Centralized control system and method for shot blasting machine and central controller

Abstract

The invention discloses a shot blasting machine centralized control system, a shot blasting machine centralized control method and a central controller. The edge controller is used for preprocessing the data monitored by the first sensor group to obtain a first data set; the second sensor group is used for monitoring first working data of the screw conveyor; the shot material flow detection device is used for monitoring the shot material flow of the shot material conveying pipeline; the guide wheel state monitoring device is used for monitoring second working data of the guide wheel; the central controller is used for determining the motor rotating speed of the driving motor, generating a first control instruction, judging whether the shot blasting machine has a spiral non-rotating jamming phenomenon or not, and generating a diagnosis result and corresponding processing information if the spiral non-rotating jamming phenomenon exists; the frequency converter is used for adjusting the rotating speed of the driving motor according to the first control instruction; and the display is used for displaying the diagnosis result and the corresponding processing information and displaying the real-time rotating speed of the driving motor. According to the invention, efficient, energy-saving and intelligent operation of the shot blasting machine can be realized.

Description

Technical Field

[0001] The embodiments of the present application relate to the field of industrial systems, and in particular to a centralized control system, method and central controller for a shot blasting machine. Background Art

[0002] Shot blasting machine is a widely used equipment for metal surface treatment. It is mainly used to remove impurities such as oxide layer, rust, welding slag, etc. on the surface of the workpiece, and at the same time improve the roughness of the workpiece surface to enhance the adhesion of the coating. With the continuous development of industrial automation technology, the control requirements of shot blasting machines are becoming increasingly complex, especially in terms of efficient operation, energy saving and consumption reduction, and fault handling. Traditional shot blasting machine control systems have gradually exposed many shortcomings.

[0003] Traditional shot blasting machine control systems usually use simple open-loop control or closed-loop control based on fixed parameters, and their core control logic relies on manual experience or preset fixed parameters. This control method has the following main problems: 1. The drive motor of the traditional shot blasting machine usually runs at a fixed speed. When the workload of the shot blasting machine is small, the motor still runs at a high speed, resulting in energy waste; when the workload is large, the motor may not be able to provide enough power, resulting in a decrease in shot blasting efficiency. 2. Since the traditional shot blasting machine control system cannot dynamically adjust the motor speed according to the actual workload, the energy utilization rate is low. Especially under low load conditions, the motor still runs at a high speed, causing a lot of electrical energy waste. 3. The screw conveyor is one of the key components of the shot blasting machine, which is responsible for conveying the shot to the shot blasting room. In actual operation, the screw conveyor may not turn due to blockage of the shot or excessive load, resulting in equipment shutdown and production interruption.

[0004] In summary, the existing shot blasting machine control system has low operating efficiency, poor energy-saving effect, and is prone to spiral jamming, which seriously affects the operating efficiency and energy utilization of the shot blasting machine. Therefore, there is an urgent need for a centralized control system that can achieve efficient and energy-saving operation. Summary of the invention

[0005] The embodiments of the present application provide a centralized control system, method and central controller for a shot blasting machine, which are used to solve the problems of low operating efficiency, poor energy-saving effect and easy occurrence of spiral jamming in traditional shot blasting machine control systems, and realize efficient, energy-saving and intelligent operation of the shot blasting machine.

[0006] To achieve the above objectives, the embodiments of the present application adopt the following technical solutions:

[0007] In a first aspect, a centralized control system for a shot blasting machine is provided, wherein the shot blasting machine includes a screw conveyor, a guide wheel, a drive motor, and a shot conveying pipeline, and the system includes:

[0008] A first sensor group, including a current sensor, a voltage sensor, a temperature sensor and a vibration sensor, is used to monitor the working data and environmental parameters of the shot blasting machine in real time;

[0009] An edge controller, used for preprocessing the working data and the environmental parameters of the shot blasting machine to obtain a first data set, and transmitting the first data set to a central controller;

[0010] A second sensor group, including a torque sensor and a rotation speed sensor installed on the screw conveyor, for real-time monitoring of first working data of the screw conveyor, and transmitting the first working data to the central controller;

[0011] A shot flow rate detection device, used for real-time monitoring of the shot flow rate of the shot conveying pipeline, and transmitting the shot flow rate to the central controller;

[0012] A guide wheel state monitoring device, used for monitoring the second working data of the guide wheel in real time and transmitting the second working data to the central controller;

[0013] a central controller, configured to receive the first data set, the first working data, the shot flow rate, and the second working data, determine the motor speed of the drive motor according to the first data set, generate a first control instruction according to the motor speed, determine whether the shot blasting machine has a spiral blocking phenomenon according to the first working data and the shot flow rate, and if the spiral blocking phenomenon exists, generate a diagnosis result and corresponding processing information;

[0014] A frequency converter, used to adjust the rotation speed of the driving motor according to the first control instruction, so as to realize variable frequency speed regulation of the shot blasting machine;

[0015] A display, used to display the diagnosis result and corresponding processing information, and to display the real-time rotation speed of the drive motor;

[0016] Wherein, the central controller is further configured as:

[0017] When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction;

[0018] According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the rotation speed of the drive motor according to the third control instruction.

[0019] In a possible implementation manner of the first aspect, the second control instruction includes a speed reduction instruction and a speed maintaining instruction, and the central controller is further configured to:

[0020] Calculating the load rate of the screw conveyor according to the first working data and the shot flow rate;

[0021] When the load rate is greater than a first preset load threshold, it is determined that the shot blasting machine has the spiral blocking phenomenon, and the severity of the spiral blocking phenomenon is calculated according to the load rate, and corresponding processing information is determined according to the severity, wherein the severity is used to represent the diagnosis result;

[0022] If the load rate is greater than a second preset load threshold, the speed reduction instruction is generated according to the load rate, so that the frequency converter reduces the speed of the drive motor according to the speed reduction instruction to reduce the load rate of the screw conveyor, wherein the second preset load threshold is greater than the first preset load threshold;

[0023] If the load rate is less than or equal to the second preset load threshold and greater than the first preset load threshold, the speed keeping instruction is generated according to the load rate, so that the inverter keeps the speed of the drive motor according to the speed keeping instruction.

[0024] In another possible implementation manner of the first aspect, determining corresponding processing information according to the severity includes:

[0025] When the severity of the screw not turning and being stuck is greater than or equal to a preset threshold, a stop command is generated as the processing information, and the stop command is executed by the frequency converter to control the drive motor to stop running;

[0026] When the severity of the screw blocking phenomenon is less than a preset threshold, a restart instruction is generated as the processing information, and the restart instruction is executed by the inverter to control the drive motor to resume operation.

[0027] In another possible implementation manner of the first aspect, a guide wheel adjustment device is further included, wherein if the working state of the guide wheel is abnormal, a third control instruction is generated so that the frequency converter adjusts the speed of the drive motor according to the third control instruction, including:

[0028] If the working state of the guide wheel is abnormal, determine the current position and current pressure of the guide wheel according to the second working data, and use a preset adjustment formula to calculate the theoretical pressure of the guide wheel according to the current position and the current pressure;

[0029] generating a guide wheel adjustment instruction according to the theoretical pressure, so that the guide wheel adjustment device executes the guide wheel adjustment instruction and adjusts the pressure of the guide wheel to the theoretical pressure;

[0030] According to the theoretical position and the theoretical pressure, a first preset speed calculation formula is used to calculate the theoretical speed of the drive motor, and the third control instruction is generated according to the theoretical speed, so that the frequency converter adjusts the speed of the drive motor according to the third control instruction.

[0031] In another possible implementation of the first aspect, the shot flow detection device is a flow sensor installed on the shot conveying pipeline, the guide wheel state monitoring device includes a pressure sensor and a displacement sensor installed on the guide wheel, and the guide wheel adjustment device includes a hydraulic cylinder and a servo motor for adjusting the pressure of the guide wheel according to the guide wheel adjustment instruction.

[0032] In another possible implementation manner of the first aspect, the second working data includes displacement data and pressure data, and determining the current position and the current pressure of the guide wheel according to the second working data, and using a preset adjustment formula to calculate the theoretical pressure of the guide wheel according to the current position and the current pressure, includes:

[0033] Determining the current position of the guide wheel according to the displacement data;

[0034] Determining the current pressure of the guide wheel according to the pressure data;

[0035] Obtaining the theoretical position of the guide wheel;

[0036] Using a preset adjustment formula, the theoretical pressure of the guide wheel is calculated according to the current position, the current pressure and the theoretical position;

[0037] Wherein, the preset adjustment formula is:

[0038] P 理论 =P 当前 +k×(X 理论 -X 当前 );

[0039] Where P 理论 is the theoretical pressure, P 当前 is the current pressure, k is the adjustment coefficient, X 理论 is the theoretical position, X 当前 is the current location.

[0040] In another possible implementation manner of the first aspect, determining the motor speed of the drive motor according to the first data set, and generating a first control instruction according to the motor speed includes:

[0041] Calculating the workload of the shot blasting machine according to the first data set using a workload calculation formula;

[0042] Using a second preset speed calculation formula to calculate the motor speed of the drive motor according to the workload;

[0043] A first control instruction is generated according to the motor speed, so that the frequency converter executes the first control instruction and adjusts the speed of the drive motor to reach the motor speed.

[0044] In another possible implementation manner of the first aspect, the central controller is further configured to:

[0045] In the case that the spiral does not turn and is stuck, and the working state of the guide wheel is abnormal, a comprehensive control instruction is generated according to the diagnosis result and the second working data, so that the frequency converter adjusts the speed of the drive motor according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel according to the comprehensive control instruction;

[0046] The step of generating a comprehensive control instruction according to the diagnosis result and the second working data includes:

[0047] According to the diagnosis result, a third preset speed calculation formula is used to determine a first target speed of the drive motor;

[0048] According to the second working data, a fourth preset speed calculation formula is used to determine a second target speed of the driving motor;

[0049] Using a comprehensive speed calculation formula, according to the first target speed and the second target speed, calculate the comprehensive target speed of the drive motor;

[0050] Calculating the ideal pressure of the guide wheel using a pressure calculation formula according to the second working data and the diagnosis result;

[0051] A comprehensive control instruction is generated according to the comprehensive target speed and the ideal pressure, so that the frequency converter adjusts the speed of the drive motor to the comprehensive target speed according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel to the ideal pressure according to the comprehensive control instruction.

[0052] In a second aspect, the present application provides a centralized control method for a shot blasting machine, the shot blasting machine comprising a screw conveyor, a guide wheel, a drive motor and a shot conveying pipeline, the method comprising:

[0053] Monitor the working data and environmental parameters of the shot blasting machine in real time through a first sensor group, and pre-process the working data and environmental parameters through an edge controller to obtain a first data set;

[0054] The first working data of the screw conveyor is monitored in real time by the second sensor group, and the shot flow rate is monitored in real time by the shot flow rate detection device;

[0055] Monitor the second working data of the guide wheel in real time through the guide wheel state monitoring device;

[0056] receiving the first data set, the first working data, the shot flow rate and the second working data, calculating the motor speed of the driving motor according to the first data set, and generating a first control instruction according to the motor speed;

[0057] Determine whether the shot blasting machine has a spiral blocking phenomenon according to the first working data and the shot material flow rate, and if the spiral blocking phenomenon exists, generate a shot blasting machine diagnosis result and corresponding processing information;

[0058] Adjusting the speed of the driving motor according to the first control instruction through the frequency converter to achieve variable frequency speed regulation of the shot blasting machine;

[0059] Displaying the shot blasting machine diagnosis result and corresponding processing information through a display, and displaying the real-time speed of the drive motor;

[0060] Wherein, the method further comprises:

[0061] When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction;

[0062] According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the rotation speed of the drive motor according to the third control instruction.

[0063] In a third aspect, the present application provides a central controller, comprising:

[0064] a memory configured to store instructions; and

[0065] The processor is configured to call the instructions from the memory and implement the above-mentioned centralized control method of the shot blasting machine when executing the instructions.

[0066] Through the above technical solution, the working data and environmental parameters of the shot blasting machine, including key indicators such as current, voltage, temperature and vibration, are first monitored in real time through the first sensor group. The edge controller preprocesses these data and generates a first data set, which is transmitted to the central controller, providing a data basis for subsequent precise control. Secondly, the second sensor group monitors the working status of the screw conveyor in real time through the torque sensor and speed sensor installed on the screw conveyor, and transmits the first working data to the central controller. Combined with the shot flow data monitored in real time by the shot flow detection device, the central controller can accurately determine whether the shot blasting machine has a spiral blocking phenomenon. If there is a spiral blocking phenomenon, the central controller generates a diagnostic result and corresponding processing information, and adjusts the speed of the drive motor through the frequency converter, and generates a second control instruction to alleviate or eliminate the blocking phenomenon, thereby avoiding equipment shutdown and production interruption, and significantly improving the operation efficiency and reliability of the equipment. In addition, the guide wheel status monitoring device monitors the second working data of the guide wheel in real time, and the central controller can determine whether the working state of the guide wheel is abnormal. If it is abnormal, a third control instruction is generated, and the speed of the drive motor is adjusted through the frequency converter. At the same time, the position and pressure of the guide wheel are adjusted in combination with the guide wheel adjustment device to avoid scratches on the surface of the steel plate, further improving the product quality. The central controller also calculates the motor speed of the drive motor according to the first data set, and dynamically adjusts the motor speed through the frequency converter to achieve variable frequency speed regulation of the shot blasting machine. When the workload of the shot blasting machine is small, the central controller reduces the motor speed to reduce energy consumption; when the workload is large, the motor speed is increased to ensure the shot blasting efficiency, thereby significantly improving energy utilization and operating efficiency. In addition, the display displays the diagnostic results, processing information, and the speed of the drive motor in real time, providing users with an intuitive operation interface and status monitoring function, further improving the ease of use and maintainability of the system. Through the above-mentioned technical means, this solution not only realizes the efficient and energy-saving operation of the shot blasting machine, but also solves the problem of spiral non-rotation jamming and steel plate scratches caused by guide wheel problems, significantly improves the operating efficiency, energy utilization rate and product quality of the equipment, realizes centralized control and intelligent speed regulation of the shot blasting machine, and effectively solves the problems of low operating efficiency, poor energy-saving effect and easy occurrence of spiral non-rotation jamming in the traditional shot blasting machine control system, realizing efficient, energy-saving and intelligent operation of the shot blasting machine.

[0067] Other features and advantages of the embodiments of the present application will be described in detail in the subsequent specific implementation section. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Figure 1 A schematic diagram of the structure of a centralized control system for a shot blasting machine provided in an embodiment of the present application;

[0069] Figure 2A schematic flow chart of a centralized control method for a shot blasting machine provided in an embodiment of the present application. DETAILED DESCRIPTION

[0070] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. It should be understood that the specific implementation methods described herein are only used to illustrate and explain the embodiments of the present application, and are not used to limit the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0071] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0072] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present application, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0073] Figure 1 The structure diagram of a centralized control system for a shot blasting machine according to an embodiment of the present application is schematically shown. Figure 1 As shown, the embodiment of the present application provides a centralized control system for a shot blasting machine, the shot blasting machine includes a screw conveyor, a guide wheel, a drive motor and a shot conveying pipeline, and the system may include:

[0074] The first sensor group 10 includes a current sensor, a voltage sensor, a temperature sensor and a vibration sensor, and is used to monitor the working data and environmental parameters of the shot blasting machine in real time;

[0075] The edge controller 20 is used to pre-process the working data and environmental parameters of the shot blasting machine to obtain a first data set, and transmit the first data set to the central controller;

[0076] The second sensor group 30 includes a torque sensor and a rotation speed sensor installed on the screw conveyor, and is used to monitor the first working data of the screw conveyor in real time and transmit the first working data to the central controller;

[0077] The shot flow rate detection device 40 is used to monitor the shot flow rate of the shot conveying pipeline in real time and transmit the shot flow rate to the central controller;

[0078] The guide wheel state monitoring device 50 is used to monitor the second working data of the guide wheel in real time and transmit the second working data to the central controller;

[0079] The central controller 60 is used to receive the first data set, the first working data, the shot flow rate, and the second working data, determine the motor speed of the driving motor according to the first data set, generate a first control instruction according to the motor speed, and determine whether the shot blasting machine has a spiral blocking phenomenon according to the first working data and the shot flow rate. If the spiral blocking phenomenon exists, generate a diagnosis result and corresponding processing information;

[0080] The frequency converter 70 is used to adjust the speed of the driving motor according to the first control instruction to achieve variable frequency speed regulation of the shot blasting machine;

[0081] A display 80, for displaying the diagnosis result and the corresponding processing information, and displaying the real-time speed of the drive motor;

[0082] The central controller is further configured as follows:

[0083] When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction;

[0084] According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the speed of the drive motor according to the third control instruction.

[0085] In this embodiment, the central controller can be a tablet computer, a desktop computer, a laptop computer, a handheld computer, a wearable device, a notebook computer, an ultra-mobile personal computer (UMPC), a netbook, or other devices with a processor. Of course, the central controller can also be a server. The embodiment of the present application does not impose any special restrictions on the specific form of the central controller.

[0086] The first sensor group 10 is composed of a current sensor, a voltage sensor, a temperature sensor and a vibration sensor, which are used to monitor the working data and environmental parameters of the shot blasting machine in real time. The current sensor is used to monitor the current value of the drive motor, the voltage sensor is used to monitor the stability of the power supply voltage, the temperature sensor is used to monitor the temperature of the key parts of the shot blasting machine (such as the motor, screw conveyor, etc.), and the vibration sensor is used to monitor the vibration of the equipment. These sensors transmit data to the edge controller 20 through a unified communication protocol (such as Modbus or CAN bus). The current sensor detects current changes through the Hall effect principle, the voltage sensor measures the voltage value through a voltage divider circuit, the temperature sensor uses thermocouple or thermistor technology, and the vibration sensor detects the vibration frequency and amplitude of the equipment through the piezoelectric effect or accelerometer. Through the real-time monitoring of the first sensor group 10, the operating status of the shot blasting machine can be fully grasped.

[0087] The edge controller 20 is responsible for preprocessing the working data and environmental parameters collected by the first sensor group 10, generating a first data set, and transmitting the data to the central controller 60. The edge controller 20 uses an embedded processor and runs a real-time operating system (RTOS), which can quickly process multi-channel sensor data. The preprocessing process includes data filtering, outlier removal and data normalization. Data filtering uses a low-pass filter or a Kalman filter algorithm to remove noise interference; outlier removal marks the data out of the range as invalid by setting a reasonable threshold range; data normalization converts the data of different sensors into a unified numerical range for subsequent processing. The preprocessed data is encapsulated as a first data set and transmitted to the central controller 60 via Ethernet or a wireless communication module. The introduction of the edge controller 20 reduces the computing burden of the central controller 60, improves the response speed and data processing efficiency of the system, and reduces the delay and bandwidth occupancy of data transmission.

[0088] The second sensor group 30 includes a torque sensor and a speed sensor installed on the screw conveyor, which are used to monitor the working state of the screw conveyor in real time. The torque sensor detects the load torque of the screw conveyor through a strain gauge or magnetoelastic principle, and the speed sensor detects the speed of the screw conveyor through a photoelectric encoder or Hall effect. These sensors transmit the first working data collected in real time to the central controller 60. The torque sensor can accurately reflect the load condition of the screw conveyor, and the speed sensor provides the operating speed information of the screw conveyor. Through the monitoring of the second sensor group 30, the abnormal state of the screw conveyor (such as excessive load or abnormal speed) can be discovered in time, providing key data support for the judgment and control of the central controller 60.

[0089] The shot flow rate detection device 40 is used to monitor the shot flow rate in the shot delivery pipeline in real time and transmit the data to the central controller 60. The device uses electromagnetic flowmeter or ultrasonic flowmeter technology to calculate the flow rate by measuring the electromagnetic induction or ultrasonic propagation time difference when the shot flows. Electromagnetic flowmeters are suitable for conductive shot materials, and ultrasonic flowmeters are suitable for non-conductive shot materials. The shot flow rate detection device 40 is installed at a preset position in the shot delivery pipeline to ensure the accuracy of the measurement results. By monitoring the shot flow rate in real time, it is possible to determine whether the shot supply is sufficient to avoid a decrease in shot blasting efficiency due to insufficient or blocked shot materials.

[0090] The guide wheel state monitoring device 50 is used to monitor the working state of the guide wheel in real time, including displacement data and pressure data. The device is composed of a displacement sensor and a pressure sensor. The displacement sensor detects the position change of the guide wheel through laser ranging or capacitive measurement technology, and the pressure sensor detects the pressure change of the guide wheel through piezoresistive or piezoelectric technology. These sensors transmit the second working data collected in real time to the central controller 60. By monitoring the state of the guide wheel, it can be determined whether the guide wheel is offset or the pressure is abnormal, so as to avoid scratches on the steel plate surface caused by problems with the guide wheel.

[0091] The central controller 60 receives the first data set from the edge controller 20, the first working data of the second sensor group 30, the shot flow rate of the shot flow rate detection device 40, and the second working data of the guide wheel state monitoring device 50, and generates control instructions according to these data. The central controller 60 first calculates the motor speed of the drive motor according to the first data set and generates a first control instruction; secondly, it determines whether there is a spiral blocking phenomenon according to the first working data and the shot flow rate, and generates a diagnosis result and processing information if there is; finally, it determines whether the guide wheel state is abnormal according to the second working data, and generates a third control instruction if it is abnormal. The central controller 60 transmits the control instruction to the inverter 70 through Ethernet or CAN bus to achieve precise control of the drive motor speed.

[0092] The inverter 70 adjusts the speed of the drive motor according to the first control instruction, the second control instruction or the third control instruction generated by the central controller 60. The inverter 70 uses pulse width modulation (PWM) technology to control the speed of the motor by changing the output frequency and voltage. When the workload of the shot blasting machine is small, the inverter 70 reduces the motor speed to reduce energy consumption; when the workload is large, the motor speed is increased to ensure the shot blasting efficiency. The inverter 70 also has overload protection and fault diagnosis functions, which can effectively extend the service life of the equipment.

[0093] The display 80 is used to display the diagnosis results, processing information and the speed of the drive motor in real time. The display 80 uses a high-resolution LCD screen, supports touch operation and a multi-language interface. Through the intuitive graphical interface, the user can monitor the operating status of the shot blasting machine in real time, view historical data and fault records. The display 80 also supports an alarm function. When an abnormal state is detected, an alarm message will automatically pop up and prompt processing suggestions, which improves the ease of use and maintainability of the system.

[0094] This embodiment first monitors the working data and environmental parameters of the shot blasting machine in real time through the first sensor group, including key indicators such as current, voltage, temperature and vibration. The edge controller preprocesses these data and generates a first data set, which is transmitted to the central controller, providing a data basis for subsequent precise control. Secondly, the second sensor group monitors the working status of the screw conveyor in real time through the torque sensor and speed sensor installed on the screw conveyor, and transmits the first working data to the central controller. Combined with the shot flow data monitored in real time by the shot flow detection device, the central controller can accurately determine whether the shot blasting machine has a spiral obstruction phenomenon. If there is a spiral obstruction phenomenon, the central controller generates a diagnostic result and corresponding processing information, and adjusts the speed of the drive motor through the frequency converter, and generates a second control instruction to alleviate or eliminate the obstruction phenomenon, thereby avoiding equipment shutdown and production interruption, and significantly improving the operation efficiency and reliability of the equipment. In addition, the guide wheel status monitoring device monitors the second working data of the guide wheel in real time, and the central controller can determine whether the working state of the guide wheel is abnormal. If it is abnormal, a third control instruction is generated, and the speed of the drive motor is adjusted through the frequency converter. At the same time, the position and pressure of the guide wheel are adjusted in combination with the guide wheel adjustment device to avoid scratches on the surface of the steel plate, further improving the product quality. The central controller also calculates the motor speed of the drive motor according to the first data set, and dynamically adjusts the motor speed through the frequency converter to achieve variable frequency speed regulation of the shot blasting machine. When the workload of the shot blasting machine is small, the central controller reduces the motor speed to reduce energy consumption; when the workload is large, the motor speed is increased to ensure the shot blasting efficiency, thereby significantly improving energy utilization and operating efficiency. In addition, the display displays the diagnostic results, processing information, and the speed of the drive motor in real time, providing users with an intuitive operation interface and status monitoring function, further improving the ease of use and maintainability of the system. Through the above-mentioned technical means, this solution not only realizes the efficient and energy-saving operation of the shot blasting machine, but also solves the problem of spiral non-rotation jamming and steel plate scratches caused by guide wheel problems, significantly improves the operating efficiency, energy utilization rate and product quality of the equipment, realizes centralized control and intelligent speed regulation of the shot blasting machine, and effectively solves the problems of low operating efficiency, poor energy-saving effect and easy occurrence of spiral non-rotation jamming in the traditional shot blasting machine control system, realizing efficient, energy-saving and intelligent operation of the shot blasting machine.

[0095] In one implementation of this embodiment, the second control instruction includes a speed reduction instruction and a speed maintenance instruction, and the central controller is further configured as follows:

[0096] Calculating the load rate of the screw conveyor according to the first working data and the shot flow rate;

[0097] When the load rate is greater than the first preset load threshold, it is determined that the shot blasting machine has a spiral blocking phenomenon, and the severity of the spiral blocking phenomenon is calculated according to the load rate, and the corresponding processing information is determined according to the severity, wherein the severity is used to represent the diagnosis result;

[0098] If the load rate is greater than a second preset load threshold, a speed reduction instruction is generated according to the load rate, so that the frequency converter reduces the speed of the drive motor according to the speed reduction instruction to reduce the load rate of the screw conveyor, wherein the second preset load threshold is greater than the first preset load threshold;

[0099] If the load rate is less than or equal to the second preset load threshold and greater than the first preset load threshold, a speed keeping instruction is generated according to the load rate, so that the inverter keeps the speed of the drive motor according to the speed keeping instruction.

[0100] The load rate of the screw conveyor is calculated by the first working data and the shot flow rate, which is used to reflect the actual working load of the screw conveyor. The first working data includes the load torque detected by the torque sensor and the speed detected by the speed sensor, and the shot flow rate is monitored in real time by the shot flow detection device 40. The calculation formula of the load rate is: load rate = (actual torque / rated torque) × 100%. Among them, the actual torque is directly measured by the torque sensor, and the rated torque is the maximum allowable torque of the screw conveyor under rated working conditions. For example, if the torque sensor detects that the actual torque is 120N·m and the rated torque is 200N·m, the load rate is (120 / 200) × 100% = 60%. By calculating the load rate in real time, the working state of the screw conveyor can be accurately judged, providing data support for subsequent fault diagnosis and control. The calculation of the load rate not only takes into account the torque data, but also combines the shot flow data to ensure the comprehensiveness and accuracy of the calculation results. For example, when the shot flow rate is abnormally reduced, even if the torque data is normal, it may indicate that the screw conveyor is at risk of blockage. Through real-time calculation of load factor, potential problems can be discovered in time to avoid equipment failure and production interruption.

[0101] When the load rate is greater than the first preset load threshold, it indicates that the screw conveyor may have a screw jam phenomenon. The first preset load threshold is set according to the rated working conditions and historical operating data of the screw conveyor, and is usually 70% of the rated load. For example, if the rated load is 200N·m, the first preset load threshold is 140N·m. When the load rate exceeds the threshold, the central controller 60 will further calculate the severity of the screw jam phenomenon. The calculation formula for the severity is: severity = (load rate-first preset load threshold) / (second preset load threshold-first preset load threshold)×100%. For example, if the load rate is 160N·m, the first preset load threshold is 140N·m, and the second preset load threshold is 180N·m, the severity is (160-140) / (180-140)×100%=50%. By calculating the severity, the scope of influence of the screw jam phenomenon can be quantified, providing a basis for subsequent processing decisions. The calculation of severity not only takes into account the absolute value of the load factor, but also combines the changing trend of the load factor to ensure the accuracy and reliability of the judgment results.

[0102] When the load rate is greater than the second preset load threshold, it indicates that the phenomenon of the screw not turning and blocking is more serious, and measures need to be taken immediately to reduce the load rate. The second preset load threshold is usually 90% of the rated load. For example, if the rated load is 200N·m, the second preset load threshold is 180N·m. The central controller 60 generates a speed reduction instruction according to the load rate, and the frequency converter 70 reduces the speed of the drive motor according to the instruction. The speed reduction range is determined by the difference between the load rate and the second preset load threshold, and the calculation formula is: speed reduction range = (load rate-second preset load threshold) / second preset load threshold×rated speed. For example, if the load rate is 190N·m, the second preset load threshold is 180N·m, and the rated speed is 1500rpm, the speed reduction range is (190-180) / 180×1500=83.3rpm. By reducing the speed of the drive motor, the load rate of the screw conveyor can be effectively reduced, the phenomenon of the screw not turning and blocking can be alleviated or eliminated, and equipment shutdown and production interruption can be avoided.

[0103] When the load rate is less than or equal to the second preset load threshold and greater than the first preset load threshold, it indicates that the spiral blocking phenomenon is relatively mild and there is no need to reduce the speed immediately. The central controller 60 will generate a speed maintenance instruction according to the load rate, and the frequency converter 70 will maintain the current speed of the drive motor according to the instruction. For example, if the load rate is 160N·m, the first preset load threshold is 140N·m, and the second preset load threshold is 180N·m, the load rate is between 140N·m and 180N·m, and the central controller 60 will generate a speed maintenance instruction. By maintaining the current speed, equipment instability caused by speed fluctuations can be avoided without reducing the shot blasting efficiency. The generation of the speed maintenance instruction not only takes into account the absolute value of the load rate, but also combines the changing trend of the load rate to ensure the rationality and effectiveness of the control strategy.

[0104] In this embodiment, the centralized control system of the shot blasting machine can monitor the load rate of the screw conveyor in real time, accurately determine the existence and severity of the screw jam phenomenon, and generate corresponding control instructions according to the load rate. When the load rate exceeds the second preset load threshold, the system alleviates the jam by reducing the speed of the drive motor; when the load rate is between the first preset load threshold and the second preset load threshold, the system maintains the current speed to ensure stable operation of the equipment. This solution not only improves the operating efficiency and reliability of the shot blasting machine, but also significantly reduces the equipment failure rate and energy consumption, realizing efficient, energy-saving and intelligent operation of the shot blasting machine.

[0105] In one implementation of this embodiment, the corresponding processing information is determined according to the severity, including:

[0106] When the severity of the screw jamming phenomenon is greater than or equal to a preset threshold, a stop command is generated as processing information, and the stop command is executed through the inverter to control the drive motor to stop running;

[0107] When the severity of the screw jamming phenomenon is less than a preset threshold, a restart command is generated as processing information, and the restart command is executed through the inverter to control the drive motor to resume operation.

[0108] When the severity of the screw not turning and blocking phenomenon is greater than or equal to the preset threshold, it indicates that the load rate of the screw conveyor is too high, there is a serious risk of blocking, and it is necessary to stop immediately to avoid equipment damage. The preset threshold is set according to the rated working conditions and historical operation data of the screw conveyor, usually 80% of the severity. For example, if the severity ranges from 0% to 100%, the preset threshold is 80%. When the severity reaches or exceeds the threshold, the central controller 60 generates a shutdown command, and executes the command through the inverter 70 to control the drive motor to stop running. The generation process of the shutdown command includes the following steps: first, the central controller 60 determines whether it is necessary to stop according to the severity; secondly, a shutdown command is generated and transmitted to the inverter 70 through a communication interface (such as CAN bus or Ethernet); finally, after the inverter 70 receives the shutdown command, it immediately cuts off the power supply of the drive motor to stop it. For example, if the severity is 85%, exceeding the preset threshold of 80%, the central controller 60 generates a shutdown command, the inverter 70 executes the command, and the drive motor stops completely within 1 second. By executing the shutdown command, equipment damage caused by the screw not turning and blocking can be effectively avoided, the service life of the equipment can be extended, and a time window can be provided for subsequent troubleshooting and maintenance.

[0109] When the severity of the screw jam phenomenon is less than the preset threshold, it indicates that although the load rate of the screw conveyor is high, it has not reached a dangerous level, and the operation can be restored by restarting the drive motor. The generation process of the restart instruction includes the following steps: first, the central controller 60 determines whether a restart is required according to the severity; second, a restart instruction is generated and transmitted to the frequency converter 70 through the communication interface; finally, after the frequency converter 70 receives the restart instruction, it gradually restores the power supply of the drive motor to restart it. For example, if the severity is 75%, which is lower than the preset threshold of 80%, the central controller 60 will generate a restart instruction, the frequency converter 70 executes the instruction, and the drive motor gradually recovers from the stopped state to the rated speed within 5 seconds. The execution of the restart instruction not only takes into account the absolute value of the severity, but also combines the changing trend of the load rate to ensure the safety and stability of the restart process. Through the execution of the restart instruction, the normal operation of the equipment can be restored without reducing the shot blasting efficiency, avoiding production interruptions caused by downtime.

[0110] The centralized control system of the shot blasting machine in this embodiment can intelligently generate a shutdown command or a restart command according to the severity of the spiral blocking phenomenon, and perform corresponding control operations through the frequency converter 70. When the severity exceeds the preset threshold, the system immediately shuts down to avoid equipment damage; when the severity is lower than the preset threshold, the system restores the equipment operation by restarting. This solution not only improves the operating safety and reliability of the shot blasting machine, but also significantly reduces the equipment failure rate and maintenance costs, and realizes efficient, energy-saving and intelligent operation of the shot blasting machine. Through precise control strategies and fast response mechanisms, the system can handle the spiral blocking phenomenon in the shortest time to ensure the continuity and stability of production.

[0111] In one implementation of this embodiment, the system further includes a guide wheel adjustment device, and if the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the speed of the drive motor according to the third control instruction, including:

[0112] If the working state of the guide wheel is abnormal, the current position and current pressure of the guide wheel are determined according to the second working data, and a preset adjustment formula is used to calculate the theoretical pressure of the guide wheel according to the current position and current pressure;

[0113] Generate a guide wheel adjustment instruction according to the theoretical pressure, so that the guide wheel adjustment device executes the guide wheel adjustment instruction and adjusts the pressure of the guide wheel to the theoretical pressure;

[0114] According to the theoretical position and the theoretical pressure, the first preset speed calculation formula is used to calculate the theoretical speed of the drive motor, and a third control instruction is generated according to the theoretical speed, so that the frequency converter adjusts the speed of the drive motor according to the third control instruction to avoid scratches on the surface of the steel plate.

[0115] When the working state of the guide wheel is abnormal, it is first necessary to determine the current position and current pressure of the guide wheel according to the second working data. The second working data includes displacement data detected by the displacement sensor and pressure data detected by the pressure sensor. The displacement sensor detects the position change of the guide wheel through laser ranging or capacitive measurement technology, and the pressure sensor detects the pressure change of the guide wheel through piezoresistive or piezoelectric technology. For example, the displacement sensor detects that the current position of the guide wheel is 50mm, and the pressure sensor detects that the current pressure is 500N. These data are transmitted to the central controller 60 through a high-precision data acquisition module to ensure the real-time and accuracy of the data. By monitoring the position and pressure of the guide wheel in real time, the abnormal state of the guide wheel (such as position offset or insufficient pressure) can be discovered in time, providing key data support for subsequent adjustment and control. The accurate measurement of position and pressure not only depends on high-precision sensors, but also needs to be combined with filtering algorithms and calibration techniques to ensure the stability and reliability of the measurement results. For example, the Kalman filter algorithm can be used to remove sensor noise and eliminate sensor drift through regular calibration.

[0116] After determining the current position and current pressure of the guide wheel, the preset adjustment formula is used to calculate the theoretical pressure of the guide wheel. The preset adjustment formula is: Ptheoretical = Pcurrent + k×(Xtheoretical-Xcurrent), where Ptheoretical is the theoretical pressure, Pcurrent is the current pressure, k is the adjustment coefficient, Xtheoretical is the theoretical position, and Xcurrent is the current position. The adjustment coefficient k is set according to the mechanical characteristics and historical operation data of the guide wheel, and is usually a constant between 0.5 and 2.0. For example, if the current pressure is 500N, the current position is 50mm, the theoretical position is 55mm, and the adjustment coefficient k is 1.0, then the theoretical pressure is 500+1.0×(55-50)=505N. By calculating the theoretical pressure, the ideal pressure value of the guide wheel at the theoretical position can be determined, providing a basis for subsequent adjustment and control. The calculation of the theoretical pressure not only takes into account the current position and current pressure, but also combines the theoretical position and the adjustment coefficient to ensure the rationality and accuracy of the calculation results. For example, when the position offset of the guide wheel is large, the adjustment coefficient k will increase accordingly to ensure that the theoretical pressure can effectively correct the position offset. Through this step, the system can accurately calculate the theoretical pressure of the guide wheel, providing a scientific basis for the subsequent generation of adjustment instructions.

[0117] According to the calculated theoretical pressure, a guide wheel adjustment instruction is generated, and the instruction is executed by the guide wheel adjustment device to adjust the pressure of the guide wheel to the theoretical pressure. The guide wheel adjustment device is composed of a hydraulic cylinder and a servo motor. The hydraulic cylinder adjusts the pressure of the guide wheel through the hydraulic system, and the servo motor adjusts the position of the guide wheel through a precision transmission mechanism. For example, if the theoretical pressure is 505N and the current pressure is 500N, the guide wheel adjustment device will increase the pressure of 5N through the hydraulic system to make the pressure of the guide wheel reach the theoretical value. The generation process of the adjustment instruction includes the following steps: first, the central controller 60 generates an adjustment instruction according to the theoretical pressure; second, the adjustment instruction is transmitted to the guide wheel adjustment device through a communication interface (such as CAN bus or Ethernet); finally, the guide wheel adjustment device executes the adjustment instruction to accurately adjust the pressure and position of the guide wheel. Through this step, the system can adjust the state of the guide wheel in real time to ensure that it operates stably at the theoretical position and theoretical pressure, and avoid scratches on the steel plate surface caused by abnormal guide wheels.

[0118] After adjusting the pressure and position of the guide wheel, the theoretical speed of the drive motor is calculated using the first preset speed calculation formula according to the theoretical position and theoretical pressure. The first preset speed calculation formula is: N 理论 =N 额定 ×(P 理论 / P 额定 )×(X 理论 / X 额定 ), where N 理论 is the theoretical speed, N 额定 is the rated speed, P 理论 is the theoretical pressure, P 额定 is the rated pressure, X 理论 is the theoretical position, X 额定 is the rated position. For example, if the rated speed is 1500rpm, the theoretical pressure is 505N, the rated pressure is 500N, the theoretical position is 55mm, and the rated position is 50mm, then the theoretical speed is 1500×(505 / 500)×(55 / 50)=1666.5rpm. By calculating the theoretical speed, the ideal speed value of the drive motor under the theoretical position and theoretical pressure can be determined, providing a basis for the subsequent generation of control instructions. The calculation of the theoretical speed not only takes into account the theoretical pressure and theoretical position, but also combines the rated speed, rated pressure and rated position to ensure the rationality and accuracy of the calculation results. For example, when the theoretical pressure or theoretical position deviates from the rated value by a large margin, the theoretical speed will be adjusted accordingly to ensure that the speed of the drive motor can adapt to the state change of the guide wheel. Through this step, the system can accurately calculate the theoretical speed of the drive motor, providing a scientific basis for the subsequent generation of the third control instruction.

[0119] According to the calculated theoretical speed, a third control instruction is generated, and the speed of the drive motor is adjusted through the frequency converter 70. The generation process of the third control instruction includes the following steps: first, the central controller 60 generates a control instruction according to the theoretical speed; second, the control instruction is transmitted to the frequency converter 70 through the communication interface; finally, the frequency converter 70 executes the control instruction and adjusts the speed of the drive motor to the theoretical value. For example, if the theoretical speed is 1666.5rpm and the current speed is 1500rpm, the frequency converter 70 will increase the speed of the drive motor to 1666.5rpm through the pulse width modulation (PWM) technology. By adjusting the speed of the drive motor, it can be ensured that the guide wheel operates stably at the theoretical position and theoretical pressure, avoiding scratches on the steel plate surface caused by speed mismatch. The execution of the third control instruction not only considers the absolute value of the theoretical speed, but also combines the change trend of the speed to ensure the stability and accuracy of the adjustment process. For example, when the theoretical speed is significantly different from the current speed, the frequency converter 70 will adopt a step-by-step adjustment method to avoid equipment vibration caused by sudden changes in speed. Through this step, the system can adjust the speed of the drive motor in real time to ensure the stable operation of the shot blasting machine and product quality.

[0120] The centralized control system of the shot blasting machine of this embodiment can monitor and adjust the working state of the guide wheel in real time to ensure its stable operation under the theoretical position and theoretical pressure. When the working state of the guide wheel is abnormal, the system generates corresponding adjustment instructions and control instructions by calculating the theoretical pressure and theoretical speed, and executes these instructions through the guide wheel adjustment device and the frequency converter 70 to accurately adjust the pressure of the guide wheel and the speed of the drive motor. This solution not only improves the operating stability and reliability of the shot blasting machine, but also significantly reduces the incidence of scratches on the steel plate surface, improves product quality and production efficiency. Through precise control strategies and rapid response mechanisms, the system can handle guide wheel anomalies in the shortest time, ensure the continuity and stability of production, and realize efficient, energy-saving and intelligent operation of the shot blasting machine.

[0121] In one implementation of this embodiment, the shot flow detection device is a flow sensor installed on the shot conveying pipeline, the guide wheel state monitoring device includes a pressure sensor and a displacement sensor installed on the guide wheel, and the guide wheel adjustment device includes a hydraulic cylinder and a servo motor for adjusting the pressure of the guide wheel according to the guide wheel adjustment instruction.

[0122] The shot flow detection device uses a flow sensor installed on the shot conveying pipeline to monitor the shot flow in the shot conveying pipeline in real time. The flow sensor usually uses electromagnetic flowmeter or ultrasonic flowmeter technology. The electromagnetic flowmeter calculates the flow rate by measuring the induced electromotive force generated when the conductive shot flows in the magnetic field, which is suitable for metal shot; the ultrasonic flowmeter calculates the flow rate by measuring the time difference of ultrasonic wave propagation in the shot, which is suitable for non-metallic shot. For example, if an electromagnetic flowmeter is used, when the shot flows at a speed of 2m / s, the flow sensor will detect the corresponding induced electromotive force and convert it into a flow value, such as 100kg / min, through the signal processing module. The installation position of the flow sensor is usually selected in the straight pipe section of the shot conveying pipeline to ensure the accuracy of the measurement results. By real-time monitoring of the shot flow, it can be judged whether the shot supply is sufficient to avoid the decrease in shot blasting efficiency caused by insufficient or blocked shot. The data of the flow sensor is transmitted to the central controller 60 through a high-precision data acquisition module to ensure the real-time and accuracy of the data. For example, when an abnormal reduction in the shot flow is detected, the system will immediately issue an alarm and adjust the speed of the drive motor to ensure the stable operation of the shot blasting machine. Through the implementation of the shot flow detection device, the system can grasp the supply situation of shot in real time and provide key data support for subsequent control decisions.

[0123] The guide wheel state monitoring device is composed of a pressure sensor and a displacement sensor installed on the guide wheel, which are used to monitor the working state of the guide wheel in real time. The pressure sensor detects the pressure change of the guide wheel through piezoresistive or piezoelectric technology, and the displacement sensor detects the position change of the guide wheel through laser ranging or capacitive measurement technology. For example, the pressure sensor detects that the current pressure of the guide wheel is 500N, and the displacement sensor detects that the current position is 50mm. These data are transmitted to the central controller 60 through a high-precision data acquisition module to ensure the real-time and accuracy of the data. By monitoring the pressure and position of the guide wheel in real time, the abnormal state of the guide wheel (such as insufficient pressure or position offset) can be discovered in time, providing key data support for subsequent adjustment and control. The installation position of the pressure sensor and the displacement sensor is usually selected at the key stress point of the guide wheel to ensure the accuracy of the measurement results. For example, when it is detected that the pressure of the guide wheel is abnormally reduced, the system will immediately generate an adjustment instruction, increase the pressure through the guide wheel adjustment device, and ensure the stable operation of the guide wheel. Through the implementation of the guide wheel state monitoring device, the system can fully grasp the real-time state of the guide wheel and provide reliable basic data for subsequent theoretical pressure calculation and adjustment.

[0124] The guide wheel adjustment device is composed of a hydraulic cylinder and a servo motor, which is used to adjust the pressure of the guide wheel according to the guide wheel adjustment instruction. The hydraulic cylinder adjusts the pressure of the guide wheel through the hydraulic system, and the servo motor adjusts the position of the guide wheel through the precision transmission mechanism. For example, if the theoretical pressure is 505N and the current pressure is 500N, the hydraulic cylinder will increase the pressure of 5N through the hydraulic system to make the pressure of the guide wheel reach the theoretical value. The servo motor will adjust the position of the guide wheel according to the theoretical position to ensure that it runs stably at the theoretical position. The execution process of the guide wheel adjustment device includes the following steps: first, the central controller 60 generates an adjustment instruction according to the theoretical pressure and theoretical position; second, the adjustment instruction is transmitted to the guide wheel adjustment device through a communication interface (such as CAN bus or Ethernet); finally, the hydraulic cylinder and the servo motor execute the adjustment instruction to accurately adjust the pressure and position of the guide wheel. Through this step, the system can adjust the state of the guide wheel in real time to ensure that it runs stably at the theoretical position and theoretical pressure, and avoid scratches on the steel plate surface caused by abnormal guide wheels. The implementation of the guide wheel adjustment device not only improves the operating stability and reliability of the shot blasting machine, but also significantly reduces the incidence of scratches on the steel plate surface, thereby improving product quality and production efficiency.

[0125] The centralized control system of the shot blasting machine of this embodiment can monitor and adjust the shot material flow and the working state of the guide wheel in real time to ensure the stable operation of the shot blasting machine and the product quality. The shot material flow detection device monitors the shot material supply in real time through a high-precision flow sensor to avoid the decrease in shot blasting efficiency caused by insufficient shot material or blockage. The guide wheel state monitoring device monitors the pressure and position of the guide wheel in real time through a pressure sensor and a displacement sensor to detect abnormal conditions in time. The guide wheel adjustment device accurately adjusts the pressure and position of the guide wheel through a hydraulic cylinder and a servo motor to ensure its stable operation at the theoretical position and theoretical pressure. This solution not only improves the operating stability and reliability of the shot blasting machine, but also significantly reduces the incidence of scratches on the steel plate surface, and improves product quality and production efficiency. Through precise control strategies and rapid response mechanisms, the system can handle shot material flow and guide wheel abnormalities in the shortest time, ensure the continuity and stability of production, and realize efficient, energy-saving and intelligent operation of the shot blasting machine.

[0126] In one implementation of this embodiment, the second working data includes displacement data and pressure data, and the current position and current pressure of the guide wheel are determined according to the second working data, and a preset adjustment formula is used to calculate the theoretical pressure of the guide wheel according to the current position and the current pressure, including:

[0127] According to the displacement data, the current position of the guide wheel is determined;

[0128] According to the pressure data, determine the current pressure of the guide wheel;

[0129] Obtaining the theoretical position of the guide wheel;

[0130] The preset adjustment formula is used to calculate the theoretical pressure of the guide wheel according to the current position, current pressure and theoretical position;

[0131] Among them, the preset adjustment formula is:

[0132] P 理论 =P 当前 +k×(X 理论 -X 当前 );

[0133] Where P 理论 is the theoretical pressure, P 当前 is the current pressure, k is the adjustment coefficient, X 理论 is the theoretical position, X 当前 is the current location.

[0134] The current position of the guide wheel is determined by the displacement data detected by the displacement sensor. The displacement sensor usually adopts laser ranging or capacitive measurement technology, which can detect the position change of the guide wheel with high precision. The laser ranging sensor calculates the distance by emitting a laser beam and measuring its reflection time, and the capacitive sensor determines the position by measuring the capacitance change between the guide wheel and the sensor. For example, if the laser ranging sensor detects that the distance between the guide wheel and the sensor is 50mm, the current position of the guide wheel is 50mm. The installation position of the displacement sensor is usually selected at the key force point of the guide wheel to ensure the accuracy of the measurement result. By monitoring the position of the guide wheel in real time, abnormal conditions such as position offset can be discovered in time, providing key data support for subsequent adjustment and control. When it is detected that the position offset of the guide wheel exceeds the allowable range, the system will immediately generate an adjustment instruction, correct the position offset through the guide wheel adjustment device, and ensure the stable operation of the guide wheel.

[0135] The current pressure of the guide wheel is determined by the pressure data detected by the pressure sensor. The pressure sensor usually adopts piezoresistive or piezoelectric technology, which can detect the pressure change of the guide wheel with high precision. The piezoresistive sensor determines the pressure value by measuring the change of resistance under the action of pressure, and the piezoelectric sensor determines the pressure value by measuring the change of charge under the action of pressure. For example, if the piezoresistive sensor detects that the pressure of the guide wheel is 500N, the current pressure is 500N. The installation position of the pressure sensor is usually selected at the key stress point of the guide wheel to ensure the accuracy of the measurement result. By monitoring the pressure of the guide wheel in real time, abnormal conditions such as insufficient pressure or overload can be discovered in time, providing key data support for subsequent adjustment and control. When it is detected that the pressure of the guide wheel is abnormally reduced, an adjustment instruction can be generated immediately, and the pressure can be increased through the guide wheel adjustment device to ensure the stable operation of the guide wheel.

[0136] The theoretical position of the guide wheel is an ideal position pre-set according to the operating parameters and historical data of the shot blasting machine. The theoretical position is usually determined by the equipment manufacturer according to the optimal operating state of the shot blasting machine and stored in the database of the central controller 60. For example, if the guide wheel position of the shot blasting machine in the optimal operating state is 55mm, the theoretical position is 55mm. The process of obtaining the theoretical position includes the following steps: First, the central controller 60 queries the database according to the current operating state of the shot blasting machine; secondly, obtains the theoretical position corresponding to the current operating state. By obtaining the theoretical position, a scientific basis can be provided for subsequent theoretical pressure calculations. The setting of the theoretical position not only takes into account the optimal operating state of the shot blasting machine, but also combines historical operating data and equipment characteristics to ensure the rationality and accuracy of the set value. For example, when the workload of the shot blasting machine is large, the theoretical position will be adjusted accordingly to ensure that the guide wheel operates stably in the optimal position.

[0137] After determining the current position, current pressure and theoretical position of the guide wheel, the preset adjustment formula is used to calculate the theoretical pressure of the guide wheel. The preset adjustment formula is: P 理论 =P 当前 +k×(X 理论 -X 当前 ), where P 理论 is the theoretical pressure, P 当前 is the current pressure, k is the adjustment coefficient, X 理论 is the theoretical position, X 当前 is the current position. The adjustment coefficient k is set according to the mechanical characteristics of the guide wheel and the historical operation data, and is usually a constant between 0.5 and 2.0. For example, if the current pressure is 500N, the current position is 50mm, the theoretical position is 55mm, and the adjustment coefficient k is 1.0, then the theoretical pressure is 500+1.0×(55-50)=505N. By calculating the theoretical pressure, the ideal pressure value of the guide wheel at the theoretical position can be determined, providing a basis for subsequent adjustment and control. The calculation of the theoretical pressure not only takes into account the current position and the current pressure, but also combines the theoretical position and the adjustment coefficient to ensure the rationality and accuracy of the calculation results. For example, when the position offset of the guide wheel is large, the adjustment coefficient k will increase accordingly to ensure that the theoretical pressure can effectively correct the position offset. Through this step, the system can accurately calculate the theoretical pressure of the guide wheel, providing a scientific basis for the subsequent generation of adjustment instructions.

[0138] The centralized control system of the shot blasting machine provided in this embodiment can monitor and adjust the position and pressure of the guide wheel in real time to ensure its stable operation under the theoretical position and theoretical pressure. The system detects the current position and current pressure of the guide wheel in real time through displacement sensors and pressure sensors, obtains the theoretical position, and calculates the theoretical pressure using a preset adjustment formula. It not only improves the operating stability and reliability of the shot blasting machine, but also significantly reduces the incidence of scratches on the steel plate surface, improves product quality and production efficiency. Through precise control strategies and rapid response mechanisms, the system can handle guide wheel anomalies in the shortest time, ensure the continuity and stability of production, and realize efficient, energy-saving and intelligent operation of the shot blasting machine.

[0139] In one implementation of this embodiment, determining the motor speed of the drive motor according to the first data set, and generating the first control instruction according to the motor speed include:

[0140] Using a workload calculation formula, the workload of the shot blasting machine is calculated based on the first data set;

[0141] Using a second preset speed calculation formula to calculate the motor speed of the drive motor according to the workload;

[0142] A first control instruction is generated according to the motor speed, so that the frequency converter executes the first control instruction and adjusts the speed of the drive motor to reach the motor speed.

[0143] The workload of the shot blasting machine is a key indicator calculated from the current, voltage, temperature and vibration data in the first data set, which is used to reflect the actual working state of the shot blasting machine. The first data set is collected in real time by the first sensor group 10, including the current value detected by the current sensor, the voltage value detected by the voltage sensor, the temperature value detected by the temperature sensor and the vibration value detected by the vibration sensor. The calculation formula of the workload is:

[0144]

[0145] Among them, I is the current current value, detected by the current sensor, I is the rated current value, which refers to the maximum allowable current of the shot blasting machine under rated conditions, V is the current voltage value, detected by the voltage sensor, V is the rated voltage value, which refers to the maximum allowable voltage of the shot blasting machine under rated conditions, T is the current temperature value, detected by the temperature sensor, T is the rated temperature value, which refers to the maximum ambient temperature of the shot blasting machine under rated conditions, A is the current vibration amplitude value, A is the rated vibration amplitude value, which refers to the maximum allowable vibration amplitude of the shot blasting machine under rated conditions, u I , w V , w T , w A are the weight coefficients of current, voltage, temperature and vibration respectively, and satisfy w I +wV +w T +w A =1.

[0146] Specifically, the weight coefficient follows the following standards: current is a direct indicator of the load of the shot blasting machine. The larger the current value, the higher the load, so the current weight coefficient is larger; voltage is an indicator of power supply stability. Voltage fluctuations may affect the operating efficiency of the equipment, and the weight coefficient is smaller; temperature is an indirect indicator of the operating status of the equipment. Excessive temperature may indicate that the equipment is overloaded or has poor heat dissipation, and the weight coefficient is smaller than the voltage weight coefficient; vibration is an indicator of the mechanical state of the equipment. Excessive vibration amplitude may indicate that the equipment has mechanical failure or imbalance, and the weight coefficient is smaller. In this embodiment, the current weight is 0.5, the voltage weight is 0.2, the temperature weight is 0.2, and the vibration weight is 0.1.

[0147] For example, refer to Table 1 below:

[0148] current Rated Current (A) 10 12 Voltage (V) 220 230 Temperature(℃) 60 80 Vibration amplitude (mm / s) 0.5 1.0

[0149] Based on the above data, substitute it into the formula to calculate the workload:

[0150]

[0151] After calculating the workload of the shot blasting machine, the second preset speed calculation formula is used to calculate the motor speed of the drive motor. The second preset speed calculation formula is: motor speed = rated speed × (workload / rated load), where the rated speed is the maximum allowable speed of the shot blasting machine under rated conditions, and the rated load is the maximum allowable load of the shot blasting machine under rated conditions. For example, if the rated speed is 1500rpm, the workload is 79.7%, and the rated load is 100%, then the motor speed is 1500×(79.7 / 100)=1195.5rpm. By calculating the motor speed, the ideal speed value of the drive motor under the current workload can be determined, providing a basis for the subsequent control instruction generation. The calculation of the motor speed not only takes into account the absolute value of the workload, but also combines the changing trend of the workload to ensure the rationality and accuracy of the calculation results. For example, when the workload gradually increases, the motor speed will increase accordingly to ensure the operating efficiency of the shot blasting machine; when the workload gradually decreases, the motor speed will decrease accordingly to reduce energy consumption. Through this step, the system can accurately calculate the motor speed of the drive motor, providing a scientific basis for the subsequent generation of the first control instruction.

[0152] According to the calculated motor speed, a first control instruction is generated, and the speed of the drive motor is adjusted by the frequency converter 70. The generation process of the first control instruction includes the following steps: first, the central controller 60 generates a control instruction according to the motor speed; second, the control instruction is transmitted to the frequency converter 70 through a communication interface (such as CAN bus or Ethernet); finally, the frequency converter 70 executes the control instruction and adjusts the speed of the drive motor to the target value. For example, if the motor speed is 1195.5rpm and the current speed is 1500rpm, the frequency converter 70 will reduce the speed of the drive motor to 1195.5rpm through pulse width modulation (PWM) technology. By adjusting the speed of the drive motor, it is possible to ensure that the shot blasting machine operates stably under the current workload and avoid energy waste or decreased shot blasting efficiency caused by speed mismatch. The execution of the first control instruction not only takes into account the absolute value of the motor speed, but also combines the change trend of the speed to ensure the stability and accuracy of the adjustment process. For example, when the motor speed is significantly different from the current speed, the frequency converter 70 will adopt a step-by-step adjustment method to avoid equipment vibration caused by sudden changes in speed. Through this step, the system can adjust the speed of the drive motor in real time to ensure the stable operation and energy utilization of the shot blasting machine.

[0153] The centralized control system of the shot blasting machine provided in this embodiment can monitor and adjust the speed of the drive motor in real time to ensure the stable operation and high efficiency and energy saving of the shot blasting machine under different workloads. The system collects current, voltage, temperature and vibration data in real time through the first sensor group 10, calculates the workload of the shot blasting machine, and calculates the motor speed of the drive motor according to the workload. By generating the first control instruction, the system can accurately adjust the speed of the drive motor to ensure the stable operation of the shot blasting machine under the current workload. This solution not only improves the operating efficiency and reliability of the shot blasting machine, but also significantly reduces energy consumption and equipment failure rate, and realizes efficient, energy-saving and intelligent operation of the shot blasting machine. Through precise control strategies and fast response mechanisms, the system can handle workload changes in the shortest time to ensure the continuity and stability of production.

[0154] In one implementation of this embodiment, the central controller is further configured as:

[0155] In the case that the spiral does not turn and is stuck, and the working state of the guide wheel is abnormal, a comprehensive control instruction is generated according to the diagnosis result and the second working data, so that the frequency converter adjusts the speed of the drive motor according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel according to the comprehensive control instruction;

[0156] Wherein, according to the diagnosis result and the second working data, a comprehensive control instruction is generated, including:

[0157] According to the diagnosis result, a third preset speed calculation formula is used to determine a first target speed of the drive motor;

[0158] According to the second working data, a second target speed of the driving motor is determined by using a fourth preset speed calculation formula;

[0159] Using a comprehensive speed calculation formula, the comprehensive target speed of the drive motor is calculated according to the first target speed and the second target speed;

[0160] According to the second working data and the diagnosis result, the ideal pressure of the guide wheel is calculated by using the pressure calculation formula;

[0161] A comprehensive control instruction is generated according to the comprehensive target speed and the ideal pressure, so that the frequency converter adjusts the speed of the drive motor to the comprehensive target speed according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel to the ideal pressure according to the comprehensive control instruction.

[0162] When the spiral does not turn and the jamming phenomenon exists and the working state of the guide wheel is abnormal, it is necessary to first determine the first target speed of the drive motor according to the diagnosis result (severity). The severity of the diagnosis result is calculated by the load rate and the preset threshold, which reflects the severity of the spiral does not turn and the jamming phenomenon. The third preset speed calculation formula is: first target speed = rated speed × (1-severity / 100). For example, if the rated speed is 1500rpm and the severity is 50%, the first target speed is 1500×(1-50 / 100)=750rpm. By calculating the first target speed, the ideal speed value of the drive motor under the spiral does not turn and the jamming phenomenon can be determined, which provides a basis for the subsequent generation of comprehensive control instructions. The calculation of the first target speed not only takes into account the absolute value of the severity, but also combines the trend of the severity change to ensure the rationality and accuracy of the calculation results. For example, when the severity gradually increases, the first target speed will be reduced accordingly to alleviate the spiral does not turn and the jamming phenomenon; when the severity gradually decreases, the first target speed will be increased accordingly to restore the operating efficiency of the shot blasting machine.

[0163] After determining the first target speed, the second target speed of the drive motor is determined according to the second working data. The second working data includes displacement data and pressure data of the guide wheel, which reflects the working state of the guide wheel. The fourth preset speed calculation formula is: second target speed = rated speed × (P 当前 / P 额定 )×(X 当前 / X 额定 ), where P 当前 is the current pressure, P 额定 is the rated pressure, X 当前 is the current position, X 额定is the rated position. For example, if the rated speed is 1500rpm, the current pressure is 500N, the rated pressure is 550N, the current position is 50mm, and the rated position is 55mm, then the second target speed is 1500×(500 / 550)×(50 / 55)=1239.7rpm. By calculating the second target speed, the ideal speed value of the drive motor under the abnormal state of the guide wheel can be determined, providing a basis for the subsequent generation of comprehensive control instructions. The calculation of the second target speed not only takes into account the current pressure and current position, but also combines the rated pressure and rated position to ensure the rationality and accuracy of the calculation results. For example, when the pressure or position of the guide wheel deviates from the rated value by a large margin, the second target speed will be adjusted accordingly to ensure that the speed of the drive motor can adapt to the state change of the guide wheel.

[0164] After determining the first target speed and the second target speed, the comprehensive speed calculation formula is used to calculate the comprehensive target speed of the drive motor. The comprehensive speed calculation formula is: comprehensive target speed = (first target speed + second target speed) / 2. For example, if the first target speed is 750rpm and the second target speed is 1239.7rpm, the comprehensive target speed is (750+1239.7) / 2=994.85rpm. By calculating the comprehensive target speed, the ideal speed value of the drive motor in the case of the spiral blocking phenomenon and the guide wheel abnormal state can be determined. When the difference between the first target speed and the second target speed is large, the comprehensive target speed will take the average of the two to ensure that the speed of the drive motor can take into account the processing requirements of the spiral blocking phenomenon and the guide wheel abnormal state.

[0165] After determining the comprehensive target speed, the ideal pressure of the guide wheel is calculated based on the second working data and the diagnosis result. The pressure calculation formula is:

[0166] P 理想 =P 当前 +k1×(X 理论 -X 当前 )+k2×S;

[0167] Where P 当前 is the current pressure, k1 and k2 are adjustment coefficients, X 理论 is the theoretical position, X 当前 is the current position, and S is the severity (diagnosis result). 理论 -X 当前is the position deviation. The larger the position deviation, the more serious the position deviation of the guide wheel is, and a greater pressure adjustment is required. The higher the severity, the more serious the screw jam is, and a greater pressure adjustment is required to alleviate the jam. k1 is the position adjustment coefficient, which is used to control the effect of position deviation on pressure adjustment. It is usually set according to the mechanical characteristics of the guide wheel and historical operating data. It is usually 1, indicating that 1N of pressure needs to be increased for every millimeter of position deviation. K2 is the severity adjustment coefficient, which is used to control the effect of severity on pressure adjustment. It is usually set according to the load characteristics and historical operating data of the screw conveyor. It is usually 0.5, indicating that 0.5N of pressure needs to be increased for every 1% of severity.

[0168] The calculation of the ideal pressure not only takes into account the current pressure and current position, but also combines the theoretical position, severity and adjustment coefficient to ensure the rationality and accuracy of the calculation result. For example, when the position offset of the guide wheel is large, the adjustment coefficient k1 will increase accordingly to ensure that the ideal pressure can effectively correct the position offset. Through this step, the system can accurately calculate the ideal pressure of the guide wheel, providing a scientific basis for the subsequent generation of comprehensive control instructions.

[0169] According to the calculated comprehensive target speed and ideal pressure, a comprehensive control instruction is generated, and the instruction is executed by the frequency converter 70 and the guide wheel adjustment device. The generation process of the comprehensive control instruction includes the following steps: first, the central controller 60 generates a comprehensive control instruction according to the comprehensive target speed and the ideal pressure; second, the comprehensive control instruction is transmitted to the frequency converter 70 and the guide wheel adjustment device through a communication interface (such as CAN bus or Ethernet); finally, the frequency converter 70 executes the comprehensive control instruction to adjust the speed of the drive motor to the comprehensive target speed, and the guide wheel adjustment device executes the comprehensive control instruction to adjust the pressure of the guide wheel to the ideal pressure. For example, if the comprehensive target speed is 994.85rpm and the ideal pressure is 505N, the frequency converter 70 will adjust the speed of the drive motor to 994.85rpm through the pulse width modulation (PWM) technology, and the guide wheel adjustment device will adjust the pressure of the guide wheel to 505N through the hydraulic system. By executing the comprehensive control instruction, the system can simultaneously handle the phenomenon of spiral blocking and the abnormal state of the guide wheel, ensuring the stable operation and product quality of the shot blasting machine. The execution of the comprehensive control instruction not only considers the absolute value of the comprehensive target speed and the ideal pressure, but also combines the changing trend of the speed and pressure to ensure the stability and accuracy of the adjustment process. For example, when the comprehensive target speed is significantly different from the current speed, the inverter 70 will adopt a step-by-step adjustment method to avoid equipment vibration caused by sudden changes in speed. Through this step, the system can adjust the speed of the drive motor and the pressure of the guide wheel in real time to ensure the stable operation and high efficiency of the shot blasting machine.

[0170] The centralized control system of the shot blasting machine provided in this embodiment can simultaneously handle the phenomenon of spiral blocking and abnormal state of the guide wheel, ensuring the stable operation and high efficiency and energy saving of the shot blasting machine under different working conditions. The system generates comprehensive control instructions through the diagnostic results and the second working data, and accurately adjusts the speed of the drive motor and the pressure of the guide wheel. This solution not only improves the operating efficiency and reliability of the shot blasting machine, but also significantly reduces the equipment failure rate and energy consumption, and realizes the efficient, energy-saving and intelligent operation of the shot blasting machine. Through precise control strategies and fast response mechanisms, the system can handle complex working conditions in the shortest time and ensure the continuity and stability of production.

[0171] Figure 2 A schematic diagram of a centralized control method for a shot blasting machine provided in an embodiment of the present application is shown. Figure 2 As shown, the embodiment of the present application also provides a centralized control method for a shot blasting machine, the shot blasting machine includes a screw conveyor, a guide wheel, a drive motor and a shot conveying pipeline, and the method includes:

[0172] The first sensor group is used to monitor the working data and environmental parameters of the shot blasting machine in real time, and the edge controller is used to pre-process the working data and environmental parameters to obtain a first data set;

[0173] The first working data of the screw conveyor is monitored in real time by the second sensor group, and the shot flow rate is monitored in real time by the shot flow rate detection device;

[0174] Monitor the second working data of the guide wheel in real time through the guide wheel state monitoring device;

[0175] Receiving a first data set, first working data, a shot flow rate, and second working data, calculating a motor speed of a driving motor according to the first data set, and generating a first control instruction according to the motor speed;

[0176] According to the first working data and the shot material flow rate, it is determined whether the shot blasting machine has a spiral blocking phenomenon, and if the spiral blocking phenomenon exists, a shot blasting machine diagnosis result and corresponding processing information are generated;

[0177] The frequency converter adjusts the speed of the driving motor according to the first control instruction to achieve variable frequency speed regulation of the shot blasting machine;

[0178] The display shows the shot blasting machine diagnosis results and corresponding processing information, as well as the real-time speed of the drive motor;

[0179] The method further includes:

[0180] When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction;

[0181] According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the speed of the drive motor according to the third control instruction.

[0182] The working data and environmental parameters of the shot blasting machine are monitored in real time through the first sensor group, which includes a current sensor, a voltage sensor, a temperature sensor and a vibration sensor. The current sensor detects the current value of the drive motor through the Hall effect principle, the voltage sensor measures the stability of the power supply voltage through a voltage divider circuit, the temperature sensor uses thermocouple or thermistor technology to detect the temperature of the key parts of the shot blasting machine, and the vibration sensor detects the vibration frequency and amplitude of the equipment through the piezoelectric effect or accelerometer. For example, the current sensor detects that the current is 10A, the voltage sensor detects that the voltage is 220V, the temperature sensor detects that the motor temperature is 60℃, and the vibration sensor detects that the vibration amplitude is 0.5mm / s. These data are transmitted to the edge controller through a high-precision data acquisition module to ensure the real-time and accuracy of the data. The edge controller uses a high-performance embedded processor and runs a real-time operating system (RTOS), which can quickly process multi-channel sensor data. The preprocessing process includes data filtering, outlier removal and data normalization. Data filtering uses a low-pass filter or Kalman filter algorithm to remove noise interference; outlier elimination marks the data beyond the range as invalid by setting a reasonable threshold range; data normalization converts the data of different sensors into a unified numerical range for subsequent processing. The preprocessed data is encapsulated as the first data set and transmitted to the central controller via Ethernet or wireless communication module. Through real-time monitoring and preprocessing, the system can fully grasp the operating status of the shot blasting machine and provide reliable basic data support for subsequent data processing and control.

[0183] The working data of the screw conveyor is monitored in real time by the second sensor group, which includes a torque sensor and a speed sensor. The torque sensor detects the load torque of the screw conveyor through a strain gauge or magnetoelastic principle, and the speed sensor detects the speed of the screw conveyor through a photoelectric encoder or Hall effect. For example, the torque sensor detects that the load torque is 120N·m, and the speed sensor detects that the speed is 30rpm. These data are transmitted to the central controller through a high-precision data acquisition module to ensure the real-time and accuracy of the data. The shot flow rate is monitored in real time by a shot flow detection device, which uses electromagnetic flowmeter or ultrasonic flowmeter technology. The electromagnetic flowmeter calculates the flow rate by measuring the induced electromotive force generated when the conductive shot flows in a magnetic field, and the ultrasonic flowmeter calculates the flow rate by measuring the time difference of ultrasonic waves propagating in the shot. For example, the electromagnetic flowmeter detects that the shot flow rate is 100kg / min. By monitoring the working data and shot flow rate of the screw conveyor in real time, the abnormal state of the screw conveyor (such as excessive load or abnormal speed) can be discovered in time, providing key data support for the judgment and control of the central controller.

[0184] The working data of the guide wheel is monitored in real time through the guide wheel status monitoring device, which includes a displacement sensor and a pressure sensor. The displacement sensor detects the position change of the guide wheel through laser ranging or capacitive measurement technology, and the pressure sensor detects the pressure change of the guide wheel through piezoresistive or piezoelectric technology. For example, the displacement sensor detects that the current position of the guide wheel is 50mm, and the pressure sensor detects that the current pressure is 500N. These data are transmitted to the central controller through a high-precision data acquisition module to ensure the real-time and accuracy of the data. By monitoring the position and pressure of the guide wheel in real time, the abnormal state of the guide wheel (such as position offset or insufficient pressure) can be discovered in time, providing key data support for subsequent adjustments and controls.

[0185] The central controller receives the first data set, the first working data, the shot flow rate, and the second working data, and calculates the motor speed of the drive motor according to the first data set. The calculation formula of the motor speed is: motor speed = rated speed × (work load / rated load), where the work load is calculated by the current, voltage, temperature, and vibration data in the first data set. For example, if the rated speed is 1500rpm, the work load is 79.7%, and the rated load is 100%, then the motor speed is 1500×(79.7 / 100)=1195.5rpm. Generate a first control instruction according to the motor speed, and adjust the speed of the drive motor through the frequency converter. For example, if the motor speed is 1195.5rpm and the current speed is 1500rpm, the frequency converter will reduce the speed of the drive motor to 1195.5rpm through pulse width modulation (PWM) technology. By adjusting the speed of the drive motor, it is possible to ensure that the shot blasting machine operates stably under the current workload, avoiding energy waste or reduced shot blasting efficiency due to speed mismatch.

[0186] According to the first working data and the shot flow rate, it is judged whether the shot blasting machine has the phenomenon of spiral blocking. The judgment basis of the spiral blocking phenomenon is the abnormal change of the load rate and the shot flow rate. The calculation formula of the load rate is: load rate = (actual torque / rated torque) × 100%. For example, if the actual torque is 120N·m and the rated torque is 200N·m, the load rate is (120 / 200) × 100% = 60%. When the load rate exceeds the preset threshold (such as 70%) and the shot flow rate decreases abnormally, it indicates that there is a spiral blocking phenomenon. The central controller generates the diagnosis result and the corresponding processing information, and displays them on the display. For example, if the load rate is 80% and the shot flow rate is 50kg / min (the normal value is 100kg / min), the diagnosis result is "the spiral blocking phenomenon is serious" and the processing information is "reduce the speed of the drive motor". Through real-time judgment and diagnosis, the spiral blocking phenomenon can be discovered in time to avoid equipment shutdown and production interruption.

[0187] The inverter adjusts the speed of the drive motor according to the first control instruction to achieve variable frequency speed regulation of the shot blasting machine. For example, if the first control instruction requires the speed of the drive motor to be reduced to 1195.5rpm, the inverter will gradually adjust the speed through pulse width modulation (PWM) technology. The display shows the diagnosis results, processing information and the speed of the drive motor in real time. For example, the display shows "the spiral does not turn and the jamming phenomenon is serious. It is recommended to reduce the speed to 1195.5rpm". Through real-time adjustment and display, the stable operation of the shot blasting machine can be ensured, and the user can be provided with an intuitive operation interface and status monitoring function.

[0188] When there is a problem of the screw not turning and being stuck, a second control instruction is generated according to the diagnosis result, and the speed of the drive motor is adjusted through the inverter. The second control instruction includes a speed reduction instruction and a speed maintenance instruction. For example, if the diagnosis result is "the screw not turning and being stuck is serious", a speed reduction instruction is generated, and the inverter reduces the speed of the drive motor to 1000rpm. By adjusting the speed of the drive motor, the problem of the screw not turning and being stuck can be effectively alleviated, avoiding equipment downtime and production interruption.

[0189] When the working state of the guide wheel is abnormal, a third control instruction is generated according to the second working data, and the speed of the drive motor is adjusted through the inverter. For example, if the pressure of the guide wheel decreases abnormally, a third control instruction is generated, and the inverter increases the speed of the drive motor to 1300rpm. By adjusting the speed of the drive motor, it is possible to ensure that the guide wheel operates stably at the theoretical position and theoretical pressure, avoiding scratches on the steel plate surface caused by the abnormality of the guide wheel.

[0190] This embodiment can monitor and adjust the operating status of the shot blasting machine in real time, ensuring the stable operation and high efficiency and energy saving of the equipment under different working conditions. The first sensor group, the second sensor group and the guide wheel status monitoring device collect working data and environmental parameters in real time, calculate the speed of the drive motor and generate control instructions, and adjust the speed of the drive motor through the frequency converter to realize the variable frequency speed regulation of the shot blasting machine. At the same time, it can judge the phenomenon of spiral blocking and abnormal state of the guide wheel in real time, generate diagnostic results and processing information, and display them through the display, which not only improves the operating efficiency and reliability of the shot blasting machine, but also significantly reduces the equipment failure rate and energy consumption, and realizes the efficient, energy-saving and intelligent operation of the shot blasting machine. Through precise control strategies and fast response mechanisms, complex working conditions can be handled in the shortest time to ensure the continuity and stability of production.

[0191] The embodiment of the present application also provides a central controller, including:

[0192] a memory configured to store instructions; and

[0193] The processor is configured to call instructions from the memory and implement the above-mentioned centralized control method of the shot blasting machine when executing the instructions.

[0194] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment or an embodiment in combination with software and hardware. Moreover, the present application may adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) that contain computer-usable program code.

[0195] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or block in the flowchart and / or block diagram and the combination of the processes and / or blocks in the flowchart and / or block diagram can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0196] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0197] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0198] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0199] The memory may include non-permanent memory in a computer-readable medium, random access memory (RAM) and / or non-volatile memory in the form of read-only memory (ROM) or flash RAM. The memory is an example of a computer-readable medium.

[0200] Computer readable media include permanent and non-permanent, removable and non-removable media that can be implemented by any method or technology to store information. Information can be computer readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disk read-only memory (CD-ROM), digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape disk storage or other magnetic storage devices or any other non-transmission media that can be used to store information that can be accessed by a computing device. As defined herein, computer readable media does not include temporary computer readable media (transitory media), such as modulated data signals and carrier waves.

[0201] It should also be noted that the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, commodity or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, commodity or device. In the absence of more restrictions, the elements defined by the sentence "comprises a ..." do not exclude the existence of other identical elements in the process, method, commodity or device including the elements.

[0202] The above are only embodiments of the present application and are not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included within the scope of the claims of the present application.

Claims

1. A centralized control system for a shot blasting machine, characterized in that: The shot blasting machine includes a screw conveyor, a guide wheel, a drive motor and a shot conveying pipeline, and the system includes: A first sensor group, including a current sensor, a voltage sensor, a temperature sensor and a vibration sensor, is used to monitor the working data and environmental parameters of the shot blasting machine in real time; An edge controller, used for preprocessing the working data and the environmental parameters of the shot blasting machine to obtain a first data set, and transmitting the first data set to a central controller; A second sensor group, including a torque sensor and a rotation speed sensor installed on the screw conveyor, for real-time monitoring of first working data of the screw conveyor, and transmitting the first working data to the central controller; A shot flow rate detection device, used for real-time monitoring of the shot flow rate of the shot conveying pipeline, and transmitting the shot flow rate to the central controller; A guide wheel state monitoring device, used for monitoring the second working data of the guide wheel in real time and transmitting the second working data to the central controller; a central controller, configured to receive the first data set, the first working data, the shot flow rate, and the second working data, determine the motor speed of the drive motor according to the first data set, generate a first control instruction according to the motor speed, determine whether the shot blasting machine has a spiral blocking phenomenon according to the first working data and the shot flow rate, and if the spiral blocking phenomenon exists, generate a diagnosis result and corresponding processing information; A frequency converter, used to adjust the rotation speed of the driving motor according to the first control instruction, so as to realize variable frequency speed regulation of the shot blasting machine; A display, used to display the diagnosis result and corresponding processing information, and to display the real-time rotation speed of the drive motor; Wherein, the central controller is further configured as: When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction; According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the rotation speed of the drive motor according to the third control instruction.

2. The system according to claim 1, characterized in that The second control instruction includes a speed reduction instruction and a speed maintenance instruction, and the central controller is further configured to: Calculating the load rate of the screw conveyor according to the first working data and the shot flow rate; When the load rate is greater than a first preset load threshold, it is determined that the shot blasting machine has the spiral blocking phenomenon, and the severity of the spiral blocking phenomenon is calculated according to the load rate, and corresponding processing information is determined according to the severity, wherein the severity is used to represent the diagnosis result; If the load rate is greater than a second preset load threshold, the speed reduction instruction is generated according to the load rate, so that the frequency converter reduces the speed of the drive motor according to the speed reduction instruction to reduce the load rate of the screw conveyor, wherein the second preset load threshold is greater than the first preset load threshold; If the load rate is less than or equal to the second preset load threshold and greater than the first preset load threshold, the speed keeping instruction is generated according to the load rate, so that the inverter keeps the speed of the drive motor according to the speed keeping instruction.

3. The system according to claim 2, characterized in that The determining corresponding processing information according to the severity includes: When the severity of the screw non-rotation jamming phenomenon is greater than or equal to a preset threshold, a stop command is generated as the processing information, and the stop command is executed by the inverter to control the drive motor to stop running; When the severity of the screw blocking phenomenon is less than a preset threshold, a restart instruction is generated as the processing information, and the restart instruction is executed by the inverter to control the drive motor to resume operation.

4. The system according to any one of claims 1 to 3, characterized in that The invention also includes a guide wheel adjustment device, which generates a third control instruction if the working state of the guide wheel is abnormal, so that the frequency converter adjusts the speed of the drive motor according to the third control instruction, including: If the working state of the guide wheel is abnormal, determine the current position and current pressure of the guide wheel according to the second working data, and use a preset adjustment formula to calculate the theoretical pressure of the guide wheel according to the current position and the current pressure; generating a guide wheel adjustment instruction according to the theoretical pressure, so that the guide wheel adjustment device executes the guide wheel adjustment instruction and adjusts the pressure of the guide wheel to the theoretical pressure; According to the theoretical position and the theoretical pressure, a first preset speed calculation formula is used to calculate the theoretical speed of the drive motor, and the third control instruction is generated according to the theoretical speed, so that the frequency converter adjusts the speed of the drive motor according to the third control instruction.

5. The system according to claim 4, characterized in that The shot flow detection device is a flow sensor installed on the shot conveying pipeline, the guide wheel state monitoring device includes a pressure sensor and a displacement sensor installed on the guide wheel, and the guide wheel adjustment device includes a hydraulic cylinder and a servo motor for adjusting the pressure of the guide wheel according to the guide wheel adjustment instruction.

6. The system according to claim 5, characterized in that The second working data includes displacement data and pressure data, and determining the current position and current pressure of the guide wheel according to the second working data, and using a preset adjustment formula to calculate the theoretical pressure of the guide wheel according to the current position and the current pressure, includes: Determining the current position of the guide wheel according to the displacement data; Determining the current pressure of the guide wheel according to the pressure data; Obtaining the theoretical position of the guide wheel; Using a preset adjustment formula, the theoretical pressure of the guide wheel is calculated according to the current position, the current pressure and the theoretical position; Wherein, the preset adjustment formula is: P 理论 =P 当前 +k×(X 理论 -X 当前 ); Where P 理论 is the theoretical pressure, P 当前 is the current pressure, k is the adjustment coefficient, X 理论 is the theoretical position, X 当前 is the current location.

7. The system according to claim 1, characterized in that The step of determining the motor speed of the driving motor according to the first data set and generating a first control instruction according to the motor speed includes: Calculating the workload of the shot blasting machine according to the first data set using a workload calculation formula; Using a second preset speed calculation formula to calculate the motor speed of the drive motor according to the workload; A first control instruction is generated according to the motor speed, so that the frequency converter executes the first control instruction and adjusts the speed of the drive motor to reach the motor speed.

8. The system according to claim 1, characterized in that The central controller is also configured to: In the case that the spiral does not turn and is stuck, and the working state of the guide wheel is abnormal, a comprehensive control instruction is generated according to the diagnosis result and the second working data, so that the frequency converter adjusts the speed of the drive motor according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel according to the comprehensive control instruction; The step of generating a comprehensive control instruction according to the diagnosis result and the second working data includes: According to the diagnosis result, a third preset speed calculation formula is used to determine a first target speed of the drive motor; According to the second working data, a fourth preset speed calculation formula is used to determine a second target speed of the driving motor; Using a comprehensive speed calculation formula, according to the first target speed and the second target speed, calculate the comprehensive target speed of the drive motor; Calculating the ideal pressure of the guide wheel using a pressure calculation formula according to the second working data and the diagnosis result; A comprehensive control instruction is generated according to the comprehensive target speed and the ideal pressure, so that the frequency converter adjusts the speed of the drive motor to the comprehensive target speed according to the comprehensive control instruction, and the guide wheel adjustment device adjusts the pressure of the guide wheel to the ideal pressure according to the comprehensive control instruction.

9. A centralized control method for a shot blasting machine, characterized in that: The central controller applied to any one of claims 1 to 8, wherein the shot blasting machine comprises a screw conveyor, a guide wheel, a drive motor and a shot conveying pipeline, and the method comprises: Monitor the working data and environmental parameters of the shot blasting machine in real time through a first sensor group, and pre-process the working data and environmental parameters through an edge controller to obtain a first data set; The first working data of the screw conveyor is monitored in real time by the second sensor group, and the shot flow rate is monitored in real time by the shot flow rate detection device; Monitor the second working data of the guide wheel in real time through the guide wheel state monitoring device; receiving the first data set, the first working data, the shot flow rate and the second working data, calculating the motor speed of the driving motor according to the first data set, and generating a first control instruction according to the motor speed; Determine whether the shot blasting machine has a spiral blocking phenomenon according to the first working data and the shot material flow rate, and if the spiral blocking phenomenon exists, generate a shot blasting machine diagnosis result and corresponding processing information; Adjusting the speed of the driving motor according to the first control instruction through the frequency converter to achieve variable frequency speed regulation of the shot blasting machine; Displaying the shot blasting machine diagnosis result and corresponding processing information through a display, and displaying the real-time speed of the drive motor; Wherein, the method further comprises: When the screw does not turn and is stuck, a second control instruction is generated according to the diagnosis result, so that the frequency converter adjusts the speed of the drive motor according to the second control instruction; According to the second working data, it is determined whether the working state of the guide wheel is abnormal. If the working state of the guide wheel is abnormal, a third control instruction is generated to enable the frequency converter to adjust the rotation speed of the drive motor according to the third control instruction.

10. A central controller, characterized in that: include: a memory configured to store instructions; as well as A processor is configured to call the instructions from the memory and implement the centralized control method of the shot blasting machine according to claim 9 when executing the instructions.

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