Dust removal control method of machine-made sand impact crusher

Abstract

The invention provides a dust removal control method for a machine-made sand impact crusher. The dust removal control method comprises the following steps that working condition parameters and dust removal parameters of the crusher are collected in real time; dynamically calculating a target negative pressure value and a dust removal triggering threshold value based on the working condition parameters and the dust removal parameters of the crusher; according to the target negative pressure value, the operation power of an exhaust fan is adjusted, so that the negative pressure strength of the dust removal system is matched with the current crushing working condition corresponding to the working condition parameters of the crusher; when the resistance of the filter bag reaches a dust removal triggering threshold value, starting a dust removal assembly, and adaptively adjusting the dust removal frequency and vibration amplitude of the dust removal assembly according to the dust concentration change rate; the weight of the dust collecting box is monitored in real time, and when the weight of the dust collecting box reaches the weight set upper limit, the automatic dust discharging device is started to convey dust to an external recycling system. According to the method, the target negative pressure value and the ash removal triggering threshold value can be dynamically calculated, so that the dust removal strength is accurately matched with the current crushing load, and the working condition self-adaptive dynamic control is realized, so that the dust removal efficiency and the energy consumption in the production and preparation process are balanced.

Description

Technical Field

[0001] This application relates to the technical field of impact crushers, and particularly to a dust removal control method for a manufactured sand impact crusher. Background Art

[0002] With the continuous exploitation of natural sand resources, the natural sand resources in some areas are approaching exhaustion, and artificial manufactured sand has begun to be widely used. Manufactured sand is sand processed by sand making machines and other auxiliary equipment, which has the characteristics of stable material source, high production efficiency, and low processing cost. Moreover, during production, manufactured sand with different particle sizes and shapes can be prepared according to process requirements to meet the needs of various construction projects. During the production and preparation process of manufactured sand, first, a coarse crusher is used to initially crush the stone material, and then a fine crusher is used for further crushing. The fine crushing process usually uses an impact crusher. The impact crusher mainly uses a high-speed rotating rotor to impact the stone material, and then the stone material is repeatedly impacted and crushed between the impact frame and the rotor until it is processed into the required particle size. When the impact crusher is working, a large amount of dust will be generated when the stone material repeatedly impacts and crushes with the high-speed rotating rotor and the impact lining plate. These dusts will float out from the discharge port and the feed port of the equipment, causing serious environmental pollution and harm to the physical health of on-site operators. To solve this problem, an impact crusher for manufactured sand preparation with a dust removal function, with the application number 202411594568.0 and the name "An impact crusher for manufactured sand preparation with dust removal function", is designed.

[0003] However, the traditional control methods for matching such devices mostly use fixed negative pressure set values and dust cleaning cycles (such as timed dust cleaning), and cannot respond in real time to dynamic working conditions such as fluctuations in the feeding rate and changes in the properties of the stone material (such as a sudden increase in the mud content), resulting in an imbalance between dust removal efficiency and energy consumption. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, this application aims to provide a dust removal control method for a manufactured sand impact crusher to balance the dust removal efficiency and energy consumption during the production and preparation process of manufactured sand; including the following steps: Real-time collect the crusher working condition parameters and the dust removal parameters; the crusher working condition parameters include the feeding rate, motor current, and discharge particle size, and the dust removal parameters include the filter bag resistance, dust concentration, and dust collector weight; Based on the crusher working condition parameters and the dust removal parameters, dynamically calculate the target negative pressure value and the dust cleaning trigger threshold; Adjust the operating power of the exhaust fan according to the target negative pressure value to make the negative pressure intensity of the dust removal system match the current crushing working condition corresponding to the crusher working condition parameters; When the resistance of the filter bag reaches the dust cleaning trigger threshold, start the dust cleaning component and adaptively adjust the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration; Monitor the weight of the dust collection box in real time. When the weight of the dust collection box reaches the upper limit of the weight setting, start the automatic dust discharging device to transport the dust to the external recovery system.

[0005] According to the technical solution provided by the embodiment of the present application, before dynamically calculating the target negative pressure value and the dust cleaning trigger threshold based on the crusher working condition parameters and the dust removal parameters, the following steps are included: Obtain the stone material attribute parameters and environmental parameters in real time. The stone material attribute parameters include the hardness of the stone material, the humidity of the stone material, and the mud content of the stone material. The environmental parameters include the environmental temperature and the environmental humidity; The dynamic calculation of the target negative pressure value and the dust cleaning trigger threshold based on the crusher working condition parameters and the dust removal parameters includes the following steps: If it is in a non-special scenario, dynamically calculate the target negative pressure value and the dust cleaning trigger threshold based on the crusher working condition parameters and the dust removal parameters; the non-special scenario is a conventional production state where the stone material attribute parameters and the environmental parameters are both within the preset normal range and the equipment is not overloaded.

[0006] According to the technical solution provided by the embodiment of the present application, after obtaining the stone material attribute parameters and environmental parameters in real time, the following steps are further included: If it is in a special scenario, calculate the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters; the special scenario is a production state other than the conventional production state; Based on the comprehensive working condition coefficient, obtain the correction amount of the target negative pressure value and the correction coefficient of the dust cleaning trigger threshold. The correction amount is greater than 0, and the correction coefficient is less than 1; Correct the target negative pressure value with the correction amount to obtain the updated negative pressure value; correct the dust cleaning trigger threshold with the correction coefficient to obtain the updated dust cleaning trigger threshold.

[0007] According to the technical solution provided by the embodiment of the present application, after starting the dust cleaning component and adaptively adjusting the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration, the following steps are included: Record the filter bag resistance recovery time and the vibration attenuation curve after each dust cleaning to predict the remaining life of the filter bag; If the remaining life of the filter bag is less than the first preset life, generate a filter bag replacement warning signal.

[0008] According to the technical solution provided by the embodiments of the present application, the special scenarios include dust adhesion sensitive scenarios and non-dust adhesion sensitive scenarios; if in a special scenario, based on the stone property parameters and the environmental parameters, calculate the comprehensive working condition coefficient, including the following steps: If in a special scenario and in the non-dust adhesion sensitive scenario, calculate the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters; After obtaining the stone property parameters and the environmental parameters in real time, the following steps are further included: If in a special scenario and in the dust adhesion sensitive scenario, monitor the dust adhesion force on the surface of the filter bag in real time to obtain the adhesion force change rate; Generate a bonding risk index according to the adhesion force change rate; If the bonding risk index is less than the first preset risk index, when the filter bag resistance reaches the updated ash cleaning trigger threshold, start the ash cleaning component and adaptively adjust the ash cleaning frequency and vibration amplitude of the ash cleaning component according to the dust concentration change rate.

[0009] According to the technical solution provided by the embodiments of the present application, after generating the bonding risk index according to the adhesion force change rate, the following steps are included: If the bonding risk index is greater than or equal to the first preset risk index, instantaneously spray an anti-sticking agent in the form of an aerosol on the surface of the filter bag. The anti-sticking agent is a nano-level hydrophobic particle suspension, and the spraying duration is positively correlated with the bonding risk index; Start the ash cleaning component and adopt a high-frequency pulse ash cleaning mode. Among them, the pulse frequency of the high-frequency pulse ash cleaning mode is related to the bonding risk index, and the negative pressure value rises in a gradient manner; When the bonding risk index drops to less than the first preset risk index, resume the conventional ash cleaning mode and stop spraying the anti-sticking agent. The conventional ash cleaning mode is to adaptively adjust the ash cleaning frequency and vibration amplitude of the ash cleaning component according to the dust concentration change rate.

[0010] According to the technical solution provided by the embodiments of the present application, if including at least one of the following, it is determined as a dust adhesion sensitive scenario: The environmental humidity is greater than the first preset humidity; The mud content of the stone is greater than the first preset mud content; The environmental temperature is less than the first preset temperature and the environmental humidity is greater than the second preset humidity, and the second preset humidity is less than the first preset humidity.

[0011] According to the technical solution provided by the embodiments of the present application, before calculating the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters, the following steps are included: The vibration acceleration signal is collected in real time by a vibration sensor installed on the bearing seat of the crusher; The vibration energy value in the high-frequency band of 1 - 3 kHz is extracted as the wear characteristic quantity; Based on the stone property parameters and the environmental parameters, calculating the comprehensive working condition coefficient includes the following steps: If the wear characteristic quantity is less than the first preset threshold, based on the stone property parameters and the environmental parameters, calculate the initial working condition coefficient, and use the initial working condition coefficient as the comprehensive working condition coefficient.

[0012] According to the technical solution provided by the embodiment of the present application, based on the stone property parameters and the environmental parameters, calculating the comprehensive working condition coefficient includes the following steps: After extracting the vibration energy value in the high-frequency band of 1 - 3 kHz as the wear characteristic quantity, the following steps are further included: If the wear characteristic quantity is greater than or equal to the first preset threshold, based on the stone property parameters and the environmental parameters, calculate the initial working condition coefficient; Raise the initial working condition coefficient to the target level to obtain the comprehensive working condition coefficient.

[0013] According to the technical solution provided by the embodiment of the present application, starting the dust cleaning component and adopting the high-frequency pulse dust cleaning mode includes the following steps: Calculate the stress distribution field of the filter bag in real time, and feedback the local stress peak value through a micro strain gauge array installed on the filter bag frame; Dynamically constrain the acceleration change rate of the pulse dust cleaning to ensure that during the process of dust cleaning using the high-frequency pulse dust cleaning mode, the local stress peak value does not exceed 80% of the fatigue limit of the filter bag material.

[0014] Compared with the prior art, the beneficial effects of the present application are as follows: The present application dynamically calculates the target negative pressure value and the dust cleaning trigger threshold by integrating core parameters of the crusher such as the feeding rate, motor current, and discharge particle size with dust removal parameters such as the filter bag resistance and dust concentration, so that the dust removal intensity accurately matches the current crushing load. For example, when it is detected that the motor current increases (reflecting an increase in the crushing load), the negative pressure value is automatically increased to enhance the dust capture ability and avoid dust escape, realizing dynamic control of working condition adaptability; at the same time, the dust concentration change rate is introduced as the adjustment basis for the dust cleaning frequency and vibration amplitude, realizing the dynamic matching of the dust cleaning intensity and the dust generation rate. For example, in the stage of rapid increase in dust concentration (such as a sudden increase in the mud content of the stone), the dust cleaning frequency is automatically increased and the vibration amplitude is increased to prevent a sharp increase in resistance caused by an overly thick dust layer on the surface of the filter bag. The dynamic negative pressure adjustment makes the power of the induced draft fan float according to the actual demand, which is more energy-efficient than the fixed power mode. Description of the Drawings

[0015] Figure 1 The flowchart of the steps of the dust removal control method for the impact crusher of manufactured sand provided by the embodiments of the present application. Detailed implementation manners

[0016] The present application will be further described in detail below in conjunction with the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the related invention, rather than limiting the invention. Additionally, it should be noted that for the convenience of description, only the parts related to the invention are shown in the drawings.

[0017] It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and embodiments.

[0018] Embodiment 1 As mentioned in the background art, in view of the problems in the prior art, this embodiment proposes an impact crusher for manufactured sand preparation with a dust removal function, as Figure 1 shown, including: A frame, inside which a crushing chamber is provided; A feed inlet and a discharge outlet, which are respectively provided at the top and bottom of the frame; A front impact frame and a rear impact frame, which are installed on the inner side wall of the crushing chamber; A crushing mechanism, which is arranged in the crushing chamber and is used for impact crushing of stones; A dust removal mechanism, which is arranged on one side of the frame and is used for filtering and cleaning the dust generated when the stones are crushed.

[0019] The crushing mechanism includes: A driving device, which is installed on one side of the frame; A rotor frame, which is rotatably connected to the inner side wall of the crushing chamber, and one end of the rotor frame is fixedly connected to the output end of the driving device; Hammer plates, and a plurality of the hammer plates are fixedly installed on the rotor frame.

[0020] The dust removal mechanism includes: A box body, which is arranged on one side of the frame, and a cavity is provided inside the box body; A wind separation plate, which is fixedly installed inside the box body, and the wind separation plate divides the cavity into a filter chamber and a clean air chamber; A negative pressure collection assembly, which is arranged on one side of the box body and is used for collecting the dust generated when the stones are crushed; Filtering component, which is arranged in the filtering chamber and used to filter the dust-containing gas collected by the negative-pressure collection component; Dust cleaning component, which is arranged on the top of the filtering component and used to shake off and clean the dust attached to the filtering component.

[0021] The negative-pressure collection component includes: Mounting frame, which is fixedly connected to the box body; Exhaust fan, which is installed on the mounting frame, and an air inlet and an air outlet are arranged on the exhaust fan; Air inlet pipe, which is installed on the air inlet, and the other end of the air inlet pipe is communicated with the clean gas chamber; Air inlet tube, a plurality of the air inlet tubes are installed on the box body, and both ends of each air inlet tube are respectively communicated with the crushing chamber and the filtering chamber.

[0022] The filtering component includes: Slip ring, a plurality of ventilation holes are formed in the air separation plate, and the slip ring is slidably connected to each ventilation hole; Skeleton, the bottom end of each slip ring is fixedly connected with the skeleton; Filter bag, the filter bag is sleeved on the outside of each skeleton, and the top end of the filter bag abuts against the bottom end of the slip ring.

[0023] The dust cleaning component includes: Motor 1, which is fixedly installed on the box body; Rotating shaft, the rotating shaft is rotatably connected to the inner side wall of the clean gas chamber, and one end of the rotating shaft is fixedly connected to the output end of the motor 1; Cam, a plurality of cams are fixedly installed on the rotating shaft; Connecting column, the top end of each slip ring is fixedly connected with a plurality of the connecting columns; Moving plate, the top ends of the plurality of connecting columns are fixedly connected with the moving plate, and the top end of the moving plate abuts against the bottom ends of the plurality of cams; Support column, the top end of the air separation plate is fixedly connected with a plurality of the support columns; Spring, the spring is sleeved on the outside of each support column, and each spring is installed between the air separation plate and the moving plate.

[0024] A clamp is installed at the bag mouth position of the top end of each filter bag to tie the filter bag tightly to the skeleton.

[0025] Embodiment 2 On the basis of Embodiment 1, this embodiment proposes a dust removal control method for a mechanism sand impact crusher, including the following steps: S1. Collect the working condition parameters and dust removal parameters of the crusher in real time; the working condition parameters of the crusher include the feeding rate, motor current, and discharge particle size, and the dust removal parameters include the filter bag resistance, dust concentration, and dust collector weight; Specifically, the specific implementation is described based on the device mentioned in Embodiment 1: the feeding rate is the weight of the material collected by the belt scale per second, a laser particle size analyzer is installed at the feeding port of the crusher to monitor the discharge particle size in real time; a current transformer is installed on the power line of the driving motor to collect the motor current; differential pressure sensors are installed before and after the filter bag (windward side and leeward side) to measure the filter bag resistance; a light scattering type dust concentration sensor is arranged at the outlet of the clean gas chamber to collect the dust concentration; a weighing sensor is installed at the bottom of the dust collector to collect the dust collector weight.

[0026] S2. Dynamically calculate the target negative pressure value and the dust cleaning trigger threshold based on the working condition parameters of the crusher and the dust removal parameters; Specifically, the non-linear relationship between the feeding rate Q (t / h) and the target negative pressure value P (kPa) is established as shown in the following formula:

[0027] where Q 基准 is the designed processing capacity (for example, 200 t / h), I is the real-time value of the motor current, and I 额定 is the rated current of the motor. When it is detected that the discharge particle size D50 increases by 10%, the target negative pressure is increased by 15% through the PID controller to enhance the dust collection ability.

[0028] S3. Adjust the operating power of the induced draft fan according to the target negative pressure value so that the negative pressure intensity of the dust removal system matches the current crushing condition corresponding to the working condition parameters of the crusher; S4. When the filter bag resistance reaches the dust cleaning trigger threshold, start the dust cleaning component and adaptively adjust the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration; Specifically, the adjustment of the dust cleaning trigger threshold: the initial setting of the dust cleaning trigger threshold is 1.2 kPa. When it is detected that the change rate of the dust concentration dC / dt exceeds 0.5 mg / (m³·s), the dust cleaning trigger threshold is dynamically reduced to 0.9 kPa through the fuzzy controller, and at the same time, the dust cleaning frequency is increased from 10 times / hour to 15 times / hour. The vibration amplitude is controlled in stages: when the dust concentration C > 50 mg / m³, the vibration amplitude is increased from 5 mm to 7 mm; when C > 100 mg / m³, the vibration amplitude is further increased to 10 mm and the high-frequency mode (20 Hz) is triggered.

[0029] S5. Monitor the weight of the dust collector in real time. When the weight of the dust collector reaches the set upper limit, start the automatic dust removal device to transport the dust to the external recovery system.

[0030] Specifically, the upper weight limit of the dust collection box is set to 800 kg (configurable parameter). When the weighing value reaches the upper limit, the PLC controls the opening angle of the pneumatic butterfly valve (Festo - VZBA series) to 90°, and at the same time starts the screw conveyor (LS200 type, rotation speed 30 rpm) to convey the dust to the external storage tank. During the dust discharge process, the weight drop rate is monitored in real time. If it does not decrease below 500 kg within 10 minutes, a blockage alarm is triggered and the reverse purging program is started.

[0031] This embodiment establishes a non - linear mapping relationship between the feed rate and the negative pressure value, and adjusts the dust removal intensity in advance through feed - forward control. Using the first - order derivative of the dust concentration to reflect the accumulation speed of the dust layer on the filter bag surface, predictive dust cleaning control is realized. This embodiment can achieve dynamic matching between the crushing load and the dust removal intensity, avoiding energy consumption waste or insufficient dust removal caused by the traditional fixed negative pressure value. By predicting the filter bag blockage trend through the change rate of the dust concentration and adjusting the dust cleaning parameters in advance before the resistance reaches the threshold, the consumption of compressed air can be reduced compared with traditional fixed - time dust cleaning.

[0032] In a preferred embodiment, before dynamically calculating the target negative pressure value and the dust cleaning trigger threshold based on the crusher operating condition parameters and the dust removal parameters, the following steps are included: Obtain the stone material property parameters and environmental parameters in real time. The stone material property parameters include stone hardness, stone humidity, and mud content in the stone, and the environmental parameters include environmental temperature and environmental humidity; Specifically, a microwave moisture meter is installed 2 m above the feeding belt to measure the stone humidity through the dielectric constant. The stone hardness detection uses acoustic emission technology: broadband sensors (Physical Acoustics Nano30, frequency response range 20 - 400 kHz) are installed on the side wall of the crushing chamber to collect the acoustic emission signals during material crushing, and the characteristic frequency fc is extracted (hard rock > 80 kHz, soft rock < 50 kHz). The mud content detection uses a dual - energy γ - ray analyzer to calculate the clay content through the attenuation ratio of low - energy (60 keV) and high - energy (662 keV) rays. The environmental parameter collection uses a temperature and humidity transmitter, which is installed at the ventilation place on the top of the dust collector.

[0033] Dynamically calculating the target negative pressure value and the dust cleaning trigger threshold based on the crusher operating condition parameters and the dust removal parameters includes the following steps: If it is in a non - special scenario, the target negative pressure value and the dust cleaning trigger threshold are dynamically calculated based on the crusher operating condition parameters and the dust removal parameters; the non - special scenario is a conventional production state where the stone material property parameters and the environmental parameters are both within the preset normal range and the equipment is not operating overloaded.

[0034] Specifically, the preset normal range is defined as follows: Stone properties: humidity ≤ 3%, Mohs hardness 4 - 6 (corresponding to limestone - granite), mud content ≤ 5%. Environmental parameters: temperature 10 - 40 °C, relative humidity ≤ 60%. Equipment status: motor current ≤ 90% of the rated value, bearing temperature ≤ 75 °C (monitored by PT100 sensor).

[0035] Special scenario determination logic: When any of the following combinations is satisfied simultaneously, it is determined as a special scenario: Stone humidity > 5% and environmental temperature < 10 °C (dew - forming condition) Mud content > 8% and environmental humidity > 70%RH (high adhesion risk) Motor current continuously > 95% of the rated value for 5 minutes (overloaded operation) Scenarios other than special scenarios are non - special scenarios.

[0036] In this embodiment, by collecting stone properties (hardness, humidity, mud content) and environmental parameters (temperature, humidity) in real - time, a multi - dimensional working condition feature matrix is constructed to achieve intelligent classification of production scenarios (conventional / special).

[0037] It can achieve the improvement of dust removal efficiency: When the stone hardness increases (such as Mohs hardness > 7), the system automatically increases the target negative pressure value (corrected by the correction amount ΔP) to compensate for the increase in fine dust generated by crushing, and the capture efficiency is increased by 15 - 20%. Energy consumption optimization: In conventional scenarios with low humidity (< 3%) and low mud content (< 5%), excessive negative pressure adjustment is avoided, and the fan power is saved by 18 - 25%. Anti - misjudgment guarantee: When the environmental humidity > 60%, even if the stone parameters are normal, special scenario processing is still triggered to prevent the risk of sudden increase in resistance caused by filter bag dew - forming.

[0038] Furthermore, after the stone property parameters and environmental parameters are obtained in real - time, the following steps are also included: If in a special scenario, based on the stone property parameters and the environmental parameters, calculate the comprehensive working condition coefficient; the special scenario is a production state other than the conventional production state; Based on the comprehensive working condition coefficient, obtain the correction amount of the target negative pressure value and the correction coefficient of the ash - cleaning trigger threshold, the correction amount is greater than 0, and the correction coefficient is less than 1; Correct the target negative pressure value with the correction amount to obtain the updated negative pressure value; correct the ash - cleaning trigger threshold with the correction coefficient to obtain the updated ash - cleaning trigger threshold.

[0039] Specifically, in the sensor configuration for special scenarios: Microwave moisture meters are used for stone humidity detection; temperature and humidity transmitters are used for environmental temperature and humidity monitoring. The formula for calculating the comprehensive working condition coefficient:

[0040] Wherein: H m is the humidity of the stone material (%), T e is the ambient temperature (°C), L is the load rate (%), and the weight coefficients are α = 0.4, β = 0.3, γ = 0.3 (determined by optimizing the principal component analysis).

[0041] Target negative pressure correction amount: ΔP = 0.2*K (kPa), Pulse cleaning threshold correction coefficient: η = 1 - 0.15*K Example: When K = 1.2, the updated negative pressure value = original value + 0.24 kPa, and the updated pulse cleaning trigger threshold = original value × 0.82.

[0042] In a preferred embodiment, after starting the pulse cleaning assembly and adaptively adjusting the pulse cleaning frequency and vibration amplitude of the pulse cleaning assembly according to the change rate of the dust concentration, the following steps are included: Record the filter bag resistance recovery time and vibration decay curve after each pulse cleaning to predict the remaining life of the filter bag; If the remaining life of the filter bag is less than the first preset life, generate a filter bag replacement warning signal.

[0043] Specifically, the filter bag resistance recovery time: Record the time required for the resistance to drop to 1 kPa after pulse cleaning through a differential pressure transmitter; Vibration decay curve: Collect the pulse cleaning vibration signal using an acceleration sensor and extract the time constant τ when the amplitude drops to 10%; Use the Weibull distribution fitting to predict the remaining life of the filter bag. When the remaining life of the filter bag < 2000 hours (the first preset life), the PLC outputs a DI signal to trigger a red warning on the HMI, and the warning signal is transmitted to the central control system through the Profibus-DP bus and a text message is sent to the maintenance personnel terminal synchronously.

[0044] In a preferred embodiment, the special scenarios include a dust adhesion sensitive scenario and a non-dust adhesion sensitive scenario; If in a special scenario, calculate the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters, including the following steps: If in a special scenario and in the non-dust adhesion sensitive scenario, calculate the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters; After obtaining the stone material attribute parameters and environmental parameters in real time, the following steps are further included: If in a special scenario and in the dust adhesion sensitive scenario, monitor the dust adhesion force on the surface of the filter bag in real time to obtain the adhesion force change rate; Generate a bonding risk index according to the adhesion force change rate; If the bonding risk index is less than the first preset risk index, when the filter bag resistance reaches the updated dust cleaning trigger threshold, the dust cleaning component is started, and the dust cleaning frequency and vibration amplitude of the dust cleaning component are adaptively adjusted according to the change rate of the dust concentration.

[0045] Furthermore, if it includes at least one of the following, it is determined as a dust adhesion sensitive scenario: The environmental humidity is greater than the first preset humidity; The mud content of the stone material is greater than the first preset mud content; The environmental temperature is less than the first preset temperature and the environmental humidity is greater than the second preset humidity, and the second preset humidity is less than the first preset humidity.

[0046] Specifically, the dust adhesion sensitive scenario refers to the working condition state in which the dust on the surface of the filter bag is likely to form a dense bonding layer due to the characteristics of the stone material or environmental conditions. The specific determination conditions include: Environmental humidity > 65% RH (the first preset humidity): The high humidity environment causes a water film to be adsorbed on the surface of the dust particles, enhancing the adhesion force between the particles.

[0047] The mud content of the stone material > 8% (the first preset mud content): The content of clay minerals (such as montmorillonite, kaolinite) is high, and its layered structure is easy to form a gel.

[0048] Low temperature and high humidity composite condition (environmental temperature < 10°C and environmental humidity > 55%): The risk of dust caking is aggravated by the condensation of moisture at low temperature.

[0049] The non-dust adhesion sensitive scenario refers to other special scenarios except the above situations, such as the pressure fluctuation of the dust removal system caused by simple equipment overload (load rate > 90%) or abnormal stone hardness (Pratt hardness coefficient > 18), but there is no significant dust adhesion tendency.

[0050] Specifically, the implementation process of the non-sensitive scenario: Monitoring of stone material properties: Online detection of the humidity and mud content of the stone material using a near-infrared spectrometer (based on the intensity ratio of the characteristic peaks of the Si-O bond). Acquisition of environmental parameters: Using an explosion-proof temperature and humidity transmitter installed on top of the crusher. By weighted fusion of multi-source parameters, the comprehensive influence degree of the working condition on the dust removal system is quantified.

[0051] Specifically, the implementation process of the dust adhesion sensitive scenario: Real-time monitoring of adhesion force: Sensor selection: Using a piezoresistive thin film force sensor array, mounted on the windward side of the filter bag, with 3×3 measurement points arranged for each bag, a sampling frequency of 200 Hz, and transmitting data to the PLC through the CAN bus. Calculation of the adhesion force change rate: ΔF / Δt = (F t - F t-1 ) / Δt, where F tis the average adhesion force at the current moment (unit: N / m²), Δt = 10 s (sliding time window); the calculation formula for the bonding risk index: R = (ΔF / Δt) × e (0.05×He) + 0.2×C m where He: environmental humidity (%), C m : mud content of the stone material (%); index meaning: comprehensively considering the dynamic adhesion trend and environmental / material factors, quantifying the bonding risk level (R = 0 - 10 points, divided into three levels) Dynamic adjustment of the dust cleaning strategy: Condition judgment: When R < 5 (the first preset risk index), start the conventional dust cleaning mode: trigger dust cleaning according to the updated threshold, frequency adjustment: when dC / dt > 0.5 mg / (m³·s), the frequency is increased to 15 times / h; amplitude classification: when C > 50 mg / m³, the amplitude is 7 mm, when C > 100 mg / m³, the amplitude is 10 mm; the dust cleaning component is driven by an electromagnetic pulse valve, and the vibration amplitude is precisely controlled by a servo motor.

[0052] In this embodiment, the bonding trend is predicted through the stone material properties (humidity, mud content) and environmental parameters, and the dust cleaning threshold is adjusted in advance. The control parameters are corrected in a closed-loop manner based on the real-time differential pressure and dust concentration data. The risk index model introduces an exponential function to reflect the non-linear influence of humidity on the bonding strength. The spatial distribution monitoring of the force sensor array can identify local bonding hotspots and guide the area-specific actions of the dust cleaning component.

[0053] The present invention can achieve anti-blocking optimization: by real-time adhesion force monitoring in sensitive scenarios, the accident rate of filter bag blockage is reduced, and the dynamic negative pressure regulation in non-sensitive scenarios reduces the energy consumption of the fan. It can also achieve an extension of the filter bag life: the classified control of the bonding risk avoids excessive dust cleaning (high-frequency vibration causes fiber fatigue), and the filter bag replacement cycle is extended. It can also achieve an improvement in safety: when R ≥ 5, it automatically switches to the enhanced dust cleaning mode to ensure that the dust concentration in the box is always lower than the explosion lower limit.

[0054] In a preferred embodiment, after generating the bonding risk index according to the adhesion force change rate, the following steps are included: If the bonding risk index is greater than or equal to the first preset risk index, an aerosol-type anti-sticking agent is instantaneously sprayed onto the surface of the filter bag. The anti-sticking agent is a nanoscale hydrophobic particle suspension, and the spraying duration is positively correlated with the bonding risk index; Start the dust cleaning component and adopt the high-frequency pulse dust cleaning mode, where the pulse frequency of the high-frequency pulse dust cleaning mode is related to the bonding risk index, and the negative pressure value rises in a gradient manner; After the bonding risk index drops below the first preset risk index, the normal dust cleaning mode is restored and the anti-sticking agent injection is stopped. The normal dust cleaning mode adaptively adjusts the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration.

[0055] Specifically, when the bonding risk index (R) ≥ the first preset risk index (R1 = 5), the combined strategy of anti-sticking agent injection and high-frequency pulse dust cleaning is started until R < 5 and then the normal mode is restored. Anti-sticking agent formula: nano-scale hydrophobic particles: fumed silica (particle size 30nm, specific surface area 300m² / g), suspension ratio: 1% nano-particles + 0.2% dispersant (sodium polyacrylate) + deionized water; the injection system is a two-fluid atomizing nozzle, gas source pressure: 0.6 - 0.8MPa (adjustable), liquid flow rate: 50 - 200mL / min. Exemplarily, when R = 7, the dust cleaning frequency = 20 + 0.8×2 = 21.6Hz; negative pressure gradient control: starting negative pressure: normal negative pressure value + 0.5×R (kPa); pressure increase per pulse cycle: 0.07 kPa (upper limit 8kPa); the actuator is selected as a pulse valve and a Venturi tube. The condition for restoring the normal dust cleaning mode is: R is continuously detected < 5 three times; stop the anti-sticking agent: close the metering pump; switch to the normal mode: frequency regression: adjust according to f = 10 + 0.5×dC / dt; amplitude regression: when the dust concentration C ≤ 50mg / m³, it drops to 5mm.

[0056] In this embodiment, the surface energy of the dust is reduced by nano-particles, the peeling strength of the bonding layer is decreased, the cleaning rate of the bonding layer is increased, and the high-frequency pulse causes the dust layer to resonate and break, so the dust cleaning efficiency is higher than that of the normal mode; after R < 5, the frequency is automatically decreased to avoid energy consumption waste caused by excessive dust cleaning, and the negative pressure gradient control ensures small pressure fluctuations in the box and prevents the filter bag from being damaged.

[0057] In a preferred embodiment, before calculating the comprehensive working condition coefficient based on the stone material property parameters and the environmental parameters, the following steps are included: Vibration acceleration signals are collected in real time through vibration sensors installed on the bearing seats of the crusher; The vibration energy value in the high-frequency band of 1 - 3kHz is extracted as the wear characteristic quantity; Calculating the comprehensive working condition coefficient based on the stone material property parameters and the environmental parameters includes the following steps: If the wear characteristic quantity is less than the first preset threshold, the initial working condition coefficient is calculated based on the stone material property parameters and the environmental parameters, and the initial working condition coefficient is used as the comprehensive working condition coefficient.

[0058] Specifically, the first preset threshold is the wear safety boundary value, which can be optionally 35 dB. The initial operating condition coefficient is the basic coefficient calculated only based on the stone material properties and environmental parameters, without equipment wear compensation. That is, when the wear characteristic quantity is less than the first preset threshold, the comprehensive operating condition coefficient is the operating condition coefficient without considering equipment wear (still calculated using this formula). 1 - 3 kHz is the bearing raceway spalling characteristic frequency range. In this embodiment, when the wear is normal, the compensation calculation is skipped, and the PLC cycle period is shortened. At the same time, the misjudgment rate can also be reduced (the high-frequency characteristic quantity avoids false alarms caused by material impact).

[0059] In a preferred embodiment, calculating the comprehensive operating condition coefficient based on the stone material property parameters and the environmental parameters includes the following steps: After extracting the vibration energy value in the 1 - 3 kHz high-frequency band as the wear characteristic quantity, the following steps are further included: If the wear characteristic quantity is greater than or equal to the first preset threshold, calculate the initial operating condition coefficient based on the stone material property parameters and the environmental parameters; Raise the initial operating condition coefficient by the target level to obtain the comprehensive operating condition coefficient.

[0060] Specifically, the target level is the compensation amplitude. For every 1 dB exceeding the threshold, the coefficient is increased by 4%. The comprehensive operating condition coefficient is the final coefficient including wear compensation and is used for negative pressure / ash cleaning threshold correction. At this time, using this formula After calculating the initial operating condition coefficient, for every 1 dB that the wear characteristic quantity exceeds the threshold, the coefficient is increased by 4%, and finally the comprehensive operating condition coefficient is obtained.

[0061] This embodiment realizes the improvement of wear adaptability: when the bearing wears, the negative pressure compensation reduces the dust escape amount, and the increase in the coefficient indirectly reduces the equipment load and prolongs the bearing life.

[0062] In a preferred embodiment, starting the ash cleaning component and adopting the high-frequency pulse ash cleaning mode includes the following steps: Calculate the stress distribution field of the filter bag in real time, and feedback the local stress peak value through the micro strain gauge array installed on the filter bag frame; Specifically, arrange the sensor network: arrange the micro strain gauge array in a 5×5 grid (spacing 150 mm), covering the middle and edge of the filter bag.

[0063] Dynamically constrain the acceleration change rate of the pulse ash cleaning to ensure that during the ash cleaning process using the high-frequency pulse ash cleaning mode, the local stress peak value does not exceed 80% of the fatigue limit of the filter bag material.

[0064] Specifically, the fatigue limit refers to the limit value of the infinite stress cycles that the filter bag material can withstand. For a polyester filter bag, it is 25 MPa. The acceleration change rate is the time derivative of the acceleration of the pulse-jet cleaning airflow. The local stress peak value refers to the maximum value in the strain gauge array, reflecting the stress state of the most dangerous point of the filter bag. During the dynamic constraint process, the direct constraint quantity is the acceleration change rate, and the adjustable quantity is the frequency. The maximum allowable frequency f max = 20×(10 - current stress peak value) / 10 Hz. Specifically, when the local stress peak value > 8 MPa (80% of the fatigue limit of 10 MPa), the PLC automatically reduces the acceleration change rate of the pulse-jet cleaning (limited to ≤500 m / s²). This embodiment can achieve filter bag protection, extend the fatigue life of the filter bag, and prevent bag rupture and leakage.

[0065] In this article, specific examples are used to elaborate on the principles and implementation manners of the present application. The descriptions of the above embodiments are only used to help understand the method and its core idea of the present application. The above are only the preferred implementation manners of the present application. It should be noted that due to the limitations of literal expression, and objectively there are infinite specific structures. For those of ordinary skill in the art in this technical field, without departing from the principle of the present invention, several improvements, refinements or changes can be made, or the above technical features can be combined in an appropriate manner; these improvements, refinements, changes or combinations, or directly applying the concept and technical solution of the invention to other occasions without improvement, shall all be regarded as the protection scope of the present application.

Claims

1. A dust removal control method for a mechanism sand impact crusher, characterized in that, It includes the following steps: Collect the working condition parameters and dust removal parameters of the crusher in real time; the working condition parameters of the crusher include the feeding rate, motor current, and discharge particle size, and the dust removal parameters include the filter bag resistance, dust concentration, and dust collector weight; Based on the working condition parameters and dust removal parameters of the crusher, dynamically calculate the target negative pressure value and the dust cleaning trigger threshold; Adjust the operating power of the induced draft fan according to the target negative pressure value, so that the negative pressure intensity of the dust removal system matches the current crushing condition corresponding to the working condition parameters of the crusher; When the filter bag resistance reaches the dust cleaning trigger threshold, start the dust cleaning component, and adaptively adjust the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration; Monitor the weight of the dust collector in real time. When the weight of the dust collector reaches the upper limit of the set weight, start the automatic dust removal device to transport the dust to the external recovery system.

2. The dust removal control method of the impact crusher for manufactured sand according to claim 1, characterized in that: Before dynamically calculating the target negative pressure value and the dust cleaning trigger threshold based on the working condition parameters and dust removal parameters of the crusher, it includes the following steps: Obtain the stone property parameters and environmental parameters in real time. The stone property parameters include stone hardness, stone humidity, and mud content in the stone, and the environmental parameters include environmental temperature and environmental humidity; The dynamically calculating the target negative pressure value and the dust cleaning trigger threshold based on the working condition parameters and dust removal parameters of the crusher includes the following steps: If it is in a non-special scenario, dynamically calculate the target negative pressure value and the dust cleaning trigger threshold based on the working condition parameters and dust removal parameters of the crusher; the non-special scenario is a conventional production state where both the stone property parameters and the environmental parameters are within the preset normal range and the equipment is not overloaded.

3. The dust removal control method of the impact crusher for manufactured sand according to claim 2, characterized in that: After obtaining the stone property parameters and environmental parameters in real time, it further includes the following steps: If it is in a special scenario, calculate the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters; the special scenario is a production state other than the conventional production state; Based on the comprehensive working condition coefficient, obtain the correction amount of the target negative pressure value and the correction coefficient of the dust cleaning trigger threshold. The correction amount is greater than 0, and the correction coefficient is less than 1; Correct the target negative pressure value with the correction amount to obtain the updated negative pressure value; correct the dust cleaning trigger threshold with the correction coefficient to obtain the updated dust cleaning trigger threshold.

4. The dust removal control method of the impact crusher for manufactured sand according to claim 3, characterized in that: After starting the dust cleaning component and adaptively adjusting the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the change rate of the dust concentration, it includes the following steps: Record the filter bag resistance recovery time and vibration attenuation curve after each dust cleaning to predict the remaining life of the filter bag; If the remaining life of the filter bag is less than the first preset life, generate a filter bag replacement warning signal.

5. The dust removal control method of the impact crusher for manufactured sand according to claim 3, characterized in that: The special scenario includes a dust adhesion sensitive scenario and a non-dust adhesion sensitive scenario; The calculating the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters if it is in a special scenario includes the following steps: If it is in a special scenario and in the non-dust adhesion sensitive scenario, calculate the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters; After obtaining the stone property parameters and environmental parameters in real time, it further includes the following steps: If in a special scenario and in the dust adhesion sensitive scenario, the dust adhesion force on the surface of the filter bag is monitored in real time to obtain the adhesion force change rate; Generate a bonding risk index according to the adhesion force change rate; If the bonding risk index is less than the first preset risk index, when the resistance of the filter bag reaches the updated dust cleaning trigger threshold, start the dust cleaning component and adaptively adjust the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the dust concentration change rate.

6. The dust removal control method of the impact crusher for manufactured sand according to claim 5, characterized in that: After generating the bonding risk index according to the adhesion force change rate, the following steps are included: If the bonding risk index is greater than or equal to the first preset risk index, instantaneously spray an anti-sticking agent in aerosol form on the surface of the filter bag. The anti-sticking agent is a nano-scale hydrophobic particle suspension, and the spraying duration is positively correlated with the bonding risk index; Start the dust cleaning component and adopt a high-frequency pulse dust cleaning mode. Among them, the pulse frequency of the high-frequency pulse dust cleaning mode is related to the bonding risk index, and the negative pressure value rises in a gradient manner; When the bonding risk index drops to less than the first preset risk index, resume the conventional dust cleaning mode and stop spraying the anti-sticking agent. The conventional dust cleaning mode is to adaptively adjust the dust cleaning frequency and vibration amplitude of the dust cleaning component according to the dust concentration change rate.

7. The dust removal control method of the impact crusher for manufactured sand according to claim 5, characterized in that: If it includes at least one of the following, it is determined as a dust adhesion sensitive scenario: The environmental humidity is greater than the first preset humidity; The mud content of the stone material is greater than the first preset mud content; The environmental temperature is less than the first preset temperature and the environmental humidity is greater than the second preset humidity, and the second preset humidity is less than the first preset humidity.

8. The dust removal control method of the impact crusher for manufactured sand according to claim 6, characterized in that: Before calculating the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters, the following steps are included: Vibration acceleration signals are collected in real time through vibration sensors installed on the bearing seats of crushers; Extract the vibration energy value in the high-frequency band of 1-3 kHz as the wear characteristic quantity; Calculating the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters includes the following steps: If the wear characteristic quantity is less than the first preset threshold, calculate the initial working condition coefficient based on the stone material attribute parameters and the environmental parameters, and use the initial working condition coefficient as the comprehensive working condition coefficient.

9. The dust removal control method of the impact crusher for manufactured sand according to claim 8, characterized in that: Calculating the comprehensive working condition coefficient based on the stone material attribute parameters and the environmental parameters includes the following steps: After extracting the vibration energy value in the high-frequency band of 1-3 kHz as the wear characteristic quantity, the following steps are further included: If the wear characteristic quantity is greater than or equal to the first preset threshold, calculate the initial working condition coefficient based on the stone material attribute parameters and the environmental parameters; Raise the initial working condition coefficient to the target level to obtain the comprehensive working condition coefficient.

10. The dust removal control method of the impact crusher for manufactured sand according to claim 6, characterized in that: Starting the dust cleaning component and adopting the high-frequency pulse dust cleaning mode includes the following steps: Calculate the stress distribution field of the filter bag in real time, and feedback the local stress peak value through a micro strain gauge array installed on the filter bag frame; Dynamically constrain the acceleration change rate of pulse dust cleaning to ensure that during the process of dust cleaning using the high-frequency pulse dust cleaning mode, the local stress peak value does not exceed 80% of the fatigue limit of the filter bag material.

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