Ceramic production line ball mill power-saving control method and device and electronic equipment

Abstract

The invention relates to the technical field of ball mill control, in particular to a ceramic production line ball mill power-saving control method and device and electronic equipment.The control method comprises the steps that formula data of ceramic production is obtained, and control parameters of a ball mill are updated according to the formula data; acquiring load data of the ball mill, and automatically controlling the speed regulation frequency of the ball mill according to the load data; wherein the load data comprises multiple pieces of motor data, the multiple pieces of motor data correspond to the multi-section speed regulation frequency of the ball mill, the multiple pieces of motor data are decreased step by step, and the multi-section speed regulation frequency is adjusted step by step corresponding to the multiple pieces of motor data; and acquiring operation data of the ball mill, recording the operation data to form a report form, and displaying the report form. The speed regulation frequency of the ball mill can be automatically controlled according to the load data, the running time of the ball mill can be better controlled according to formula data capable of effectively running, the running efficiency of the ball mill is improved, and electric energy is saved.

Description

Technical Field

[0001] This invention relates to the field of ball mill control, specifically to a method, device, and electronic equipment for energy-saving control of ball mills in ceramic production lines. Background Technology

[0002] Existing energy-saving technologies for ceramic ball mills are implemented individually for each product type. Each product type is operated using a formula; when switching to a different product, a different formula is selected and downloaded to the PLC. When the formula needs updating, the control equipment is updated directly. However, the data in the formulas is based on experience, and different production processes result in different formula data, requiring frequent modifications and failing to achieve optimal results.

[0003] In existing technologies, the main functions of ball mill control systems include displaying the current operating status, the formulation time for each segment, the running time for each segment, and the total power consumption. Therefore, existing technologies only display individual real-time data points and do not provide reports summarizing key data or offer protection against temperature and current fluctuations. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this invention is to provide a method, device and electronic equipment for energy saving control of ball mills in ceramic production lines, which can automatically control the operating frequency of ball mills without the need for frequent modification of formula data.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: Acquire ceramic production formula data and update the ball mill control parameters based on the formula data; acquire the ball mill load data and automatically control the ball mill speed regulation frequency based on the load data; wherein the load data includes multiple motor data, the multiple motor data corresponds to multiple speed regulation frequencies of the ball mill, the multiple motor data decreases step by step, and the multiple speed regulation frequencies are adjusted step by step according to the multiple motor data; acquire the ball mill operating data, record the operating data to form a report and display it.

[0006] In one embodiment of the present invention, acquiring the load data of the ball mill and automatically controlling the speed regulation frequency of the ball mill based on the load data includes: The speed regulation frequency of the ball mill is automatically controlled based on the real-time current of the frequency converter of the ball mill.

[0007] As one embodiment of the present invention, the automatic control of the speed regulation frequency of the ball mill based on the real-time current of the ball mill's frequency converter includes: When the real-time current of the frequency converter is less than a preset value compared to the rated current, the frequency of the ball mill is adjusted to the frequency band corresponding to the real-time current based on the real-time current of the frequency converter.

[0008] As one embodiment of the present invention, the speed regulation frequency of the ball mill includes: 48HZ, 46HZ, 43HZ, and 41HZ.

[0009] In one embodiment of the present invention, the load data of the ball mill includes a first current data, a second current data, a third current data, and a fourth current data. The first current data, the second current data, the third current data, and the fourth current data are all less than the rated current, and the first current data is less than the second current data, the third current data is less than the second current data, and the fourth current data is less than the third current data.

[0010] As one embodiment of the present invention, the energy-saving control method for the ball mill in the ceramic production line further includes recording the number of times the ball mill runs and displaying the number of times the ball mill is started, the power consumption, ball start time, end time, ball milling time, maximum power, and ball start date for each start.

[0011] In one embodiment of the present invention, the step of acquiring the operating data of the ball mill, recording the operating data to form a report and displaying it includes: The system acquires the temperature, power consumption records, current motor status, motor output frequency, remaining slurry testing time, and remaining slurry discharge time for each motor in the ball mill, and displays these data on the ball mill's display screen.

[0012] As one embodiment of the present invention, the energy-saving control method for ball mill in ceramic production line further includes acquiring the set total running time, slurry measurement time, and slurry discharge time, and controlling the ball mill to automatically stop and issue an alarm when the total running time, slurry measurement time, or slurry discharge time is reached.

[0013] The present invention also provides a ball mill energy-saving control device for a ceramic production line that applies the aforementioned energy-saving control method for ball mills, comprising: The acquisition module is used to acquire formula data for ceramic production and update the control parameters of the ball mill according to the formula data; the automatic adjustment module is used to acquire the load data of the ball mill and automatically control the speed regulation frequency of the ball mill according to the load data; wherein the load data includes multiple motor data, the multiple motor data corresponds to multiple speed regulation frequencies of the ball mill, the multiple motor data decreases step by step, and the multiple speed regulation frequencies are adjusted step by step according to the multiple motor data; The report display module is used to acquire the operating data of the ball mill, record the operating data to form a report and display it.

[0014] To achieve the above objectives, the present invention also adopts the following technical solution: An electronic device includes: at least one processor; and at least one memory communicatively connected to the processor, wherein: the memory stores program instructions executable by the processor, and the processor can execute the above-described energy-saving control method for ball mills in ceramic production lines by invoking the program instructions.

[0015] Compared with the prior art, the beneficial effects of the present invention are: it can automatically control the speed regulation frequency of the ball mill according to the load data, and can effectively run the formula data for different production processes, thereby better controlling the running time of the ball mill, improving the operating efficiency of the ball mill, and achieving the purpose of saving energy.

[0016] The present invention also acquires the operating data of the ball mill, records the operating data into reports and displays them, so that operators can know in advance and make preparations for operation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram illustrating the operation of an energy-saving control method for ball mills in ceramic production lines in the existing technology.

[0019] Figure 2 This is a schematic diagram of the energy-saving control method for ball mills in ceramic production lines according to the present invention.

[0020] Figure 3 This is a schematic diagram of the energy-saving control device for the ball mill in the ceramic production line of the present invention.

[0021] Figure 4 This is a schematic diagram of the structure of an electronic device according to an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached diagram: Acquisition module 31, Automatic adjustment module 32, Report display module 33. Detailed Implementation

[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Furthermore, it should be understood that the specific embodiments described herein are only for illustration and explanation of this application and are not intended to limit this application.

[0024] It should be understood that the terms "first," "second," and "third," etc., in the claims, specification, and drawings of this disclosure are used to distinguish different objects, not to describe a specific order. The terms "comprising" and "including" as used in the specification and claims of this disclosure indicate the presence of the described features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or sets thereof.

[0025] It should be noted that the order of description of the following embodiments is not intended to limit the preferred order of the embodiments of this application. Furthermore, the descriptions of each embodiment in the following embodiments have their own emphasis; for parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0026] like Figure 1 As shown, previously, when producing each variety, one would first select the formula type in button B, then press the formula input button in C, and the formula values ​​for each parameter would be displayed in area D. Switching between different varieties required selecting the corresponding formula, which was inconvenient and could not be done incorrectly.

[0027] In view of this, such as Figure 2 As shown, the present invention provides a method for energy-saving control of ball mills in ceramic production lines, comprising the following steps.

[0028] S100: Obtain the formula data for ceramic production and update the control parameters of the ball mill according to the formula data. Obtain the running time and frequency of the ball mill, write the running time and frequency into the formula, and update the running time and frequency of the ball mill (the frequency is the motor output frequency).

[0029] S200: Obtain the load data of the ball mill, and automatically control the speed regulation frequency of the ball mill according to the load data.

[0030] In one embodiment, the present invention automatically controls the speed regulation frequency of the ball mill based on the real-time current of the frequency converter of the ball mill.

[0031] In another embodiment, the present invention automatically controls the speed regulation frequency of the ball mill based on the running time of the ball mill.

[0032] The load data includes multiple motor data points, each corresponding to a different speed control frequency of the ball mill. These motor data points decrease progressively, and the speed control frequencies are adjusted sequentially according to these motor data points. This is because the ball mill load decreases with increasing operating time. Based on this load reduction process, the corresponding speed control frequency is automatically calculated.

[0033] Specifically, in the first embodiment, when the real-time current of the frequency converter is less than a preset value compared with the rated current, the frequency of the ball mill is adjusted to the frequency band corresponding to the real-time current according to the real-time current of the frequency converter.

[0034] The ball mill will operate for a period of time in each frequency band, specifically in four bands: 48Hz, 46Hz, 43Hz, and 41Hz. All of these are lower than the rated frequency of 50Hz. The rated frequency is the initial operating frequency of the ball mill. After operating for a period of time, the load on the ball mill will decrease, and the frequency will be adjusted accordingly.

[0035] Accordingly, the real-time current of the frequency converter is compared with multiple preset values, and the comparison results correspond to four frequency bands.

[0036] For example, the load data of the ball mill includes a first current data, a second current data, a third current data, and a fourth current data, where the first current data is 20 amps less than the rated current, the second current data is 40 amps less than the rated current, the third current data is 50 amps less than the rated current, and the fourth current data is 70 amps less than the rated current. All of the first, second, third, and fourth current data are less than the rated current.

[0037] As described above, the first current data is less than the second current data, the third current data is less than the second current data, and the fourth current data is less than the third current data; the current data decreases progressively. Therefore, when the real-time current of the frequency converter is 20 amps less than the rated current (first current data), the frequency of the ball mill is automatically adjusted to 48 Hz; sequentially, when the current of the frequency converter is the second current data, the frequency of the ball mill is automatically adjusted to 46 Hz; when the current of the frequency converter is the third current data, the frequency of the ball mill is automatically adjusted to 43 Hz; and when the current of the frequency converter is the fourth current data, the frequency of the ball mill is automatically adjusted to 41 Hz.

[0038] In the second embodiment, the running time of the ball mill is inversely proportional to the load of the ball mill to some extent. The longer the running time, the lower the load of the ball mill. Therefore, the control can be based on the running time.

[0039] Because the operation of the ball mill on-site is unstable due to the eccentric force of the loaded material, the difference between the maximum and minimum current is generally around 80 amps. The average current decreases as the operating time increases. First, the total operating time of the ball mill is set. The first operating period is 0.15 times the total operating time, in seconds. The second operating period is 0.075 times the total operating time; the third operating period is 0.105 times the total operating time; the fourth operating period is 0.12 times the total operating time; and the fifth operating period is the remaining time.

[0040] Different adjustment frequencies can be corresponding to the above time periods. For example, the first operating time corresponds to a rated frequency of 50 Hz, the second operating time corresponds to a frequency of 48 Hz, the third operating time corresponds to a frequency of 46 Hz, the fourth operating time corresponds to a frequency of 43 Hz, and the fifth operating time corresponds to a frequency of 42 Hz.

[0041] Energy can be saved by adjusting the operating frequency of the ball mill.

[0042] S300: Obtain the operating data of the ball mill, record the operating data to form a report and display it.

[0043] For example, the temperature, power consumption record report, current motor status, motor output frequency, remaining slurry testing time, remaining slurry discharging time, total running time, and remaining running time of each motor in the ball mill can be obtained and displayed on the display screen of the ball mill.

[0044] The ball mill also records the number of times it runs and displays the number of times it is started, along with the power consumption, ball start time, end time, milling time, maximum power, and ball start date for each start-up. This recorded and displayed data allows operators to anticipate operations and prepare accordingly.

[0045] For example, the ball mill records the number of times it starts up, and a total of 17 times can be statistically analyzed in real time. Through power consumption, the total power consumption for each start-up and shutdown can be determined. The report also includes the start-up time, end time, milling time, maximum power output, and date of each start-up. The ball mill records these data in automatically generated reports, providing real-time recording of start-up and shutdown times. This facilitates management, such as identifying peak-hour power usage, which greatly helps in energy conservation. It also tracks whether each ball mill completes slurry testing and discharging within the normal timeframe, and whether any interruptions constitute a ball mill stoppage. This helps improve ball mill efficiency. Furthermore, it can monitor the power consumption and maximum power output for each start-up and shutdown, checking for overload.

[0046] The ball mill can also acquire the set total running time, slurry measurement time, and slurry discharge time. When the total running time, slurry measurement time, or slurry discharge time is reached, the ball mill will automatically stop and issue an alarm.

[0047] For example, during ball mill operation, the operator inputs the total running time, slurry testing time, and slurry discharge time. When the slurry testing time or slurry discharge time is reached, the ball mill will automatically stop and display the corresponding information. An alarm light will flash and a bell will ring on the ball mill site to prompt the operator to take timely action. When the total set running time is reached, the ball mill will automatically stop and an alarm will sound to save electricity.

[0048] In some specific implementation processes, the ball mill can monitor the output current in real time. By setting the rated current, alarm time, reminder set current, maintenance set current, and trip current, and in conjunction with various indicator lights, alarm reminders can be achieved. For example, green indicates normal operation and red indicates abnormal operation.

[0049] The ball mill can monitor output frequency, output voltage, output current, output power, output torque, operating speed, and bus voltage. It can also monitor the temperature of the motor, the front bearing of the motor, the rear bearing of the motor, the left bearing of the ball, the right bearing of the ball, and the reducer.

[0050] The system determines whether any abnormalities are detected by setting the temperature values ​​for the motor, front bearing, rear bearing, left ball bearing, right ball bearing, and reducer. If an abnormality is detected, an alarm will be triggered by the temperature alarm lights for the motor, front bearing, rear bearing, left ball bearing, right ball bearing, and reducer.

[0051] Please see Figure 3 The present invention also provides a ball mill energy-saving control device for a ceramic production line that applies the energy-saving control method for ball mills in a ceramic production line, comprising: an acquisition module 31, an automatic adjustment module 32, and a report display module 33.

[0052] The acquisition module 31 is used to acquire the formula data for ceramic production and update the control parameters of the ball mill according to the formula data.

[0053] The automatic adjustment module 32 is used to acquire the load data of the ball mill and automatically control the speed regulation frequency of the ball mill according to the load data; wherein the load data includes multiple motor data, the multiple motor data corresponds to multiple speed regulation frequencies of the ball mill, the multiple motor data decreases step by step, and the multiple speed regulation frequencies are adjusted step by step according to the multiple motor data.

[0054] The report display module 33 is used to acquire the operating data of the ball mill, record the operating data to form a report and display it.

[0055] For an explanation of the energy-saving control device for ball mills in ceramic production lines, please refer to the description of the energy-saving control method for ball mills in ceramic production lines; further details will not be provided here.

[0056] like Figure 4 As shown, the present invention also provides an electronic device, comprising: At least one processor; and at least one memory communicatively connected to the processor, wherein the memory stores program instructions executable by the processor, and the processor can execute the ceramic production conversion management method by invoking the program instructions.

[0057] In some embodiments of the present invention, the electronic device may include a controller or a processor. The controller is a microcontroller chip that integrates a processor, memory, communication module, etc. The processor may refer to the processor included in the controller. The processor may be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc.

[0058] Any process or method description in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of the invention includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as will be understood by those skilled in the art to which embodiments of the invention pertain.

[0059] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of each example have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0060] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for energy-saving control of a ball mill in a ceramic production line, characterized in that, include: Acquire ceramic production formula data and update ball mill control parameters based on the formula data; acquire ball mill load data and automatically control ball mill speed regulation frequency based on the load data; wherein the load data includes multiple motor data, the multiple motor data corresponds to multiple speed regulation frequencies of the ball mill, the multiple motor data decreases step by step, and the multiple speed regulation frequencies are adjusted step by step according to the multiple motor data. Obtain the operating data of the ball mill, record the operating data to form a report and display it.

2. The energy-saving control method for ball mills in ceramic production lines according to claim 1, characterized in that, The step of acquiring the load data of the ball mill and automatically controlling the speed regulation frequency of the ball mill based on the load data includes: The speed regulation frequency of the ball mill is automatically controlled based on the real-time current of the frequency converter of the ball mill.

3. The energy-saving control method for ball mills in ceramic production lines according to claim 2, characterized in that, The automatic control of the ball mill's speed regulation frequency based on the real-time current of the ball mill's frequency converter includes: When the real-time current of the frequency converter is less than a preset value compared to the rated current, the frequency of the ball mill is adjusted to the frequency band corresponding to the real-time current based on the real-time current of the frequency converter.

4. The energy-saving control method for ball mills in ceramic production lines according to claim 3, characterized in that, The speed regulation frequencies of the ball mill include: 48HZ, 46HZ, 43HZ, and 41HZ.

5. The energy-saving control method for ball mills in ceramic production lines according to claim 4, characterized in that, The load data of the ball mill includes a first current data, a second current data, a third current data, and a fourth current data. The first current data, the second current data, the third current data, and the fourth current data are all less than the rated current, and the first current data is less than the second current data, the third current data is less than the second current data, and the fourth current data is less than the third current data.

6. The energy-saving control method for ball mills in ceramic production lines according to claim 5, characterized in that, It also includes recording the number of times the ball mill runs and displaying the number of times the ball mill is started, the power consumption, ball start time, end time, ball milling time, maximum power, and ball start date for each start.

7. The energy-saving control method for ball mills in ceramic production lines according to claim 1, characterized in that, The process of acquiring the operating data of the ball mill, recording the operating data to form a report, and displaying it includes: The system acquires the temperature, power consumption records, current motor status, motor output frequency, remaining slurry testing time, and remaining slurry discharge time for each motor in the ball mill, and displays these data on the ball mill's display screen.

8. The energy-saving control method for ball mills in ceramic production lines according to claim 1, characterized in that, It also includes acquiring the set total running time, slurry measurement time, and slurry discharge time, and controlling the ball mill to automatically stop and issue an alarm when the total running time, slurry measurement time, or slurry discharge time is reached.

9. A ball mill energy-saving control device for a ceramic production line that applies the energy-saving control method for a ball mill according to any one of claims 1 to 8, characterized in that, include: The acquisition module is used to acquire formula data for ceramic production and update the control parameters of the ball mill based on the formula data. An automatic adjustment module is used to acquire the load data of the ball mill and automatically control the speed regulation frequency of the ball mill according to the load data; wherein the load data includes multiple motor data, the multiple motor data corresponds to multiple speed regulation frequencies of the ball mill, the multiple motor data decreases step by step, and the multiple speed regulation frequencies are adjusted step by step according to the multiple motor data. The report display module is used to acquire the operating data of the ball mill, record the operating data to form a report and display it.

10. An electronic device, characterized in that, include: At least one processor; And at least one memory communicatively connected to the processor, wherein: the memory stores program instructions executable by the processor, and the processor can execute the energy-saving control method for ball mills in ceramic production lines as described in claims 1 to 8 by calling the program instructions.

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