A dust removal control method of a mechanism sand impact crusher

Abstract

The application provides a dust removal control method of a mechanism sand impact crusher, comprising the following steps: collecting crusher working condition parameters and dust removal parameters in real time; dynamically calculating a target negative pressure value and a dust cleaning trigger threshold value based on the crusher working condition parameters and the dust removal parameters; adjusting the running power of an air extractor according to the target negative pressure value, so that the negative pressure intensity of the dust removal system matches the current crushing working condition corresponding to the crusher working condition parameters; when the filter bag resistance reaches the dust cleaning trigger threshold value, starting a dust cleaning assembly and adaptively adjusting the dust cleaning frequency and vibration amplitude of the dust cleaning assembly according to the dust concentration change rate; monitoring the weight of a dust collection box in real time, and when the weight of the dust collection box reaches the upper limit of the weight setting, starting an automatic dust removal device to deliver dust to an external recycling system. The method can dynamically calculate the target negative pressure value and the dust cleaning trigger threshold value, so that the dust removal intensity accurately matches the current crushing load, realizes the dynamic control of the working condition adaptation, and balances the dust removal efficiency and energy consumption in the production preparation process.

Description

Technical Field

[0001] This application relates to the field of impact crusher technology, specifically to a dust control method for a manufactured sand impact crusher. Background Technology

[0002] With the continuous exploitation of natural sand resources, natural sand resources in some areas have become nearly exhausted, and artificial manufactured sand has begun to be widely used. Manufactured sand is sand processed by sand making machines and other auxiliary equipment. It has the characteristics of stable material source, high production efficiency and low processing cost. Moreover, during production, it can be prepared into manufactured sand of different particle sizes and shapes according to process requirements, thereby meeting the needs of various construction projects. In the production and preparation process of manufactured sand, the stone is first initially crushed by a coarse crusher, and then further crushed by a fine crusher. The fine crushing process usually uses an impact crusher. The impact crusher mainly uses a high-speed rotating rotor to impact the stone. The stone is then repeatedly impacted and crushed between the impact frame and the rotor until it is processed into the required particle size. When an impact crusher is working, the stone material is repeatedly crushed by impact with the high-speed rotating rotor and impact liner, which generates a large amount of dust. This dust will drift out from the discharge port and feed port of the equipment, causing serious environmental pollution and harming the health of on-site workers. In order to solve this problem, an impact crusher for preparing manufactured sand with dust removal function was designed, as shown in application number 202411594568.0.

[0003] However, traditional control methods for these types of devices often use fixed negative pressure settings and cleaning cycles (such as timed cleaning), which cannot respond in real time to dynamic conditions such as fluctuations in feed rate and changes in stone properties (such as a sudden increase in 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 control method for a manufactured sand impact crusher to balance dust removal efficiency and energy consumption during the production and preparation of manufactured sand; including the following steps: Real-time acquisition of crusher operating parameters and dust removal parameters; the crusher operating parameters include feed rate, motor current, and discharge particle size; the dust removal parameters include filter bag resistance, dust concentration, and dust collection box weight. Based on the crusher operating parameters and the dust removal parameters, the target negative pressure value and the dust removal trigger threshold are dynamically calculated. Adjust the operating power of the exhaust 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 crusher operating parameters; When the filter bag resistance reaches the dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate. The weight of the dust collection box is monitored in real time. When the weight of the dust collection box reaches the upper limit of the weight setting, the automatic dust removal device is activated to transport the dust to the external recycling system.

[0005] According to the technical solution provided in the embodiments of this application, before dynamically calculating the target negative pressure value and the dust removal trigger threshold based on the crusher operating parameters and the dust removal parameters, the following steps are included: Real-time acquisition of stone property parameters and environmental parameters, including stone hardness, stone moisture content, and stone mud content, and environmental parameters including ambient temperature and ambient humidity; The dynamic calculation of the target negative pressure value and dust removal trigger threshold based on the crusher operating parameters and the dust removal parameters includes the following steps: If it is not a special scenario, the target negative pressure value and the dust removal trigger threshold are dynamically calculated based on the crusher operating parameters and the dust removal parameters; the non-special scenario is the normal production state in which the stone property 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 in the embodiments of this application, after acquiring the stone property parameters and environmental parameters in real time, the method further includes the following steps: If a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters; the special scenario refers to a production state other than the normal production state. Based on the comprehensive working condition coefficient, the correction amount of the target negative pressure value and the correction coefficient of the dust removal trigger threshold are obtained, wherein the correction amount is greater than 0 and the correction coefficient is less than 1; The target negative pressure value is corrected by the correction amount to obtain the updated negative pressure value; the dust removal trigger threshold is corrected by the correction coefficient to obtain the updated dust removal trigger threshold.

[0007] According to the technical solution provided in the embodiments of this application, after activating the dust removal component and adaptively adjusting the dust removal frequency and vibration amplitude of the dust removal component according to the dust concentration change rate, the process 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 lifespan of the filter bag is less than the first preset lifespan, a filter bag replacement warning signal is generated.

[0008] According to the technical solution provided in the embodiments of this application, the special scenarios include dust-sensitive scenarios and non-dust-sensitive scenarios; if a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters, including the following steps: If the situation is in a special scenario and is in a non-dust-sensitive scenario, then the comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters. After acquiring the stone property parameters and environmental parameters in real time, the following steps are also included: If it is in a special scenario and is in a 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; An adhesion risk index is generated based on the rate of change of adhesion force. If the adhesion risk index is less than the first preset risk index, then when the filter bag resistance reaches the updated dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate.

[0009] According to the technical solution provided in the embodiments of this application, after generating the adhesion risk index based on the adhesion force change rate, the following steps are included: If the adhesion risk index is greater than or equal to the first preset risk index, an aerosol-type anti-adhesion agent is sprayed instantaneously onto the surface of the filter bag. The anti-adhesion agent is a suspension of nano-sized hydrophobic particles, and the spraying time is positively correlated with the adhesion risk index. The dust removal component is activated and a high-frequency pulse dust removal mode is adopted, wherein the pulse frequency of the high-frequency pulse dust removal mode is related to the adhesion risk index, and the negative pressure value increases gradually. When the adhesion risk index drops to less than the first preset risk index, the normal dust removal mode is restored and the anti-adhesion agent spraying is stopped. The normal dust removal mode is to adaptively adjust the dust removal frequency and vibration amplitude of the dust removal component according to the dust concentration change rate.

[0010] According to the technical solutions provided in the embodiments of this application, if at least one of the following is included, the scenario is determined to be sensitive to dust adhesion: The ambient humidity is greater than a first preset humidity. The mud content of the stone is greater than the first preset mud content; The ambient temperature is lower than a first preset temperature and the ambient humidity is higher than a second preset humidity, wherein the second preset humidity is lower than the first preset humidity.

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

[0012] According to the technical solution provided in the embodiments of this application, the step of calculating the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters includes the following steps: After extracting the vibration energy value in the 1-3kHz high-frequency band as the wear characteristic quantity, the following steps are also included: If the wear characteristic quantity is greater than or equal to the first preset threshold, then the initial working condition coefficient is calculated based on the stone property parameters and the environmental parameters. The initial operating condition coefficient is increased to the target level to obtain the comprehensive operating condition coefficient.

[0013] According to the technical solution provided in the embodiments of this application, the activation of the dust removal component and the adoption of a high-frequency pulse dust removal mode include the following steps: The stress distribution field of the filter bag is calculated in real time, and the local stress peak value is fed back through the array of micro strain gauges installed on the filter bag frame; The acceleration change rate of the pulse cleaning is dynamically constrained to ensure that the local stress peak does not exceed 80% of the fatigue limit of the filter bag material during the high-frequency pulse cleaning process.

[0014] Compared with the prior art, the beneficial effects of this application are as follows: This application integrates core crusher parameters such as feed rate, motor current, and discharge particle size with dust removal parameters such as filter bag resistance and dust concentration to dynamically calculate the target negative pressure value and the dust removal trigger threshold, enabling precise matching of dust removal intensity to the current crushing load. For example, when an increase in motor current is detected (reflecting an increase in crushing load), the negative pressure value is automatically increased to enhance dust collection capacity, prevent dust escape, and achieve adaptive dynamic control. Simultaneously, the dust concentration change rate is introduced as the basis for adjusting the dust removal frequency and vibration amplitude, achieving dynamic matching between dust removal intensity and dust generation rate. For example, during a rapid increase in dust concentration (such as a sudden increase in the mud content of the stone), the dust removal frequency is automatically increased and the vibration amplitude is increased to prevent a surge in resistance caused by an excessively thick dust layer on the filter bag surface. Dynamic negative pressure adjustment allows the exhaust fan power to fluctuate according to actual demand, resulting in energy savings compared to a fixed power mode. Attached Figure Description

[0015] Figure 1 A flowchart illustrating the steps of a dust control method for a manufactured sand impact crusher provided in this application embodiment. Detailed Implementation

[0016] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0017] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0018] Example 1 As mentioned in the background section, in view of the problems in the prior art, this embodiment proposes an impact crusher for preparing manufactured sand with dust removal function, such as... Figure 1 As shown, it includes: A frame, the inside of which is provided with a crushing chamber; The feed inlet and the discharge outlet are respectively provided at the top and bottom of the frame; The front and rear impact frames are installed on the inner wall of the crushing chamber. A crushing mechanism is disposed inside the crushing chamber and is used to crush the stone by impact. A dust removal mechanism is installed on one side of the frame and is used to filter and clean the dust generated during stone crushing.

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

[0020] The dust removal mechanism includes: A housing, which is disposed on one side of the frame and has an internal cavity; An air baffle is fixedly installed inside the housing, dividing the cavity into a filter chamber and a clean air chamber. A negative pressure collection component is disposed on one side of the housing and is used to collect dust generated when the stone is crushed; A filter assembly, disposed within the filter chamber, is used to filter the dust-laden gas collected by the negative pressure collection assembly; A dust removal component is disposed on top of the filter component and is used to shake off and clean the dust adhering to the filter component.

[0021] The negative pressure collection component includes: Mounting bracket, the mounting bracket is fixedly connected to the housing; An exhaust fan is mounted on the mounting bracket and has an air inlet and an air outlet. An air inlet duct is installed on the air inlet, and the other end of the air inlet duct is connected to the clean air chamber; The housing has multiple air intake pipes, each of which is connected to the crushing chamber and the filter chamber at both ends.

[0022] The filtering component includes: The slip ring is slidably connected to the air baffle plate, which has multiple ventilation holes. The frame is fixedly connected to the bottom end of each slip ring; The filter bag is fitted on the outside of each of the skeletons, and the top of the filter bag abuts against the bottom of the slip ring.

[0023] The dust removal assembly includes: Motor 1, which is fixedly mounted on the housing; A rotating shaft is rotatably connected to the inner wall of the clean air chamber, and one end of the rotating shaft is fixedly connected to the output end of the motor. Cams, and multiple cams are fixedly mounted on the rotating shaft; Connecting posts: Each slip ring has multiple connecting posts fixedly connected to its top end; A movable plate is fixedly connected to the top of the plurality of connecting columns, and the top of the movable plate abuts against the bottom of the plurality of cams. The top of the windbreak plate is fixedly connected to multiple support pillars; A spring is fitted on the outer side of each of the aforementioned pillars, and each of the springs is installed between the windbreak plate and the movable plate.

[0024] Each filter bag has a clamp installed at the top opening to secure it to the frame.

[0025] Example 2 Based on Example 1, this example proposes a dust control method for a manufactured sand impact crusher, including the following steps: S1. Real-time acquisition of crusher operating parameters and dust removal parameters; the crusher operating parameters include feed rate, motor current, and discharge particle size; the dust removal parameters include filter bag resistance, dust concentration, and dust collection box weight. Specifically, the following is a description of the specific implementation based on the device mentioned in Example 1: the feeding rate is such that the weight of the material is collected per second by a belt scale; a laser particle size analyzer is installed at the feed inlet of the crusher to monitor the output particle size in real time; a current transformer is installed on the power line of the drive motor to collect the motor current; differential pressure sensors are installed before and after the filter bag (windward and leeward sides) to measure the filter bag resistance; a light scattering dust concentration sensor is arranged at the outlet of the clean air chamber to collect the dust concentration; and a weighing sensor is installed at the bottom of the dust collection box to collect the weight of the dust collection box.

[0026] S2. Based on the crusher operating parameters and the dust removal parameters, dynamically calculate the target negative pressure value and the dust removal trigger threshold; Specifically, the nonlinear relationship between the feed rate Q (t / h) and the target negative pressure value P (kPa) is established as shown in the following formula:

[0027] Among them, Q 基准 For the design throughput (e.g., 200 t / h), I is the real-time value of the motor current. 额定 This is the rated current of the motor. When the output particle size D50 is detected to increase by 10%, the target negative pressure is increased by 15% through the PID controller to enhance the dust collection capability.

[0028] S3. Adjust the operating power of the exhaust 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 crusher operating parameters; S4. When the filter bag resistance reaches the dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate. Specifically, the dust removal trigger threshold is adjusted as follows: The initial dust removal trigger threshold is set to 1.2 kPa. When the detected dust concentration change rate dC / dt exceeds 0.5 mg / (m³·s), the dust removal trigger threshold is dynamically lowered to 0.9 kPa via a fuzzy controller, while the dust removal frequency is increased from 10 times / hour to 15 times / hour. 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 a high-frequency mode (20 Hz) is triggered.

[0029] S5. 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 removal device to transport the dust to the external recycling system.

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

[0031] This embodiment establishes a nonlinear mapping relationship between feed rate and negative pressure value, and adjusts the dust removal intensity in advance through feedforward control. Utilizing the first derivative of dust concentration to reflect the dust accumulation rate on the filter bag surface, predictive cleaning control is achieved. This embodiment can achieve dynamic matching between crushing load and dust removal intensity, avoiding energy waste or insufficient dust removal caused by traditional fixed negative pressure values. By predicting the filter bag clogging trend through the dust concentration change rate, the cleaning parameters are adjusted in advance before the resistance reaches the threshold, reducing compressed air consumption compared to traditional timed cleaning.

[0032] In a preferred embodiment, before dynamically calculating the target negative pressure value and the dust removal trigger threshold based on the crusher operating parameters and the dust removal parameters, the following steps are included: Real-time acquisition of stone property parameters and environmental parameters, including stone hardness, stone moisture content, and stone mud content, and environmental parameters including ambient temperature and ambient humidity; Specifically, a microwave moisture meter is installed 2m above the feed conveyor belt to measure the moisture content of the stone by measuring its dielectric constant. Stone hardness is detected using acoustic emission technology: a broadband sensor (Physical Acoustics Nano30, frequency response range 20-400kHz) is installed on the sidewall of the crushing chamber to collect acoustic emission signals during material crushing and extract the characteristic frequency fc (hard rock > 80kHz, soft rock < 50kHz). Clay content is detected using a dual-energy gamma-ray analyzer; the clay content is calculated by the attenuation ratio of low-energy (60keV) and high-energy (662keV) rays. Environmental parameters are collected using temperature and humidity transmitters installed at the top ventilation point of the dust collector.

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

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

[0035] Special scenario determination logic: A scenario is determined to be special when any of the following combinations are met simultaneously: Stone moisture content > 5% and ambient temperature < 10℃ (prone to condensation) Mud content >8% and ambient humidity >70%RH (high risk of adhesion) Motor current exceeding 95% of rated value for 5 minutes (overload operation) All scenarios other than special scenarios are considered non-special scenarios.

[0036] This implementation method collects stone properties (hardness, moisture content, mud content) and environmental parameters (temperature, humidity) in real time to construct a multi-dimensional working condition feature matrix, thereby realizing intelligent classification of production scenarios (normal / special).

[0037] It can improve dust removal efficiency: When the hardness of the stone increases (e.g., 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, improving the collection efficiency by 15-20%. Energy consumption optimization: In normal scenarios with low humidity (<3%) and low mud content (<5%), excessive negative pressure adjustment is avoided, saving 18-25% of the fan power. Misjudgment prevention guarantee: When the ambient humidity is >60%, even if the stone parameters are normal, special scenario processing is still triggered to prevent the risk of a sudden increase in resistance caused by condensation on the filter bag.

[0038] Furthermore, after acquiring the stone property parameters and environmental parameters in real time, the process also includes the following steps: If a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters; the special scenario refers to a production state other than the normal production state. Based on the comprehensive working condition coefficient, the correction amount of the target negative pressure value and the correction coefficient of the dust removal trigger threshold are obtained, wherein the correction amount is greater than 0 and the correction coefficient is less than 1; The target negative pressure value is corrected by the correction amount to obtain the updated negative pressure value; the dust removal trigger threshold is corrected by the correction coefficient to obtain the updated dust removal trigger threshold.

[0039] Specifically, sensor configurations for special scenarios: a microwave moisture meter is used for stone moisture detection; a temperature and humidity transmitter is used for environmental temperature and humidity monitoring; the comprehensive operating condition coefficient calculation formula is as follows:

[0040] Wherein: H m The moisture content of the stone (%), T e denoted as ambient temperature (°C), L as loading rate (%), and weighting coefficients α=0.4, β=0.3, γ=0.3 (determined through principal component analysis optimization).

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

[0042] In a preferred embodiment, after activating the dust removal component and adaptively adjusting the dust removal frequency and vibration amplitude of the component according to the dust concentration change rate, the process 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 lifespan of the filter bag is less than the first preset lifespan, a filter bag replacement warning signal is generated.

[0043] Specifically, the filter bag resistance recovery time is recorded by a differential pressure transmitter, showing the time required for the resistance to drop to 1 kPa after cleaning; the vibration decay curve is obtained by using an accelerometer to collect the cleaning vibration signal and extracting the time constant τ when the amplitude drops to 10%; the remaining lifespan of the filter bag is predicted by fitting the Weibull distribution. When the remaining lifespan of the filter bag is less than 2000 hours (the first preset lifespan), the PLC outputs a DI signal to trigger a red warning from the HMI. The warning signal is transmitted to the central control system via the Profibus-DP bus and a text message is sent to the maintenance personnel's terminal simultaneously.

[0044] In a preferred embodiment, the special scenario includes dust adhesion-sensitive scenarios and non-dust adhesion-sensitive scenarios; if a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters, including the following steps: If the situation is in a special scenario and is in a non-dust-sensitive scenario, then the comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters. After acquiring the stone property parameters and environmental parameters in real time, the following steps are also included: If it is in a special scenario and is in a 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; An adhesion risk index is generated based on the rate of change of adhesion force. If the adhesion risk index is less than the first preset risk index, then when the filter bag resistance reaches the updated dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate.

[0045] Furthermore, a scenario is deemed to be sensitive to dust adhesion if it includes at least one of the following: The ambient humidity is greater than a first preset humidity. The mud content of the stone is greater than the first preset mud content; The ambient temperature is lower than a first preset temperature and the ambient humidity is higher than a second preset humidity, wherein the second preset humidity is lower than the first preset humidity.

[0046] Specifically, dust-sensitive scenarios refer to working conditions where dust on the filter bag surface easily forms a dense adhesive layer due to the characteristics of the stone or environmental conditions. Specific criteria for determination include: Ambient humidity > 65% RH (first preset humidity): High humidity environment causes water film to be adsorbed on the surface of dust particles, which enhances the adhesion between particles.

[0047] Stone with mud content >8% (first preset mud content): High content of clay minerals (such as montmorillonite and kaolinite), whose layered structure easily forms a gel-like substance.

[0048] Low temperature and high humidity combined conditions (ambient temperature <10℃ and ambient humidity >55%): Low temperature moisture condensation exacerbates the risk of dust caking.

[0049] Non-dust adhesion sensitive scenarios refer to other special scenarios besides the above situations, such as pressure fluctuations in the dust removal system caused by simple equipment overload (load rate > 90%) or abnormal stone hardness (Protodyakonov hardness coefficient > 18), but without significant dust adhesion tendency.

[0050] Specifically, the implementation process for non-sensitive scenarios is as follows: Stone property monitoring: Near-infrared spectrometer is used to detect stone moisture content and mud content online (based on the intensity ratio of Si-O bond characteristic peaks). Environmental parameter acquisition: Explosion-proof temperature and humidity transmitters are installed on top of the crusher. By weighted fusion of multi-source parameters, the overall impact of the working conditions on the dust removal system is quantified.

[0051] Specifically, the implementation process for dust adhesion-sensitive scenarios is as follows: Real-time adhesion force monitoring: Sensor selection: A piezoresistive thin-film force sensor array is used, mounted on the windward side of the filter bag, with 3×3 measuring points per bag, a sampling frequency of 200Hz, and data transmitted to the PLC via a CAN bus. Adhesion force change rate calculation: ΔF / Δt = (F t - F t-1 ) / Δt, where F tThe average adhesion force at the current moment (unit: N / m²), Δt = 10s (sliding time window); the formula for calculating the adhesion risk index is: R = (ΔF / Δt) × e (0.05×He) + 0.2×C m Wherein, He: ambient humidity (%), C m : Mud content of stone (%); Index significance: Quantifies the adhesion risk level (R=0-10 points, three levels) by comprehensively considering dynamic adhesion trends and environmental / material factors. Dynamic adjustment of dust removal strategy: Condition judgment: When R<5 (first preset risk index), start the normal dust removal mode: trigger dust removal 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 7mm, and when C>100 mg / m³, the amplitude is 10mm; the dust removal component is driven by an electromagnetic pulse valve, and the vibration amplitude is precisely controlled by a servo motor.

[0052] This implementation predicts bonding trends based on stone properties (moisture content, mud content) and environmental parameters, adjusting the dust removal threshold in advance. Control parameters are corrected in a closed-loop manner based on real-time differential pressure and dust concentration data. A risk index model incorporates an exponential function to reflect the nonlinear impact of humidity on bonding strength. Spatial distribution monitoring of the force sensor array identifies local bonding hotspots, guiding targeted actions of the dust removal components in specific areas.

[0053] This invention achieves optimized anti-clogging: in sensitive scenarios, real-time adhesion force monitoring reduces the filter bag clogging rate, while dynamic negative pressure adjustment in non-sensitive scenarios reduces fan energy consumption. It also extends filter bag lifespan: graded control of adhesion risk avoids excessive cleaning (high-frequency vibration leads to fiber fatigue), extending filter bag replacement cycles. Furthermore, it enhances safety: when R≥5, it automatically switches to enhanced cleaning mode, ensuring the dust concentration inside the chamber remains below the lower explosive limit.

[0054] In a preferred embodiment, after generating the adhesion risk index based on the rate of change of adhesion force, the process includes the following steps: If the adhesion risk index is greater than or equal to the first preset risk index, an aerosol-type anti-adhesion agent is sprayed instantaneously onto the surface of the filter bag. The anti-adhesion agent is a suspension of nano-sized hydrophobic particles, and the spraying time is positively correlated with the adhesion risk index. The dust removal component is activated and a high-frequency pulse dust removal mode is adopted, wherein the pulse frequency of the high-frequency pulse dust removal mode is related to the adhesion risk index, and the negative pressure value increases gradually. When the adhesion risk index drops to less than the first preset risk index, the normal dust removal mode is restored and the anti-adhesion agent spraying is stopped. The normal dust removal mode is to adaptively adjust the dust removal frequency and vibration amplitude of the dust removal component according to the dust concentration change rate.

[0055] Specifically, when the adhesion risk index (R) ≥ the first preset risk index (R1=5), the anti-adhesion agent spraying and high-frequency pulse cleaning combination strategy is activated until R < 5, at which point the normal mode is restored. Anti-adhesion agent formulation: nano-sized hydrophobic particles: fumed silica (particle size 30nm, specific surface area 300m² / g); suspension ratio: 1% nanoparticles + 0.2% dispersant (sodium polyacrylate) + deionized water; the spraying system is a dual-fluid atomizing nozzle; air source pressure: 0.6-0.8MPa (adjustable); liquid flow rate: 50-200mL / min. For example, when R=7, the cleaning frequency = 20 + 0.8 × 2 = 21.6Hz; negative pressure gradient control: initial 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 venturi tube. The conditions for resuming the normal dust removal mode are: R is less than 5 for 3 consecutive tests; stop the anti-sticking agent: turn off the metering pump; switch to normal mode: frequency reduction: adjust according to f=10 + 0.5×dC / dt; amplitude reduction: reduce to 5mm when the dust concentration C≤50mg / m³.

[0056] This implementation reduces the surface energy of dust by using nanoparticles, thereby decreasing the peel strength of the adhesive layer and improving the removal rate of the adhesive layer. High-frequency pulses cause the dust layer to resonate and break, improving the dust removal efficiency compared to the conventional mode. When R < 5, the frequency is automatically reduced to avoid energy waste caused by excessive dust removal. Negative pressure gradient control ensures small pressure fluctuations inside the chamber and prevents filter bag damage.

[0057] In a preferred embodiment, before calculating the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters, the following steps are included: Vibration acceleration signals are collected in real time by vibration sensors installed in the crusher bearing housing; The vibration energy value in the 1-3kHz high-frequency band was extracted as a wear characteristic quantity; The calculation of the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters includes the following steps: If the wear characteristic quantity is less than the first preset threshold, then based on the stone property parameters and the environmental parameters, the initial working condition coefficient is calculated, 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 selected as 35dB. The initial operating condition coefficient is only a basic coefficient calculated based on the stone 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 that does not consider equipment wear (or uses...). (This formula is used for calculation). 1-3kHz is the characteristic frequency range for bearing raceway spalling. This implementation skips compensation calculations when wear is normal, shortening the PLC cycle time; at the same time, it can also reduce the false alarm rate (high-frequency characteristic quantities avoid false alarms caused by material impact).

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

[0060] Specifically, the target level is the compensation range, with a 4% increase in the coefficient for every 1dB exceeding the threshold. The comprehensive operating condition coefficient includes the final coefficient for wear compensation and is used for negative pressure / dust cleaning threshold correction. At this point, this formula is used. After calculating the initial operating condition coefficient, the coefficient is increased by 4% for every 1dB that the wear characteristic quantity exceeds the threshold, and finally the comprehensive operating condition coefficient is obtained.

[0061] This implementation method improves wear adaptability: negative pressure compensation during bearing wear reduces dust escape, and the increased coefficient indirectly reduces equipment load and extends bearing life.

[0062] In a preferred embodiment, activating the dust removal component and employing a high-frequency pulse dust removal mode includes the following steps: The stress distribution field of the filter bag is calculated in real time, and the local stress peak value is fed back through the array of micro strain gauges installed on the filter bag frame; Specifically, the sensor network is arranged as follows: a micro-strain gauge array is arranged in a 5×5 grid (150mm spacing), covering the middle and edges of the filter bag.

[0063] The acceleration change rate of the pulse cleaning is dynamically constrained to ensure that the local stress peak does not exceed 80% of the fatigue limit of the filter bag material during the high-frequency pulse cleaning process.

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

[0065] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. The above descriptions are merely preferred embodiments of this application. It should be noted that due to the limitations of written expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of this invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of this application.

Claims

1. A dust control method for a manufactured sand impact crusher, characterized in that, Includes the following steps: Real-time acquisition of crusher operating parameters and dust removal parameters; the crusher operating parameters include feed rate, motor current, and discharge particle size; the dust removal parameters include filter bag resistance, dust concentration, and dust collection box weight. Based on the crusher operating parameters and the dust removal parameters, the target negative pressure value and the dust removal trigger threshold are dynamically calculated. Adjust the operating power of the exhaust 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 crusher operating parameters; When the filter bag resistance reaches the dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate. The weight of the dust collection box is monitored in real time. When the weight of the dust collection box reaches the upper limit of the weight setting, the automatic dust removal device is activated to transport the dust to the external recycling system. Among them, a nonlinear relationship between the feeding rate and the target negative pressure value is established. The target negative pressure value is calculated based on the feeding rate, the real-time value of the motor current and the rated current. When the output particle size increases, the target negative pressure value is increased by the PID controller. An initial value of the dust removal trigger threshold is set. When the dust concentration change rate is detected to exceed the preset change rate, the dust removal trigger threshold is dynamically lowered by the fuzzy controller.

2. The dust control method for a manufactured sand impact crusher according to claim 1, characterized in that: Before dynamically calculating the target negative pressure value and the dust removal trigger threshold based on the crusher operating parameters and the dust removal parameters, the following steps are included: Real-time acquisition of stone property parameters and environmental parameters, including stone hardness, stone moisture content, and stone mud content, and environmental parameters including ambient temperature and ambient humidity; The dynamic calculation of the target negative pressure value and dust removal trigger threshold based on the crusher operating parameters and the dust removal parameters includes the following steps: If it is not a special scenario, the target negative pressure value and the dust removal trigger threshold are dynamically calculated based on the crusher operating parameters and the dust removal parameters; the non-special scenario is the normal production state in which the stone property parameters and the environmental parameters are both within the preset normal range and the equipment is not overloaded.

3. The dust control method for a manufactured sand impact crusher according to claim 2, characterized in that: After acquiring the stone property parameters and environmental parameters in real time, the following steps are also included: If a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters; the special scenario refers to a production state other than the normal production state. Based on the comprehensive working condition coefficient, the correction amount of the target negative pressure value and the correction coefficient of the dust removal trigger threshold are obtained, wherein the correction amount is greater than 0 and the correction coefficient is less than 1; The target negative pressure value is corrected by the correction amount to obtain the updated negative pressure value; the dust removal trigger threshold is corrected by the correction coefficient to obtain the updated dust removal trigger threshold.

4. The dust control method for a manufactured sand impact crusher according to claim 3, characterized in that: After activating the dust removal component and adaptively adjusting its cleaning frequency and vibration amplitude according to the dust concentration change rate, the process 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 lifespan of the filter bag is less than the first preset lifespan, a filter bag replacement warning signal is generated.

5. The dust control method for a manufactured sand impact crusher according to claim 3, characterized in that: The special scenarios include dust adhesion-sensitive scenarios and non-dust adhesion-sensitive scenarios; If a special scenario is encountered, a comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters, including the following steps: If the situation is in a special scenario and is in a non-dust-sensitive scenario, then the comprehensive working condition coefficient is calculated based on the stone property parameters and the environmental parameters. After acquiring the stone property parameters and environmental parameters in real time, the following steps are also included: If it is in a special scenario and is in a 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; An adhesion risk index is generated based on the rate of change of adhesion force. If the adhesion risk index is less than the first preset risk index, then when the filter bag resistance reaches the updated dust removal trigger threshold, the dust removal component is activated, and the dust removal frequency and vibration amplitude of the dust removal component are adaptively adjusted according to the dust concentration change rate.

6. The dust control method for a manufactured sand impact crusher according to claim 5, characterized in that: After generating the adhesion risk index based on the rate of change of adhesion force, the process includes the following steps: If the adhesion risk index is greater than or equal to the first preset risk index, an aerosol-type anti-adhesion agent is sprayed instantaneously onto the surface of the filter bag. The anti-adhesion agent is a suspension of nano-sized hydrophobic particles, and the spraying time is positively correlated with the adhesion risk index. The dust removal component is activated and a high-frequency pulse dust removal mode is adopted, wherein the pulse frequency of the high-frequency pulse dust removal mode is related to the adhesion risk index, and the negative pressure value increases gradually. When the adhesion risk index drops to less than the first preset risk index, the normal dust removal mode is restored and the anti-adhesion agent spraying is stopped. The normal dust removal mode is to adaptively adjust the dust removal frequency and vibration amplitude of the dust removal component according to the dust concentration change rate.

7. The dust control method for a manufactured sand impact crusher according to claim 5, characterized in that: A scenario is considered to be sensitive to dust adhesion if it includes at least one of the following: The ambient humidity is greater than a first preset humidity. The mud content of the stone is greater than the first preset mud content; The ambient temperature is lower than a first preset temperature and the ambient humidity is higher than a second preset humidity, wherein the second preset humidity is lower than the first preset humidity.

8. The dust control method for a manufactured sand impact crusher according to claim 6, characterized in that: Before calculating the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters, the following steps are included: Vibration acceleration signals are collected in real time by a vibration sensor installed in the bearing housing of the crusher; The vibration energy value in the 1-3kHz high-frequency band was extracted as a wear characteristic quantity; The calculation of the comprehensive working condition coefficient based on the stone property parameters and the environmental parameters includes the following steps: If the wear characteristic quantity is less than the first preset threshold, then based on the stone property parameters and the environmental parameters, the initial working condition coefficient is calculated, and the initial working condition coefficient is used as the comprehensive working condition coefficient.

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

10. The dust control method for a manufactured sand impact crusher according to claim 6, characterized in that: The activation of the dust removal component, employing a high-frequency pulse dust removal mode, includes the following steps: The stress distribution field of the filter bag is calculated in real time, and the local stress peak value is fed back through the array of micro strain gauges installed on the filter bag frame; The acceleration change rate of the pulse cleaning is dynamically constrained to ensure that the local stress peak does not exceed 80% of the fatigue limit of the filter bag material during the high-frequency pulse cleaning process.

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