An adaptive intelligent ball mill control system and method

Abstract

The application discloses a kind of self-adapting intelligent ball mill control systems, comprising: intelligent detection subsystem, based on acoustic noise energy spectrum, computer vision, sensor, the process parameter data of ore situation, feeding condition, return material condition, water supply condition are detected and collected;Self-adapting intelligent control model subsystem is used to obtain the real-time process parameter data collected by intelligent detection subsystem, calculates the best feeding amount, water supply amount, real-time intelligent adjustment ball mill feeding amount, water supply amount, and can complete the processing of abnormal condition;Dynamic adjustment execution subsystem.The application can make ball mill can multimodal, multi-angle detection the influence caused by the change of feeding ore properties and the load condition of ball mill by automatically adjusting the control system of feeding amount, water supply amount, and according to the production situation of upstream and downstream process section, under the premise of guaranteeing ball mill production stable, efficient, maximize the output of ball mill.

Description

Technical Field

[0001] This invention belongs to the field of intelligent ball mill technology, specifically, it relates to an adaptive intelligent ball mill control system and method. Background Technology

[0002] In modern industrial production, ball mills, as important grinding equipment, are widely used in ore processing, cement production, and chemical raw material preparation. The operating efficiency and output of ball mills directly affect the economic benefits of the entire production line. However, in actual production, controlling the feed rate and water supply of ball mills often faces many challenges, such as fluctuations in ore properties and changes in production in upstream and downstream process sections. These factors directly affect the production efficiency and output of ball mills.

[0003] Currently, the feed rate and water supply of large ball mills used in industry mainly rely on on-site manual judgment and estimation, or estimation through monitoring one or a few process parameters, such as detecting the particle size of the feed ore and the size of the return material. This method of judging and controlling the feed and water supply cannot reflect the actual working load of the ball mill in real time and accurately. When the hardness, particle size, or other properties of the ore change, the feed rate and water supply cannot be adjusted accordingly in time, causing the ball mill to frequently overflow due to excessive load, or the ball mill to be underloaded for a long time, affecting the ball mill's capacity and production efficiency. These situations will affect the production efficiency of ball mill workshops in industrial enterprises, and the use of manual monitoring and feeding settings also increases the human resource costs for enterprises.

[0004] In view of this, the present invention is proposed. Summary of the Invention

[0005] The technical problem this invention aims to solve is to overcome the shortcomings of existing technologies and provide an adaptive intelligent ball mill control system and method. By real-time monitoring of process parameters such as ore, feed, return material, and water supply, and intelligently adjusting the feed and water supply, the ball mill can detect the impact of changes in the properties of the feed ore and the load status of the ball mill through multi-modal and multi-angle detection methods. Based on the production status of upstream and downstream process sections, and under the premise of ensuring stable and efficient ball mill production, the system automatically adjusts the feed and water supply of the ball mill to maximize ball mill output and avoid energy waste and raw material consumption caused by overfeeding or underfeeding, thereby reducing production costs. At the same time, it can automatically adjust the control strategy according to the changes in the properties of different ores to ensure stable operation of the ball mill under various operating conditions.

[0006] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by the present invention is as follows: The present invention provides an adaptive intelligent ball mill control system, comprising: The intelligent detection subsystem, based on acoustic noise energy spectrum, computer vision, and sensors, detects and collects process parameter data on ore condition, feeding condition, return material condition, and water supply condition. The adaptive intelligent control model subsystem is used to acquire real-time process parameter data collected by the intelligent detection subsystem, calculate the optimal feed rate and water rate, intelligently adjust the ball mill feed rate and water rate in real time, and handle abnormal situations. The dynamic adjustment execution subsystem, including the automated equipment of the intelligent ball mill control system, is used to control the automated equipment in the ball mill control system according to the control instructions of the adaptive intelligent control model subsystem.

[0007] Furthermore, the intelligent detection subsystem includes: The intelligent noise detection module is used to collect and analyze noise signals during the ball mill production process through intelligent electric ear devices to determine the load inside the ball mill and the wear status of the steel balls and liners. The feed particle size detection module, return material detection module, and feed inlet blockage monitoring module are based on computer vision (CV) small model recognition technology. They are used to detect the size of ore particles in the feed, assess the amount of return material, and detect the amount and time of ore retained at the ball mill feed inlet to determine whether blockage has occurred. The leakage detection module, based on a pressure sensor, is used to detect the amount of leakage.

[0008] Furthermore, the intelligent detection subsystem also includes: The actual feed rate detection module uses a combination of belt scale detection and motor speed detection to detect the actual feed rate. The slurry concentration detection module is used to detect the slurry concentration in real time. The motor current monitoring module is used to monitor the operating status of the motor. The medium-sized ore pool level detection module is used to collect medium-sized ore pool level data through a radar level gauge to detect the level. The actual water supply detection module is used to collect the actual water supply through a liquid flow meter.

[0009] Furthermore, the adaptive intelligent control model subsystem specifically includes: The data processing module is used to receive and process data from the intelligent detection subsystem; The intelligent control algorithm module is used to calculate the feed rate and water flow adjustment values ​​that are suitable for the current ore properties and ball mill load by using the data received from the intelligent detection subsystem and the preset control strategy. The execution module is used to automatically adjust the feeding device and water supply device of the ball mill by controlling the calculation results of the algorithm unit; The exception handling module is used to automatically handle abnormal situations according to the set handling plan.

[0010] Furthermore, the dynamic adjustment execution subsystem includes: The feed motor frequency converter is used to control the speed of the feed motor, control the feed rate, the opening degree of the water supply regulating valve, and the operating status of the intermediate ore pool water pump, so as to achieve precise control of the feed rate, water supply and intermediate ore pool liquid level, and ensure the stability, efficiency and safety of the ball mill production process. A water supply regulating valve controller is used to control the water supply by adjusting the opening degree of the water supply regulating valve; The ore pool water pump controller is used to regulate the water level in the ore pool by controlling the operation of the water pump.

[0011] The present invention also provides an adaptive intelligent ball mill control method, the control method comprising the following steps: S1. Start the ball mill, initialize the process parameters, and acquire data collected by the intelligent detection subsystem; S2. Based on the acquired data, control the ball mill according to the set control process to achieve the feeding control target and water supply control target; The defined control process includes: S21, Feeding Control Sub-method S22, Water supply control sub-method.

[0012] Furthermore, the S21 feeding control sub-method includes the following steps: S211. Obtain the feed particle size detection data, and calculate and adjust the electric ear control range based on the rate of change of the calibrated electric ear range; S212. Obtain the electric ear noise detection value, determine whether the electric ear noise detection value is within the electric ear control range, and if so, calculate and output the feed value after electric ear noise evaluation based on the position of the electric ear noise detection value in the current electric ear control range. S213. Obtain the amount of returned material, calculate and adjust the feed value after the electric ear noise assessment based on the amount of returned material, and output the feed value after the returned material amount assessment. S214. Obtain the motor current value, calculate and adjust the feed value after the return material amount assessment based on the current value, and output the feed value after the current assessment. S215. Determine if there is any leakage or blockage. If so, reduce the feed rate or shut down the machine. S216. Obtain the actual feed value. Determine if there is a material shortage by calculating the difference between the actual feed value and the feed value. If so, the system will automatically operate in the material shortage mode. If not, the final calculated feed value will be output to the corresponding actuator to achieve the feeding control target.

[0013] Furthermore, step S212 specifically includes the following steps: S2121. Determine whether the noise value of the electric ear is higher than the upper limit of the electric ear control range. If yes, calculate the increase in the target value of feeding and set a new target value. If no, proceed to step S2122. S2122. Determine whether the noise value of the electric ear is lower than the lower limit of the electric ear control range. If so, calculate the reduction amount of the feed target value and set a new target value.

[0014] Furthermore, the S22 water supply control sub-method includes the following steps: S221. Obtain feed particle size detection data and calculate the corresponding slurry concentration range; S222. Obtain the current concentration range of the slurry and determine whether the current concentration of the slurry is within the calculated slurry concentration range. If so, calculate a reasonable water supply based on the feed particle size and feed rate. S223. Adjust the water supply controller according to the calculated water supply volume so that the actual water supply volume reaches the calculated value.

[0015] Furthermore, step S222 also includes the following steps: S2221. Determine whether the current slurry concentration is higher than the calculated slurry concentration range. If yes, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the upper limit of the reasonable water supply range as the calculated water supply value. If no, proceed to step S2222. S2222 Determine whether the current slurry concentration is lower than the calculated slurry concentration range. If so, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the lower limit of the reasonable water supply range as the calculated water supply value.

[0016] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art: (1) By real-time monitoring of process parameters such as ore, feed, return material, and water supply, and intelligent adjustment of feed rate and water supply, the ball mill can detect the impact of changes in the properties of the feed ore and the load of the ball mill through multi-modal and multi-angle detection methods. Based on the production conditions of the upstream and downstream process sections, the ball mill feed rate and water supply can be automatically adjusted to maximize the ball mill output while ensuring stable and efficient production. This avoids energy waste and raw material consumption caused by over- or under-feeding, thereby reducing production costs. At the same time, the control strategy can be automatically adjusted according to the changes in the properties of different ores to ensure that the ball mill can operate stably under various working conditions.

[0017] (2) The comprehensive detection and judgment method of "water supply detection + mineral quantity detection + visual calibration" is used to achieve comprehensive and accurate monitoring of ball mills or similar equipment, ensure stable operation and efficient production of equipment, and improve product quality and production safety.

[0018] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0019] The accompanying drawings, as part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention, but do not constitute an undue limitation of the invention. Obviously, the drawings described below are merely some embodiments, and those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings: Figure 1 This is a block diagram of an adaptive intelligent ball mill control system according to the present invention; Figure 2 This is a detailed block diagram of an adaptive intelligent ball mill control system according to the present invention; Figure 3 This is a flowchart of an adaptive intelligent ball mill control method according to the present invention; Figure 4 This is a flowchart of the feeding control sub-method in step S21 of the present invention; Figure 5 This is the present invention. Figure 4 Flowchart for step S212, determining whether the detected ear noise value is within the ear control range; Figure 6 This is a flowchart of the water supply control sub-method in step S22 of the present invention; Figure 7 This is the present invention. Figure 6 The flowchart for step S222, determining whether the current slurry concentration is higher than the calculated slurry concentration range, is shown in the diagram.

[0020] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, embodiments of the present disclosure will be described below with reference to the accompanying drawings. However, it should be understood that these descriptions are exemplary only and are not intended to limit the scope of the present disclosure. In the following detailed description, many specific details are set forth to provide a comprehensive understanding of the embodiments of the present disclosure for ease of explanation. However, it will be apparent that one or more embodiments may be practiced without these specific details. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concepts of the present disclosure.

[0022] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. The terms “comprising,” “including,” etc., as used herein indicate the presence of features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0023] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0024] When using expressions such as "at least one of A, B, and C," the expression should generally be interpreted in accordance with the meaning commonly understood by a person skilled in the art (e.g., "a system having at least one of A, B, and C" should include, but is not limited to, systems having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or having A, B, and C, etc.). When using expressions such as "at least one of A, B, or C," the expression should generally be interpreted in accordance with the meaning commonly understood by a person skilled in the art (e.g., "a system having at least one of A, B, or C" should include, but is not limited to, systems having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or having A, B, and C, etc.).

[0025] The accompanying drawings illustrate several block diagrams and / or flowcharts. It should be understood that some blocks, or combinations thereof, in the block diagrams and / or flowcharts can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device, such that, when executed by the processor, these instructions can create means for implementing the functions / operations described in these block diagrams and / or flowcharts. The technology of this disclosure can be implemented in hardware and / or software (including firmware, microcode, etc.). Alternatively, the technology of this disclosure can take the form of a computer program product stored on a computer-readable storage medium, which is available for use by or in conjunction with an instruction execution system.

[0026] like Figure 1 As shown, the adaptive intelligent ball mill control system of the present invention includes: The intelligent detection subsystem, based on acoustic noise energy spectrum, computer vision, and sensors, detects and collects process parameter data on ore condition, feeding condition, return material condition, and water supply condition.

[0027] The adaptive intelligent control model subsystem is used to acquire real-time process parameter data collected by the intelligent detection subsystem, calculate the optimal feed rate and water supply, intelligently adjust the ball mill feed rate and water supply in real time, and handle abnormal situations.

[0028] The dynamic adjustment execution subsystem, including the automated equipment of the intelligent ball mill control system, is used to control the automated equipment in the ball mill control system according to the control instructions of the adaptive intelligent control model subsystem.

[0029] This invention, by setting up an intelligent detection subsystem, an adaptive intelligent control model subsystem, and a dynamic adjustment execution subsystem, enables the ball mill system to automatically detect and collect key process parameters such as ore, feed, return material, and water supply. Through the adaptive intelligent control model, it adjusts the feed and water supply in real time, achieving intelligent control of the ball mill. This reduces reliance on operators, improves production efficiency and automation, and automatically adjusts the control strategy according to the properties of different ores and process requirements, ensuring stable operation of the ball mill under various operating conditions. This helps reduce production costs and improve product quality. Intelligent and precise control of feed and water supply ensures the ball mill operates under optimal conditions, avoiding excessive or insufficient feeding and water supply, further reducing energy consumption and costs. The system has abnormal situation handling capabilities, and can take timely measures such as alarms and shutdowns when equipment malfunctions or parameters are abnormal, ensuring production safety. Furthermore, the system's real-time monitoring and intelligent adjustment functions also help prevent potential safety hazards.

[0030] Specifically, the intelligent detection subsystem uses acoustic noise energy spectrum analysis, computer vision technology, and sensors to monitor and collect data on key process parameters such as ore, feed, return material, and water supply in real time, and transmits this data to the adaptive intelligent control model subsystem for processing. The adaptive intelligent control model subsystem will calculate the optimal feed rate and water supply from the received data, and the system will intelligently adjust the feed rate and water supply of the ball mill to ensure that the ball mill operates in the best condition. If the system detects an abnormal situation (such as equipment failure or abnormal parameters), it will automatically take corresponding measures, such as alarms and shutdowns.

[0031] Finally, the dynamic adjustment execution subsystem controls the automated equipment (such as feeders and water pumps) in the ball mill control system according to the control instructions of the adaptive intelligent control model subsystem. By adjusting the speed or flow rate of these devices, it achieves precise control of the feed rate and water supply of the ball mill.

[0032] During execution, the system will continuously monitor changes in process parameters and adjust the control strategy in real time as needed to ensure stable operation and efficient production of the ball mill.

[0033] Furthermore, the intelligent detection subsystem includes: The intelligent noise detection module is used to collect and analyze noise signals during the ball mill production process through intelligent electric ear devices, and to determine the load inside the ball mill and the wear status of the steel balls and liners.

[0034] The feed particle size detection module, return material detection module, and feed inlet blockage monitoring module are based on computer vision (CV) small model recognition technology. They are used to detect the size of ore particles in the feed, assess the amount of return material, and detect the amount and time of ore retained at the ball mill feed inlet to determine whether blockage has occurred.

[0035] The leakage detection module, based on a pressure sensor, is used to detect the amount of leakage.

[0036] Through the intelligent noise detection module, the system can determine the load inside the ball mill and the wear status of the steel balls and liners in real time, thereby precisely adjusting the feed rate and water supply to ensure the ball mill operates under optimal conditions. Simultaneously, the feed particle size detection module and the return material detection module ensure the stability of feeding and return material, further improving production efficiency and output. The feed inlet blockage monitoring module can promptly detect the amount of ore stuck at the ball mill feed inlet; once blockage is detected, the system can quickly take measures to prevent equipment failure and safety accidents. Furthermore, the leakage detection module monitors the leakage amount in real time to promptly identify potential safety hazards and take corresponding measures to ensure production safety.

[0037] Specifically, the intelligent detection subsystem is a multimodal, multi-angle process parameter detection system that can use acoustic noise energy spectrum, computer vision, and various sensors to conduct comprehensive detection of ore conditions, feeding conditions, return material conditions, and water supply conditions.

[0038] The intelligent noise detection module, based on the noise detection of the intelligent electric ear, collects and analyzes the noise signals during the ball mill production process through the electric ear device, obtains the energy changes of noise at different frequencies, and judges the load inside the ball mill and the wear status of the steel balls and liners.

[0039] The feed particle size detection module, based on computer vision (CV) small model recognition technology, detects the size of ore particles in the feed and evaluates the overall coarseness of the ball mill feed.

[0040] The return material quantity detection module, based on computer vision (CV) small model recognition technology, detects data such as the width and thickness of the return material flow in the return material conveying device and evaluates the amount of return material.

[0041] The feed inlet blockage monitoring module uses computer vision (CV) small model recognition technology to detect the amount and time of ore retained at the ball mill feed inlet and determine whether blockage has occurred.

[0042] The leakage detection module, based on a pressure sensor, detects whether leakage has occurred and the amount of leakage.

[0043] CV, or Computer Vision, simply means that computers simulate humans to understand the meaning of images or perform rational operations on images, such as segmentation and classification.

[0044] Furthermore, the intelligent detection subsystem also includes: The actual feed rate detection module uses a combination of belt scale detection and motor speed detection to detect the actual feed rate.

[0045] The slurry concentration detection module is used to detect the slurry concentration in real time.

[0046] The motor current monitoring module is used to monitor the operating status of the motor.

[0047] The medium-sized ore pool level detection module is used to collect medium-sized ore pool level data through a radar level gauge to detect the level.

[0048] The actual water supply detection module is used to collect the actual water supply through a liquid flow meter.

[0049] Specifically, the actual feed rate detection module detects the ore flow rate through a belt scale and, in conjunction with motor speed detection, calculates the actual feed rate. The belt scale measures the weight and speed of the ore on the belt in real time, while the motor speed detection provides information on the speed at which the motor drives the belt, thus accurately calculating the actual feed rate.

[0050] The slurry concentration detection module uses a combination of technologies such as visual recognition, conductivity, and ultrasound to detect the slurry concentration in real time. The sensors transmit the collected data to the control system, which adjusts parameters such as water supply based on the concentration data. Simultaneously, it achieves comprehensive and accurate monitoring of ball mills or similar equipment through a comprehensive detection and judgment method of "water supply detection + slurry quantity detection + visual calibration," ensuring stable operation and efficient production, and improving product quality and production safety.

[0051] Motor current monitoring module: It collects and monitors the changes in motor current in real time through an ammeter to determine the motor's operating status. If the current is abnormal, the system can issue an early warning signal to remind the operator to check the motor status.

[0052] The medium ore pool level detection module: collects the liquid level data of the medium ore pool in real time through a radar level gauge. After processing, the liquid level data is transmitted to the control system, which adjusts parameters such as feed rate and return rate according to the liquid level.

[0053] Actual water supply detection module: The actual water supply is detected in real time using a liquid flow meter. The flow meter transmits the collected data to the control system, which then adjusts parameters such as the water supply based on the water supply data.

[0054] Furthermore, the adaptive intelligent control model subsystem specifically includes: The data processing module is used to receive and process data from the intelligent detection subsystem.

[0055] The intelligent control algorithm module is used to calculate the feed rate and water flow adjustment values ​​that are suitable for the current ore properties and ball mill load by using the data received from the intelligent detection subsystem and the preset control strategy.

[0056] The execution module is used to automatically adjust the feeding device and water supply device of the ball mill by controlling the calculation results of the algorithm unit.

[0057] The exception handling module is used to automatically handle abnormal situations according to the set handling plan.

[0058] The data processing module continuously receives data from the intelligent detection subsystem, including key data such as ore properties (hardness, moisture content, etc.), real-time load of the ball mill, current, and temperature. This raw data is then cleaned, integrated, and formatted to ensure accuracy and usability. The intelligent control algorithm module then receives the processed data and, in conjunction with preset control strategies (which may be based on machine learning models, fuzzy logic, or other advanced control algorithms), calculates the appropriate feed and water flow rates based on the data and strategies, optimizing the ball mill's operating efficiency and product quality. Finally, the execution module receives the calculation results from the intelligent control algorithm module and converts them into actual control commands, sending them to the ball mill's feeding and water supply devices to automatically adjust the feed and water flow rates.

[0059] During operation, the anomaly handling module continuously monitors the system status. Once an anomaly is detected (such as blockage, leakage, insufficient material, high liquid level, or current overload), it automatically handles the emergency according to the pre-defined procedures. Through the adaptive intelligent control model subsystem, the ball mill's feed and water supply can be adjusted in real time to adapt to changes in ore properties and load, thereby improving the ball mill's working efficiency. The system can automatically receive and process data, perform calculations based on the control strategy, and automatically adjust the ball mill, reducing the probability of errors caused by manual intervention and improving the level of intelligence in the production process.

[0060] Furthermore, the dynamic adjustment execution subsystem includes: The feed motor frequency converter is used to control the speed of the feed motor, the feed rate, the opening degree of the water supply regulating valve, and the operating status of the intermediate ore pool water pump. This enables precise control of the feed rate, water supply, and intermediate ore pool liquid level, ensuring the stability, efficiency, and safety of the ball mill production process.

[0061] A water supply regulating valve controller is used to control the water supply by adjusting the opening degree of the water supply regulating valve.

[0062] The ore pool water pump controller is used to regulate the water level in the ore pool by controlling the operation of the water pump.

[0063] The dynamic adjustment execution subsystem of the present invention is mainly composed of various automated devices that complete the execution of control commands for feeding, water supply and abnormal handling, and is not limited to feed motor frequency converter controller, water supply regulating valve controller and medium ore pool water pump controller, but also includes belt frequency converter motor, etc.

[0064] The present invention also provides an adaptive intelligent ball mill control method, the control method comprising the following steps: S1. Start the ball mill, initialize the process parameters, and acquire data collected by the intelligent detection subsystem.

[0065] S2. Based on the acquired data, control the ball mill according to the set control process to achieve the feeding control target and water supply control target.

[0066] The defined control process includes: S21, Feeding control sub-method; S22, Water supply control sub-method.

[0067] Furthermore, the S21 feeding control sub-method includes the following steps: S211. Obtain the feed particle size detection data, and calculate and adjust the electric ear control range based on the rate of change of the calibrated electric ear range.

[0068] First, real-time detection data of the feed particle size is acquired. Based on the change in feed particle size and combined with the pre-set standard for the change rate of the electric ear interval, the system calculates the adjustment amount of the electric ear control interval. The adjusted electric ear control interval will serve as the benchmark for judging whether the electric ear noise is normal in subsequent steps. Real-time adjustment of the electric ear control interval can ensure that the system has better adaptability to feed materials of different particle sizes, and improve the automation level and control accuracy of the system.

[0069] S212. Obtain the electric ear noise detection value, determine whether the electric ear noise detection value is within the electric ear control range, and if so, calculate and output the feed value after electric ear noise evaluation based on the position of the electric ear noise detection value in the current electric ear control range.

[0070] S213. Obtain the amount of returned material, calculate and adjust the feed value after the electric ear noise assessment based on the amount of returned material, and output the feed value after the returned material amount assessment.

[0071] S214. Obtain the motor current value, calculate and adjust the feed value after the return material amount assessment based on the current value, and output the feed value after the current assessment.

[0072] S215. Determine if there is any leakage or blockage. If so, reduce the feed rate or shut down the machine.

[0073] S216. Obtain the actual feed value. Determine if there is a material shortage by calculating the difference between the actual feed value and the feed value. If so, the system will automatically operate in the material shortage mode. If not, the final calculated feed value will be output to the corresponding actuator to achieve the feeding control target.

[0074] During operation, in step S213, the amount of returned material is detected in real time. Based on the changes in the amount of returned material, the system calculates the adjustment amount for the feed value and applies this adjustment to the feed value after the electric ear noise assessment to obtain a new feed value. Next, the system executes step S214, which acquires the motor current value in real time. The current value is used to determine the load and operating efficiency of the ball mill. Based on the changes in the current value, the system calculates the adjustment amount for the feed value and applies it to the feed value after the returned material amount assessment. The amount of returned material directly affects the operating efficiency and product quality of the ball mill. By detecting and adjusting the feed value in real time, the production process can be optimized, and the system's response speed and adaptability to changes in production conditions can be improved.

[0075] Next, the system uses sensors or other detection methods to determine if there is any leakage or blockage. If these problems exist, the system will decide, based on preset rules and algorithms, whether to appropriately reduce the feed rate or shut down the system. Timely detection and handling of abnormalities such as leakage and blockage can prevent equipment damage and production accidents.

[0076] Finally, the system obtains the actual feed value. By comparing the calculated feed value with the actual feed value, it determines whether there is a material shortage. If a material shortage exists, the system automatically switches to material shortage mode; if there is no material shortage, the system outputs the final calculated feed value to the actuator. In the event of a material shortage, the system can automatically switch to material shortage mode to avoid production interruptions and product quality issues.

[0077] Specifically, the feed control sub-method first adjusts the electro-optic control range based on particle size detection data and the calibrated electro-optic range change rate. Then, based on the position of the electro-optic noise detection value within the current control range, it calculates the adjustment strategy for the calculated and target feed rates. When the electro-optic noise value is at the high end of the control range or above the upper limit, the feed rate is appropriately increased according to the control strategy; when the electro-optic noise value is at the low end of the control range or below the lower limit, the feed rate is appropriately decreased according to the control strategy. Finally, based on the current return material detection data, the feed rate is adjusted according to the control strategy. If the calculated feed rate is too high and the return material is too low, the calculated and target feed rates should be appropriately reduced. If the return material is too low, the calculated and target feed rates should be appropriately increased. The system should also check for sudden increases in motor current; if so, the feed rate should be appropriately reduced. If blockages or leaks are detected, the feed rate should be appropriately reduced or the system should be shut down. The system should determine if there is a shortage in the silo by comparing the calculated feed rate (expected value) with the actual feed rate; if so, the system should automatically operate in shortage mode. Finally, the calculated feed rate should be output to the corresponding actuator to achieve the feed control target.

[0078] Furthermore, step S212 specifically includes the following steps: S2121. Determine whether the noise value of the electric ear is higher than the upper limit of the electric ear control range. If yes, calculate the increase in the target value of feeding and set a new target value. If no, proceed to step S2122.

[0079] Specifically, the system first acquires the electric ear noise detection value in real time.

[0080] Next, the system compares the detected value with the upper limit of the electro-ear control range.

[0081] If the noise value of the electric ear is higher than the upper limit of the electric ear control range, the system will calculate the increase in the target feed value based on a preset algorithm or model. This increase is obtained by comprehensively considering factors such as the current production situation, the operating status of the ball mill, and the characteristics of the material.

[0082] Finally, the system will set a new feed target value based on the calculated increase, and adjust the feed rate by controlling the actuator to increase the material filling amount inside the ball mill and reduce the noise level.

[0083] S2122. Determine whether the noise value of the electric ear is lower than the lower limit of the electric ear control range. If so, calculate the reduction amount of the feed target value and set a new target value.

[0084] Specifically, if the electric ear noise value is not higher than the upper limit of the electric ear control range (i.e., the condition in step S2121 is not met), the system will further determine whether the electric ear noise value is lower than the lower limit of the electric ear control range.

[0085] If the noise level of the electric ear is lower than the lower limit of the electric ear control range, the system will also calculate the reduction amount of the feed target value according to the preset algorithm or model. The reduction amount is derived by comprehensively considering factors such as the current production situation, the operating status of the ball mill, and the characteristics of the material.

[0086] Finally, the system will set a new feed target value based on the calculated reduction amount, and reduce the feed amount by controlling the actuator to reduce the amount of material filling inside the ball mill and improve the ball milling effect.

[0087] By monitoring the electric ear noise value in real time through the above process and adjusting the target feed value according to its changes, the ball mill's operating status can be precisely controlled, thereby improving production efficiency and product quality, and reducing production costs and failure rate.

[0088] Furthermore, the S22 water supply control sub-method includes the following steps: S221. Obtain the feed particle size detection data and calculate the corresponding slurry concentration range.

[0089] S222. Obtain the current concentration range of the slurry and determine whether the current concentration of the slurry is within the calculated slurry concentration range. If so, calculate a reasonable water supply based on the feed particle size and feed rate.

[0090] S223. Adjust the water supply controller according to the calculated water supply volume so that the actual water supply volume reaches the calculated value.

[0091] Specifically, during operation, the system first acquires real-time detection data of the feed particle size through sensors or detection devices, and then uses a preset algorithm or model to calculate the corresponding slurry concentration range based on the acquired feed particle size data.

[0092] The calculated slurry concentration range is determined comprehensively based on factors such as the physical properties of the material, the design parameters of the ball mill, and the production process requirements.

[0093] Next, the system obtains the current slurry concentration range through a slurry concentration detection device, compares the current slurry concentration range with the slurry concentration range calculated in step S221, and determines whether the current slurry concentration is within a reasonable range. If the current slurry concentration is within a reasonable range, the system will calculate a reasonable water supply based on the feed particle size and feed rate using a preset algorithm or model. By comparing the current slurry concentration with the ideal range in real time, concentration deviations can be detected in a timely manner, and the water supply can be adjusted accordingly.

[0094] Finally, based on the water supply calculated in step S222, the system adjusts the actual water supply by controlling the water supply controller.

[0095] Furthermore, step S222 further includes the following steps: S2221. Determine whether the current slurry concentration is higher than the calculated slurry concentration range. If yes, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the upper limit of the reasonable water supply range as the calculated water supply value. If no, proceed to step S2222.

[0096] S2222 Determine whether the current slurry concentration is lower than the calculated slurry concentration range. If so, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the lower limit of the reasonable water supply range as the calculated water supply value.

[0097] Specifically, the system first compares the current slurry concentration with the upper limit of the calculated slurry concentration range. If the current slurry concentration is higher than this upper limit, it indicates that the slurry concentration is too high and needs to be adjusted. Based on the feed particle size and feed rate, the system uses a preset algorithm or model to calculate a reasonable water supply range. Then, the system takes the average of the current water supply and the upper limit of the reasonable water supply range as the new water supply calculation value, increases the water supply, and thus reduces the slurry concentration.

[0098] When the slurry concentration is too high, the concentration can be quickly reduced by increasing the water supply, ensuring that the ball mill operates within a suitable slurry concentration range. The average of the current water supply and the reasonable upper limit of the water supply is used as the new water supply calculation value, reducing the range of water supply adjustment and making the system more stable.

[0099] If the current slurry concentration is not higher than the upper limit of the slurry concentration range, the system then determines whether the current slurry concentration is lower than the calculated lower limit of the slurry concentration range. If it is lower than the lower limit, it indicates that the slurry concentration is too low and needs adjustment. Similarly, based on the feed particle size and feed rate, the system calculates a reasonable feed rate range. The system takes the average of the current feed rate and the lower limit of the reasonable feed rate range as the new calculated feed rate value. When the slurry concentration is too low, reducing the feed rate can quickly increase the concentration, ensuring that the ball mill operates within a suitable slurry concentration range. Likewise, using the average of the current feed rate and the lower limit of the reasonable feed rate range as the new calculated feed rate value reduces the magnitude of feed rate adjustments and improves system stability.

[0100] Through the above steps, the system can dynamically adjust the water feed rate in real time based on the comparison between the current slurry concentration and the calculated slurry concentration range, ensuring that the ball mill operates within a suitable slurry concentration range. This dynamic adjustment strategy reduces the magnitude and frequency of water feed rate adjustments, improves system stability and reliability, and lowers the failure rate and maintenance costs.

[0101] Furthermore, the water supply control process first calculates a reasonable slurry concentration range; based on the slurry concentration detection and calculation results, it is determined whether the current slurry concentration is within a reasonable range. If the concentration is too high or too low, a reasonable water supply calculation value is calculated based on the model and output to the corresponding actuator to achieve the water supply control target.

[0102] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present invention. The implementation schemes in the above embodiments can also be further combined or replaced. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An adaptive intelligent ball mill control system, characterized in that, include: The intelligent detection subsystem, based on acoustic noise energy spectrum, computer vision, and sensors, detects and collects process parameter data on ore condition, feeding condition, return material condition, and water supply condition. The adaptive intelligent control model subsystem is used to acquire real-time process parameter data collected by the intelligent detection subsystem, calculate the optimal feed rate and water rate, intelligently adjust the ball mill feed rate and water rate in real time, and handle abnormal situations. The dynamic adjustment execution subsystem, including the automated equipment of the intelligent ball mill control system, is used to control the automated equipment in the ball mill control system according to the control instructions of the adaptive intelligent control model subsystem. The intelligent detection subsystem includes: The intelligent noise detection module is used to collect and analyze noise signals during the ball mill production process through intelligent electric ear devices to determine the load inside the ball mill and the wear status of the steel balls and liners. The feed particle size detection module, return material detection module, and feed inlet blockage monitoring module are based on computer vision (CV) small model recognition technology. They are used to detect the size of ore particles in the feed, assess the amount of return material, and detect the amount and time of ore retained at the ball mill feed inlet to determine whether blockage has occurred. The motor current monitoring module is used to monitor the operating status of the motor. The leakage detection module, based on a pressure sensor, is used to detect the amount of leakage. The actual feed rate detection module uses a combination of belt scale detection and motor speed detection to detect the actual feed rate. The adaptive intelligent ball mill control system includes the following steps when performing feed control: Obtain feed particle size detection data, and calculate and adjust the electric ear control range based on the rate of change of the calibrated electric ear range; Obtain the electric ear noise detection value, determine whether the electric ear noise detection value is within the electric ear control range, and if so, calculate and output the feed value after electric ear noise evaluation based on the position of the electric ear noise detection value in the current electric ear control range; Obtain the amount of returned material, calculate and adjust the feed value after the electric ear noise assessment based on the amount of returned material, and output the feed value after the returned material amount assessment. Obtain the motor current value, calculate and adjust the feed value after the return material amount assessment based on the current value, and output the feed value after the current assessment. Determine if there is any leakage or blockage. If so, reduce the feed rate or shut down the machine. The system obtains the actual feed value and determines whether there is a material shortage by calculating the difference between the actual feed value and the actual feed value. If so, the system automatically operates in the material shortage mode. If not, the system outputs the final calculated feed value to the corresponding actuator to achieve the feeding control target.

2. The adaptive intelligent ball mill control system according to claim 1, characterized in that, The intelligent detection subsystem also includes: The slurry concentration detection module is used to detect the slurry concentration in real time. The medium-sized ore pool level detection module is used to collect medium-sized ore pool level data through a radar level gauge to detect the level. The actual water supply detection module is used to collect the actual water supply through a liquid flow meter.

3. The adaptive intelligent ball mill control system according to claim 1, characterized in that, The adaptive intelligent control model subsystem specifically includes: The data processing module is used to receive and process data from the intelligent detection subsystem; The intelligent control algorithm module is used to calculate the feed rate and water flow adjustment values ​​that are suitable for the current ore properties and ball mill load by using the data received from the intelligent detection subsystem and the preset control strategy. The execution module is used to automatically adjust the feeding device and water supply device of the ball mill by controlling the calculation results of the algorithm unit; The exception handling module is used to automatically handle abnormal situations according to the set handling plan.

4. The adaptive intelligent ball mill control system according to claim 1, characterized in that, The dynamic adjustment execution subsystem includes: The feed motor frequency converter is used to control the speed of the feed motor; A water supply regulating valve controller is used to control the water supply by adjusting the opening degree of the water supply regulating valve; The ore pool water pump controller is used to regulate the water level in the ore pool by controlling the operation of the water pump.

5. An adaptive intelligent ball mill control method, characterized in that, The control method includes the following steps: S1. Start the ball mill, initialize the process parameters, and acquire data collected by the intelligent detection subsystem; S2. Based on the acquired data, control the ball mill according to the set control process to achieve the feeding control target and water supply control target; The defined control process includes: S21, Feeding control sub-method; S22, Water supply control sub-method; The S21 feeding control sub-method includes the following steps: S211. Obtain the feed particle size detection data, and calculate and adjust the electric ear control range based on the rate of change of the calibrated electric ear range; S212. Obtain the electric ear noise detection value, determine whether the electric ear noise detection value is within the electric ear control range, and if so, calculate and output the feed value after electric ear noise evaluation based on the position of the electric ear noise detection value in the current electric ear control range. S213. Obtain the amount of returned material, calculate and adjust the feed value after the electric ear noise assessment based on the amount of returned material, and output the feed value after the returned material amount assessment. S214. Obtain the motor current value, calculate and adjust the feed value after the return material amount assessment based on the current value, and output the feed value after the current assessment. S215. Determine if there is any leakage or blockage. If so, reduce the feed rate or shut down the machine. S216. Obtain the actual feed value. Determine if there is a material shortage by calculating the difference between the actual feed value and the feed value. If so, the system will automatically operate in the material shortage mode. If not, the final calculated feed value will be output to the corresponding actuator to achieve the feeding control target.

6. The adaptive intelligent ball mill control method according to claim 5, characterized in that, S212 specifically includes the following steps: S2121. Determine whether the noise value of the electric ear is higher than the upper limit of the electric ear control range. If yes, calculate the increase in the target value of feeding and set a new target value. If no, proceed to step S2122. S2122. Determine whether the noise value of the electric ear is lower than the lower limit of the electric ear control range. If so, calculate the reduction amount of the feed target value and set a new target value.

7. The adaptive intelligent ball mill control method according to claim 5, characterized in that, The S22 water supply control sub-method includes the following steps: S221. Obtain feed particle size detection data and calculate the corresponding slurry concentration range; S222. Obtain the current concentration range of the slurry and determine whether the current concentration of the slurry is within the calculated slurry concentration range. If so, calculate a reasonable water supply based on the feed particle size and feed rate. S223. Adjust the water supply controller according to the calculated water supply volume so that the actual water supply volume reaches the calculated value.

8. The adaptive intelligent ball mill control method according to claim 7, characterized in that, Step S222 further includes the following steps: S2221. Determine whether the current slurry concentration is higher than the calculated slurry concentration range. If yes, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the upper limit of the reasonable water supply range as the calculated water supply value. If no, proceed to step S2222. S2222 Determine whether the current slurry concentration is lower than the calculated slurry concentration range. If so, calculate a reasonable water supply range based on the feed particle size and feed rate, and take the average of the current water supply and the lower limit of the reasonable water supply range as the calculated water supply value.

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