A DCS sand making control system and intelligent control method

Abstract

The present invention relates to the technical field of sand making control system, and discloses a DCS sand making control system and intelligent control method, the system includes a strategy module, a control module, and a detection module; wherein: the strategy module is used to set the sand making control strategy, and matches and adjusts the sand making control strategy based on the target diameter of the sand particles and the coarse particle size of the sand particles; the control module includes a sand making control unit and a feeding control unit; wherein: the sand making control unit controls the rotation speed of the sand making machine based on the sand making control strategy; the feeding control unit controls the feeding rate of the feeding system based on the sand making control strategy; the detection module is used to control the operation of the screening equipment, monitor the particle size distribution of the sand particles, and calculate the coarse particle size of the sand particles based on the diameter of the sand particles and the target diameter. The present invention improves the intelligence level and economic benefits of the sand making process, and provides strong support for the development of the machine-made sand industry.

Description

Technical Field

[0001] The present invention relates to the technical field of sand making control systems, and in particular to a DCS sand making control system and an intelligent control method. Background Art

[0002] In the sand production process, the particle size distribution of sand and gravel will affect the quality and application scope of the product. In order to obtain high-quality sand particles, it is necessary to accurately control various parameters in the sand making process, such as the speed of the sand making machine and the feeding speed. Traditional sand making control systems often use fixed parameter settings, which can ensure production efficiency to a certain extent, but when faced with changing product specifications, their adaptability is poor and it is difficult to achieve refined management. Most of the sand making control systems on the market currently have the following shortcomings: many existing control systems still rely on preset parameters, have poor adjustment capabilities for fluctuations in product demand, and cannot adjust the sand making process in time, resulting in unstable product quality; traditional PID control and other simple feedback control methods have low control accuracy and are difficult to cope with complex nonlinear sand making processes and maintain stable product particle size. Due to the lack of effective energy management strategies, traditional sand making systems often have high energy consumption, especially when the material supply is unstable, the sand making machine is prone to blockage or idling, resulting in over-processing or under-processing, resulting in energy waste and equipment loss. Although some systems have introduced sensor networks and remote monitoring functions, there is still much room for improvement in data analysis and feedback utilization. In many cases, the collected data is not effectively utilized to provide real-time optimization suggestions for the sand making process.

[0003] For example, the Chinese patent with the authorization announcement number CN204009543U discloses a control system for sand making equipment, including PLC, feeding system drive mechanism motor inverter, crusher power transmitter, AS system, powder tank sensor, air screen sensor, air screen motor actuator, blower sensor, blower motor drive mechanism, dust collector induced draft fan control panel sensor, dust collector fan motor drive mechanism, feeding system drive mechanism motor inverter, AS system and powder tank sensor are respectively connected to PLC, crusher power transmitter, air screen sensor, air screen motor actuator, blower sensor, blower motor drive mechanism, dust collector induced draft fan control panel sensor and dust collector fan motor drive mechanism are respectively connected to AS system. Compared with the prior art, the utility model greatly reduces the intermediate crushing links, the operation function is more concise and smooth, the manual intervention links are less, and the quality of the finished sand is easy to control.

[0004] For example, a Chinese patent application with publication number CN115712247A discloses a control method and control device, a processor and a sand making system for a sand making system, which belongs to the field of machine-made sand technology. The sand making system includes a sand making machine, a feeder and a frequency converter. The control method for the sand making system includes: obtaining the target sand making power of the sand making machine; based on the relationship between the predetermined feeding frequency and the sand making power, determining the target feeding frequency corresponding to the target sand making power according to the target sand making power; controlling the frequency converter to work according to the target feeding frequency, so as to control the feeding speed of the feeder through the frequency converter. This embodiment of the invention can reduce the probability of misadjustment of the sand making system.

[0005] The above patents all have the problems raised by this background technology: poor ability to adjust to fluctuations in product demand and inability to adjust the sand making process in a timely manner, resulting in unstable product quality.

[0006] The information disclosed in this background technology section is only intended to enhance the understanding of the overall background of the invention and should not be regarded as an acknowledgement or any form of suggestion that the information constitutes the prior art already known to ordinary technicians in this field. Summary of the invention

[0007] The technical problem to be solved by the present invention is to overcome the defects of the prior art, provide a DCS sand making control system and an intelligent control method, improve the intelligence level and economic benefits of the sand making process, and provide support for the development of the machine-made sand industry.

[0008] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0009] On the one hand, the present invention provides a DCS sand making control system, including a strategy module, a control module, and a detection module; wherein:

[0010] The strategy module is used to set the sand making control strategy, and match and adjust the sand making control strategy based on the target diameter of the sand particles and the coarse particle size of the sand particles;

[0011] The control module includes a sand making control unit and a feeding control unit; wherein: the sand making control unit controls the rotation speed of the sand making machine based on the sand making control strategy; the feeding control unit controls the feeding rate of the feeding system based on the sand making control strategy;

[0012] The detection module is used to control the operation of the screening device, monitor the particle size distribution of the sand particles, and calculate the coarse particle size of the sand particles based on the diameter of the sand particles and the target diameter.

[0013] As a preferred solution of the DCS sand making control system of the present invention, the strategy module includes a strategy formulation unit, a strategy matching unit, and a control instruction unit; wherein:

[0014] The strategy formulation unit is used to set a sand making control strategy; the sand making control strategy includes the rotation speed of the sand making machine and the feeding rate of the feeding system; the strategy formulation unit presets M target diameters of sand grains, conducts sand making experiments, and sets sand making control strategies for the target diameters of M sand grains respectively through a genetic algorithm;

[0015] The strategy matching unit matches the sand making control strategy based on the target diameter of the sand particles; obtains the target diameter and sends a query instruction to the strategy formulation unit to obtain the sand making control strategy corresponding to the target diameter;

[0016] The control instruction unit generates control instructions based on the sand making control strategy and sends them to the control module; the control instructions include speed control instructions and feeding control instructions; wherein the speed control instructions are used to control the speed of the sand making machine, and the feeding control instructions are used to control the feeding rate of the feeding system.

[0017] As a preferred solution of the DCS sand making control system of the present invention, the method in which the strategy formulation unit sets the sand making control strategy for the target diameter of any sand grain through a genetic algorithm is as follows:

[0018] S100: Set the population size, crossover probability, and mutation probability, and generate N individuals to form the initial population, where N is the population size; any individual contains a chromosome, corresponding to a sand making control strategy; any chromosome contains two genes, corresponding to the rotation speed of the sand making machine and the feeding rate of the feeding system respectively;

[0019] S200: Calculate the fitness of each individual;

[0020] S300: performing selection operation, crossover operation, and mutation operation in sequence, and generating the next generation population;

[0021] S400: repeat steps S200-S300 until the highest fitness of all individuals in the population converges;

[0022] S500: The sand-making control strategy corresponding to the individual with the highest fitness is saved as the sand-making control strategy corresponding to the target diameter of the sand particles.

[0023] As a preferred solution of the DCS sand making control system of the present invention, the calculation formula of the fitness is as follows:

[0024]

[0025] Where H represents the fitness of any individual; D represents the average diameter of sand particles; D0 represents the target diameter of sand particles; r(D b ) represents the proportion of over-coarse sand particles to the total number of sand particles; the over-coarse sand particles are sand particles with a diameter higher than the over-coarse threshold; r(D s) represents the proportion of overfine sand particles to the total number of sand particles; the overfine sand particles are sand particles whose diameter is lower than the overfine threshold; w1 represents the first weight coefficient, w2 represents the second weight coefficient, w3 represents the third weight coefficient, α is the adjustment coefficient, and ε is the adjustment factor.

[0026] As a preferred solution of the DCS sand making control system of the present invention, the method of controlling the speed of the sand making machine by the sand making control unit is as follows: responding to and parsing the speed control instruction, obtaining the speed of the sand making machine in the sand making control strategy and generating a motor drive signal, and controlling and adjusting the speed of the sand making machine through the motor drive signal;

[0027] The method for the feeding control unit to control the feeding rate of the feeding system is as follows: respond to and analyze the feeding control instruction, obtain the feeding rate of the feeding system in the sand making control strategy and generate a pulse control signal, and control and adjust the feeding rate of the feeding system through the pulse control signal.

[0028] As a preferred solution of the DCS sand making control system of the present invention, wherein: the detection module includes a screening control unit and a sand particle detection unit;

[0029] The screening control unit controls the operation of the screening device based on the target diameter and is used to measure the diameter of the sand particles;

[0030] The sand detection unit is used to calculate the coarseness of the sand particles, and the formula is as follows:

[0031] C=(1-r(D h ))·(D-D0);

[0032] Where C represents the coarse-grained size of sand particles; r(D h ) represents the proportion of qualified sand grains to the total number of sand grains; the sand grain detection unit is configured with a first diameter threshold and a second diameter threshold, and sand grains with a diameter not lower than the first diameter threshold and not higher than the second diameter threshold are qualified sand grains.

[0033] As a preferred solution of the DCS sand making control system of the present invention, the detection module further includes a feedback unit, and the feedback unit is configured with a first threshold value of coarse grain size, which is used to feedback the abnormality of sand grains to the strategy module, as follows:

[0034] If the coarseness of the sand particles is higher than the first threshold of the coarseness, the sand particles are too coarse, and the feedback unit sends an over-coarse adjustment signal to the strategy matching unit; the strategy formulation unit is configured with an over-coarse adjustment strategy corresponding to each target diameter, and the strategy matching unit responds to the over-coarse adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-coarse adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-coarse control instruction based on the over-coarse adjustment strategy and sends it to the control module, the control module responds and parses the over-coarse control instruction, and adjusts the speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy.

[0035] As a preferred solution of the DCS sand making control system described in the present invention, wherein: the feedback unit is also configured with a second threshold value of coarse particle size. If the coarse particle size of the sand particles is lower than the second threshold value of the coarse particle size, the sand particles are too fine, and the feedback unit sends an over-fine adjustment signal to the strategy matching unit; the strategy formulation unit is also configured with an over-fine adjustment strategy corresponding to each target diameter. The strategy matching unit responds to the over-fine adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-fine adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-fine control instruction based on the over-fine adjustment strategy and sends it to the control module. The control module responds to and parses the over-fine control instruction, and adjusts the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-fine adjustment strategy.

[0036] As a preferred solution of the DCS sand making control system of the present invention, the over-coarse adjustment strategy and the over-fine adjustment strategy corresponding to each target diameter both include the rotation speed of the sand making machine and the feeding rate of the feeding system, and are both formulated by genetic algorithms; when formulating the over-coarse adjustment strategy corresponding to any target diameter by genetic algorithms, r(D b ) is greater than the second weight coefficient w2;

[0037] When the genetic algorithm is used to formulate a fine-tuning strategy corresponding to any target diameter, r(D s )’s weight coefficient is greater than the third weight coefficient w3.

[0038] In a second aspect, the present invention provides a DCS sand making intelligent control method, comprising the following steps:

[0039] S1: preset the target diameters of M sand grains, and set the corresponding sand making control strategy, over-coarse adjustment strategy, and over-fine adjustment strategy for the target diameter of each sand grain;

[0040] S2: Obtain the target diameter and match the sand making control strategy based on the target diameter;

[0041] S3: Control the speed of the sand making machine and the feeding rate of the feeding system based on the sand making control strategy; control the operation of the screening equipment based on the target diameter, and sample and calculate the average diameter and coarse particle size of the sand particles;

[0042] S4: judging whether the sand grains are too coarse or too fine based on the average diameter and coarse-grainedness of the sand grains, obtaining an over-coarse adjustment strategy if the sand grains are too coarse, and obtaining an over-fine adjustment strategy if the sand grains are too fine;

[0043] S5: Control the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy or the over-fine adjustment strategy.

[0044] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0045] By optimizing the sand making control strategy through genetic algorithm, the sand making machine can automatically adjust the speed and feeding rate according to the target diameter of the sand particles, which improves the accuracy of sand particle size control, helps to produce sand and gravel products that meet specific specifications, and reduces the product failure rate caused by particle size deviation. By optimizing the matching relationship between the speed of the sand making machine and the feeding rate of the feeding system, unnecessary energy consumption is avoided and production costs are reduced.

[0046] The present invention integrates a detection module and a feedback mechanism, and can dynamically adjust the sand making process parameters according to the actual particle size distribution of the sand particles, thereby ensuring the stability and consistency of the product quality, automatically executing the over-coarse or over-fine adjustment strategy, reducing the need for manual intervention, and improving the automation of the production line. A variety of sand target diameters and their corresponding sand making control strategies are preset for different engineering needs. The system can be flexibly switched according to actual needs, meeting the requirements of various application scenarios such as construction, roads, and water conservancy. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them:

[0048] Figure 1 A schematic diagram of the structure of the DCS sand making control system provided by the present invention;

[0049] Figure 2 A flow chart of the DCS sand making intelligent control method provided by the present invention;

[0050] Figure 3 A flow chart of the method for setting sand making control strategy through genetic algorithm provided by the present invention. DETAILED DESCRIPTION

[0051] The technical solution of the present invention is described in detail below through the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solution of the present invention, rather than limitations on the technical solution of the present invention. The embodiments of the present invention and the technical features in the embodiments may be combined with each other unless there is a conflict.

[0052] Example 1

[0053] This embodiment introduces a DCS sand making control system. Figure 1 , a DCS sand making control system, including a strategy module, a control module, and a detection module; wherein:

[0054] The strategy module is used to set the sand making control strategy, and match and adjust the sand making control strategy based on the target diameter of the sand particles and the coarse particle size of the sand particles;

[0055] The strategy module includes a strategy formulation unit, a strategy matching unit, and a control instruction unit;

[0056] The strategy formulation unit is used to set the sand making control strategy; the sand making control strategy includes the rotation speed of the sand making machine and the feeding rate of the feeding system; the strategy formulation unit presets the target diameters of M sand grains, where M is a positive integer, conducts sand making experiments and sets the sand making control strategy for the target diameters of M sand grains respectively through a genetic algorithm; presets the target diameters of multiple sand grains according to user needs or industry standards. These target diameters correspond to different specifications such as coarse sand, medium sand, and fine sand to meet the needs of different construction, road, water conservancy and other projects. Figure 3 , the method of setting the sand making control strategy for the target diameter of any sand grain through genetic algorithm is as follows:

[0057] S100: Set the population size, crossover probability, and mutation probability, and generate N individuals to form the first-generation population, where N is the population size; any individual contains a chromosome, corresponding to a sand-making control strategy; any chromosome contains two genes, corresponding to the speed of the sand-making machine and the feeding rate of the feeding system, respectively; first set the value range of the speed of the sand-making machine and the feeding rate of the feeding system, and then randomly generate individuals within the value range;

[0058] S200: Calculate the fitness of each individual, the formula is as follows:

[0059]

[0060] Where H represents the fitness of any individual; D represents the average diameter of sand particles; D0 represents the target diameter of sand particles; r(D b) represents the proportion of over-coarse sand particles to the total number of sand particles; the over-coarse sand particles are sand particles with a diameter higher than the over-coarse threshold; r(D s ) represents the proportion of overfine sand particles to the total number of sand particles; the overfine sand particles are sand particles with diameters lower than the overfine threshold; the overcoarse threshold and the overfine threshold are set by technicians in this field based on actual needs; by conducting the sand making experiment, sand making is carried out under the control of the sand making control strategy corresponding to each individual, the finished sand particles are sampled and the sand particle diameters are measured, and the average diameter D and r(D b )、r(D s ); w1 represents the first weight coefficient, w2 represents the second weight coefficient, w3 represents the third weight coefficient, α is the adjustment coefficient, ε is the adjustment factor, all of which are set by technical personnel in this field based on actual needs; based on the above fitness formula, while satisfying the sand particle diameter close to the target diameter, the excessively coarse sand particles and the excessively fine sand particles are reduced as much as possible, ensuring that the rotation speed of the sand making machine and the feeding rate of the feeding system are adapted and reasonably set, thereby ensuring high product quality; the adjustment coefficient and the adjustment factor ensure that the fitness value is within a reasonable range.

[0061] S300: performing selection operation, crossover operation, and mutation operation in sequence, and generating the next generation population;

[0062] S400: repeat steps S200-S300 until the highest fitness of all individuals in the population converges;

[0063] The individual with the highest fitness in the population is the individual closest to the optimal solution to the problem. The highest fitness convergence means that the highest fitness value in the population no longer changes significantly within two or more iteration cycles. During the iteration process, if the highest fitness converges, it is considered that the genetic algorithm has found the optimal solution, and the iteration can be stopped at this time. During the iteration process, the highest fitness in each generation of the population is recorded and compared with the highest fitness value of the previous generation. Set a change threshold for the highest fitness. If the change in the highest fitness value is less than the change threshold for several consecutive generations, it is considered that the highest fitness converges.

[0064] S500: The sand-making control strategy corresponding to the individual with the highest fitness is saved as the sand-making control strategy corresponding to the target diameter of the sand particles.

[0065] The strategy matching unit matches the sand making control strategy based on the target diameter of the sand particles; obtains the target diameter and sends a query instruction to the strategy formulation unit to obtain the sand making control strategy corresponding to the target diameter;

[0066] The control instruction unit generates a control instruction based on the sand making control strategy and sends it to the control module; the control instruction includes a speed control instruction and a feeding control instruction; wherein the speed control instruction is used to control the speed of the sand making machine, and the feeding control instruction is used to control the feeding rate of the feeding system;

[0067] The control module includes a sand making control unit and a feeding control unit;

[0068] The sand making control unit controls the speed of the sand making machine based on the sand making control strategy; specifically, responds to and analyzes the speed control instruction, obtains the speed of the sand making machine in the sand making control strategy and generates a motor drive signal, and controls and adjusts the speed of the sand making machine through the motor drive signal;

[0069] The feeding control unit controls the feeding rate of the feeding system based on the sand making control strategy; specifically, responds to and parses the feeding control instruction, obtains the feeding rate of the feeding system in the sand making control strategy and generates a pulse control signal, and controls and adjusts the feeding rate of the feeding system through the pulse control signal.

[0070] Fine-tuning the speed of the sand making machine according to the target diameter of the sand particles can optimize energy consumption and improve the quality of the finished sand. Adjusting the feed rate according to the real-time processing capacity of the sand making machine (which is positively correlated with the speed) can prevent the sand making machine from blocking and idling, and improve sand making efficiency.

[0071] The detection module is used to control the operation of the screening device, monitor the particle size distribution of the sand particles, and calculate the coarse particle size of the sand particles based on the diameter of the sand particles and the target diameter.

[0072] The detection module includes a screening control unit, a sand particle detection unit, and a feedback unit;

[0073] The screening control unit controls the operation of the screening equipment based on the target diameter and is used to measure the diameter of the sand particles; the screening control unit screens out sand particles with diameters that meet the requirements by controlling the screen combination and graded screening process of the screening machine. Screens of different specifications can intercept sand particles of different diameters, thereby retaining sand particles that meet the requirements and achieving accurate sand screening. The screening control unit samples the sand particles once every fixed sampling period, measures the diameter of each sand particle and calculates the mean as the average diameter of the sand particles;

[0074] The sand detection unit is used to calculate the coarseness of the sand particles, and the formula is as follows:

[0075] C=(1-r(D h ))·(D-D0);

[0076] Where C represents the coarse-grained size of sand particles; r(D h) represents the proportion of qualified sand particles to the total number of sand particles; the sand particle detection unit is configured with a first diameter threshold and a second diameter threshold, and the sand particles whose diameter is not lower than the first diameter threshold and not higher than the second diameter threshold are qualified sand particles; based on the above-mentioned coarse-grainedness calculation formula, the fewer the qualified sand particles, the greater the absolute value of the coarse-grainedness; at the same time, if the average diameter of the sand particles is higher than the target diameter, the coarse-grainedness is positive, and the more the average diameter of the sand particles exceeds the target diameter, the greater the coarse-grainedness; conversely, if the average diameter of the sand particles is lower than the target diameter, the coarse-grainedness is negative, and the more the average diameter of the sand particles is lower than the target diameter, the greater the negative value of the coarse-grainedness, that is, the smaller the coarse-grainedness.

[0077] The feedback unit is configured with a first threshold and a second threshold of coarse granularity, which are used to feedback the abnormality of sand grains to the strategy module, as follows:

[0078] If the coarseness of the sand particles is higher than the first threshold of the coarseness, the sand particles are too coarse, and the feedback unit sends an over-coarse adjustment signal to the strategy matching unit; the strategy formulation unit is configured with an over-coarse adjustment strategy corresponding to each target diameter, and the strategy matching unit responds to the over-coarse adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-coarse adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-coarse control instruction based on the over-coarse adjustment strategy and sends it to the control module, the control module responds and parses the over-coarse control instruction, and adjusts the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy;

[0079] If the coarse particle size of the sand particles is lower than the second threshold value of the coarse particle size, the sand particles are too fine, and the feedback unit sends an over-fine adjustment signal to the strategy matching unit; the strategy formulation unit is also configured with an over-fine adjustment strategy corresponding to each target diameter, and the strategy matching unit responds to the over-fine adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-fine adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-fine control instruction based on the over-fine adjustment strategy and sends it to the control module, the control module responds and parses the over-fine control instruction, and adjusts the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-fine adjustment strategy;

[0080] The over-coarse adjustment strategy and over-fine adjustment strategy corresponding to each target diameter include the rotation speed of the sand making machine and the feeding rate of the feeding system, and are both formulated by genetic algorithms. When formulating the over-coarse adjustment strategy corresponding to any target diameter by genetic algorithms, r(D b ) is greater than the second weight coefficient w2; and in addition to r(D b), the process of the genetic algorithm and other parts of the fitness function are the same as steps S100-S400; that is, only w2 in the fitness calculation formula involved in step S200 is adjusted to increase its value so as to improve the guiding role of the over-coarse sand particles in the fitness function and promote the over-coarse adjustment strategy explored by the genetic algorithm to focus more on solving the problem of over-coarse sand particles.

[0081] When the genetic algorithm is used to formulate a fine-tuning strategy corresponding to any target diameter, r(D s ) is greater than the third weight coefficient w3; and in addition to r(D s ), the process of the genetic algorithm and other parts of the fitness function are the same as steps S100-S400; that is, only w3 in the fitness calculation formula involved in step S200 is adjusted to increase its value so as to enhance the guiding role of the excessively fine sand particles in the fitness function and promote the excessively fine adjustment strategy explored by the genetic algorithm to focus more on solving the problem of excessively fine sand particles.

[0082] Based on the above feedback adjustment strategy, when the coarseness of the sand particles is too high or too low, the present invention can adjust the rotation speed of the sand making machine to optimize the crushing effect; then, the feeding rate of the feeding system is adjusted according to the processing capacity of the sand making machine to make the sand particles reach an ideal particle size distribution.

[0083] Example 2

[0084] Based on the same inventive concept as in Example 1, refer to Figure 2 This embodiment introduces a DCS sand making intelligent control method, which includes the following steps:

[0085] S1: preset the target diameters of M sand grains, and set the corresponding sand making control strategy, over-coarse adjustment strategy, and over-fine adjustment strategy for the target diameter of each sand grain;

[0086] Any sand making control strategy, over-coarse adjustment strategy, and over-fine adjustment strategy all include the rotation speed of the sand making machine and the feeding rate of the feeding system; the corresponding sand making control strategy, over-coarse adjustment strategy, and over-fine adjustment strategy are set for each target diameter of the sand particles through the genetic algorithm. The fitness functions are roughly the same, and the fitness function when setting the sand making control strategy is used as the benchmark. The difference is that when formulating the over-coarse adjustment strategy, the weight coefficient of the proportion of over-coarse sand particles in the fitness function is increased; when formulating the over-fine adjustment strategy, the weight coefficient of the proportion of over-fine sand particles in the fitness function is increased;

[0087] S2: Obtain the target diameter and match the sand making control strategy based on the target diameter;

[0088] S3: Control the rotation speed of the sand making machine and the feeding rate of the feeding system based on the sand making control strategy; control the operation of the screening equipment based on the target diameter, and sample and calculate the average diameter and coarse particle size of the sand particles;

[0089] S4: judging whether the sand grains are too coarse or too fine based on the average diameter and coarse-grainedness of the sand grains, obtaining an over-coarse adjustment strategy if the sand grains are too coarse, and obtaining an over-fine adjustment strategy if the sand grains are too fine;

[0090] Among them, the coarse-grainedness is calculated based on the proportion of qualified sand particles, the average diameter of the sand particles and the target diameter. The more the average diameter of the sand particles exceeds the target diameter, the greater the coarse-grainedness; the more the average diameter of the sand particles is lower than the target diameter, the greater the negative value of the coarse-grainedness, that is, the smaller the coarse-grainedness.

[0091] S5: Control the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy or the over-fine adjustment strategy.

[0092] The specific functions of the above modules are realized by referring to the relevant contents in the DCS sand making control system described in Example 1 and will not be elaborated here.

[0093] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0094] The embodiments of the present invention are described above in conjunction with the accompanying drawings, but the present invention is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of the present invention, ordinary technicians in this field can also make many forms without departing from the purpose and scope of protection of the present invention, which are all within the protection of the present invention.

Claims

1. A DCS sand making control system, characterized by: It includes a strategy module, a control module, and a detection module; among which: The strategy module is used to set the sand making control strategy, and match and adjust the sand making control strategy based on the target diameter of the sand particles and the coarse particle size of the sand particles; The strategy module includes a strategy formulation unit, a strategy matching unit, and a control instruction unit; wherein: The strategy formulation unit is used to set a sand making control strategy; the sand making control strategy includes the rotation speed of the sand making machine and the feeding rate of the feeding system; the strategy formulation unit presets M target diameters of sand grains, conducts sand making experiments, and sets sand making control strategies for the target diameters of M sand grains respectively through a genetic algorithm; The method for the strategy formulation unit to set the sand making control strategy for the target diameter of any sand grain by using a genetic algorithm is as follows: S100: Set the population size, crossover probability, and mutation probability, and generate N individuals to form the first-generation population, where N is the population size; any individual contains a chromosome, corresponding to a sand making control strategy; any chromosome contains two genes, corresponding to the rotation speed of the sand making machine and the feeding rate of the feeding system respectively; S200: Calculate the fitness of each individual; The calculation formula of the fitness is as follows: Where H represents the fitness of any individual; D represents the average diameter of sand particles; D0 represents the target diameter of sand particles; r(D b ) represents the proportion of over-coarse sand particles to the total number of sand particles; the over-coarse sand particles are sand particles with a diameter higher than the over-coarse threshold; r(D s ) represents the proportion of overfine sand particles to the total number of sand particles; the overfine sand particles are sand particles with a diameter lower than the overfine threshold; w1 represents the first weight coefficient, w2 represents the second weight coefficient, w3 represents the third weight coefficient, α represents the adjustment coefficient, and ε represents the adjustment factor; S300: performing selection operation, crossover operation, and mutation operation in sequence, and generating the next generation population; S400: repeat steps S200-S300 until the highest fitness of all individuals in the population converges; S500: saving the sand-making control strategy corresponding to the individual with the highest fitness as the sand-making control strategy corresponding to the target diameter of the sand particles; The strategy matching unit matches the sand making control strategy based on the target diameter of the sand particles; obtains the target diameter and sends a query instruction to the strategy formulation unit to obtain the sand making control strategy corresponding to the target diameter; The control instruction unit generates a control instruction based on the sand making control strategy and sends it to the control module; the control instruction includes a speed control instruction and a feeding control instruction; wherein the speed control instruction is used to control the speed of the sand making machine, and the feeding control instruction is used to control the feeding rate of the feeding system; The control module includes a sand making control unit and a feeding control unit; wherein: the sand making control unit controls the rotation speed of the sand making machine based on the sand making control strategy; the feeding control unit controls the feeding rate of the feeding system based on the sand making control strategy; The detection module is used to control the operation of the screening device, monitor the particle size distribution of the sand particles, and calculate the coarse particle size of the sand particles based on the diameter of the sand particles and the target diameter.

2. A DCS sand making control system as claimed in claim 1, characterized in that: The method of the sand making control unit controlling the speed of the sand making machine is as follows: responding to and parsing the speed control instruction, obtaining the speed of the sand making machine in the sand making control strategy and generating a motor drive signal, and controlling and adjusting the speed of the sand making machine through the motor drive signal; The method for the feeding control unit to control the feeding rate of the feeding system is as follows: respond to and analyze the feeding control instruction, obtain the feeding rate of the feeding system in the sand making control strategy and generate a pulse control signal, and control and adjust the feeding rate of the feeding system through the pulse control signal.

3. A DCS sand making control system as claimed in claim 2, characterized in that: The detection module includes a screening control unit and a sand particle detection unit; The screening control unit controls the operation of the screening device based on the target diameter and is used to measure the diameter of the sand particles; The sand detection unit is used to calculate the coarseness of the sand particles, and the formula is as follows: C=(1-r(D h ))·(D-D0); Where C represents the coarse-grained size of the sand; r(D h ) represents the proportion of qualified sand grains to the total number of sand grains; the sand grain detection unit is configured with a first diameter threshold and a second diameter threshold, and sand grains with a diameter not lower than the first diameter threshold and not higher than the second diameter threshold are qualified sand grains.

4. A DCS sand making control system as claimed in claim 3, characterized in that: The detection module further includes a feedback unit, which is configured with a first threshold of coarse granularity and is used to feedback abnormal sand grains to the strategy module, as follows: If the coarseness of the sand particles is higher than the first threshold of the coarseness, the sand particles are too coarse, and the feedback unit sends an over-coarse adjustment signal to the strategy matching unit; the strategy formulation unit is configured with an over-coarse adjustment strategy corresponding to each target diameter, and the strategy matching unit responds to the over-coarse adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-coarse adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-coarse control instruction based on the over-coarse adjustment strategy and sends it to the control module, the control module responds and parses the over-coarse control instruction, and adjusts the speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy.

5. A DCS sand making control system as claimed in claim 4, characterized in that: The feedback unit is also configured with a second threshold value of coarse grain size. If the coarse grain size of the sand particles is lower than the second threshold value of the coarse grain size, the sand particles are too fine, and the feedback unit sends an over-fine adjustment signal to the strategy matching unit; the strategy formulation unit is also configured with an over-fine adjustment strategy corresponding to each target diameter. The strategy matching unit responds to the over-fine adjustment signal, sends a query instruction to the strategy formulation unit, obtains the over-fine adjustment strategy corresponding to the target diameter and sends it to the control instruction unit; the control instruction unit generates an over-fine control instruction based on the over-fine adjustment strategy and sends it to the control module. The control module responds and parses the over-fine control instruction, and adjusts the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-fine adjustment strategy.

6. A DCS sand making control system as claimed in claim 5, characterized in that: The over-coarse adjustment strategy and over-fine adjustment strategy corresponding to each target diameter include the rotation speed of the sand making machine and the feeding rate of the feeding system, and are both formulated by genetic algorithms. When formulating the over-coarse adjustment strategy corresponding to any target diameter by genetic algorithms, r(D b ) is greater than the second weight coefficient w2; When the genetic algorithm is used to formulate a fine-tuning strategy corresponding to any target diameter, r(D s )’s weight coefficient is greater than the third weight coefficient w3.

7. A DCS sand making intelligent control method, implemented based on a DCS sand making control system according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: preset the target diameters of M sand grains, and set the corresponding sand making control strategy, over-coarse adjustment strategy, and over-fine adjustment strategy for the target diameter of each sand grain; S2: Obtain the target diameter and match the sand making control strategy based on the target diameter; S3: Control the rotation speed of the sand making machine and the feeding rate of the feeding system based on the sand making control strategy; control the operation of the screening equipment based on the target diameter, and sample and calculate the average diameter and coarse particle size of the sand particles; S4: judging whether the sand grains are too coarse or too fine based on the average diameter and coarse-grainedness of the sand grains, obtaining an over-coarse adjustment strategy if the sand grains are too coarse, and obtaining an over-fine adjustment strategy if the sand grains are too fine; S5: Control the rotation speed of the sand making machine and the feeding rate of the feeding system based on the over-coarse adjustment strategy or the over-fine adjustment strategy.

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