Weighing and metering equipment and control program for batching industrial raw materials

Abstract

The invention relates to the technical field of control regulation, in particular to a device and a control program for weighing and metering during industrial raw material batching, the device comprises an upper computer and a control subprogram which are in signal connection, and the control subprogram comprises an interaction control subprogram, a feeding control subprogram, a quality estimation subprogram and a compensation control subprogram which are in signal connection. The control subprogram is further in signal connection with a sensing module, the sensing module comprises a first sensing unit, a second sensing unit and a third sensing unit which are in signal connection, and the first sensing unit, the second sensing unit and the third sensing unit are all arranged at different positions on the feeding hopper; detection of the conveying quality of the vibration raw materials is achieved through the multiple sets of sensing units, the vibration raw material quality detected by the sensing units can be obtained in combination with the corresponding fluctuation coefficients, and the problem that dynamic particle material flow cannot be accurately metered in the prior art is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of control and regulation, and specifically refers to an equipment and a control program for weighing and metering during the batching of industrial raw materials. Background Art

[0002] In industrial fields such as plastic molding processing and food and drug production, accurate raw material ratio is crucial for ensuring product quality. However, there is a significant problem in the current process of metering granular industrial raw materials: the vibration of the feeding hopper causes unstable fluctuations in the measurement values. This problem directly affects the accuracy and efficiency of batching.

[0003] Specifically, the traditional method of manually controlling the injection amount of raw materials often leads to deviations in the injection amount of raw materials due to operation errors, deviating from the preset ratio. In this case, manual supplementary injection is required to reach the preset ratio, which is not only inefficient but also increases production costs.

[0004] In the actual batching process, pressure sensors are usually used to measure the weight of raw materials in the discharging hopper. However, these sensors cannot measure the raw materials in the suspended state, resulting in a lag in the weighing and control process of the metering equipment. This lag may cause the actual ratio of raw materials to exceed the preset value, thus having a negative impact on the precision of industrial production.

[0005] Due to the vibration generated by the feeding hopper during operation, the sensor readings are unstable, and this jumping phenomenon further exacerbates the inaccuracy of metering. The vibration not only affects the real-time monitoring of the raw material weight by the sensor but also may cause uneven distribution of raw materials during transportation, thereby affecting the quality and consistency of the final product.

[0006] Therefore, there is an urgent need for an equipment and a control program for weighing and metering during the batching of industrial raw materials to control the transportation process of industrial raw materials and accurately calculate the metering process. Summary of the Invention

[0007] The object of the present invention is to provide a control program for weighing and metering during the batching of industrial raw materials, which is used to control the transportation process of industrial raw materials, and also to provide an equipment for weighing and metering during the batching of industrial raw materials, which improves the batching accuracy by calculating and processing the outputs of multiple sensing units.

[0008] The present invention is achieved by the following technical solutions: A control program for weighing and metering during industrial raw material batching, including a host computer and a control subroutine with signal connection. The control subroutine includes the following parts with signal connection: an interactive control subroutine for realizing signal interaction with the host computer; a feeding control subroutine for switching the feeding mode of the feeding module, and the feeding mode includes a first mode and a second mode, where the feeding speed in the first mode is greater than that in the second mode; a mass estimation subroutine for estimating the conveying mass of the raw materials in the feeding hopper in the second mode; a compensation control subroutine for calculating the advance amount of the feeding module to stop according to the conveying mass of the raw materials, and controlling the feeding module to close through the advance amount. The control subroutine is also signal-connected to a sensing module, and the sensing module includes a first sensing unit, a second sensing unit, and a third sensing unit with signal connection. The first sensing unit, the second sensing unit, and the third sensing unit are all arranged at different positions on the feeding hopper. The mass estimation process is as follows: within a detection period, the fluctuating mass of the raw materials in the feeding hopper in the second mode is collected through the first sensing unit, the second sensing unit, and the third sensing unit, and then the fluctuating mass is estimated and processed with the AD value and the AD value curve to obtain the raw material mass.

[0009] An equipment for weighing and metering during industrial raw material batching, including a feeding bin, the feeding hopper is arranged below the feeding bin, the feeding module is arranged on the side of the feeding hopper, a conveying module is arranged below the feeding hopper, and the pressure sensing unit, the first sensing unit, the second sensing unit, and the third sensing unit are all arranged on the feeding hopper.

[0010] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1. The present invention incorporates a correction control subroutine into the control subroutine. Through the multiple iterative calculation process of the correction control subroutine, and calculating the gap between the calculated mass and the actual mass in the feeding hopper during the previous control processes. During the determination of the actual mass, when it is determined that the vibrating raw materials tend to settle and stabilize, the mass is calculated by weighing through the pressure sensing unit, and the result of this weighing calculation is regarded as the actual mass in the feeding hopper at this time; 2. The present invention realizes the detection of the conveying mass of vibrating raw materials through multiple groups of sensing units, and combines the corresponding fluctuation coefficients to obtain the mass of the vibrating raw materials detected between the sensing units, solving the problem in the prior art that dynamic granular material flow cannot be accurately metered; 3. The present invention integrates a pressure sensing unit, a first sensing unit, a second sensing unit, and a third sensing unit on the feeding hopper. The layout of these sensors is carefully designed to achieve comprehensive monitoring of the state of the raw materials in the feeding hopper. The pressure sensing unit is arranged collinearly with the central axis of the feeding hopper to directly measure the pressure of the raw materials on the bottom of the feeding hopper, thereby obtaining the mass of the raw materials. Description of the Drawings

[0011] The accompanying drawings described herein are used to provide a further understanding of the embodiments of the present invention, which form a part of the present invention and do not limit the embodiments of the present invention. In the drawings: Figure 1 is a schematic diagram of the control program; Figure 2 is a schematic diagram of the brief structure of the device to which the control program of the present invention is applied; Marks in the accompanying drawings and corresponding part names: 1 - feeding bin, 2 - feeding hopper, 3 - feeding module, 4 - conveying module. Specific embodiments

[0012] To make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in combination with embodiments and the accompanying drawings. The illustrative embodiments of the present invention and their descriptions are only used to explain the present invention and do not limit the present invention. It should be noted that the present invention has been in the actual R & D and use stage.

[0013] To make the technical solutions of the present invention clearer, the professional terms involved in the present invention are explained herein; In the present invention, the term "host computer" refers to a computer system that communicates with the lower computer program and is responsible for monitoring, managing and controlling the work of the lower computer. Preferably, it includes a PLC, an industrial control computer and necessary control devices, specifically such as the commercially available IPC610 series; In the present invention, the term "feeding speed" refers to the speed of the feeding module when conveying raw materials. For the feeding module, preferably a vibrator, the feeding speed is affected by the vibration frequency and amplitude of the vibrator; In the present invention, the term "lead time" refers to the advance time for the feeding module to stop as calculated according to the quality in the control program and is used to control the feeding module to close in advance before reaching the predetermined quality to ensure accurate batching; In the present invention, the term "AD value" refers to the value after the analog signal is converted into a digital signal. The data collected by the first sensing unit, the second sensing unit and the third sensing unit are converted into AD values for subsequent processing and quality estimation; In the present invention, the term "AD value curve" refers to the graph of the AD value changing with time within a certain time or detection period; In the present invention, the term "pressure sensing unit" refers to a sensor that obtains the quality by measuring the pressure, preferably a pressure sensor; In the present invention, the term "set quality" refers to the theoretical quality required for industrial raw material batching and is set through the interactive control subroutine; In the present invention, the term "conveying quality" refers to the quality of the raw materials measured by the sensing module, which can be equivalent to the actual quality in a completely static state; In the present invention, the term "fluctuation coefficient" is used to describe the relationship between the AD value output by the sensing module and the pressure (mass) actually applied to the sensor.

[0014] Embodiment 1: As shown in the attached Figure 1 As shown, a control program for weighing and metering during the batching of industrial raw materials includes a host computer and a control subroutine connected by signals. The control subroutine includes the following subroutines connected by signals: an interactive control subroutine for realizing signal interaction with the host computer; a feeding control subroutine for switching the feeding mode of the feeding module 3, where the feeding mode includes a first mode and a second mode, and the feeding speed in the first mode is greater than that in the second mode; a mass estimation subroutine for estimating the conveying mass of the raw materials in the feeding hopper 2 in the second mode; a compensation control subroutine for calculating the advance amount of the shutdown of the feeding module 3 according to the conveying mass of the raw materials and controlling the closing of the feeding module 3 through the advance amount. The control subroutine is also connected by signals to a sensing module, and the sensing module includes a first sensing unit, a second sensing unit, and a third sensing unit connected by signals. The first sensing unit, the second sensing unit, and the third sensing unit are all arranged at different positions on the feeding hopper 2. The mass estimation process is as follows: within a detection period, the fluctuation mass of the raw materials in the feeding hopper 2 in the second mode is collected by the first sensing unit, the second sensing unit, and the third sensing unit, and then the raw material mass is obtained through estimation processing of the fluctuation mass, the AD value, and the AD value curve.

[0015] It should be noted that due to the vibration generated by the feeding hopper 2 during operation, the sensor readings are unstable, and this jumping phenomenon further exacerbates the inaccuracy of metering. Vibration not only affects the real-time monitoring of the raw material weight by the sensor but also may cause uneven distribution of the raw materials during transportation, thereby affecting the quality and consistency of the final product. In addition, existing pressure sensors often use multiple groups in combination, and the different layout positions will also affect the final measurement results. Therefore, it is also necessary to comprehensively process the data of multiple groups of pressure sensors to obtain a more reliable metering result.

[0016] Based on the above problems, the applicant proposed a control program for weighing and metering during the batching of industrial raw materials. The program includes a host computer and a control subroutine connected by signals. The control subroutine includes an interactive control subroutine, a feeding control subroutine, a mass estimation subroutine, and a compensation control subroutine. These subroutines work together to achieve precise control and metering of the industrial raw material batching process. Specifically, the interactive control subroutine is used to achieve signal interaction with the host computer; the feeding control subroutine is used to switch the feeding mode of the feeding module 3, including the first mode (fast feeding) and the second mode (slow feeding); the mass estimation subroutine is used to estimate the conveying mass of the raw materials in the feeding hopper 2 in the second mode; the compensation control subroutine calculates the advance amount of the shutdown of the feeding module 3 according to the conveying mass of the raw materials, and controls the feeding module 3 to close through the advance amount. In addition, the control subroutine is also connected to a sensing module by signals, including a first sensing unit, a second sensing unit, and a third sensing unit. These sensing units are all arranged at different positions on the feeding hopper 2 to collect the fluctuating mass of the raw materials in the feeding hopper 2 in the second mode, and estimate and process it with the AD value and the AD value curve to obtain the raw material mass. By controlling the different feeding speeds of the feeding module 3 through the control program, the volume of the raw materials in the air can be reduced, and the accuracy of the industrial raw material conveying and batching process can be improved. In the initial stage of raw material conveying, the first mode with a faster feeding speed is adopted, and after the raw materials are conveyed to two-thirds of the set mass, the feeding module 3 is controlled to switch to the second mode with a slower feeding speed, which can reduce the volume of the industrial raw materials in the air suspension state. Secondly, the conveying mass of the vibrating raw materials is detected through multiple groups of sensing units, and the vibrating raw material mass detected between the sensing units can be obtained by combining the corresponding fluctuation coefficients, solving the problem that the dynamic granular material flow cannot be accurately metered in the prior art. Finally, by correcting the multiple iterative calculation process of the control subroutine and calculating the gap between the calculated mass and the actual mass in the feeding hopper 2 in the previous control processes, the uncertain variables in the metering process are reduced, and the estimation accuracy is further improved. These technical effects not only improve the automation and accuracy of batching, reduce the error rate of manual operations, but also enhance the efficiency and product quality of industrial raw material batching, while reducing raw material waste, with significant economic and operational benefits.

[0017] Embodiment 2: This embodiment only describes the parts different from Embodiment 1. Specifically, the sensing module further includes a pressure sensing unit for measuring the mass of the raw materials in the feeding hopper 2 in real time; a set mass is set through the interactive control subroutine; the control subroutine further includes: a correction control subroutine, which is signal-connected to the compensation control subroutine, and a threshold value of the fluctuation mass is set through the interactive control subroutine. When the fluctuation mass is lower than the threshold value, the actual mass in the feeding hopper 2 is determined by the pressure sensing unit. The correction control subroutine corrects the mass of the next control process based on the actual mass and the set mass, and iteratively calculates the lead of the next control process.

[0018] The iterative calculation process is: calculating the deviation, calculating the integral term, calculating the differential term, calculating the control output, updating the mass, calculating the lead, and iteratively updating.

[0019] The correction control subroutine only runs within no more than ten control processes after the control program is started.

[0020] It should be noted that the correction control subroutine only runs within no more than ten control processes after the control program is started. During the process of transporting raw materials to the feeding bin 1 and the feeding hopper 2, since the mass of the vibrating raw materials in the feeding hopper 2 is not directly weighed but obtained through indirect data calculation, there are some uncertain variables. In order to further improve the estimation accuracy and reduce the influence of uncertain factors, in this embodiment, a correction control subroutine is connected to the control subroutine. Through the multiple iterative calculation process of the correction control subroutine, and calculating the difference between the calculated mass and the actual mass in the feeding hopper 2 within the previous several control processes. During the determination of the actual mass, when it is determined that the vibrating raw materials tend to settle and stabilize, it is weighed and calculated by the pressure sensing unit, and the result of this weighing calculation is regarded as the actual mass in the feeding hopper 2 at this time. In addition, in order to save the time of transporting and proportioning, the correction process of the correction control subroutine only runs within no more than ten control processes after the control program is started, and the preferred number of correction controls is 8 times.

[0021] In this embodiment, the PID control is also preferably adopted for the iterative calculation process. Specifically: For calculating the deviation, it can be expressed as: ; For calculating the integral term, it can be expressed as: ; For calculating the differential term, it can be expressed as: ; For calculating the control output, it can be expressed as: ; For updating the mass, it can be expressed as: ; For calculating the lead, it can be expressed as: 。

[0022] For the parameters involved in the above process: is the set quality; is the actual quality; is the initial value of the quality deviation; is the control process cycle; is the proportional control coefficient; is the integral control coefficient; is the differential control coefficient; is the sampling time; is the integral term of the previous control process cycle; is the control output of the current control process cycle; is the lead function; is the lead;

[0023] During the iterative calculation process, repeat the above steps until the correction control subroutine reaches a stable state or a predetermined number of iterations. The above iterative calculation realizes the accurate estimation and control of the quality of vibrating raw materials. By calculating the deviation, integral term, differential term, control output, updating the quality, calculating the lead, and iteratively updating, the control strategy is continuously optimized, reducing the weighing error caused by the suspended state of the raw materials. The above method improves the automation and accuracy of the batching process, reduces the error rate of manual operations, improves the efficiency and product quality of industrial raw material batching, and at the same time reduces raw material waste, with significant economic and operational benefits.

[0024] Example 3: In this example, only the parts different from Example 1 are described. Specifically, The estimation process satisfies: where, are the fluctuation coefficients of the first sensing unit, the second sensing unit, and the third sensing unit respectively; are the maximum and minimum AD values of the first sensing unit within a detection cycle respectively; are the maximum and minimum AD values of the second sensing unit within a detection cycle respectively; They are respectively the maximum and minimum AD values of the third sensing unit within a detection period; They are respectively the AD value curves of the first sensing unit, the second sensing unit and the third sensing unit; It is the quality after estimation and processing.

[0025] In the feeding control subroutine, a fuzzy self-tuning parameter PID control algorithm is used to control the speed of the motor in the feeding module 3.

[0026] For the specific control process of the feeding control subroutine: System initialization: Before the feeding control subroutine starts running, the system will perform initialization, setting the initial PID parameters (proportional coefficient Kp, integral coefficient Ki, differential coefficient Kd) and the parameters of fuzzy control (fuzzy sets, fuzzy rules, etc.); Real-time data acquisition: The running state of the feeding module 3 is collected in real time through sensors, including the current speed of the motor, the conveying quality of raw materials, etc.; Error calculation: Calculate the error between the actual speed and the set speed, as well as the change rate of the error; Fuzzy inference: Convert the error and the error change rate into fuzzy sets, and perform inference through fuzzy rules to obtain the fuzzy control quantity; PID parameter self-tuning: Dynamically adjust the PID parameters according to the fuzzy control quantity. The fuzzy self-tuning mechanism can automatically adjust the PID parameters according to the real-time response of the system and the changes in the external environment to optimize the control effect; PID control: Calculate the control output according to the adjusted PID parameters; Motor speed adjustment: Apply the calculated control output to the motor driver to adjust the speed of the motor to reduce the error and make the actual speed approach the set speed; Feedback and iteration: The system will continuously monitor the actual speed of the motor and feedback it to the control algorithm to form a closed-loop control. This process will be continuously iterated until the system reaches a stable state or a predetermined control target. By accurately controlling the motor speed, it can ensure that the raw materials are accurately proportioned according to the predetermined ratio, improving the product quality; in addition, optimizing the motor speed control can reduce unnecessary energy consumption and lower the production cost.

[0027] Embodiment 4: In this embodiment, only the parts different from Embodiment 1 are described. Specifically, Such as attached Figure 2As shown in the figure, a device for weighing and metering industrial raw materials during batching includes a feed bin 1. A feeding hopper 2 is arranged below the feed bin 1. A feeding module 3 is arranged on the side of the feeding hopper 2. A conveying module 4 is arranged below the feeding hopper 2. A pressure sensing unit, a first sensing unit, a second sensing unit and a third sensing unit are all arranged on the feeding hopper 2.

[0028] The pressure sensing unit is collinear with the central axis of the feeding hopper 2.

[0029] The first sensing unit, the second sensing unit and the third sensing unit are symmetrically arranged outside the pressure sensing unit; or the first sensing unit, the second sensing unit, the third sensing unit and the pressure sensing unit are all arranged on the feeding hopper 2 and are arranged in a circumferential integral array with the central axis of the feeding hopper 2 as the reference.

[0030] The feeding module 3 includes a vibrator.

[0031] Due to the vibration generated by the feeding hopper 2 during operation, the sensor readings are unstable, and this jumping phenomenon exacerbates the inaccuracy of metering; secondly, the existing pressure sensors cannot measure the raw materials in the suspended state, resulting in a lag in the weighing and control processes of the metering device; finally, the uneven distribution of the raw materials during the conveying process affects the quality and consistency of the final product. These problems together lead to low efficiency and increased costs in the industrial raw material batching process.

[0032] To solve the above technical problems, the following technical means are adopted in this embodiment: The device integrates a pressure sensing unit, a first sensing unit, a second sensing unit, and a third sensing unit on the feeding hopper 2. The layout of these sensors is carefully designed to achieve comprehensive monitoring of the raw material state in the feeding hopper 2. The pressure sensing unit is arranged collinearly with the central axis of the feeding hopper 2 to directly measure the pressure of the raw material on the bottom of the feeding hopper 2, thereby obtaining the mass of the raw material. The other three sensing units are symmetrically arranged outside the pressure sensing unit or are arranged in a circumferential array with the central axis of the feeding hopper 2 as the reference to monitor the fluctuations and distribution of the raw material. The feeding module 3 includes a vibrator, and this design helps to reduce the air retention time and volume of the raw material during the feeding process, thereby reducing the measurement error caused by vibration. The vibrator can control the feeding speed by adjusting the vibration frequency and vibration amplitude to adapt to different batching requirements. The device integrates an intelligent control program, which can dynamically adjust the working state of the feeding module 3 according to the real-time data fed back by the sensors to achieve accurate weighing and metering. The data fusion technology adopted by the device comprehensively processes the data of multiple sensors to improve the accuracy and reliability of the measurement results. The adaptive control algorithm adopted by the device, such as the fuzzy self-tuning parameter PID control algorithm, dynamically adjusts the operating parameters of the feeding module 3 to ensure that the raw material is accurately batched according to the predetermined ratio.

[0033] The specific embodiments described above further elaborate on the purpose, technical solutions, and beneficial effects of the present invention. It should be understood that the above description is only the specific embodiments of the present invention and is not used to limit the protection scope of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included in the protection scope of the present invention.

Claims

1. A control program for weighing and metering during the batching of industrial raw materials, including a host computer and a control subroutine connected by signals, characterized in that: The control subroutine includes the following components connected by signals: An interactive control subroutine for realizing signal interaction with the host computer; A feeding control subroutine for switching the feeding mode of the feeding module (3). The feeding mode includes a first mode and a second mode. Among them, the feeding speed in the first mode is greater than that in the second mode; A quality estimation subroutine for estimating the conveying quality of the raw materials in the feeding hopper (2) in the second mode; A compensation control subroutine for calculating the advance amount of the shutdown of the feeding module (3) according to the conveying quality of the raw materials and controlling the closing of the feeding module (3) through the advance amount; The control subroutine is also connected to a sensing module by signals. The sensing module includes a first sensing unit, a second sensing unit, and a third sensing unit connected by signals. The first sensing unit, the second sensing unit, and the third sensing unit are all arranged at different positions on the feeding hopper (2); The quality estimation process is as follows: within a detection cycle, the fluctuating quality of the raw materials in the feeding hopper (2) in the second mode is collected through the first sensing unit, the second sensing unit, and the third sensing unit, and then the fluctuating quality is estimated and processed with the AD value and the AD value curve to obtain the raw material quality.

2. The control program for weighing and metering during the batching of industrial raw materials according to claim 1, wherein: The sensing module also includes a pressure sensing unit for real-time measurement of the raw material quality in the feeding hopper (2); A set quality is set through the interactive control subroutine; The control subroutine also includes: A correction control subroutine, which is connected to the compensation control subroutine by signals, and a threshold value of the fluctuating quality is set through the interactive control subroutine. When the fluctuating quality is lower than the threshold value, the actual quality in the feeding hopper (2) is determined through the pressure sensing unit. The correction control subroutine corrects the quality of the next control process through the actual quality and the set quality, and iteratively calculates the advance amount of the next control process.

3. A control program for weighing and metering during the batching of industrial raw materials according to claim 1, characterized in that: The estimation and processing process satisfies: ； Among them, are the fluctuation coefficients of the first sensing unit, the second sensing unit, and the third sensing unit, respectively; They are respectively the maximum and minimum AD values of the first sensing unit within a detection period; They are respectively the maximum and minimum AD values of the second sensing unit within a detection cycle; They are respectively the maximum and minimum AD values of the third sensing unit within a detection cycle; AD value curves of the first sensing unit, the second sensing unit, and the third sensing unit respectively; To estimate the quality after processing.

4. A control program for weighing and metering during industrial raw material batching according to claim 2, characterized in that: In the feeding control subroutine, a fuzzy self-tuning parameter PID control algorithm is used to control the speed of the motor in the feeding module (3).

5. A control program for weighing and metering during the batching of industrial raw materials according to claim 2, characterized in that: The iterative calculation process is: calculating the deviation, calculating the integral term, calculating the differential term, calculating the control output, updating the quality, calculating the advance amount, and iteratively updating.

6. A control program for weighing and metering during the batching of industrial raw materials according to claim 2, characterized in that: The correction control subroutine only runs within no more than ten control processes after the control program is started and run.

7. An apparatus for weighing and metering during the batching of industrial raw materials, comprising a feed bin (1), wherein a feed hopper (2) is arranged below the feed bin (1), and is characterized in that: Based on the control program for weighing and metering during industrial raw material batching described in claim 2, the feeding module (3) is arranged on the side of the feeding hopper (2), a conveying module (4) is arranged below the feeding hopper (2), and the pressure sensing unit, the first sensing unit, the second sensing unit, and the third sensing unit are all arranged on the feeding hopper (2).

8. An apparatus for weighing and metering during the batching of industrial raw materials according to claim 7, characterized in that: The pressure sensing unit is collinear with the central axis of the feeding hopper (2).

9. An apparatus for weighing and metering during the batching of industrial raw materials according to claim 7, characterized in that: The first sensing unit, the second sensing unit, and the third sensing unit are symmetrically arranged outside the pressure sensing unit; or the first sensing unit, the second sensing unit, the third sensing unit, and the pressure sensing unit are all arranged on the feeding hopper (2) and are arranged in a circumferential integral array with the central axis of the feeding hopper (2) as the reference.

10. An apparatus for weighing and metering during industrial raw material batching, as claimed in claim 8 or 9, characterized in that: The feeding module (3) includes a vibrator.

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