Intelligent, feedback and linkage control mode for discharge of silo

Abstract

This invention discloses an intelligent, feedback-based, and interconnected storage tank discharge control method. The control method specifically includes the following steps: S1, determining a baseline speed based on the storage tank feed rate; S2, feedback correction; S21, correcting the discharge speed based on the material level in the tank; S22, adjusting the discharge speed based on feedback from the material height on the discharge canvas; S3, interconnecting with other equipment. This invention's discharge control mode automatically identifies the storage tank feed rate and intelligently determines the discharge speed. It adjusts the speed in real time through the matching of material distribution patterns within the tank and the current material discharge stage, as well as negative feedback from the material height on the discharge canvas. It also maintains interconnected operation with upstream and downstream equipment such as the feeding rollers and conveyor belts, ensuring continuous, stable, and efficient storage tank discharge.

Description

Technical Field

[0001] This invention belongs to the field of automated control technology for tobacco production equipment, and more specifically, relates to an intelligent, feedback-based, and linkage-based storage tank discharge control method. Background Technology

[0002] Storage tanks are the main storage equipment used on the silk production line. Their main functions are to store materials, balance moisture content, and perform aging. The storage tanks receive materials from top to bottom via a material feeding cart and a material feeding belt, and the materials are stored on the bottom belt of the storage tank. When discharging, the reducer drives the bottom belt to run, and the materials follow the bottom belt to move horizontally. After being loosened by the material feeding rollers at the head of the tank, the materials are unloaded onto the conveyor belt, which transports the materials to the downstream process.

[0003] The current operating method involves operators setting the bottom conveyor speed before discharging from the storage tank, and then manually adjusting the speed setting during production if necessary. This operating mode has several drawbacks: First, manually setting the discharge speed, based on subjective experience, lacks scientific rationality and often results in low discharge efficiency; second, relying on manual speed adjustment makes it impossible to make timely adjustments for abnormal situations, easily causing blockages and other malfunctions; third, it increases the operator's workload, requiring adjustments for each tank discharge. Based on these problems, an automatic discharge method for the storage tank is needed, which can identify abnormal situations and make timely adjustments to avoid blockages and other malfunctions, thereby ensuring efficient and stable discharge from the storage tank. Summary of the Invention

[0004] To address the aforementioned technical problems in existing technologies, this invention provides an intelligent, feedback-based, and interconnected storage tank discharge control method. The discharge control mode of this invention automatically identifies the storage tank feed rate and intelligently determines the discharge speed. It makes real-time adjustments based on the material distribution pattern within the tank, the current material discharge stage, and the negative feedback of the material height on the discharge canvas. Furthermore, it maintains interconnected operation with upstream and downstream equipment such as the feeding rollers and conveyor belts, ensuring continuous, stable, and efficient discharge from the storage tank.

[0005] The technical solution adopted in this invention is:

[0006] A smart, feedback-based, and linkage-based storage tank discharge control method, characterized in that the control method specifically includes the following steps:

[0007] S1. Determine the baseline speed based on the feed rate of the storage tank;

[0008] S2, Feedback Correction;

[0009] S21. Adjust the discharge speed according to the material storage situation in the cabinet;

[0010] S22. Adjust the discharge speed based on the material height feedback on the discharge canvas;

[0011] S3, Linkage Equipment.

[0012] Furthermore, in step S1, the specific process for determining the reference speed based on the tank feed rate is as follows:

[0013] The storage capacity of the mixing cabinet is:

[0014] W=ρ*l*a*h (1)

[0015] Where ρ is the material density, in kg / m³. 3 ; l is the length of the mixing cabinet, in meters; a is the width of the mixing cabinet, in meters; h is the material storage height of the mixing cabinet, in meters.

[0016] The discharge flow rate is:

[0017] Q=ρ*a*h*v (2)

[0018] Where v is the speed of the bottom belt of the mixing cabinet, in m / s;

[0019] Given that the downstream container loading station has a container loading capacity of Q 装箱 If the mixing cabinet discharges material from a single cabinet, then the discharge flow rate Q = Q 装箱 If the mixing cabinet discharges material from the top cabinet simultaneously, then the discharge flow rate Q = Q 装箱 / 2;

[0020] Calculate the discharge time based on the material storage capacity W and discharge flow rate Q of the mixing cabinet:

[0021] T=W / Q=ρ*l*a*h / (ρ*a*h*v)=l / v (3)

[0022] The discharge speed of the bottom belt of the mixing cabinet can then be obtained:

[0023] v=Q*l / W (4)

[0024] The motor speed is:

[0025] N1=60*f1*(1-s1) / p1 (5)

[0026] Where f1 is the inverter output frequency, s1 is the slip rate, and p1 is the number of pole pairs of the rotating magnetic field of the motor; setting i1 as the speed ratio of the reducer, the output shaft speed of the reducer is:

[0027] n1 = N1 / i1 (6)

[0028] z1 is the number of teeth on the driving sprocket on the reducer output shaft, and z2 is the number of teeth on the driven sprocket on the bottom belt drive shaft. Therefore, the rotational speed of the bottom belt drive shaft is:

[0029] n2=n1*z1 / z2 (7)

[0030] d is the diameter of the bottom belt drive sprocket, in meters. Therefore, the running speed of the bottom belt is equal to the linear velocity of the bottom belt drive sprocket.

[0031] v=n2*π*d / 60 (8)

[0032] Therefore, we can conclude that:

[0033] v=f1*[π*d*z1*(1-s1) / (p1*i1*z2)]=f1*k1 (9)

[0034] Where, k1=π*d*z1*(1-s1) / (p1*i1*z2), for a certain specific drive system, k1 is a constant, that is, the running speed of the bottom belt is proportional to the running frequency of the motor;

[0035] Therefore, when the material storage capacity W and the discharge flow rate Q of the mixing cabinet are met, the reference frequency for the drive motor at the bottom of the cabinet is:

[0036] f 基准 =v / k=Q*l / (W*k1) (10)

[0037] Furthermore, in step S21, the specific process for adjusting the discharge speed based on the material inventory in the cabinet is as follows:

[0038] Given the characteristics of material storage inside the mixing cabinet, the entire cabinet of material can be divided into five discharge stages based on material height in the discharge direction: pre-filling, head of material, normal material, tail of material, and empty material. The variable for the current discharge stage is...

[0039] G = [G1, G2, G3, G4, G5] (11)

[0040] The above five stages G are divided based on the length b of the material on the bottom belt in the discharge direction from the discharge port. The indexing variables are:

[0041] B=[b1,b2,b3,b4] (12)

[0042] Current discharge length is:

[0043] b=π*d*n3 / Num (13)

[0044] Where n3 is the number of pulses triggered by the encoder on the bottom belt drive shaft, and Num is the number of encoder pulses triggered by one revolution of the bottom belt drive shaft;

[0045] Based on the actual discharge status, there is only one G value of 1 at any given time. If b < b1, then G1 = 1; when b ∈ [b1, b1 = 1, G ... i-1 ,b i ), then G i=1, where 2≤i≤4; when b>b4, G5=1;

[0046] Define the underbelly speed correction variables for each stage:

[0047] X = [X1, X2, X3, X4, X5] T (14)

[0048] Among them, X i For G i The correction variable value for the discharge stage is 1≤i≤5; the product of the discharge stage variable G and the bottom belt speed correction variable X for each stage is used to obtain the material storage speed correction coefficient in the cabinet:

[0049] C=G*X=[G1,G2,G3,G4,G5]*[X1,X2,X3,X4,X5] T (15)

[0050] Based on the operating frequency f of the drive motor at the bottom of the cabinet: 基准 The correction factor C for the material stored in the cabinet is used to obtain the correction value for the material discharge frequency at the bottom of the cabinet.

[0051] f 修正 =f 基准 *C (16)

[0052] Furthermore, in step S22, the specific process of adjusting the discharge speed based on the material height feedback on the discharge canvas includes:

[0053] The height h of the material on the conveyor belt 实时 The current discharge volumetric flow rate is reflected in the material height h, while the throughput capacity of the conveying equipment is reflected in the material height h. 标准 For standard purposes; when the mixing cabinet discharges material, the material level sensor located at the discharge conveyor belt measures the material height h on the conveyor belt in real time. 实时 The material height data is transmitted to the PLC, and the PLC calculates the material height based on the real-time discharge height h. 实时 With respect to the standard discharge height h 标准 The difference Δh is used to adjust the set frequency f of the bottom-band drive inverter. 调整 =f 修正 +△f, thereby adjusting the discharge speed of the bottom belt of the mixing cabinet to control the material height on the discharge conveyor belt and keep it stable.

[0054] Furthermore, in step S3, the specific process of the linkage device is as follows:

[0055] The speed of the geared motor is:

[0056] N2=60*f2*(1-s2) / p2 (17)

[0057] Given that the reduction ratio of the geared motor is i2, then the output shaft speed of the geared motor is:

[0058] n3 = N2 / i2 (18)

[0059] By setting the number of teeth of the gear on the output shaft of the geared motor and the gear on the feed roller shaft to z3 and z4 respectively, the rotational speed of the feed roller can be obtained:

[0060] n4=n3*z3 / z4 (19)

[0061] According to the matching and linkage principle, the bottom strip travels a fixed distance S. 固定 When the feeding roller rotates one revolution, the running time of both is equal, as detailed below:

[0062] t = S 固 Fixed / v=60 / n4 (20)

[0063] Where v is the running speed of the bottom belt, the drive frequency of the feed roller inverter can be obtained according to the equation:

[0064] f2=f 修正 *k1 / (k2*S 固定 ) (twenty one)

[0065] k2=(1-s2)*z3 / (p2*i2*z4) (22)

[0066] From this, we can see that k1 and k2 are both constants, in S 固定 Under certain conditions, the operating frequency of the feed roller inverter is proportional to the operating frequency of the bottom belt motor inverter, that is, the rotational speed of the feed roller is proportional to the running speed of the bottom belt.

[0067] Furthermore, in step S3, to prevent material discharge blockage, the speed of the shift roller is optimized at different bottom belt speeds, as follows:

[0068] Operating frequency f of the baseband inverter 调整 Identify the baseband operating speed and define the boundary frequency f. 慢 f 快 , where 0 < f 慢 <f 快 <50;

[0069] When f 修正 ∈[0, f 慢 When [the material is discharged], it is in the slow discharge stage U1;

[0070] When f 修正 ∈(f 慢 f 快 At this time, it is the normal speed discharge stage U2;

[0071] When f修正 ∈(f 快 When

[50] , it is the rapid discharge stage U3;

[0072] For different discharge stages U, an optimization coefficient β is defined, then the optimized speed of the roller is:

[0073] f 优化 =f2*U*β=f2*[U1,U2,U3]*[β1,β2,β3] T (twenty three)

[0074] Furthermore, in step S3, the specific process of the linkage equipment also includes:

[0075] To ensure stable material output, the conveyor belt transmission efficiency is monitored, and the discharge speed is adjusted according to the real-time transmission efficiency. The belt slippage detection device installed on each conveyor belt transmits the monitoring signal to the PLC. The PLC calculates the belt transmission efficiency η in real time based on the monitoring signal, where 0≤η≤1. The closer η is to 1, the higher the belt transmission efficiency.

[0076] When η = 1, the belt does not slip; the overall efficiency of the conveyor belt is:

[0077] η 总 ={(y1,η1),(y2,η2),…,(y j ,η j )} (twenty four)

[0078] Where y represents the conveyor belt identifier and j represents the number of conveyor belts;

[0079] For different conveyor belts y, define different belt transmission efficiency values ​​η. 警告 η 动作 η 停止 , where η 警告 >η 动作 >η 停止 ;

[0080] When η 动作 <η≤η 警告 When this happens, the system will display a message indicating an abnormality in the corresponding conveyor belt transmission.

[0081] When η 停止 <η≤η 动作 At this time, the conveyor belt's transmission efficiency decreases significantly, and the speed of the storage tank's bottom belt is adjusted accordingly. In this situation, the negative feedback control of the material height on the discharge conveyor belt should be disabled, and the set frequency of the bottom belt drive inverter should be:

[0082] f 联动 =(η-0.1)*f 修正 (25)

[0083] When η≤η停止 At that time, the belt slipped severely, and the bottom belt stopped discharging material;

[0084] When η > η 警告 When the storage tank resumes discharging, the negative feedback control of the material height of the discharge conveyor belt is reactivated.

[0085] Compared with the prior art, the beneficial effects of the present invention are reflected in:

[0086] 1. This invention calculates the discharge speed of the storage tank by converting the feed rate of the storage tank, which replaces manual operation, reduces the operational burden, and its automatic calculation results are more accurate and reasonable than manual preset. At the same time, it calculates the current discharge position based on the encoder feedback signal and combines it with the accumulation status of the material inside the storage tank to achieve real-time adjustment that cannot be achieved by manual operation.

[0087] 2. This invention utilizes a material level sensor on the discharge canvas to monitor the material height. The PLC then adjusts the discharge speed based on the difference between this data and the standard discharge height, which helps to maintain a stable material flow rate from the storage tank and facilitates efficient material discharge from the storage tank.

[0088] 3. This invention is not limited to the individual adjustment of the discharge speed of the storage tank. By matching the speed of the feeding roller and monitoring the transmission efficiency of the conveyor belt, a discharge system that links the upstream and downstream equipment is formed. The system provides real-time feedback and adjusts the operating status of each piece of equipment in the discharge system, thereby effectively avoiding blockages and other faults caused by the lack of linkage between upstream and downstream equipment, and maintaining the continuous and stable operation of the discharge process. At the same time, it keeps the material crushing at a low level, improving the product process quality. Attached Figure Description

[0089] Figure 1 Schematic diagram of the storage tank discharge system.

[0090] Figure 2 Schematic diagram of the conveyor belt discharge speed control process at the bottom of the storage tank. Detailed Implementation

[0091] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0092] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0093] The present invention will now be described in detail with reference to the accompanying drawings and exemplary embodiments.

[0094] Example 1

[0095] refer to Figure 2The present invention provides an intelligent, feedback-based, and linkage-based storage tank discharge control method, the control method specifically including the following steps:

[0096] S1. Determine the baseline speed based on the feed rate of the storage tank;

[0097] In step S1, the specific process for determining the baseline speed based on the tank feed rate is as follows:

[0098] The storage capacity of the mixing cabinet is:

[0099] W=ρ*l*a*h (1)

[0100] Where ρ is the material density, in kg / m³. 3 ; l is the length of the mixing cabinet, in meters; a is the width of the mixing cabinet, in meters; h is the material storage height of the mixing cabinet, in meters.

[0101] The discharge flow rate is:

[0102] Q=ρ*a*h*v (2)

[0103] Where v is the speed of the bottom belt of the mixing cabinet, in m / s;

[0104] Given that the downstream container loading station has a container loading capacity of Q 装箱 If the mixing cabinet discharges material from a single cabinet, then the discharge flow rate Q = Q 装箱 If the mixing cabinet discharges material from the top cabinet simultaneously, then the discharge flow rate Q = Q 装箱 / 2;

[0105] Calculate the discharge time based on the material storage capacity W and discharge flow rate Q of the mixing cabinet:

[0106] T=W / Q=ρ*l*a*h / (ρ*a*h*v)=l / v (3)

[0107] The discharge speed of the bottom belt of the mixing cabinet can then be obtained:

[0108] v=Q*l / W (4)

[0109] The motor speed is:

[0110] N1=60*f1*(1-s1) / p1 (5)

[0111] Where f1 is the inverter output frequency, s1 is the slip rate, and p1 is the number of pole pairs of the rotating magnetic field of the motor; setting i1 as the speed ratio of the reducer, the output shaft speed of the reducer is:

[0112] n1 = N1 / i1 (6)

[0113] z1 is the number of teeth on the driving sprocket on the reducer output shaft, and z2 is the number of teeth on the driven sprocket on the bottom belt drive shaft. Therefore, the rotational speed of the bottom belt drive shaft is:

[0114] n2=n1*z1 / z2 (7)

[0115] d is the diameter of the bottom belt drive sprocket, in meters. Therefore, the running speed of the bottom belt is equal to the linear velocity of the bottom belt drive sprocket.

[0116] v=n2*π*d / 60 (8)

[0117] Therefore, we can conclude that:

[0118] v=f1*[π*d*z1*(1-s1) / (p1*i1*z2)]=f1*k1 (9)

[0119] Where, k1=π*d*z1*(1-s1) / (p1*i1*z2), for a certain specific drive system, k1 is a constant, that is, the running speed of the bottom belt is proportional to the running frequency of the motor;

[0120] Therefore, when the material storage capacity W and the discharge flow rate Q of the mixing cabinet are met, the reference frequency for the drive motor at the bottom of the cabinet is:

[0121] f 基准 =v / k=Q*l / (W*k1) (10)

[0122] Furthermore, in step S21, the specific process for adjusting the discharge speed based on the material inventory in the cabinet is as follows:

[0123] Given the characteristics of material storage inside the mixing cabinet, the entire cabinet of material can be divided into five discharge stages based on material height in the discharge direction: pre-filling, head of material, normal material, tail of material, and empty material. The variable for the current discharge stage is...

[0124] G = [G1, G2, G3, G4, G5] (11)

[0125] The above five stages G are divided based on the length b of the material on the bottom belt in the discharge direction from the discharge port. The indexing variables are:

[0126] B=[b1,b2,b3,b4] (12)

[0127] Current discharge length is:

[0128] b=π*d*n3 / Num (13)

[0129] Where n3 is the number of pulses triggered by the encoder on the bottom belt drive shaft, and Num is the number of encoder pulses triggered by one revolution of the bottom belt drive shaft;

[0130] Based on the actual discharge status, there is only one G value of 1 at any given time. If b < b1, then G1 = 1; when b ∈ [b1, b1 = 1, G ... i-1 ,b i ), then G i =1, where 2≤i≤4; when b>b4, G5=1;

[0131] Define the underbelly speed correction variables for each stage:

[0132] X = [X1, X2, X3, X4, X5] T (14)

[0133] Among them, X i For G i The correction variable value for the discharge stage is 1≤i≤5; the product of the discharge stage variable G and the bottom belt speed correction variable X for each stage is used to obtain the material storage speed correction coefficient in the cabinet:

[0134] C=G*X=[G1,G2,G3,G4,G5]*[X1,X2,X3,X4,X5] T (15)

[0135] Based on the operating frequency f of the drive motor at the bottom of the cabinet: 基准 The correction factor C for the material stored in the cabinet is used to obtain the correction value for the material discharge frequency at the bottom of the cabinet.

[0136] f 修正 =f 基准 *C (16)

[0137] S2, Feedback Correction;

[0138] S21. Adjust the discharge speed according to the material storage situation in the cabinet;

[0139] S22. Adjust the discharge speed based on the material height feedback on the discharge canvas;

[0140] In step S22, the specific process of adjusting the discharge speed based on the material height feedback on the discharge canvas includes:

[0141] The height h of the material on the conveyor belt 实时 The current discharge volumetric flow rate is reflected in the material height h, while the throughput capacity of the conveying equipment is reflected in the material height h. 标准 For standard purposes; when the mixing cabinet discharges material, the material level sensor located at the discharge conveyor belt measures the material height h on the conveyor belt in real time. 实时 The material height data is transmitted to the PLC, and the PLC calculates the material height based on the real-time discharge height h. 实时 With respect to the standard discharge height h 标准 The difference Δh is used to adjust the set frequency f of the bottom-band drive inverter. 调整 =f 修正+△f, thereby adjusting the discharge speed of the bottom belt of the mixing cabinet to control the material height on the discharge conveyor belt and keep it stable.

[0142] S3, Linkage Equipment.

[0143] In step S3, the specific process of the linkage equipment is as follows:

[0144] The discharge port of the storage tank has several sets of material-discharging rollers. During discharge, the rotation of the rollers loosens and throws the material, ensuring continuous and stable discharge. The rotational speed of the rollers has a significant impact on the discharge status and process quality. If the speed is too high, the material will be severely broken; if the speed is too low, the discharge will be uneven and prone to clogging. Therefore, the rotational speed of the rollers should be matched with the discharge speed of the bottom belt and change accordingly.

[0145] The speed of the geared motor is:

[0146] N2=60*f2*(1-s2) / p2 (17)

[0147] Given that the reduction ratio of the geared motor is i2, then the output shaft speed of the geared motor is:

[0148] n3 = N2 / i2 (18)

[0149] By setting the number of teeth of the gear on the output shaft of the geared motor and the gear on the feed roller shaft to z3 and z4 respectively, the rotational speed of the feed roller can be obtained:

[0150] n4=n3*z3 / z4 (19)

[0151] According to the matching and linkage principle, the bottom strip travels a fixed distance S. 固定 When the feeding roller rotates one revolution, the running time of both is equal, as detailed below:

[0152] t = S fixed / v = 60 / n4 (20)

[0153] Where v is the running speed of the bottom belt, the drive frequency of the feed roller inverter can be obtained according to the equation:

[0154] f2=f 修正 *k1 / (k2*S 固定 ) (twenty one)

[0155] k2=(1-s2)*z3 / (p2*i2*z4) (22)

[0156] From this, we can see that k1 and k2 are both constants, in S 固定 Under certain conditions, the operating frequency of the feed roller inverter is proportional to the operating frequency of the bottom belt motor inverter, that is, the rotational speed of the feed roller is proportional to the running speed of the bottom belt.

[0157] To prevent material discharge blockage, the speed of the shift rollers was optimized for different bottom belt speeds, as follows:

[0158] Operating frequency f of the baseband inverter 调整 Identify the baseband operating speed and define the boundary frequency f. 慢 f 快 , where 0 < f 慢 <f 快 <50;

[0159] When f 修正 ∈[0, f 慢 When [the material is discharged], it is in the slow discharge stage U1;

[0160] When f 修正 ∈(f 慢 f 快 At this time, it is the normal speed discharge stage U2;

[0161] When f 修正 ∈(f 快 When

[50] , it is the rapid discharge stage U3;

[0162] For different discharge stages U, an optimization coefficient β is defined, then the optimized speed of the roller is:

[0163] f 优化 =f2*U*β=f2*[U1,U2,U3]*[β1,β2,β3] T (twenty three)

[0164] The specific process of the linkage equipment also includes:

[0165] Material is loosened and thrown onto the conveyor belt by the feeding rollers, and then transported by multiple conveyor belts to the packing station for packaging. As the sole path for material transport, the conveyor belt's transmission efficiency has a significant impact on the stability of the packaging process. If the conveyor belt's transmission efficiency is insufficient, i.e., if the conveyor belt slips, the material will not flow smoothly, and will accumulate on the conveyor belt, causing blockages.

[0166] To ensure stable material output, the conveyor belt transmission efficiency is monitored, and the discharge speed is adjusted according to the real-time transmission efficiency. The belt slippage detection device installed on each conveyor belt transmits the monitoring signal to the PLC. The PLC calculates the belt transmission efficiency η in real time based on the monitoring signal, where 0≤η≤1. The closer η is to 1, the higher the belt transmission efficiency.

[0167] When η = 1, the belt does not slip; the overall efficiency of the conveyor belt is:

[0168] η 总 ={(y1,η1),(y2,η2),…,(y j,η j )} (twenty four)

[0169] Where y represents the conveyor belt identifier and j represents the number of conveyor belts;

[0170] For different conveyor belts y, define different belt transmission efficiency values ​​η. 警告 η 动作 η 停止 , where η 警告 >η 动作 >η 停止 ;

[0171] When η 动作 <η≤η 警告 When this happens, the system will display a message indicating an abnormality in the corresponding conveyor belt transmission.

[0172] When η 停止 <η≤η 动作 At this time, the conveyor belt's transmission efficiency decreases significantly, and the speed of the storage tank's bottom belt is adjusted accordingly. In this situation, the negative feedback control of the material height on the discharge conveyor belt should be disabled, and the set frequency of the bottom belt drive inverter should be:

[0173] f 联动 =(η-0.1)*f 修正 (25)

[0174] When η≤η 停止 At that time, the belt slipped severely, and the bottom belt stopped discharging material;

[0175] When η > η 警告 When the storage tank resumes discharging, the negative feedback control of the material height of the discharge conveyor belt is reactivated.

[0176] Example 2

[0177] refer to Figure 1 The storage tank discharge system includes a storage tank body 1, a bottom belt 2 installed at the bottom of the storage tank body 1, and several feeding rollers 5 installed inside the storage tank body 2. The feeding rollers 5 are driven by a geared motor through chain transmission, and the geared motor is driven by a frequency converter. A discharge port is opened on one side of the bottom of the storage tank body, and one end of the bottom belt 2 is located above the discharge port. Drive shafts are set on both sides of the bottom belt 2, driven by a geared motor through chain transmission, and the geared motor is driven by a frequency converter. An encoder 4 is installed on the drive shaft. A conveyor belt 6 is set below the discharge port. A slippage monitoring device 7 is set on the driven shaft of the conveyor belt 6, and a material level height sensor 8 is set on the conveyor belt 6.

[0178] The geared motor, frequency converter, slippage monitoring device 7, encoder, and material level height sensor 8 are all connected to the controller.

[0179] The slippage monitoring device has been disclosed in Chinese Patent Application No. 2024102086689.

[0180] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A smart, feedback-based, and linkage-based method for controlling the discharge of materials from a storage tank, characterized in that: The control method specifically includes the following steps: S1. Determine the baseline speed based on the feed rate of the storage tank; S2, Feedback Correction; S21. Adjust the discharge speed according to the material storage situation in the cabinet; S22. Adjust the discharge speed based on the material height feedback on the discharge canvas; S3, linkage equipment; In step S1, the specific process for determining the baseline speed based on the tank feed rate is as follows: The storage capacity of the mixing cabinet is: （1） in, This refers to the density of the material, expressed in kg / m³. 3 ; 'a' represents the length of the mixing cabinet (in meters); 'a' represents the width of the mixing cabinet (in meters); 'h' represents the material storage height of the mixing cabinet (in meters). The discharge flow rate is: （2） Where v is the speed of the bottom belt of the mixing cabinet, in m / s; Given that the downstream container loading station has a container loading capacity of Q 装箱 If the mixing cabinet discharges material from a single cabinet, then the discharge flow rate is... If the mixing cabinet discharges material from the top cabinet simultaneously, the discharge flow rate will be... ; Calculate the discharge time based on the material storage capacity W and discharge flow rate Q of the mixing cabinet: （3） The discharge speed of the bottom belt of the mixing cabinet can then be obtained: （4） The motor speed is: （5） Where f1 is the inverter output frequency, s1 is the slip rate, and p1 is the number of pole pairs of the rotating magnetic field of the motor; setting i1 as the speed ratio of the reducer, the output shaft speed of the reducer is: （6） This refers to the number of teeth on the drive sprocket on the output shaft of the reducer. Let be the number of teeth on the driven sprocket of the bottom belt drive shaft, then the rotational speed of the bottom belt drive shaft is: （7） d is the diameter of the bottom belt drive sprocket, in meters. Therefore, the running speed of the bottom belt is equal to the linear velocity of the bottom belt drive sprocket. （8） Therefore, we get: （9） in, ; Therefore, when the material storage capacity W and the discharge flow rate Q of the mixing cabinet are met, the reference frequency for the drive motor at the bottom of the cabinet is: （10） In step S21, the specific process for adjusting the discharge speed based on the material storage situation in the cabinet is as follows: Given the characteristics of material storage inside the mixed-filament cabinet, the entire cabinet's material is divided into five discharge stages based on material height in the discharge direction: pre-filling, head of material, normal material, tail of material, and empty material. The variable for the current discharge stage is... （11） The five-stage discharge phase is based on the length of the material on the bottom belt in the discharge direction from the discharge port. To divide, the scale variable: （12） Current discharge length is: （13） in, This refers to the number of pulses triggered by the encoder on the bottom drive shaft. The number of encoder trigger pulses for one revolution of the bottom belt drive shaft; Based on the actual discharge status, there is only one G value of 1 at any given time. < ,but ;when ,but ,in ;when > hour, ; Define the underbelly speed correction variables for each stage: X=[X1,X2,X3,X4,X5] T (14) in, for The correction variable value for the discharge stage is 1≤i≤5; the product of the discharge stage variable G and the bottom belt speed correction variable X for each stage is used to obtain the material storage speed correction coefficient in the cabinet: C=G*X=[G1,G2,G3,G4,G5]*[X1,X2,X3,X4,X5] T (15) Based on the operating reference frequency of the drive motor at the bottom of the cabinet The correction factor C for the material stored in the cabinet is used to obtain the correction value for the material discharge frequency at the bottom of the cabinet. （16） In step S22, the specific process of adjusting the discharge speed based on the material height feedback on the discharge canvas includes: Based on the height of the material on the conveyor belt The current discharge volume flow rate is reflected by the material height, while the throughput capacity of the conveying equipment is reflected by the material height. As a standard; when the mixing cabinet discharges material, the material level sensor located at the discharge conveyor belt measures the material height on the conveyor belt in real time. The material height data is transmitted to the PLC, which then calculates the material height based on the real-time discharge height. With respect to the standard height of the discharge The difference Adjust the set frequency of the bottom-band drive inverter. This allows for adjustment of the discharge speed of the bottom belt of the mixing cabinet to control the material height on the discharge conveyor belt and maintain stability; among which, This is the frequency compensation amount that is dynamically adjusted as Δh changes; In step S3, the specific process of the linkage equipment is as follows: The speed of the geared motor is: （17） Given that the reduction ratio of the geared motor is i2, then the output shaft speed of the geared motor is: （18） The number of teeth on the gear on the output shaft of the geared motor and the gear on the feed roller shaft are set as follows: , The rotational speed of the feeding roller can be obtained as follows: （19） According to the matching and linkage principle, the bottom strip travels a fixed distance S. 固定 When the feeding roller rotates one revolution, the running time of both is equal, as detailed below: （20） Where v is the running speed of the bottom belt, the drive frequency of the feed roller inverter can be obtained according to the equation: （21） （22） Where k1 and k2 are both constants, in S 固定 Under certain conditions, the operating frequency of the feed roller inverter is proportional to the operating frequency of the bottom belt motor inverter, that is, the rotational speed of the feed roller is proportional to the running speed of the bottom belt. In step S3, to prevent material discharge blockage, the speed of the shift roller is optimized at different bottom belt speeds, as follows: Operating frequency of the baseband inverter Identify the baseband operating speed and define the boundary frequency. ,in ; when At this time, it is the slow discharge stage U1; when At this time, it is the normal speed discharge stage U2; when At this time, it is the rapid discharge stage U3; For different discharge stages U, define optimization coefficients. The optimized speed of the roller is: f 优化 =f2*U* =f2*[U1,U2,U3]*[ 1, 2, 3] T (23) In step S3, the specific process of the linkage equipment also includes: To ensure stable material output, the conveyor belt efficiency is monitored, and the discharge speed is adjusted based on the real-time efficiency. A belt slippage detection device installed on each conveyor belt transmits the monitoring signal to the PLC, which then calculates the belt conveying efficiency in real time based on the signal. ,in , The closer the value is to 1, the higher the belt transmission efficiency. when At this time, the belt does not slip; the overall efficiency of the conveyor belt is: （24） Where y represents the conveyor belt identifier and j represents the number of conveyor belts; Different belt transmission efficiency values ​​are defined for different conveyor belts y. , , ,in ; when When this happens, the system will display a message indicating an abnormality in the corresponding conveyor belt transmission. when At this time, the conveyor belt's transmission efficiency decreases significantly, and the speed of the storage tank's bottom belt is adjusted accordingly. In this situation, the negative feedback control of the material height on the discharge conveyor belt should be disabled, and the set frequency of the bottom belt drive inverter should be: （25） when At that time, the belt slipped severely, and the bottom belt stopped discharging material; when When the storage tank resumes discharging, the negative feedback control of the material height of the discharge conveyor belt is reactivated.

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