An on-line monitoring device and method for grinding roller health

Abstract

A kind of grinding roller health on-line monitoring device and method, including: grinding roller device, grinding roller rotational speed measuring unit, grinding disc and transmission disc device, gear box, display transmission unit, machine base, motor, computing unit and storage unit;Grinding roller rotational speed measuring unit is made of tachometer and signal transmitter, and signal transmitter transmits the rotational speed collected by tachometer to signal receiver, signal receiver is connected computing unit and storage unit, and transmits rotational speed to computing unit and storage unit.Display transmission unit is connected computing unit, and uses wireless communication to receive signal from grinding roller rotational speed measuring unit.Overcome the problem that the existing monitoring means can cause excessive repair and cannot find serious wear in time, while overcoming the problem that indirect method measurement accuracy is very poor, ensure the accuracy and reliability of monitoring.

Description

Technical Field

[0001] This invention belongs to the technical field of vertical roller mill equipment, and more specifically, relates to an online health monitoring device and method for grinding rollers. Background Technology

[0002] When grinding materials, pulverizing equipment such as coal mills or slag mills will cause wear and tear on the grinding parts of the equipment to varying degrees. When the wear reaches a certain level, the grinding efficiency will decrease and may even affect the normal and stable operation of the equipment. Therefore, it is essential to monitor the wear of the grinding parts.

[0003] Existing monitoring methods generally employ methods such as periodic replacement, empirical methods, and template measurement. Periodic replacement involves replacing or repairing the grinding parts at fixed intervals, but its disadvantages include the possibility of over-maintenance and failure to detect severe wear in a timely manner. Empirical methods estimate the wear degree of the grinding parts based on factors such as equipment operating current and vibration noise, but its disadvantages include indirect measurement, poor accuracy, and inaccurate results after changing the grinding material. Template measurement uses a template to measure the wear degree of the grinding parts, which has the advantage of direct measurement and high accuracy, but its disadvantages include long measurement time and lack of real-time capability.

[0004] Prior art document 1 (CN 109012886 B) provides an online monitoring system for the speed difference between the grinding roller and grinding disc of a vertical mill. It discloses a first speed detection component for monitoring the grinding disc rotation speed; a second speed detection component for monitoring the grinding roller rotation speed; and a processor for receiving the grinding disc rotation speed and grinding roller rotation speed signals and calculating the difference between them. The processor interacts with the first and second speed detection components respectively. The shortcoming of prior art document 1 is that it infers the grinding roller wear rate by measuring the speed difference between the grinding roller and grinding disc online, without providing a specific judgment method. Typically, the rotation speed of the grinding disc in a vertical mill is a fixed value, determined by the rated speed of the motor and the gearbox ratio. Therefore, it is unnecessary to set up a speed detection component for the grinding disc. Even if a variable frequency motor is used, the speed can be compared with the variable frequency frequency, making a speed detection component for the grinding disc unnecessary. Secondly, based on field experience, the grinding disc speed cannot reflect the failure of the reducer or thrust bearing. Since there is a design margin when selecting the motor and reducer, the grinding disc speed will not change significantly when a non-serious failure occurs. Usually, the fault point and fault type are determined by the motor current and temperature sensors at various locations on the reducer. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an online health monitoring device and method for grinding rollers.

[0006] The present invention adopts the following technical solution.

[0007] The first aspect of the present invention provides an online health monitoring device for grinding rollers.

[0008] Includes: grinding roller assembly, grinding roller speed measurement unit, grinding disc and transmission disc assembly, gearbox, display and transmission unit, base, motor, calculation unit and storage unit;

[0009] The grinding roller speed measuring unit is installed on the grinding roller device;

[0010] The display and transmission unit is mounted on the machine base and connected to the computing unit. It is used to display the wear degree and operating status information of the grinding roller sleeve and transmit the information to the upper control system.

[0011] The motor is mounted on the side of the base to provide power;

[0012] The storage unit is used to store the rotational speed information collected by the grinding roller rotational speed measurement unit, including the wear degree of the grinding roller sleeve and the grinding roller operating status information calculated by the calculation unit.

[0013] Preferably, the grinding roller speed measuring unit is located on the leeward side, and the grinding roller health online monitoring device further includes: a signal receiver connected to the calculation unit and the storage unit, used to receive the speed collected by the tachometer from the signal transmitter, and transmit the speed to the calculation unit and the storage unit; the signal transmitter includes: a tachometer and a signal transmitter, the tachometer is used to collect the rotation speed of the object, and the transmitter is used to send the collected speed to the signal receiver.

[0014] Preferably, the input end of the calculation unit is connected to the grinding roller speed measurement unit to calculate the roller sleeve size, wear degree and operating status of the grinding roller; the output end is connected to the display transmission unit and the storage unit, the storage unit is used to save the current roller sleeve size, the initial roller sleeve size, the initial speed of the grinding roller and the real-time speed of the grinding roller.

[0015] Preferably, the display transmission unit is connected to the calculation unit to display the wear degree of the grinding roller sleeve and the operating status information of the grinding roller, and to receive signals from the grinding roller speed measurement unit and the grinding disc speed measurement unit using wireless communication.

[0016] A second aspect of the present invention provides a method for online measurement of grinding roller health, comprising the following steps:

[0017] Step 1: Calculate the current dimensions of the roller sleeve of the grinding roller to be tested based on the pre-collected initial dimensions of the grinding roller and the real-time collected grinding roller speed.

[0018] Step 2: Compare the initial size of the roller sleeve with the current size of the roller sleeve to obtain the wear amount of the roller sleeve;

[0019] Step 3: Determine the degree of wear of the grinding roller based on the wear amount, grinding roller speed, and grinding disc speed, and monitor the health status of the grinding roller.

[0020] Preferably, in step 1, the current size of the roller sleeve is calculated as follows:

[0021]

[0022] In the formula, The initial rotational speed of the grinding roller. This is the current rotational speed of the grinding roller. This represents the initial dimensions of the roller sleeve.

[0023] Preferably, in step 2, after the lifting device disengages the grinding roller from the grinding disc, the grinding roller device gradually stops rotating under the action of frictional resistance torque. The signal collected by the grinding roller speed measurement unit is transmitted to the calculation unit. The calculation unit calculates the wear amount of the roller sleeve based on the current size and initial size of the roller sleeve of the grinding roller to be tested. The wear amount calculation formula is as follows:

[0024]

[0025] In the formula, Δm represents the wear amount, and k is the wear amount correction coefficient.

[0026] Preferably, in step 3, the calculation unit uses the following equation to calculate the angular acceleration α of the grinding roller device:

[0027]

[0028] In the formula, Δn is the change in the roller speed over the time interval Δt.

[0029] Preferably, the formula for calculating the moment of inertia is as follows:

[0030] J = m·r 2

[0031] In the formula, m is the mass of the rotating grinding roller, and r is the perpendicular distance between the mass and the axis of rotation;

[0032] When the roller sleeve wears down, both m and r will be less than the limit value, causing the moment of inertia J to be less than the limit value.

[0033] Preferably, based on the obtained wear amount k and the initial size of the roller sleeve Current dimensions of the roller sleeve The formula for calculating the frictional resistance torque, based on the angular acceleration α of the grinding roller device, is as follows:

[0034]

[0035] In the formula, The frictional resistance torque is m0, and the original mass of the grinding roller assembly is m0.

[0036] When the computing unit calculates With initial value When the deviation reaches 10%, it is considered that the lubricating oil has deteriorated or the bearing has failed, causing the resistance torque to be higher than the set value. An alarm signal is sent, and maintenance personnel conduct a detailed inspection of the rotating parts of the grinding roller device.

[0037] Compared with the prior art, the beneficial effects of the present invention include at least the following: The online health detection method for grinding rollers proposed in this invention can monitor the wear degree and operating status of grinding rollers in real time, quickly and accurately, requiring fewer additional devices and resulting in low modification costs; The present invention overcomes the problems of excessive maintenance and failure to detect severe wear in a timely manner by setting up grinding roller speed measurement units and grinding disc speed measurement units, while also overcoming the problem of poor accuracy of indirect measurement methods, ensuring accurate and reliable monitoring; The method of the present invention is real-time, realizing real-time acquisition and display of speed and wear status simply by setting the monitoring device on the vertical mill structure, reducing the long working time of measuring wear parts and providing real-time performance. Attached Figure Description

[0038] Figure 1 This is a block diagram illustrating the configuration of the online health monitoring device for grinding rollers provided according to an embodiment of the present invention;

[0039] Figure 2 This is a schematic diagram of the arrangement of the online health monitoring device for grinding rollers provided in accordance with an embodiment of the present invention;

[0040] Figure 3 This is a schematic diagram of the online measurement method for grinding roller health provided according to an embodiment of the present invention;

[0041] Figure 4 This is a flowchart of an online health monitoring method for grinding rollers provided according to an embodiment of the present invention. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this invention. The embodiments described in this application are merely some embodiments of this invention, and not all embodiments. Based on the spirit of this invention, other embodiments obtained by those skilled in the art without creative effort are all within the protection scope of this invention.

[0043] Figure 1 A block diagram illustrating the configuration of an online health monitoring device for grinding rollers according to an exemplary embodiment of the present disclosure.

[0044] refer to Figure 1 The online health monitoring device for grinding rollers according to Exemplary Example 1 of this disclosure includes a grinding roller speed measuring unit, a calculation unit, a display and transmission unit, and a storage unit.

[0045] The grinding roller speed measuring unit is used to measure the rotational speed of the grinding roller. This speed measuring unit can be composed of a tachometer. The tachometer is a device for measuring the rotational speed of an object, and its common unit is revolutions per minute, expressed as rpm.

[0046] The input of the calculation unit is connected to the grinding roller speed measurement unit, and the output is connected to the display and transmission unit and the storage unit, respectively. Based on the change in grinding roller speed measured by the grinding roller speed measurement unit, the size of the grinding roller sleeve is calculated. The size of the sleeve can be calculated by radius or diameter. The storage unit is used to save the current size of the sleeve, the initial size of the sleeve, the initial mass of the grinding roller, the initial speed of the grinding roller, and the real-time speed of the grinding roller.

[0047] like Figure 2 As shown, the present invention provides an online health monitoring device for grinding rollers:

[0048] Includes: a grinding roller device 101, a grinding roller speed measuring unit 102, a grinding disc and transmission disc device 103, a gearbox 104, a display and transmission unit 105, a base 106, a motor 107, a calculation unit, and a storage unit;

[0049] The grinding roller speed measuring unit 102 is connected to the grinding roller device 101 and is positioned above the grinding disc and transmission disc device 103;

[0050] The display and transmission unit 105 is mounted on the base 106 and connected to the computing unit. It is used to display the wear degree and operating status information of the grinding roller sleeve and transmit the information to the upper control system.

[0051] The motor 107 is located on the side of the machine base 106 and is used to provide power. The calculation unit is connected to the grinding roller speed measuring unit 102.

[0052] The storage unit is used to store the rotational speed information collected by the grinding roller rotational speed measurement unit 102, including the wear degree of the grinding roller sleeve and the grinding roller operating status information calculated by the calculation unit.

[0053] Preferably, the grinding roller speed measuring unit 102 is located on the leeward side, and consists of a tachometer and a signal transmitter. The signal transmitter transmits the speed collected by the tachometer to the signal receiver, and the signal receiver is connected to the calculation unit and the storage unit, and transmits the speed to the calculation unit and the storage unit.

[0054] Preferably, the input end of the calculation unit is connected to the grinding roller speed measurement unit 102 to calculate the roller sleeve size, wear degree and operating status of the grinding roller; the output end is connected to the display transmission unit 105 and the storage unit, which is used to save the current roller sleeve size, the initial roller sleeve size, the initial speed of the grinding roller and the real-time speed of the grinding roller.

[0055] Preferably, the display transmission unit is connected to the calculation unit and is used to display the wear degree of the grinding roller sleeve and the operating status information of the grinding roller, and to receive signals from the grinding roller speed measurement unit 102 and the grinding disc speed measurement unit using wireless communication.

[0056] Figure 3 The diagram illustrates the principle of an online measurement method for grinding roller health according to an exemplary embodiment of the present disclosure.

[0057] exist Figure 3 The middle is displayed as The first one is a grinding roller device with no worn roller sleeve, and the second one is a grinding roller device with worn roller sleeve.

[0058] The grinding roller assembly and the grinding disc and transmission disc assembly rotate relative to each other at the meshing point due to the friction between the roller sleeve and the material. After stable operation, the linear velocities of the grinding roller assembly, the grinding disc and transmission disc assembly at the meshing point should be the same.

[0059] Although the grinding disc experiences wear during operation, the continuous feeding of material prevents the position of the meshing point from changing. Based on the relationship between the roller sleeve size and the grinding disc size, the linear velocities of the grinding roller and the grinding disc are the same at the meshing point. Therefore, the rotational speed of the grinding roller assembly before and after wear must be different. The roller sleeve diameter decreases due to wear. Reduce to The rotational speed of the grinding roller is then determined by... Increase to The change in the diameter of the roller sleeve is inversely proportional to the change in the rotational speed of the grinding roller.

[0060] Furthermore, while keeping the grinding disc rotation speed constant, the rotation speed of the grinding rollers was recorded when they were initially in good condition. Record its rotational speed after wear. The relative wear of the roller sleeve can also be determined by comparing the changes in rotational speed before and after.

[0061] Foreign objects may get stuck or even fall off inside the grinding roller. Years of practical experience have shown that not all of these abnormalities can be detected. In some cases, the abnormalities may not produce abnormal noise or vibration or cause significant changes in motor current.

[0062] When the above-mentioned abnormal situation occurs in the grinding roller, the grinding roller speed n g If the speed drops to 0 or deviates significantly from its normal speed, it can be determined that the grinding roller is malfunctioning and requires maintenance.

[0063] like Figure 4 As shown, the present invention provides a method for online monitoring of grinding roller health, comprising the following steps:

[0064] Step 1: Calculate the current dimensions of the roller sleeve of the grinding roller to be tested based on the pre-collected initial dimensions of the grinding roller and the real-time collected grinding roller speed.

[0065] Step 1 specifically includes: pre-collecting the initial dimensions of the roller sleeve and the initial rotational speed of the grinding roller to be tested, wherein the grinding roller rotational speed measurement unit collects the grinding roller rotational speed in real time.

[0066] Record the initial rotational speed of the grinding roller when it is in its initial state. Record the current rotational speed of the grinding roller after wear. Initial dimensions of the collecting roller sleeve And calculate the current dimensions of the roller sleeve. The current dimensions of the roller sleeve are calculated as follows:

[0067]

[0068] In the formula, The initial rotational speed of the grinding roller. This is the current rotational speed of the grinding roller. This represents the initial size of the roller sleeve. From the above formula, it can be seen that the roller sleeve diameter decreases due to wear from the initial size. Reduce to the current size of the roller sleeve The grinding roller speed is then determined by the initial grinding roller speed. Increase to the current rotational speed of the grinding roller The change in the diameter of the roller sleeve is inversely proportional to the change in the rotational speed of the grinding roller. Therefore, by comparing it with the initial size of the roller sleeve, the amount of wear on the roller sleeve can be obtained.

[0069] Preferably, in this application, a computing unit is used to implement the above calculation process, and data such as the current size of the roller sleeve, the initial size of the roller sleeve, and the initial speed of the grinding roller are stored in the storage unit.

[0070] Step 2: Compare the initial size of the roller sleeve with the current size of the roller sleeve to obtain the wear amount of the roller sleeve;

[0071] Preferably, in step 2, after the lifting roller device 101 disengages from the grinding disc 103, the roller device gradually stops rotating under the action of frictional resistance torque. The signal collected by the roller speed measuring unit 102 is transmitted to the calculation unit. The calculation unit calculates the roller sleeve wear amount using the current size and initial size of the roller sleeve of the roller to be tested. The wear amount calculation formula is as follows:

[0072]

[0073] In the formula, Δm represents the wear amount, and k is the wear amount correction coefficient.

[0074] Step 3: Determine the degree of wear of the grinding roller based on the wear amount, grinding roller speed, and grinding disc speed, and monitor the health status of the grinding roller.

[0075] Preferably, in step 3, the calculation unit uses the following equation to calculate the angular acceleration α of the grinding roller device:

[0076]

[0077] In the formula, Δn is the change in the roller speed over the time interval Δt.

[0078] Preferably, the formula for calculating the moment of inertia is as follows:

[0079] J = m·r 2

[0080] In the formula, m is the mass of the rotating grinding roller, and r is the perpendicular distance between the mass and the axis of rotation;

[0081] When the roller sleeve wears down, both m and r will be less than the limit value, causing the moment of inertia J to be less than the limit value.

[0082] Preferably, based on the obtained wear amount k and the initial size of the roller sleeve Current dimensions of the roller sleeve The formula for calculating the frictional resistance torque, based on the angular acceleration α of the grinding roller device, is as follows:

[0083]

[0084] In the formula, The frictional resistance torque is m0, and the original mass of the grinding roller assembly is m0.

[0085] When the computing unit calculates With initial value When the deviation reaches 10%, it is considered that the lubricating oil has deteriorated or the bearing has failed, resulting in the resistance torque being higher than the set value. An alarm signal is sent, and maintenance personnel conduct a detailed inspection of the rotating parts of the grinding roller device 101.

[0086] Finally, the grinding roller device is lowered to complete the testing process.

[0087] The online measurement method for grinding roller health according to exemplary embodiments of the present disclosure advantageously enables users to monitor the wear level and operating status of the grinding roller in real time without stopping the grinding operation.

[0088] The beneficial effects of this invention include at least the following: The online health detection method for grinding rollers proposed in this invention can monitor the wear degree and operating status of grinding rollers in real time, quickly and accurately, requiring fewer additional devices and resulting in low modification costs; This invention overcomes the problems of excessive maintenance and failure to detect severe wear in a timely manner by setting up grinding roller speed measurement units and grinding disc speed measurement units, while also overcoming the problem of poor accuracy of indirect measurement methods, ensuring accurate and reliable monitoring; The method of this invention is real-time, achieving real-time acquisition and display of speed and wear status simply by setting the monitoring device on the vertical mill structure, reducing the long working time of measuring wear parts and providing real-time performance.

[0089] This disclosure can be a system, method, and / or computer program product. A computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for causing a processor to implement various aspects of this disclosure.

[0090] Computer-readable storage media can be tangible devices capable of holding and storing instructions for use by an instruction execution device. Computer-readable storage media can be, for example—but not limited to—electrical storage devices, magnetic storage devices, optical storage devices, electromagnetic storage devices, semiconductor storage devices, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of computer-readable storage media include: portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), static random access memory (SRAM), portable compact disc read-only memory (CD-ROM), digital multifunction disc (DVD), memory sticks, floppy disks, mechanical encoding devices, such as punch cards or recessed protrusions storing instructions thereon, and any suitable combination of the foregoing. The computer-readable storage media used herein are not to be construed as transient signals themselves, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through waveguides or other transmission media (e.g., light pulses through fiber optic cables), or electrical signals transmitted through wires.

[0091] The computer-readable program instructions described herein can be downloaded from computer-readable storage media to various computing / processing devices, or downloaded via a network, such as the Internet, local area network, wide area network, and / or wireless network, to an external computer or external storage device. The network may include copper transmission cables, fiber optic transmission, wireless transmission, routers, firewalls, switches, gateway computers, and / or edge servers. A network adapter card or network interface in each computing / processing device receives the computer-readable program instructions from the network and forwards them to the computer-readable storage media in the respective computing / processing device.

[0092] Computer program instructions used to perform the operations of this disclosure may be assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine-dependent instructions, microcode, firmware instructions, status setting data, or source code or object code written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Smalltalk, C++, etc., and conventional procedural programming languages ​​such as the "C" language or similar programming languages. The computer-readable program instructions may execute entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving a remote computer, the remote computer may be connected to the user's computer via any type of network—including a local area network (LAN) or a wide area network (WAN)—or may be connected to an external computer (e.g., via the Internet using an Internet service provider). In some embodiments, electronic circuitry, such as programmable logic circuitry, field-programmable gate arrays (FPGAs), or programmable logic arrays (PLAs), is personalized by utilizing the status information of the computer-readable program instructions to implement various aspects of this disclosure.

[0093] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A method for online monitoring of grinding roller health, applied to an online monitoring device for grinding roller health, the device comprising: The device comprises a grinding roller assembly (101), a grinding roller speed measuring unit (102), a grinding disc and transmission disc assembly (103), a gearbox (104), a display and transmission unit (105), a base (106), a motor (107), a calculation unit, and a storage unit; the grinding roller speed measuring unit (102) is mounted on the grinding roller assembly (101); the display and transmission unit (105) is mounted on the base (106) and connected to the calculation unit, used to display the wear degree and operating status information of the grinding roller sleeve, and transmit the information to the upper control system; the motor (107) is located on the side of the base (106) and used to provide power; the storage unit is used to store the speed information collected by the grinding roller speed measuring unit (102), including the wear degree and operating status information of the grinding roller sleeve calculated by the calculation unit; characterized in that it includes the following steps: Step 1: Calculate the current dimensions of the roller sleeve of the grinding roller to be tested based on the pre-collected initial dimensions of the grinding roller and the real-time collected grinding roller speed; the calculation method for the current dimensions of the roller sleeve is as follows: In the formula: The initial rotational speed of the grinding roller. This is the current rotational speed of the grinding roller. This refers to the initial dimensions of the roller sleeve; Step 2: Compare the initial size of the roller sleeve with the current size of the roller sleeve to obtain the wear amount of the roller sleeve; When the lifting device (101) disengages the grinding roller from the grinding disc and transmission disc device (103), the grinding roller will gradually stop rotating under the action of frictional resistance torque. The signal collected by the grinding roller speed measurement unit (102) is transmitted to the calculation unit. The calculation unit calculates the wear amount of the roller sleeve based on the current size and initial size of the roller sleeve of the grinding roller to be tested. The wear amount calculation formula is as follows: In the formula: This refers to the amount of wear. k This is a wear correction factor; Step 3: Determine the degree of wear of the grinding roller based on the wear amount, grinding roller speed, and grinding disc speed, and monitor the health status of the grinding roller; The calculation unit uses the following equation to calculate the angular acceleration of the grinding roller assembly. : In the formula: For the roller sleeve speed at Change over time; The formula for calculating the moment of inertia is as follows: In the formula: m is the mass of the rotating grinding roller, and r is the perpendicular distance between the mass point and the axis of rotation; When the roller sleeve wears down, both m and r will fall below the specified values, resulting in a decrease in the moment of inertia. Less than the limit; Based on the obtained wear amount Initial dimensions of the roller sleeve Current dimensions of roller sleeves Angular acceleration of grinding roller device The formula for calculating the frictional resistance torque is as follows: In the formula: For frictional resistance torque, The original mass of the grinding roller assembly; When the computing unit calculates With initial value When the deviation reaches 10%, it is considered that the lubricating oil has deteriorated or the bearing has failed, resulting in the resistance torque being higher than the set value. An alarm signal is sent, and maintenance personnel conduct a detailed inspection of the rotating parts of the grinding roller device (101).

2. The online health monitoring method for grinding rollers according to claim 1, characterized in that: The input end of the calculation unit is connected to the grinding roller speed measurement unit (102) to calculate the roller sleeve size, wear degree and operating status of the grinding roller; the output end is connected to the display transmission unit (105) and the storage unit, which is used to save the current roller sleeve size, the initial roller sleeve size, the initial speed of the grinding roller and the real-time speed of the grinding roller.

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