Equipment and control program products for weighing and metering of industrial raw materials

Abstract

The present invention relates to the field of control and regulation technology, and specifically refers to a device and a control program product for weighing and metering industrial raw materials during batching, including a control subroutine connected to a host computer signal, the control subroutine including: an interactive control subroutine, a feeding control subroutine, a mass estimation subroutine, and a compensation control subroutine connected by signals, the control subroutine also being signal-connected to a sensing module, the sensing module including 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 being all arranged at different positions on a feeding hopper; the present invention realizes the detection of the conveying quality of vibrating raw materials through multiple groups of sensing units, and can obtain the mass of the vibrating raw materials detected between the sensing units in combination with the corresponding fluctuation coefficient, thereby solving the problem in the prior art that dynamic particle material flow cannot be accurately measured.

Description

Technical Field

[0001] The present invention relates to the field of control and regulation technology, in particular to a device and a control program for weighing and metering industrial raw materials during batching. Background Art

[0002] In industries such as plastic molding and food and pharmaceutical production, precise raw material proportioning is crucial for ensuring product quality. However, current processes for metering granular industrial raw materials suffer from a significant problem: vibration in the feed hopper causes unstable and fluctuating measurement values. This issue directly impacts both batching accuracy and efficiency.

[0003] Specifically, the traditional method of manually controlling the raw material injection volume often leads to deviations from the preset ratio due to operator errors. In such cases, manual refilling is required to achieve the preset ratio, which is not only inefficient but also increases production costs.

[0004] In actual batching processes, pressure sensors are typically used to measure the weight of raw materials within the discharge hopper. However, these sensors cannot measure empty raw materials, resulting in hysteresis in the weighing and control processes of the metering equipment. This hysteresis can cause the actual raw material ratio to exceed the preset value, negatively impacting the accuracy of industrial production.

[0005] The vibration generated by the hopper during operation causes the sensor readings to be unstable. This jumping phenomenon further aggravates the inaccuracy of measurement. The vibration not only affects the sensor's real-time monitoring of the raw material weight, but may also cause uneven distribution of the raw materials during the transportation process, thereby affecting the quality and consistency of the final product.

[0006] Therefore, there is an urgent need for a device and a control program for weighing and metering when mixing industrial raw materials, so as to control the conveying process of industrial raw materials and accurately measure the metering process. Summary of the Invention

[0007] The present invention aims to provide a control program for weighing and metering industrial raw materials during batching, which is used to control the transportation process of industrial raw materials. It also aims to provide a device for weighing and metering industrial raw materials during batching, which improves the accuracy of batching by measuring and processing the outputs of multiple sensor units.

[0008] The present invention is achieved through the following technical solutions:

[0009] A control program for weighing and metering industrial raw materials during batching, comprising a host computer and a control subroutine connected by signals, wherein the control subroutine comprises: 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, wherein the feeding mode comprises a first mode and a second mode, wherein the feeding speed of the first mode is greater than the feeding speed of the second mode; a mass estimation subroutine for estimating the conveying mass of the raw materials in the feeding hopper under the second mode; and a compensation control subroutine for calculating the stopping speed of the feeding module according to the conveying mass of the raw materials. The advance amount is used to control the feeding module to be closed; the control subroutine is also signal-connected with a sensing module, and the sensing module includes a first sensing unit, a second sensing unit and a third sensing unit that are signal-connected, and the first sensing unit, the second sensing unit and the third sensing unit are all arranged at different positions on the feeding hopper; the quality estimation process is: within one detection cycle, the first sensing unit, the second sensing unit and the third sensing unit are used to collect the fluctuating quality of the raw material in the feeding hopper under the second mode, and then the fluctuating quality is estimated and processed with the AD value and the AD value curve to obtain the quality of the raw material.

[0010] A device for weighing and metering industrial raw materials during batching, comprising a feeding bin, a feeding hopper arranged below the feeding bin, a feeding module arranged on the side of the feeding hopper, a conveying module arranged below the feeding hopper, and a pressure sensing unit, a first sensing unit, a second sensing unit and a third sensing unit all arranged on the feeding hopper.

[0011] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0012] 1. The present invention integrates a correction control subroutine into the control subroutine, and through multiple iterative calculation processes of the correction control subroutine, calculates the difference between the calculated mass and the actual mass in the feeding hopper in the previous control processes. In the process of determining the actual mass, when it is determined that the vibrated raw material tends to settle steadily, it is weighed and calculated by the pressure sensing unit, and the result of the weighing calculation is regarded as the actual mass in the feeding hopper at this time;

[0013] 2. The present invention uses multiple sets of sensing units to detect the conveying quality of the vibrating raw material. Combined with the corresponding fluctuation coefficient, the quality of the vibrating raw material detected between the sensing units can be obtained, solving the problem of the inability to accurately measure the dynamic particle flow in the prior art.

[0014] 3. The present invention integrates a pressure sensor unit, a first sensor unit, a second sensor unit, and a third sensor unit into the hopper. These sensors are meticulously designed to comprehensively monitor the state of the raw materials within the hopper. The pressure sensor unit is collinear with the central axis of the hopper to directly measure the pressure exerted by the raw materials on the bottom of the hopper, thereby providing information on the raw material's quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The drawings described herein are used to provide a further understanding of the embodiments of the present invention, constitute a part of the present invention, and do not constitute a limitation of the embodiments of the present invention. In the drawings:

[0016] Figure 1 is a schematic diagram of the control program;

[0017] Figure 2 A schematic diagram of the structure of a control program application device according to the present invention;

[0018] Markings and corresponding parts names in the accompanying drawings:

[0019] 1-feeding bin, 2-feeding hopper, 3-feeding module, 4-conveying module. DETAILED DESCRIPTION

[0020] To make the objectives, technical solutions, and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the examples and accompanying drawings. The exemplary embodiments of the present invention and their descriptions are only used to explain the present invention and are not intended to limit the present invention. It should be noted that the present invention is already in the actual development and use stage.

[0021] In order to make the technical solution of the present invention clearer, the professional terms involved in the present invention are explained here;

[0022] In the present invention, the term "host computer" refers to a computer system that communicates with the slave computer program and is responsible for monitoring, managing and controlling the work of the slave computer, preferably including a PLC, an industrial computer and necessary control equipment, specifically the commercially available IPC610 series;

[0023] 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 rapper, the feeding speed is affected by the rapping frequency and rapping amplitude of the rapper;

[0024] In the present invention, the term "advance amount" refers to the advance time of the feeding module shutdown calculated according to the quality in the control program, and is used to control the feeding module to shut down in advance before the predetermined quality is reached to ensure accurate batching;

[0025] In the present invention, the term "AD value" refers to the value of an analog signal 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.

[0026] In the present invention, the term "AD value curve" refers to a graph showing the change of AD value over time within a certain period of time or a detection period;

[0027] In the present invention, the term "pressure sensing unit" refers to a sensor that obtains mass by measuring pressure, preferably a pressure sensor;

[0028] In the present invention, the term "set mass" refers to the theoretical mass required when batching industrial raw materials and is set by the interactive control subroutine;

[0029] In the present invention, the term "delivery mass" refers to the mass of the raw material measured by the sensing module, which can be equivalent to the actual mass in a completely stationary state;

[0030] In the present invention, the term "fluctuation coefficient" is used to describe the relationship between the AD value output by the sensor module and the pressure (mass) actually applied to the sensor.

[0031] Example 1:

[0032] As attached Figure 1 As shown, a control program for weighing and metering industrial raw materials during batching includes a host computer and a control subroutine connected by signals, wherein the control subroutine includes:

[0033] Interactive control subroutine, used to realize signal interaction with the host computer;

[0034] A feeding control subroutine is used to switch the feeding mode of the feeding module, the feeding mode includes a first mode and a second mode, wherein the feeding speed of the first mode is greater than the feeding speed of the second mode;

[0035] The quality estimation subroutine is used to estimate the conveying quality of the raw materials in the feeding hopper under the second mode; the compensation control subroutine is used to calculate the advance amount of shutdown of the feeding module according to the conveying quality of the raw materials, and control the shutdown of the feeding module through the advance amount; the control subroutine is also signal-connected to a sensor module, and the sensor module includes a first sensor unit, a second sensor unit and a third sensor unit that are signal-connected, and the first sensor unit, the second sensor unit and the third sensor unit are all arranged at different positions on the feeding hopper; the quality estimation process is: within one detection cycle, the first sensor unit, the second sensor unit and the third sensor unit are used to collect the fluctuating quality of the raw materials in the feeding hopper under the second mode, and then the fluctuating quality is estimated and processed with the AD value and the AD value curve to obtain the quality of the raw materials.

[0036] It should be noted that the vibration generated by the hopper during operation causes unstable sensor readings. This jitter further exacerbates measurement inaccuracies. Vibration not only affects the sensor's real-time monitoring of raw material weight but can also lead to uneven distribution of raw materials during transportation, thus affecting the quality and consistency of the final product. Furthermore, existing pressure sensors are often used in groups, and their different placement can also affect the final measurement results. Therefore, it is necessary to comprehensively process the data from multiple pressure sensor groups to obtain more reliable measurement results.

[0037] To address the above-mentioned issues, the applicant has proposed a control program for weighing and metering industrial raw material batching. This program comprises a host computer and a control subroutine, each 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 in tandem to achieve precise control and metering of the industrial raw material batching process. Specifically, the interactive control subroutine is used to implement signal interaction with the host computer; the feeding control subroutine is used to switch the feeding mode of the feeding module, including a first mode (fast feeding) and a second mode (slow feeding); the mass estimation subroutine is used to estimate the mass of the raw material conveyed within the hopper in the second mode; and the compensation control subroutine calculates the lead time for shutting down the feeding module based on the conveyed mass of the raw material and controls the shutting down of the feeding module based on the lead time. Furthermore, the control subroutine is signal-connected to a sensor module, comprising a first sensor unit, a second sensor unit, and a third sensor unit. These sensor units are located at different locations on the hopper and are used to collect the fluctuating mass of the raw material within the hopper in the second mode and estimate the raw material mass by comparing it with the AD value and the AD value curve. By controlling the feeding speeds of the feeding module through a control program, the volume of suspended raw materials can be reduced, improving the accuracy of the industrial raw material delivery and batching process. During the initial stage of raw material delivery, a first mode with a faster feeding speed is used. After the raw materials have been delivered to two-thirds of the set mass, the feeding module is controlled to switch to a second mode with a slower feeding speed. This reduces the volume of industrial raw materials in a suspended state. Secondly, the conveying mass of the vibrating raw materials is detected by multiple sets of sensing units. Combined with the corresponding fluctuation coefficient, the mass of the vibrating raw materials detected between the sensing units can be obtained, solving the problem of the inability to accurately measure dynamic particle flow in the prior art. Finally, by modifying the multiple iterative calculation process of the control subroutine and calculating the difference between the calculated mass and the actual mass in the feeding hopper during the previous control steps, the uncertainty in the metering process is reduced, further improving the estimation accuracy. These technical effects not only improve the automation and accuracy of batching, reduce the error rate of manual operation, but also improve the efficiency and product quality of industrial raw material batching, while also reducing raw material waste, with significant economic and operational benefits.

[0038] Example 2:

[0039] This embodiment only describes the parts that are different from Example 1. Specifically, the sensing module also includes a pressure sensing unit, which is used to measure the quality of raw materials in the feeding hopper in real time; 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 signal, and a threshold value of the fluctuating quality is set through the interactive control subroutine. When the fluctuating quality is lower than the threshold, the actual quality in the feeding hopper is determined by the pressure sensing unit, and the correction control subroutine corrects the quality of the next control process by the actual quality and the set quality, and iteratively calculates the advance amount of the next control process.

[0040] The iterative calculation process is: calculating deviation, calculating integral term, calculating differential term, calculating control output, updating quality, calculating lead time and iterative update.

[0041] The correction control subroutine is only executed within a control process that is no more than ten times executed after the control program is started.

[0042] It should be noted that the correction control subroutine is only run in the control process that is no more than ten times after the control program is started. In the process of conveying raw materials in the feeding bin and the hopper, since the mass of the vibrating raw materials in the hopper is not directly weighed, but calculated through indirect data, 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, and the correction control subroutine is used to perform multiple iterative calculation processes, and the difference between the calculated mass and the actual mass in the hopper in the previous control processes is calculated. In the process of determining the actual mass, when it is determined that the vibrating raw materials tend to settle and stabilize, the weight is calculated by the pressure sensing unit, and the result of the weighing calculation is regarded as the actual mass in the hopper at this time. In addition, in order to save the time of conveying ingredients, the correction process of the correction control subroutine is only run in the control process that is no more than ten times after the control program is started, and the preferred number of correction controls is 8 times.

[0043] In this embodiment, PID control is also preferably used for the iterative calculation process, specifically:

[0044] For calculating the deviation, it can be expressed as: ;

[0045] The calculation of the integral term can be expressed as: ;

[0046] The calculation of the differential term can be expressed as: ;

[0047] The control output can be expressed as: ;

[0048] The update quality can be expressed as: ;

[0049] The calculation advance can be expressed as: .

[0050] For the parameters involved in the above process:

[0051] To set quality;

[0052] is the actual mass;

[0053] is the initial value of mass deviation;

[0054] To control the process cycle;

[0055] is the proportional control coefficient;

[0056] is the integral control coefficient;

[0057] is the differential control coefficient;

[0058] is the sampling time;

[0059] is the integral term of the previous control process cycle;

[0060] It is the control output of the current control process cycle;

[0061] is the advance function;

[0062] For advance amount.

[0063] During the iterative calculation process, the above steps are repeated until the correction control subroutine reaches a stable state or a predetermined number of iterations. The above iterative calculation achieves accurate estimation and control of the mass of the vibrating raw materials. By calculating the deviation, integral term, differential term, control output, updating the mass, calculating the lead time, and iterative updates, 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 operation, improves the efficiency of industrial raw material batching and product quality, and reduces raw material waste, with significant economic and operational benefits.

[0064] Example 3:

[0065] This embodiment only describes the parts that are different from the embodiment 1. Specifically,

[0066] The estimation process satisfies:

[0067]

[0068] in, are the fluctuation coefficients of the first sensing unit, the second sensing unit, and the third sensing unit respectively;

[0069] are respectively the maximum and minimum AD values ​​of the first sensing unit in a detection cycle;

[0070] are respectively the maximum and minimum AD values ​​of the second sensing unit in one detection cycle;

[0071] are the maximum and minimum AD values ​​of the third sensing unit in a detection cycle respectively;

[0072] AD value curves of the first sensor unit, the second sensor unit, and the third sensor unit respectively;

[0073] To estimate the quality after processing.

[0074] 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.

[0075] For the specific control process of the feeding control subroutine:

[0076] System initialization: Before the feeding control subroutine starts running, the system will be initialized to set the initial PID parameters (proportional coefficient Kp, integral coefficient Ki, differential coefficient Kd) and fuzzy control parameters (fuzzy sets, fuzzy rules, etc.);

[0077] Real-time data collection: The sensor collects the running status of the feeding module in real time, including the current speed of the motor, the conveying quality of the raw materials, etc.

[0078] Error calculation: calculate the error between the actual speed and the set speed, as well as the rate of change of the error;

[0079] Fuzzy reasoning: convert the error and error change rate into fuzzy sets, and perform reasoning through fuzzy rules to obtain the fuzzy control quantity;

[0080] PID parameter self-tuning: Dynamically adjust PID parameters according to the fuzzy control quantity. The fuzzy self-tuning mechanism can automatically adjust PID parameters according to the real-time response of the system and changes in the external environment to optimize the control effect.

[0081] PID control: Calculate the control output based on the adjusted PID parameters;

[0082] Motor speed adjustment: Apply the calculated control output to the motor driver to adjust the motor speed to reduce the error and make the actual speed close to the set speed;

[0083] Feedback and Iteration: The system continuously monitors the actual motor speed and feeds it back into the control algorithm, forming a closed-loop control process. This process iterates until the system reaches a stable state or achieves the desired control target. Precisely controlling motor speed ensures that raw materials are accurately proportioned according to the desired ratio, improving product quality. Furthermore, optimizing motor speed control reduces unnecessary energy consumption and lowers production costs.

[0084] Example 4:

[0085] This embodiment only describes the parts that are different from the embodiment 1. Specifically,

[0086] As attached Figure 2 As shown, a device for weighing and metering industrial raw materials comprises 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.

[0087] The pressure sensing unit is collinear with a central axis of the feeding hopper.

[0088] The first sensing unit, the second sensing unit and the third sensing unit are symmetrically arranged on the outside of 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 and distributed in a circular array based on the central axis of the feeding hopper.

[0089] The feeding module includes a rapper.

[0090] The vibrations generated by the hopper during operation cause unstable sensor readings, exacerbating metering inaccuracies. Furthermore, existing pressure sensors are unable to measure materials that are suspended in the air, resulting in lags in the weighing and control processes of the metering equipment. Finally, the uneven distribution of raw materials during transportation affects the quality and consistency of the final product. These issues collectively lead to inefficiencies and increased costs in the industrial raw material batching process.

[0091] In order to solve the above technical problems, the following technical means are adopted in this implementation:

[0092] The equipment integrates a pressure sensor unit, a primary sensor unit, a secondary sensor unit, and a tertiary sensor unit within the hopper. These sensors are meticulously designed to comprehensively monitor the state of the raw materials within the hopper. The pressure sensor unit is collinear with the hopper's central axis to directly measure the pressure exerted by the raw materials on the hopper bottom, thereby providing information on the raw material's quality. The other three sensor units are symmetrically positioned around the pressure sensor unit or arranged in a circular pattern around the hopper's central axis to monitor raw material fluctuations and distribution. The feeding module includes a vibrator, a design that helps reduce the air time and volume of raw materials during feeding, thereby minimizing metering errors caused by vibration. The vibrator controls the feeding speed by adjusting the vibration frequency and amplitude to accommodate varying batching requirements. The equipment incorporates an intelligent control program that dynamically adjusts the operating state of the feeding module based on real-time sensor feedback, ensuring precise weighing and metering. The equipment utilizes data fusion technology to integrate data from multiple sensors to improve the accuracy and reliability of metering results. The equipment adopts adaptive control algorithms, such as fuzzy self-tuning parameter PID control algorithm, to dynamically adjust the operating parameters of the feeding module to ensure that the raw materials are accurately dosed according to the predetermined ratio.

[0093] The specific implementation methods described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific implementation method of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A control program product for weighing and metering industrial raw materials during batching, comprising a control subroutine connected to a host computer signal, characterized in that: The control subroutine includes signal connections: Interactive control subroutine, used to realize signal interaction with the host computer; A feeding control subroutine is used to switch the feeding mode of the feeding module, the feeding mode includes a first mode and a second mode, wherein the feeding speed of the first mode is greater than the feeding speed of the second mode; the feeding module is arranged on the side of the feeding hopper; a mass estimation subroutine for estimating the conveying mass of the raw material in the feeding hopper in the second mode; The compensation control subroutine is used to calculate the advance amount of the feeding module shutdown according to the conveying quality of the raw materials, and control the feeding module shutdown according to the advance amount; The control subroutine is further signal-connected to a sensor module, the sensor module including a first sensor unit, a second sensor unit, and a third sensor unit that are signal-connected, the first sensor unit, the second sensor unit, and the third sensor unit being arranged at different positions on the feeding hopper; The estimation process of the quality estimation subroutine is as follows: within one detection cycle, the first sensor unit, the second sensor unit and the third sensor unit collect the fluctuating mass, AD value and AD value curve of the raw material in the feeding hopper under the second mode, and then the fluctuating mass, AD value and AD value curve are estimated and processed to obtain the conveying quality of the raw material.

2. A control program product for weighing and metering industrial raw materials according to claim 1, characterized in that: The sensing module further comprises a pressure sensing unit, which is used to measure the quality of the raw materials in the feeding hopper in real time; A set quality is set by the interactive control subroutine; The control subroutine also includes: The correction control subroutine is connected to the compensation control subroutine signal, and a threshold value of the fluctuating mass is set through the interactive control subroutine. When the fluctuating mass is lower than the threshold value, the actual mass in the feeding hopper is determined by the pressure sensing unit. The correction control subroutine corrects the mass of the next control process by the actual mass and the set mass, and iteratively calculates the advance amount of the next control process.

3. A control program product for weighing and metering industrial raw materials according to claim 1, characterized in that: The estimation process satisfies: in, are the fluctuation coefficients of the first sensing unit, the second sensing unit, and the third sensing unit respectively; are respectively the maximum and minimum AD values ​​of the first sensing unit in a detection cycle; are respectively the maximum and minimum AD values ​​of the second sensing unit in one detection cycle; are the maximum and minimum AD values ​​of the third sensing unit in a detection cycle respectively; AD value curves of the first sensor unit, the second sensor unit, and the third sensor unit respectively; To estimate the delivery quality of processed raw materials.

4. A control program product for weighing and metering industrial raw materials 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.

5. A control program product for weighing and metering industrial raw materials according to claim 2, characterized in that: The iterative calculation process is: calculating deviation, calculating integral term, calculating differential term, calculating control output, updating quality, calculating lead time and iterative update.

6. A control program product for weighing and metering industrial raw materials according to claim 2, characterized in that: The correction control subroutine is only executed within a control process that is no more than ten times executed after the control program is started.

7. A device for weighing and metering industrial raw materials during batching, comprising a feed bin, wherein the feed hopper is arranged below the feed bin, and wherein: Based on the control program product for weighing and metering industrial raw materials when batching according to claim 2, the feeding module is arranged on the side of the feeding hopper, and a conveying module is arranged below the feeding hopper. The pressure sensing unit, the first sensing unit, the second sensing unit and the third sensing unit are all arranged on the feeding hopper; the pressure sensing unit is collinear with the central axis of the feeding hopper.

8. The device for weighing and metering 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 on the outside of the pressure sensing unit; or the first sensing unit, the second sensing unit and the third sensing unit are distributed in a circular array with the central axis of the feeding hopper as a reference.

9. The device for weighing and metering industrial raw materials according to claim 8, characterized in that: The feeding module includes a rapper.

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