Intelligent material sealing gas device and method, and screw conveyor

Abstract

The present invention discloses an intelligent material sealing gas device and method, and a screw conveyor. The device and the screw conveyor include a shell, a main shaft is provided in the shell, and at least two disconnected spiral blades are provided on the main shaft, an interruption zone is provided between two adjacent spiral blades, and a barrier valve is provided in the interruption zone. The barrier valve includes a valve plate that can move up and down in the shell, and an actuator for controlling the up and down movement of the valve plate is connected to the barrier valve. A material level detector is also provided on the shell, and the actuator and the material level detector are connected to a controller. The device of the present invention has the advantages of being able to adapt to changes in material properties and production load changes, sustainably maintaining a gas-locked material seal, and having a good sealing effect. When used to construct a screw conveyor, it can not only improve production efficiency and meet production needs, but also can timely eliminate the backflow or leakage of gas and dust, and can effectively eliminate safety hazards, environmental pollution, heat loss and other adverse effects. It has high use value and good application prospects.

Description

Technical Field

[0001] The invention belongs to the technical field of material sealing gas blocking, and relates to an intelligent material sealing gas blocking device and method, and a screw conveyor. Background Art

[0002] As an important equipment widely used in building materials, chemical industry, metallurgy and other industries, the sealing performance of the inlet and outlet system of the rotary kiln directly affects safety, environment, quality and energy consumption. The traditional inlet and outlet system of the rotary kiln mainly uses a screw conveyor for material transportation. Due to the problems of easy wear of the seals, large wear and poor sealing performance of the screw conveyor, high-temperature gas, powdery materials, etc. leak out from the gaps. In particular, when the treated materials (such as oily sludge) are prone to form flammable and explosive high-temperature gases during the treatment process of the rotary kiln, it is easy to cause flash explosions due to the entry of air into the rotary kiln. Therefore, in order to ensure the continuity and stability of the production process, prevent the gas and dust in the kiln from direct contact with the external environment, and avoid safety hazards, environmental pollution, heat loss, etc., it is crucial to effectively seal the inlet and outlet of the rotary kiln.

[0003] In order to prevent gas and dust from flowing back or leaking from the rotary kiln through the screw conveyor, the screw conveyor is required to be able to lock air and seal during operation, specifically to prevent air from flowing into the rotary kiln through the screw conveyor, and to prevent dust and flammable and explosive gases from leaking out of the rotary kiln. Based on this, the existing screw conveyor mainly forms a material seal pile (material seal layer) by accumulating materials in the shell, thereby using the material seal pile (material seal layer) to isolate the gas inside and outside the rotary kiln. However, the existing screw conveyors with air-locking and sealing functions still have the following defects: (1) In order to solve the problem of excessive material accumulation leading to obstruction of material transportation, a feeding port and a discharge port are set on the shell. On the one hand, excessive material can be discharged from the discharge port, and on the other hand, the material can be added to the shell through the feeding port. However, these feeding ports and discharge ports set on the shell will also serve as the entrance of external air, resulting in poor sealing performance of the screw conveyor. It is difficult to effectively prevent external air from entering the shell through the feeding port and the discharge port, and eventually it is easy for air to enter the rotary kiln along with the material during the operation of the screw conveyor. At the same time, the setting of these feeding ports and discharge ports will also increase the structural complexity of the screw conveyor; (2) It is difficult to fill the cross section of the shell with materials by using shaftless spiral blades to rotate and push materials, and the sealing effect of the material seal pile formed is poor. In particular, when the characteristics of the material change and the production load changes, the sealing effect of the material seal pile is even worse, and it is difficult to continuously maintain the air-locking material seal, which is very likely to pose a safety hazard. It pollutes the environment and may also cause material waste and reduced production efficiency; (3) Although a sealing valve plate is provided at the outlet end of the shell to have a certain air-locking function, which may prevent dust pollution, it is difficult to form a material seal pile that fills the entire shell cross section. In particular, the sealing surface of the sealing valve plate and / or the shell outlet is prone to adhere to powder materials. During the material conveying process, external air can still enter the rotary kiln through the shell, making it difficult to continuously maintain the air-locking material seal. At the same time, the air-locking device constructed based on the sealing valve plate has a complex structure, a large volume, and poor compatibility with the rotary kiln. It is not only difficult to improve production efficiency, but also difficult to reduce production costs. In addition, the air-locking device constructed based on the sealing valve plate is also easily affected by the high temperature of the rotary kiln and often fails, resulting in high life cycle costs; (4) In the existing screw conveyor, it is impossible to obtain the filling status of the material in the pipeline in a timely and accurate manner, so it is difficult to timely and effectively isolate the gas inside and outside the rotary kiln, resulting in safety hazards, environmental pollution, heat loss and other adverse phenomena that are difficult to effectively avoid.

[0004] Therefore, obtaining an intelligent material sealing gas sealing device and method that can adapt to changes in material properties and production load changes, sustainably maintain gas locking and material sealing, and have good sealing effect is of great significance for timely and effective isolation of gas inside and outside the rotary kiln and promoting the widespread application of screw conveyors in rotary kilns. Summary of the invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide an intelligent material sealing airtightness device and method that can adapt to changes in material properties and changes in production load, sustainably maintain air-locking material seals, and have good sealing effects. A screw conveyor is also provided that includes an intelligent material sealing airtightness device.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0007] An intelligent material sealing and air-blocking device comprises a shell, a rotatable main shaft is arranged in the shell, at least two disconnected spiral blades are arranged on the main shaft, and an interruption zone is arranged between two adjacent spiral blades; the interruption zone is provided with a barrier valve for blocking the flow of materials in the shell, and the barrier valve comprises a valve plate which can move up and down in the shell; the barrier valve is connected to an actuator for controlling the up and down movement of the valve plate; a material level detector for detecting the material level in the cross section of the interruption zone (the material level in the cross section of the interruption zone is the material level of the material seal pile in the interruption zone, and the material seal pile in the interruption zone is the material pile forming the material seal in the interruption zone) is also arranged on the shell or around it, and the actuator and the material level detector are connected to a controller.

[0008] As a further improvement of the above technical solution: the barrier valve includes a valve body and a valve stem; the valve body is fixedly connected to the shell, specifically, the valve body is embedded in the shell; the valve plate is movably arranged in the valve body; one end of the valve stem is connected to the valve plate, and the other end is connected to the actuator.

[0009] As a further improvement of the above technical solution: the valve body is connected to the shell by flange connection or welding; a U-shaped groove is provided at the lower end of the valve plate, the U-shaped groove is sleeved around the main shaft, the gap width between the U-shaped groove and the main shaft is 1mm to 6mm, the outer contour of the valve plate is the same as the inner contour of the shell, or the outer contour of the valve plate is the contour remaining after a straight line cuts the inner contour of the shell cross section; when the shell is a cylinder, the outer contour of the valve plate is circular or circular arc sector; the actuator is connected to the valve stem by a connecting rod or a direct connection.

[0010] As a further improvement of the above technical solution: a flow detector for detecting the material flow is also provided at the front end of the shell feed port, and the flow detector is connected to the controller; the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector.

[0011] As a further improvement of the above technical solution: the input end of the main shaft is connected with a driving mechanism.

[0012] As a further improvement of the above technical solution: the actuator is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator; the actuator also includes a limit switch and a position sensor.

[0013] As a further improvement of the above technical solution: the controller is one of an embedded controller, a programmable logic controller, a distributed control system, and an artificial intelligence-based controller.

[0014] As a further improvement of the above technical solution: the material level detector is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary paddle type material level switch, a heavy hammer type material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector.

[0015] As a general technical concept, the present invention also provides an intelligent material sealing gas method of the above-mentioned intelligent material sealing gas device, comprising the following steps:

[0016] S1, close the barrier valve, start the spiral blade, and continuously input material into the shell to form a material seal pile in the interruption area;

[0017] S2, setting a preset threshold value of the material level detector, and using the material level detector to continuously detect the material level of the material seal pile;

[0018] S3. When the material level of the material seal pile detected by the material level detector is within the preset threshold range, the barrier valve is opened to allow the material to be continuously transported to the discharge port of the shell through the gap between the barrier valve and the shell; during the material transportation process, when the material level of the material seal pile detected by the material level detector is lower than the preset threshold, the controller sends an instruction to reduce the opening of the barrier valve, and the actuator continuously adjusts the opening of the barrier valve according to the instruction sent by the controller until the material level of the material seal pile reaches the preset threshold.

[0019] As a further improvement of the above technical solution: Step S3 also includes the following processing: during the material transportation process, the flow detector is used to detect the material flow at the shell feed port; when the flow detected by the flow detector is lower than the flow required by the system production, the controller issues an instruction to increase the opening of the barrier valve, and the actuator continuously adjusts the opening of the barrier valve according to the instruction issued by the controller to increase the material flow in the shell, and in the process of increasing the opening of the barrier valve, the material level of the material seal pile is not lower than a preset threshold.

[0020] As a general technical concept, the present invention also provides a screw conveyor, comprising a shell, a rotatable main shaft is provided in the shell, the main shaft is provided with at least two disconnected spiral blades, and an interruption zone is provided between two adjacent spiral blades; the interruption zone is provided with a barrier valve for blocking the flow of material in the shell, the barrier valve includes a valve plate that can move up and down in the shell; the barrier valve is connected to an actuator for controlling the up and down movement of the valve plate; the shell is also provided with a level detector for detecting the material level in the cross-section of the interruption zone, and the actuator and the level detector are connected to a controller.

[0021] As a further improvement of the above technical solution: the barrier valve includes a valve body and a valve stem; the valve body is installed on the shell, specifically, the valve body is embedded in the shell; the valve plate can be moved up and down in the valve body; one end of the valve stem is connected to the valve plate, and the other end is connected to the actuator; the valve body and the shell are connected by flange or welding; a U-shaped groove is provided at the lower end of the valve plate, and the U-shaped groove is sleeved around the main shaft, and the gap width between the U-shaped groove and the main shaft is 1mm~6mm, the outer contour of the valve plate is the same as the inner contour of the shell, or the outer contour of the valve plate is the contour remaining after the inner contour of the shell cross section is cut straightly; when the shell is a cylinder, the outer contour of the valve plate is circular or circular arc sector; the actuator is connected to the valve stem by a connecting rod or a direct connection.

[0022] As a further improvement of the above technical solution: a flow detector for detecting material flow is also provided at the front end of the shell feed port, and the flow detector is connected to the controller; the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector.

[0023] As a further improvement of the above technical solution: the input end of the main shaft is connected with a driving mechanism.

[0024] As a further improvement of the above technical solution: the actuator is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator; the actuator also includes a limit switch and a position sensor.

[0025] As a further improvement of the above technical solution: the controller is one of an embedded controller, a programmable logic controller, a distributed control system, and an artificial intelligence-based controller.

[0026] As a further improvement of the above technical solution: the material level detector is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary paddle type material level switch, a heavy hammer type material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector.

[0027] Compared with the prior art, the advantages of the present invention are:

[0028] (1) In the intelligent material sealing and air-blocking device of the present invention, a barrier valve for blocking the flow of materials is arranged in the interruption zone of the spiral blades. Specifically, a valve plate that can move up and down is arranged in the shell. Under the joint action of the spiral blades, the valve plate and the shell, the material can fill the entire cross-section or most of the cross-section of the interruption zone to form a material seal pile, and then the gas flow is effectively blocked under the action of the valve plate, the shell and the material seal pile. Even if there is a gap above the material seal pile, the barrier effect of the valve plate can be used to block the gas and dust inside and outside the rotary kiln. It has very excellent air tightness and can effectively prevent gas leakage or backflow. On this basis, by setting a material level detector for detecting the material level in the cross-section of the interruption zone, the material level of the material seal pile can be obtained in real time, and then the controller can issue instructions in time and use the actuator to adjust the opening of the barrier valve, specifically, the distance between the bottom of the valve plate and the inner wall of the shell. Therefore, during the material transportation process, it can not only adapt to changes in material properties and production load changes, but also realize continuous material sealing and air-blocking of the shell. The material seal gas sealing device of the present invention has the advantages of being able to adapt to changes in material properties and changes in production load, sustainably maintaining a gas-locked material seal, and having a good sealing effect. When it is used to construct a screw conveyor, it can not only improve production efficiency and meet production needs, but also can timely eliminate the backflow or leakage of gas and dust. Therefore, when the screw conveyor is used for feeding or discharging a rotary kiln, it can effectively eliminate safety hazards, environmental pollution, heat loss and other adverse effects, and has high use value and good application prospects.

[0029] (2) In the intelligent material seal gas blocking method of the present invention, during the process of continuously inputting materials into the shell, the material level of the material seal pile is continuously detected by the material level detector to obtain the real-time material level of the material seal pile. When the material level of the material seal pile detected by the material level detector is within the preset threshold range, the barrier valve is opened to allow the material to be continuously transported to the discharge port of the shell through the gap between the barrier valve and the shell (specifically, the gap between the bottom of the valve plate and the shell); when the material level of the material seal pile detected by the material level detector is lower than the preset threshold, the material level data is transmitted to the controller, which, after processing, sends the data to the execution unit. When the actuator sends a command to reduce the opening of the barrier valve, the actuator can continuously adjust the opening of the barrier valve after receiving the command until the material level of the material seal pile is within the target range, thereby continuously maintaining the material seal airtightness during the material transportation process, so that the shell body always maintains very good airtightness; in particular, during the material transportation process, the material level of the material seal pile is continuously detected by the material level detector, so that the material filling degree changes caused by changes in material properties and changes in production load can be obtained in time, so that the opening of the barrier valve can be adjusted in time, which is conducive to ensuring that the shell body always maintains very good airtightness.

[0030] (3) In the intelligent material sealing and air blocking method of the present invention, during the process of continuously inputting materials into the shell, a flow meter is used to detect the material flow entering the shell, and the real-time flow of the material can be obtained. Therefore, while ensuring that the shell always maintains very good airtightness, the opening of the barrier valve can be increased, thereby increasing the material feed rate, which is beneficial to improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to make the purpose, technical solution and advantages of the embodiments of the present invention more clear, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention.

[0032] Figure 1 It is a schematic structural diagram of the material sealing gas device in Example 1 of the present invention.

[0033] Legend:

[0034] 1. Screw conveyor; 11. Shell; 12. Screw blade; 13. Main shaft; 2. Barrier valve; 21. Valve plate; 3. Actuator; 4. Controller; 5. Material level detector; 6. Flange. DETAILED DESCRIPTION

[0035] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0036] In the description of the present invention, it should be noted that the terms "center", "up", "down", "front", "back", "left", "right", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, or are the directions or positional relationships in which the inventive product is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0037] Example 1

[0038] like Figure 1As shown, the intelligent material sealing and air-blocking device of this embodiment includes a housing 11, a rotatable main shaft 13 is provided in the housing 11, at least two disconnected spiral blades 12 are provided on the main shaft 13, and the spiral blades 12 are wound on the main shaft 13, and an interruption zone is provided between two adjacent spiral blades 12; the interruption zone is provided with a blocking valve 2 for blocking the flow of materials in the housing 11, the blocking valve 2 includes a valve plate 21 that can move up and down in the housing 11, and an actuator 3 for controlling the valve plate 21 to move up and down is connected to the blocking valve 2, and a material level detector 5 for detecting the material level of the material seal pile in the interruption zone is also provided on the housing 11, and the actuator 3 and the material level detector 5 are connected to the controller 4. In another embodiment, the material level detector 5 can also be arranged around the housing 11.

[0039] In this embodiment, a barrier valve for blocking the flow of materials is provided in the interruption zone of the spiral blades in the shell. Specifically, a valve plate that can move up and down is provided in the shell. Under the joint action of the spiral blades, the valve plate and the shell, the material can fill the entire cross section or most of the cross section to form a material seal pile, and then the gas flow is effectively blocked under the action of the valve plate, the shell and the material seal pile. Even if there is a gap above the material seal pile, the gas and dust inside and outside the rotary kiln can be blocked under the blocking action of the valve plate. It has very excellent airtightness and can effectively prevent gas leakage or backflow. Specifically, when the materials enter the shell, they are accumulated in the shell under the action of gravity. At the same time, with the rotation of the spiral blades, the materials are transferred to the interruption zone. When the materials reach the barrier valve, in the interruption zone of the spiral blades, the materials cannot be transported by relying on the rotation of the spiral blades. The materials that are not transported will accumulate to form a material pile (i.e., a material seal pile). As time goes by, more and more materials will accumulate. Although there is no direct push from the spiral blades, the materials will still be subject to the pressure of the materials above and around them, and this pressure will prompt the materials to move toward the outlet. In other parts of the shell, the spiral blades generate thrust by rotating to push the material forward; there are no blades in the interruption area of ​​the spiral blades, but the material in this area will still be indirectly affected by the pushing action of the front blades; the shell constrains the material and limits the lateral movement of the material, which allows the material to form a material seal pile in the interruption area of ​​the spiral blade, thereby filling the cross-section of the shell, and can fill the entire cross-section, completely blocking the gas flow and preventing gas leakage or backflow; on this basis, by setting up a level detector for detecting the material level of the material seal pile in the interruption area, the material level of the material seal pile can be obtained in real time, and then the controller can issue instructions in time and use the actuator to adjust the opening of the barrier valve. Therefore, in the process of material transportation, it can not only adapt to changes in material properties and production load changes, but also realize continuous sealing and gas locking of the shell. The intelligent material seal and air-locking device of the present invention has the advantages of being able to adapt to changes in material properties and changes in production load, sustainably maintaining air-locking and material seals, and having good sealing effects. When it is used to construct a screw conveyor, it can not only improve production efficiency and meet production needs, but also can timely eliminate the backflow or leakage of gas and dust. Therefore, when the screw conveyor is used for feeding or discharging a rotary kiln, it can effectively eliminate safety hazards, environmental pollution, heat loss and other adverse effects, and has high use value and good application prospects.

[0040] In the present invention, the material seal gas is formed by the joint action of the spiral blades, the valve plate and the shell to form a material seal pile, thereby blocking or restricting the flow of gas through the physical existence of the material.

[0041] In this embodiment, the input end of the main shaft 13 is connected to a driving mechanism (not shown in the figure).

[0042] In this embodiment, the barrier valve 2 is a gate valve or a gate valve, wherein the barrier valve 2 includes a valve body (not marked in the figure), a valve plate 21 and a valve stem (not marked in the figure); the valve body is mounted on the housing 11, specifically: the valve body and the housing 11 are connected by a flange 6, and in another embodiment, the valve body and the housing 11 are connected by welding. In another embodiment, the barrier valve 2 is a gate valve.

[0043] In this embodiment, the valve plate 21 is movably arranged in the valve body and can move up and down in the valve body, wherein a U-shaped groove is provided at the lower end of the valve plate 21, and the U-shaped groove is sleeved around the main shaft 13, and the gap width between the U-shaped groove and the main shaft 13 is 1mm to 6mm, specifically, the gap width is 3mm, and the outer contour of the valve plate 21 is the same as the inner contour of the shell 11. Specifically, in this embodiment, the shell 11 is a cylinder, and the outer contour of the valve plate 21 is a circle. In another embodiment, the outer contour of the valve plate 21 is the contour remaining after the inner contour of the cross section of the shell 11 is cut by a straight line.

[0044] In this embodiment, one end of the valve stem is connected to the valve plate 21, and the other end is connected to the actuator 3. Specifically, the actuator 3 and the valve stem are connected by a connecting rod to ensure force transmission and position consistency. In another embodiment, the actuator 3 and the valve stem are connected by a direct connection.

[0045] In this embodiment, a flow detector (not shown in the figure) for detecting the amount of material is provided at the front end of the feed port of the shell 11. The flow detector is connected to the controller 4, wherein the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector. Specifically, the flow detector used in this embodiment is an ultrasonic flow detector.

[0046] In the present invention, when selecting a flow meter, factors such as fluid characteristics, usage scenarios, flow range, measurement accuracy, reliability, and maintenance requirements should be comprehensively considered. Ultrasonic flow meters use the speed and time difference of ultrasonic waves propagating in the fluid to measure the flow rate of the fluid. They have the advantages of high precision, fast response speed, low maintenance cost, wide application range, and contactless measurement. The Coriolis mass flow meter is a direct mass flow meter made by using the principle that the fluid is in a rotating system while in linear motion, generating a Coriolis force proportional to the mass flow rate. It has the advantages of high accuracy, wide measurement range, insensitivity to fluid viscosity, no upstream and downstream straight pipe section requirements, and can perform multi-parameter measurement. Weighing mass flow detectors usually use a resistance strain type weighing sensor based on an elastomer (elastic element, sensitive beam) that produces elastic deformation under the action of external force. When the fluid passes through the flow detector, the elastomer will be deformed, and the resistance strain gauge attached to the surface will also be deformed. The resistance value of the resistance strain gauge changes with the deformation. By measuring this resistance change and converting it into an electrical signal (voltage or current), the mass flow rate of the fluid can be obtained. It has the advantages of directly measuring mass flow, high accuracy, strong stability, and a wide range of applications.

[0047] In this embodiment, the actuator 3 is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator. Specifically, the actuator 3 is an electric actuator.

[0048] In the present invention, when selecting an actuator, it is necessary to comprehensively consider multiple factors such as application requirements, working conditions, action characteristics, control signals, safety, reliability, maintainability, cost-effectiveness, supplier support, etc. to ensure that the selected actuator can meet the needs of specific applications. Pneumatic actuator: receives pneumatic signals (such as compressed air) and converts them into linear or rotational motion through the movement of the piston or diaphragm in the cylinder; suitable for occasions requiring fast response and simple control, as well as environments where explosive gases may exist. Electric actuator: uses electrical energy to drive the motor, and the rotation of the motor is converted into linear motion of the valve stem through gears or threaded mechanisms; provides more precise control and feedback, and is suitable for occasions requiring complex control logic and remote monitoring. Hydraulic actuator: uses the pressure of hydraulic oil to generate force and motion through the hydraulic cylinder; suitable for high torque and high power application scenarios.

[0049] In this embodiment, the actuator 3 is also equipped with a limit switch and a position sensor for feeding back the actual position of the valve plate to the controller to form a closed-loop control to ensure that the valve plate stays accurately at the desired position.

[0050] In this embodiment, the barrier valve further includes a handwheel mechanism, which serves as a backup. When the power supply or gas source fails, the operator can manually control the valve plate.

[0051] In this embodiment, the controller 4 is one of an embedded controller, a programmable logic controller (PLC), a distributed control system (DCS), and an artificial intelligence-based controller. Specifically, the controller 4 is a programmable logic controller.

[0052] In the present invention, when selecting a controller, factors such as application scenarios, functional requirements, compatibility, system stability, processing power, storage capacity, communication interface, power requirements, scalability, security, and cost need to be considered to ensure that the selected controller can meet the needs of specific applications. Embedded controller: This type of controller is usually based on an embedded system, integrating computer hardware and software to form a dedicated computer system. They usually have a high-performance microprocessor or microcontroller as the core, running specially designed control software; embedded intelligent controllers are widely used in various devices that require intelligent control, such as industrial automation control systems, smart phones, smart home devices, etc. Programmable logic controller (PLC): PLC is a digital computing and operating electronic system designed specifically for industrial environments. It uses a programmable memory to store instructions for performing operations such as logical operations, sequential control, timing, counting, and arithmetic operations, and controls various types of mechanical equipment or production processes through digital or analog input / output; PLC has powerful logical control capabilities and reliability and is widely used in the field of industrial automation. Distributed Control System (DCS): Although DCS itself is not a single intelligent controller, it contains multiple intelligent controller nodes, which are connected together through a network to jointly control the entire industrial process; DCS is highly flexible and scalable and can adapt to complex industrial control system requirements. Each node can be regarded as an intelligent controller responsible for controlling a part of the industrial process. Artificial Intelligence-based Controllers: With the development of artificial intelligence technology, more and more intelligent controllers have begun to adopt artificial intelligence technology, such as fuzzy control, neural network control, genetic algorithms, etc. These controllers can automatically adjust control strategies based on real-time data and empirical knowledge to achieve more intelligent and adaptive control; artificial intelligence-based controllers have significant advantages in complex system control, fault diagnosis and predictive maintenance. The above classifications are not mutually exclusive, and an intelligent controller may have multiple technical features at the same time. For example, a PLC may use an artificial intelligence-based control algorithm.

[0053] In this embodiment, the material level detector 5 is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary level switch, a heavy hammer material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector. Specifically, the material level detector 5 is a radar material level detector.

[0054] In the present invention, when selecting a material level detector, it is necessary to comprehensively consider factors such as the specific pipeline environment, material characteristics, and measurement requirements. For example, if the material in the pipeline is prone to clogging, a non-contact sensor may need to be selected; if high-precision measurement is required, a sensor with more stable performance needs to be selected. At the same time, factors such as the installation and maintenance costs of the sensor, as well as compatibility with other equipment, also need to be considered. Radar level detector: Uses high-frequency pulses or continuous wave radar signals to measure the distance to the surface of the material. It can be used in complex environments, such as high temperature, high pressure, or dusty environments. Capacitive level detector: Uses capacitance changes to detect the presence of a material or its height, and is suitable for powder and granular materials. Ultrasonic level detector: Emits ultrasonic pulses and measures the echo time to calculate the distance to the material surface, and is suitable for non-corrosive and non-explosive environments. Rotary paddle level switch: When the material contacts the rotating blade, it prevents it from rotating, triggering a switch signal, which is usually used to monitor whether the material level has reached a specific high or low point. Hammer-type level detector: It uses a drooping hammer to physically contact the surface of the material and measure the distance the hammer falls. Although it is simple and reliable, it may require regular maintenance. Radio frequency admittance level detector: Based on radio frequency admittance technology, it can distinguish between materials and air, and can accurately measure even in the presence of wall hanging or adhered materials. Nuclear radiation level detector: It uses gamma rays or neutron rays to penetrate the material and determines the material level by measuring the attenuation of the rays. Because it involves radioactive materials, its use is strictly regulated.

[0055] A material sealing gas sealing method of the intelligent material sealing gas sealing device of the present embodiment comprises the following steps:

[0056] S1, close the barrier valve 2, start the spiral blade 12, and continuously input the material into the shell 11 to form a material seal pile in the cross section of the interruption area;

[0057] S2, setting a preset threshold value of the material level detector 5, and using the material level detector 5 to continuously detect the material level of the material seal pile;

[0058] S3. When the material level of the material seal pile detected by the material level detector 5 is within the preset threshold range, the barrier valve 2 is opened to allow the material to be continuously transported to the discharge port of the shell 11 through the gap between the barrier valve 2 and the shell 11; during the material transportation process, when the material level of the material seal pile detected by the material level detector 5 is lower than the preset threshold, the controller 4 issues an instruction to reduce the opening of the barrier valve, and the actuator 3 continuously adjusts the opening of the barrier valve 2 according to the instruction issued by the controller 4 until the material level of the material seal pile reaches the preset threshold.

[0059] In the material seal and air-locking method of the present invention, in the process of continuously inputting materials into the shell, the material level of the material seal pile is continuously detected by the material level detector to obtain the real-time material level of the material seal pile. When the material level of the material seal pile detected by the material level detector is within the preset threshold range, the barrier valve is opened to allow the material to be continuously transported to the discharge port of the shell through the gap between the barrier valve and the shell 11; when the material level of the material seal pile detected by the material level detector is lower than the preset threshold, the material level data is transmitted to the controller, and after being processed by the controller, an instruction to reduce the opening of the barrier valve is sent to the actuator. After receiving the instruction, the actuator can continuously adjust the opening of the barrier valve until the material level of the material seal pile is within the target range, thereby continuously maintaining the material seal and air-locking during the material transportation process, so that the shell always maintains very good air tightness; in particular, in the material transportation process, the material level of the material seal pile is continuously detected by the material level detector, so that the material filling degree change caused by the change of material properties and the change of production load can be timely obtained, so that the opening of the barrier valve can be adjusted in time, which is conducive to ensuring that the shell always maintains very good air tightness.

[0060] In this embodiment, step S3 also includes the following processing: during the material transportation process, a flow meter is used to detect the material flow entering the shell feed port; when the flow detected by the flow meter is lower than the material flow required by the system production, the controller 4 issues an instruction to increase the opening of the barrier valve, and the actuator 3 continuously adjusts the opening of the barrier valve 2 according to the instruction issued by the controller 4 to increase the material flow in the shell. When the opening of the barrier valve is increased, the material level of the material seal pile is not lower than the preset threshold, and priority is given to ensuring that the material level is maintained at the preset threshold.

[0061] In the material sealing and air blocking method of the present invention, during the process of continuously inputting materials into the shell, a flow detector is used to detect the material flow entering the shell, so as to obtain the real-time flow of the material. Thus, while ensuring that the shell always maintains very good airtightness, the opening of the barrier valve can be increased, thereby increasing the material feed rate, which is beneficial to improving production efficiency.

[0062] In the present invention, the material level detector and the flow detector continuously feed back the latest data to the controller. According to the rule of giving priority to ensuring that the material level maintains the preset threshold and adjusting the flow rate to the system production requirement as much as possible, the controller can continuously adjust the opening of the barrier valve according to the feedback data, so as to continuously and effectively prevent the gas flow inside and outside the rotary kiln. Furthermore, the controller can be used to automatically adjust the opening of the barrier valve to ensure that the material level in the shell is always maintained at a predetermined level and the material flow rate meets the system production requirements as much as possible. This method can ensure the material sealing performance of the shell, improve production efficiency and automation, and reduce the need for manual intervention.

[0063] Example 2

[0064] The screw conveyor 1 of this embodiment includes a shell 11, a rotatable main shaft 13 is provided in the shell 11, at least two disconnected spiral blades 12 are provided on the main shaft 13, and the spiral blades 12 are wound around the main shaft 13, and an interruption zone is provided between two adjacent spiral blades; the interruption zone is provided with a barrier valve 2 for adjusting the material flow in the shell 11, the barrier valve 2 includes a valve plate 21 that can move up and down in the shell 11, and an actuator 3 for controlling the upward and downward movement of the valve plate 21 is connected to the barrier valve 2. The shell 11 is also provided with a level detector 5 for detecting the material level of the material seal pile in the interruption zone, and the actuator 3 and the level detector 5 are connected to the controller 4.

[0065] In this embodiment, the input end of the main shaft 13 is connected to a driving mechanism (not shown in the figure).

[0066] In this embodiment, the barrier valve 2 is a gate valve or a gate valve, wherein the barrier valve 2 includes a valve body (not marked in the figure), a valve plate 21 and a valve stem (not marked in the figure); the valve body is fixedly connected to the housing 11, specifically: the valve body and the housing 11 are connected by a flange 6, and in another embodiment, the valve body and the housing 11 are connected by welding. In another embodiment, the barrier valve 2 is a gate valve.

[0067] In this embodiment, the valve plate 21 is movably arranged in the valve body, wherein a U-shaped groove is provided at the lower end of the valve plate 21, and the U-shaped groove is sleeved around the main shaft 13, and the gap width between the U-shaped groove and the main shaft 13 is 1mm to 6mm, specifically, the gap width is 3mm, and the outer contour of the valve plate 21 is the same as the inner contour of the shell 11. Specifically, in this embodiment, the shell 11 is a cylinder, and the outer contour of the valve plate 21 is a circle. In another embodiment, the outer contour of the valve plate 21 is the contour remaining after the inner contour of the cross section of the shell 11 is cut straightly.

[0068] In this embodiment, one end of the valve stem is connected to the valve plate 21, and the other end is connected to the actuator 3. Specifically, the actuator 3 and the valve stem are connected by a connecting rod to ensure force transmission and position consistency. In another embodiment, the actuator 3 and the valve stem are connected by a direct connection.

[0069] In this embodiment, a flow detector for detecting the material flow is provided at the front end of the feed port of the shell 11, and the flow detector is connected to the controller 4, wherein the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector. Specifically, the flow detector used in this embodiment is an ultrasonic flow detector.

[0070] In the present invention, when selecting a flow meter, factors such as fluid characteristics, usage scenarios, flow range, measurement accuracy, reliability, and maintenance requirements should be comprehensively considered. Ultrasonic flow meters use the speed and time difference of ultrasonic waves propagating in the fluid to measure the flow rate of the fluid. They have the advantages of high precision, fast response speed, low maintenance cost, wide application range, and contactless measurement. The Coriolis mass flow meter is a direct mass flow meter made by using the principle that the fluid is in a rotating system while in linear motion, generating a Coriolis force proportional to the mass flow rate. It has the advantages of high accuracy, wide measurement range, insensitivity to fluid viscosity, no upstream and downstream straight pipe section requirements, and can perform multi-parameter measurement. Weighing mass flow detectors usually use a resistance strain type weighing sensor based on an elastomer (elastic element, sensitive beam) that produces elastic deformation under the action of external force. When the fluid passes through the flow detector, the elastomer will be deformed, and the resistance strain gauge attached to the surface will also be deformed. The resistance value of the resistance strain gauge changes with the deformation. By measuring this resistance change and converting it into an electrical signal (voltage or current), the mass flow rate of the fluid can be obtained. It has the advantages of directly measuring mass flow, high accuracy, strong stability, and a wide range of applications.

[0071] In this embodiment, the actuator 3 is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator. Specifically, the actuator 3 is an electric actuator.

[0072] In the present invention, when selecting an actuator, it is necessary to comprehensively consider multiple factors such as application requirements, working conditions, action characteristics, control signals, safety, reliability, maintainability, cost-effectiveness, supplier support, etc. to ensure that the selected actuator can meet the needs of specific applications. Pneumatic actuator: receives pneumatic signals (such as compressed air) and converts them into linear or rotational motion through the movement of the piston or diaphragm in the cylinder; suitable for occasions requiring fast response and simple control, as well as environments where explosive gases may exist. Electric actuator: uses electrical energy to drive the motor, and the rotation of the motor is converted into linear motion of the valve stem through gears or threaded mechanisms; provides more precise control and feedback, and is suitable for occasions requiring complex control logic and remote monitoring. Hydraulic actuator: uses the pressure of hydraulic oil to generate force and motion through the hydraulic cylinder; suitable for high torque and high power application scenarios.

[0073] In this embodiment, the actuator 3 is also equipped with a limit switch and a position sensor for feeding back the actual position of the valve plate to the controller to form a closed-loop control to ensure that the valve plate stays accurately at the desired position.

[0074] In this embodiment, the barrier valve further includes a handwheel mechanism, wherein the handwheel mechanism serves as a backup, and when the power supply or gas source fails, the operator can manually control the valve plate.

[0075] In this embodiment, the controller 4 is one of an embedded controller, a programmable logic controller (PLC), a distributed control system (DCS), and an artificial intelligence-based controller. Specifically, the controller 4 is a programmable logic controller.

[0076] In the present invention, when selecting a controller, factors such as application scenarios, functional requirements, compatibility, system stability, processing power, storage capacity, communication interface, power requirements, scalability, security, and cost need to be considered to ensure that the selected controller can meet the needs of specific applications. Embedded controller: This type of controller is usually based on an embedded system, integrating computer hardware and software to form a dedicated computer system. They usually have a high-performance microprocessor or microcontroller as the core, running specially designed control software; embedded intelligent controllers are widely used in various devices that require intelligent control, such as industrial automation control systems, smart phones, smart home devices, etc. Programmable logic controller (PLC): PLC is a digital computing and operating electronic system designed specifically for industrial environments. It uses a programmable memory to store instructions for performing operations such as logical operations, sequential control, timing, counting, and arithmetic operations, and controls various types of mechanical equipment or production processes through digital or analog input / output; PLC has powerful logical control capabilities and reliability and is widely used in the field of industrial automation. Distributed Control System (DCS): Although DCS itself is not a single intelligent controller, it contains multiple intelligent controller nodes, which are connected together through a network to jointly control the entire industrial process; DCS is highly flexible and scalable and can adapt to complex industrial control system requirements. Each node can be regarded as an intelligent controller responsible for controlling a part of the industrial process. Artificial Intelligence-based Controllers: With the development of artificial intelligence technology, more and more intelligent controllers have begun to adopt artificial intelligence technology, such as fuzzy control, neural network control, genetic algorithms, etc. These controllers can automatically adjust control strategies based on real-time data and empirical knowledge to achieve more intelligent and adaptive control; artificial intelligence-based controllers have significant advantages in complex system control, fault diagnosis and predictive maintenance. The above classifications are not mutually exclusive, and an intelligent controller may have multiple technical features at the same time. For example, a PLC may use an artificial intelligence-based control algorithm.

[0077] In this embodiment, the material level detector 5 is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary level switch, a heavy hammer material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector. Specifically, the material level detector 5 is a radar material level detector.

[0078] In the present invention, when selecting a material level detector, it is necessary to comprehensively consider factors such as the specific pipeline environment, material characteristics, and measurement requirements. For example, if the material in the pipeline is prone to clogging, a non-contact sensor may need to be selected; if high-precision measurement is required, a sensor with more stable performance needs to be selected. At the same time, factors such as the installation and maintenance costs of the sensor, as well as compatibility with other equipment, also need to be considered. Radar level detector: Uses high-frequency pulses or continuous wave radar signals to measure the distance to the surface of the material. It can be used in complex environments, such as high temperature, high pressure, or dusty environments. Capacitive level detector: Uses capacitance changes to detect the presence of a material or its height, and is suitable for powder and granular materials. Ultrasonic level detector: Emits ultrasonic pulses and measures the echo time to calculate the distance to the material surface, and is suitable for non-corrosive and non-explosive environments. Rotary paddle level switch: When the material contacts the rotating blade, it prevents it from rotating, triggering a switch signal, which is usually used to monitor whether the material level has reached a specific high or low point. Hammer-type level detector: It uses a drooping hammer to physically contact the surface of the material and measure the distance the hammer falls. Although it is simple and reliable, it may require regular maintenance. Radio frequency admittance level detector: Based on radio frequency admittance technology, it can distinguish between materials and air, and can accurately measure even in the presence of wall hanging or adhered materials. Nuclear radiation level detector: It uses gamma rays or neutron rays to penetrate the material and determines the material level by measuring the attenuation of the rays. Because it involves radioactive materials, its use is strictly regulated.

[0079] The above embodiments are only preferred implementations of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. An intelligent material sealing gas device, characterized in that: The invention comprises a shell (11), wherein a rotatable main shaft (13) is arranged in the shell (11), and at least two disconnected spiral blades (12) are arranged on the main shaft (13), and an interruption zone is arranged between two adjacent spiral blades (12); the interruption zone is provided with a barrier valve (2) for blocking the flow of material in the shell (11), and the barrier valve (2) comprises a valve plate (21) that can move up and down in the shell (11); the barrier valve (2) is connected to an actuator (3) for controlling the upward and downward movement of the valve plate (21); a material level detector (5) for detecting the material level in the cross section of the interruption zone is also arranged on or around the shell (11); the actuator (3) and the material level detector (5) are connected to a controller (4).

2. The intelligent material sealing gas blocking device according to claim 1 is characterized in that: The barrier valve (2) further comprises a valve body and a valve stem; the valve body is embedded in the housing (11); the valve plate (21) is arranged in the valve body so as to be movable up and down; one end of the valve stem is connected to the valve plate (21), and the other end is connected to the actuator (3).

3. The intelligent material sealing gas blocking device according to claim 2 is characterized in that: The valve body is connected to the shell (11) via a flange (6) or by welding; a U-shaped groove is provided at the lower end of the valve plate (21), the U-shaped groove is sleeved around the main shaft (13), the width of the gap between the U-shaped groove and the main shaft (13) is 1 mm to 6 mm, the outer contour of the valve plate (21) is the same as the inner contour of the shell (11), or the outer contour of the valve plate (21) is the contour remaining after the inner contour of the cross section of the shell (11) is cut straightly; when the shell (11) is a cylinder, the outer contour of the valve plate (21) is circular or circular arc sector-shaped.

4. The intelligent material sealing gas sealing device according to claim 3 is characterized in that: A flow detector for detecting material flow is provided at the front end of the feed port of the shell (11), and the flow detector is connected to the controller (4); the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector.

5. The intelligent material sealing gas sealing device according to claim 4 is characterized in that: The actuator (3) is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator; the actuator (3) further comprises a limit switch and a position sensor; The controller (4) is one of an embedded controller, a programmable logic controller, a distributed control system, and an artificial intelligence-based controller; The material level detector (5) is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary paddle type material level switch, a heavy hammer type material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector.

6. An intelligent material sealing gas method using the intelligent material sealing gas device as claimed in claim 5, characterized in that: The following steps are involved: S1, closing the barrier valve (2), starting the spiral blade (12), continuously inputting material into the housing (11), and forming a material seal pile in the interruption area; S2, setting a preset threshold value of the material level detector (5), and using the material level detector (5) to continuously detect the material level of the material seal pile; S3. When the material level of the material seal pile detected by the material level detector (5) is within a preset threshold range, the barrier valve (2) is opened to allow the material to be continuously transported to the discharge port of the shell (11) through the gap between the barrier valve (2) and the shell (11); during the material transportation process, when the material level of the material seal pile detected by the material level detector (5) is lower than the preset threshold, the controller (4) issues an instruction to reduce the opening of the barrier valve (2), and the actuator (3) continuously adjusts the opening of the barrier valve (2) according to the instruction issued by the controller (4) until the material level of the material seal pile reaches the preset threshold.

7. The intelligent material sealing gas blocking method according to claim 6, characterized in that: Step S3 also includes the following processing: during the material conveying process, the flow rate detector is used to detect the material flow rate entering the shell (11); when the material flow rate detected by the flow rate detector is lower than the material flow rate required by the system production, the controller (4) issues an instruction to increase the opening of the barrier valve (2), and the actuator (3) continuously adjusts the opening of the barrier valve (2) according to the instruction issued by the controller (4) to increase the material flow rate in the shell (11); in the process of increasing the opening of the barrier valve (2), the material level of the material seal pile is not lower than a preset threshold value.

8. A screw conveyor, characterized in that: The invention comprises a shell (11), wherein a rotatable main shaft (13) is arranged in the shell (11), and at least two disconnected spiral blades (12) are arranged on the main shaft (13), and an interruption zone is arranged between two adjacent spiral blades (12); the interruption zone is provided with a barrier valve (2) for blocking the flow of materials in the shell (11), and the barrier valve (2) comprises a valve plate (21) that can move up and down in the shell (11); the barrier valve (2) is connected to an actuator (3) for controlling the upward and downward movement of the valve plate (21); a material level detector (5) for detecting the material level of the material seal pile in the interruption zone is also arranged on or around the shell (11); the actuator (3) and the material level detector (5) are connected to a controller (4).

9. The screw conveyor according to claim 8, characterized in that: The barrier valve (2) comprises a valve body and a valve stem; the valve body is embedded in the shell (11); the valve plate (21) is movably arranged in the valve body; one end of the valve stem is connected to the valve plate (21), and the other end is connected to the actuator (3); the valve body and the shell (11) are connected by a flange (6) or welding; a U-shaped groove is provided at the lower end of the valve plate (21), the U-shaped groove is sleeved around the main shaft (13), the gap width between the U-shaped groove and the main shaft (13) is 1 mm to 6 mm, the outer contour of the valve plate (21) is the same as the inner contour of the shell (11), or the outer contour of the valve plate (21) is the contour remaining after the inner contour of the cross section of the shell (11) is cut straight; when the shell (11) is a cylinder, the outer contour of the valve plate (21) is circular or circular arc sector.

10. The screw conveyor according to claim 8 or 9, characterized in that: A flow detector for detecting material flow is provided at the front end of the feed port of the housing (11), and the flow detector is connected to the controller (4); the flow detector is one of an ultrasonic flow detector, a Coriolis mass flow detector, and a weighing mass flow detector; The actuator (3) is one of an electric actuator, a pneumatic actuator, and a hydraulic actuator; the actuator (3) further comprises a limit switch and a position sensor; The controller (4) is one of an embedded controller, a programmable logic controller, a distributed control system, and an artificial intelligence-based controller; The material level detector (5) is one of a radar material level detector, a capacitive material level detector, an ultrasonic material level detector, a rotary paddle type material level switch, a heavy hammer type material level detector, a radio frequency admittance material level detector, and a nuclear radiation material level detector.

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