Disc separator system based on digital twinning and deslagging method

Abstract

The invention relates to the technical field of disc type separators, in particular to a disc type separator system based on digital twinning and a deslagging method.The disc type separator system comprises an entity data acquisition module used for acquiring experimental data of a disc type separator and basic data of the disc type separator; the digital twinborn module presentation layer is used for constructing a twinborn body model of the disc separator; the data layer is used for constructing an offline database; the logic layer is used for mapping of the disc separator from a physical space to a virtual model, and three-dimensional visualization of an internal flow field of the disc separator is carried out through finite elements; and the man-machine interaction module is used for displaying the operation of the twin dynamic simulation model of the disc separator, displaying an internal flow field of the twin dynamic simulation model and monitoring whether the heavy phase content at a light phase outlet is abnormal or not. The problems that the internal structure and the flow field of an existing disc type separator cannot be visually perceived, the basic operation condition cannot be reproduced, and a slag discharging opening is blocked due to the fact that the solid content is too large during slag discharging are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of disc separators, and in particular to a disc separator system and a slag discharge method based on digital twins. Background Art

[0002] As a common separation equipment, disc separator has been widely used in many industrial fields such as chemical industry, metallurgy, petroleum and food due to its advantages such as good separation performance, simple structure and easy operation. However, there is currently a lack of effective monitoring methods for disc separators.

[0003] The existing monitoring of disc separators is all passive operation and maintenance. This operation and maintenance method is not only inefficient, but also easily leads to untimely warnings and potential dangerous accidents. It is impossible to achieve refined and intelligent high-standard control requirements. Therefore, a system for comprehensive management and control of disc separators is needed.

[0004] Digital twin technology maps the properties, structure, state, performance, function and behavior of physical entities and systems into the virtual world to form a high-fidelity dynamic multi-dimensional, multi-scale, multi-physical quantity model, providing an effective means to observe, recognize, understand, control and transform the physical world.

[0005] The publication number is CN113868898A. This method can maintain a high degree of consistency between the equipment and the digital twin model, which is beneficial to improving the accuracy of the simulation results of the digital twin model and meeting the needs of staff for multi-directional observation. However, the standards and specifications required for digital twins in different industries and fields are not the same. The method of this patent cannot be fully adapted to separation technology. Summary of the invention

[0006] In view of the shortcomings of the existing methods, the present invention solves the problem that the internal structure and flow field of the existing disc separator cannot be intuitively perceived and the basic operating conditions cannot be reproduced; and the existing separator is prone to clogging the slag discharge port when the solid content is too high when discharging slag through the slag discharge port.

[0007] The technical solution adopted by the present invention is: the disc separator system based on digital twins includes: a physical data acquisition module, a digital twin module and a human-computer interaction module; wherein,

[0008] The entity data acquisition module is used to collect the experimental data and basic data of the disc separator;

[0009] As a preferred embodiment of the present invention, the experimental data of the disc separator includes: material parameters, operating speed, processing volume and separation efficiency data.

[0010] As a preferred embodiment of the present invention, the basic data of the disc separator includes: size data, quality data and structure data.

[0011] The digital twin module includes presentation layer, logic layer and data layer. The presentation layer is used to build a twin model of the disc separator; the data layer is used to build an offline database; the logic layer is used to map the disc separator from physical space to the virtual model, and to perform three-dimensional visualization of the internal flow field of the disc separator through finite elements.

[0012] As a preferred embodiment of the present invention, the construction of the twin model of the disc separator includes:

[0013] Use SolidWorks software to perform 3D modeling of the disc separator;

[0014] Lightweight the 3D model in 3dMax;

[0015] As a preferred embodiment of the present invention, the lightweight processing includes: establishing a part model of the disc separator in SolidWorks, importing the part model into 3dMax, and determining whether there are redundant vertices and lines; if so, deleting the redundant vertices and lines; if not, determining whether to simplify the part model.

[0016] The 3D model is integrated into Unity3D, physical property components are added, and offline database data is called to drive the dynamic simulation model movement of the disc separator twin.

[0017] The human-computer interaction module is used to display the operation of the disc separator twin dynamic simulation model, display its internal flow field, and monitor whether the heavy phase content at the light phase outlet is abnormal.

[0018] As a preferred embodiment of the present invention, whether the heavy phase content at the light phase outlet is abnormal includes: comparing the heavy phase content with a set threshold value, and automatically shutting down and triggering an alarm when the threshold value is exceeded.

[0019] As a preferred embodiment of the present invention, it also includes a data transmission module for data transmission between the physical data acquisition module and the digital twin module.

[0020] As a preferred embodiment of the present invention, a slag discharge method of a disc separator system based on digital twin includes:

[0021] The solid content in the disc separator is detected, and the detected solid content is compared with a first threshold value. When the solid content is lower than the first threshold value, the first slag discharge port is opened and the second slag discharge port is closed; when the solid content exceeds the first threshold value, the first slag discharge port is closed and the second slag discharge port is opened.

[0022] As a preferred embodiment of the present invention, the solid content is detected by a sensor arranged on the inner wall surface of the drum.

[0023] Beneficial effects of the present invention:

[0024] 1. The present invention uses digital twin technology to perform three-dimensional modeling of the disc separator, construct a digital twin model of the disc separator, reproduce the operation process of the disc separator, visualize the working conditions of the disc separator, simulate the flow field and structure of the disc separator in operation, and then analyze the changes in its internal flow field and structure, so that the staff can observe the changes in the internal flow field in real time;

[0025] 2. The internal structure and flow field of the traditional disc separator cannot be intuitively perceived and the operating conditions cannot be reproduced after operation. The digital twin presents intuitive results, accurately judges the operating conditions of the disc separator, and effectively reduces the occurrence of safety accidents;

[0026] 3. The sensor on the inner wall of the disc separator drum monitors the solid content inside the disc separator in real time, judges the solid content through the first and second thresholds, and selects slag discharge ports with different apertures to achieve efficient slag discharge;

[0027] 4. The present invention can not only utilize the data analysis capabilities of the digital twin model to enable the disc separator to automatically perform safe slag discharge shutdown, but also promptly alarm and provide maintenance suggestions when a slag discharge shutdown failure occurs. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a block diagram of the disc separator system and slag discharge method based on digital twin of the present invention;

[0029] Figure 2 It is a lightweight processing flow chart of the present invention. DETAILED DESCRIPTION

[0030] The present invention is further described below in conjunction with the accompanying drawings and embodiments. This figure is a simplified schematic diagram, which only illustrates the basic structure of the present invention in a schematic manner, and therefore it only shows the components related to the present invention.

[0031] like Figure 1 As shown, the disc separator system based on digital twins includes: a physical data acquisition module, a digital twin module and a human-computer interaction module; wherein,

[0032] The entity data acquisition module includes: collecting the experimental data of the disc separator and the basic data of the disc separator;

[0033] The experimental data of the disc separator include: material parameters, operating speed, processing capacity and separation efficiency collected through separation performance experiments, such as the concentration of the separated material, the speed of the material in the disc, the total amount of the material and the solid content of the material;

[0034] The basic data of the disc separator include: the size data and structure data of the disc separator;

[0035] Structural data include: inner diameter of the drum, equivalent sedimentation area, disc size and total number of discs, etc.

[0036] The data transmission module transmits the data collected by the physical data acquisition module to the digital twin module through the data interface;

[0037] The digital twin module uses the experimental data and basic data of the disc separator to build a data-driven architecture based on the presentation layer, logic layer, and data layer; builds a twin model of the disc separator in the presentation layer; builds an offline database in the data layer; in the logic layer, the data of the physical data acquisition module is transferred to the three-dimensional virtual model of the presentation layer to complete the mapping of the disc separator from the physical space to the virtual model, and the finite element software is used for simulation verification to achieve three-dimensional visualization of the internal flow field of the disc separator.

[0038] The twin model established by digital twin technology refers to the use of digital recovery technology to verify the data of the disc separator. Through the data-driven architecture, the metadata is stored in the database built on the data layer, and the information model of the disc separator is established. In addition, the data is transferred to the presentation layer through script control at the logical layer to complete the mapping of the disc separator from the physical space to the virtual model.

[0039] The information model of the disc separator is divided into a static information model and a dynamic information model. The static information model contains the disc separator's ontological information and general information, which is mainly divided into basic information and ontological information; the dynamic information model contains the information during the operation of the disc separator, which is mainly divided into material parameter information, speed information, processing volume information, efficiency information, etc.; the basic information includes information during the separation process such as concentration content, rotation speed, and separation efficiency, and the ontological information refers to the disc separator's size, size, number of discs, and other information.

[0040] The twin model of the disc separator was jointly modeled using software such as SolidWorks, 3dMax and Unity3D;

[0041] First, the disc separator is 3D modeled using SolidWorks software. According to the size of the disc separator in the laboratory, the approximate size and outline of each component are drawn in the component sketch, and the components are assembled in the assembly sketch to build a 3D model of the disc separator.

[0042] like Figure 2 Secondly, the texture of the part model is enhanced in 3dMax, and the three-dimensional model is lightweighted to obtain the optimized three-dimensional model of the disc separator; the lightweight processing of the model is to establish the part model of the disc separator in SolidWorks, import the part model into the 3dMax software, and determine whether there are redundant vertices and lines; if so, delete the redundant vertices and lines; if not, proceed to the next step to determine whether the part model needs to be streamlined to obtain a lightweight processing model.

[0043] At the same time, the test data of the disc separator during operation is used to build an offline database, and the separation efficiency, concentration, solid content, slag discharge and other data are optimized by extracting data through experiments;

[0044] Secondly, the three-dimensional model of the disc separator is integrated into Unity3D. By adding the physical property components in the Unity3D software, the data of the offline database is called to drive the movement of the three-dimensional model of the disc separator. The dynamic simulation model of the disc separator twin is constructed in Unity3D to ensure that each sub-model follows the corresponding behavioral characteristics, reduce the complexity of the disc separator twin model production, and improve the simulation effect and fluency, thereby enhancing the realism of the disc separator twin model; the sub-models include: feed pipe model, disc model, and slag discharge model.

[0045] The behavioral characteristics of the sub-model are to integrate the sub-modules on Unity3D and adjust the relationships between the sub-models, such as parallel relationships, vertical relationships, and "father-child" relationships; when the model is driven by the script, the initial state setting of the disc separator is debugged by using simulation data multiple times, so that the entire modeling work has a clear hierarchy, which is convenient for the staff to monitor the overall working condition of the disc separator.

[0046] Using Unity3D to build a dynamic simulation model of the disc separator twin is to use Unity3D as the simulation engine tool, import the lightweight 3D model into Unity3D, call the data in the offline database through the data transmission interface, drive the model movement of the disc separator twin, and realize the visualization of the simulation.

[0047] The human-computer interaction module refers to the use of digital twin technology to receive and display the operation process of the disc separator and visualize it, analyze the simulation results of the internal flow field and structure of the disc separator, so that the staff can observe the changes in the internal flow field in real time. At the same time, the solid phase content in the sediment area of ​​the drum is monitored through sensors to realize the self-thinking slag discharge of the disc separator.

[0048] A solid content detection sensor is arranged on the inner wall surface of the drum of the disc separator to detect the solid content in the disc separator in real time, and compare the detected solid content with a first threshold value. When the solid content is lower than the first threshold value, the first slag discharge port is opened, and the second slag discharge port arranged at the bottom of the disc separator is closed; when the solid content exceeds the first threshold value, the first slag discharge port is closed, the second slag discharge port is opened, and slag is discharged through the second slag discharge port.

[0049] Among them, the first slag discharge port is the existing slag discharge port of the centrifuge, and the aperture of the slag discharge port is relatively small, usually 10mm. When the solid content of the material to be separated in the centrifuge is high, it is easy to cause the first slag discharge port to be blocked, so it is necessary to set a second slag discharge port for slag discharge. The aperture of the second slag discharge port is 20mm, which can effectively solve the problem of being unable to discharge slag after the first slag discharge port is blocked.

[0050] The digital twin technology is used to virtually simulate the basic data of the disc separator. After three-dimensional modeling, the twin model of the disc separator is optimized to visualize the operating status of the disc separator and fully reproduce its operating process. The virtual simulation platform is used to observe its operating conditions, which makes it convenient for staff to observe the overall movement and analyze its internal flow field and structural changes, so as to achieve the purpose of real-time monitoring of its working status.

[0051] The human-computer interaction module refers to the use of digital twin technology to receive and display the operation process of the disc separator and visualize it, analyze the simulation results of the internal flow field and structure of the disc separator, so that the staff can observe the changes in the internal flow field in real time, and detect whether the heavy phase content in the slag area of ​​the drum exceeds the threshold. When the threshold is exceeded, the slag area will be blocked, affecting the slag discharge. When the threshold is exceeded, the machine will automatically shut down and trigger an alarm. The staff will check the disc separator and manually adjust the operating parameters to resume the disc separator, thereby improving the reliability and safety of the disc separator operation, meeting the requirements of safe slag discharge and shutdown of the disc separator, and reducing equipment failure rate and maintenance costs.

[0052] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. The disc separator system based on digital twin is characterized by: include: Entity data acquisition module, digital twin module and human-computer interaction module; among them, The entity data acquisition module is used to collect the experimental data and basic data of the disc separator; The digital twin module includes a presentation layer, a logic layer, and a data layer. The presentation layer is used to build a twin model of the disc separator. The data layer is used to build an offline database; the logic layer is used to map the disc separator from physical space to the virtual model, and to perform three-dimensional visualization of the internal flow field of the disc separator through finite elements; The human-computer interaction module is used to display the operation of the disc separator twin dynamic simulation model, display its internal flow field, and display whether the heavy phase content at the light phase outlet is abnormal.

2. The disc separator system based on digital twin according to claim 1, characterized in that: The construction of the twin model of the disc separator includes: Use SolidWorks software to perform 3D modeling of the disc separator; Lightweight the 3D model in 3dMax; The 3D model is integrated into Unity3D, physical property components are added, and offline database data is called to drive the dynamic simulation model movement of the disc separator twin.

3. The disc separator system based on digital twin according to claim 2, characterized in that: The lightweight processing includes: establishing a part model of the disc separator in SolidWorks, importing the part model into 3dMax, and determining whether there are redundant vertices and lines; if so, deleting the redundant vertices and lines; if not, determining whether to simplify the part model.

4. The disc separator system based on digital twin according to claim 1, characterized in that: Whether the heavy phase content at the light phase outlet is abnormal includes: comparing the heavy phase content with the set threshold, and automatically shutting down and triggering an alarm when the threshold is exceeded.

5. The disc separator system based on digital twin according to claim 1, characterized in that: The experimental data of the disc separator include: material parameters, operating speed, processing capacity and separation efficiency data.

6. The disc separator system based on digital twin according to claim 1, characterized in that: The basic data of disc separator include: size data, quality data and structure data.

7. The disc separator system based on digital twin according to claim 1, characterized in that: It also includes a data transmission module for data transmission between the physical data acquisition module and the digital twin module.

8. A slag discharge method for a disc separator system based on digital twinning according to any one of claims 1 to 7, characterized in that: include: Detecting the solid content in the disc separator, comparing the detected solid content with a first threshold value, and opening the first slag discharge port and closing the second slag discharge port when the solid content is lower than the first threshold value; When the solid content exceeds the first threshold value, the first slag discharge port is closed and the second slag discharge port is opened.

9. The slag discharge method of the disc separator system based on digital twin according to claim 8, characterized in that: The solid content is detected by a sensor installed on the inner wall of the drum.

10. The slag discharge method of the disc separator system based on digital twin according to claim 8, characterized in that: The second slag discharge port is located at the bottom of the disc separator.

Images