Intelligent monitoring system for high-strength pellet production

Abstract

The application belongs to the technical field of balling regulation of high-strength pellet production, and discloses an intelligent monitoring system for high-strength pellet production, which comprises a balling image acquisition module, a balling stage identification module, a balling disc rotating speed regulation module, a balling disc angle regulation module and a parameter dynamic regulation module. The application identifies whether the balling stage of the target pellet production process is in the nucleation period, the growth period or the whole grain period based on the main body proportion, avoids fuzzy stage identification, can perform corresponding parameter control according to different stages, improves the pellet quality stability, and enhances the adaptability of the system. The application dynamically constructs the balling disc rotating speed regulation target value and the balling disc angle regulation target value, and then performs relevant parameter regulation, can accurately match the production demand, improves the production efficiency, reduces the cost, and reduces the waste products and equipment loss.

Description

Technical Field

[0001] This invention belongs to the field of high-strength pellet production pelleting control technology, and relates to an intelligent monitoring system for high-strength pellet production. Background Technology

[0002] High-strength pellets are an iron-containing raw material with important application value in the metallurgical industry. The production process of high-strength pellets refers to the process of making iron-containing raw materials such as iron concentrate into spherical materials with a certain particle size, shape and high strength through specific processes. It generally includes raw material preparation, batching, mixing, pelletizing, drying and roasting.

[0003] In the high-strength pellet production process, the pelletizing stage is a critical link, directly affecting the initial strength of green pellets. An efficient pelletizing process can increase green pellet yield. Among these components, the pelletizing disc is a key piece of equipment used in the pelletizing process to form powdered materials into spherical particles. It is widely used in industries such as metallurgy and mineral processing, playing a decisive role in pellet quality and production efficiency. Reasonable setting of pelletizing disc parameters can optimize the pelletizing process, ensuring stable pellet quality, improving production efficiency, and reducing equipment wear. Therefore, research on parameter monitoring and control in the pelletizing stage of high-strength pellet production is of great significance.

[0004] Existing technologies also include technical solutions for monitoring and controlling parameters in the pelletizing process. For example, Chinese invention patent application CN105087910A discloses a pelletizing control method and device, which includes obtaining the flow rate of qualified green pellets WI1 and the flow rate of unqualified green pellets WI2; calculating the pelletizing rate rb based on WI1 and WI2; and adjusting the given disk water spraying volume FI_Water, the given disk rotation speed SI_TURN, and the given disk tilt angle SI_ANGLE according to a preset strategy based on the pelletizing rate rb.

[0005] Another Chinese invention patent application, CN119287155A, discloses a method for improving the pelletizing performance of laboratory vanadium-titanium pellets. This method involves pelletizing using a commonly used laboratory pelletizing disc and sieve to screen out mother pellets with a particle size of 10–12.5 mm as qualified vanadium-titanium pellets. The pellets obtained by this method are uniform in size, and their raw and cooked compressive strength, drop strength, and yield are all superior to conventional pelletizing methods. This ensures that the pellet performance fully meets the requirements of experimental research and allows for accurate control of the experimental objectives.

[0006] While the two schemes mentioned above offer some solutions for monitoring and controlling parameters in the pelletizing process, they still have certain limitations. For example, the scheme one, which adjusts the water spray volume, rotation speed, and tilt angle of the given disc according to a preset strategy, can improve the quality of the pelletizing stage to some extent. However, its dynamic adjustment process has low adaptability and cannot accurately analyze and control the relevant parameters of the actual pelletizing process, thus reducing the production efficiency and quality of the raw pellets.

[0007] Option 2, which involves multiple screenings to obtain qualified green pellets, ensures that the resulting green pellets have a particle size and related process parameters close to the required quality. However, this approach sacrifices the continuity of the production process, requires multiple screenings and analyses, lacks adaptive pelletizing stage analysis, and reduces pelletizing efficiency. Summary of the Invention

[0008] In view of this, in order to solve the problems of mismatch in dynamic parameter control and low pelleting efficiency mentioned in the background technology, an intelligent monitoring system for high-strength pellet production is proposed.

[0009] The objective of this invention can be achieved through the following technical solution: an intelligent monitoring system for high-strength pellet production, comprising: a pellet image acquisition module, used to acquire time-series images of each production process of the target pellet in real time using an image acquisition device based on a preset acquisition frequency.

[0010] The pelletizing stage identification module is used to extract scale features based on the time-series images of the production process to obtain the main body proportion of the green pellet diameter, and then identify the pelletizing stage of the target pellet production process and obtain the appropriate rotation speed and appropriate angle of the pelletizing disc. The pelletizing stage includes the nucleation stage, the growth stage and the pelletizing stage.

[0011] The pelletizing disc speed control module is used to process the production time sequence image to generate information on the appearance defects of green pellets and the degree of deviation of the waterfall area shape. At the same time, it uses online pressure monitoring equipment to obtain the degree of deviation of green pellet compressive strength, and combines these with the appropriate speed of the pelletizing disc to construct the target value for pelletizing disc speed control.

[0012] The pelletizing disc angle control module is used to analyze the centrifugal motion vector of green pellets in the time-series image of the production process using optical flow method, assess the degree of deviation of the centrifugal ejection direction of green pellets, and combine it with the appropriate angle of the pelletizing disc to construct the target value for pelletizing disc angle control.

[0013] The parameter dynamic control module is used to control the relevant parameters of the target turntable according to the target values ​​of the ball-forming disc rotation speed and the ball-forming disc angle.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention identifies whether the pelleting stage of the target pellet production process is in the nucleation stage, growth stage or pelletizing stage based on the main body proportion of the green pellet diameter, avoids stage identification ambiguity, and can perform corresponding parameter control for different stages, improve the quality stability of the pellets, and enhance the adaptability of the system.

[0015] (2) This invention dynamically constructs target values ​​for the rotation speed and angle of the pelletizing disc, and then adjusts the relevant parameters to accurately match production needs, improve production efficiency, reduce costs, and reduce waste and equipment wear.

[0016] (3) By analyzing the appearance defects of green pellets, the degree of deviation of the shape of the waterfall area and the degree of deviation of the compressive strength of green pellets, this invention can comprehensively identify the needs for adjusting the speed of the pelletizing disc, accurately locate production problems, and adjust the speed in a timely manner for different problems, thus ensuring the efficient and stable production of pellets.

[0017] (4) By assessing the degree of deviation of the centrifugal throwing direction of green pellets, the present invention identifies the need for adjusting the angle of the pelletizing tray, thereby avoiding problems such as scattering and collision breakage of green pellets caused by deviation of the throwing direction, ensuring the integrity and quality of the pellets, and also making the material distribution in the pelletizing tray more uniform and improving the pelletizing efficiency. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram showing the connections of the various modules in the system of the present invention.

[0020] Figure 2 A schematic diagram of the ball-forming plate angle corresponding to an embodiment is provided.

[0021] Figure 3 A schematic diagram of the ball-forming stage sequence is provided for an embodiment.

[0022] Attached diagram labels: 1 – ball-forming plate, 2 – angle of ball-forming plate. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1 As shown, the present invention provides an intelligent monitoring system for high-strength pellet production, including a pelleting image acquisition module, a pelleting stage identification module, a pelletizing disc rotation speed control module, a pelletizing disc angle control module, and a parameter dynamic control module. The pelleting image acquisition module is connected to the pelleting stage identification module, the pelleting stage identification module is connected to both the pelletizing disc rotation speed control module and the pelletizing disc angle control module, and both the pelletizing disc rotation speed control module and the pelletizing disc angle control module are connected to the parameter dynamic control module.

[0025] The pellet image acquisition module is used to acquire time-series images of each production process of the target pellet in real time using an image acquisition device based on a preset acquisition frequency.

[0026] It should be explained that the core task of the above module is to perform full-process visual monitoring of the green pellet production process within the pelletizing tray using an image acquisition device (such as an industrial camera). The acquired image sequences (time-series images) are used for subsequent analysis of key parameters such as the particle size distribution, surface defects, and movement trajectory of the green pellets.

[0027] The pelletizing stage identification module is used to extract scale features based on the time-series images of the production process to obtain the main body proportion of the green pellet diameter, and then identify the pelletizing stage of the target pellet production process and obtain the appropriate rotation speed and appropriate angle of the pelletizing disc. The pelletizing stage includes the nucleation stage, the growth stage and the pelletizing stage.

[0028] In a preferred embodiment of the present invention, the specific analysis method for the proportion of green pellet diameter of the main body is as follows: extract the time sequence images of each production process of the target pellet, use image processing software to obtain the diameter of each green pellet in the time sequence image of each production process, match the diameter of each green pellet with the pre-set green pellet diameter-forming stage correspondence to obtain the forming stage of each green pellet, and count the number of green pellets corresponding to each forming stage.

[0029] In one embodiment, please refer to Figure 3 As shown, the relationship between the green bulb diameter and the bulb formation stage is as follows: nucleation stage (green bulb diameter < 3 mm), growth stage (3 mm ≤ green bulb diameter ≤ 10 mm), and pelleting stage (green bulb diameter > 10 mm).

[0030] The number of green balls in each ball-forming stage is compared. The total number of green balls in other ball-forming stages besides the maximum number of green balls is summed to obtain the non-maximum number of green balls. The maximum number of green balls is compared with the total number of non-maximum green balls. If the maximum number of green balls is greater than or equal to the total number of non-maximum green balls, the average diameter of each green ball in the ball-forming stage corresponding to the maximum number of green balls is calculated to obtain the proportion of green ball diameter of the main body in each production process time sequence image.

[0031] If the maximum number of green balls is less than the total number of non-maximum green balls, then the average diameter of the green balls in each ball-forming stage is used to calculate the proportion of the green ball diameter in the main body of each production process time sequence image.

[0032] The average proportion of the green pellet diameter to the main body of the target pellet production process is calculated by taking the average proportion of the green pellet diameter to the main body of the time sequence images of each production process.

[0033] It should be noted that the above process is a method for dynamically determining the proportion of green bulb diameter to the main body by statistically analyzing the distribution of green bulb quantity. Its core logic is to judge the dominant state of the current production stage based on the quantity advantage. It can dynamically adapt to production fluctuations, accurately reflect the characteristics of each stage, and ensure that the proportion of green bulb diameter to the main body accurately reflects the core characteristics of the current production stage, providing a scientific basis for identifying the pelleting stage and adjusting pelleting parameters.

[0034] In one feasible embodiment, data analysis is performed on the above process, and the results are as follows.

[0035] Table 1. Original data corresponding to an example of main body proportion and bulb diameter analysis.

[0036] stage quantity Average bulb diameter Nucleation period 20 2 Growing up 60 6 Granulation period 20 13

[0037] Based on the above raw data, the maximum number of bulbs is 60, and the total number of non-maximum bulbs is 40. Since the maximum number of bulbs is greater than the total number of non-maximum bulbs, the main proportion of bulb diameter is 6, corresponding to the bulb formation stage as the growth stage.

[0038] In a preferred embodiment of the present invention, the specific process of identifying the pelletizing stage of the target pellet production process is as follows: the proportion of the green pellet diameter in the main body of the target pellet production process is matched with a pre-set green pellet diameter-pelletizing stage correspondence, thereby identifying the pelletizing stage into which the proportion of the green pellet diameter in the main body of the target pellet production process falls as the pelletizing stage of the target pellet production process.

[0039] Specifically, if the main proportion of green pellet diameter falls within the range of green pellet diameter corresponding to the nucleation stage, then the pelleting stage of the target pellet production process is identified as the nucleation stage.

[0040] If the main proportion of green pellet diameter falls within the range of green pellet diameter corresponding to the growth stage, then the pelleting stage of the target pellet production process is identified as the growth stage.

[0041] If the main proportion of green pellet diameter falls within the range of green pellet diameter corresponding to the pelletizing stage, then the pelletizing stage of the target pellet production process is identified as the pelletizing stage.

[0042] It should be noted that this invention identifies whether the target pellet production process is in the nucleation stage, growth stage, or pelletizing stage based on the proportion of green pellet diameter. This avoids ambiguity in stage identification, enables corresponding parameter control for different stages, improves pellet quality stability, and enhances the system's adaptability.

[0043] The pelletizing disc speed control module is used to process the production time sequence image to generate information on the appearance defects of green pellets and the degree of deviation of the waterfall area shape. At the same time, it uses online pressure monitoring equipment to obtain the degree of deviation of green pellet compressive strength, and combines these with the appropriate speed of the pelletizing disc to construct the target value for pelletizing disc speed control.

[0044] In a preferred embodiment of the present invention, the specific method for generating the apparent defect situation of the green ball is as follows: using image processing software to obtain the apparent defect area and apparent surface area of ​​each green ball in the time-series images of each production process, and then performing a proportion calculation to obtain the proportion of the apparent defect area of ​​each green ball in the time-series images of each production process.

[0045] It should be noted that the aforementioned production process time sequence image is an image of the inside of the pelletizing tray at a certain moment in the target green pellet production process, and the image contains several green pellets.

[0046] The apparent defect area ratio of each green pellet in the time sequence images of each production process is averaged to obtain the green pellet apparent defect evaluation index corresponding to the target pellet production process.

[0047] The green bulb appearance defect evaluation index is used to assess the severity of green bulb appearance defects.

[0048] It's important to explain that the increased speed and collision frequency and intensity of green balls within the pelletizing tray can easily lead to surface defects such as cracks and dents. When the green ball appearance defect evaluation index is high, the module will reduce the rotation speed (e.g., by 2 rpm) to minimize collisions and mitigate defects. Rotation speed is a core parameter affecting green ball appearance defects, and the two are negatively correlated. By monitoring the defect area ratio in real time and dynamically adjusting the rotation speed, the defect rate can be effectively reduced, ensuring green ball quality.

[0049] In a preferred embodiment of the present invention, the specific analysis method for the deviation of the shape of the waterfall area is as follows: high-definition image processing software is used to obtain the throwing point and landing point of each raw ball corresponding to the time sequence image of each production process, and then the length of the waterfall area corresponding to each raw ball is obtained.

[0050] The deviation between the length of the waterfall zone of each green pellet in the time sequence image of each production process and the pre-set suitable length of the waterfall zone is calculated, and then normalization and mean processing are performed to analyze and obtain the waterfall zone shape deviation index of the target pellet production process.

[0051] In one feasible embodiment, the waterfall zone shape deviation index of the target pellet production process is specifically analyzed as follows: using the formula The analysis yields the waterfall zone shape deviation index Γ in the target pellet production process, where i represents the number of the time-series images of the production process, i = 1, 2...I, I represents the number of time-series images of the production process, j represents the number of green pellets, j = 1, 2...J, J represents the number of green pellets, and L... ij L0 represents the length of the waterfall zone corresponding to the j-th production ball in the i-th production process time sequence image, and L0 represents the pre-set suitable waterfall zone length.

[0052] The waterfall area shape deviation index is used to assess the degree of deviation of the waterfall area's shape.

[0053] It needs to be explained that the correlation mechanism between the pelleting disc rotation speed and the degree of deviation of the waterfall zone shape is as follows: 1. Rotation speed directly affects the shape of the waterfall zone: Increased centrifugal force of the green pellets and faster ejection speed lead to a greater deviation in the length L of the waterfall zone. ij If the length exceeds the preset suitable length L0, the shape deviation index Γ of the waterfall zone is negative, triggering adjustment (such as reducing the speed by 1-2 rpm). If the centrifugal force is insufficient, the trajectory of the green pellets is abnormal, the length of the waterfall zone is shortened, and the shape may present as an irregular parabola or sticky clumps. The shape deviation index Γ of the waterfall zone is positive, and the speed needs to be increased by 0.5-1 rpm.

[0054] 2. Excessive or insufficient rotation speed will cause the length of the waterfall zone to deviate from the preset value, triggering regulation. By calculating the shape deviation index in real time and dynamically adjusting the rotation speed, the material throwing trajectory can be optimized, ensuring the quality of the green pellets.

[0055] In a preferred embodiment of the present invention, the specific analysis method for the degree of deviation of the green pellet compressive strength is as follows: the compressive strength of each tested green pellet is obtained by using an online pressure monitoring device, and the difference and mean values ​​of the pre-set expected compressive strength and the compressive strength of each tested green pellet are analyzed to obtain the green pellet compressive strength deviation index of the target pellet production process.

[0056] For example, a method for analyzing the green pellet compressive strength deviation index is as follows: the compressive strength of each tested green pellet is obtained using an online pressure monitoring device; the difference between the pre-set expected compressive strength and the compressive strength of each tested green pellet is calculated to obtain the compressive strength deviation of each tested green pellet; then, the ratio of this deviation to the pre-set expected compressive strength is calculated to obtain the green pellet compressive strength deviation index of each tested green pellet; finally, the average of the green pellet compressive strength deviation indices of each tested green pellet is calculated to obtain the green pellet compressive strength deviation index of the target pellet production process.

[0057] The green pellet compressive strength deviation index is used to assess the degree of deviation in green pellet compressive strength.

[0058] It should be explained that if the rotation speed is too low, the probability of green balls sticking together increases, the structure becomes loose, and the compressive strength decreases. Therefore, the rotation speed needs to be increased by 0.5-1 rpm to enhance the compactness of the green balls.

[0059] In a preferred embodiment of the present invention, the specific analysis method for constructing the target value of the pelletizing disc rotation speed control is as follows: extract the green pellet appearance defect evaluation index, waterfall zone shape deviation index and green pellet compressive strength deviation index of the target pellet production process, multiply them with the preset reference unit speed correction amount respectively, and then sum them to obtain the pelletizing disc rotation speed control amount.

[0060] It should be noted that the reference unit speed correction is set based on multiple factors. The production process determines the base speed, and key indicators of green pellet quality, such as defects and compressive strength deviations, are crucial. Adjusting the speed accordingly ensures quality. Equipment characteristics and raw material characteristics also have an impact; large-diameter discs and coarse-grained raw materials require different speeds. Simultaneously, by referencing historical production data, conducting experimental research, and incorporating feedback from online monitoring, a comprehensive correction is determined to ensure the pelletizing disc speed matches production needs and stabilizes green pellet quality.

[0061] The appropriate rotation speed of the pelletizing disc for the current pelletizing stage is obtained by matching the pelletizing stage of the target pellet production process with the pre-set appropriate parameters of the pelletizing disc.

[0062] The target value for pelletizing disc speed control is obtained by summing the pelletizing disc speed control value with the suitable pelletizing disc speed.

[0063] It should be noted that this invention analyzes the appearance defects of green pellets, the degree of deviation in the shape of the waterfall zone, and the degree of deviation in the compressive strength of green pellets to comprehensively identify the needs for adjusting the speed of the pelletizing disc. This allows for precise location of production problems and timely adjustment of the speed for different problems, ensuring efficient and stable pellet production.

[0064] Please see Figure 2As shown, the pelletizing disc angle control module is used to analyze the centrifugal motion vector of the green pellets in the time-series image of the production process using optical flow method, evaluate the degree of deviation of the centrifugal ejection direction of the green pellets, and construct the target value of pelletizing disc angle control by combining it with the appropriate angle of the pelletizing disc.

[0065] In a preferred embodiment of the present invention, the specific evaluation method for the deviation of the green pellet centrifugal ejection direction is as follows: The trajectory of each green pellet in the time-series images of each production process of the target pellet is tracked using optical flow method to obtain the instantaneous velocity vector of each pellet.

[0066] It should be noted that optical flow is a method for calculating object motion by utilizing the time-varying information of pixel intensity in an image sequence. In the target pellet production process, applying optical flow to each time-series image allows tracking the positional changes of each green pellet at different times. Through these positional changes, the instantaneous velocity vector of each green pellet in a two-dimensional plane (denoted as the xy-plane) can be calculated. v represents the instantaneous velocity vector of the j-th ball. j,x It is the instantaneous velocity component of the ball in the x-direction, v j,y It is the instantaneous velocity component in the y-direction.

[0067] The friction coefficient between the material and the disc surface and the radius of the pelletizing disc are obtained. At the same time, the current angle and rotation speed of the pelletizing disc are obtained in real time. Then, based on the theory of object motion, the theoretical centrifugal projectile direction and the corresponding angle are analyzed.

[0068] Based on the instantaneous velocity vector analysis of each pellet, the centrifugal ejection direction angle of each pellet is analyzed, and then the deviation analysis of the angle corresponding to the theoretical centrifugal ejection direction is performed and normalized to obtain the centrifugal ejection direction deviation index of each green pellet. Then, the mean value is calculated to obtain the centrifugal ejection direction deviation index of the target pellet production process.

[0069] In one feasible embodiment, the specific calculation method for the deviation index of the green pellet centrifugal ejection direction in the target pellet production process is as follows: using the formula The deviation index Δφ of the green pellet centrifugal ejection direction in the target pellet production process is constructed, where θ0 represents the angle corresponding to the theoretical centrifugal ejection direction. Where μ represents the pre-set friction coefficient between the material and the disc surface, R represents the radius of the pelletizing disc, α represents the current angle of the pelletizing disc, g represents the gravitational acceleration, and v0 represents the current rotational speed of the pelletizing disc.

[0070] It is necessary to further explain the specific construction logic of the above formula: 1. Theoretical modeling: Determine the ideal projectile direction θ0, in the formula The physical meaning is: the theoretical projectile angle when centrifugal force and friction are in equilibrium.

[0071] Centrifugal force component μ×v0 2 ×cosα: Determined by angle α and friction coefficient μ, it reflects the centrifugal tendency of the material on the disc surface.

[0072] Gravitational component: g serves as a reference point to balance the influence of centrifugal force on the projectile direction.

[0073] Geometric meaning: θ0 is the angle between the launch direction of the raw ball and the tangent of the disk surface, produced by the balance of centrifugal force and friction under ideal conditions.

[0074] 2. Positive deviation (Δφ>0): The actual projectile direction is steeper than the theoretical direction, indicating that the centrifugal force is too strong (the angle is too large).

[0075] Negative deviation (Δφ<0): The actual projectile direction is flat, indicating insufficient friction (angle is too small).

[0076] In one feasible embodiment, data simulation calculations are performed based on the analysis formula for the deviation index of the centrifugal projectile direction of the green pellets, and the corresponding simulation calculation results are obtained. Some simulation results can be found in Table 1, where the preset values ​​are μ = 0.5, R = 1m, α = π / 4, and g = 9.81m / s. 2 Meanwhile, J=5 is preset, and for ease of calculation, v in the data simulation process is... j,x =v j,y ,

[0077] Table 2. Simulation results of deviation index of centrifugal ball ejection direction for some green balls

[0078]

[0079] Based on the simulation results above, the calculation results show that: 1. θ0 is the angle corresponding to the theoretical centrifugal projection direction calculated based on the friction coefficient between the material and the disc surface, the radius and angle of the pelletizing disc, the gravitational acceleration, and the rotational speed of the pelletizing disc. As v0 (rotational speed of the pelletizing disc) increases, θ0 also increases. This is because the increase in rotational speed will enhance the centrifugal force on the material, thereby changing the theoretical projection angle.

[0080] 2. Δφ is the deviation index of the green pellet centrifugal ejection direction, reflecting the degree of deviation of the actual ejection direction from the theoretical ejection direction. The results show that when v0 is small, the Δφ value is large, indicating that at lower rotational speeds, the actual ejection direction deviates significantly from the theoretical direction. As v0 increases, the Δφ value decreases, meaning that as the rotational speed increases, the actual ejection direction approaches the theoretical ejection direction more closely. This is of significant reference value for controlling the green pellet ejection direction and improving pellet production quality during the target pellet production process. The operating parameters of the pelletizing disc can be adjusted based on this index.

[0081] The green pellet centrifugal ejection direction deviation index is used to assess the degree of deviation of the green pellet centrifugal ejection direction during the target pellet production process.

[0082] In a preferred embodiment of the present invention, the specific method for constructing the target value for adjusting the angle of the pelletizing disc is as follows: extract the deviation index of the centrifugal ejection direction of the green pellets in the target pellet production process, and then multiply it with the pre-set unit correction amount of the pelletizing disc angle to obtain the adjustment amount of the pelletizing disc angle.

[0083] The target value for adjusting the angle of the pelletizing disc is obtained by calculating the difference between the suitable angle of the pelletizing disc and the angle adjustment amount of the pelletizing disc.

[0084] It should be noted that this invention assesses the degree of deviation in the centrifugal throwing direction of green pellets, thereby identifying the need for adjusting the angle of the pelletizing tray. This avoids problems such as scattering and collision breakage of green pellets caused by deviation in the throwing direction, ensuring the integrity and quality of the pellets. It also makes the material distribution in the pelletizing tray more uniform and improves the pelletizing efficiency.

[0085] The parameter dynamic control module is used to control the relevant parameters of the target turntable according to the target values ​​of the ball-forming disc rotation speed and the ball-forming disc angle.

[0086] In a preferred embodiment of the present invention, the specific method for adjusting the relevant parameters of the target turntable is as follows: extract the target value for adjusting the rotation speed of the ball-forming disc and the target value for adjusting the angle of the ball-forming disc, and then compare them with the preset allowable ranges for the rotation speed and angle of the ball-forming disc, respectively.

[0087] It's important to explain that the permissible speed range of the pelletizing disc is the range of speeds required for normal equipment operation and to ensure green pellet quality, commonly 10-14 rpm, but varying due to various factors. Equipment performance limits the upper speed limit to prevent component overload and malfunction. Material characteristics have a significant impact; for example, fine-grained materials with high moisture content are not suitable for high speeds, otherwise they are easily thrown off. Simultaneously, to meet pellet quality requirements, improper speed will lead to uneven green pellet size and poor strength. Considering all these factors, a reasonable speed range ensures efficient and stable equipment operation and high-quality green pellet production. The permissible angle range of the pelletizing disc refers to the reasonable range of the angle between the disc surface and the horizontal plane, typically between 40° and 45°. This directly affects the material residence time; a larger angle results in shorter residence time, and vice versa. The appropriate duration is crucial to the quality of green pellet formation. The angle also determines the material's rolling trajectory; an appropriate angle allows the material to rise in a stable spiral, which is beneficial for green pellet density. From the equipment's perspective, an excessively large angle causes a shift in the center of gravity and poor stability, while an excessively small angle affects material flow. Therefore, a suitable angle range is crucial for equipment stability and good pelletizing results.

[0088] If the target value for the pelletizing disc speed control is within the allowable range of the pelletizing disc speed, then the target value for the pelletizing disc speed control will be used as the benchmark for speed control; otherwise, the boundary value that is closer to the target value for the pelletizing disc speed control will be used as the benchmark for speed control.

[0089] It should be noted that this control step calculates the target values ​​for the rotational speed and angle of the pelletizing disc in real time, and combines them with a preset safe operating range to ensure that parameter adjustments meet process optimization requirements without exceeding the physical limitations of the equipment. The specific logic is as follows: First, target values ​​for rotational speed and angle are dynamically generated based on green pellet quality indicators (defects, strength, ejection direction, etc.); then, these target values ​​are compared with pre-set allowable ranges (e.g., rotational speed 10-14 rpm, angle 40°-45°); if the target value is within the allowable range, it is directly adopted; if it exceeds the range, the closest boundary value is selected as the control benchmark. This strategy, through the combination of safe boundary constraints and dynamic optimization, approximates the ideal process state as closely as possible while ensuring stable equipment operation, achieving a balance between green pellet quality and production efficiency.

[0090] It needs further explanation that in the ball-forming disc control, when the calculated target value for speed or angle control exceeds the preset allowable range, the system will select the boundary value closest to the target value as the actual control benchmark. For example, if the allowable speed range is 10-14 rpm, and the control target value is 15 rpm, then 14 rpm (difference of 1 rpm) will be selected instead of 10 rpm (difference of 5 rpm).

[0091] The allowable angle range is 40°-45°. If the target value is 38°, then choose 40° (difference of 2°) instead of 45° (difference of 7°).

[0092] It should be noted that the boundary value is selected by comparing the absolute difference between the target value and the upper and lower limits, with the smaller value being taken. This strategy, while ensuring safe equipment operation, maximizes the preservation of process optimization effects and avoids reduced pelletizing efficiency due to excessive restrictions.

[0093] Similarly, adjust the angle of execution.

[0094] It should be added that if the target value for adjusting the ball-forming plate angle is within the allowable range of the ball-forming plate angle, then the target value for adjusting the ball-forming plate angle will be used as the benchmark for angle adjustment; otherwise, the boundary value that is closer to the target value for adjusting the ball-forming plate angle will be used as the benchmark for angle adjustment.

[0095] It should be noted that this invention dynamically constructs target values ​​for the rotational speed and angle of the pelletizing disc, thereby adjusting relevant parameters to accurately match production needs, improve production efficiency, reduce costs, and minimize waste and equipment wear.

[0096] The above content is merely an example and illustration of the concept of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, and all such modifications and additions should fall within the protection scope of the present invention.

Claims

1. An intelligent monitoring system for high-strength pellet production, characterized in that, include: The pellet image acquisition module is used to acquire time-series images of each production process of the target pellet in real time using an image acquisition device based on a preset acquisition frequency; The pelletizing stage identification module is used to extract scale features based on the time-series images of the production process to obtain the main body proportion of the green pellet diameter, and then identify the pelletizing stage of the target pellet production process and obtain the appropriate rotation speed and appropriate angle of the pelletizing disc. The pelletizing stage includes the nucleation stage, the growth stage and the pelletizing stage. The pelletizing disc speed control module is used to process the production process time sequence image to generate the appearance defects of green pellets and the degree of deviation of the waterfall area shape. At the same time, it uses online pressure monitoring equipment to obtain the degree of deviation of green pellet compressive strength, and combines it with the appropriate speed of the pelletizing disc to construct the target value of pelletizing disc speed control. The pelletizing disc angle control module is used to analyze the centrifugal motion vector of green pellets in the time sequence image of the production process using optical flow method, evaluate the degree of deviation of the centrifugal ejection direction of green pellets, and combine it with the appropriate angle of the pelletizing disc to construct the target value for pelletizing disc angle control. The parameter dynamic control module is used to control the relevant parameters of the target turntable according to the target values ​​of the ball-forming disc rotation speed and the ball-forming disc angle.

2. The intelligent monitoring system for high-strength pellet production as described in claim 1, characterized in that: The specific analysis method for the proportion of the main body to the diameter of the green bulb is as follows: Extract time-series images of each production process of the target pellet, use image processing software to obtain the diameter of each green pellet in the time-series image of each production process, match the diameter of each green pellet with the pre-set green pellet diameter-forming stage correspondence to obtain the forming stage of each green pellet, and count the number of green pellets corresponding to each forming stage. The number of green balls in each ball-forming stage is compared. The total number of green balls in other ball-forming stages besides the maximum number of green balls is summed to obtain the non-maximum number of green balls. The maximum number of green balls is compared with the total number of non-maximum green balls. If the maximum number of green balls is greater than or equal to the total number of non-maximum green balls, the average diameter of each green ball in the ball-forming stage corresponding to the maximum number of green balls is calculated to obtain the proportion of green ball diameter of the main body in each production process time sequence image. If the maximum number of green balls is less than the total number of non-maximum green balls, the average diameter of green balls in each ball-forming stage is used to calculate the proportion of green ball diameter in the main body of each production process time sequence image. The average proportion of the green pellet diameter to the main body of the target pellet production process is calculated by taking the average proportion of the green pellet diameter to the main body of the time sequence images of each production process.

3. The intelligent monitoring system for high-strength pellet production as described in claim 2, characterized in that: The specific process for identifying the pelletizing stage of the target pellet production process is as follows: The main proportion of green pellet diameter in the production process of the target pellet is matched with the pre-set green pellet diameter-sphericization stage correspondence. The phericization stage in which the main proportion of green pellet diameter in the production process of the target pellet is located is then taken as the phericization stage of the production process of the target pellet.

4. The intelligent monitoring system for high-strength pellet production as described in claim 1, characterized in that: The specific method for generating the apparent defects of the green bulbs is as follows: Image processing software is used to obtain the apparent defect area and apparent surface area of ​​each raw ball in the time sequence images of each production process, and then the proportion is calculated to obtain the proportion of the apparent defect area of ​​each raw ball in the time sequence images of each production process. The apparent defect area ratio of each green pellet in the time sequence images of each production process is averaged to obtain the green pellet apparent defect evaluation index corresponding to the target pellet production process.

5. The intelligent monitoring system for high-strength pellet production as described in claim 4, characterized in that: The specific analysis method for the degree of deviation in the shape of the waterfall area is as follows: High-definition image processing software is used to obtain the release point and landing point of each green ball corresponding to the time sequence image of each production process, and then the length of the waterfall area of ​​each green ball is obtained. The deviation between the length of the waterfall zone of each green pellet in the time sequence image of each production process and the pre-set suitable length of the waterfall zone is calculated, and then normalization and mean processing are performed to analyze and obtain the waterfall zone shape deviation index of the target pellet production process.

6. The intelligent monitoring system for high-strength pellet production as described in claim 5, characterized in that: The specific analysis method for the degree of deviation in the compressive strength of the green pellets is as follows: The compressive strength of each green pellet is obtained by using online pressure monitoring equipment. The difference and mean values ​​of the pre-set expected compressive strength and the compressive strength of each green pellet are analyzed to obtain the green pellet compressive strength deviation index in the target pellet production process.

7. The intelligent monitoring system for high-strength pellet production as described in claim 6, characterized in that: The specific analysis method for constructing the target value of the pelletizing disc rotation speed control is as follows: The green pellet appearance defect evaluation index, waterfall zone shape deviation index, and green pellet compressive strength deviation index are extracted from the target pellet production process. After multiplying them with the pre-set reference unit speed correction amount, the sum is obtained to obtain the pelletizing disc speed control amount. The appropriate rotation speed of the pelletizing disc for the current pelletizing stage is obtained by matching the pelletizing stage of the target pellet production process with the pre-set appropriate parameters of the pelletizing disc. The target value for pelletizing disc speed control is obtained by summing the pelletizing disc speed control value with the suitable pelletizing disc speed.

8. The intelligent monitoring system for high-strength pellet production as described in claim 1, characterized in that: The specific evaluation method for the degree of deviation in the centrifugal ball ejection direction is as follows: The instantaneous velocity vector of each pellet is obtained by tracing the trajectory of each green pellet in the time-series images of each production process of the target pellet using optical flow method. The friction coefficient between the material and the disc surface and the radius of the pelletizing disc are obtained. At the same time, the current angle and rotation speed of the pelletizing disc are obtained in real time. Then, based on the theory of object motion, the theoretical centrifugal projection direction and the corresponding angle are analyzed. Based on the instantaneous velocity vector analysis of each pellet, the centrifugal ejection direction angle of each pellet is analyzed, and then the deviation analysis of the angle corresponding to the theoretical centrifugal ejection direction is performed and normalized to obtain the centrifugal ejection direction deviation index of each green pellet. Then, the mean value is calculated to obtain the centrifugal ejection direction deviation index of the target pellet production process.

9. The intelligent monitoring system for high-strength pellet production as described in claim 8, characterized in that: The specific method for constructing the target value for adjusting the angle of the ball-forming disc is as follows: The deviation index of the centrifugal ejection direction of green pellets in the target pellet production process is extracted, and then multiplied with the pre-set unit correction amount of the pelletizing disc angle to obtain the pelletizing disc angle control amount. The target value for adjusting the angle of the pelletizing disc is obtained by calculating the difference between the suitable angle of the pelletizing disc and the angle adjustment amount of the pelletizing disc.

10. The intelligent monitoring system for high-strength pellet production as described in claim 1, characterized in that: The specific methods for adjusting the relevant parameters of the target turntable are as follows: Extract the target values ​​for pelletizing disc rotation speed control and pelletizing disc angle control, and then compare them with the preset allowable ranges for pelletizing disc rotation speed and pelletizing disc angle, respectively. If the target value for the pelletizing disc speed control is within the allowable range of the pelletizing disc speed, then the target value for the pelletizing disc speed control will be used as the benchmark for speed control; otherwise, the boundary value that is closer to the target value for the pelletizing disc speed control will be used as the benchmark for speed control. Similarly, adjust the angle of execution.

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