interface height of the remaining cement ash based on the acoustic signal.

3. The residual ash monitoring system according to claim 1 or 2, characterized in that, The residual ash monitoring system further includes: an automatic valve device installed on the outer wall of the discharge port pipeline of the cement ash silo to be monitored, wherein the automatic valve device includes: A second data transceiver device that communicates with the information processing device; The discharge valve is located inside the discharge port and is used to adjust its opening degree under the action of the first command, thereby controlling the discharge flow rate of the cement ash hopper to be monitored. A discharge switch, connected to the discharge port valve, is used to receive discharge control commands sent from the information processing device via the second data transceiver device, and convert them into the first command for controlling the discharge port valve to close or open.

4. The residual ash monitoring system according to claim 3, characterized in that, The information processing device is also used to send the discharge control command to the discharge switch to instruct the discharge port valve to gradually open or fully open.

5. The residual ash monitoring system according to claim 2, characterized in that, The process of constructing the interface recognition model includes: establishing a basic neural network model, then extracting signal features from sound wave signals without cement dust and sound wave signals with cement dust as training input data, and using the recognition results marked with or without cement dust as training output data to train the basic neural network model, thereby constructing the interface recognition model.

6. The residual ash monitoring system according to claim 1 or 2, characterized in that, The information processing device includes: a third data transceiver device communicating with the signal detection device, a data control module, a data processing module, and a display module.

7. The residual ash monitoring system according to claim 1, characterized in that, The information processing device communicates with automatic valve devices located on multiple cement ash hoppers.

8. A method for monitoring the residual ash content in cement ash silos, characterized in that, The remaining ash volume monitoring method is implemented by the remaining ash volume monitoring system as described in any one of claims 1 to 7, wherein the remaining ash volume monitoring method includes the following steps: The characteristic signal used to characterize the current position of the interface of the remaining ash in the cement ash hopper is collected in real time by a signal detection device set on the guide rail on the outer wall of the cement ash hopper to be monitored. The information processing device quantitatively analyzes the remaining amount of cement ash in the current monitoring cement ash hopper by processing the received characteristic signals.

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