A strand cooler bed depth measuring system

Abstract

The application discloses a grate cooler material layer thickness measuring system, which comprises a real-time monitoring module, a numerical control module and a verification module, wherein the real-time monitoring module is used for monitoring the profile, temperature and air pressure of the material layer of the grate cooler in real time, and real-time monitoring data of the profile, temperature and air pressure of the material layer of the grate cooler are obtained; the numerical control module is used for calculating the material layer thickness of the grate cooler according to the real-time monitoring data of the profile, temperature and air pressure of the material layer of the grate cooler, and an initial material layer thickness value is obtained; and the verification module is used for intermittently measuring the material layer thickness of the grate cooler at multiple points, and multiple-point material layer thickness data are obtained. The grate cooler material layer thickness measuring system provided by the application realizes accurate thickness measurement in combination with multiple environmental parameters, and the thickness measurement result is calibrated intermittently, so that the measurement result verification and correction purposes are achieved, the grate bed speed and the air chamber air pressure are accurately controlled, the loose material layer is prevented from being compacted or red material or equipment overload phenomenon is prevented, the clinker quality is improved, and the continuous operation of the system is ensured.

Description

Technical Field

[0001] This invention relates to the field of grate cooler material layer thickness measurement technology, and specifically to a grate cooler material layer thickness measurement system. Background Technology

[0002] The grate cooler is a crucial main equipment in the clinker calcination system of a cement plant. Its primary functions are to cool and transport cement clinker, and to provide hot air for rotary kilns and precalciners. It is a key piece of equipment for heat recovery in the calcination system. During clinker production, the drive control system of the grate cooler directly affects the stability of the entire cement production system, impacting cement quality and heat recovery efficiency. The clinker layer thickness is one of the main control parameters in the grate cooler control system, determining the grate speed and affecting the performance of the air supply system.

[0003] However, most existing methods for measuring the thickness of the material layer in grate coolers use the wind pressure method for non-contact detection. However, the wind pressure method uses a single-point static pressure difference measurement, which does not take into account the uneven distribution of airflow and changes in the resistance characteristics of the material. In practical applications, the error is relatively large, and the wind pressure method 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 self-calibration function to solve the problems mentioned in the background art. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art, this invention provides a grate cooler material layer thickness measurement system. This system combines multiple environmental parameters to achieve accurate thickness measurement. Simultaneously, it intermittently calibrates the thickness measurement results to verify and correct the measurement results. It also precisely controls the grate speed and air chamber pressure to prevent the loose material layer from being compacted or to cause red material or equipment overload, thereby improving clinker quality and ensuring continuous system operation. This solves the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A grate cooler material layer thickness measurement system includes: a real-time monitoring module, a numerical control module, and a calibration module. The real-time monitoring module monitors the contour, temperature, and air pressure of the grate cooler material layer in real time, obtaining real-time monitoring data for these parameters. The numerical control module calculates the material layer thickness based on the real-time monitoring data, obtaining an initial material layer thickness value. The calibration module intermittently measures the material layer thickness at multiple points, obtaining multi-point material layer thickness data. The calibration module calculates the median value of the multi-point material layer thickness data, obtaining the median measured material layer thickness value. The calibration module calculates the difference between the initial material layer thickness value and the median measured material layer thickness value, obtaining a thickness error value. The calibration module compensates for the initial material layer thickness value calculated by real-time monitoring based on the thickness error value, obtaining a material layer thickness correction value. The numerical control module adjusts the air pressure in the grate cooler's air chamber and the residence time of the clinker in the high-temperature zone based on the material layer thickness correction value to prevent the loose material layer from being compacted, or to prevent red-hot material or equipment overload.

[0007] As a further aspect of the present invention, the real-time monitoring module includes: a contour monitoring unit, a temperature monitoring unit, and a wind pressure monitoring unit. 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 acquire 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 of each area of ​​the material layer in real time to prevent wind pressure changes from causing poor ventilation or temperature rise in the material layer.

[0008] As a further aspect of the present invention: the verification module includes a thickness measurement sampling unit and a thickness monitoring compensation unit, wherein the thickness measurement sampling unit intermittently measures the thickness of the material layer of the grate cooler at multiple points to obtain multi-point material layer thickness data; the thickness monitoring compensation unit calculates the intermediate value of the multi-point material layer thickness data to obtain the intermediate value of the measured material layer thickness; the thickness monitoring compensation unit calculates the difference between the initial material layer thickness value and the intermediate value of the measured material layer thickness to obtain the thickness error value; and the initial material layer thickness value calculated in real time is compensated based on the thickness error value to obtain the material layer thickness correction value.

[0009] As a further embodiment of the present invention: the CNC module includes a data processing unit, a control unit, and an anomaly warning unit. The data processing unit calculates the thickness of the grate cooler material layer based on real-time monitoring data of the material layer profile, temperature, and air pressure, and obtains an initial material layer thickness value. The control unit adjusts the air pressure of the grate cooler air chamber and the residence time of the clinker in the high-temperature zone based on the material layer thickness correction value to prevent the loose material layer from being compacted or from becoming red-hot or overloaded. The anomaly warning unit alerts the operator based on the thickness error value. When the thickness error value is ±20mm, the anomaly warning unit activates a buzzer alarm and a visual warning.

[0010] As a further embodiment 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 set above the grate of the grate cooler to collect three-dimensional contour data of the material layer surface in real time. The radar sensor is vertically set on both sides of the center line of the grate with a spacing of 0.8-1.2m. The laser rangefinder is arranged in a cross pattern with an inclination angle of 20°-30° and an adjacent spacing of ≦0.5m.

[0011] As a further aspect of the present invention, the temperature monitoring unit includes several infrared thermal imagers, which are arranged below the grate bed, and the horizontal spacing of the infrared thermal imagers is consistent with the width of the grate bed partitions, with each partition corresponding to one thermal imager.

[0012] As a further aspect of the present invention: the wind pressure monitoring unit includes several differential pressure transmitters, which are respectively installed in each independent zone of the grate air chamber to detect the wind pressure intensity.

[0013] As a further aspect of the present invention: the data processing unit incorporates a multi-level data correction algorithm based on Kalman filtering, and the data processing unit calculates the material layer thickness of the grate cooler based on the multi-level data correction algorithm based on Kalman filtering to obtain the initial material layer thickness value.

[0014] Compared with existing technologies, the advantages of this invention are as follows: The grate cooler material layer thickness measurement system proposed in this invention uses a contour monitoring unit to collect three-dimensional contour data of the material layer surface in real time, a temperature monitoring unit to acquire material layer temperature distribution data and monitor material layer temperature changes in real time, and a wind pressure monitoring unit to monitor the wind pressure intensity in each area of ​​the material layer in real time to prevent wind pressure changes from causing poor ventilation or temperature rise in the material layer. Combined with multiple environmental parameters, accurate thickness measurement is achieved. Simultaneously, a thickness measurement sampling unit intermittently measures the material layer thickness at multiple points in the grate cooler to obtain multi-point material layer thickness data, and a thickness compensation unit calculates the material layer thickness at multiple points. The median value of the thickness data is used to obtain the median value of the measured material layer thickness. The difference between the initial material layer thickness value and the median value of the measured material layer thickness is calculated to obtain the thickness error value, which achieves the purpose of verification and correction of the measurement results. At the same time, the thickness compensation unit compensates for the initial material layer thickness value calculated in real time based on the thickness error value to obtain the material layer thickness correction value. The CNC module adjusts the air pressure of the grate cooler air chamber and the residence time of the clinker in the high temperature zone based on the material layer thickness correction value, and precisely controls the grate speed and air chamber air pressure to prevent the loose material layer from being compacted or red material from appearing, equipment overload, improve clinker quality, and ensure continuous operation of the system. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of a grate cooler material layer thickness measurement system according to an embodiment of the present invention; Figure 2This is a schematic flowchart of a grate cooler material layer thickness measurement system according to an embodiment of the present invention. Detailed Implementation

[0016] Combination Figures 1-2 As shown in this embodiment, a material layer thickness measurement system for a grate cooler includes: a real-time monitoring module, a numerical control module, and a calibration module. The real-time monitoring module includes: a contour monitoring unit, a temperature monitoring unit, and a wind pressure monitoring unit. The system uses the contour monitoring unit to collect three-dimensional contour data of the material layer surface in real time, the temperature monitoring unit to obtain material layer temperature distribution data and monitor material layer temperature changes in real time, and the wind pressure monitoring unit to monitor the wind pressure intensity in each area of ​​the material layer in real time to prevent wind pressure changes from causing poor ventilation or temperature rise in the material layer. The system combines multiple environmental parameters to achieve accurate thickness measurement.

[0017] In this embodiment, the CNC module includes a data processing unit, a control unit, and an anomaly warning unit. The data processing unit calculates the grate cooler material layer thickness based on real-time monitoring data of the grate cooler material layer profile, temperature, and air pressure, obtaining an initial material layer thickness value. The control unit adjusts the air pressure in the grate cooler air chamber and the residence time of the clinker in the high-temperature zone based on the material layer thickness correction value to prevent the loose material layer from being compacted, or from exhibiting red material or equipment overload. The anomaly warning unit alerts personnel based on the thickness error value; when the thickness error value is ±20mm, the anomaly warning unit activates a buzzer alarm and a visual warning. The system calculates the grate cooler material layer thickness based on a multi-level data correction algorithm using Kalman filtering to obtain the initial material layer thickness value. It then calculates the difference between the initial material layer thickness value and the median measured material layer thickness to obtain the thickness error value. When the thickness error value is ±20mm, the anomaly warning unit activates a buzzer alarm and a visual warning. Simultaneously, the system adjusts the grate cooler air chamber air pressure and the residence time of the clinker in the high-temperature zone through the control unit to prevent the loose material layer from being compacted, or from exhibiting red material or equipment overload.

[0018] In this embodiment, the verification module includes a thickness measurement sampling unit and a thickness monitoring compensation unit. 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 thickness monitoring compensation unit calculates the median value of the multi-point material layer thickness data to obtain the median measured material layer thickness. The thickness monitoring compensation unit calculates the difference between the initial material layer thickness value and the median measured material layer thickness to obtain the thickness error value. Based on the thickness error value, the initial material layer thickness value calculated by real-time monitoring is compensated to obtain the material layer thickness correction value. The method of intermittently measuring the material layer thickness of the grate cooler material layer by the thickness measurement sampling unit is mechanical probe detection. Multiple points are selected to detect the material layer thickness, the median value of the material layer thickness at each point is taken, and the difference between the initial material layer thickness value and the median measured material layer thickness is calculated to obtain the thickness error value. Based on the thickness error value, the initial material layer thickness value calculated by real-time monitoring is compensated to obtain the material layer thickness correction value, thereby achieving the purpose of verification and correction of the measurement results.

[0019] In this embodiment, the contour monitoring unit includes a non-contact sensor array, which comprises a radar sensor and a laser rangefinder. The radar sensor and laser rangefinder are positioned above the grate of the grate cooler to collect three-dimensional contour data of the material layer surface in real time. The radar sensor is vertically positioned on both sides of the center line of the grate with a spacing of 0.8-1.2m. The laser rangefinder is arranged in a crisscross pattern at an angle of 20°-30° with an adjacent spacing of ≤0.5m. The radar sensor and laser rangefinder are installed above the grate 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.

[0020] In this embodiment, the temperature monitoring unit includes several infrared thermal imagers, which are set below the grate bed. The horizontal spacing of the infrared thermal imagers is consistent with the width of the grate bed partitions, and each partition corresponds to one thermal imager. The infrared thermal imagers are used to acquire material layer temperature distribution data, monitor material layer temperature changes in real time, locate poorly cooled areas through temperature gradients, and confirm whether the material layer is too thick or the ventilation is blocked.

[0021] In this embodiment, the wind pressure monitoring unit includes several differential pressure transmitters, which are respectively installed in each independent zone of the grate air chamber to detect the wind pressure intensity. The differential pressure transmitters are used to detect the wind pressure intensity in each independent zone of the grate air chamber to prevent wind pressure changes from causing poor ventilation or temperature rise in the material layer, and to suppress the error of the material layer thickness.

[0022] The grate cooler material layer thickness measurement system proposed in this invention employs a contour monitoring unit to collect real-time three-dimensional contour data of the material layer surface, a temperature monitoring unit to acquire material layer temperature distribution data and monitor material layer temperature changes in real time, and a wind pressure monitoring unit to monitor wind pressure intensity in various areas of the material layer in real time to prevent wind pressure changes from causing poor ventilation or temperature rise in the material layer. Combining multiple environmental parameters achieves accurate thickness measurement. Simultaneously, a thickness measurement sampling unit intermittently measures the grate cooler material layer thickness at multiple points to obtain multi-point material layer thickness data, and a thickness compensation unit calculates the median value of the multi-point material layer thickness data. The intermediate value of the measured material layer thickness is obtained, and the difference between the initial material layer thickness value and the intermediate value of the measured material layer thickness is calculated to obtain the thickness error value, which achieves the purpose of verification and correction of measurement results. At the same time, the thickness compensation unit compensates for the initial material layer thickness value calculated in real time according to the thickness error value to obtain the material layer thickness correction value. The CNC module adjusts the air pressure of the grate cooler air chamber and the residence time of clinker in the high temperature zone according to the material layer thickness correction value, and precisely controls the grate speed and air chamber air pressure to prevent the loose material layer from being compacted or red material from appearing, equipment overload, improve clinker quality, and ensure continuous operation of the system.

[0023] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A material layer thickness measurement system for a grate cooler, characterized in that, include: The system comprises a real-time monitoring module, a numerical control module, and a verification module. The real-time monitoring module monitors the contour, temperature, and air pressure of the material layer in the grate cooler in real time, obtaining real-time monitoring data for these parameters. The numerical control module calculates the material layer thickness based on the real-time monitoring data, obtaining an initial material layer thickness value. The verification module intermittently measures the material layer thickness at multiple points, obtaining multi-point material layer thickness data. The verification module calculates the median value of the multi-point material layer thickness data, obtaining a measured median material layer thickness value. The verification module calculates the difference between the initial material layer thickness value and the measured median material layer thickness value, obtaining a thickness error value. The verification module compensates for the initial material layer thickness value calculated by real-time monitoring based on the thickness error value, obtaining a material layer thickness correction value. The numerical control module adjusts the air pressure in the grate cooler's air chamber and the residence time of the clinker in the high-temperature zone based on the material layer thickness correction value to prevent the loose material layer from being compacted, or to prevent red-hot material or equipment overload.

2. The material layer thickness measurement system for a grate cooler 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. 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 acquire temperature distribution data of the material layer and monitor temperature changes in 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 wind pressure changes from causing poor ventilation or temperature rise in the material layer.

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

4. The material layer thickness measurement system for a grate cooler according to claim 1, characterized in that, The CNC module includes a data processing unit, a control unit, and an anomaly warning unit. The data processing unit calculates the material layer thickness of the grate cooler based on real-time monitoring data of the material layer profile, temperature, and air pressure, obtaining an initial material layer thickness value. The control unit adjusts the air pressure in the grate cooler's air chamber and the residence time of the clinker in the high-temperature zone based on the material layer thickness correction value to prevent the loose material layer from being compacted or to prevent red material or equipment overload. The anomaly warning unit alerts operators based on the thickness error value. When the thickness error value is ±20mm, the anomaly warning unit activates a buzzer alarm and a visual warning.

5. The material layer thickness measurement system for a grate cooler 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 laser rangefinder are positioned above the grate of the grate cooler to collect three-dimensional contour data of the material layer surface in real time. The radar sensor is vertically positioned on both sides of the center line of the grate with a spacing of 0.8-1.2m. The laser rangefinder is arranged in a crisscross pattern at an inclination angle of 20°-30° with an adjacent spacing of ≤0.5m.

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

7. The material layer thickness measurement system for a grate cooler according to claim 2, characterized in that, The wind pressure monitoring unit includes several differential pressure transmitters, which are respectively installed in each independent zone of the grate air chamber to detect wind pressure intensity.

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

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