Device and method for realizing tamping control by detecting density of coal cake in real time

Abstract

The invention discloses a device and method for achieving tamping control by detecting the density of a coal cake in real time, and belongs to the technical field of coke oven smelting. The method comprises the following steps that when a sound frequency detector operates normally, the sound frequency of the coal cake before tamping is completed is obtained based on the sound frequency detector; carrying out amplification, filtering, digitization and frequency domain conversion processing on the sound frequency based on a signal processing module; the processed sound frequency is judged based on a tamping machine PLC system; and when the processed sound frequency meets the preset sound frequency, the vibration frequency of the coal cake meets the preset vibration frequency, then the density of the coal cake meets the requirement, and tamping is stopped. The tamping process of the tamping machine can be accurately controlled, the function of detecting the production quality of coal cakes in real time is achieved, manual intervention is reduced, and meanwhile the production efficiency of high-quality coal cakes is greatly improved.

Description

Technical Field

[0001] The invention belongs to the technical field of coke oven smelting, and in particular relates to a device and method for real-time detection of coal cake density to realize tamping control. Background Art

[0002] The production of high-quality coal briquettes plays an important role in the coking industry. Improving the tamping machine has enabled it to develop in the direction of intelligence, automation, and unmanned operation, which can greatly improve the efficiency and safety of high-quality coal briquettes production.

[0003] Today's coking enterprises mostly use traditional manual estimation and visual estimation methods to control the tamping process. Some methods use technical equipment to measure the height of the tamping hammer to achieve intelligent control of the tamping hammer, but it is still difficult to meet the demand for real-time detection of coal cake density. Therefore, it is necessary to improve the tamping hammer intelligently and use more intelligent and accurate detection equipment.

[0004] Therefore, it is urgent to propose a real-time coal cake density detection and tamping control method that can detect the coal cake production quality in real time and improve the production efficiency of high-quality coal cakes. Summary of the invention

[0005] In order to solve the above technical problems, the present invention proposes a device and method for real-time detection of coal cake density to achieve tamping control, so as to solve the problems existing in the above prior art.

[0006] To achieve the above object, the present invention provides a device for real-time detection of coal cake density to realize tamping control, comprising: a coal car operating room, in which a tamping machine frame and a tamping machine PLC system are arranged;

[0007] A tamping hammer is installed on the tamping machine frame, and sound insulation boards are installed on both sides for tamping the coal cakes;

[0008] The tamping machine PLC system is electrically connected to a sound frequency detector for real-time detection of the state of the coal cakes during the tamping process.

[0009] Optionally, the sound frequency detector is equipped with a signal processing module;

[0010] The signal processing module comprises an amplifier, a filter and an analog-to-digital converter, which are used to sequentially amplify, filter and digitalize the sound signal of the coal cake detected by the sound frequency detector.

[0011] Optionally, the amplifier adopts an instrument amplifier circuit composed of three operational amplifiers.

[0012] Optionally, the filter adopts an integrated filter circuit of a high-pass filter, a low-pass filter and a band-pass filter;

[0013] The high-pass filter is used to remove low-frequency noise and DC bias in the sound signal;

[0014] The low-pass filter is used to remove high-frequency noise in the sound signal;

[0015] The bandpass filter is used to retain sound signals within a specific frequency range.

[0016] Optionally, the analog-to-digital converter is a high-precision analog-to-digital converter for converting a continuous analog sound signal into a discrete digital signal.

[0017] Optionally, the signal processing module further includes a frequency domain conversion unit, which is used to perform a fast Fourier transform on the converted digital signal, transform the digital signal from the time domain to the frequency domain, and obtain amplitude and phase information of the digital signal in the frequency domain.

[0018] The present invention also provides a method for real-time detection of coal cake density to achieve tamping control. The device for real-time detection of coal cake density to achieve tamping control comprises the following steps:

[0019] When the sound frequency detector operates normally, the sound frequency of the coal cake before the tamping is completed is obtained based on the sound frequency detector;

[0020] Amplifying, filtering, digitizing and frequency-domain converting the sound frequency based on a signal processing module;

[0021] The processed sound frequency is judged based on the tamping machine PLC system;

[0022] When the processed sound frequency meets the preset sound frequency, the vibration frequency of the coal cake meets the preset vibration frequency, and then the density of the coal cake meets the requirement, the tamping is stopped.

[0023] Optionally, the process of determining whether the sound frequency detector operates normally includes:

[0024] Acquiring a first sound frequency and a second sound frequency at the beginning and the end of tamping based on a sound frequency detector;

[0025] When the value from the first sound frequency to the second sound frequency changes continuously, it is determined that the sound frequency detector operates normally;

[0026] When the values ​​from the first sound frequency to the second sound frequency remain equal, it is determined that the sound frequency detector is not operating normally.

[0027] Optionally, the calculation formula for frequency domain conversion is as follows:

[0028] ,

[0029] in, is the complex spectrum in frequency domain representation, is the signal function in the time domain representation, is the angular frequency.

[0030] Optionally, the vibration frequency calculation formula of the briquette is as follows:

[0031] ,

[0032] in, is the vibration frequency after damping, is the undamped vibration frequency, is the damping ratio;

[0033] The damping ratio is calculated as follows:

[0034] ,

[0035] Among them, β is the damping coefficient, k is the elastic stiffness coefficient, and m is the mass of the object.

[0036] Compared with the prior art, the present invention has the following advantages and technical effects:

[0037] The present invention detects the frequency of sound waves emitted by forced vibration of coal cakes through a sound frequency detector, thereby inferring the density of coal cakes in the tamping process, and promptly feeds back the information to the PLC system of the tamping machine, thereby achieving precise control of the tamping process of the tamping machine and realizing the function of real-time detection of coal cake production quality, reducing manual intervention while greatly improving the production efficiency of high-quality coal cakes.

[0038] The present invention detects the signal of the coal cake according to the sound frequency detector, and processes and analyzes it through the signal processing module, which can further improve the intelligence of the tamping process and lay a technical foundation for realizing full-automatic unmanned tamping process in the future. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0040] Figure 1 is a schematic diagram of a control device according to an embodiment of the present invention;

[0041] Figure 2 A partial schematic diagram of a control device according to an embodiment of the present invention;

[0042] Figure 3 A schematic diagram of a sound signal processing flow in an embodiment of the present invention;

[0043] Figure 4A schematic diagram of a control method flow chart of an embodiment of the present invention;

[0044] Among them, 1. tamping hammer, 2. tamping machine frame, 3. sound insulation board, 4. tamping machine PLC system, 5. coal car operating room, 6. sound frequency detector, 7. coal cake. DETAILED DESCRIPTION

[0045] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0046] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0047] Embodiment 1

[0048] like Figure 1-Figure 2 As shown, in this embodiment, a device for real-time detection of coal cake density to realize tamping control is provided, comprising: a coal car operating room 5, in which a tamping machine frame 2 and a tamping machine PLC system 4 are arranged;

[0049] A tamping hammer 1 is installed on the tamping machine frame 2 for tamping the coal cakes; sound insulation boards 3 are installed on both sides for reducing the influence of the adjacent tamping machines on the current sound frequency detector.

[0050] The tamping machine PLC system 4 is electrically connected to the sound frequency detector 6 for real-time detection of the state of the coal cakes during the tamping process in the middle of each tamping machine.

[0051] Implementable, such as Figure 3 As shown, the sound frequency detector 6 is equipped with a signal processing module; the signal processing module includes an amplifier, a filter and an analog-to-digital converter, which is used to amplify, filter and digitize the sound signal of the coal cake detected by the sound frequency detector 6 in sequence to ensure the accuracy and reliability of the signal.

[0052] Furthermore, the amplifier of this embodiment adopts an instrument amplifier circuit composed of three op amp amplifiers. The instrument amplifier has the characteristics of high input impedance and high common mode rejection ratio, which is very suitable for processing weak differential signals. The design purpose of this amplifier circuit is to preliminarily amplify the signal detected by the sensor and increase the amplitude of the signal for subsequent processing. Specifically, the instrument amplifier circuit of the three op amp structure includes two input op amps and one output op amp. The high input impedance of the input op amp prevents the sensor signal from being disturbed, and the high common mode rejection ratio can effectively suppress common mode noise and ensure the accuracy of signal amplification. The gain of the circuit can be flexibly set by adjusting the resistance value to adapt to frequency signals of different intensities.

[0053] It is feasible that after the frequency signal is amplified, the filter circuit processes the amplified signal to remove unnecessary noise and interference signals. Filter circuits usually include different types such as high-pass filters, low-pass filters and band-pass filters, which are used to suppress noise within a specific frequency range and retain useful signal components. Among them, the high-pass filter is used to remove low-frequency noise and DC bias to ensure that only the vibration signal in the high-frequency part is retained. The low-pass filter is used to remove high-frequency noise and only retain the signal in the low-frequency and medium-frequency parts. The band-pass filter combines the functions of the high-pass and low-pass filters, and only retains the signal within the effective frequency range in the sound frequency acquisition, that is, it filters out the unusable high-frequency and low-frequency signals.

[0054] This embodiment can effectively improve the signal-to-noise ratio of the signal by reasonably designing and combining the above-mentioned filter circuits, so that subsequent frequency signal acquisition and processing are more accurate.

[0055] It is feasible that the analog-to-digital converter uses a high-precision analog-to-digital converter to convert the continuous analog sound signal into a discrete digital signal. The high-precision analog-to-digital converter can provide a higher resolution and a faster sampling rate, which is very important for capturing rapidly changing vibration signals. In this embodiment, the sampling bit number of the analog-to-digital converter is usually 12 bits or higher, and the sampling frequency is set to 5kHz or higher to ensure that the signal can be accurately and quickly converted and processed.

[0056] It is feasible that the signal processing module further includes a frequency domain conversion unit, which is used to perform a fast Fourier transform on the converted digital signal, transform the digital signal from the time domain to the frequency domain, and obtain the amplitude and phase information of the digital signal in the frequency domain.

[0057] Furthermore, in order to achieve efficient spectrum analysis, this embodiment uses a fast Fourier transform algorithm. The fast Fourier transform is an optimization algorithm for the discrete Fourier transform. The fast Fourier transform reduces unnecessary operations by changing the processing order of data, which can greatly improve the operating efficiency of spectrum analysis. The fast Fourier transform spectrum analysis method performs a fast Fourier transform on the digital signal collected within a specific time range, transforming the signal from the time domain to the frequency domain, thereby obtaining information such as the amplitude and phase of the signal in the frequency domain, and then studying the spectrum structure and change law of the signal.

[0058] Among them, the formula of fast Fourier transform is:

[0059] ,

[0060] in, is the complex spectrum in frequency domain representation, is the signal function in the time domain representation, is the angular frequency, represents the imaginary unit, Represents a time variable.

[0061] After Fourier transform, the signal is represented as a series of complex numbers, each of which represents a component with a specific frequency. The frequency domain representation obtained by Fourier transform is analyzed and processed, and the frequency domain representation is displayed in the form of a graph, usually visualized using a spectrum diagram, which is fed back to the monitoring station in real time.

[0062] According to the characteristics of the spectrum graph, the monitoring station determines the frequency components, frequency intensity, frequency changes and other information in the signal, analyzes the peak values ​​in the spectrum graph, identifies and determines the main frequency components in the signal, and then analyzes and determines the tamping process.

[0063] The signal processing module of this embodiment uses a variety of digital signal processing technologies such as amplification, filtering, spectrum analysis, Fourier transform, etc. to process the received sound signal. Filtering can further remove residual noise and interference signals, and spectrum analysis and Fourier transform are used to extract frequency components and other characteristics in the signal, so as to more accurately analyze the density state of the coal cake, and feed the analysis results back to the control and monitoring station, and send the analysis results and commands to the tamping machine controller to control the operation of the tamping machine, which can further improve the intelligence of the tamping process and lay a technical foundation for the future full-automatic unmanned tamping process.

[0064] like Figure 4 As shown, the present invention also provides a method for real-time detection of coal cake density to achieve tamping control, and a device for real-time detection of coal cake density to achieve tamping control includes the following steps:

[0065] When the sound frequency detector 6 operates normally, the sound frequency of the coal cake before the tamping is completed is obtained based on the sound frequency detector 6;

[0066] Amplify, filter, digitize and convert the sound frequency into frequency domain based on the signal processing module;

[0067] The processed sound frequency is judged based on the tamping machine PLC system 4;

[0068] When the processed sound frequency meets the preset sound frequency, the vibration frequency of the coal cake meets the preset vibration frequency, and then the density of the coal cake meets the requirement, the tamping is stopped.

[0069] The process of determining whether the sound frequency detector 6 is operating normally may include:

[0070] When the tamping machine tamps the coal, the density of the coal cake changes, and the frequency received by the sound frequency measuring instrument 6 changes, so the first sound frequency f1 and the second sound frequency f2 at the beginning and the end of tamping are obtained based on the sound frequency detector 6;

[0071] When the value from the first sound frequency f1 to the second sound frequency f2 changes continuously, it is determined that the sound frequency detector 6 operates normally;

[0072] When the values ​​of the first sound frequency f1 to the second sound frequency f2 are continuously equal, it is determined that the sound frequency detector 6 is not operating normally.

[0073] It is feasible that during the process of coal material changing into coal cakes, the density is constantly changing, and the damping of the interaction is also changing. Through the following process, it can be determined that the vibration frequency of coal material under different damping coefficients is different, and the damping ratio can be calculated according to the formula :

[0074] ,

[0075] Among them, β is the damping coefficient, k is the elastic stiffness coefficient, and m is the mass of the object;

[0076] When the damping ratio is known, the change in vibration frequency can be verified using the following formula:

[0077]

[0078] in, is the vibration frequency after damping, It is the vibration frequency without damping. It can be judged that as the damping changes, the vibration frequency of the briquette will also change, and the frequency detected by the sound frequency detector 6 will also change accordingly.

[0079] The present invention detects the frequency of sound waves emitted by forced vibration of coal cakes through a sound frequency detector 6, thereby inferring the density of coal cakes in the tamping process, and promptly feeds back the information to the tamping machine PLC system 4, thereby achieving precise control of the tamping process of the tamping machine, realizing the function of real-time detection of coal cake production quality, reducing manual intervention and greatly improving the production efficiency of high-quality coal cakes.

[0080] The above are only preferred specific implementations of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A device for real-time detection of coal cake density to achieve tamping control, characterized in that: include: A coal car operating room, wherein a tamping machine frame and a tamping machine PLC system are arranged in the coal car operating room; A tamping hammer is installed on the tamping machine frame, and sound insulation boards are installed on both sides for tamping the coal cakes; The tamping machine PLC system is electrically connected to a sound frequency detector for real-time detection of the state of the coal cakes during the tamping process.

2. The device for real-time detection of coal cake density and tamping control according to claim 1 is characterized in that: The sound frequency detector is equipped with a signal processing module; The signal processing module comprises an amplifier, a filter and an analog-to-digital converter, which are used to sequentially amplify, filter and digitalize the sound signal of the coal cake detected by the sound frequency detector.

3. The device for real-time detection of coal cake density and tamping control according to claim 2 is characterized in that: The amplifier adopts an instrument amplifier circuit composed of three operational amplifiers.

4. The device for real-time detection of coal cake density and tamping control according to claim 2 is characterized in that: The filter adopts an integrated filter circuit of a high-pass filter, a low-pass filter and a band-pass filter; The high-pass filter is used to remove low-frequency noise and DC bias in the sound signal; The low-pass filter is used to remove high-frequency noise in the sound signal; The bandpass filter is used to retain the sound signal within the effective frequency range.

5. The device for real-time detection of coal cake density and tamping control according to claim 2 is characterized in that: The analog-to-digital converter adopts a high-precision analog-to-digital converter, which is used to convert a continuous analog sound signal into a discrete digital signal.

6. The device for real-time detection of coal cake density and tamping control according to claim 5 is characterized in that: The signal processing module also includes a frequency domain conversion unit, which is used to perform a fast Fourier transform on the converted digital signal, transform the digital signal from the time domain to the frequency domain, and obtain the amplitude and phase information of the digital signal in the frequency domain.

7. A method for real-time detection of coal cake density to achieve tamping control, characterized in that: The device for real-time detection of coal cake density and tamping control according to any one of claims 1 to 6 comprises the following steps: When the sound frequency detector operates normally, the sound frequency of the coal cake before the tamping is completed is obtained based on the sound frequency detector; Amplifying, filtering, digitizing and frequency-domain converting the sound frequency based on a signal processing module; The processed sound frequency is judged based on the tamping machine PLC system; When the processed sound frequency meets the preset sound frequency, the vibration frequency of the coal cake meets the preset vibration frequency, and then the density of the coal cake meets the requirement, the tamping is stopped.

8. The method for real-time detection of coal cake density to achieve tamping control according to claim 7, characterized in that: The process of determining whether the sound frequency detector is operating properly includes: Acquiring a first sound frequency and a second sound frequency at the beginning and the end of tamping based on a sound frequency detector; When the value from the first sound frequency to the second sound frequency changes continuously, it is determined that the sound frequency detector operates normally; When the values ​​from the first sound frequency to the second sound frequency remain equal, it is determined that the sound frequency detector is not operating normally.

9. The method for real-time detection of coal cake density to achieve tamping control according to claim 7, characterized in that: The calculation formula for frequency domain conversion is as follows: , in, is the complex spectrum in the frequency domain, is the signal function in the time domain representation, is the angular frequency, represents the imaginary unit, Represents a time variable.

10. The method for real-time detection of coal cake density to achieve tamping control according to claim 7, characterized in that: The calculation formula of the vibration frequency of coal cake is as follows: ， in, is the vibration frequency after damping, is the undamped vibration frequency, is the damping ratio; The damping ratio is calculated as follows: ， Among them, β is the damping coefficient, k is the elastic stiffness coefficient, and m is the mass of the object.

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