Powder packaging and feeding device based on long screw and frequency conversion control system

Abstract

The invention relates to the technical field of packaging and feeding, and discloses a powder packaging and feeding device based on a long screw and a frequency conversion control system, the system comprises a data acquisition unit, a frequency conversion control unit, a fault processing unit and an abnormity judgment unit; the precision of the feeding speed and the feeding amount is guaranteed, the packaging precision requirement is met, the motor frequency is adjusted according to the difference between the actual value and the set value, feeding continuity and stability are guaranteed, the production efficiency is improved, meanwhile, the fault monitoring and analyzing capacity is achieved, the fault processing unit detects the sensor in a specific mode, abnormity is found in time, and the product quality is improved. In addition, accurate fault positioning can be achieved, the abnormality judgment unit provides a specific positioning method for different sensor abnormalities, quick troubleshooting is facilitated, and shutdown and maintenance cost is reduced. In conclusion, the system is high in reliability, it is ensured that powder packaging is smooth, and the product quality and benefits are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of packaging feeding, and particularly to a powder packaging feeding device based on a long screw and a variable frequency control system. Background Art

[0002] In the field of powder packaging, the performance of the feeding device directly affects the packaging efficiency and quality. Traditional powder packaging feeding devices face many technical problems during operation.

[0003] On the one hand, there are deficiencies in the precise control of the feeding speed and feeding quantity. Existing devices are difficult to flexibly and precisely adjust the feeding speed according to actual needs, resulting in either too fast feeding speed, causing material waste and dust flying during the packaging process, affecting the working environment and product quality; or too slow feeding speed, greatly reducing the packaging efficiency and unable to meet the rhythm of large-scale production. In terms of the control of the feeding quantity, due to the lack of an effective real-time monitoring and feedback adjustment mechanism, there are often large deviations between the actual feeding quantity and the set feeding quantity, resulting in poor weight consistency of the packaged products, easily triggering product quality disputes, and increasing production costs.

[0004] On the other hand, the monitoring of the material storage quantity is not perfect enough. Traditional level monitoring methods cannot timely and accurately feedback the level height in the storage bin. When the level is too low, it cannot timely remind the staff to supplement the material, resulting in the interruption of the feeding process and affecting the production continuity; while when the level is too high, it may cause problems such as material overflow, resulting in material loss and equipment failure.

[0005] In addition, during the operation of existing feeding devices, there are also problems with the stability and reliability of sensors. Level sensors, speed sensors, and weight sensors are prone to being interfered by factors such as material characteristics (such as dust, humidity, etc.), equipment vibration, and complex electromagnetic environments during long-term use, resulting in inaccurate monitoring data or even failures. And when a sensor fails, it is difficult to quickly and accurately locate and handle the fault, further affecting the normal operation and production efficiency of the feeding device. Summary of the Invention

[0006] The purpose of the present invention is to provide a powder packaging feeding device based on a long screw and a variable frequency control system, which solves the technical problems raised in the background art.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] A powder packaging feeding device based on a long screw includes:

[0009] An operation panel for an operator to set feeding parameters; among them, the feeding parameters include a set value of the feeding speed and a set value of the feeding quantity;

[0010] The sensor module includes a level sensor, a speed sensor, and a weight sensor. The level sensor is used to monitor the real-time level height in the feeding device; the speed sensor is used to detect the actual operating speed of the feeding device; the weight sensor is used to measure the actual feeding amount within a specified unit of time;

[0011] The frequency conversion controller is used to receive data from the sensor module and then perform frequency conversion control on the motor of the feeding device according to a preset control strategy;

[0012] The drive motor is used to provide a power source for the feeding device under the control of the frequency conversion controller.

[0013] As a further solution of the present invention: Among them, the level sensor adopts a capacitive level sensor and is installed in the storage bin of the feeding device;

[0014] The speed sensor selects a photoelectric speed sensor and is installed on one side of the drive shaft of the feeding device; the actual operating speed of the feeding device is designated as the rotational speed of the drive shaft;

[0015] The weight sensor is arranged on the bearing platform below the discharge port of the feeding device; the actual feeding amount of the feeding device is designated as the discharge weight of the material.

[0016] The frequency conversion control system of the powder packaging feeding device based on a long screw realizes through the powder packaging feeding device based on a long screw. This system includes:

[0017] The data acquisition unit is used to collect the feeding parameters set through the control panel and the monitoring data obtained through the sensor module. The monitoring data includes the real-time monitoring of the material storage amount in the feeding device, the detection of the actual operating speed of the feeding device, and the measurement of the discharge weight within a specified unit of time;

[0018] The frequency conversion control unit is used to receive the feeding parameters set through the control panel and the monitoring data collected by the data acquisition unit, and then perform frequency conversion control on the drive motor of the feeding device through the frequency conversion controller.

[0019] As a further solution of the present invention: The frequency conversion control method is as follows:

[0020] The first step, feeding speed adjustment:

[0021] During the operation of the feeding device, the speed sensor monitors the rotational speed of the drive shaft in real time, that is, the actual operating speed of the feeding device, and transmits it to the frequency conversion controller;

[0022] The frequency conversion controller compares the actual operating speed with the set value of the feeding speed:

[0023] Among them, the actual operating speed and the set value of the feeding speed are respectively marked as VS and VD;

[0024] If VS < VD, then calculate the first frequency increase value F1 of the drive motor through: F1 = u1×(VD - VS);

[0025] If VS > VD, then calculate the first frequency decrease value F2 of the drive motor through: F2 = u2×(VS - VD);

[0026] In the formula, u1 is the preset frequency - speed increase adjustment ratio of the drive motor, and u2 is the preset frequency - speed decrease adjustment ratio of the drive motor;

[0027] Then, the variable frequency controller adjusts and controls the drive motor according to the first frequency decrease value or the second frequency increase value;

[0028] Step 2: Feed quantity adjustment:

[0029] The weight sensor measures the weight of the discharged material per unit time in real - time, that is, the actual feed quantity, and transmits it to the variable frequency control unit;

[0030] The variable frequency controller compares the actual feed quantity with the set value of the feed quantity:

[0031] Among them, mark the actual feed quantity and the set value of the feed quantity as LS and LD respectively;

[0032] If LS < LD, then calculate the second frequency increase value H1 of the drive motor through: H1 = g1×(LD - LS);

[0033] If LS > LD, then calculate the second frequency decrease value H2 of the drive motor through: H2 = g2×(LS - LD);

[0034] In the formula, g1 is the preset frequency - feed quantity increase adjustment ratio of the drive motor, and g2 is the preset frequency - feed quantity decrease adjustment ratio of the drive motor;

[0035] Then, the variable frequency controller adjusts and controls the drive motor according to the second frequency decrease value or the second frequency increase value;

[0036] Step 3: Supplementary feeding control:

[0037] When the variable frequency controller receives the feeding parameters set on the control panel, it extracts the current material level height detected by the material level sensor and marks it as the initial material level height H0;

[0038] At the same time, compare the initial material level height H0 with the preset low material level threshold H min : If H0 < H min , then generate a material supplement prompt.

[0039] As a further solution of the present invention: It further includes:

[0040] A fault processing unit, configured to perform sensor fault analysis on the sensor module based on the real-time monitoring results of the material level, weight, and speed continuously monitored by the sensor module;

[0041] An abnormality determination unit, configured to perform fault location on the abnormal monitoring results according to the sensor fault analysis results of the fault processing unit.

[0042] As a further solution of the present invention: The sensor fault analysis method is as follows:

[0043] StepK1. Detection of material level sensor fault:

[0044] StepK1.1. During the operation of the feeding system, the real-time material level height of the material level sensor within the specified analysis period is obtained in real time and marked as H j , j = 1, 2,..., m, where m represents the number of real-time material level heights collected within the specified analysis period;

[0045] StepK1.2. Among all Hj, select a real-time material level height and re-mark it as HB, and then compare Hj with HB:

[0046] If all Hj = HB, it is determined that the real-time material level height measured by the material level sensor remains unchanged within the specified analysis period;

[0047] StepK1.3. Then, measure the actual feeding amount within the specified analysis period through the weight sensor. If the actual feeding amount is greater than 0 and the real-time material level height measured by the material level sensor remains unchanged within the specified analysis period, it is determined that there is an abnormality in the monitoring result of the material level sensor;

[0048] StepK2. Detection of speed sensor fault:

[0049] StepK2.1. During the operation of the feeding system, the actual operating speed of the material level sensor within the specified analysis period is obtained in real time and marked as V j , j = 1, 2,..., m, where m represents the number of actual operating speeds collected within the specified analysis period;

[0050] StepK2.2. Among all V j , calculate the difference between two adjacent V j , and then calculate the standard deviation of the differences between all adjacent two V j ;

[0051] Among them, the calculation formula for the standard deviation is:

[0052] wherein, PV is the average value of the differences between every two adjacent Vs j and BV is the standard deviation of the differences between every two adjacent Vs j ;

[0053] StepK2.3. Compare the standard deviation BV of the differences between every two adjacent Vs j with a preset standard deviation threshold value BVy:

[0054] If BV > BVy, it is determined that the monitoring result of the speed sensor is abnormal;

[0055] StepK3. Weight sensor fault detection:

[0056] StepK3.1. During the operation of the feeding system, obtain the actual feeding amount of the weight sensor within a specified analysis period in real time, and mark it as L j , where j = 1, 2,..., m, and m represents the number of actual feeding amounts collected within the specified analysis period;

[0057] StepK3.2. Calculate the standard deviation of all L j ;

[0058] Among them, the calculation formula of the standard deviation is:

[0059] wherein, PL is the average value of all L j , and BL is the standard deviation of all L j ;

[0060] StepK3.3. Compare the standard deviation BL of all L j with a preset standard deviation threshold value BLy:

[0061] If BL > BLy, it is determined that the monitoring result of the weight sensor is abnormal.

[0062] As a further solution of the present invention: the fault location method is as follows:

[0063] StepM1. When the monitoring result of the level sensor is abnormal, add a specified volume of material into the storage bin of the feeding device manually, and then obtain the current real-time level height of the level sensor;

[0064] If the current real-time level height value is equal to HB, it is determined that the level sensor is faulty;

[0065] If the current real-time level height value is not equal to HB, it is determined that there is a material blockage in the storage bin;

[0066] StepM2. When the monitoring result of the speed sensor is abnormal, then manually check whether the operating state of the drive motor and the control signal are normal:

[0067] If the motor is operating normally and the control signal is correct, but the measured value of the speed sensor is abnormal, then manually rotate the drive shaft, and obtain the actual operating speed collected by the speed sensor before and after the manual rotation of the drive shaft, and then compare the actual operating speeds before and after the rotation of the drive shaft:

[0068] When the actual operating speeds before and after the rotation of the drive shaft are the same, it is determined that the speed sensor is faulty;

[0069] When the actual operating speeds before and after the rotation of the drive shaft are different, it is determined that there is a fault in the drive motor or the corresponding part of the drive shaft;

[0070] StepM3. When the monitoring result of the weight sensor is abnormal, first check the operating state of the feeding device. If the feeding device is operating normally but the weight sensor data is abnormal, then add a specified weight of material to the storage bin of the feeding device, and then obtain the actual feeding amount monitored by the weight sensor before and after adding the specified weight of material;

[0071] When the actual feeding amounts before and after adding the specified weight of material are the same, it is determined that the weight sensor is faulty;

[0072] When the actual feeding amounts before and after adding the specified weight of material are different, it is determined that there is a blockage or material breakage at the discharge port of the feeding device.

[0073] Advantages of the present invention:

[0074] In the present invention, parameters such as the feeding speed set value and the feeding amount set value can be set through the control panel. At the same time, the sensor module is used to monitor in real time data such as the real-time material level height, actual operating speed, and actual feeding amount in the feeding device, and transmit them to the frequency conversion controller. The frequency conversion controller performs frequency conversion control on the drive motor according to the preset control strategy, realizing precise adjustment of the feeding speed and feeding amount, improving the accuracy and stability of feeding, and meeting the requirements for feeding accuracy in powder packaging.

[0075] The present invention adopts a step-by-step frequency conversion control method, including feeding speed adjustment, feeding amount adjustment, and replenishment control. In the feeding speed adjustment, the drive motor frequency is adjusted in real time according to the comparison between the actual operating speed and the set value; the feeding amount adjustment adjusts the frequency according to the difference between the actual feeding amount and the set value; the replenishment control generates a material replenishment prompt in a timely manner by comparing the initial material level height with the low material level threshold, ensuring the continuity and stability of the feeding process and improving production efficiency.

[0076] In the present invention, a fault handling unit is provided to perform fault analysis on the sensor module based on the real-time monitoring results of the material level, weight, and speed continuously monitored by the sensor module. By adopting specific fault detection methods, such as the material level sensor determines faults by comparing the real-time material level height within a specified analysis period and combining the actual feeding amount; the speed sensor determines faults by calculating the standard deviation of the difference between adjacent actual operating speeds and comparing it with a threshold; the weight sensor determines faults by calculating the standard deviation of the actual feeding amount and comparing it with a threshold, it is possible to promptly detect abnormalities in the sensor monitoring results and ensure the normal operation of the system.

[0077] In the present invention, an abnormality determination unit performs fault location based on the analysis results of the fault handling unit. For the abnormal conditions of different sensors, specific fault location methods are provided. For example, the material level sensor determines whether it is a sensor fault or a storage bin blockage by manually adding materials; the speed sensor determines the fault location by checking the motor operating status, control signal, and manually rotating the drive shaft; the weight sensor determines whether it is a sensor fault or an issue with the discharge port by checking the device operating status, adding materials, and comparing the actual feeding amount. This accurate fault location helps to quickly eliminate faults, reduce equipment downtime, and lower maintenance costs.

[0078] In the present invention, through the above functions such as precise control, flexible adjustment, fault monitoring and analysis, and accurate fault location, the overall reliability and stability of the powder packaging feeding device based on a long screw and its variable frequency control system are improved, ensuring the smooth progress of the powder packaging process, and improving product quality and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] The present invention will be further described below with reference to the accompanying drawings.

[0080] Figure 1 FIG. is a system block diagram of the variable frequency control system of the powder packaging feeding device based on a long screw according to the present invention.

[0081] Figure 2 FIG. is a schematic flow diagram of the variable frequency control unit in the variable frequency control system of the powder packaging feeding device based on a long screw according to the present invention.

[0082] Figure 3 FIG. is a schematic flow diagram of the fault handling unit in the variable frequency control system of the powder packaging feeding device based on a long screw according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0083] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0084] Example 1

[0085] Please refer to Figure 1 、 Figure 2 and Figure 3 as shown. The present invention is a powder packaging feeding device based on a long screw, including:

[0086] An operation panel for an operator to set feeding parameters; among them, the feeding parameters include a set value of feeding speed and a set value of feeding amount;

[0087] A sensor module, including a level sensor, a speed sensor and a weight sensor;

[0088] The level sensor is used to monitor the real-time level height in the feeding device in real time; the level sensor adopts a capacitive level sensor and is installed in the storage bin of the feeding device. Its working principle is based on that the capacitance value changes with the change of the material filling height;

[0089] When the material height is h, the capacitance value C of the sensor = C0 + k×h;

[0090] In the formula, C0 is the initial capacitance value without material, and k1 is a preset proportional coefficient corresponding to the sensor characteristics;

[0091] The speed sensor is used to detect the actual running speed of the feeding device; the speed sensor selects a photoelectric speed sensor and is installed on one side of the driving shaft of the feeding device. Among them, a toothed code disk is fixedly connected to the driving shaft. When the driving shaft rotates, the code disk rotates accordingly. The photoelectric speed sensor measures the rotation speed by detecting the light pulse signal generated when the holes or teeth on the code disk pass by;

[0092] In this embodiment, assuming that the number of pulses detected within the unit time t is n and the number of teeth of the code disk is N, then the rotation speed v of the driving shaft = n / N; among them, the rotation speed of the driving shaft is the actual running speed of the feeding device;

[0093] The weight sensor is used to measure the actual feeding amount within a specified unit time; the weight sensor is arranged on the bearing platform below the discharge port of the feeding device; the weight sensor is based on the principle of pressure induction. When there is material falling on the bearing platform, its pressure signal is converted into a weight signal, and the discharge weight, that is, the actual feeding amount of the feeding device, is obtained;

[0094] A frequency conversion controller, which is used to receive data from the sensor module and then perform frequency conversion control on the motor of the feeding device according to a preset control strategy;

[0095] A driving motor, which is used to provide a power source for the feeding device under the control of the frequency conversion controller;

[0096] In the first embodiment, the operation panel is provided to facilitate the operator to flexibly set the feeding parameters, including the set value of the feeding speed and the set value of the feeding amount, to meet different packaging requirements. The level sensor in the sensor module is a capacitive one, which can monitor the real-time level height in the feeding device in real time based on the principle that the capacitance value changes with the filling height of the material, providing data support for level management; the photoelectric speed sensor measures the actual running speed of the feeding device by detecting the optical pulse signal generated by the rotation of the toothed code disk, and the measurement method is accurate and reliable; the weight sensor measures the actual feeding amount within a specified unit time based on the principle of pressure induction, providing a basis for controlling the feeding amount. The frequency conversion controller performs frequency conversion control on the motor according to the data of the sensor module, so that the driving motor can stably provide an adapted power source for the feeding device. The whole device constructs a basic and effective powder packaging feeding system, and each component works together to ensure the stability and monitorability of the feeding process.

[0097] The second embodiment

[0098] Please refer to Figure 1 、 Figure 2 and Figure 3 As shown in

[0099] The data acquisition unit is used to collect the feeding parameters set through the operation panel and the monitoring data obtained through the sensor module. The monitoring data includes the real-time monitoring of the material storage amount in the feeding device, the detection of the actual running speed of the feeding device, and the measurement of the discharging weight within a specified unit time;

[0100] The frequency conversion control unit is used to receive the feeding parameters set through the operation panel and the monitoring data collected by the data acquisition unit, and then perform frequency conversion control on the driving motor of the feeding device through the frequency conversion controller;

[0101] The frequency conversion control method is as follows:

[0102] The first step, feeding speed adjustment:

[0103] During the operation of the feeding device, the speed sensor monitors the rotation speed of the driving shaft in real time, that is, the actual running speed of the feeding device, and transmits it to the frequency conversion controller;

[0104] The frequency conversion controller compares the actual running speed with the set value of the feeding speed:

[0105] Among them, the actual running speed and the set value of the feeding speed are respectively marked as VS and VD;

[0106] If VS < VD, then: F1 = u1 × (VD - VS) is used to calculate the first frequency increase value F1 of the drive motor;

[0107] If VS > VD, then: F2 = u2 × (VS - VD) is used to calculate the first frequency decrease value F2 of the drive motor;

[0108] In the formula, u1 is the preset frequency - speed increase adjustment ratio of the drive motor, and u2 is the preset frequency - speed decrease adjustment ratio of the drive motor;

[0109] Subsequently, the frequency conversion controller adjusts and controls the drive motor according to the first frequency decrease value or the second frequency increase value;

[0110] Step 2: Feed rate adjustment:

[0111] The weight sensor measures the weight of the discharged material per unit time in real time, that is, the actual feed rate, and transmits it to the frequency conversion control unit;

[0112] The frequency conversion controller compares the actual feed rate with the set value of the feed rate:

[0113] Among them, the actual feed rate and the set value of the feed rate are respectively marked as LS and LD;

[0114] If LS < LD, then: H1 = g1 × (LD - LS) is used to calculate the second frequency increase value H1 of the drive motor;

[0115] If LS > LD, then: H2 = g2 × (LS - LD) is used to calculate the second frequency decrease value H2 of the drive motor;

[0116] In the formula, g1 is the preset frequency - feed rate increase adjustment ratio of the drive motor, and g2 is the preset frequency - feed rate decrease adjustment ratio of the drive motor;

[0117] Subsequently, the frequency conversion controller adjusts and controls the drive motor according to the second frequency decrease value or the second frequency increase value;

[0118] In this embodiment:

[0119] The frequency - speed increase adjustment ratio u1: is a preset proportional coefficient, which is used to calculate the first frequency increase value F1 of the drive motor when the actual running speed VS of the feeding device is less than the set feeding speed VD;

[0120] The frequency - speed decrease adjustment ratio u2: is a preset proportional coefficient, which is used to calculate the first frequency decrease value F2 of the drive motor when the actual running speed VS of the feeding device is greater than the set feeding speed VD;

[0121] Frequency - material quantity increase adjustment ratio g1: It is a preset proportional coefficient used to calculate the second frequency increase value H1 of the drive motor when the actual feeding quantity LS is less than the set feeding quantity LD;

[0122] Frequency - material quantity decrease adjustment ratio g2: It is a preset proportional coefficient used to calculate the second frequency decrease value H2 of the drive motor when the actual feeding quantity LS is greater than the set feeding quantity LD;

[0123] In this embodiment, the method for obtaining the relevant adjustment ratio is as follows

[0124] Select a batch of representative long - screw powder packaging feeding devices with similar specifications and operating environments as the experimental objects, and prepare high - precision speed measurement equipment, weight measurement equipment, and a frequency converter controller that can accurately adjust the frequency of the drive motor;

[0125] First, set different set feeding speeds respectively, let the drive motor run at different initial frequencies, and record the actual running speed; then gradually increase or decrease the frequency of the drive motor, and record the corresponding actual running speed changes after each frequency change; obtain multiple groups of data of speed change amounts and frequency change amounts through multiple experiments;

[0126] At the same time, set different set feeding quantity values, let the drive motor run at different initial frequencies, measure the discharged material weight within a specified unit time; then gradually increase or decrease the frequency of the drive motor, and measure the change in the actual feeding quantity within the same specified unit time after each frequency change, and obtain multiple groups of data of material quantity change amounts and frequency change amounts;

[0127] After that, perform linear regression analysis on the experimental data related to speed and material quantity respectively. Take the change amount of speed or material quantity as the independent variable and the change amount of frequency as the dependent variable to obtain the regression equation, and the coefficient in the equation is the corresponding adjustment ratio.

[0128] The third step, replenishment control:

[0129] When the frequency converter controller receives the feeding parameters set on the control panel, it extracts the current material level height detected by the material level sensor and marks it as the initial material level height H0;

[0130] At the same time, compare the initial material level height H0 with the preset low material level threshold H min If H0 < H min , a material replenishment prompt is generated;

[0131] Based on Embodiment 1, Embodiment 2 constructs a variable-frequency control system for the powder packaging feeding device based on a long screw. The data acquisition unit can comprehensively collect the feeding parameters set on the control panel and the monitoring data of the sensor module, covering the material storage quantity, actual running speed, and discharging weight. The variable-frequency control unit adjusts the feeding speed and feeding quantity precisely through a specific variable-frequency control method according to these data. In the adjustment of the feeding speed, the actual running speed is compared with the set value of the feeding speed, and the driving motor frequency is calculated and adjusted according to different situations; the adjustment of the feeding quantity is the same, and the frequency is adjusted by comparing the actual feeding quantity with the set value of the feeding quantity. The replenishment control can generate a material replenishment prompt in a timely manner by comparing the initial material level height with the preset low material level threshold to ensure sufficient materials in the storage bin. The variable-frequency control system of this embodiment improves the precise control ability of the feeding device for the feeding speed and feeding quantity and the timeliness of material replenishment.

[0132] Embodiment 3

[0133] Please refer to Figure 1 、 Figure 2 and Figure 3 As shown in, as Embodiment 3 of the present invention, in the specific implementation of this application, compared with Embodiment 1 and Embodiment 2, the technical solution of this embodiment is to combine and implement the solutions of the above Embodiment 1 and Embodiment 2. The difference between the technical solution of this embodiment and Embodiment 1 and Embodiment 2 is only that in this embodiment, the variable-frequency control system of the powder packaging feeding device based on a long screw further includes:

[0134] A fault handling unit for performing sensor fault analysis on the sensor module through the real-time monitoring results of the material level, weight, and speed continuously by the sensor module;

[0135] The sensor fault analysis method is as follows:

[0136] StepK1. Detection of material level sensor fault:

[0137] StepK1.1. During the operation of the feeding system, the real-time material level height of the material level sensor within the specified analysis period is obtained in real time and marked as H j , j = 1, 2,..., m, where m represents the number of real-time material level heights collected within the specified analysis period;

[0138] StepK1.2. Among all Hj, a real-time material level height is selected and re-marked as HB, and then Hj is compared with HB:

[0139] If all Hj = HB, it is determined that the real-time material level height measured by the material level sensor remains unchanged within the specified analysis period;

[0140] StepK1.3. Subsequently, measure the actual feeding amount within the specified analysis period through a weight sensor. If the actual feeding amount is greater than 0 and the real-time material level height measured by the material level sensor remains unchanged within the specified analysis period, it is determined that there is an abnormality in the monitoring result of the material level sensor;

[0141] StepK2. Speed sensor fault detection:

[0142] StepK2.1. During the operation of the feeding system, obtain the actual operating speed of the material level sensor within the specified analysis period in real time and mark it as V j , j = 1, 2,..., m, where m represents the number of actual operating speeds collected within the specified analysis period;

[0143] StepK2.2. Among all V j , calculate the difference between two adjacent V j , and then calculate the standard deviation of the differences between all adjacent two V j ;

[0144] Among them, the calculation formula for the standard deviation is:

[0145] In the formula, PV is the average value of the differences between all adjacent two V j , and BV is the standard deviation of the differences between all adjacent two V j ;

[0146] StepK2.3. Compare the standard deviation BV of the differences between all adjacent two V j with the preset standard deviation threshold value BVy:

[0147] If BV > BVy, it is determined that there is an abnormality in the monitoring result of the speed sensor;

[0148] StepK3. Weight sensor fault detection:

[0149] StepK3.1. During the operation of the feeding system, obtain the actual feeding amount of the weight sensor within the specified analysis period in real time and mark it as L j , j = 1, 2,..., m, where m represents the number of actual feeding amounts collected within the specified analysis period;

[0150] StepK3.2. Calculate the standard deviation of all L j ;

[0151] Among them, the calculation formula for the standard deviation is:

[0152] In the formula, PL is the average value of all L j , and BL is all L jStandard deviation;

[0153] StepK3.3. Add all L j Compare the standard deviation BL of

[0154] If BL > BLy, it is determined that the monitoring result of the weight sensor is abnormal;

[0155] Anomaly determination unit, used to perform fault location on the abnormal monitoring result according to the sensor fault analysis result of the fault processing unit;

[0156] The fault location method is as follows:

[0157] StepM1. When the monitoring result of the level sensor is abnormal, add a specified volume of material into the storage bin of the feeding device manually, and then obtain the current real-time level height of the level sensor;

[0158] If the current real-time level height value is equal to HB, it is determined that the level sensor is faulty;

[0159] If the current real-time level height value is not equal to HB, it is determined that there is a material blockage in the storage bin;

[0160] StepM2. When the monitoring result of the speed sensor is abnormal, manually check whether the operating state and control signal of the drive motor are normal:

[0161] If the motor is running normally and the control signal is correct, but the measured value of the speed sensor is abnormal, manually rotate the drive shaft, and obtain the actual operating speed collected by the speed sensor before and after the manual rotation of the drive shaft, and then compare the actual operating speeds before and after the rotation of the drive shaft:

[0162] When the actual operating speeds before and after the rotation of the drive shaft are the same, it is determined that the speed sensor is faulty;

[0163] When the actual operating speeds before and after the rotation of the drive shaft are different, it is determined that there is a fault in the drive motor or the corresponding part of the drive shaft;

[0164] StepM3. When the monitoring result of the weight sensor is abnormal, first check the operating state of the feeding device. If the feeding device is running normally but the weight sensor data is abnormal, then add a specified weight of material into the storage bin of the feeding device, and then obtain the actual feeding amount monitored by the weight sensor before and after adding the specified weight of material;

[0165] When the actual feeding amounts before and after adding the specified weight of material are the same, it is determined that the weight sensor is faulty;

[0166] If the actual feeding rate before and after adding the specified weight of materials is inconsistent, it is determined that there is a blockage or material cutoff at the discharge port of the feeding device.

[0167] Based on Embodiment 1 and Embodiment 2, Embodiment 3 further improves the variable frequency control system and adds a fault handling unit and an abnormality determination unit. The fault handling unit can detect faults in the level sensor, speed sensor, and weight sensor through specific analysis methods. For example, the fault detection of the level sensor is determined by analyzing the real-time level height and combining with the actual feeding rate; the fault detection of the speed sensor is determined by calculating the standard deviation of the difference in adjacent running speeds and comparing it with a preset threshold; the fault detection of the weight sensor is determined by calculating the standard deviation of the actual feeding rate and comparing it with a preset threshold. The abnormality determination unit locates faults based on the results of the fault handling unit. For example, when the level sensor is abnormal, adding materials is used to determine whether it is a sensor fault or a blockage in the storage bin; when the speed sensor is abnormal, the operating state of the motor, control signals, and manually rotating the drive shaft are checked to determine the fault location; when the weight sensor is abnormal, the operating state of the feeding device and adding materials are checked to determine the fault location. These two units greatly improve the system's fault diagnosis and location capabilities, ensuring the stable and reliable operation of the feeding device.

[0168] Embodiment 4

[0169] Please refer to Figure 1 、 Figure 2 and Figure 3 As shown in [relevant figures], as Embodiment 4 of the present invention, in the specific implementation of this application, compared with Embodiment 1, Embodiment 2, and Embodiment 3, the technical solution of this embodiment is to combine and implement the solutions of the above-mentioned Embodiment 1, Embodiment 2, Embodiment 3, and Embodiment 4.

[0170] Embodiment 4 combines and implements the solutions of multiple previous embodiments, integrating the construction of the feeding device based on Embodiment 1, the precise variable frequency control of Embodiment 2, and the comprehensive fault diagnosis and location function of Embodiment 3. This enables the powder packaging feeding device based on the long screw to not only achieve basic feeding operations, but also achieve precision in the control of the feeding speed and feeding amount. At the same time, it has high-efficiency fault detection and location capabilities, comprehensively improving the performance and stability of the feeding device, providing a more reliable, precise, and easy-to-maintain solution for the powder packaging process, and better meeting the complex requirements for powder packaging feeding in industrial production.

[0171] The above formulas are all dimensionless and take their numerical values for calculation. The formulas are obtained by collecting a large amount of data for software simulation to obtain a formula closest to the real situation. The preset parameters and threshold selection in the formulas are set by those skilled in the art according to the actual situation.

[0172] As described above, it is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application who can easily think of changes or substitutions should be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims described above.

Claims

1. A variable frequency control system for a powder packaging and feeding device based on a long screw, characterized in that: include: The data acquisition unit is used to collect the feeding parameters set through the control panel and the monitoring data obtained through the sensor module. The monitoring data includes real-time monitoring of the material storage volume in the feeding device, detection of the actual operating speed of the feeding device, and measurement of the discharge weight within a specified unit time; The frequency conversion control unit is used to receive the feeding parameters set by the control panel and the monitoring data collected by the data acquisition unit, and then perform frequency conversion control on the driving motor of the feeding device through the frequency conversion controller; A fault processing unit, used to perform sensor fault analysis on the sensor module based on the real-time monitoring result of the sensor module, and determine whether the monitoring result of the sensor module is abnormal; The abnormality determination unit is used to locate the fault of the abnormal monitoring result according to the sensor fault analysis result of the fault processing unit.

2. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 1 is characterized in that: The frequency conversion control method is as follows: Step 1: During the operation of the feeding device, the speed sensor monitors the speed of the drive shaft in real time, that is, the actual operating speed of the feeding device, and transmits it to the frequency conversion controller; The frequency converter compares the actual operating speed with the feed speed setting value, and determines the relevant control instructions for the drive motor based on the comparison results: Then the frequency conversion controller adjusts and controls the drive motor according to the relevant control instructions; The second step is that the weight sensor measures the weight of the material discharged per unit time in real time, that is, the actual feeding amount, and transmits it to the frequency conversion control unit; The frequency conversion controller compares the actual feeding amount with the feeding amount setting value, and determines the relevant control instructions for the drive motor based on the comparison result: Then the frequency conversion controller adjusts and controls the drive motor according to the relevant control instructions; Step 3: After the frequency converter receives the feeding parameters set by the control panel, the material level sensor detects the current material level height and marks it as the initial material level height H0; At the same time, the initial material level height H0 and the preset low material level threshold H min Compare: If H0<H min , a material replenishment prompt will be generated.

3. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 2 is characterized in that: In the first step: If VS<VD, the first frequency increase value F1 of the driving motor is calculated by: F1=u1×(VD-VS); If VS>VD, the first frequency reduction value F2 of the driving motor is calculated by: F2=u2×(VS-VD); Wherein, VS and VD are the actual operating speed and the feed speed setting values ​​respectively, u1 is the preset frequency-speed increase adjustment ratio of the drive motor, and u2 is the preset frequency-speed decrease adjustment ratio of the drive motor.

4. The variable frequency control system of the powder packaging and feeding device based on the long screw according to claim 3 is characterized in that: In the second step: If LS<LD, the second frequency increase value H1 of the driving motor is calculated by: H1=g1×(LD-LS); If LS>LD, the second frequency reduction value H2 of the driving motor is calculated by: H2=g2×(LS-LD); Wherein, LS and LD are the actual feeding amount and the feeding amount setting value, g1 is the preset frequency-feeding amount increase adjustment ratio of the driving motor, and g2 is the preset frequency-feeding amount decrease adjustment ratio of the driving motor.

5. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 1 is characterized in that: The fault analysis and fault location of the material level sensor are as follows: Step K1.

1. During the operation of the feeding system, obtain the real-time material level height of the material level sensor within the specified analysis period and mark it as H j , j = 1, 2, ... m, m represents the number of real-time material level heights collected within a specified analysis period; Step K1.2, select a real-time material level height among all Hj, re-mark it as HB, and then compare Hj with HB: If all Hj=HB, it is determined that the real-time material level height measured by the material level sensor within the specified analysis period remains unchanged; Step K1.3, then measure the actual feeding amount within the specified analysis period through the weight sensor. If the actual feeding amount is greater than 0, and the real-time material level height measured by the material level sensor within the specified analysis period remains unchanged, it is determined that the monitoring result of the material level sensor is abnormal; When the monitoring result of the material level sensor is abnormal, a specified volume of material is added to the storage bin of the feeding device manually, and the current real-time material level height of the material level sensor is obtained; If the current real-time material level height value is equal to HB, it is judged that the material level sensor is faulty; If the current real-time material level height value is not equal to HB, it is determined that there is material blockage in the storage bin.

6. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 5 is characterized in that: Speed ​​sensor fault analysis and fault location methods are as follows: Step K2.

1. During the operation of the feeding system, obtain the actual operating speed of the material level sensor in the specified analysis cycle in real time and mark it as V j , j = 1, 2, ... m, m represents the number of actual running speeds collected within a specified analysis period; Step K2.2, in all V j , calculate the two adjacent V j The difference between the two adjacent V j The standard deviation of the difference between the two values ​​is labeled BV; Step K2.3, set all two adjacent V j The standard deviation BV of the difference is compared with the preset standard deviation threshold BVy: If BV>BVy, it is determined that the monitoring result of the speed sensor is abnormal; When the speed sensor's monitoring result is abnormal, manually check whether the drive motor's operating status and control signal are normal: If the motor runs normally and the control signal is correct, but the speed sensor measurement value is abnormal, manually rotate the drive shaft and obtain the actual running speed of the drive shaft before and after the manual rotation, and then compare the actual running speed before and after the drive shaft is rotated: When the actual running speed of the drive shaft before and after rotation is consistent, it is judged that the speed sensor is faulty; When the actual running speed of the drive shaft before and after rotation is inconsistent, it is determined that there is a fault in the corresponding part of the drive motor or the drive shaft.

7. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 6 is characterized in that: The weight sensor fault analysis and fault location methods are as follows: Step K3, sensor fault detection: Step K3.

1. During the operation of the feeding system, the actual feeding amount of the weight sensor within the specified analysis period is obtained in real time and marked as L j , j = 1, 2, ... m, m represents the number of actual feed amounts collected within a specified analysis period; StepK3.2, calculate all L j The standard deviation of , and mark it as BL; Step K3.3, all L j The standard deviation BL is compared with the preset standard deviation threshold BLy: If BL>BLy, it is determined that the monitoring result of the weight sensor is abnormal; When the monitoring result of the weight sensor is abnormal, the operation status of the feeding device is checked first. If the feeding device is operating normally but the weight sensor data is abnormal, a specified weight of material is added to the storage bin of the feeding device. Then, before and after the specified weight of material is added, the actual feeding amount monitored by the weight sensor is obtained. When the actual feeding amount before and after adding the specified weight of material is consistent, it is judged that the weight sensor is faulty; When the actual feeding amount before and after adding the specified weight of material is inconsistent, it is judged that there is a blockage or material flow interruption at the discharge port of the feeding device.

8. The variable frequency control system of the powder packaging and feeding device based on a long screw according to claim 4 is characterized in that: in, The first frequency reduction value, the second frequency increase value, the second frequency reduction value, and the second frequency increase value are related control instructions for driving the motor.

9. A powder packaging and feeding device based on a long screw, the device being used to execute the program of the variable frequency control system of the powder packaging and feeding device based on a long screw according to any one of claims 1 to 8, characterized in that: The device includes: The control panel is used by the operator to set the feeding parameters; the feeding parameters include the feeding speed setting value and the feeding amount setting value; The sensor module includes a material level sensor, a speed sensor and a weight sensor. The material level sensor is used to monitor the material level height in the feeding device in real time; the speed sensor is used to detect the actual running speed of the feeding device; and the weight sensor is used to measure the actual feeding amount within a specified unit time. A frequency conversion controller is used to receive data from the sensor module and then perform frequency conversion control on the motor of the feeding device according to a preset control strategy; The driving motor is used to provide a power source for the feeding device under the control of the frequency conversion controller.

10. The powder packaging and feeding device based on a long screw according to claim 9, characterized in that: The material level sensor adopts a capacitive material level sensor, which is installed in the storage bin of the feeding device; The speed sensor is a photoelectric speed sensor, which is installed on one side of the driving shaft of the feeding device; the actual running speed of the feeding device refers to the speed of the driving shaft; The weight sensor is arranged on the bearing platform below the discharge port of the feeding device; the actual feeding amount of the feeding device refers to the discharge weight of the material.

Images