Intelligent control and pipe pressing prevention system and related equipment thereof

Abstract

The invention relates to the technical field of nodular cast iron pipe production, and discloses an intelligent control and pipe pressing prevention system and related equipment thereof, which are used for solving the problems of low sensing precision, slow response speed and the like of a basement chain in the nodular cast iron pipe production process. The system comprises an intelligent control module, a position monitoring module, a speed control module, an abnormity monitoring and alarming module, an interlocking safety module, a pipe descending machine control module and a user interface. The equipment comprises a chain driving system, a coded disc counter, a pipe descending machine, a sensor, a control panel, a communication network and the intelligent control and pipe pressing prevention system, accurate control over a chain and safe placement of pipes are achieved, an intelligent prediction algorithm and a coded disc counting control algorithm are applied to an intelligent control module, the production efficiency and the product quality are improved, and the production cost is reduced. And through real-time monitoring and intelligent adjustment, the risks of crushing and disorder of the pipes are reduced, the coordination and stability of the production process are improved, and the maintenance difficulty and cost are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of ductile iron pipe production, and particularly relates to an intelligent control and anti-pressuring pipe system and related equipment. Background Art

[0002] During the production process of ductile iron pipes, the water-cooled centrifuge is one of the key equipment, which casts molten iron into pipes through centrifugal force. In this process, the basement chain plays an important role, which is responsible for transporting the pipes out of the centrifuge. However, there are often some technical problems in the traditional basement chain control system.

[0003] Currently, in the production of ductile iron pipes using water-cooled centrifuges, the control of the basement chain usually depends on the limit switch installed in front of the unit's pipe-taking device for action control. This control method relies on physical contact and simple sensors, and its working principle is as follows: when the chain runs to the position of the limit switch, the limit switch sends a signal to control the chain to stop or change its running state. The pipe-lowering machine performs the pipe-taking action after receiving the signal.

[0004] However, the traditional limit switch has limited sensing accuracy and cannot accurately control the position of the chain, which easily leads to pipe-pressing or pipe-disorder phenomena. The response speed of the limit switch is slow and cannot meet the requirements of high-efficiency production. Especially when multiple centrifuges are working simultaneously, it is difficult to achieve precise synchronization. Due to the limitations of sensing accuracy and response speed, the operating rhythms and times of each unit are difficult to be completely synchronized, resulting in poor coordination during the production process. The existing technology lacks the ability to monitor the running state of the chain in real time and make intelligent adjustments, and cannot adjust the speed and position of the chain in a timely manner according to the actual production situation. In case of abnormal situations, the traditional system often cannot respond quickly, increasing the risk of equipment damage or production accidents.

[0005] In view of this, we propose an intelligent control and anti-pressuring pipe system and related equipment, which can effectively solve these problems and improve production efficiency and product quality by introducing highly customized program design, innovative application of advanced algorithms, and real-time monitoring and precise control. Summary of the Invention

[0006] The present invention aims to solve the technical problems of low sensing accuracy, slow response speed of the basement chain, and poor coordination among multiple centrifuges in the above-mentioned prior art.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] An intelligent control and anti-pressuring pipe system, comprising:

[0009] An intelligent control module, which is responsible for the operation logic and algorithm implementation of the entire system;

[0010] A position monitoring module that monitors the actual position of the chain through a code disk counter and feeds it back to the intelligent control module in real time;

[0011] A speed control module that adjusts the running speed of the chain according to the instructions of the intelligent control module to achieve fast startup or slow stop;

[0012] An abnormal monitoring and alarm module that monitors the running state of the system in real time and immediately issues an alarm once an abnormality is detected, such as chain position deviation or speed abnormality;

[0013] An interlock safety module that ensures the system can stop safely in case of abnormality to prevent equipment damage or accidents;

[0014] A pipe lowering machine control module that receives commands from the intelligent control module and controls the actions of the pipe lowering machine to ensure that the pipes are accurately placed on the specified V-shaped supports.

[0015] Preferably, it further includes a user interface that provides an interaction interface for the operator, displays the system status, and receives operation instructions.

[0016] Preferably, the intelligent control module communicates with the position monitoring module, speed control module, abnormal monitoring and alarm module, interlock safety module, pipe lowering machine control module, and user interface to send control instructions and receive status feedback.

[0017] Preferably, the intelligent control module includes an intelligent prediction algorithm, a code disk counting control algorithm, and a fuzzy control technology.

[0018] An intelligent control and anti-pressing pipe device, which includes a chain drive system, a code disk counter, a pipe lowering machine, sensors, and the above intelligent control and anti-pressing pipe system;

[0019] Preferably, the chain drive system is used to drive the chain to move, the code disk counter is used to accurately measure the position of the chain, the pipe lowering machine is used to place the pipes on the V-shaped supports, and the sensors are used to detect various states and abnormalities in the system.

[0020] Preferably, the intelligent control and anti-pressing pipe device further includes a control panel and a communication network. The control panel is the hardware part of the user interface for operation and monitoring, and the communication network is used to connect each module component to achieve data exchange and transmission of control instructions.

[0021] The present invention is based on the synergistic effect of real-time monitoring and intelligent algorithms. When production starts, the intelligent control module calculates the running speed and stop position of the chain according to the production plan and the operating status of the centrifuge. The position monitoring module real-time feeds back the actual position of the chain, and the speed control module adjusts the chain speed according to the instruction. When the chain runs to the specified position, the downpipe machine control module receives the command and starts the downpipe machine to place the pipe at the calculated fixed V-support position.

[0022] The pipe falling on the fixed V-support position is determined by the precise calculation of the system, which can prevent the phenomenon of pipe pressing and significantly improve production efficiency. The automated system determines which V-support the pipe should be placed on and sends this command to the centrifuge. The centrifuge uses the downpipe machine to accurately place the pipe on the specified V-support. The automated system also tracks the positions of the cast pipes and V-supports, coordinates the downpipe actions, ensures that there will be no conflict (pipe pressing) between the cast pipes during the production process, thus avoiding production accidents and improving the overall production coordination and stability.

[0023] Compared with the prior art, the technical effects and advantages of the present invention are:

[0024] (1) The intelligent control and anti-pipe-pressing system and its related equipment, through a carefully designed program, achieve the precise synchronous operation of the chain and three centrifuges. Corresponding position data are set according to different downpipe times and speeds, fully considering various changing factors in the production process, and improving the system coordination. An intelligent prediction algorithm is introduced to predict the operation trend of the centrifuge in advance, optimize the chain control strategy, ensure the stable progress of the production process, and improve the consistency and quality of products.

[0025] (2) The intelligent control and anti-pipe-pressing system and its related equipment apply the code disk counting control algorithm and logic, combined with fuzzy control technology, to ensure the accuracy and orderliness of the chain operation and the downpipe machine operation. Automatically adjust the chain operation parameters according to different production conditions and environmental factors, improve the adaptability and stability of the system. Through functions such as program interlock, ensure the safety and stability of the system and reduce the operation risk.

[0026] (3) The intelligent control and anti-pipe-pressing system and its related equipment establish data monitoring and curve screens to achieve real-time monitoring of the chain operation. It has an intelligent alarm function to detect and solve potential problems in a timely manner and avoid the occurrence of production accidents. Operators can clearly understand the running status of the chain through the intuitive curve screen and improve the management and control level of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a block diagram of the connection of each module of the present invention;

[0028] Figure 2 It is a working flow chart of the chain operation of the present invention. Detailed implementation manners

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention 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.

[0030] The following will further describe in detail Figures 1 to 2 this application.

[0031] The embodiment of this application discloses an intelligent control and anti-pressure pipe system, which includes an intelligent control module, a position monitoring module, a speed control module, an abnormal monitoring and alarm module, an interlock safety module, a pipe lowering machine control module, and a user interface;

[0032] The intelligent control module is responsible for the operation logic and algorithm implementation of the entire system; the intelligent control module communicates with the position monitoring module, the speed control module, the abnormal monitoring and alarm module, the interlock safety module, the pipe lowering machine control module, and the user interface to send control instructions and receive status feedback. The intelligent control module includes an intelligent prediction algorithm, a code disk counting control algorithm, and a fuzzy control technology.

[0033] The position monitoring module monitors the actual position of the chain through a code disk counter and feeds it back to the intelligent control module in real time;

[0034] The speed control module adjusts the running speed of the chain according to the instructions of the intelligent control module to achieve fast start or slow stop;

[0035] The abnormal monitoring and alarm module monitors the running state of the system in real time. Once an abnormality is detected, such as a deviation in the position of the chain or an abnormal speed, an alarm is immediately issued;

[0036] The interlock safety module ensures that the system can stop safely in case of an abnormality to prevent equipment damage or accidents;

[0037] The pipe lowering machine control module receives the commands of the intelligent control module and controls the actions of the pipe lowering machine to ensure that the pipe is accurately placed on the specified V-shaped support.

[0038] The user interface provides an interactive interface for the operator, displays the system state, and receives operation instructions.

[0039] The intelligent control and anti-pinch tube system of the present invention coordinates the work of each sub-module through an intelligent control module to achieve precise control of the chain. The intelligent control module uses an intelligent prediction algorithm and a code disk counting control algorithm to process the chain position information from the position monitoring module and generates a control signal to send to the speed control module to adjust the running speed of the chain. The abnormal monitoring and alarm module monitors the running state of the system in real time. Once an abnormality is detected, it will trigger an alarm and notify the interlock safety module to perform a safety stop. The tube lowering machine control module controls the actions of the tube lowering machine according to the instructions of the intelligent control module, and the user interface provides a platform for the operator to interact with the system.

[0040] Through the intelligent algorithm and the code disk counter, the system can more accurately monitor and adjust the position and speed of the chain, thereby reducing the phenomena of tube pinching and tube disorder, and improving production efficiency. The intelligent control module can synchronize the operation of multiple centrifuges to ensure the coordinated actions between the chain and the tube lowering machine, reducing problems caused by out-of-sync. The interlock safety module can quickly stop the system in case of an abnormality, preventing equipment damage and safety accidents, and ensuring production safety. The application of the intelligent prediction algorithm and fuzzy control technology enables the system to make self-adjustments based on real-time data and historical information, enhancing the adaptability and intelligence level of the system. The user interface provides intuitive system status display and operation instruction receiving functions, enabling the operator to more easily monitor and control the production process.

[0041] An intelligent control and anti-pinch tube device, which includes a chain drive system, a code disk counter, a tube lowering machine, sensors, and the above-mentioned intelligent control and anti-pinch tube system;

[0042] The chain drive system is used to drive the chain to move, the code disk counter is used to accurately measure the chain position, the tube lowering machine is used to place the tube on the V support, and the sensors are used to detect various states and abnormalities in the system.

[0043] The intelligent control and anti-pinch tube device also includes a control panel and a communication network. The control panel is the hardware part of the user interface for operation and monitoring, and the communication network is used to connect each module component to achieve data exchange and transmission of control instructions.

[0044] The intelligent control and anti-pinch tube device realizes precise control of the chain and safe placement of the tube during the production process of ductile iron pipes by integrating the chain drive system, the code disk counter, the tube lowering machine, the sensors, and the intelligent control and anti-pinch tube system.

[0045] The chain drive system drives the movement of the chain according to the instructions of the intelligent control module to achieve the transportation of pipes. The encoder counter monitors the position of the chain in real time and feeds the position data back to the intelligent control module for precise control of the running position of the chain. The pipe lowering machine executes actions according to the commands of the intelligent control module and accurately places the pipes on the V-shaped supports. The sensors are used to detect various states and abnormalities in the system, such as the running speed and position deviation of the chain, and transmit the detected information to the intelligent control module. The control panel, as the hardware part of the user interface, can establish data monitoring and curve screens to achieve real-time monitoring of the chain operation, display the system status, and receive operation instructions. The communication network connects all module components to ensure data exchange and the transmission of control instructions, enabling the entire system to work in coordination.

[0046] Compared with traditional control methods, through the encoder counter and intelligent algorithms, it is possible to achieve precise measurement and adjustment of the chain position, reducing the risk of pipe crushing and disorder. The intelligent control system can respond quickly, improve production efficiency, and reduce the time wasted due to manual adjustment of the chain position. The intelligent algorithm can predict and adjust potential problems during the chain operation, maintain the stable operation of the system, and reduce downtime. The real-time monitoring of sensors and the control panel can detect abnormalities in a timely manner, and the interlock safety module can respond quickly to ensure the safety of equipment and personnel. The control panel provides an intuitive user interface, making the operation more convenient. At the same time, the intelligent system reduces manual intervention, lowering the maintenance difficulty and cost.

[0047] As Figure 2 shown, when production starts, the equipment is started. The intelligent control module calculates the running speed and stop position of the chain according to the production plan and the operating status of the centrifuge. The position monitoring module feeds back the actual position of the chain in real time, and the speed control module adjusts the chain speed according to the instructions. When the position feedback is normal and it reaches the pipe lowering position, the pipe lowering machine control module receives the command and starts the pipe lowering machine to place the pipes at the calculated fixed V-shaped support position. The automation system determines which V-shaped support the pipes should be placed on and sends this command to the centrifuge. The centrifuge uses the pipe lowering machine to accurately place the pipes on the specified V-shaped supports. The automation system also tracks the positions of the cast pipes and V-shaped supports, coordinates the pipe lowering actions, and ensures that there will be no conflicts (pipe pressing) between the cast pipes during the production process, thus avoiding production accidents and improving the overall production coordination and stability.

[0048] If the position feedback is abnormal, an alarm will be issued to remind the operation.

[0049] During the production process, when the running chain starts the system automatic mode, the chain walks quickly under the action of the start signal. As the chain runs, the coder disk counting control algorithm starts to work. When the coder disk data reaches the specified slow position, the chain automatically adjusts to the slow running state. The chain runs slowly to the specified stop position, and at this time, the pipe lowering machine executes the pipe placing and connecting action command according to the system instruction. Due to the precise design of the positional relationship between the chain and the three centrifuges in the present invention, when the centrifuge lowers the pipe, the pipe can be accurately placed on the V-shaped support, and the pipe is stably conveyed to the sandblasting station, avoiding the phenomena of pipe disorder and pipe pressing.

[0050] First of all, through highly customized program design, the present invention carefully writes the automatic operation process program, fully considering the different pipe lowering times and speed differences of the three centrifuges. By accurately determining the pipe connecting operation of the chain at the corresponding unit position and designing appropriate position data, the pipe lowering and pipe discharging times, speeds and the chain stop positions of the three centrifuges are accurately matched, so as to achieve highly synchronous operation. This design greatly improves the coordination and stability of the production process, ensuring that all links can cooperate closely and operate efficiently. An intelligent prediction algorithm is also introduced into the program, which can predict the operation trend of each centrifuge in advance according to historical production data and real-time operation status, further optimizing the control strategy of the chain and improving the response speed and accuracy of the system.

[0051] Secondly, the present invention adopts the innovative application of advanced algorithms, and innovatively uses the coder disk counting control algorithm and logic in the program. In the automatic mode, the chain can walk quickly under the action of the start signal. When the coder disk data reaches the specified slow position, the chain will run slowly to the specified stop position. At this time, the pipe lowering machine executes the pipe connecting action command to ensure the accuracy and orderliness of the whole operation process. This algorithm also combines automatic control technology, which can automatically adjust the running speed and stop position of the chain according to different production conditions and environmental factors, improving the adaptability and stability of the system. At the same time, through functions such as program interlock, the safety and stability of the system are guaranteed, and the operation risk is reduced.

[0052] Thirdly, through real-time monitoring and precise control, the present invention establishes the coder disk counting control algorithm data, and performs automatic position determination through coder disk counting, pipe lowering instructions and program interlock. At the same time, a chain running curve screen is created to real-time monitor the chain running data. The operator can master the running state of the chain at any time through this screen, discover and solve potential problems in time, greatly improving the control level of the production process.

[0053] Through the coordinated action of each part of the above system, the present invention successfully solves the problems of pipe pressing and pipe disorder caused by insufficient induction accuracy and response speed of the chain in the basement of the water-cooled centrifuge during the production process, significantly improving the production efficiency and product quality.

[0054] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An intelligent control and pressure-proof pipe system, characterized in that: include: Intelligent control module, responsible for the operation logic and algorithm implementation of the entire system; The position monitoring module monitors the actual position of the chain through the encoder counter and provides real-time feedback to the intelligent control module; The speed control module adjusts the running speed of the chain according to the instructions of the intelligent control module to achieve fast start or slow stop; The abnormality monitoring and alarm module monitors the system operation status in real time and issues an alarm immediately once an abnormality is detected; Interlock safety module ensures that the system can stop safely under abnormal conditions to prevent equipment damage or accidents; The tube lowering machine control module receives commands from the intelligent control module, controls the action of the tube lowering machine, and ensures that the tube is accurately placed on the designated V-support.

2. The intelligent control and pressure-proof pipe system according to claim 1, characterized in that: It also includes a user interface, which provides an interactive interface for operators, displays system status, and receives operating instructions.

3. The intelligent control and pressure-proof pipe system according to claim 2, characterized in that: The intelligent control module communicates with the position monitoring module, the speed control module, the abnormal monitoring and alarm module, the interlocking safety module, the pipe lowering machine control module, and the user interface to send control instructions and receive status feedback.

4. The intelligent control and pressure-proof pipe system according to claim 1, characterized in that: The intelligent control module includes intelligent prediction algorithm, code disc counting control algorithm and fuzzy control technology.

5. An intelligent control and pressure-proof pipe device, characterized in that: The intelligent control and anti-pressure pipe equipment includes a chain drive system, a code disc counter, a pipe lowering machine, a sensor, and the intelligent control and anti-pressure pipe system as described in any one of claims 1-4.

6. The intelligent control and pressure-proof pipe device according to claim 5, characterized in that: The chain drive system is used to drive the chain movement, the code disc counter is used to accurately measure the chain position, the tube lowering machine is used to place the tube on the V-support, and the sensor is used to detect various states and abnormalities in the system.

7. The intelligent control and pressure-proof pipe equipment according to claim 5, characterized in that: It also includes a control panel and a communication network. The control panel is the hardware part of the user interface and is used for operation and monitoring. The communication network is used to connect the various module components to achieve data exchange and the transmission of control instructions.

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