Method for describing dynamic distribution of gypsum boards in drying machine

Abstract

The invention discloses a method for describing dynamic distribution of gypsum boards in a drying machine, and relates to the field of drying machine control. According to the specific implementation scheme, a current queue is created, and gypsum board information is stored in the current queue; when a signal rising edge is generated in board feeding, gypsum board information of board feeding is stored in a cache region data structure according to the state of the current queue; the head coordinates of the gypsum boards in the cache region data structure are increased in real time from zero along with time according to the transmission speed of the gypsum boards, meanwhile, the upper computer displays the positions of the gypsum boards in real time according to changes of the head and tail coordinates of the gypsum boards, and visualization of dynamic distribution of the gypsum boards is achieved. The digital twinning technology is utilized to construct the virtual plasterboard strip, the production state of the plasterboard in the drying machine is continuously analyzed based on the plasterboard information, the transmission state of the plasterboard is displayed in real time through the upper computer, the control strategy of the drying machine is optimized, the production efficiency can be improved, and the production quality can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of dryer control, and in particular to a method for describing the dynamic distribution of gypsum boards in a dryer. Background Art

[0002] The existing dryer control technology in China is still in the traditional way of controlling the temperature at the entrance of each zone and controlling the free water evaporation of the board through the temperature curve. When the belt speed changes during factory production, the factory stops or optimizes production to achieve a change in the type of gypsum board with the least downtime, the temperature curve will be affected. At this time, even experienced operators will encounter difficulties in basic control because they are not clear about the status of the gypsum board in the dryer. The existing gypsum board tracking technology can only locate the approximate position of the gypsum board, lacks the gypsum board data status related to the dryer control, and the data interaction with the previous and next sections in the production line is not close enough. Assuming that several types of boards are in the dryer at the same time, it is difficult to make the best adjustment to production control based on the operator's experience, which will lead to an increase in the amount of waste boards. Summary of the invention

[0003] Based on this, the present invention provides a method for describing the dynamic distribution of gypsum boards in a dryer to solve the problem that the existing gypsum board tracking technology can only locate the approximate position of the gypsum board, making it difficult to make the best adjustment to production control, resulting in an increase in the amount of waste boards.

[0004] The present invention provides a method for describing the dynamic distribution of gypsum boards in a dryer, comprising:

[0005] Creating a current queue and storing the gypsum board information in the current queue;

[0006] When the board entry signal rises, the gypsum board information of the board entry is stored in the buffer data structure according to the state of the current queue;

[0007] The gypsum board head coordinates in the cache data structure increase in real time from zero according to the gypsum board transmission speed. At the same time, the host computer displays the gypsum board position in real time according to the changes in the gypsum board head and tail coordinates, thereby realizing the visualization of the dynamic distribution of the gypsum board.

[0008] The specific operations of creating a queue and storing the gypsum board information in the queue include:

[0009] N queues represent X gypsum board strips in the dryer, each queue is a series of data structures including the gypsum board information, including the presence / absence of gypsum board, gypsum board head coordinates, gypsum board tail coordinates, gypsum board model, gypsum board length, gypsum board width, gypsum board thickness, evaporation amount and quality mark.

[0010] The status of the current queue includes the queue being idle, the queue being neither empty nor full, and the queue being full.

[0011] If the current queue is in an idle state, when the first board input generates a rising edge of the signal, the gypsum board model of the board input in the wet end section is read in real time to index the gypsum board information of the board input in the forming section, and the gypsum board information is stored in the buffer area data structure. The gypsum board head coordinates in the buffer area data structure are increased in real time from zero according to the gypsum board transmission speed;

[0012] When the falling edge of the signal is generated after the board is loaded, a new queue is created, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and the board is continuously loaded into the current queue.

[0013] If the current queue is in a state of neither empty nor full, when the board input signal rises, the gypsum board model of the board input in the wet end section is read in real time to index the gypsum board information of the board input in the forming section, and the gypsum board information is stored in the buffer area data structure. The gypsum board head coordinates in the buffer area data structure are increased in real time from zero according to the gypsum board transmission speed;

[0014] If the gypsum board model changes or the tail of the gypsum board in the current queue is more than the set value away from the board entry detection position, a new queue is created when a falling edge of the signal is generated at the end of board entry, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and boards continue to be entered into the current queue;

[0015] If the gypsum board model has not changed and the distance between the tail of the gypsum board in the current queue and the board entry detection position is within the set value, when the falling edge of the signal is generated at the end of board entry, no new queue will be created. Only the tail coordinates of the gypsum board in the data structure of the current queue will be cleared, and the cache data will be cleared. The gypsum board head coordinates and the gypsum board tail coordinates in the data structure of the current queue will increase in real time according to the transmission speed of the gypsum board.

[0016] If the current queue is full, when the board generates a rising edge of the signal, a current queue error alarm will be generated;

[0017] If the coordinates of the gypsum board head in the current queue data structure are greater than or equal to the entire dryer length, the coordinates of the gypsum board head will no longer increase; if the coordinates of the gypsum board tail in the current queue data structure are greater than or equal to the entire dryer length, the current queue data will be passed to the dry end conveying system and then cleared.

[0018] The dryer comprises a plurality of drying zones, each of which has a different degree of drying.

[0019] The evaporation of water from the gypsum board depends on the location of the gypsum board;

[0020] Create a fixed ratio evaporation table (k1, k2...k i ), divide each drying area into i equal parts according to the evaporation table, create a data storage area for each equal grid in the PLC, and when the gypsum board position reaches the position of the first equal grid, e1, e2, ... e i Write the 1st, 2nd, ..., i-th equally divided cells in sequence to obtain the moving evaporation table (e1, e2...e i ), the fixed ratio evaporation table (k1, k2...k i ) and the evaporation amount table (e1, e2...e i ) through Σk i ×e i Calculate the evaporation load of each zone of the dryer, where k i represents the evaporation coefficient of the ith portion, e i Represents the evaporation amount of the i-th portion.

[0021] include,

[0022] The upper computer displays the position of the gypsum board in real time according to the changes of the head and tail coordinates of the gypsum board, and calculates the filling rate of each drying area through the head and tail coordinates of the gypsum board.

[0023] include,

[0024] The temperature control mode and temperature of the dryer are adjusted based on the gypsum board position, the fill rate of each drying zone and the evaporative load of each zone.

[0025] Beneficial effects: The present invention uses digital twin technology to construct a virtual gypsum board strip, continuously analyzes the production status of the gypsum board in the dryer based on the gypsum board information, and displays the gypsum board transmission dynamics in real time through the host computer, thereby optimizing the control strategy of the dryer, thereby improving production efficiency and production quality.

[0026] It should be understood that the contents described in this section are not intended to identify the key or important features of the embodiments of the present invention, nor are they intended to limit the scope of the present invention. Other features of the present invention will become easily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are used to better understand the present invention and do not constitute a limitation of the present invention.

[0028] Figure 1 is a flow chart provided according to the present invention;

[0029] Figure 2 It is a schematic diagram of the prior art effect;

[0030] Figure 3It is a schematic diagram of the effect provided by the present invention. DETAILED DESCRIPTION

[0031] The following is a description of exemplary embodiments of the present invention in conjunction with the accompanying drawings, including various details of the embodiments of the present invention to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the present invention. Similarly, for clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0032] like Figure 1 As shown, the present invention provides a method for describing the dynamic distribution of gypsum boards in a dryer, comprising:

[0033] S1: Create the current queue and store the gypsum board information in the current queue. It should be noted that:

[0034] The specific operations of creating a queue and storing the gypsum board information in the queue include:

[0035] N queues represent X gypsum board strips in the dryer, and each queue is a series of data structures including gypsum board information, including presence / absence of gypsum board, gypsum board head coordinates, gypsum board tail coordinates, gypsum board model, gypsum board length, gypsum board width, gypsum board thickness, evaporation amount, and quality mark.

[0036] S2: When the board input signal rises, the information of the incoming gypsum board is stored in the buffer data structure according to the current queue status.

[0037] The current queue status includes the queue being idle, the queue being neither empty nor full, and the queue being full.

[0038] If the current queue is in an idle state, when the first board input generates a rising edge of the signal, the gypsum board model of the wet end section is read in real time to index the gypsum board information of the board input to the molding section, and the gypsum board information is stored in the buffer area data structure. The gypsum board head coordinates in the buffer area data structure increase in real time from zero according to the gypsum board transmission speed;

[0039] When the falling edge of the signal is generated when the board is loaded, a new queue is created, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and the board continues to be loaded into the current queue.

[0040] If the current queue is in a state of neither empty nor full, when the board input signal rises, the gypsum board model of the wet-end section is read in real time to index the gypsum board information of the board input to the molding section, and the gypsum board information is stored in the buffer data structure. The gypsum board head coordinates in the buffer data structure increase in real time from zero according to the gypsum board transmission speed;

[0041] If the gypsum board model changes or the tail of the gypsum board in the current queue is more than the set value from the board entry detection position, a new queue is created when the falling edge of the signal is generated at the end of board entry, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and the board continues to be entered into the current queue;

[0042] If the gypsum board model has not changed and the distance between the tail of the gypsum board in the current queue and the board entry detection position is within the set value, when the falling edge of the signal is generated at the end of board entry, no new queue will be created. Only the coordinates of the tail of the gypsum board in the data structure of the current queue will be cleared, the buffer data will be cleared, and the coordinates of the head and tail of the gypsum board in the data structure of the current queue will be increased in real time according to the transmission speed of the gypsum board.

[0043] If the current queue is full, when the board generates a rising edge of the signal, an error alarm will be generated for the current queue;

[0044] If the coordinates of the gypsum board head in the current queue data structure are greater than or equal to the entire dryer length, the coordinates of the gypsum board head will no longer increase; if the coordinates of the gypsum board tail in the current queue data structure are greater than or equal to the entire dryer length, the current queue data will be passed to the dry end conveying system and then cleared.

[0045] Furthermore, the present invention adopts real-time reading of the gypsum board model and inputting the board information to the molding section, which can quickly respond to changes in the gypsum board, reduce waiting time, and improve overall production efficiency.

[0046] Through the cache data structure, the gypsum board information can be temporarily saved when the current queue is not full, preventing data loss due to the current queue being full. When the current queue has space, the data in the cache will be written to the queue; a new queue will be created only when the gypsum board model changes or the distance between the tail of the gypsum board in the current queue and the board entry detection position exceeds the set value, reducing memory usage and reducing system burden.

[0047] In the case of changes in gypsum board models, the system can automatically identify and create new queues to ensure that different models of gypsum boards can be correctly classified and processed to avoid confusion.

[0048] When the queue is full, the system will issue an error alarm to alert operators to possible problems, helping to solve the problem in time and prevent production interruptions.

[0049] Dynamically adjusting the data in the queue according to the transmission speed of the gypsum board can avoid the accumulation of invalid data, which is conducive to the reasonable arrangement of the distribution of the gypsum boards in the dryer and improves the drying efficiency.

[0050] By tracking the location and model of gypsum boards, the production process can be better controlled to ensure consistent and stable product quality.

[0051] S3: The coordinates of the head of the gypsum board in the data structure of the buffer area increase in real time from zero according to the transmission speed of the gypsum board. At the same time, the host computer displays the position of the gypsum board in real time according to the changes in the head and tail coordinates of the gypsum board, realizing the visualization of the dynamic distribution of the gypsum board. It should be noted that:

[0052] The dryer includes multiple drying zones, each with a different degree of drying.

[0053] The evaporation of moisture from the drywall depends on where the drywall is located;

[0054] Create a fixed ratio evaporation table (k1, k2...k i ), divide each drying area into i equal parts according to the evaporation table, create a data storage area for each equal grid in the PLC, and when the gypsum board position reaches the position of the first equal grid, e1, e2, ... e i Write the 1st, 2nd, ..., i-th equally divided cells in sequence to obtain the moving evaporation table (e1, e2...e i ), the fixed ratio evaporation table (k1, k2...k i ) and evaporation table (e1, e2...e i ) through Σk i ×e i Calculate the evaporation load of each zone of the dryer, where k i represents the evaporation coefficient of the ith portion, e i Represents the evaporation amount of the i-th portion.

[0055] include,

[0056] The host computer displays the position of the gypsum board in real time according to the changes in the head and tail coordinates of the gypsum board, and calculates the filling rate of each drying area through the head and tail coordinates of the gypsum board.

[0057] include,

[0058] The dryer's temperature control mode and temperature are adjusted based on the drywall position, fill rate of each drying zone, and the evaporative load of each zone.

[0059] By reading the data of the head and tail positions of all gypsum boards in the current queue for comparison, the earliest arrival time of the head of the board and the time when the gypsum board is finished from the dryer can be calculated and displayed on the host computer, which is convenient for the start and stop preparation of the board delivery section.

[0060] The length of the dryer is different, and the number of zones and the length of each zone are also different. The number of zones is determined according to the drying cycle, usually divided into two, three or four zones, each zone is 15 to 100 meters long. The higher drying rate occurs in zones 1 and 2, where the gypsum board allows higher drying conditions (200 to 250°C). In the last zone, the temperature is reduced (100 to 150°C), and the gypsum board is in the critical moisture drying stage (critical period), and a lower drying rate must be guaranteed.

[0061] Take a layer of a three-zone dryer as an example: the boundary coordinates of each zone of the dryer are fixed values, and the coordinates of the head and tail of the gypsum board in the current queue are compared with the boundary coordinates of each zone.

[0062] When the head coordinate of the gypsum board is greater than the coordinate of the upper boundary of zone 3, if the tail coordinate of the gypsum board is less than the lower boundary of zone 1, the filling rate of each zone of the dryer is 100%; if the tail coordinate of the gypsum board strip is between the lower boundary of zone 1 and the upper boundary of zone 1, the filling rates of zones 2 and 3 are 100%, and the filling rate of zone 1 is calculated by coordinates; if the tail coordinate of the gypsum board strip is between the upper boundary of zone 2 and the upper boundary of zone 1, the filling rate of zone 3 is 100%, the filling rate of zone 2 is calculated by coordinates, and the filling rate of zone 1 is 0; if the tail coordinate of the gypsum board strip is between the upper boundary of zone 3 and the upper boundary of zone 2, the filling rate of zone 3 is calculated by coordinates, and the filling rates of zones 1 and 2 are 0.

[0063] When the head coordinate of the gypsum board is between the coordinates of the upper boundary of zone 2 and the upper boundary of zone 3, if the tail coordinate of the gypsum board is less than the lower boundary of zone 1, the filling rate of zone 3 is calculated by coordinates, and the filling rates of zones 1 and 2 are 100%; if the tail coordinate of the gypsum board is between the lower boundary of zone 1 and the upper boundary of zone 1, the filling rates of zones 1 and 3 are calculated by coordinates, and the filling rate of zone 2 is 100%; if the tail coordinate of the gypsum board is between the upper boundary of zone 2 and the upper boundary of zone 1, the filling rates of zones 2 and 3 are calculated by coordinates, and the filling rate of zone 1 is 0; if the tail coordinate of the gypsum board is between the upper boundary of zone 3 and the upper boundary of zone 2, the filling rate of zone 3 is calculated by coordinates, and the filling rates of zones 1 and 2 are 0.

[0064] When the head coordinate of the gypsum board is between the coordinates of the upper boundary of zone 1 and the upper boundary of zone 2, if the tail coordinate of the gypsum board is less than the lower boundary of zone 1, the filling rate of zone 3 is 0, the filling rate of zone 2 is calculated by coordinates, and the filling rate of zone 1 is 100%; if the tail coordinate of the gypsum board is between the lower boundary of zone 1 and the upper boundary of zone 1, the filling rate of zone 3 is 0, and the filling rates of zones 1 and 2 are calculated by coordinates; if the tail coordinate of the gypsum board is between the upper boundary of zone 2 and the upper boundary of zone 1, the filling rate of zone 2 is calculated by coordinates, and the filling rates of zones 1 and 3 are 0.

[0065] When the head coordinates of the gypsum board are between the coordinates of the upper boundary of zone 1 and the lower boundary of zone 1, the filling rates of zones 2 and 3 are 0, and the filling rate of zone 1 is calculated based on the position of the tail coordinates of the gypsum board.

[0066] like Figure 2 As shown, it can be seen that the traditional technical solution only tracks the position of the gypsum board.

[0067] Figure 3 This is the effect diagram of the present invention, which can show the location of the gypsum board, the filling rate of each zone, the evaporation amount of each zone, and the filling rate information. In production, the temperature control mode and temperature of the dryer can be adjusted according to these data, which can better optimize the control strategy of the dryer, improve production efficiency, and enhance production quality. Figure 3 In the gypsum board, you can also see abnormalities (such as Figure 3 The red area on the tenth floor in the middle is convenient for detecting abnormalities of the gypsum board, and the board feeding speed can be adjusted according to the transmission speed and local arrival time.

[0068] The present invention simulates the production process through Siemens upper software wincc, builds a digital twin scene, drives the movement of the virtual gypsum board according to the acquired real-time data and displays the real-time gypsum board data status, realizes the visualization of the dynamic distribution of the gypsum board, and provides data support for the intelligent control of the dryer.

[0069] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A method for describing the dynamic distribution of gypsum boards in a dryer, characterized in that include: Creating a current queue and storing the gypsum board information in the current queue; When the board entry signal rises, the gypsum board information of the board entry is stored in the buffer data structure according to the state of the current queue; The gypsum board head coordinates in the cache data structure increase in real time from zero according to the gypsum board transmission speed. At the same time, the host computer displays the gypsum board position in real time according to the changes in the gypsum board head and tail coordinates, thereby realizing the visualization of the dynamic distribution of the gypsum board.

2. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 1, characterized in that: The specific operations of creating a queue and storing the gypsum board information in the queue include: N queues represent X gypsum board strips in the dryer, each queue is a series of data structures including the gypsum board information, including the presence / absence of gypsum board, gypsum board head coordinates, gypsum board tail coordinates, gypsum board model, gypsum board length, gypsum board width, gypsum board thickness, evaporation amount and quality mark.

3. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 2, characterized in that: The status of the current queue includes the queue being idle, the queue being neither empty nor full, and the queue being full.

4. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 3, characterized in that: If the current queue is in an idle state, when the first board input generates a rising edge of the signal, the gypsum board model of the board input in the wet end section is read in real time to index the gypsum board information of the board input in the forming section, and the gypsum board information is stored in the buffer area data structure. The gypsum board head coordinates in the buffer area data structure are increased in real time from zero according to the gypsum board transmission speed; When the falling edge of the signal is generated after the board is loaded, a new queue is created, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and the board is continuously loaded into the current queue.

5. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 4, characterized in that: If the current queue is in a state of neither empty nor full, when the board input signal rises, the gypsum board model of the board input in the wet end section is read in real time to index the gypsum board information of the board input in the forming section, and the gypsum board information is stored in the buffer area data structure. The gypsum board head coordinates in the buffer area data structure are increased in real time from zero according to the gypsum board transmission speed; If the gypsum board model changes or the tail of the gypsum board in the current queue is more than the set value away from the board entry detection position, a new queue is created when a falling edge of the signal is generated at the end of board entry, the gypsum board information in the buffer data structure is written into the new queue, the current queue is cleared, and boards continue to be entered into the current queue; If the gypsum board model has not changed and the distance between the tail of the gypsum board in the current queue and the board entry detection position is within the set value, when the falling edge of the signal is generated at the end of board entry, no new queue will be created. Only the tail coordinates of the gypsum board in the data structure of the current queue will be cleared, and the cache data will be cleared. The gypsum board head coordinates and the gypsum board tail coordinates in the data structure of the current queue will increase in real time according to the transmission speed of the gypsum board.

6. A method for describing the dynamic distribution of gypsum boards in a dryer according to any one of claims 3 to 5, characterized in that: If the current queue is full, when the board generates a rising edge of the signal, a current queue error alarm will be generated; If the coordinates of the gypsum board head in the current queue data structure are greater than or equal to the entire dryer length, the coordinates of the gypsum board head will no longer increase; if the coordinates of the gypsum board tail in the current queue data structure are greater than or equal to the entire dryer length, the current queue data will be passed to the dry end conveying system and then cleared.

7. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 6, characterized in that: The dryer comprises a plurality of drying zones, each of which has a different degree of drying.

8. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 7, characterized in that: The evaporation of water from the gypsum board depends on the location of the gypsum board; Create a fixed ratio evaporation table (k1, k2...k i ), divide each drying area into i equal parts according to the evaporation table, create a data storage area for each equal grid in the PLC, and when the gypsum board position reaches the position of the first equal grid, e1, e2, ... e i Write the 1st, 2nd, ..., i-th equally divided cells in sequence to obtain the moving evaporation table (e1, e2...e i ), the fixed ratio evaporation table (k1, k2...k i ) and the evaporation amount table (e1, e2...e i ) through Σk i ×e i Calculate the evaporation load of each zone of the dryer, where k i represents the evaporation coefficient of the ith portion, e i Represents the evaporation amount of the i-th portion.

9. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 8, characterized in that: include, The upper computer displays the position of the gypsum board in real time according to the changes of the head and tail coordinates of the gypsum board, and calculates the filling rate of each drying area through the head and tail coordinates of the gypsum board.

10. A method for describing the dynamic distribution of gypsum boards in a dryer according to claim 9, characterized in that: include, The temperature control mode and temperature of the dryer are adjusted based on the gypsum board position, the fill rate of each drying zone and the evaporative load of each zone.

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