Grate cooler material layer thickness measuring system

Abstract

The invention discloses a grate cooler material layer thickness measuring system, which comprises a real-time monitoring module, a numerical control module and a verification module, and is characterized in that the real-time monitoring module monitors the contour, temperature and air pressure of a grate cooler material layer in real time to obtain real-time monitoring data of the contour, temperature and air pressure of the grate cooler material layer; the numerical control module calculates the thickness of the grate cooler material layer according to the real-time monitoring data of the grate cooler material layer contour, the temperature and the air pressure, and an initial material layer thickness value is obtained; and the verification module intermittently measures the thickness of the grate cooler material layer in a multi-point manner to obtain multi-point material layer thickness data. The grate cooler material layer thickness measuring system combines multiple environmental parameters to achieve accurate thickness measurement, meanwhile, the thickness measurement result is intermittently calibrated, the purpose of checking and correcting the measurement result is achieved, the grate bed speed and the air chamber air pressure are accurately controlled, the phenomena that a loose material layer is compacted or red materials or equipment is overloaded are prevented, the clinker quality is improved, and the quality of the clinker is improved. And continuous operation of the system is ensured.

Description

Technical Field

[0001] The invention relates to the technical field of grate cooler material layer thickness measurement, and in particular to a grate cooler material layer thickness measurement system. Background Art

[0002] Grate cooler is an important main equipment in the clinker burning system of cement plant. Its main function is to cool and transport cement clinker; at the same time, it provides hot air to rotary kiln and decomposition furnace, etc., and is the main equipment for heat recovery in the burning system. During the clinker production process, the transmission control system of the grate cooler directly affects the stability of the entire cement production system, affecting the cement quality and the efficiency of heat recovery. The thickness of the clinker layer is one of the main control parameters in the grate cooler control system. The thickness of the material layer determines the speed of the grate and affects the working effect of the air supply system.

[0003] However, most of the existing grate cooler material layer thickness measurements use the wind pressure method to achieve non-contact detection. However, the wind pressure method uses a single-point static pressure difference measurement, which does not take into account the uneven airflow distribution and changes in material resistance characteristics. The error is large in actual application, and the wind pressure measurement system lacks online self-calibration function and has poor stability.

[0004] Therefore, there is an urgent need for a grate cooler material layer thickness measurement system that can improve measurement accuracy and has a self-calibration function to solve the problems raised in the above background technology. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides a grate cooler material layer thickness measurement system, which combines multiple environmental parameters to achieve accurate thickness measurement. At the same time, it intermittently calibrates the thickness measurement results to achieve the purpose of verification and correction of the measurement results, accurately controls the grate bed speed and the wind chamber wind pressure, prevents the loose material layer from being compacted or the occurrence of red material and equipment overload, improves the quality of clinker, and ensures the continuous operation of the system to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A grate cooler material layer thickness measurement system comprises: a real-time monitoring module, a numerical control module and a calibration module, wherein the real-time monitoring module monitors the profile, temperature and wind pressure of the grate cooler material layer in real time to obtain real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure; the numerical control module calculates the grate cooler material layer thickness based on the real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure to obtain an initial material layer thickness value; the calibration module intermittently measures the grate cooler material layer thickness at multiple points to obtain multi-point material layer thickness data; the calibration module calculates the median value of the multi-point material layer thickness data to obtain the median value of the measured material layer thickness; the calibration module calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value; the calibration module compensates the initial material layer thickness value calculated by real-time monitoring based on the thickness error value to obtain a material layer thickness correction value; the numerical control module adjusts the grate cooler air chamber wind pressure and the clinker high-temperature zone residence time based on the material layer thickness correction value to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload.

[0008] As a further solution of the present invention: the real-time monitoring module includes: a contour monitoring unit, a temperature monitoring unit and a wind pressure monitoring unit, wherein the contour monitoring unit is used to collect three-dimensional contour data of the material layer surface in real time; the temperature monitoring unit is used to obtain the temperature distribution data of the material layer and monitor the temperature change of the material layer in real time; the wind pressure monitoring unit monitors the wind pressure intensity in each area of the material layer in real time to prevent the wind pressure change from causing poor ventilation of the material layer or temperature rise.

[0009] As a further solution of the present invention: the verification module includes: a thickness measurement sampling unit and a monitoring thickness compensation unit, wherein the thickness measurement sampling unit intermittently measures the thickness of the grate cooler material layer at multiple points to obtain multi-point material layer thickness data; the monitoring thickness compensation unit calculates the median value of the multi-point material layer thickness data to obtain the median value of the measured material layer thickness; the monitoring thickness compensation unit calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value, and compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain a material layer thickness correction value.

[0010] As a further solution of the present invention: the CNC module includes: a data processing unit, a control unit and an abnormal warning unit, wherein the data processing unit calculates the grate cooler material layer thickness based on the real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure to obtain the initial material layer thickness value; the control unit adjusts the grate cooler air chamber wind pressure and the clinker high temperature zone residence time according to the material layer thickness correction value to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload; the abnormal alarm unit warns the staff based on the thickness error value. When the thickness error value is ±20mm, the abnormal alarm unit will operate to issue a buzzer alarm and a visual warning.

[0011] As a further solution of the present invention: the contour monitoring unit includes a non-contact sensor array, which includes a radar sensor and a laser rangefinder. The radar sensor and the laser rangefinder are arranged above the grate bed of the grate cooler to collect three-dimensional contour data of the material layer surface in real time, and the radar sensors are vertically arranged on both sides of the center line of the grate bed with a spacing of 0.8-1.2m; the laser rangefinders are cross-arranged at an inclination angle of 20°-30°, and the adjacent spacing is ≤0.5m.

[0012] As a further solution of the present invention: it is characterized in that the temperature monitoring unit includes a plurality of infrared thermal imagers, the plurality of infrared thermal imagers are arranged below the grate bed, and the lateral distribution spacing of the plurality of infrared thermal imagers is consistent with the width of the grate bed partition, and each partition corresponds to a thermal imager.

[0013] As a further solution of the present invention: the wind pressure monitoring unit includes a plurality of differential pressure transmitters, and the plurality of differential pressure transmitters are respectively arranged in independent partitions of the grate bed air chamber to detect the wind pressure intensity.

[0014] As a further solution of the present invention: the data processing unit has a built-in multi-stage data correction algorithm of Kalman filtering, and the data processing unit calculates the grate cooler material layer thickness based on the multi-stage data correction algorithm of Kalman filtering to obtain an initial material layer thickness value.

[0015] Compared with the prior art, the advantages of the present invention are: the grate cooler material layer thickness measurement system proposed in the present invention adopts a contour monitoring unit to collect the three-dimensional contour data of the material layer surface in real time, the temperature monitoring unit obtains the temperature distribution data of the material layer, and monitors the temperature change of the material layer in real time. The wind pressure monitoring unit monitors the wind pressure intensity of each area of the material layer in real time to prevent the wind pressure change from causing poor ventilation of the material layer or temperature rise, and combines multiple environmental parameters to achieve accurate thickness measurement. At the same time, the thickness measurement sampling unit intermittently measures the grate cooler material layer thickness at multiple points to obtain the multi-point material layer thickness data, and the monitoring thickness compensation unit calculates the multi-point material layer The middle value of the thickness data is used to obtain the middle value of the measured material layer thickness, and the difference between the initial material layer thickness value and the middle value of the measured material layer thickness is calculated to obtain the thickness error value, so as to achieve the purpose of verifying and correcting the measurement results. At the same time, the monitoring thickness compensation unit compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain the material layer thickness correction value. The CNC module adjusts the grate cooler air chamber pressure and the clinker high temperature zone residence time according to the material layer thickness correction value, accurately controls the grate bed speed and air chamber pressure, prevents the loose material layer from being compacted or the occurrence of red material and equipment overload, improves the clinker quality, and ensures the continuous operation of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the structure of a grate cooler material layer thickness measurement system according to one embodiment of the present invention;

[0017] Figure 21 is a flow chart of a grate cooler material layer thickness measurement system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0018] Combine Figure 1-Figure 2 As shown, in this embodiment, a grate cooler material layer thickness measurement system includes: a real-time monitoring module, a numerical control module and a calibration module, wherein the real-time monitoring module includes: a contour monitoring unit, a temperature monitoring unit and a wind pressure monitoring unit. The system adopts the contour monitoring unit to collect the three-dimensional contour data of the material layer surface in real time, the temperature monitoring unit obtains the temperature distribution data of the material layer, and monitors the temperature change of the material layer in real time. The wind pressure monitoring unit monitors the wind pressure intensity of each area of the material layer in real time to prevent the wind pressure change from causing poor ventilation of the material layer or temperature rise, and combines multiple environmental parameters to achieve accurate thickness measurement.

[0019] In this embodiment, the CNC module includes: a data processing unit, a control unit and an abnormal warning unit, wherein the data processing unit calculates the grate cooler material layer thickness based on the real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure to obtain the initial material layer thickness value; the control unit adjusts the grate cooler air chamber wind pressure and the clinker high temperature zone residence time according to the material layer thickness correction value to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload; the abnormal alarm unit warns the staff based on the thickness error value. When the thickness error value is ±20mm, the abnormal alarm unit will emit a buzzer alarm and a visual warning; the system calculates the grate cooler material layer thickness based on the multi-level data correction algorithm of the Kalman filter to obtain the initial material layer thickness value, calculates the difference between the initial material layer thickness value and the middle value of the measured material layer thickness to obtain the thickness error value. When the thickness error value is ±20mm, the abnormal alarm unit will emit a buzzer alarm and a visual warning. At the same time, the system adjusts the grate cooler air chamber wind pressure and the clinker high temperature zone residence time through the control unit to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload.

[0020] In this embodiment, the verification module includes: a thickness measurement sampling unit and a monitoring thickness compensation unit, wherein the thickness measurement sampling unit intermittently measures the thickness of the grate cooler material layer at multiple points to obtain material layer thickness data at multiple points; the monitoring thickness compensation unit calculates the median value of the material layer thickness data at multiple points to obtain the median value of the measured material layer thickness; the monitoring thickness compensation unit calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value, and compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain a material layer thickness correction value; the method for the thickness measurement sampling unit to intermittently measure the thickness of the grate cooler material layer at multiple points is mechanical probe detection, selects multiple points to detect the material layer thickness, takes the median value of the material layer thickness at each point, and calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value, and compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain a material layer thickness correction value, thereby achieving the purpose of verifying and correcting the measurement results.

[0021] In this embodiment, the contour monitoring unit includes a non-contact sensor array, which includes a radar sensor and a laser rangefinder. The radar sensor and the laser rangefinder are arranged above the grate bed of the grate cooler to collect three-dimensional contour data of the material layer surface in real time, and the radar sensor is vertically arranged on both sides of the center line of the grate bed with a spacing of 0.8-1.2m; the laser rangefinder is cross-arranged at an inclination angle of 20°-30°, and the adjacent spacing is ≤0.5m; the radar sensor and the laser rangefinder are installed above the grate bed of the grate cooler in a specific spatial configuration to collect three-dimensional contour data of the material layer surface in real time, which can eliminate measurement blind spots and improve the accuracy of measurement results.

[0022] In this embodiment, the temperature monitoring unit includes several infrared thermal imagers, which are arranged under the grate bed, and the lateral distribution spacing of the several infrared thermal imagers is consistent with the width of the grate bed partition, and each partition corresponds to a thermal imager; the infrared thermal imager is used to obtain the temperature distribution data of the material layer, monitor the temperature change of the material layer in real time, locate the poor cooling area through the temperature gradient, and confirm whether the material layer is too thick or the ventilation is blocked.

[0023] In this embodiment, the wind pressure monitoring unit includes several differential pressure transmitters, and the several differential pressure transmitters are respectively arranged in each independent partition of the grate bed wind chamber to detect the wind pressure intensity; the differential pressure transmitter is used to detect the wind pressure intensity in each independent partition of the grate bed wind chamber to prevent the wind pressure change from causing poor ventilation of the material layer or temperature rise, thereby suppressing the virtual thickness error of the material layer.

[0024] The grate cooler material layer thickness measurement system proposed in the present invention adopts a contour monitoring unit to collect the three-dimensional contour data of the material layer surface in real time, a temperature monitoring unit to obtain the temperature distribution data of the material layer, and to monitor the temperature change of the material layer in real time. The wind pressure monitoring unit monitors the wind pressure intensity in each area of the material layer in real time to prevent the wind pressure change from causing poor ventilation of the material layer or temperature rise. It combines multiple environmental parameters to achieve accurate thickness measurement. At the same time, the thickness measurement sampling unit intermittently measures the thickness of the grate cooler material layer at multiple points to obtain the multi-point material layer thickness data. The monitoring thickness compensation unit calculates the median value of the multi-point material layer thickness data. The middle value of the measured material layer thickness is obtained, and the difference between the initial material layer thickness value and the middle value of the measured material layer thickness is calculated to obtain the thickness error value, thereby achieving the purpose of verifying and correcting the measurement results. At the same time, the monitoring thickness compensation unit compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain the material layer thickness correction value. The CNC module adjusts the grate cooler air chamber pressure and the clinker high-temperature zone residence time according to the material layer thickness correction value, accurately controls the grate bed speed and air chamber pressure, prevents the loose material layer from being compacted or the occurrence of red material and equipment overload, improves the clinker quality, and ensures the continuous operation of the system.

[0025] 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 grate cooler material layer thickness measurement system, characterized in that: include: A real-time monitoring module, a numerical control module and a verification module, wherein the real-time monitoring module monitors the profile, temperature and wind pressure of the grate cooler material layer in real time to obtain real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure; the numerical control module calculates the grate cooler material layer thickness based on the real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure to obtain an initial material layer thickness value; the verification module intermittently measures the grate cooler material layer thickness at multiple points to obtain multi-point material layer thickness data; the verification module calculates the median value of the multi-point material layer thickness data to obtain the median value of the measured material layer thickness; the verification module calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value; the verification module compensates the initial material layer thickness value calculated by real-time monitoring based on the thickness error value to obtain a material layer thickness correction value; the numerical control module regulates the grate cooler air chamber wind pressure and the clinker high-temperature zone residence time based on the material layer thickness correction value to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload.

2. A grate cooler material layer thickness measurement system according to claim 1, characterized in that: The real-time monitoring module includes: a contour monitoring unit, a temperature monitoring unit and a wind pressure monitoring unit, wherein the contour monitoring unit is used to collect three-dimensional contour data of the material layer surface in real time; the temperature monitoring unit is used to obtain temperature distribution data of the material layer and monitor the temperature change of the material layer in real time; the wind pressure monitoring unit monitors the wind pressure intensity in each area of the material layer in real time to prevent the wind pressure change from causing poor ventilation or temperature rise of the material layer.

3. A grate cooler material layer thickness measurement system according to claim 1, characterized in that: The verification module includes: a thickness measurement sampling unit and a monitoring thickness compensation unit, wherein the thickness measurement sampling unit intermittently measures the thickness of the grate cooler material layer at multiple points to obtain multi-point material layer thickness data; the monitoring thickness compensation unit calculates the median value of the multi-point material layer thickness data to obtain the median value of the measured material layer thickness; the monitoring thickness compensation unit calculates the difference between the initial material layer thickness value and the median value of the measured material layer thickness to obtain a thickness error value, and compensates the initial material layer thickness value calculated by real-time monitoring according to the thickness error value to obtain a material layer thickness correction value.

4. A grate cooler material layer thickness measurement system according to claim 1, characterized in that: The numerical control module includes: a data processing unit, a control unit and an abnormal warning unit, wherein the data processing unit calculates the thickness of the grate cooler material layer based on the real-time monitoring data of the grate cooler material layer profile, temperature and wind pressure to obtain the initial material layer thickness value; the control unit adjusts the wind pressure in the grate cooler air chamber and the residence time of the clinker high-temperature zone according to the material layer thickness correction value to prevent the loose material layer from being compacted or the occurrence of red material and equipment overload; the abnormal alarm unit warns the staff based on the thickness error value. When the thickness error value is ±20mm, the abnormal alarm unit will operate to issue a buzzer alarm and a visual warning.

5. A grate cooler material layer thickness measurement system according to claim 2, characterized in that: The contour monitoring unit includes a non-contact sensor array, which includes a radar sensor and a laser rangefinder. The radar sensor and the laser rangefinder are arranged above the grate bed of the grate cooler to collect three-dimensional contour data of the material layer surface in real time. The radar sensors are arranged vertically on both sides of the center line of the grate bed with a spacing of 0.8-1.2m; the laser rangefinders are arranged crosswise at an inclination angle of 20°-30°, and the adjacent spacing is ≤0.5m.

6. A grate cooler material layer thickness measurement system according to claim 2, characterized in that: The temperature monitoring unit includes a plurality of infrared thermal imagers, which are arranged below the grate bed. The lateral distribution spacing of the plurality of infrared thermal imagers is consistent with the width of the grate bed partition, and each partition corresponds to a thermal imager.

7. A grate cooler material layer thickness measurement system according to claim 2, characterized in that: The wind pressure monitoring unit includes a plurality of differential pressure transmitters, and the plurality of differential pressure transmitters are respectively arranged in independent partitions of the grate bed air chamber to detect wind pressure intensity.

8. The grate cooler material layer thickness measurement system according to claim 4, characterized in that: The data processing unit has a built-in multi-stage data correction algorithm of Kalman filtering. The data processing unit calculates the thickness of the grate cooler material layer based on the multi-stage data correction algorithm of Kalman filtering to obtain an initial material layer thickness value.

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