Comprehensive regulation and control system for ceramic production equipment

Abstract

The invention discloses a comprehensive regulation and control system for ceramic production equipment, and relates to the technical field of ceramic production regulation and control. Comprising a data acquisition module, a data analysis module, a scheme making module, a drying adjustment module and a product feedback module, the data acquisition module is used for acquiring ceramic raw material ball milling data, ceramic blank data, environment data, sintered ceramic data and working data of a ball mill, drying equipment and sintering equipment in the ceramic production and processing process; according to the technical key points, the system is combined with the characteristics that an existing automatic ball mill can automatically recognize the particle size and adaptively adjust the ball milling time length, the influence characteristics of ceramic raw materials are researched, the influence characteristics are further analyzed, and a new sintering scheme is formulated by combining the influence characteristics and a standard sintering scheme; and the quality of the sintered ceramic is stable, the qualified rate of the sintered ceramic is high, the using effect is good, and the good using prospect is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic production control, and in particular to a comprehensive control system for ceramic production equipment. Background Art

[0002] Ceramics is a general term for pottery and porcelain. Traditional ceramics, also known as ordinary ceramics, are products made from natural silicates such as clay as the main raw materials. Modern ceramics are also called new ceramics, fine ceramics or special ceramics. They are commonly made of non-silicate chemical raw materials or artificial synthetic raw materials, such as oxides (aluminum oxide, zirconium oxide, titanium oxide, etc.) and non-oxides (silicon nitride, boron carbide, etc.). Ceramics have many advantages such as excellent insulation, corrosion resistance, high temperature resistance, high hardness, low density, and radiation resistance, and have been widely used in various fields of the national economy.

[0003] In order to better fire ceramics and increase the success rate of firing ceramic products, people have invented some management or control systems for the ceramic production process.

[0004] The prior art patent authorization announcement number is CN115127339B, and the patent name is an invention patent for a ceramic mixed-firing roller kiln control system, which records that it includes a planning module, a supplement module, a control module and a server; the planning module is used to carry out mixed-firing planning of ceramics; the supplement module is used to supplement equipment based on the current ceramic production line and establish a process model; the control module is used to control the firing of the target ceramic, obtain the current production plan, identify the target ceramic type to be fired, match the corresponding mixed-firing classification, perform priority sorting, determine the firing order of each target ceramic, and set the firing node table of the target ceramic according to the control time between the sub-control matching library and each mixed-firing classification; obtain the process model, set the verification unit, and transport the target ceramic to the ceramic roller kiln at the corresponding time; match the corresponding internal sub-control scheme according to the target ceramic type, and control the ceramic roller kiln for firing according to the obtained internal sub-control scheme.

[0005] The prior art patent authorization announcement number is CN116518722B, and the patent name is an invention patent for a temperature control system for a semiconductor ceramic sintering furnace, which records that: an infrared camera acquires real-time ceramic video and temperature values ​​in the ceramic sintering furnace; a data processing module analyzes the acquired ceramic video and temperature values; a temperature control module analyzes and makes decisions on abnormal image signals and temperature values ​​sent by the data processing module to determine whether the temperature value is within a preset temperature range; when the temperature is not within the preset temperature range, a high temperature or low temperature signal is sent to the execution module; the execution module triggers the cooling module or the electric heating module to cool or heat; and real-time monitoring and reasonable regulation of the temperature in the ceramic sintering furnace are realized to produce high-quality ceramics.

[0006] The solution described in the above patent is mainly to regulate the sintering step, so that the temperature control during sintering is more precise and the temperature fluctuation is smaller, thereby improving the sintering effect.

[0007] However, the existing ceramic production system still has certain drawbacks. The technology adopted in the existing scheme is to adopt a uniformly set standard scheme during drying and sintering. However, due to the presence of trace elements in the clay used to produce ceramics and the different hardness of the clay in different regions, there are certain differences in the qualified rates of different batches of ceramic products produced by the above method, and there are also certain differences in the quality of the produced ceramic products, which do not meet the production requirements. For this reason, we propose a comprehensive control system for ceramic production equipment. Summary of the invention

[0008] 1. Technical issues to be resolved

[0009] In view of the deficiencies of the prior art, the present invention provides a comprehensive control system for ceramic production equipment, which combines the existing automatic ball mill to automatically identify the particle size, adaptively adjust the ball milling time, study the influencing characteristics of ceramic raw materials, and further analyze the influencing characteristics, and formulate a new sintering scheme in combination with the influencing characteristics and the standard sintering scheme, so that the quality of the sintered ceramics is relatively stable, the qualified rate of the sintered ceramics is relatively high, the use effect is good, and it has a good use prospect. It can effectively solve the problems raised in the background technology.

[0010] (II) Technical solution

[0011] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0012] A comprehensive control system for ceramic production equipment, including a data acquisition module, a data analysis module, a program formulation module, a drying adjustment module and a product feedback module:

[0013] Data acquisition module: used to collect ceramic raw material ball milling data, ceramic body data, environmental data, ceramic data after sintering, and working data of ball mill, drying equipment and sintering equipment during ceramic production and processing. The working data of sintering equipment includes the working parameters of sintering equipment itself and the hot air flow rate and hot air temperature transmitted to the drying chamber in real time;

[0014] Data analysis module: used to analyze the ball milling data of ceramic raw materials, determine the influencing characteristics of ceramic raw materials, and analyze the collected ceramic green body data to obtain the moisture content data of the ceramic green body in the current state, and calculate the drying moisture content based on the moisture content data in the current state and the sintering moisture content corresponding to the influencing characteristics of the ceramic raw materials;

[0015] Plan formulation module: used to obtain the influencing characteristics and drying moisture content of ceramic raw materials, and further analyze and formulate hot air drying and sintering plans;

[0016] Drying adjustment module: used to summarize and analyze the acquired hot air drying scheme, environmental data, and the hot air flow rate and hot air temperature transmitted to the drying chamber by the sintering equipment in real time, generate a dynamic temperature compensation scheme for the drying equipment, and control the drying equipment to operate according to the dynamic temperature compensation scheme;

[0017] Product feedback module: used to analyze the ceramic data after sintering, calculate the qualified rate of ceramics, and compare the standard value and excellent value set for the qualified rate;

[0018] If the qualified rate is lower than the set standard value, the operation will be stopped and a comprehensive test will be carried out;

[0019] If the qualified rate is between the standard value and the excellent value, the ceramic data is defect analyzed to obtain the cause of the defect, and an adjustment plan is formulated based on the cause of the defect, and the adjustment plan is implemented, and the qualified rate of the ceramic is recalculated and compared again;

[0020] If the pass rate is higher than the excellent value, no adjustment is required.

[0021] Furthermore, the ceramic raw material ball milling data includes the ball milling time, the amount of material used in the ball milling and the ball milling power, the ceramic green body data is the moisture content data of the ceramic green body, the environmental data is the real-time temperature data inside and outside the drying room, and the ceramic data after sintering is the number of qualified ceramic products and the reasons for unqualified ceramic products.

[0022] Furthermore, the ball milling data of ceramic raw materials was analyzed and the calculation formula for the influencing characteristics of ceramic raw materials was determined as follows:

[0023]

[0024] Where, INCH is the influencing characteristic value of ceramic raw materials, α and β are constant coefficients, α and β are both greater than 1, Tj is the actual ball milling time of ceramic raw materials, Tb is the ball milling time of ceramic raw materials under standard raw material amount, Gwl is the amount of added ceramic raw materials, Gwlb is the standard raw material amount, pj is the actual ball milling power, and pb is the set standard ball milling power.

[0025] Further, the steps of analyzing the collected ceramic body data to obtain the ceramic body moisture content data in the current state are as follows:

[0026] Randomly select M groups of ceramic bodies from a batch, measure the moisture content data of K positions of each ceramic body by infrared measurement method, and retrieve the moisture content data measured by infrared measurement method under the same external environment as the batch of ceramic raw materials from the database;

[0027] Retrieving the moisture content data of the ceramic green body measured by the infrared measurement method and then by the drying method in the database;

[0028] Calculate the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method. The specific formula is as follows:

[0029]

[0030] Where Var is the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method, n is the number of moisture content data measured by the infrared measurement method extracted, Humg i is the moisture content data measured by the drying method of the i-th group, Humh i is the moisture content data of the i-th group measured by infrared measurement method;

[0031] Calculate the average value of the moisture content data of K positions of the ceramic, and calculate the moisture content data of the ceramic body in the current state based on the average value data;

[0032]

[0033] Where Hums is the moisture content of the ceramic body in the current state. is the average water content of the i-th position of M ceramic bodies, Cjxs i is the adjustment ratio of the moisture content at the i-th position of the ceramic body, Hum ij is the water content of the i-th position of the j-th ceramic body;

[0034] The steps to calculate the drying moisture content are as follows:

[0035] The material of the collected ceramic body is used to search the database for the corresponding influencing characteristics and standard sintering moisture content of the material;

[0036] The sintering moisture content of the batch of ceramic green bodies is calculated, and then the drying moisture content is calculated based on the calculated sintering moisture content. The specific calculation formula is as follows:

[0037]

[0038] Where Humgz is the dry moisture content, is the sintering moisture content of this batch of ceramic green bodies, Humgzb is the standard sintering moisture content of this material, γ is the constant coefficient, γ>1, and INCHb is the influencing characteristic corresponding to the set ceramic material.

[0039] Further, the steps to formulate a sintering plan are as follows:

[0040] Obtain all sintering schemes corresponding to the ceramic body material recorded in the database;

[0041] Analyze the sintering schemes, screen out sintering schemes with the same sintering temperature, and extract the corresponding sintering time data and influencing characteristic data in the screened sintering schemes;

[0042] The sintering time data and the influencing characteristic data are input into a two-dimensional coordinate system and processed using the Gaussian process regression method to generate a curve equation;

[0043] Input INCH into the curve equation to calculate the sintering time of the batch, and combine the sintering temperature, influencing characteristics and sintering time to form a sintering plan.

[0044] Further, the steps for formulating a hot air drying plan are as follows:

[0045] Obtaining the standard hot air drying scheme corresponding to the ceramic body material recorded in the database;

[0046] Obtain the influencing characteristic values ​​of sintering moisture content and ceramic raw materials, and calculate the actual hot air drying time in combination with the standard hot air drying time in the standard hot air drying scheme. The calculation formula is as follows;

[0047]

[0048] Where, Tgs is the actual hot air drying time, Tgb is the standard hot air drying time, δ is a constant, 1<δ<2;

[0049] The actual hot air drying time replaces the standard hot air drying time to form a hot air drying plan.

[0050] Furthermore, the steps for generating a dynamic temperature compensation scheme for the drying equipment are as follows:

[0051] Obtain the hot air flow rate and hot air temperature transmitted from the sintering equipment to the drying chamber in real time, and calculate the transmitted heat value;

[0052] The specific calculation formula is as follows:

[0053] Qcs=ρ T ×π×r 2 ×Vc×C T ×T

[0054] Where Qcs is the transferred heat value, ρ T is the density of air at temperature T, π is the circumference of a circle, r is the radius of the hot air pipe, Vc is the hot air velocity, C T is the specific heat capacity of air at temperature T, T is the hot air temperature;

[0055] Obtain the heat loss Qs of the drying chamber at the standard hot air drying temperature, further calculate the compensation heat, and then calculate the heating current of the heater based on the compensation heat;

[0056]

[0057] Where Ij is the heating current of the heater, Rj is the resistance of the heater, and URl is the heat utilization rate of the heater;

[0058] Calculate the heater advance adjustment time Where Lc is the distance required for the hot air to move from the detection position to the drying chamber, and Ty is the time required for the heater to automatically adjust and transmit data;

[0059] The heating time and heating current are combined to form a dynamic temperature compensation scheme.

[0060] Furthermore, the formula for calculating the pass rate is:

[0061]

[0062] Where FPY is the qualified rate of ceramics produced in this batch, Zs is the number of sintered ceramic bodies in this batch, and Zh is the number of qualified ceramics produced in this batch;

[0063] The steps to analyze the defects of ceramic data, obtain the causes of defects, and formulate adjustment plans based on the causes of defects are as follows:

[0064] Classify the reasons for unqualified ceramic products, and count the number of unqualified ceramics caused by too high moisture content after drying, n1, and the number of unqualified ceramics caused by too low moisture content after drying, n2;

[0065] Determine the size of n1 and n2;

[0066] If n1<n2, the actual hot air drying time is extended, and the actual hot air drying time after extension is Tgs1=Tgs×(1+η);

[0067] If n1>n2, the actual hot air drying time is shortened, and the shortened actual hot air drying time is Tgs1=Tgs×(1-η), where η is the adjustment ratio, 0.01≤η≤0.03.

[0068] Furthermore, a real-time monitoring module is included: used to compare the working data of the ball mill, the drying equipment and the sintering equipment with the set working values, calculate the difference fluctuation data, and determine whether the difference data is within the fluctuation range;

[0069] If the difference data is within the fluctuation range, no response will be made;

[0070] If the difference data is outside the fluctuation range, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined, and the corresponding alarm strategy is executed according to the distance.

[0071] Furthermore, the formula for calculating the difference fluctuation data is as follows: Where Dvalue is the difference fluctuation data, Gj is the monitored equipment working data, and Gb is the monitored equipment standard working data;

[0072] The fluctuation range is (-A, A). If the calculated Dvalue is less than -A or Dvalue is greater than A, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined. The following alarm strategies are implemented according to the distance:

[0073] Calculate the level of the distance between the difference data and the fluctuation range boundary Jbc is the difference between the upper and lower limits of the set level, and LV is compared with the set online maintenance interval (0, B) and shutdown maintenance interval [B, MAX]. If LV is in the online maintenance interval, online maintenance is performed; if LV is in the shutdown maintenance interval, shutdown maintenance is performed.

[0074] (III) Beneficial effects

[0075] The present invention provides a comprehensive control system for ceramic production equipment, which has the following beneficial effects:

[0076] First, the present invention provides a comprehensive control system for ceramic production equipment. The system combines the existing automatic ball mill to automatically identify the particle size, adaptively adjust the ball milling time, study the influencing characteristics of ceramic raw materials, and further analyze the influencing characteristics. Combining the influencing characteristics and the standard sintering scheme, a new sintering scheme is formulated, so that the quality of the sintered ceramics is relatively stable, the qualified rate of the sintered ceramics is relatively high, the use effect is good, and it has a good prospect for use.

[0077] Second, the present invention provides a comprehensive control system for ceramic production equipment. This system studies the influencing characteristics of ceramic raw materials, and further analyzes the influencing characteristics of ceramic raw materials to generate a relatively scientific and reasonable drying plan, and further combines the feedback of sintering temperature to formulate a temperature compensation plan in advance, so that the stability fluctuation inside the drying chamber during the drying process is small, the drying effect is good, and the ceramic blank can be dried to the set sintering moisture content more accurately, thereby effectively improving the sintering effect of the ceramic, thereby effectively improving the processing effect of the ceramic, and having a good use effect and a good prospect for use.

[0078] Third, the present invention provides a comprehensive control system for ceramic production equipment, which can also realize effective monitoring of the working data of ball milling, drying and sintering equipment, and can provide timely feedback when the operation is abnormal, effectively reducing the losses caused by equipment abnormalities, and can further analyze the leveling data of ceramics after sintering, summarize the reasons for unqualified sintered products, and further formulate adjustment plans based on the reasons, which can optimize the process, effectively improve the qualified rate of ceramics, have good use effect, and have good prospects for use. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 This is a flow chart of a comprehensive control system for ceramic production equipment of the present invention;

[0080] Figure 2 The present invention is a flowchart of the equipment monitoring steps in the comprehensive control system for ceramic production equipment. DETAILED DESCRIPTION

[0081] 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.

[0082] R&D concept: The technology used in the scheme recorded in the existing system is to adopt a uniformly set standard scheme during drying and sintering. However, due to the presence of trace elements in the clay used to produce ceramics and the different hardness of the clay in different regions, there are certain differences in the qualified rates of different batches of ceramic products produced by the above method, and there are certain differences in the quality of the ceramic products produced, which do not meet the production requirements.

[0083] Therefore, in the early stage of research and development, the characteristics of the clay materials for ceramic production are studied, and large-scale testing and analysis are carried out on the clay materials for ceramic production. Then, according to the results of the analysis, the relevant processes of ceramic body drying and ceramic sintering in the ceramic production process are adjusted. The qualified rate of the adjusted ceramics is higher.

[0084] However, it was found during application that this method takes a very long time, and because the soil itself has certain differences, it needs to be analyzed each time, and the manpower and material costs are also relatively high. Therefore, the above solution is only suitable for the processing of high-precision ceramic products, and is not applicable to ordinary ceramic products.

[0085] Therefore, in the middle stage of research and development, a rough plan to judge the soil impact characteristics was adopted, and the data displayed by the automatic ball mill was used to analyze the soil impact characteristics. There was no need to test the soil separately during the entire process, so there was no need to increase manpower and material costs, and the overall use effect was good.

[0086] However, during later use, it was found that although the plan formulated based on a rough judgment of soil impact characteristics was better than the initial plan, there was still room for adjustment, and the plan was still affected by whether it could be implemented completely according to the plan.

[0087] Therefore, in the later stage of research and development, a comprehensive analysis of the previous plans was conducted to develop a system that can monitor the equipment and improve the accuracy of the implementation of the plans. This system can improve the qualification rate of ceramic products at a lower cost and has good use effect. The specific plan of the system is as follows:

[0088] See also Figure 1 This embodiment provides a comprehensive control system for ceramic production equipment, which consists of two parts: hardware and software. The hardware part is mainly a server and corresponding supporting facilities, and the software part includes a data acquisition module, a data analysis module, a program formulation module, a drying adjustment module and a product feedback module:

[0089] The implementation of this system is based on rich historical data and real-time collected data, and data acquisition is based on the data acquisition module.

[0090] Data acquisition module: used to collect ceramic raw material ball milling data, ceramic body data, environmental data, sintered ceramic data and the working data of ball mills, drying equipment and sintering equipment during the ceramic production and processing process. The working data of the sintering equipment includes the working parameters of the sintering equipment itself and the hot air flow rate and hot air temperature transmitted to the drying chamber in real time.

[0091] Historical data can be directly found and searched from the database that records historical data. The search technology is commonly used by existing browsers, so no further description is given. As for the collected data, the existing ceramic production plants and equipment are equipped with corresponding sensors. Therefore, the collected data can be directly obtained from the existing central control management equipment without the need to transform the production workshop. Therefore, the cost of applying this system is relatively low.

[0092] The ball milling data of ceramic raw materials include the ball milling time, the amount of material used in the ball milling and the ball milling power. The ceramic body data is the moisture content data of the ceramic body. The environmental data is the real-time temperature data inside and outside the drying room. The ceramic data after sintering is the number of qualified ceramic products and the reasons for unqualified ceramic products.

[0093] The ball milling time, the amount of material used in ball milling and the ball milling power can be directly obtained from the automatic ball mill. The existing automatic ball mill has two modes, one is to set the time and unload the material when the time is reached, the other is to set the ball milling degree and automatically unload the material when the ball milling reaches the set degree. This scheme is based on setting the ball milling degree. This method is convenient for obtaining data and will not result in over-milling or under-milling as in the first scheme, and has a good use effect.

[0094] The environmental data is the real-time temperature data inside and outside the drying room, which is detected by temperature sensors installed inside and outside the drying room. Therefore, the sintering process is relatively mature. Except for ceramic damage caused by some operational errors, most ceramic failures are caused by moisture content problems. Therefore, there is no need to focus on data such as the temperature during ceramic firing when using it.

[0095] If the water content of the ceramic body is too high, it will cause excessive steam pressure inside the ceramic body during the firing process, causing quality problems such as deformation or cracking. If the water content of the ceramic body is too low, the ceramic will not be fully sintered due to lack of sufficient water during the firing process, affecting the strength and appearance of the ceramic. Therefore, it is possible to judge whether the ceramic body is sufficiently dried or over-dried based on the cause of the defect, thereby facilitating the adjustment of the drying time.

[0096] After obtaining the required data, the collected data must be further analyzed to extract the required information and the influencing characteristics of the ceramic raw materials, so as to facilitate the further formulation of sintering plans based on the influencing characteristics of the ceramic raw materials. Further analysis of the collected data is based on the data analysis module.

[0097] The present invention provides a comprehensive control system for ceramic production equipment. The system combines the existing automatic ball mill to automatically identify the particle size, adaptively adjust the ball milling time, study the influencing characteristics of ceramic raw materials, and further analyze the influencing characteristics. Combining the influencing characteristics and the standard sintering scheme, a new sintering scheme is formulated, so that the quality of the sintered ceramics is relatively stable, the qualified rate of the sintered ceramics is relatively high, the use effect is good, and it has a good use prospect.

[0098] The data analysis module is used to analyze the ball milling data of ceramic raw materials, determine the influencing characteristics of ceramic raw materials, and analyze the collected ceramic green body data to obtain the moisture content data of the ceramic green body in the current state, and calculate the drying moisture content based on the moisture content data in the current state and the sintering moisture content corresponding to the influencing characteristics of the ceramic raw materials.

[0099] By analyzing the ball milling data of ceramic raw materials, the calculation formula for determining the influencing characteristics of ceramic raw materials is as follows:

[0100]

[0101] Where, INCH is the influencing characteristic value of ceramic raw materials, α and β are constant coefficients, α and β are both greater than 1, Tj is the actual ball milling time of ceramic raw materials, Tb is the ball milling time of ceramic raw materials under standard raw material amount, Gwl is the amount of added ceramic raw materials, Gwlb is the standard raw material amount, pj is the actual ball milling power, and pb is the set standard ball milling power.

[0102] Under the condition of the same ball milling power and ball milling raw material amount, the longer the ball milling time is, the greater the influence of the material is. This influence is mainly caused by the hardness of the material. The greater the hardness, the more time it takes to ball mill.

[0103] The above-calculated influencing characteristics of ceramic raw materials are rough estimation schemes, which can roughly calculate the influencing characteristics of ceramic raw materials and improve the accuracy and qualified rate of ceramic production to a certain extent.

[0104] The steps of analyzing the collected ceramic body data to obtain the ceramic body moisture content data in the current state are as follows:

[0105] Randomly select M groups of ceramic bodies from a batch, measure the moisture content data of K positions of each ceramic body by infrared measurement method, and retrieve the moisture content data measured by infrared measurement method under the same external environment as the batch of ceramic raw materials from the database;

[0106] Retrieving the moisture content data of the ceramic green body measured by the infrared measurement method and then by the drying method in the database;

[0107] Calculate the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method. The specific formula is as follows:

[0108]

[0109] Where Var is the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method, n is the number of moisture content data measured by the infrared measurement method extracted, Humg i is the moisture content data measured by the drying method of the i-th group, Humh i is the moisture content data of the i-th group measured by infrared measurement method;

[0110] Since the soil contains different trace elements, it will cause certain interference to the detection of water content, resulting in certain differences in the detection of water content by infrared measurement method.

[0111] However, analyzing the moisture content data measured by infrared measurement method under the same external environment as that of the batch of ceramic raw materials (most of the main parts are the same, but not exactly the same, such as using clay from the same region) can greatly improve the accuracy.

[0112] For example, there are 5 groups of moisture content data of this ceramic material measured by infrared measurement method and moisture content data measured by drying method, and the data are shown in the following table:

[0113] 1 2 3 4 5 Infrared method water content (%) 21.4 20.7 20.4 21.9 22.1 Water content by drying method (%) 19.6 18.8 18.8 20.1 19.9 Difference (%) 1.8 1.9 1.6 1.8 2.2

[0114] After calculation, the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method for this ceramic material is 1.86.

[0115] Calculate the average value of the moisture content data of K positions of the ceramic, and calculate the moisture content data of the ceramic body in the current state based on the average value data;

[0116] Ceramics have different shapes. The larger the volume of the ceramic, the more locations to collect moisture. The longer the ceramic body is placed, the water content in the lower half of the ceramic will naturally be higher than that in the upper half. Therefore, it is necessary to consider comprehensively and calculate the moisture content data of the entire ceramic.

[0117]

[0118] Where Hums is the moisture content of the ceramic body in the current state. is the average water content of the i-th position of M ceramic bodies, Cjxs i is the adjustment ratio of the moisture content at the i-th position of the ceramic body, Hum ij is the water content of the i-th position of the j-th ceramic body;

[0119] It is very important to calculate the moisture content of the ceramic body. Only when the moisture content of the ceramic body in its current state and the sintering moisture content are known can a better drying plan be formulated to effectively avoid the situation where the ceramic body in the drying chamber is not dried for long enough or is dried for long enough.

[0120] The steps to calculate the drying moisture content are as follows:

[0121] The material of the collected ceramic body is used to search the database for the corresponding influencing characteristics and standard sintering moisture content of the material;

[0122] The sintering moisture content of the batch of ceramic green bodies is calculated, and then the drying moisture content is calculated based on the calculated sintering moisture content. The specific calculation formula is as follows:

[0123]

[0124] Where Humgz is the dry moisture content, is the sintering moisture content of this batch of ceramic green bodies, Humgzb is the standard sintering moisture content of this material, γ is the constant coefficient, γ>1, and INCHb is the influencing characteristic corresponding to the set ceramic material.

[0125] Normally, The above sintering moisture content is calculated through the corresponding influencing characteristics of the ceramic material and is therefore relatively accurate.

[0126] The drying moisture content is the difference between the moisture content of the ceramic body before drying and the moisture content after sintering, that is, the moisture content that needs to be dried.

[0127] The existing scheme adopts a fixed drying time, but in actual processing, due to the influence of the external environment and the characteristics of the raw materials, there is a certain difference in the moisture content of the ceramic body after blanking. Therefore, it is easy for the ceramic body to have a high or low moisture content after drying. If it is directly sintered, there will be a certain deviation in the qualified rate.

[0128] When the drying moisture content is calculated, further analysis is required to plan a more scientific and reasonable hot air drying plan, and this process is based on the plan formulation module.

[0129] The program formulation module is used to obtain the influencing characteristics and drying moisture content of ceramic raw materials, and further analyze and formulate hot air drying and sintering plans;

[0130] The steps to develop a sintering plan are as follows:

[0131] Obtain all sintering schemes corresponding to the ceramic body material recorded in the database (historical sintering schemes for this material);

[0132] Analyze the sintering schemes, screen out sintering schemes with the same sintering temperature, and extract the corresponding sintering time data and influencing characteristic data in the screened sintering schemes;

[0133] The existing system of sintering plan can realize accurate monitoring. The sintering temperature is mainly determined by the characteristics of the sintering material. Therefore, the main content of formulating the sintering plan is to analyze the sintering time.

[0134] The sintering time data and the influencing characteristic data are input into a two-dimensional coordinate system and processed using the Gaussian process regression method to generate a curve equation;

[0135] This scheme is a commonly used scheme for linear fitting of existing data. This patent does not improve this step, so it will not be described in detail.

[0136] Input INCH into the curve equation to calculate the sintering time of the batch, and combine the sintering temperature, influencing characteristics and sintering time to form a sintering plan.

[0137] The steps to develop a hot air drying plan are as follows:

[0138] Obtaining a standard hot air drying scheme corresponding to the ceramic green body material recorded in a database, where the standard hot air drying scheme is a scheme used in the past for sintering the ceramic green body material;

[0139] Obtain the influencing characteristic values ​​of sintering moisture content and ceramic raw materials, and calculate the actual hot air drying time in combination with the standard hot air drying time in the standard hot air drying scheme. The calculation formula is as follows;

[0140]

[0141] Where, Tgs is the actual hot air drying time, Tgb is the standard hot air drying time, δ is a constant, 1<δ<2;

[0142] The actual hot air drying time replaces the standard hot air drying time to form a hot air drying plan.

[0143] The lower the value, the harder the material is. The faster the moisture content decreases when it is air-dried. Calculated To reduce the extent.

[0144] After the hot air drying plan is formulated, it will be implemented according to the hot air drying plan. However, in actual drying, in order to make full use of energy, part of the heat source for hot air drying comes from sintering. There is a certain fluctuation in the transmission of the sintering heat source to the drying chamber, and it is not enough to allow the green ceramic body to be dried to the set degree in a short time. Therefore, it is necessary to use heating equipment in the drying chamber to assist, and the operating strategy of the heating equipment is formulated through the drying adjustment module.

[0145] Drying adjustment module: used to summarize and analyze the acquired hot air drying scheme, environmental data, and the hot air flow rate and hot air temperature transmitted to the drying chamber by the sintering equipment in real time, generate a dynamic temperature compensation scheme for the drying equipment, and control the drying equipment to operate according to the dynamic temperature compensation scheme;

[0146] The steps to generate a dynamic temperature compensation solution for drying equipment are as follows:

[0147] Obtain the hot air flow rate and hot air temperature transmitted from the sintering equipment to the drying chamber in real time, and calculate the transmitted heat value;

[0148] The specific calculation formula is as follows:

[0149] Qcs=ρ T ×π×r 2 ×Vc×C T ×T

[0150] Where Qcs is the transferred heat value, ρ Tis the density of air at temperature T, π is the circumference of a circle, r is the radius of the hot air pipe, Vc is the hot air velocity, C T is the specific heat capacity of air at temperature T, T is the hot air temperature;

[0151] The transferred heat value is the heat that the heater needs to replenish in real time.

[0152] Obtain the heat loss Qs of the drying chamber at the standard hot air drying temperature, further calculate the compensation heat, and then calculate the heating current of the heater based on the compensation heat;

[0153]

[0154] Where Ij is the heating current of the heater, Rj is the resistance of the heater, and URl is the heat utilization rate of the heater;

[0155] Calculate the heater advance adjustment time Where Lc is the distance required for the hot air to move from the detection position to the drying chamber, and Ty is the time required for the heater to automatically adjust and transmit data;

[0156] The heating time and heating current are combined to form a dynamic temperature compensation scheme.

[0157] For example, the distance Lc required for hot air to move from the detection position to the drying chamber is 10 meters, and the hot air flow rate is 2m / s. The heater is always in a heating state during drying, and the temperature that needs to be dynamically adjusted generally does not exceed 10°C. In addition, the data transmission is fast, so Ty is usually 2 seconds. Therefore, the calculated advance adjustment time Tj is 3 seconds, that is, the heater current is adjusted to the calculated data 3 seconds after receiving the calculated heating current data of the heater, so as to better ensure the required temperature of the drying chamber and improve the drying effect.

[0158] When the drying plan is completely determined, the corresponding ceramic products are processed according to the set plan (the existing system for supervising the sintering process is very effective, so no improvement is needed), and then the data of the sintered ceramic products is collected and feedback is provided. This process is based on the product feedback module.

[0159] The present invention provides a comprehensive control system for ceramic production equipment. The system studies the influencing characteristics of ceramic raw materials, further analyzes the influencing characteristics of ceramic raw materials, generates a relatively scientific and reasonable drying plan, and further combines the feedback of sintering temperature to formulate a temperature compensation plan in advance, so that the stability fluctuation inside the drying chamber is small during the drying process, and the drying effect is good, so that the ceramic blank can be dried to the set sintering moisture content more accurately, thereby effectively improving the sintering effect of the ceramic, thereby effectively improving the processing effect of the ceramic, and having a good use effect and a good use prospect.

[0160] Product feedback module: used to analyze the ceramic data after sintering, calculate the qualified rate of ceramics, and compare the standard value and excellent value set for the qualified rate;

[0161] The formula for calculating the pass rate is:

[0162]

[0163] Where FPY is the qualified rate of ceramics produced in this batch, Zs is the number of sintered ceramic bodies in this batch, and Zh is the number of qualified ceramics produced in this batch;

[0164] If the qualified rate is lower than the set standard value, the operation will be stopped and a comprehensive test will be carried out;

[0165] If the qualified rate is between the standard value and the excellent value, the ceramic data is defect analyzed to obtain the cause of the defect, and an adjustment plan is formulated based on the cause of the defect, and the adjustment plan is implemented, and the qualified rate of the ceramic is recalculated and compared again;

[0166] If the pass rate is higher than the excellent value, no adjustment is required.

[0167] The steps to analyze the defects of ceramic data, obtain the causes of defects, and formulate adjustment plans based on the causes of defects are as follows:

[0168] Classify the reasons for unqualified ceramic products, and count the number of unqualified ceramics caused by too high moisture content after drying, n1, and the number of unqualified ceramics caused by too low moisture content after drying, n2;

[0169] Determine the size of n1 and n2;

[0170] If n1<n2, the actual hot air drying time is extended, and the actual hot air drying time after extension is Tgs1=Tgs×(1+η);

[0171] If n1>n2, the actual hot air drying time is shortened, and the shortened actual hot air drying time is Tgs1=Tgs×(1-η), where η is the adjustment ratio, 0.01≤η≤0.03.

[0172] For example, the original drying time for a batch of ceramic blanks was set to 30 hours. After testing, the moisture content after drying is too high, and the actual hot air drying time needs to be extended. η is taken as 0.02, then the calculated actual hot air drying time after extension Tgs1 is 30.6 hours.

[0173] The above is fine-tuning. Since the basic setting data is relatively accurate, the error is mainly due to equipment error. After adjusting the corresponding ratio, the error caused by the equipment can be further compressed, thereby further improving the qualified rate of ceramic products.

[0174] See also Figure 2 , and also includes a real-time monitoring module: used to compare the working data of the ball mill, the drying equipment and the sintering equipment with the set working values, and calculate the difference fluctuation data, and determine whether the difference data is within the fluctuation range;

[0175] If the difference data is within the fluctuation range, no response will be made;

[0176] If the difference data is outside the fluctuation range, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined, and the corresponding alarm strategy is executed according to the distance.

[0177] The formula for calculating the difference fluctuation data is as follows: Where Dvalue is the difference fluctuation data, Gj is the monitored equipment working data, and Gb is the monitored equipment standard working data. This step can determine whether the equipment is running according to the set data and determine the impact caused by the equipment error;

[0178] The fluctuation range is (-A, A). If the calculated Dvalue is less than -A or Dvalue is greater than A, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined. The following alarm strategies are executed according to the distance. This situation indicates that the equipment error has exceeded the set range, which will have a certain impact on the quality of the produced ceramics. Therefore, specific strategies must be adopted for control to ensure the qualified rate and high-quality rate of the produced ceramics:

[0179] Calculate the level of the distance between the difference data and the fluctuation range boundary Jbc is the difference between the upper and lower limits of the set level, and LV is compared with the set online maintenance interval (0, B) and the shutdown maintenance interval [B, MAX]. MAX is the maximum difference level corresponding to the equipment. The MAX value of different equipment is different. If LV is in the online maintenance interval, online maintenance is performed. If LV is in the shutdown maintenance interval, shutdown maintenance is performed. This situation indicates that the production of ceramics is seriously affected. If no maintenance is performed, it will cause great losses.

[0180] The real-time monitoring module is mainly used to reduce the interference caused by the equipment, control the equipment to stop running when a failure occurs, and reduce the losses caused by equipment abnormality.

[0181] The present invention provides a comprehensive control system for ceramic production equipment, which can also realize effective monitoring of the working data of ball milling, drying and sintering equipment, can provide timely feedback when working abnormally, effectively reduce the loss caused by equipment abnormality, and can further analyze the product data of sintered ceramics, summarize the reasons for unqualified sintered products, and further formulate adjustment plans based on the reasons, which can optimize the process and effectively improve the qualified rate of ceramics, has good use effect and has a good use prospect.

[0182] The weight coefficient used in this system is determined by the coefficient of variation method. The coefficient of variation method is a method of weighting each indicator according to the degree of variation between the current value of each evaluation indicator and the target value. If the numerical difference of an indicator is large, it can clearly distinguish the evaluated objects, indicating that the indicator has rich discrimination information, and thus the indicator should be given a larger weight. On the contrary, if the numerical difference of each evaluated object on a certain indicator is small, then the ability of this indicator to distinguish the evaluation objects is weak, and thus the indicator should be given a smaller weight. This method directly uses the information contained in each indicator to obtain the weight of the indicator through calculation, and therefore is objective.

[0183] In the application, the several formulas involved are all calculated by taking their numerical values ​​after removing the dimensions, and the formulas are established by collecting a large amount of data and performing software simulation to obtain a formula for the most recent actual situation. Some coefficients or weights in the formulas are set by technical personnel in this field according to actual conditions, so they will not be elaborated here.

[0184] The above embodiments may be implemented in whole or in part by software, hardware, firmware or any other combination thereof. When implemented using software, the above embodiments may be implemented in whole or in part in the form of a computer program product. A person of ordinary skill in the art may appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein may be implemented in electronic hardware, or in a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution.

[0185] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, and may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0186] The above description is only a specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application.

Claims

1. A comprehensive control system for ceramic production equipment, characterized in that: include: Data acquisition module: used to collect ceramic raw material ball milling data, ceramic body data, environmental data, ceramic data after sintering, and working data of ball mill, drying equipment and sintering equipment during ceramic production and processing. The working data of sintering equipment includes the working parameters of sintering equipment itself and the hot air flow rate and hot air temperature transmitted to the drying chamber in real time; Data analysis module: used to analyze the ball milling data of ceramic raw materials, determine the influencing characteristics of ceramic raw materials, and analyze the collected ceramic green body data to obtain the moisture content data of the ceramic green body in the current state, and calculate the drying moisture content based on the moisture content data in the current state and the sintering moisture content corresponding to the influencing characteristics of the ceramic raw materials; Plan formulation module: used to obtain the influencing characteristics and drying moisture content of ceramic raw materials, and further analyze and formulate hot air drying and sintering plans; Drying adjustment module: used to summarize and analyze the acquired hot air drying scheme, environmental data, and the hot air flow rate and hot air temperature transmitted to the drying chamber by the sintering equipment in real time, generate a dynamic temperature compensation scheme for the drying equipment, and control the drying equipment to operate according to the dynamic temperature compensation scheme; Product feedback module: used to analyze the ceramic data after sintering, calculate the qualified rate of ceramics, and compare the standard value and excellent value set for the qualified rate; If the qualified rate is lower than the set standard value, the operation will be stopped and a comprehensive test will be carried out; If the qualified rate is between the standard value and the excellent value, the ceramic data is defect analyzed to obtain the cause of the defect, and an adjustment plan is formulated based on the cause of the defect, and the adjustment plan is implemented, and the qualified rate of the ceramic is recalculated and compared again; If the pass rate is higher than the excellent value, no adjustment is required.

2. The comprehensive control system for ceramic production equipment according to claim 1, characterized in that: The ball milling data of ceramic raw materials include the ball milling time, the amount of material used in the ball milling and the ball milling power. The ceramic body data is the moisture content data of the ceramic body. The environmental data is the real-time temperature data inside and outside the drying room. The ceramic data after sintering is the number of qualified ceramic products and the reasons for unqualified ceramic products.

3. The comprehensive control system for ceramic production equipment according to claim 2, characterized in that: By analyzing the ball milling data of ceramic raw materials, the calculation formula for determining the influencing characteristics of ceramic raw materials is as follows: Where, INCH is the influencing characteristic value of ceramic raw materials, α and β are constant coefficients, α and β are both greater than 1, Tj is the actual ball milling time of ceramic raw materials, Tb is the ball milling time of ceramic raw materials under standard raw material amount, Gwl is the amount of added ceramic raw materials, Gwlb is the standard raw material amount, pj is the actual ball milling power, and pb is the set standard ball milling power.

4. The comprehensive control system for ceramic production equipment according to claim 3, characterized in that: The steps of analyzing the collected ceramic body data to obtain the ceramic body moisture content data in the current state are as follows: Randomly select M groups of ceramic bodies from a batch, measure the moisture content data of K positions of each ceramic body by infrared measurement method, and retrieve the moisture content data measured by infrared measurement method under the same external environment as the batch of ceramic raw materials from the database; Retrieving the moisture content data of the ceramic green body measured by the infrared measurement method and then by the drying method in the database; Calculate the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method. The specific formula is as follows: Where Var is the difference between the moisture content data measured by the infrared measurement method and the moisture content data measured by the drying method, n is the number of moisture content data measured by the infrared measurement method extracted, Humg i is the moisture content data measured by the drying method of the i-th group, Humh i is the moisture content data of the i-th group measured by infrared measurement method; Calculate the average value of the moisture content data of K positions of the ceramic, and calculate the moisture content data of the ceramic body in the current state based on the average value data; Where Hums is the moisture content of the ceramic body in the current state. is the average water content of the i-th position of M ceramic bodies, Cjxs i is the adjustment ratio of the moisture content at the i-th position of the ceramic body, Hum ij is the water content of the i-th position of the j-th ceramic body; The steps to calculate the drying moisture content are as follows: The material of the collected ceramic body is used to search the database for the corresponding influencing characteristics and standard sintering moisture content of the material; The sintering moisture content of the batch of ceramic green bodies is calculated, and then the drying moisture content is calculated based on the calculated sintering moisture content. The specific calculation formula is as follows: Where Humgz is the dry moisture content, is the sintering moisture content of this batch of ceramic green bodies, Humgzb is the standard sintering moisture content of this material, γ is the constant coefficient, γ>1, and INCHb is the influencing characteristic corresponding to the set ceramic material.

5. The comprehensive control system for ceramic production equipment according to claim 4, characterized in that: The steps to develop a sintering plan are as follows: Obtain all sintering schemes corresponding to the ceramic body material recorded in the database; Analyze the sintering schemes, screen out sintering schemes with the same sintering temperature, and extract the corresponding sintering time data and influencing characteristic data in the screened sintering schemes; The sintering time data and the influencing characteristic data are input into a two-dimensional coordinate system and processed using the Gaussian process regression method to generate a curve equation; Input INCH into the curve equation to calculate the sintering time of the batch, and combine the sintering temperature, influencing characteristics and sintering time to form a sintering plan.

6. The comprehensive control system for ceramic production equipment according to claim 5, characterized in that: The steps to develop a hot air drying plan are as follows: Obtaining the standard hot air drying scheme corresponding to the ceramic body material recorded in the database; Obtain the influencing characteristic values ​​of sintering moisture content and ceramic raw materials, and calculate the actual hot air drying time in combination with the standard hot air drying time in the standard hot air drying scheme. The calculation formula is as follows; Where, Tgs is the actual hot air drying time, Tgb is the standard hot air drying time, δ is a constant, 1<δ<2; The actual hot air drying time replaces the standard hot air drying time to form a hot air drying plan.

7. The comprehensive control system for ceramic production equipment according to claim 6, characterized in that: The steps to generate a dynamic temperature compensation solution for drying equipment are as follows: Obtain the hot air flow rate and hot air temperature transmitted from the sintering equipment to the drying chamber in real time, and calculate the transmitted heat value; The specific calculation formula is as follows: Qcs=ρ T ×π×r 2 ×Vc×C T ×T In the formula, Qcs is the transferred heat value, T is the hot air temperature, ρ T is the density of air at temperature T, π is the circumference of a circle, r is the radius of the hot air pipe, Vc is the hot air velocity, C T is the specific heat capacity of air at temperature T; Obtain the heat loss Qs of the drying chamber at the standard hot air drying temperature, further calculate the compensation heat, and then calculate the heating current of the heater based on the compensation heat; Where Ij is the heating current of the heater, Rj is the resistance of the heater, and URl is the heat utilization rate of the heater; Calculate the heater's lead time Where Lc is the distance required for the hot air to move from the detection position to the drying chamber, and Ty is the time required for the heater to automatically adjust and transmit data; The heating time and heating current are combined to form a dynamic temperature compensation scheme.

8. The comprehensive control system for ceramic production equipment according to claim 7, characterized in that: The formula for calculating the pass rate is: Where FPY is the qualified rate of ceramics produced in this batch, Zs is the number of sintered ceramic bodies in this batch, and Zh is the number of qualified ceramics produced in this batch; The steps to analyze the defects of ceramic data, obtain the causes of defects, and formulate adjustment plans based on the causes of defects are as follows: Classify the reasons for unqualified ceramic products, and count the number of unqualified ceramics caused by too high moisture content after drying, n1, and the number of unqualified ceramics caused by too low moisture content after drying, n2; Determine the size of n1 and n2; If n1<n2, the actual hot air drying time is extended, and the actual hot air drying time after extension is Tgs1=Tgs×(1+η); If n1>n2, the actual hot air drying time is shortened, and the shortened actual hot air drying time is Tgs1=Tgs×(1-η), where η is the adjustment ratio, 0.01≤η≤0.

03.

9. The comprehensive control system for ceramic production equipment according to claim 8, characterized in that: It also includes a real-time monitoring module: used to compare the working data of the ball mill, drying equipment and sintering equipment with the set working values, calculate the difference fluctuation data, and determine whether the difference data is within the fluctuation range; If the difference data is within the fluctuation range, no response will be made; If the difference data is outside the fluctuation range, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined, and the corresponding alarm strategy is executed according to the distance.

10. The comprehensive control system for ceramic production equipment according to claim 9, characterized in that: The formula for calculating the difference fluctuation data is as follows: Where Dvalue is the difference fluctuation data, Gj is the monitored equipment working data, and Gb is the monitored equipment standard working data; The fluctuation range is (-A, A). If the calculated Dvalue is less than -A or Dvalue is greater than A, an early warning is issued, and the distance between the difference data and the boundary of the fluctuation range is determined. The following alarm strategies are implemented according to the distance: Calculate the level of the distance between the difference data and the fluctuation range boundary Jbc is the difference between the upper and lower limits of the set level, and LV is compared with the set online maintenance interval (0, B) and shutdown maintenance interval [B, MAX]. If LV is in the online maintenance interval, online maintenance is performed; if LV is in the shutdown maintenance interval, shutdown maintenance is performed.

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