Precise metal crushing and screening integrated system

Abstract

The invention relates to the technical field of precision metal production and processing, and discloses a precision metal crushing and screening integrated system which is characterized in that a crushing monitoring module is used for monitoring and collecting data of a crushing flow set and a particle size set; a power monitoring module monitors and collects data of a voltage data set, a current data set, a temperature data set and a vibration data set, a comprehensive analysis module calculates a flow abnormal index and a granularity abnormal index, and a power equipment health index is calculated according to the voltage data set, the current data set, the temperature data set and the vibration data set. The evaluation module judges the abnormal working condition of the crusher according to the flow abnormal index and the granularity abnormal index, judges the abnormal working condition of the power equipment according to the health index of the power equipment, identifies whether maintenance is needed or not according to a judgment result, and sends a signal to the feedback module when maintenance is needed; and whether the equipment is blocked or not and whether the cutter screen and the power equipment have faults or not can be found in time.

Description

Technical Field

[0001] The present invention relates to the technical field of precision metal production and processing, and in particular to a precision metal crushing and screening integrated system. Background Art

[0002] Precision metals refer to metal parts that can achieve extremely high accuracy and fully meet strict specifications during the manufacturing process. Such metals are often used in high-tech products, and both the appearance and internal parts need to achieve micron-level accuracy. Precision metal processing involves a variety of metal materials, such as steel, aluminum, stainless steel, brass, copper, titanium and precious metals, etc., which are achieved through technical means such as CNC machining, brazing, polishing, anodizing and rapid prototype manufacturing. Through precision metal processing, high-quality parts can be produced, and the accuracy and quality of these parts directly affect the performance of the final product. For example, in the field of automobile manufacturing, engine parts, transmission system components and body structural parts produced by precision metal processing directly determine the performance and safety of the car. Through crushing and screening, large pieces of metal materials can be broken into small pieces or particles of the required particle size. These small pieces or particles can be used as raw materials for subsequent processing. Screening further ensures the uniformity of the particle size of the raw materials, thereby improving the utilization rate of materials and reducing waste.

[0003] During the crushing and screening process of the crusher, the screen and crushing tools are subjected to the impact and friction of the materials for a long time, which are easy to wear, affecting the processing efficiency and causing a decrease in processing accuracy. At the same time, the motor is the power source of the crusher. It transmits power to the main shaft or other key components of the crusher through transmission devices such as belts, gears or chains. Before the motor fails, it is impossible to conduct effective evaluation and prediction, which will result in consequences that affect production. Summary of the invention

[0004] 1. Technical issues to be resolved In response to the deficiencies in the prior art, the present invention provides an integrated precision metal crushing and screening system, which has the ability to monitor the production status of the equipment in real time, can promptly detect equipment blockage and tool screen failure problems, and can monitor the operating status of the power equipment to help detect signs of failure in advance, thereby preventing sudden equipment shutdowns, ensuring that the equipment always operates in the best condition, reducing production interruptions caused by equipment failures, and improving production efficiency. Predictive maintenance can reduce the number and cost of emergency repairs, while extending the service life of the equipment, thereby reducing overall operating costs and other advantages.

[0005] (II) Technical solution To achieve the above-mentioned object, the present invention provides the following technical solutions: an integrated system for precision metal crushing and screening, comprising a crushing monitoring module and a power monitoring module; The crushing monitoring module includes a production flow monitoring unit and a production particle size monitoring unit; The production flow monitoring unit is connected to an electromagnetic flowmeter, which is used to measure the actual flow data of the crushed product inside the crusher, and save the measured data to form a crushing flow set. The production particle size monitoring unit is connected to a particle size analyzer, which is used to monitor the particle size of the crushed product of the crusher, and save the monitored particle size data to form a particle size set. The crushing monitoring module sends the crushing flow set and the particle size set to the comprehensive analysis module; The power monitoring module includes a power voltage monitoring unit, a power current monitoring unit, a power temperature monitoring unit and a power vibration monitoring unit; The power voltage monitoring unit is connected to a voltage sensor, which is used to measure the voltage data of the power equipment and save the measured data to form a voltage data set. The power current monitoring unit is connected to a current sensor, which is used to measure the current data of the power equipment and save the measured current data to form a current data set. The power temperature monitoring unit is connected to a temperature sensor, which is used to measure the temperature data of the power equipment and save the measured temperature data to form a temperature data set. The power vibration monitoring unit is connected to a vibration sensor, which is used to measure the vibration data of the power equipment and save the measured vibration data to form a vibration data set. The power voltage monitoring unit sends the voltage data set, the current data set, the temperature data set and the vibration data set to the comprehensive analysis module; The comprehensive analysis module includes a crushing analysis unit and a power analysis unit; The fragmentation analysis unit calculates the flow anomaly index and the particle size anomaly index according to the fragmentation flow set and the particle size set and sends them to the evaluation module; The power analysis unit calculates the power equipment health index based on the voltage data set, the current data set, the temperature data set, and the vibration data set and sends it to the evaluation module; The evaluation module determines the abnormal working condition of the crusher according to the flow abnormality index and the particle size abnormality index, determines the abnormal working condition of the power equipment according to the power equipment health index, and identifies whether a maintenance signal needs to be sent based on the judgment result. If a maintenance signal needs to be sent, the signal is sent to the feedback module.

[0006] Preferably, the electromagnetic flowmeter is installed in the upstream straight pipe section of the crusher discharge port and is at a position at least 3 to 5 times the pipe diameter away from the upstream interference element, and the particle size analyzer is installed at the crusher discharge port.

[0007] Preferably, the saved data of the fragmented traffic set is marked as: , the saved data of the granularity size set is marked as: The data collection period, interval time and data quantity of the broken flow set and the particle size set are consistent.

[0008] Preferably, the voltage sensor is installed on the power line of the motor, the current sensor is installed on the three-phase cable of the motor, the temperature sensor is mainly used to monitor the crusher main shaft, and the vibration sensor is installed on the main body casing of the power equipment.

[0009] Preferably, the stored data of the voltage data set is marked as: , the saved data of the current data set are marked as: , the saved data of the temperature data set are marked as: , the saved data of the vibration data set are marked as: The data collection period, interval time and data quantity of the voltage data set, current data set, temperature data set and vibration data set are consistent.

[0010] Preferably, the calculation formula of the flow anomaly index is:

[0011] in, Represents the traffic anomaly index, is the average flow index of the broken flow set, is the standard flow difference of the broken flow set, which is used to measure the discrete degree of the broken flow set data. To break down traffic data in real time, The first Broken flow data, is the number of data in the dataset.

[0012] Preferably, the particle size anomaly index is calculated as follows:

[0013] in, represents the particle size anomaly index, is the average particle size data of the particle size set, is the standard granularity data difference of the granularity set, which is used to measure the discreteness of the granularity set data. For real-time granularity data, The particle size is the first Granularity size data, is the number of data in the dataset.

[0014] Preferably, when the flow abnormality index or the particle size abnormality index is greater than the corresponding flow threshold or particle size threshold, it indicates internal blockage or a malfunction of the cutter or filter inside the crusher, and a maintenance signal is sent to the feedback module.

[0015] Preferably, the power equipment health index is calculated as follows:

[0016] in:

[0017] Represents the average difference of voltage data in the voltage data set;

[0018] represents the average difference of the current data in the current data set;

[0019] Represents the average difference of temperature data in the temperature data set;

[0020] Represents the average difference of vibration data in the vibration data set; in, , , , Represent the health score functions of voltage, current, temperature, and vibration data respectively, , , , Represents the weights of the factors corresponding to voltage, current, temperature, and vibration data respectively. Represents the running time of the device. The number of times the equipment is repaired. Represents the service age regression factor, which is used to describe the impact of repair activities on the system failure rate and reflects the change in the health status of the equipment after maintenance. is the number of data in the dataset.

[0021] Preferably, when the power equipment health index is greater than a power equipment threshold, it indicates that there is a fault in the power equipment, and a power equipment maintenance signal is sent to the feedback module; The feedback module issues a corresponding alarm according to the corresponding signal.

[0022] Compared with the prior art, the present invention provides an integrated system for precision metal crushing and screening, which has the following beneficial effects: 1. The present invention calculates the flow anomaly index by crushing the flow set, which directly reflects the processing capacity of the equipment, reflects the amount of material that the equipment can process per unit time, determines whether the equipment can meet production needs, and is convenient for understanding the efficiency of the equipment. The particle size set calculates the particle size anomaly index, thereby reflecting the processing capacity and screening effect of the equipment. At the same time, the particle size set also indirectly reflects the crushing efficiency and production capacity of the equipment. The particle size set directly determines the quality of the material after screening. In addition, the particle size set also reflects the quality and performance of the screen or sieve plate. The high-quality screen or sieve plate can more accurately screen out materials of a specific particle size, thereby ensuring the stability and reliability of the screening effect.

[0023] 2. The present invention calculates the power equipment health index through voltage data sets, current data sets, temperature data sets, and vibration data sets to reflect the real-time status and potential problems of the equipment, help discover signs of failure in advance, thereby preventing sudden shutdown of the equipment, ensuring that the equipment always operates in the best condition, reducing production interruptions caused by equipment failures, and improving production efficiency. Predictive maintenance can reduce the number and cost of emergency repairs, while extending the service life of the equipment, thereby reducing overall operating costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the structural system of the present invention; DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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.

[0026] See also Figure 1 , a precision metal crushing and screening integrated system, including a crushing monitoring module and a power monitoring module; The crushing monitoring module includes a production flow monitoring unit and a production particle size monitoring unit; The production flow monitoring unit is connected to an electromagnetic flowmeter, which is used to measure the actual flow data of the crushed products inside the crusher. The electromagnetic flowmeter is installed in the upstream straight pipe section of the crusher discharge port and is at a distance of at least 3 to 5 times the pipe diameter from the upstream interference element. The measured data is saved to form a crushing flow set. The production particle size monitoring unit is connected to a particle size analyzer, which is used to monitor the particle size of the crushed products of the crusher. The particle size analyzer is installed at the crusher discharge port and the monitored particle size data is saved to form a particle size set. The crushing monitoring module sends the crushing flow set and particle size set to the comprehensive analysis module.

[0027] The crushing flow set directly reflects the processing capacity of the equipment, reflects the amount of material that the equipment can process per unit time, determines whether the equipment can meet production needs, and facilitates understanding of the efficiency of the equipment. The saved data of the crushing flow set is marked as: .

[0028] The particle size set reflects the processing capacity and screening effect of the equipment. At the same time, the particle size set also indirectly reflects the crushing efficiency and production capacity of the equipment. The particle size set directly determines the quality of the material after screening. If the particle size set is stable and meets the requirements, it means that the screening effect is good and the materials that meet the requirements can be effectively separated. In addition, the particle size set also reflects the quality and performance of the screen or screen plate. High-quality screens or screen plates can more accurately screen out materials of a specific particle size, thereby ensuring the stability and reliability of the screening effect. The saved data of the particle size set is marked as: .

[0029] The data collection cycle, interval time, and data quantity of the broken flow set and the particle size set are consistent; The power monitoring module includes a power voltage monitoring unit, a power current monitoring unit, a power temperature monitoring unit and a power vibration monitoring unit.

[0030] The power voltage monitoring unit is connected to a voltage sensor, which is used to measure the voltage data of the power equipment. The voltage sensor is installed on the power line of the motor, and the measured data is saved to form a voltage data set. The power current monitoring unit is connected to a current sensor, which is used to measure the current data of the power equipment. The current sensor is installed on the three-phase cable of the motor, and the measured current data is saved to form a current data set. The power temperature monitoring unit is connected to a temperature sensor, which is used to measure the temperature data of the power equipment. The temperature sensor is mainly used to monitor the main shaft of the crusher, and the measured temperature data is saved to form a temperature data set. The power vibration monitoring unit is connected to a vibration sensor, which is used to measure the vibration data of the power equipment. The vibration sensor is installed on the main body shell of the power equipment, and the measured vibration data is saved to form a vibration data set. The power voltage monitoring unit sends the voltage data set, current data set, temperature data set and vibration data set to the comprehensive analysis module.

[0031] The voltage data set, current data set, temperature data set, and vibration data set can be used to understand the operating status of power equipment in real time, and to promptly detect potential faults or abnormal conditions, which helps prevent sudden equipment shutdowns, reduce production interruptions and losses caused by equipment failures, and promptly detect safety hazards and prevent accidents. The saved data of the voltage dataset are marked as: ; The saved data of the current dataset are marked as: ; The saved data of the temperature dataset are marked as: ; The saved data of the vibration dataset are marked as: ; The data collection period, interval time, and data quantity of the voltage data set, current data set, temperature data set, and vibration data set are consistent.

[0032] The comprehensive analysis module includes a crushing analysis unit and a dynamic analysis unit; The fragmentation analysis unit calculates the flow anomaly index and the particle size anomaly index according to the fragmentation flow set and the particle size set and sends them to the evaluation module; The calculation formula of traffic anomaly index is:

[0033] in, Represents the traffic anomaly index, is the average flow index of the broken flow set, is the standard flow difference of the broken flow set, which is used to measure the discrete degree of the broken flow set data. To break down traffic data in real time, The first Broken flow data, is the number of data in the dataset.

[0034] The calculation method of particle size anomaly index is:

[0035] in, represents the particle size anomaly index, is the average particle size data of the particle size set, is the standard granularity data difference of the granularity set, which is used to measure the discreteness of the granularity set data. For real-time granularity data, The particle size is the first Granularity size data, is the number of data in the dataset.

[0036] The power analysis unit calculates the power equipment health index based on the voltage data set, the current data set, the temperature data set, and the vibration data set and sends it to the evaluation module.

[0037] Calculating the power equipment health index through voltage data sets, current data sets, temperature data sets, and vibration data sets can reflect the real-time status and potential problems of the equipment, help detect signs of failure in advance, thereby preventing sudden equipment shutdowns, ensuring that the equipment always operates in the best condition, reducing production interruptions caused by equipment failures, and improving production efficiency. Predictive maintenance can reduce the number and cost of emergency repairs, while extending the service life of equipment, thereby reducing overall operating costs.

[0038] The calculation method of power equipment health index is:

[0039] in:

[0040] Represents the average difference of voltage data in the voltage data set;

[0041] represents the average difference of the current data in the current data set;

[0042] Represents the average difference of temperature data in the temperature data set;

[0043] Represents the average difference of vibration data in the vibration data set; in, , , , The health scoring functions represent voltage, current, temperature, and vibration data respectively. By calculating the values ​​of these scoring functions, the health scores of various monitoring parameters of the equipment can be obtained, and then the overall health index of the equipment can be calculated comprehensively. These scoring functions give a score according to the size of the characteristic value. Generally, the closer to the ideal state, the higher the score. , , , Represents the weights of the factors corresponding to voltage, current, temperature, and vibration data respectively. Represents the running time of the device. The number of times the equipment is repaired. Represents the service age regression factor, which is used to describe the impact of repair activities on the system failure rate and reflects the change in the health status of the equipment after maintenance. is the number of data in the dataset.

[0044] The evaluation module determines the abnormal working condition of the crusher according to the flow abnormality index and the particle size abnormality index. When the flow abnormality index or the particle size abnormality index is greater than the corresponding flow threshold or particle size threshold, it means that there is an internal blockage or a fault in the cutter or filter inside the crusher, and a maintenance signal is sent to the feedback module; when the power equipment health index is greater than the power equipment threshold, it means that there is a fault in the power equipment, and a power equipment maintenance signal is sent to the feedback module; the feedback module issues a corresponding alarm according to the corresponding signal.

[0045] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A precision metal crushing and screening integrated system, characterized by: Including crushing monitoring module and power monitoring module; The crushing monitoring module includes a production flow monitoring unit and a production particle size monitoring unit; The production flow monitoring unit is connected to an electromagnetic flowmeter, which is used to measure the actual flow data of the crushed product inside the crusher, and save the measured data to form a crushing flow set. The production particle size monitoring unit is connected to a particle size analyzer, which is used to monitor the particle size of the crushed product of the crusher, and save the monitored particle size data to form a particle size set. The crushing monitoring module sends the crushing flow set and the particle size set to the comprehensive analysis module; The power monitoring module includes a power voltage monitoring unit, a power current monitoring unit, a power temperature monitoring unit and a power vibration monitoring unit; The power voltage monitoring unit is connected to a voltage sensor, which is used to measure the voltage data of the power equipment, and save the measured data to form a voltage data set. The power current monitoring unit is connected to a current sensor, which is used to measure the current data of the power equipment, and save the measured current data to form a current data set. The power temperature monitoring unit is connected to a temperature sensor, which is used to measure the temperature data of the power equipment, and save the measured temperature data to form a temperature data set. The power vibration monitoring unit is connected to a vibration sensor, which is used to measure the vibration data of the power equipment, and save the measured vibration data to form a vibration data set. The power voltage monitoring unit sends the voltage data set, the current data set, the temperature data set and the vibration data set to the comprehensive analysis module; The comprehensive analysis module includes a crushing analysis unit and a power analysis unit; The fragmentation analysis unit calculates the flow anomaly index and the particle size anomaly index according to the fragmentation flow set and the particle size set and sends them to the evaluation module; The power analysis unit calculates the power equipment health index based on the voltage data set, the current data set, the temperature data set, and the vibration data set and sends it to the evaluation module; The evaluation module determines the abnormal working condition of the crusher according to the flow abnormality index and the particle size abnormality index, determines the abnormal working condition of the power equipment according to the power equipment health index, and identifies whether a maintenance signal needs to be sent based on the judgment result. If a maintenance signal needs to be sent, the signal is sent to the feedback module.

2. The integrated precision metal crushing and screening system according to claim 1 is characterized in that: The electromagnetic flowmeter is installed in the upstream straight pipe section of the crusher discharge port and is at a position at least 3 to 5 times the pipe diameter away from the upstream interference element. The particle size analyzer is installed at the crusher discharge port.

3. The integrated precision metal crushing and screening system according to claim 2 is characterized in that: The saved data of the fragmented traffic set is marked as ; The saved data of the granularity set is marked as The data collection period, interval time and data quantity of the broken flow set and the particle size set are consistent.

4. The integrated precision metal crushing and screening system according to claim 1 is characterized in that: The voltage sensor is installed on the power line of the motor, the current sensor is installed on the three-phase cable of the motor, the temperature sensor is mainly used to monitor the main shaft of the crusher, and the vibration sensor is installed on the main body shell of the power equipment.

5. The integrated precision metal crushing and screening system according to claim 4 is characterized in that: The saved data of the voltage data set is marked as ; The saved data of the current data set are marked as ; The saved data of the temperature data set is marked as ; The saved data of the vibration data set is marked as ; The data collection period, interval time and data quantity of the voltage data set, current data set, temperature data set and vibration data set are consistent.

6. The integrated precision metal crushing and screening system according to claim 3 is characterized in that: The calculation formula of the flow anomaly index is: in, Represents the traffic anomaly index, is the average flow index of the broken flow set, is the standard flow difference of the broken flow set, which is used to measure the discrete degree of the broken flow set data. To break down traffic data in real time, The first Broken flow data, is the number of data in the dataset.

7. The integrated precision metal crushing and screening system according to claim 3 is characterized by: The particle size anomaly index is calculated as follows: in, represents the particle size anomaly index, is the average particle size data of the particle size set, is the standard granularity data difference of the granularity set, which is used to measure the discreteness of the granularity set data. For real-time granularity data, The particle size is the first Granularity size data, is the number of data in the dataset.

8. The integrated precision metal crushing and screening system according to claim 7 is characterized in that: When the flow abnormality index or the particle size abnormality index is greater than the corresponding flow threshold or particle size threshold, it indicates internal blockage or a failure of the cutter or filter inside the crusher, and a maintenance signal is sent to the feedback module.

9. The integrated precision metal crushing and screening system according to claim 5, characterized in that: The calculation method of the power equipment health index is: in, Represents the average difference of voltage data in the voltage data set; represents the average difference of the current data in the current data set; Represents the average difference of temperature data in the temperature data set; Represents the average difference of vibration data in the vibration data set; in, , , , Represent the health score functions of voltage, current, temperature, and vibration data respectively, , , , Represents the weights of the factors corresponding to voltage, current, temperature, and vibration data respectively. Represents the running time of the device. The number of times the equipment is repaired. Represents the service age regression factor, which is used to describe the impact of repair activities on the system failure rate and reflects the change in the health status of the equipment after maintenance. is the number of data in the dataset.

10. The integrated precision metal crushing and screening system according to claim 9, characterized in that: When the power equipment health index is greater than the power equipment threshold, it means that there is a fault in the power equipment, and a power equipment maintenance signal is sent to the feedback module; The feedback module issues a corresponding alarm according to the corresponding signal.

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