Zinc powder screening device and intelligent control method thereof

Abstract

The invention discloses a zinc powder screening device and an intelligent control method thereof.The zinc powder screening device comprises a first shell, a conveying belt is arranged in the first shell, a discharging chute is formed below the conveying belt, a fixing block is fixedly connected to the side face of the first shell, and a first driving motor is fixedly connected to the upper portion of the fixing block; a zinc powder screening mechanism is fixedly connected to the upper portion of the first shell, and a third shell is fixedly connected to the upper portion of the zinc powder screening mechanism. The feeding speed of zinc powder can be accurately controlled by adjusting the coincidence degree of the discharging holes between the upper punching plate and the lower punching plate, the stability of a production line can be kept, blockages on a screen can be effectively removed by combining the design of the screening plate with the reciprocating movement of a cleaning brush, the smoothness and screening efficiency of the screen are kept, and the production efficiency of the production line is improved. The gap can be adjusted according to the granularity of the zinc powder through the first grinding roller and the second grinding roller in the grinding cavity, and it is ensured that the zinc powder is ground to the needed granularity.

Description

Technical Field

[0001] The present invention relates to the technical field of zinc powder processing equipment, in particular to a zinc powder screening device and an intelligent control method thereof. Background Art

[0002] Most traditional zinc powder screening devices lack a mechanism for accurately controlling the feeding speed. The feeding speed of zinc powder is determined by the manually controlled feeding gap and feeding amount, which makes it difficult to control the feeding speed of zinc powder. It is easy to be too fast or too slow, thereby affecting the stability and continuity of the production line and causing production problems. At the same time, most traditional screening equipment lacks a means to effectively clean the blockage on the screen. Manual cleaning is required, and the blockage on the screen cannot be cleaned during the working process, resulting in screen blockage, reduced screening efficiency, and affecting the continuity and efficiency of the work. Therefore, a zinc powder screening device and an intelligent control method thereof are provided to solve the above problems. Summary of the Invention

[0003] The purpose of the present invention is to provide a zinc powder screening device and an intelligent control method thereof in order to solve the problems raised by the above-mentioned background technology, which has the advantages of being able to accurately control the zinc powder feeding speed, clean up blockages on the screen during the working process, maintain screening efficiency, and solve the problems raised by the above-mentioned background technology.

[0004] To achieve the above-mentioned object, the present invention provides the following technical solution: a zinc powder screening device, comprising: a first shell, a conveyor belt is provided inside the first shell, a discharging chute is provided below the conveyor belt, a fixed block is fixedly connected to the side surface of the first shell, a first drive motor is fixedly connected above the fixed block, a zinc powder screening mechanism is fixedly connected above the first shell, a third shell is fixedly connected above the zinc powder screening mechanism, a crushing chamber is opened inside the third shell, two groups of electric telescopic rods are fixedly connected inside the crushing chamber, the movable ends of the two groups of electric telescopic rods are fixedly connected to a first rotating base, a first crushing roller is rotatably connected to the inside of the first rotating base, a second rotating base is fixedly connected inside the crushing chamber, a second crushing roller is rotatably connected to the inside of the second rotating base, and a feeding mechanism is fixedly connected above the third shell;

[0005] The zinc powder screening mechanism includes a second shell, a shaking screen support frame is provided on the inner side of the second shell, and limited sliding bars are fixedly connected to the two sides of the shaking screen support frame, and the screening plate is fixedly connected to the inner side of the shaking screen support frame at a position below the screening plate. Two groups of slide blocks are fixedly connected to the position of the inner side of the shaking screen support frame, one group of which is rotatably connected to the inner side of the sliding block, and a second driving motor is fixedly connected to the side of the shaking screen support frame. A moving cross bar is provided between the two groups of sliding blocks, and a cleaning brush is fixedly connected to the upper part of the moving cross bar. The second shell is fixedly connected to an L-shaped fixing plate, and a third driving motor is fixedly connected to the upper part of the L-shaped fixing plate. The rotating shaft of the third driving motor is fixedly connected to the rotating disk, and the side of the rotating disk is rotatably connected to the pushing arm, and two groups of limited sliding grooves are opened on the inner side of the second shell.

[0006] As a further solution of the present invention: the feeding mechanism includes a feeding hopper, an upper punching plate is fixedly connected below the feeding hopper, a fourth driving motor is fixedly connected above the upper punching plate, and the rotating shaft of the fourth driving motor passes through the upper punching plate and is fixedly connected to the lower punching plate.

[0007] As a further solution of the present invention: the rotating shaft of the first driving motor passes through the first shell and is fixedly connected to the transmission shaft inside the conveyor belt.

[0008] As a further solution of the present invention: the bottom of the feeding mechanism passes through the third shell to the inside of the crushing chamber, and the bottom of the crushing chamber passes through to the bottom of the third shell.

[0009] As a further solution of the present invention: the rotating shaft of the second driving motor passes through the shaking screen support frame and the chute block and is fixedly connected to the threaded rod.

[0010] As a further solution of the present invention: a slide groove is opened inside the two groups of slide blocks, and sliders adapted to the slide groove blocks are fixedly connected to both ends of the movable cross bar, and a threaded hole adapted to the slide groove is opened on the inner side of the slider close to the threaded rod.

[0011] As a further solution of the present invention: one end of the pushing arm is rotatably connected to the rotating disk, and the other end is rotatably connected to the inner side of the shaking screen support frame, the limiting sliding bar is adapted to the limiting sliding groove, and the shaking screen support frame is slidably connected to the second shell.

[0012] As a further solution of the present invention: the upper punching plate and the lower punching plate are both provided with four groups of blanking holes of the same size and position, and the axes of the upper punching plate and the lower punching plate are located in the same straight line.

[0013] An intelligent control method for a zinc powder screening device is characterized by comprising the following steps:

[0014] Step 1: Zinc powder first enters the device through the feed hopper. A feed hole is provided between the upper punching plate and the lower punching plate. Their relative position can be adjusted by the fourth drive motor. The fourth drive motor is started to drive the lower punching plate to rotate, thereby adjusting the overlap degree of the feed holes between the upper and lower punching plates. By accurately controlling the overlap degree of the feed holes, the feeding speed of the zinc powder can be accurately controlled to ensure the smooth progress of subsequent processes.

[0015] Step 2: The zinc powder enters the crushing chamber in the third housing from the feeding mechanism. The electric telescopic rod adjusts the distance between the first rotating base and the second rotating base according to the particle size of the zinc powder, thereby changing the gap between the first crushing roller and the second crushing roller. The first crushing roller and the second crushing roller rotate relative to each other to crush the zinc powder to the required particle size. The crushed zinc powder enters the zinc powder screening mechanism through the opening below the crushing chamber.

[0016] Step 3: The crushed zinc powder falls on the screening plate, which screens the zinc powder. The zinc powder with smaller particles passes through the screen and falls on the conveyor belt, and is then sent out by the discharging chute. The zinc powder with larger particles is retained on the screening plate and is sent out for collection due to the inclined design of the screening plate. Driven by the second drive motor and the threaded rod, the cleaning brush moves back and forth above the screening plate to clear the blockage on the screen and maintain the screening efficiency.

[0017] Step 4: When the third driving motor is driven, the rotating disk drives the pushing arm to move. Through the linkage between the pushing arm and the shaking screen support frame, the shaking screen support frame slides back and forth in the direction of the limiting sliding groove opened on the inner side of the second shell. This shaking method can increase the efficiency and effect of screening and ensure that the zinc powder on the screening plate can be fully screened.

[0018] Furthermore, in step three, machine vision technology is introduced. The intelligent algorithm can monitor the distribution of zinc powder on the screen plate in real time and automatically adjust the movement trajectory and frequency of the cleaning brush, as well as the tilt angle of the screen plate, to minimize the occurrence of blockages and maintain screening efficiency. The specific process is as follows:

[0019] 1. Equipment and sensor configuration

[0020] 1. Camera system:

[0021] Installation position: The camera is installed 50 cm above the screening device to ensure that the field of view covers the entire screening board;

[0022] Parameter variables: The resolution was set to 1920 × 1080 and the frame rate was set to 30 frames per second to ensure real-time capture of zinc powder distribution images;

[0023] Connection method: connected to CCU via GigE interface, with a data transmission rate of 1Gbps;

[0024] 2. Cleaning brush system:

[0025] Brush motor: Maxon EC-i40 motor, speed is adjusted by PWM control, initially set to 3000RPM;

[0026] Position sensor: Optical encoder monitors brush position in real time with a resolution of 1024 pulses / revolution;

[0027] Motion trajectory: The brush moves linearly on the guide rail, regulated by a NEMA 17 stepper motor with a step angle of 1.8 degrees;

[0028] 3. Screen plate tilt adjustment system:

[0029] Tilt motor: Oriental Motor PKP264D28B motor, precise adjustment is achieved through closed-loop control, and the initial tilt angle is set to 15 degrees;

[0030] Tilt sensor: MPU-6050 gyroscope measures the angle of the sub-board in real time with an accuracy of 0.01 degrees;

[0031] Control method: Using PID control algorithm, set the target angle to 20 degrees, and the adjustment accuracy to 0.1 degrees;

[0032] 4. Central Control Unit (CCU)

[0033] Processor: Intel Core i7-10700K, ensuring fast processing of images and sensor data, memory: 16GB DDR4, ensuring no memory bottlenecks when multitasking;

[0034] Storage: 1TB SSD to ensure data storage and access speed;

[0035] GPU: NVIDIA GTX 3080, for accelerating image processing and deep learning algorithms;

[0036] 2. Data Processing

[0037] 1. Image preprocessing:

[0038] Image denoising: Use Gaussian Blur for image denoising with a kernel size of 5×5;

[0039] Edge detection: The Canny edge detection algorithm was used with thresholds set to 100 and 200 to extract the edges of zinc powder particles;

[0040] 2. Image enhancement:

[0041] Contrast enhancement: Use histogram equalization to enhance the image contrast, making zinc powder particles easier to identify;

[0042] 3. Sensor data preprocessing:

[0043] Filtering: Perform low-pass filtering on the position and acceleration sensor data, with the filter cutoff frequency set to 5 Hz to remove high-frequency noise;

[0044] 3. Image Segmentation

[0045] UNet model:

[0046] Input layer: accepts a single-channel grayscale image of size 256×256;

[0047] Encoder: consists of 4 convolutional layers, each layer uses two 3×3 convolution kernels, the activation function is ReLU, and a 2×2 maximum pooling layer is used for downsampling;

[0048] Bottle pre-layer: The bottom layer uses two 3×3 convolution kernels, and the output feature map size is 16×16;

[0049] Decoder: consists of 4 deconvolution layers, each of which uses two 3×3 convolution kernels and one 2×2 deconvolution kernel for upsampling, and finally restores to 256×256 size;

[0050] Output layer: Use 1×1 convolution kernel, Siqmoid activation function, and output the segmented binary image;

[0051] Model training:

[0052] Dataset: Use the labeled zinc powder distribution image dataset with a dataset size of 1000 images;

[0053] Loss function:

[0054] Binary cross entropy loss function:

[0055]

[0056] Among them, L seg is the segmentation loss function; N is the total number of pixels; y i is the true label of the i-th pixel (0 or 1); is the predicted probability of the i-th pixel;

[0057] Optimizer: Adam optimizer, learning rate set to 0.001, batch size to 16, and number of training rounds to 50;

[0058] 4. Generative Adversarial Network (GAN) Optimization

[0059] 1. Generator Network:

[0060] The input is a 100-dimensional noise vector z. The dimension selection is based on experimental verification: when the noise dimension is less than 80, the generated image details are insufficient, and when it is greater than 120, the training convergence speed decreases. The noise distribution adopts the standard normal distribution N(0, 1), and the KL divergence constraint is used to generate image diversity.

[0061] Use 4 fully connected layers, each layer uses the LeakyReLU activation function, the output size increases layer by layer, and the last layer outputs an image of size 256×256;

[0062] 2. Discriminator network:

[0063] The input is a real image of 256×256

[0064] Use 4 convolutional layers, each layer uses LeakyReLU activation function and batch normalization (BatchNormalization). The last layer uses Siqmoid activation function to output the probability of the image being real or generated;

[0065] 3. Training process:

[0066] The generator and discriminator are trained alternately; the generator tries to generate realistic zinc powder distribution images, and the discriminator tries to distinguish between real images and generated images;

[0067] Generator loss function:

[0068]

[0069] in, is the mathematical expectation; L G is the generator loss; z is the noise vector; pz(z) is the noise distribution; G(z) is the image generated by the generator; D(G(z)) is the discriminator’s evaluation of the generated image;

[0070] Discriminator loss function:

[0071]

[0072] in, is the mathematical expectation; L D is the discriminator loss; x is the real image; p data (x) is the real data distribution; D(x) is the discriminator’s evaluation of the real image;

[0073] Optimizer: Adam optimizer, the learning rate of the generator and discriminator are both set to 0.0002, and β1 is set to 0.5;

[0074] 5. Soft Actor-Critic (SAC) Algorithm

[0075] 1. Environment settings and status representation

[0076] Status t Definition:

[0077] s t =[R, L, V, A]

[0078] Current zinc powder distribution image processing result R: segmented image data, indicating the location and size of zinc powder particles and blockages;

[0079] Brush current position L: indicates the current physical position of the brush on the screening plate;

[0080] Brush movement speed V: indicates the current movement speed of the brush;

[0081] Screen plate inclination angle A: indicates the current inclination angle of the screen plate;

[0082] Action a t Definition:

[0083] a t =[d, v, f, g]

[0084] Adjust the moving direction d of the brush;

[0085] Adjust the brush's movement speed v;

[0086] Adjust the vibration frequency f of the brush;

[0087] Adjust the inclination angle g of the screening plate;

[0088] 2. Reward Function

[0089] Reward function r t The design needs to take into account the screening efficiency and clogging situation; the definitions are as follows:

[0090] r t =α×E t -β×A t

[0091] Among them, E t is the screening efficiency, and the calculation formula is as follows:

[0092]

[0093] A t is the blocked area, and the calculation formula is as follows:

[0094] A t =P block ×S

[0095] α and β are weight coefficients, representing the importance of screening efficiency and clogging area; S is the total area of the screen;

[0096] Reward function weight coefficient setting:

[0097] Weight coefficients α = 0.7, β = 0.3, determined by orthogonal test method: at a fixed screening area S = 1m 2 Under these conditions, 10 (α, β) combinations were tested and the optimal combination that increased screening efficiency by 15% and reduced clogging area by 20% was selected;

[0098] The discount factor Y = 0.99 is set based on the long-term return decay characteristics of the Markov decision process;

[0099] The batch size is 32, which is set according to the GPU memory capacity;

[0100] The experience replay pool is 50,000, which is set based on the sample size covering typical working conditions;

[0101] The entropy weight coefficient is 0.2, which is set according to the convergence experiment of the SAC algorithm;

[0102] 3. Critics Network Update

[0103] SAC uses a dual critic network and The goal is to minimize the following loss function:

[0104]

[0105] Among them, the TD target value y(r, s′, d) is defined as:

[0106]

[0107] in, is the mathematical expectation; γ is the discount factor; is the Q value of the target critic network; θ′ i are the parameters of the target network, a′ is the action sampled from the policy network; J Q (θ i ) is the loss function of the i-th critic network; θ i is the parameter of the i-th critic network; s is the current state; a is the current action; r is the reward; s′ is the next state; d is the end flag; For the experience replay pool; is the Q value of the critic network; y(r, s′, d) is the target value;

[0108] The Q-value network uses bilinear interpolation to downsample the 256×256 image to a 64×64 grid and then calculate the local feature weights. The formula is:

[0109]

[0110] where w ij is the weight coefficient of the grid (i, j), which is initialized through offline pre-training and dynamically adjusted in the online stage;

[0111] 4. Actor Network Update

[0112] Actor Network π φ (a|s) is updated by maximizing the following objective function

[0113]

[0114] in, is the mathematical expectation; α is the weight coefficient of entropy; J π is the loss function of the actor network; π φ is the strategy of the actor network; φ is the parameter of the actor network; α is the entropy weight coefficient;

[0115] 5. Target network update

[0116] The target network parameters are updated via soft update:

[0117] θ′ i ←τθ i +(1-τ)θ′ i

[0118] Where τ is the step size of soft update; θ′ i is the target network parameter;

[0119] 7. Real-time Adjustment and Feedback

[0120] The sieve plate image is collected every 30 seconds, and the blockage area is calculated using the UNet model. If the blockage area is greater than 5% of the sieve area, the following adjustments are triggered:

[0121] The brush speed is increased to 4000RPM (original baseline value 3000RPM) and the screen plate inclination angle is increased to 25° (original baseline value 20°);

[0122] Feeding speed is reduced by 20%;

[0123] The adjusted parameters remain in effect until the blockage area is less than 2%, and then the baseline parameters are restored;

[0124] The status of the screening device is continuously updated and optimized in an iterative cycle. Through the above process, the purpose of intelligent optimization of the zinc powder screening device is achieved, and the separation efficiency and overall performance of the equipment are improved.

[0125] Compared with the prior art, the present invention has the following beneficial effects:

[0126] 1. In the present invention, the feeding speed of zinc powder can be precisely controlled by adjusting the overlap degree of the feeding holes between the upper punching plate and the lower punching plate. This precise control helps to maintain the stability and continuity of the production line and avoid production problems caused by too fast or too slow feeding speed of zinc powder.

[0127] 2. In the present invention, the design of the screening plate combined with the reciprocating movement of the cleaning brush can effectively clean the blockage on the screen, maintain the smooth flow of the screen and the screening efficiency. In addition, the back and forth sliding of the shaking screen support frame further increases the efficiency and effect of the screening, ensuring that the zinc powder can be fully screened.

[0128] 3. In the present invention, the gap between the first and second rolling rollers in the crushing chamber can be adjusted according to the particle size of the zinc powder to ensure that the zinc powder is crushed to the required particle size. This efficient crushing helps to improve the efficiency and accuracy of subsequent screening work.

[0129] 4. By incorporating the SAC algorithm, the system can dynamically adjust the screen plate's tilt angle and brush speed based on real-time zinc powder distribution, thereby precisely controlling the zinc powder feed rate. This dynamic adjustment capability offers greater flexibility and accuracy than traditional fixed parameter control.

[0130] 5. By incorporating intelligent algorithms and a real-time monitoring system, the present invention enables the screening device to adaptively adjust operating parameters to ensure adequate screening of zinc powder. This adaptability significantly improves screening efficiency and effectiveness, particularly under complex and changing operating conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0131] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0132] Figure 2 It is a schematic structural diagram of the second viewing angle of the present invention;

[0133] Figure 3 It is a schematic structural diagram of the conveyor belt and the crushing chamber in the present invention;

[0134] Figure 4 It is a structural schematic diagram of the zinc powder screening mechanism of the present invention;

[0135] Figure 5 It is a schematic structural diagram of the cleaning brush of the present invention;

[0136] Figure 6 It is a structural schematic diagram of the limiting sliding groove in the present invention;

[0137] Figure 7It is a structural diagram of the feeding mechanism in the present invention;

[0138] Figure 8 It is a structural schematic diagram of the lower punching plate in the present invention;

[0139] Figure 9 It is a flow chart of the intelligent algorithm in the present invention.

[0140] In the figure: 1. first shell; 2. conveyor belt; 3. discharging chute; 4. fixed block; 5. first drive motor; 6. zinc powder screening mechanism; 61. second shell; 62. shaking screen support frame; 63. limit sliding bar; 64. screening plate; 65. slide block; 66. threaded rod; 67. second drive motor; 68. moving cross bar; 69. cleaning brush; 610. L-shaped fixed plate; 611. third drive motor; 612. rotating disk; 613. pushing arm; 614. limit sliding groove; 7. third shell; 8. crushing chamber; 9. electric telescopic rod; 10. first rotating base; 11. first crushing roller; 12. second rotating base; 13. second crushing roller; 14. feeding mechanism; 141. feeding hopper; 142. upper punching plate; 143. fourth drive motor; 144. lower punching plate. DETAILED DESCRIPTION

[0141] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0142] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and should not be understood as indicating or implying relative importance. In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected, detachably connected, or connected in one piece; they can be mechanically connected or electrically connected; they can be directly connected, or indirectly connected through an intermediate medium, or they can be internal connections between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The following describes an embodiment of the present invention based on its overall structure.

[0143] Reference Figures 1 to 6 In an embodiment of the present invention, a zinc powder screening device includes: a first shell 1, a conveyor belt 2 is provided inside the first shell 1, a discharging chute 3 is provided below the conveyor belt 2, a fixed block 4 is fixedly connected to the side of the first shell 1, a first drive motor 5 is fixedly connected above the fixed block 4, a rotating shaft of the first drive motor 5 passes through the first shell 1 and is fixedly connected to the transmission shaft inside the conveyor belt 2, a zinc powder screening mechanism 6 is fixedly connected above the first shell 1, a third shell 7 is fixedly connected above the zinc powder screening mechanism 6, and a third shell 7 is provided inside the third shell 7. There is a crushing chamber 8, two sets of electric telescopic rods 9 are fixedly connected to the crushing chamber 8, the movable ends of the two sets of electric telescopic rods 9 are fixedly connected to a first rotating base 10, a first crushing roller 11 is rotatably connected to the inside of the first rotating base 10, a second rotating base 12 is fixedly connected to the crushing chamber 8, a second crushing roller 13 is rotatably connected to the inside of the second rotating base 12, a feeding mechanism 14 is fixedly connected to the top of the third shell 7, the bottom of the feeding mechanism 14 passes through the third shell 7 to the inside of the crushing chamber 8, and the bottom of the crushing chamber 8 passes through the bottom of the third shell 7;

[0144] The zinc powder screening mechanism 6 includes a second shell 61, a shaking screen support frame 62 is provided on the inner side of the second shell 61, and limited sliding bars 63 are fixedly connected on both sides of the shaking screen support frame 62, and a screening plate 64 is fixedly connected to the inner side of the shaking screen support frame 62. Two groups of chute blocks 65 are fixedly connected to the position below the screening plate 64 on the inner side of the shaking screen support frame 62, and one group of chute blocks 65 is rotatably connected to the inner side of the threaded rod 66. A second driving motor 67 is fixedly connected to the side of the shaking screen support frame 62, and the rotating shaft of the second driving motor 67 passes through the shaking screen support frame 62 and the chute block 65 and is fixedly connected to the threaded rod 66. A moving cross bar 68 is provided in the middle of the two groups of chute blocks 65, and a cleaning brush 69 is fixedly connected to the top of the moving cross bar 68. A chute is provided inside the two groups of chute blocks 65, and sliders adapted to the chute blocks 65 are fixedly connected at both ends of the moving cross bar 68. The inner side of the slider of the rod 66 is provided with a threaded hole that matches it. The second shell 61 is fixedly connected to an L-shaped fixing plate 610, and a third drive motor 611 is fixedly connected above the L-shaped fixing plate 610. The rotating shaft of the third drive motor 611 is fixedly connected to a rotating disk 612, and the side of the rotating disk 612 is rotatably connected to a pushing arm 613. Two sets of limiting sliding grooves 614 are provided on the inner side of the second shell 61. One end of the pushing arm 613 is rotatably connected to the rotating disk 612, and the other end is rotatably connected to the inner side of the shaking screen support frame 62. The limiting sliding bar 63 is adapted to the limiting sliding groove 614, and the shaking screen support frame 62 is slidably connected to the second shell 61. When the third drive motor 611 is driven, the shaking screen support frame 62 can slide back and forth in the direction of the limiting sliding groove 614 opened on the inner side of the second shell 61 through the linkage action of the rotating disk 612 and the pushing arm 613.

[0145] According to the above solution, zinc powder enters the crushing chamber 8 within the third housing 7, and the electric telescopic rod 9 controls the distance between the first rotating base 10 and the second rotating base 12, thereby adjusting the gap between the first crushing roller 11 and the second crushing roller 13 to accommodate zinc powders of different particle sizes. The first crushing roller 11 and the second crushing roller 13 rotate relative to each other to crush the zinc powder to a smaller particle size. The crushed zinc powder then enters the zinc powder screening mechanism 6 through the opening below the crushing chamber 8.

[0146] The crushed zinc powder falls on the screening plate 64, which screens the zinc powder. The zinc powder with smaller particles passes through the screening plate 64 and falls on the conveyor belt 2 and is sent out by the discharging chute 3. The larger particles are intercepted and sent out for collection through the inclined design of the screening plate 64. The cleaning brush 69, driven by the second drive motor 67 and the threaded rod 66, moves back and forth above the screening plate 64 to clean the blockage on the screen and maintain the screening efficiency.

[0147] When the third driving motor 611 is driven, the rotating disk 612 drives the pushing arm 613 to move. Through the linkage between the pushing arm 613 and the shaking screen support frame 62, the shaking screen support frame 62 slides back and forth in the direction of the limiting sliding groove 614 opened on the inner side of the second shell 61, thereby increasing the efficiency and effect of screening.

[0148] Reference Figure 7 and Figure 8 The feeding mechanism 14 includes a feeding hopper 141, an upper punching plate 142 is fixedly connected to the bottom of the feeding hopper 141, and a fourth driving motor 143 is fixedly connected to the top of the upper punching plate 142. The rotating shaft of the fourth driving motor 143 passes through the upper punching plate 142 and is fixedly connected to the lower punching plate 144. The upper punching plate 142 and the lower punching plate 144 are both provided with four groups of blanking holes of the same size and position, and the axes of the upper punching plate 142 and the lower punching plate 144 are located in the same straight line. By driving the fourth driving motor 143, the lower punching plate 144 can be driven to rotate, thereby adjusting the degree of overlap of the blanking holes between the upper punching plate 142 and the lower punching plate 144 to control the blanking speed.

[0149] The above scheme is adopted: zinc powder enters the device through the feed hopper 141, and discharge holes are provided inside the upper punching plate 142 and the lower punching plate 144. By driving the fourth drive motor 143, the lower punching plate 144 is driven to rotate, thereby adjusting the degree of overlap of the discharge holes between the upper punching plate 142 and the lower punching plate 144. The degree of overlap of the discharge holes determines the feeding speed of the zinc powder, thereby realizing precise control of the feeding amount.

[0150] An intelligent control method for a zinc powder screening device includes the following steps:

[0151] Step 1: Zinc powder first enters the device through the feed hopper 141. A feed hole is provided between the upper punching plate 142 and the lower punching plate 144. Their relative positions can be adjusted by the fourth drive motor 143. The fourth drive motor 143 is started to drive the lower punching plate 144 to rotate, thereby adjusting the overlap degree of the feed holes between the upper punching plate 142 and the lower punching plate 144. By precisely controlling the overlap degree of the feed holes, the feeding speed of the zinc powder can be precisely controlled to ensure the smooth progress of subsequent processes.

[0152] Step 2: Zinc powder enters the crushing chamber 8 within the third housing 7 from the feeding mechanism 14. The electric telescopic rod 9 adjusts the distance between the first rotating base 10 and the second rotating base 12 according to the particle size of the zinc powder, thereby changing the gap between the first crushing roller 11 and the second crushing roller 13. The first crushing roller 11 and the second crushing roller 13 rotate relative to each other, crushing the zinc powder to the desired particle size. The crushed zinc powder enters the zinc powder screening mechanism 6 through the opening below the crushing chamber 8.

[0153] Step 3: The crushed zinc powder falls on the screening plate 64, which screens the zinc powder. The zinc powder with smaller particles passes through the screen and falls on the conveyor belt 2, and is then sent out by the discharging chute 3. The zinc powder with larger particles is retained on the screening plate 64 and is sent out for collection due to the inclined design of the screening plate 64. The cleaning brush 69, driven by the second drive motor 67 and the threaded rod 66, moves back and forth above the screening plate 64 to clean the blockage on the screen and maintain the screening efficiency.

[0154] Step 4: When the third driving motor 611 is driven, the rotating disk 612 drives the pushing arm 613 to move. Through the linkage between the pushing arm 613 and the shaking screen support frame 62, the shaking screen support frame 62 slides back and forth in the direction of the limiting sliding groove 614 opened on the inner side of the second shell 61. This shaking method can increase the efficiency and effect of screening and ensure that the zinc powder on the screening plate 64 can be fully screened.

[0155] In step three, machine vision technology is introduced. The intelligent algorithm can monitor the distribution of zinc powder on the screen plate in real time and automatically adjust the movement trajectory and frequency of the cleaning brush, as well as the tilt angle of the screen plate, to minimize the occurrence of blockages and maintain screening efficiency. The specific process is as follows:

[0156] 1. Equipment and sensor configuration

[0157] Camera resolution: 256×256 pixels.

[0158] Brush movement speed range: 0-10cm / s.

[0159] Screen plate inclination angle range: 0-15 degrees.

[0160] 2. Data Collection and Processing

[0161] Image capture frequency: 10 frames / second.

[0162] The segmented image is binarized: 1 represents zinc powder particles and 0 represents background.

[0163] 3. Image Preprocessing

[0164] The collected original images were Gaussian blurred to smooth the noise.

[0165] The original image is I raw

[0166] The image after GaussianBlur processing is I smooth =GaussianBlur(I raw )

[0167] 4. Image Segmentation

[0168] Use the UNet model to perform image segmentation and output the segmentation result I seg

[0169] Segmented Image Example I seg =UNet(I smooth )

[0170] 5. GAN generates data enhancement

[0171] The generator G generates a simulated zinc powder distribution image, and the discriminator D evaluates the authenticity of the image. The generator output example is: I gen =G(z), where z is a random noise vector.

[0172] 6. Status indication

[0173] s t =[I seg ,(12,34),5,5]

[0174] 7. Action Selection

[0175] a t =[6, 10, 7, 5]

[0176] 8. Reward Function

[0177] r t =10×0.9-5×10=9-50=-41

[0178] 9. Critics Network Update

[0179]

[0180] Wherein, the discount factor γ = 0.99; there is no end marker (d = 0);

[0181] Update the critic network parameters:

[0182]

[0183] 10. Actor Network Update

[0184] Actor Network Objective Function:

[0185]

[0186] Update the actor network parameters using gradient descent.

[0187] 11. Target network update The target network parameters are updated via soft update:

[0188] θ′ i ←τθ i +(1-τ)θ′ i

[0189] Where τ = 0.005.

[0190] 12. Real-time adjustment and feedback:

[0191] Enter the current state s t To the SAC model, output action a t

[0192] a t =π φ (s t )

[0193] Execute action a t , update the brush speed and screen plate angle.

[0194] The above is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A zinc powder screening device, characterized in that: include: The first shell (1) is provided with a conveyor belt (2) inside the first shell (1), a discharging chute (3) is provided below the conveyor belt (2), a fixed block (4) is fixedly connected to the side of the first shell (1), a first driving motor (5) is fixedly connected above the fixed block (4), a zinc powder screening mechanism (6) is fixedly connected above the first shell (1), a third shell (7) is fixedly connected above the zinc powder screening mechanism (6), a crushing chamber (8) is provided inside the third shell (7), two groups of electric telescopic rods (9) are fixedly connected inside the crushing chamber (8), the movable ends of the two groups of electric telescopic rods (9) are fixedly connected to a first rotating base (10), a first rolling roller (11) is rotatably connected inside the first rotating base (10), a second rotating base (12) is fixedly connected inside the crushing chamber (8), a second rolling roller (13) is rotatably connected inside the second rotating base (12), and a feeding mechanism (14) is fixedly connected above the third shell (7); The zinc powder screening mechanism (6) includes a second shell (61), a shaking screen support frame (62) is provided inside the second shell (61), and the two sides of the shaking screen support frame (62) are fixedly connected with limited sliding bars (63), the inner side of the shaking screen support frame (62) is fixedly connected with a screening plate (64), and the inner side of the shaking screen support frame (62) is fixedly connected with two groups of chute blocks (65) located below the screening plate (64), one group of the chute blocks (65) is rotatably connected to the inner side of a threaded rod (66), and the side of the shaking screen support frame (62) is fixedly connected with a second driving motor. The machine (67) is provided with a movable cross bar (68) between the two groups of slide blocks (65), a cleaning brush (69) is fixedly connected to the top of the movable cross bar (68), the second shell (61) is fixedly connected to an L-shaped fixed plate (610), a third driving motor (611) is fixedly connected to the top of the L-shaped fixed plate (610), the rotating shaft of the third driving motor (611) is fixedly connected to a rotating disk (612), the side of the rotating disk (612) is rotatably connected to a pushing arm (613), and two groups of limiting sliding grooves (614) are opened on the inner side of the second shell (61).

2. A zinc powder screening device according to claim 1, characterized in that: The feeding mechanism (14) comprises a feeding hopper (141), an upper punching plate (142) is fixedly connected below the feeding hopper (141), a fourth driving motor (143) is fixedly connected above the upper punching plate (142), and a rotating shaft of the fourth driving motor (143) passes through the upper punching plate (142) and is fixedly connected to a lower punching plate (144).

3. A zinc powder screening device according to claim 1, characterized in that: The rotating shaft of the first driving motor (5) passes through the first housing (1) and is fixedly connected to the transmission shaft inside the conveyor belt (2).

4. A zinc powder screening device according to claim (1), characterized in that: The bottom of the feeding mechanism (14) passes through the third shell (7) to the inside of the crushing chamber (8), and the bottom of the crushing chamber (8) passes through to the bottom of the third shell (7).

5. A zinc powder screening device according to claim 1, characterized in that: The rotating shaft of the second driving motor (67) passes through the shaking screen support frame (62) and the chute block (65) and is fixedly connected to the threaded rod (66).

6. A zinc powder screening device according to claim 1, characterized in that: The two groups of chute blocks (65) are provided with chute inside, and the two ends of the movable cross bar (68) are fixedly connected with sliders adapted to the chute blocks (65), and the inner side of the slider close to the threaded rod (66) is provided with a threaded hole adapted thereto.

7. A zinc powder screening device according to claim 1, characterized in that: One end of the pushing arm (613) is rotatably connected to the rotating disk (612), and the other end is rotatably connected to the inner side of the shaking screen support frame (62). The limiting sliding bar (63) is adapted to the limiting sliding groove (614), and the shaking screen support frame (62) is slidably connected to the second shell (61).

8. A zinc powder screening device according to claim 2, characterized in that: The upper punching plate (142) and the lower punching plate (144) are both provided with four groups of blanking holes of the same size and position, and the axes of the upper punching plate (142) and the lower punching plate (144) are located in the same straight line.

9. An intelligent control method for a zinc powder screening device, characterized in that: It includes the following steps: Step 1: Zinc powder first enters the device through the feed hopper (141), and a feed hole is provided between the upper punching plate (142) and the lower punching plate (144). The relative position of the feed holes can be adjusted by the fourth drive motor (143). The fourth drive motor (143) is started to drive the lower punching plate (144) to rotate, thereby adjusting the overlap degree of the feed holes between the upper punching plate (142) and the lower punching plate (144). By accurately controlling the overlap degree of the feed holes, the feeding speed of the zinc powder can be accurately controlled, thereby ensuring the smooth progress of the subsequent processes. Step 2: Zinc powder enters the crushing chamber (8) in the third housing (7) from the feeding mechanism (14), and the electric telescopic rod (9) adjusts the distance between the first rotating base (10) and the second rotating base (12) according to the particle size of the zinc powder, thereby changing the gap between the first crushing roller (11) and the second crushing roller (13). The first crushing roller (11) and the second crushing roller (13) rotate relative to each other to crush the zinc powder to a desired particle size. The crushed zinc powder enters the zinc powder screening mechanism (6) through the opening below the crushing chamber (8); Step 3: The crushed zinc powder falls on the screening plate (64), and the screening plate (64) screens the zinc powder. The zinc powder with smaller particles passes through the screen and falls on the conveyor belt (2), and is then sent out by the discharge chute (3). The zinc powder with larger particles is retained on the screening plate (64) and is sent out for collection due to the inclined design of the screening plate (64). The cleaning brush (69) moves back and forth above the screening plate (64) under the drive of the second drive motor (67) and the threaded rod (66), clearing the blockage on the screen to maintain the screening efficiency; Step 4: When the third driving motor (611) is driven, the rotating disk (612) drives the pushing arm (613) to move. Through the linkage between the pushing arm (613) and the shaking screen support frame (62), the shaking screen support frame (62) slides back and forth in the direction of the limiting sliding groove (614) opened on the inner side of the second shell (61). This shaking method can increase the efficiency and effect of screening and ensure that the zinc powder on the screening plate (64) can be fully screened.

10. The intelligent control method for zinc powder screening device according to claim 9, characterized in that: In step three, machine vision technology is introduced to monitor the distribution of zinc powder on the screen plate in real time. The system automatically adjusts the movement trajectory and frequency of the cleaning brush, as well as the tilt angle of the screen plate, to minimize blockages and maintain screening efficiency. The specific process is as follows:

1. Equipment and sensor configuration 1. Camera system: Installation position: The camera is installed 50 cm above the screening device to ensure that the field of view covers the entire screening board; Parameter variables: The resolution was set to 1920 × 1080 and the frame rate was set to 30 frames per second to ensure real-time capture of zinc powder distribution images; Connection method: connected to CCU via GigE interface, with a data transmission rate of 1Gbps; 2. Cleaning brush system: Brush motor: Maxon EC-i40 motor, speed is adjusted by PWM control, initially set to 3000RPM; Position sensor: Optical encoder monitors brush position in real time with a resolution of 1024 pulses / revolution; Motion trajectory: The brush moves linearly on the guide rail, regulated by a NEMA 17 stepper motor with a step angle of 1.8 degrees; 3. Screen plate tilt adjustment system: Tilt motor: Oriental Motor PKP264D28B motor, precise adjustment is achieved through closed-loop control, and the initial tilt angle is set to 15 degrees; Tilt sensor: MPU-6050 gyroscope measures the angle of the sub-board in real time with an accuracy of 0.01 degrees; Control method: Using PID control algorithm, set the target angle to 20 degrees, and the adjustment accuracy to 0.1 degrees; 4. Central Control Unit (CCU) Processor: Intel Core i7-10700K, ensuring fast processing of images and sensor data, Memory: 16GB DDR4, ensuring no memory bottlenecks when multitasking; Storage: 1TB SSD to ensure data storage and access speed; GPU: NVIDIA GTX 3080, for accelerating image processing and deep learning algorithms; 2. Data Processing 1. Image preprocessing: Image denoising: Use Gaussian Blur for image denoising with a kernel size of 5×5; Edge detection: The Canny edge detection algorithm was used with thresholds set to 100 and 200 to extract the edges of zinc powder particles; 2. Image enhancement: Contrast enhancement: Use histogram equalization to enhance the image contrast, making zinc powder particles easier to identify; 3. Sensor data preprocessing: Filtering: Perform low-pass filtering on the position and acceleration sensor data, with the filter cutoff frequency set to 5 Hz to remove high-frequency noise; 3. Image Segmentation UNet model: Input layer: accepts a single-channel grayscale image of size 256×256; Encoder: consists of 4 convolutional layers, each layer uses two 3×3 convolution kernels, the activation function is ReLU, and a 2×2 maximum pooling layer is used for downsampling; Bottle pre-layer: The bottom layer uses two 3×3 convolution kernels, and the output feature map size is 16×16; Decoder: consists of 4 deconvolution layers, each of which uses two 3×3 convolution kernels and one 2×2 deconvolution kernel for upsampling, and finally restores to 256×256 size; Output layer: Use 1×1 convolution kernel, Siqmoid activation function, and output the segmented binary image; Model training: Dataset: Use the labeled zinc powder distribution image dataset with a dataset size of 1000 images; Loss function: Binary cross entropy loss function: Among them, L seg is the segmentation loss function; N is the total number of pixels; y i is the true label of the i-th pixel (0 or 1); is the predicted probability of the i-th pixel; Optimizer: Adam optimizer, learning rate set to 0.001, batch size to 16, and number of training rounds to 50; 4. Generative Adversarial Network (GAN) Optimization 1. Generator Network: The input is a 100-dimensional noise vector z. The dimension selection is based on experimental verification: when the noise dimension is less than 80, the generated image details are insufficient, and when it is greater than 120, the training convergence speed decreases. The noise distribution adopts the standard normal distribution N(0, 1), and the KL divergence constraint is used to generate image diversity. Use 4 fully connected layers, each layer uses the LeakyReLU activation function, the output size increases layer by layer, and the last layer outputs an image of size 256×256; 2. Discriminator network: The input is a real image of 256×256 Use 4 convolutional layers, each layer uses LeakyReLU activation function and batch normalization (Batch Normalization). The last layer uses Siqmoid activation function to output the probability of the image being real or generated; 3. Training process: The generator and discriminator are trained alternately; the generator tries to generate realistic zinc powder distribution images, and the discriminator tries to distinguish between real images and generated images; Generator loss function: in, is the mathematical expectation; L G is the generator loss; z is the noise vector; p z (z) is the noise distribution; G(z) is the image generated by the generator; D(G(z)) is the evaluation of the generated image by the discriminator; Discriminator loss function: in, is the mathematical expectation; L D is the discriminator loss; x is the real image; p data (x) is the real data distribution; D(x) is the discriminator’s evaluation of the real image; Optimizer: Adam optimizer, the learning rate of the generator and discriminator are both set to 0.0002, and β1 is set to 0.5; 5. Soft Actor-Critic (SAC) Algorithm 1. Environment settings and status representation Status t Definition: s t =[R,LV,A] Current zinc powder distribution image processing result R: segmented image data, indicating the location and size of zinc powder particles and blockages; Brush current position L: indicates the current physical position of the brush on the screening plate; Brush movement speed V: indicates the current movement speed of the brush; Screen plate inclination angle A: indicates the current inclination angle of the screen plate; Action a t Definition: a t =[d,v,f,g] Adjust the moving direction d of the brush; Adjust the brush's movement speed v; Adjust the vibration frequency f of the brush; Adjust the inclination angle g of the screening plate; 2. Reward Function Reward function r t The design needs to take into account the screening efficiency and clogging situation; the definitions are as follows: r t =α×E t -β×A t in, E t is the screening efficiency, and the calculation formula is as follows: A t is the blocked area, and the calculation formula is as follows: A t =P block ×S α and β are weight coefficients, representing the importance of screening efficiency and clogging area; S is the total area of the screen; 3. Critics Network Update SAC uses a dual critic network and The goal is to minimize the following loss function: Among them, the TD target value y(r, s′, d) is defined as: in, is the mathematical expectation; γ is the discount factor; is the Q value of the target critic network; θ′ i are the parameters of the target network, a′ is the action sampled from the policy network; J Q (θ i ) is the loss function of the i-th critic network; θ i is the parameter of the i-th critic network; s is the current state; a is the current action; r is the reward; s′ is the next state; d is the end flag; For the experience replay pool; is the Q value of the critic network; y(r, s′, d) is the target value; The Q-value network uses bilinear interpolation to downsample the 256×256 image to a 64×64 grid and then calculate the local feature weights. The formula is: where w ij is the weight coefficient of the grid (i, j), which is initialized by offline pre-training and dynamically adjusted in the online stage; f ij represents the state-action value function; 4. Actor Network Update Actor Network π φ (a|s) is updated by maximizing the following objective function in, is the mathematical expectation; α is the weight coefficient of entropy; J π is the loss function of the actor network; π φ is the strategy of the actor network; φ is the parameter of the actor network; α is the entropy weight coefficient; 5. Target network update The target network parameters are updated via soft update: θ′ i ←tth i +(1-τ)θ′ i Where τ is the step size of soft update; θ′ i is the target network parameter; 6. Real-time Adjustment and Feedback The sieve plate image is collected every 30 seconds, and the blockage area is calculated using the UNet model. If the blockage area is greater than 5% of the sieve area, the following adjustments are triggered: Increase the brush speed to 4000RPM and the screen plate inclination angle to 25°; reduce the feed rate by 20%; adjust the parameters until the blockage area is less than 2%, and then restore the baseline parameters; The status of the screening device is continuously updated and optimized in an iterative cycle. Through the above process, the purpose of intelligent optimization of the zinc powder screening device is achieved, and the separation efficiency and overall performance of the equipment are improved.

Images