Permanent magnet synchronous motor direct drive flotation machine transmission structure optimization method

Abstract

The application discloses a permanent magnet synchronous motor direct-drive flotation machine transmission structure optimization method, relates to the technical field of transmission structure optimization, and comprises the following steps: constructing a matching model of a permanent magnet synchronous motor and a flotation machine transmission structure, performing energy efficiency analysis on the transmission structure based on the matching model, automatically generating a plurality of adjustment schemes according to the energy efficiency analysis result, optimizing and adjusting the transmission structure of the flotation machine according to the plurality of adjustment schemes, analyzing motor vibration during simulation operation, adjusting the transmission shaft of the motor and the flotation machine multiple times based on the motor vibration analysis result, selecting an optimal adjustment scheme when convergence occurs, and applying the optimal adjustment scheme to the transmission structure of the flotation machine. When the flotation machine operates based on the adjusted transmission structure, a variable frequency control algorithm is used to automatically control the motor speed. The optimization method significantly improves the energy efficiency, stability and response speed of the transmission structure through simulation optimization design and a variable frequency control algorithm, effectively reduces energy consumption and vibration, and improves the working efficiency and equipment service life of the flotation machine.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of transmission structure optimization, in particular to a permanent magnet synchronous motor direct drive flotation machine transmission structure optimization method. BACKGROUND

[0002] The flotation machine is a key equipment for separating useful minerals and gangue in mineral processing, and is widely used in metal and non-metal mineral extraction processes. Its transmission structure has long been in the form of asynchronous motor + reducer + coupling. Although this structure is mature and stable, it has problems such as low energy efficiency, large maintenance amount, and large space occupation, which cannot meet the needs of intelligent and green mine development. Therefore, the transmission structure of the flotation machine needs to be optimized.

[0003] The existing flotation machine transmission structure has the following defects:

[0004] The existing flotation machine transmission structure optimization usually lacks multiple optimization adjustments of the motor and the flotation machine transmission shaft. In traditional design, the matching of the transmission shaft and the motor is usually not adjusted after preliminary design. The motor vibration analysis results and optimization adjustment are not fully applied, which leads to the inability to realize the efficient operation and high stability of the system. When vibration and unstable performance occur, it is difficult to optimize and adjust in time, and usually only manual intervention or traditional modification methods can be used to improve the efficiency and service life of the flotation machine.

[0005] Therefore, the present application provides a permanent magnet synchronous motor direct drive flotation machine transmission structure optimization method, which significantly improves the energy efficiency, stability and response speed of the transmission structure through simulation optimization design and frequency conversion control algorithm, effectively reduces energy consumption, vibration and improves the working efficiency and service life of the flotation machine. SUMMARY

[0006] The purpose of the present application is to provide a permanent magnet synchronous motor direct drive flotation machine transmission structure optimization method to solve the problems in the background art.

[0007] In order to achieve the above purpose, the present application provides the following technical scheme: a permanent magnet synchronous motor direct drive flotation machine transmission structure optimization method, the optimization method comprising the following steps:

[0008] S1: obtaining the physical parameters of the transmission structure of the flotation machine through the API interface of the flotation machine management platform;

[0009] S2: loading the physical parameters of the permanent magnet synchronous motor to the simulation platform, combining the working requirements of the flotation machine, performing matching analysis of the motor drive system and the flotation machine, and constructing a matching model of the permanent magnet synchronous motor and the flotation machine transmission structure;

[0010] S3: Perform energy efficiency analysis on the transmission structure based on the matching model, and automatically generate several adjustment schemes according to the energy efficiency analysis results;

[0011] S4: In each simulation process, optimize and adjust the transmission structure of the flotation machine according to the several adjustment schemes, and analyze the motor vibration during simulation running;

[0012] S5: Based on the motor vibration analysis results, adjust the transmission shaft of the motor and the flotation machine several times, and when convergence is reached, select the optimal adjustment scheme to apply to the transmission structure of the flotation machine;

[0013] S6: When the flotation machine runs based on the adjusted transmission structure, use a variable frequency control algorithm to automatically control the motor speed.

[0014] In a preferred embodiment, the transmission structure is analyzed for energy efficiency based on the matching model, and several adjustment schemes are automatically generated based on the energy efficiency analysis results, including the following steps:

[0015] The efficiency of each link in the energy transfer process will affect the performance of the transmission structure, and the energy transfer efficiency calculation formula is: where, is the total energy transfer efficiency of the entire transmission structure, is the energy transfer efficiency of the ith transmission component, and n is the total number of transmission components;

[0016] Based on the energy efficiency analysis results, several adjustment schemes are automatically generated, including adjusting motor parameters, optimizing reducer reduction ratio, and transmission component configuration optimization.

[0017] In a preferred embodiment, the transmission structure of the flotation machine is optimized and adjusted according to several adjustment schemes, and the motor vibration is analyzed during simulation running, including the following steps:

[0018] According to different adjustment schemes, several simulations are performed, and the transmission structure of the flotation machine is adjusted during each simulation process. The adjustment scheme content includes adjusting motor parameters, optimizing reducer reduction ratio, and transmission component configuration optimization;

[0019] In each simulation process, the motor vibration is analyzed by the finite element analysis method to obtain the motor vibration amplitude.

[0020] In a preferred embodiment, based on the motor vibration analysis results, the transmission shaft of the motor and the flotation machine is adjusted several times, and when convergence is reached, the optimal adjustment scheme is selected to apply to the transmission structure of the flotation machine, including the following steps:

[0021] After each adjustment, the simulation platform adjusts the motor and the transmission shaft of the flotation machine according to the vibration analysis results of the motor and the transmission shaft, and recalculates the vibration amplitude of the motor after each adjustment;

[0022] The adjustment is stopped when the number of adjustments reaches the maximum number of adjustments, or when the mechanical loss is less than or equal to the loss threshold and the motor vibration is less than or equal to the vibration threshold;

[0023] When the convergence is reached, the mechanical loss and the motor vibration are normalized, and the normalized mechanical loss and motor vibration are weighted to obtain a poor selection index. The adjustment scheme with the smallest poor selection index is selected as the optimal adjustment scheme and applied to the transmission structure of the flotation machine.

[0024] In a preferred embodiment, a matching model of the permanent magnet synchronous motor and the flotation machine transmission structure is constructed, including the following steps:

[0025] The working requirements of the flotation machine include the working load and the stirring speed;

[0026] The output power of the motor is compared with the working requirements of the flotation machine to verify whether the motor can meet the working requirements of the flotation machine. If not, the simulation platform adjusts the output parameters of the motor until the output of the motor matches the working requirements of the flotation machine.

[0027] When the output of the motor matches the working requirements of the flotation machine, a matching model of the permanent magnet synchronous motor and the flotation machine transmission structure is constructed. The matching model optimizes the working state of the motor according to the working load and the stirring speed of the flotation machine.

[0028] In a preferred embodiment, the physical parameters of the existing flotation machine transmission structure are obtained through the API interface of the flotation machine management platform, including the power, torque output, and efficiency curve of the permanent magnet synchronous motor, as well as the parameters of the reducer and the coupling transmission components.

[0029] In a preferred embodiment, the optimization method further includes:

[0030] S7: The motor automatically adjusts the speed and output power according to the real-time changes of the working load of the flotation machine through a dynamic adjustment algorithm.

[0031] In a preferred embodiment, the motor automatically adjusts the speed and output power according to the real-time changes of the working load of the flotation machine through a dynamic adjustment algorithm, including the following steps:

[0032] The dynamic adjustment algorithm automatically adjusts the output power of the motor by monitoring the real-time load changes of the flotation machine and inputting the load changes into the control system. The adjustment algorithm expression is: wherein, is the adjusted motor output power, a rated power of the motor, a proportional factor of load variation, a load variation amount.

[0033] In a preferred embodiment, the optimization method further comprises:

[0034] S8: analyzing heat distribution in the operation process of the permanent magnet synchronous motor, and judging whether a cooling system needs to be added in the transmission structure according to the analysis result.

[0035] In a preferred embodiment, the analysis of heat distribution in the operation process of the permanent magnet synchronous motor and the judgment of whether a cooling system needs to be added in the transmission structure according to the analysis result comprise the following steps:

[0036] The temperature rise of the motor is calculated, and the expression is: wherein, ΔW is the temperature rise of the motor, is the total loss power of the motor, m is the mass of the motor, and c is the specific heat capacity of the motor material.

[0037] If the temperature of the motor calculated by the temperature rise analysis exceeds the safe working temperature threshold, it is judged that a cooling system needs to be added in the transmission structure.

[0038] In the above technical solution, the present application provides the following technical effects and advantages:

[0039] The present application constructs a matching model of the permanent magnet synchronous motor and the transmission structure of the flotation machine, performs energy efficiency analysis on the transmission structure based on the matching model, and automatically generates a plurality of adjustment schemes according to the energy efficiency analysis result. In each simulation process, the transmission structure of the flotation machine is optimized and adjusted according to the plurality of adjustment schemes, and the motor vibration is analyzed during the simulation operation. Based on the motor vibration analysis result, the transmission shaft of the motor and the flotation machine is adjusted multiple times. When convergence is achieved, the optimal adjustment scheme is selected and applied to the transmission structure of the flotation machine. When the flotation machine operates based on the adjusted transmission structure, a variable frequency control algorithm is used to automatically control the motor speed. The optimization method significantly improves the energy efficiency, stability and response speed of the transmission structure through simulation optimization design and variable frequency control algorithm, effectively reduces energy consumption and vibration, and improves the working efficiency and equipment life of the flotation machine. BRIEF DESCRIPTION OF DRAWINGS

[0040] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can also be obtained by those skilled in the art based on these drawings.

[0041] Figure 1Flow chart for the optimization method of the present application.

[0042] Figure 2 Timing chart for the optimization method of the present application. DETAILED DESCRIPTION

[0043] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0044] Embodiment 1: Please refer to Figure 1 and Figure 2 The present embodiment provides an optimization method for a direct-drive flotation machine transmission structure of a permanent magnet synchronous motor. The optimization method comprises the following steps:

[0045] S1: First, the physical parameters of the transmission structure of the existing flotation machine are obtained through the API interface of the flotation machine management platform, including the power, torque output and efficiency curve of the permanent magnet synchronous motor, and the parameters of the transmission components such as the speed reducer and the shaft coupling. By understanding the design of the current transmission structure, we can clearly define the optimization goals, especially the potential problems in energy efficiency and structural complexity.

[0046] S2: Load the physical parameters of the permanent magnet synchronous motor into the simulation platform, and combine the working requirements of the flotation machine (input by artificial, including working load and stirring speed) to perform matching analysis of the motor drive system and the flotation machine, construct a matching model of the permanent magnet synchronous motor and the flotation machine transmission structure, and ensure that the motor output matches the requirements of the flotation machine, thereby laying a foundation for subsequent energy efficiency optimization and control strategy design.

[0047] S3: Based on the matching model, perform energy efficiency analysis on the entire transmission structure (including the motor, speed reducer and transmission shaft), and automatically generate several adjustment schemes according to the energy efficiency analysis results. At this time, the focus is on analyzing the energy transmission efficiency in the transmission structure. Several adjustment schemes are proposed, including adjusting the motor parameters, transmission component configuration and other measures to reduce energy consumption and ensure efficient operation of the system.

[0048] S4: In each simulation process, the transmission structure of the flotation machine is optimized and adjusted according to the several adjustment schemes (as many times as the number of adjustment schemes, the transmission structure of the flotation machine is optimized and adjusted), and the motor vibration is analyzed during the simulation operation.

[0049] S5: Based on the motor vibration analysis results, adjust the motor and flotation machine transmission shaft multiple times, when convergence (set a maximum adjustment times, when the maximum adjustment times (such as 5 times or 8 times) are reached or the mechanical loss is less than or equal to the preset loss threshold and the motor vibration is less than or equal to the vibration threshold, stop adjusting), select the optimal adjustment scheme (the weighted mechanical loss and motor vibration to get the selection index, select the adjustment scheme with the smallest selection index as the optimal adjustment scheme) applied to the transmission structure of the flotation machine, to improve the stability and long-term reliability of the equipment.

[0050] S6: When the flotation machine is running based on the adjusted transmission structure, use the variable frequency control algorithm to accurately control the motor speed, so that it can realize fast start and stop and stable operation in the flotation process, thereby improving the control accuracy and response speed, and meeting the demand of the flotation machine for speed adjustment under different working conditions.

[0051] S7: Through the dynamic adjustment algorithm, the motor can automatically adjust the speed and output power according to the real-time changes of the working load of the flotation machine (such as fluctuations in flotation conditions, material load, etc.), improving the adaptability and real-time response ability of the system.

[0052] S8: Analyze the heat distribution of the permanent magnet synchronous motor during operation, and determine whether a cooling system needs to be added to the transmission structure based on the analysis results, to ensure that the motor maintains a stable working temperature under high load, thereby improving the safety and reliability of the flotation machine operation.

[0053] The present application constructs a matching model of the permanent magnet synchronous motor and the transmission structure of the flotation machine, performs energy efficiency analysis on the transmission structure based on the matching model, and automatically generates several adjustment schemes according to the energy efficiency analysis results. In each simulation process, the transmission structure of the flotation machine is optimized and adjusted according to the several adjustment schemes, and the motor vibration is analyzed during simulation operation. Based on the motor vibration analysis results, the motor and the flotation machine transmission shaft are adjusted multiple times, and when convergence is reached, the optimal adjustment scheme is selected and applied to the transmission structure of the flotation machine. When the flotation machine is running based on the adjusted transmission structure, the variable frequency control algorithm is used to automatically control the motor speed. This optimization method significantly improves the energy efficiency, stability and response speed of the transmission structure through simulation optimization design and variable frequency control algorithm, effectively reduces energy consumption and vibration, and improves the working efficiency and equipment life of the flotation machine.

[0054] Example 2: S1: First, obtain the physical parameters of the existing transmission structure of the flotation machine through the API interface of the flotation machine management platform, including the power, torque output, efficiency curve of the permanent magnet synchronous motor, and the parameters of the transmission components such as the reducer and the coupling. By understanding the current design of the transmission structure, we can clearly identify the optimization goals, especially the potential problems in terms of energy efficiency and structural complexity.

[0055] The physical parameters of the transmission structure of existing flotation machines are obtained through the API interface of the flotation machine management platform. The design of the flotation machine transmission structure is complex and variable, involving multiple key components such as permanent magnet synchronous motors, reducers, and couplings. The purpose of obtaining these physical parameters is to clarify the current working status and existing problems of the transmission structure, thereby providing basic data support for subsequent optimization.

[0056] The parameters obtained are those of the permanent magnet synchronous motor, including power, torque output, and efficiency curves. The permanent magnet synchronous motor is a high-efficiency electric motor, and its high power density and low energy consumption characteristics are particularly important in flotation machine applications.

[0057] Specifically, the power (P) of a permanent magnet synchronous motor can be calculated using the following formula: Where P is the motor power, T is the motor torque (unit: N·m), and ω is the motor angular velocity (unit: rad / s). The relationship between motor torque and power illustrates how the motor adjusts its output according to load changes to ensure the stable operation of the flotation machine's drive structure. Where Z is the motor speed (unit: RPM), Here, ω represents the angular velocity of the motor (unit: rad / s). These formulas allow us to calculate the motor's output power and compare it with the operating requirements of the flotation machine, ensuring that the motor's power output matches the load demands of the flotation machine.

[0058] When obtaining the efficiency curve of a motor, we need to analyze its operating efficiency under different load conditions. Typically, the efficiency (η) of a motor is defined as the ratio of output power to input power, as shown in the following formula: ,in, t is the motor output power. Input power to the motor. The motor efficiency curve reveals the motor's operating status under different loads, thus helping to identify energy efficiency bottlenecks during motor operation. This curve allows for the evaluation of the motor's performance under various load conditions during the optimization process, ensuring maximum energy efficiency.

[0059] Next, we obtain the parameters of transmission components such as the speed reducer and coupling. The main function of the speed reducer is to convert the high-speed rotation of the motor into the low-speed, high-torque output required by the flotation machine. The characteristics of the speed reducer are usually described by the reduction ratio. The reduction ratio is defined as the ratio of the motor input speed to the speed reducer output speed: ,in, The reduction ratio, Input the motor speed. The speed is the output speed of the reducer. The selection of the reduction ratio directly affects the efficiency and load capacity of the transmission structure. Therefore, during the optimization process, it is necessary to consider how to adjust the parameters of the reducer to improve the overall system performance.

[0060] As a key component connecting the motor and the reducer or other transmission parts, the main function of the coupling is to transmit torque and absorb the vibration and error of the system. The design parameters of the coupling include its stiffness, flexibility, and load-carrying capacity, etc. Reasonable selection of the coupling can effectively reduce the transmission error and vibration in the system and improve the transmission efficiency.

[0061] By comprehensively obtaining the physical parameters of the flotation machine transmission structure, including the motor power, torque output, efficiency curve, reducer reduction ratio, and coupling design parameters, the optimization scheme can accurately identify the problems of energy efficiency and structural complexity in the current transmission structure, and clearly define the optimization target. These data provide a solid foundation for subsequent optimization steps, enabling the scheme to improve the performance of the transmission structure in a targeted manner, particularly in terms of improving energy efficiency, reducing mechanical losses, reducing system complexity and vibration, etc.

[0062] S2: Load the physical parameters of the permanent magnet synchronous motor into the simulation platform, and conduct matching analysis of the motor drive system and the flotation machine based on the working requirements of the flotation machine (input by manual, including working load, stirring speed). Build a matching model of the permanent magnet synchronous motor and the flotation machine transmission structure to ensure that the motor output matches the requirements of the flotation machine, laying a foundation for subsequent energy efficiency optimization and control strategy design.

[0063] During the optimization process, the physical parameters of the permanent magnet synchronous motor are loaded into the simulation platform, and the matching analysis of the motor drive system and the flotation machine is conducted based on the working requirements of the flotation machine. The working requirements of the flotation machine are mainly input by manual, including working load, stirring speed, and other key parameters. Through these input data, a matching model that meets the actual working conditions can be established to ensure that the motor output matches the requirements of the flotation machine, thereby laying a solid foundation for subsequent energy efficiency optimization and control strategy design.

[0064] In addition, the working requirements of the flotation machine, such as working load and stirring speed, also need to be considered during the simulation process. These requirements are usually input by manual as external working conditions. In the transmission structure of the flotation machine, load and stirring speed are key factors that determine the working requirements of the motor. The stirring power of the flotation machine can be estimated by the following formula: where, is the stirring power required by the flotation machine (unit: W), C is the constant of the stirring device (determined according to the type and design of the flotation machine), ρ is the density of the liquid (unit: kg / m³), D is the diameter of the stirrer (unit: m), is the rotational speed of the stirrer (unit: RPM). This formula shows that the stirring power of the flotation machine is closely related to the rotational speed and diameter of the stirrer, so the matching of the motor drive needs to be adjusted according to the actual working conditions of the flotation machine.

[0065] Generally, the agitation equipment constant (C) is specified in the design specifications and technical literature of the flotation machine. In practical engineering applications, this constant is usually determined through experiments or based on experience data from similar equipment. The specific constant value is usually adjusted according to the capacity of the flotation machine, the size of the agitator, the properties of the material, etc.

[0066] For small-scale flotation machines (such as laboratory-scale), the agitation equipment constant C is usually small, ranging from 0.2 to 1.0.

[0067] For medium-sized flotation machines, the value of C ranges from 1.0 to 2.0.

[0068] For large-scale flotation machines, due to the requirements of material flow and stirring force, the value of C is larger, ranging from 2.0 to 5.0.

[0069] Through the above formula, the simulation platform compares the output power of the motor with the working requirements of the flotation machine, verifying whether the motor can meet the working requirements of the flotation machine. If not, the simulation platform will adjust the output parameters of the motor (such as speed, torque, etc.) until the motor output matches the requirements of the flotation machine. This process not only ensures the optimal working state of the motor, but also estimates the performance of the motor under different working conditions, providing data support for subsequent energy efficiency optimization and control strategy design.

[0070] The core purpose of this process is to build a matching model of the permanent magnet synchronous motor and the transmission structure of the flotation machine. This model can optimize the working state of the motor according to the working load, stirring speed, etc. of the flotation machine, so as to achieve the purpose of maximum energy efficiency. In the subsequent optimization process, the speed, power and torque output of the motor can be further adjusted, so that the motor can adjust in real time according to the dynamic working condition changes of the flotation machine, ensuring the stable and efficient operation of the system. Through precise matching analysis and optimization model, energy waste can be reduced, the overall efficiency of the system can be improved, and the basis for implementing advanced control strategies such as variable frequency control algorithm can be provided.

[0071] S3: Based on the matching model, perform energy efficiency analysis on the entire transmission structure (including motor, reducer and transmission shaft), and automatically generate several adjustment schemes according to the energy efficiency analysis results. At this time, the focus is on analyzing the energy transmission efficiency in the transmission structure. And put forward several adjustment schemes, adjustment scheme content includes adjusting motor parameters, transmission component configuration and other measures to reduce energy consumption, ensure the efficient operation of the system.

[0072] Based on the previously constructed matching model of the motor and the flotation machine, an energy efficiency analysis of the entire transmission structure (including the motor, the speed reducer, and the transmission shaft) is performed. The core objective of this step is to identify and evaluate the mechanical losses and energy transmission efficiency in the transmission structure, and to propose several adjustment schemes based on the analysis results, aiming to reduce energy losses in the system, improve overall efficiency, and ensure efficient operation of the system.

[0073] In the transmission structure, energy transmission efficiency is an important indicator for analyzing the energy efficiency of the transmission structure. The energy transmission efficiency in the entire system depends on the coordination and adjustment between various components (such as the motor, the speed reducer, and the coupling). In particular, in a multi-stage transmission structure, the efficiency of each link in the energy transmission process will affect the overall performance. Energy transmission efficiency can be evaluated by the following formula: where, is the total energy transmission efficiency of the entire transmission structure, is the energy transmission efficiency of the i-th transmission component, and n is the total number of transmission components. This formula shows that the efficiency of each transmission component will have a cumulative effect on the energy efficiency of the overall system. In this way, the role of each component in energy transmission can be understood in depth, and the low-efficiency links can be identified, providing a theoretical basis for subsequent optimization schemes.

[0074] Suppose a transmission system contains 3 key components: a motor (efficiency ), a speed reducer (efficiency ), and a coupling (efficiency ). Through energy efficiency analysis, the following data is obtained: motor efficiency , speed reducer efficiency , coupling efficiency , and total system energy efficiency can be calculated by the formula: which indicates that the energy transmission efficiency of the entire transmission system is about 72.6896. Based on this result, the following adjustment schemes may be proposed:

[0075] Increase motor efficiency: for example, select a more efficient motor to increase . Optimize speed reducer design: reduce friction loss of the speed reducer to improve . Optimize coupling coordination: reduce wear and tear in the transmission to improve .

[0076] Based on the above energy efficiency analysis results, the system will automatically generate several adjustment schemes. The core objective of the adjustment schemes is to optimize the working state of the motor, improve the performance of each component in the transmission structure, and reduce energy waste. Specific adjustment schemes may include the following aspects:

[0077] Adjusting motor parameters: Based on the energy efficiency analysis results, adjust the motor's speed, output power, or torque output to better match the flotation machine's working requirements. Especially in low-load or large-load fluctuation conditions, by adjusting the motor's operating point, the energy efficiency can be effectively improved.

[0078] Optimizing the reduction ratio of the reduction gearbox: The reduction ratio of the reduction gearbox directly affects the efficiency of the system, especially in low-speed high-torque applications. If the reduction ratio is not properly selected, it may cause excessive energy loss. By adjusting the reduction ratio of the reduction gearbox to better match the motor output and the working requirements of the flotation machine, the transmission efficiency of the system can be effectively improved.

[0079] Optimizing the configuration of transmission components: In the existing transmission structure, there may be a lot of friction and loss in the coupling and other transmission components, affecting the overall efficiency. By optimizing the selection and configuration of transmission components, such as using low-friction, high-transmission-efficiency couplings, reducing unnecessary mechanical contact and vibration, the transmission efficiency can be further improved.

[0080] Through the implementation of these adjustment schemes, the energy efficiency of the entire transmission structure will be significantly improved, thereby reducing operating costs and energy consumption and improving the production efficiency of the flotation machine. Energy efficiency analysis based on matching models is a key step in the entire optimization scheme. By analyzing the mechanical losses and energy transmission efficiency in the transmission structure, the energy efficiency bottlenecks in the existing transmission structure can be accurately identified, and specific adjustment schemes can be proposed based on the analysis results. Optimized motor parameters, transmission component configurations, and vibration control measures will effectively improve the energy efficiency of the system, ensuring that the flotation machine operates stably in a high-efficiency, low-energy-consumption state, providing a reliable foundation for subsequent variable frequency control and intelligent adjustment strategies.

[0081] S4: In each simulation process, the transmission structure of the flotation machine is optimized and adjusted according to several adjustment schemes (as many adjustment schemes as there are, as many times as the transmission structure of the flotation machine is optimized and adjusted), and the motor vibration is analyzed during the simulation run.

[0082] Optimizing and adjusting the transmission structure of the flotation machine through the simulation process. Based on the previous energy efficiency analysis, the system performs several simulations according to different adjustment schemes and adjusts the transmission structure of the flotation machine during each simulation process. These adjustment schemes include adjusting motor parameters, optimizing the reduction ratio of the reduction gearbox, and optimizing the configuration of transmission components, etc.

[0083] During each simulation, the motor vibration also needs to be analyzed. Motors inevitably produce vibrations during operation, which not only affect the stability of the motor itself, but also may cause vibrations in other components of the transmission structure, leading to increased mechanical wear and noise. In order to effectively control vibration and ensure smooth operation of the system, motor vibration analysis must be performed in the simulation, and the configuration of the transmission structure must be adjusted based on the results of the vibration analysis.

[0084] Finite Element Analysis (FEA) is one of the most commonly used methods for motor vibration simulation. By discretizing the geometric model of the motor and transmission structure into a finite number of elements (such as triangular, quadrilateral or cubic elements), a detailed analysis of the motor structure can be performed, and its vibration response under working conditions can be predicted. By analyzing the motor vibration during simulation using finite element analysis, the impact on the transmission structure can be analyzed, and by adjusting the stiffness, material of the transmission shaft, and the motor installation position, etc., unnecessary vibration can be reduced.

[0085] First, based on the preliminary energy efficiency analysis results and motor vibration analysis, multiple optimization schemes are generated. For example, adjustment schemes may include: adjusting the power output, torque and speed of the motor to adapt to the different load requirements of the flotation machine. According to the working conditions of the flotation machine, select the appropriate reduction ratio to match the speed and torque of the motor and the flotation machine, and reduce transmission loss. For example, select a low-friction, low-vibration coupling, or optimize the size and material of the transmission shaft to reduce mechanical loss and vibration in the system. After selecting an adjustment scheme each time, perform simulation and observe the working state of the transmission structure. The simulation will simulate the operation of the motor and flotation machine under different loads and working conditions, and evaluate the impact of the adjustment scheme on the energy efficiency, vibration and stability of the system.

[0086] During each simulation, the motor vibration is analyzed using Finite Element Analysis (FEA). Finite element analysis discretizes the geometric structure of the motor and its transmission system, and calculates the vibration response of each discrete element to obtain the vibration characteristics of the overall structure. The following are the basic steps of finite element analysis:

[0087] Based on the design parameters of the motor and transmission system (such as motor size, material, speed, etc.), a geometric model of the motor and transmission system is established in the simulation platform. At this time, the rotor, stator, bearing of the motor and the components connecting the transmission system are considered.

[0088] In the simulation, set the operating conditions and external working conditions of the motor, such as speed, load, friction, wind resistance, etc., to simulate the vibration sources in actual operation.

[0089] The vibration mode of the motor in the working state is calculated by finite element analysis. Through modal analysis, the vibration response and vibration mode of the motor at different frequencies can be obtained.

[0090] During the simulation process, the vibration amplitude of the motor is obtained by calculating the vibration displacement and velocity of each component. The motor vibration amplitude (A) is usually expressed in displacement (unit: mm), velocity (unit: m / s) or acceleration (unit: m / s²). The size of the vibration amplitude is directly related to the stability and reliability of the motor and the entire transmission system.

[0091] Each adjustment scheme will optimize the transmission structure of the flotation machine during the simulation process. After each optimization adjustment, the simulation platform will evaluate the effect of the optimization scheme according to the analysis results, and further adjust the system according to the vibration analysis and energy efficiency analysis results. Multiple optimization schemes will gradually adjust the motor speed, transmission component matching and vibration control strategy to maximize the performance of each link. Through this multiple optimization adjustment, the system will continuously approach the optimal solution, reduce mechanical loss, improve transmission efficiency, enhance structural compactness, and control motor vibration, ultimately achieving the purpose of improving the overall performance and stability of the flotation machine transmission structure.

[0092] Through multiple optimization adjustments of the transmission structure, mechanical loss in the system is effectively reduced, the structural compactness of the transmission structure is improved, and the motor vibration is analyzed and optimized. Through the precise simulation process, it can ensure that the transmission structure of the flotation machine runs in the optimal state, so as to achieve the goal of improving energy efficiency, reducing energy consumption, improving work efficiency and prolonging the service life of the equipment.

[0093] S5: Based on the motor vibration analysis results, multiple adjustments of the motor and the transmission shaft of the flotation machine are needed, and the performance after each adjustment is evaluated, and the optimal adjustment scheme is finally selected. The optimal adjustment scheme is applied to the transmission structure of the flotation machine to improve the stability and long-term reliability of the equipment.

[0094] Based on the motor vibration analysis results, multiple adjustments of the motor and the transmission shaft of the flotation machine are needed, and the performance after each adjustment is evaluated, and the optimal adjustment scheme is finally selected. Through this adjustment process, not only can mechanical loss be effectively reduced, but also motor vibration can be controlled, and the stability and long-term reliability of the equipment can be improved. The key indicators in the adjustment process are mechanical loss and motor vibration, and the optimization scheme needs to converge after multiple simulations and adjustments.

[0095] First, after each adjustment, the simulation platform will adjust the motor and the drive shaft of the flotation machine based on the vibration analysis results of the motor and the drive shaft. These adjustments will be refined based on the motor output characteristics, load changes, and vibration analysis results. During the simulation process, the vibration amplitude of the motor will be recalculated after each adjustment, and it will be checked whether the vibration is within an acceptable range.

[0096] To avoid wasting computational resources due to ineffective adjustments, a maximum number of adjustments is set. Assuming the maximum number of adjustments is N_max (for example, 5 or 8), when the maximum number of adjustments is reached, the system will stop further adjustments. In addition, a mechanical loss threshold and a vibration threshold will be set during the adjustment process. When the mechanical loss is less than or equal to the preset loss threshold and the motor vibration is less than or equal to the vibration threshold, the adjustment will also be stopped in advance. The formula is as follows: where, is the mechanical loss after each adjustment, is the preset loss threshold, is the motor vibration amplitude, is the preset vibration threshold. This means that if the adjusted system performs well enough, i.e. the mechanical loss and vibration meet the expected requirements, the adjustment process will be stopped in advance, saving time and computational resources.

[0097] The calculation expression of mechanical loss is: where, is the mechanical loss (i.e. friction loss power (unit: W)), μ is the friction coefficient, F is the force (unit: N), and v is the relative speed (unit: m / s). Once the convergence condition is reached, the system will select the optimal adjustment scheme based on the two key performance indicators: mechanical loss and motor vibration. To comprehensively evaluate the pros and cons of each adjustment scheme, we use a weighted calculation method to consider mechanical loss and motor vibration, and obtain a selection index, whose calculation formula is as follows: where, is the selection index, is the normalized value of mechanical loss, is the normalized value of motor vibration amplitude, and are the weight coefficients of mechanical loss and vibration, respectively, The weight coefficients can be adjusted according to actual needs. This formula shows the importance of mechanical loss and vibration, and the weight can be adjusted flexibly according to actual needs to ensure that the final selected adjustment scheme can minimize mechanical loss and vibration.

[0098] Specifically:

[0099] The coefficient of friction (μ) is an important parameter that affects mechanical losses, and is generally related to the properties of the materials, surface treatment, lubrication conditions, and the state of the contact surfaces. The range of values for the coefficient of friction depends on the type of materials and the friction conditions. Here are some common materials and the range of values for the coefficient of friction. The range of values for the coefficient of friction:

[0100] Metal on metal (without lubrication):

[0101] Copper on steel: 0.3-0.6;

[0102] Steel on steel: 0.3-0.8;

[0103] Aluminum on steel: 0.3-0.6;

[0104] Metal on metal (with lubrication):

[0105] Steel on steel (oil lubrication): 0.05-0.15;

[0106] Aluminum on steel (oil lubrication): 0.05-0.1;

[0107] Copper on steel (oil lubrication): 0.03-0.1;

[0108] Rubber on metal:

[0109] Rubber on steel: 0.6-1.0;

[0110] Wood on metal:

[0111] Wood on steel: 0.4-0.7;

[0112] Plastic on metal:

[0113] Polyvinyl chloride on steel: 0.2-0.3;

[0114] Polyethylene on steel: 0.1-0.3.

[0115] For example, the coefficient of friction for steel on steel (without lubrication) is generally between 0.3 and 0.8, while under oil lubrication conditions, the coefficient of friction typically decreases to 0.05 to 0.15, demonstrating the significant impact of lubrication on reducing friction.

[0116] The coefficient of friction for aluminum on steel is approximately 0.3 to 0.6 without lubrication, while after lubrication, the coefficient of friction can decrease to 0.05 to 0.1.

[0117] By calculating the inferiority index for each adjustment scheme, the scheme with the smallest inferiority index is selected as the optimal adjustment scheme. The selection of the optimal adjustment scheme is based on a comprehensive consideration of the balance between mechanical loss and vibration control, ensuring that the flotation machine transmission structure operates in the optimal working state, thereby improving the stability and long-term reliability of the equipment.

[0118] Through multiple adjustments, convergence judgments, and optimal adjustment scheme selection, the optimized transmission structure can significantly reduce mechanical losses and effectively control motor vibration. This process ensures the stability and reliability of the flotation machine during operation. Reducing vibration not only helps to improve the service life of the equipment, but also reduces maintenance frequency and operation and maintenance costs. With the optimization of the transmission structure, the working efficiency and stability of the flotation machine will be improved, enabling it to maintain high efficiency during long-term operation, reduce energy waste, reduce failure rate, and enhance the overall performance of the equipment.

[0119] This optimization step ensures that the transmission structure of the flotation machine reaches the optimal state through comprehensive consideration of motor vibration analysis and mechanical loss control, using multiple optimization adjustments and optimal adjustment scheme selection. By setting convergence conditions, limiting the maximum number of adjustments, and introducing a poor selection index, the system can efficiently find the optimal adjustment scheme with the best performance, improving the operational stability and reliability of the equipment, and ensuring long-term efficient and stable operation of the flotation machine.

[0120] S6: When the flotation machine operates based on the adjusted transmission structure, a variable frequency control algorithm is adopted to accurately control the motor speed, enabling it to achieve rapid start-stop and stable operation during the flotation process, thereby improving control accuracy and response speed to meet the needs of the flotation machine for speed adjustment under different working conditions.

[0121] In this optimization step, the variable frequency control algorithm is used to accurately control the speed of the permanent magnet synchronous motor, enabling it to achieve rapid start-stop and stable operation during the flotation process. As an efficient speed regulation method, variable frequency control technology can dynamically adjust the speed of the motor according to the working load and working conditions of the flotation machine, thereby effectively improving control accuracy and response speed. This not only meets the needs of the flotation machine for speed adjustment under different working conditions, but also improves the operational stability and energy efficiency of the system.

[0122] The variable frequency control algorithm adjusts the input frequency and voltage of the motor to control its speed, enabling it to maintain optimal operating conditions under different load conditions. The relationship between the speed of the permanent magnet synchronous motor and the power supply frequency can be described by the following formula: where Z is the motor speed (in RPM), f is the power supply frequency (in Hz), and DS is the number of motor pole pairs (unitless). This formula shows that the speed of the motor is proportional to the supply frequency, and by adjusting the frequency f, the speed n of the motor can be accurately controlled to achieve the desired operating state.

[0123] The number of pole pairs of the motor usually depends on the design of the motor and the intended application. For different types of motors, the range of values for the number of pole pairs can be referred to the following common standards:

[0124] Small motors (for some low-power applications): The number of pole pairs is usually 2 or 4, i.e., the motor has 2 or 4 pole pairs.

[0125] Medium-sized motors (for industrial applications): Generally use 4-pole or 6-pole designs.

[0126] Large motors (for high-power drive systems): Generally choose 6-pole or 8-pole to achieve lower rotational speed.

[0127] Variable frequency control technology not only accurately controls the motor speed, but also realizes the rapid start-stop and stable operation of the motor. Especially in the working process of the flotation machine, the load and working conditions change greatly, and the traditional motor control method often cannot respond in time. Through variable frequency control, the motor can adjust according to the real-time working condition changes to ensure that the system can quickly adapt to load fluctuations.

[0128] Rapid start-stop refers to the motor being able to quickly start and enter the working state from the stopped state in a short time, while stable operation refers to the motor being able to maintain a constant rotational speed during operation, avoiding excessive speed fluctuations, which is crucial for the accurate operation of the flotation machine. Variable frequency control technology can automatically adjust the motor speed according to the load conditions and working requirements of the flotation machine, achieving smooth start and stop, reducing mechanical impact and motor loss.

[0129] The variable frequency control algorithm can dynamically adjust according to the actual load requirements of the flotation machine, thereby achieving high-precision speed control. For example, in light load conditions, the system can reduce the motor speed to save energy; while in heavy load conditions, the system will automatically increase the motor speed to maintain the flotation efficiency. In addition, variable frequency control can also improve the system response speed, allowing the motor to quickly adjust the speed to respond to sudden changes in working conditions, avoiding the lag response of traditional control methods.

[0130] In actual operation, due to factors such as the nature of the minerals, the concentration of the ore pulp, and the flow rate, the rotational speed often needs to be flexibly adjusted under different working conditions. Through the variable frequency control algorithm, the motor can automatically adjust the rotational speed according to the real-time working requirements of the flotation machine to meet the requirements of different working conditions. For example, when the concentration of the ore pulp increases, the load of the flotation machine will increase, and the system will automatically increase the motor speed to ensure the flotation efficiency; while in low ore pulp concentration, the system will reduce the speed to reduce energy waste.

[0131] This dynamic speed control based on working conditions not only improves the production efficiency of the flotation machine, but also ensures the long-term stable operation of the equipment. Compared with traditional fixed speed control methods, variable frequency control can significantly reduce energy consumption and reduce mechanical wear and failure rate caused by load fluctuations.

[0132] By adopting variable frequency control algorithm, the permanent magnet synchronous motor can dynamically adjust the speed according to the working load and working condition of the flotation machine, so as to realize fast start and stop and stable operation. This technology not only improves the control accuracy and response speed, but also effectively meets the demand of the flotation machine for speed adjustment under different working conditions. The flexibility and accuracy of variable frequency control make the system maintain efficient and stable operation state in the flotation process, reduce energy consumption, prolong the service life of the equipment, and greatly improve the production efficiency and economy of the flotation machine.

[0133] S7: Through dynamic adjustment algorithm, the motor can automatically adjust the speed and output power according to the real-time changes of the working load of the flotation machine (such as fluctuations in flotation conditions, material load, etc.), improving the adaptability and real-time response ability of the system.

[0134] The introduction of dynamic adjustment algorithm enables the motor to automatically adjust the speed and output power according to the real-time changes of the working load of the flotation machine (such as fluctuations in flotation conditions, material load, etc.). In the actual operation process of the flotation machine, the working conditions change frequently and complexly, such as pulp concentration, flow fluctuation, material type and other factors that will affect the load demand. In order to ensure that the motor always runs in the best state, the dynamic adjustment algorithm can adjust the speed and output power of the motor in real time, so as to improve the adaptability and response ability of the system and meet the demand of the flotation machine under different loads and conditions.

[0135] The dynamic adjustment algorithm monitors the real-time working state of the flotation machine, especially the load changes, inputs the load information into the control system, and then automatically adjusts the speed and output power of the motor. The load fluctuation of the flotation machine is a key factor affecting the performance of the motor. In the working process, the load of the flotation machine may fluctuate sharply due to factors such as pulp concentration, flow rate change or equipment maintenance. When the load increases, the motor needs to increase the output power to provide enough torque to maintain the flotation efficiency; on the contrary, when the load decreases, the motor reduces the power output to save energy. The adjustment of motor output power can be dynamically calculated by the following control formula: , where, is the adjusted motor output power, is the rated power of the motor, is the proportional factor of load change, is the load change amount (unit: N). Through this formula, the power output of the motor can be accurately adjusted according to the load change, so as to ensure that the flotation machine always works in the best state.

[0136] The proportional factor of load change is used to represent the factor of adjusting the motor output power with the load change. It plays an important role in adjusting the motor power output, helping the motor to adjust the output power according to the load change. Through this adjustment method, the motor can more effectively respond to load changes, save energy and improve operating efficiency.

[0137] The load change ratio factor is usually obtained based on the following aspects:

[0138] Motor load characteristics: The impact of load changes on power output is determined by the load curve of the motor. In cases where load changes are small or stable, the ratio factor may be small; when load fluctuations are large, the ratio factor may be large.

[0139] Design and operating conditions of the motor: The design parameters of the motor, such as rated power, efficiency, etc., also affect the value of the ratio factor. Higher efficiency motors may require smaller ratio factors when the load changes, while lower efficiency motors may require larger ratio factors to ensure efficient operation.

[0140] The value range of the load change ratio factor generally depends on the load response characteristics of the motor, reflecting the sensitivity of power output adjustment to load changes.

[0141] Small motors: For small motors, load changes may be more frequent, and the value of the load change ratio factor is usually small, ranging from 0.1 to 0.3. In this case, the output power adjustment of the motor is relatively sensitive.

[0142] Medium-sized motors: For medium-sized motors, load changes are relatively stable, and the load change ratio factor is between 0.2 and 0.5.

[0143] Large motors: For large motors, due to small load fluctuations and slow changes, the load change ratio factor is usually between 0.3 and 0.6. The load regulation of this type of motor is usually slow, so a larger ratio factor is required.

[0144] The dynamic adjustment algorithm continuously monitors the real-time working conditions of the flotation machine and automatically adjusts the motor speed and power according to load fluctuations and working condition changes, significantly improving the adaptability and response capability of the system. Especially when the working conditions of the flotation machine fluctuate greatly, traditional control methods often cannot respond in time, while the dynamic adjustment algorithm can adjust the motor operating state in a very short time to ensure that the flotation machine can quickly adapt to load changes and maintain efficient and stable operation.

[0145] In addition, the dynamic adjustment algorithm can also optimize the adjustment of motor speed according to the needs of different working conditions, further improving the operating efficiency of the system. Through this mechanism, the flotation machine can automatically adjust the motor power in different working stages, ensuring sufficient power during high load and saving energy during light load, achieving intelligent dynamic energy efficiency management.

[0146] The dynamic adjustment algorithm enables the motor to automatically adjust the speed and output power according to the real-time changes of the flotation machine's working load, greatly improving the system's adaptability and response speed. By precisely controlling the motor's working state, it can effectively cope with fluctuations and load changes in flotation conditions, ensuring that the flotation machine always operates efficiently and stably under various conditions. This not only optimizes energy efficiency but also reduces energy consumption and equipment wear, improving the working efficiency and economy of the flotation machine.

[0147] S8: Analyze the heat distribution during the operation of the permanent magnet synchronous motor, and determine whether a cooling system needs to be added to the transmission structure based on the analysis results, to ensure that the motor maintains stable operating temperature under high load, thereby improving the safety and reliability of the flotation machine operation.

[0148] In-depth analysis of the heat distribution of the permanent magnet synchronous motor during operation, and determine whether a cooling system needs to be added to the transmission structure based on the analysis results. Since the motor generates heat when running under high load, if effective thermal management is not performed, the temperature of the motor may rise to an unsafe level, affecting the working efficiency and service life of the motor. Therefore, ensuring that the motor can maintain stable operating temperature under high load is a key factor in improving the safety and reliability of the flotation machine.

[0149] During the operation of the motor, energy conversion inevitably generates heat. The heat of the permanent magnet synchronous motor mainly comes from electromagnetic loss (heat generated by current in the stator winding), mechanical loss (heat caused by friction, wind resistance, etc.), and iron loss (heat caused by magnetic field changes). If these heat is not effectively dissipated, it will cause the temperature of the motor to rise, affecting its performance and life. The temperature rise of the motor can be estimated by the following formula: where ΔW is the temperature rise of the motor (unit: ℃), is the total loss power of the motor (unit: W), m is the mass of the motor (unit: kg), and c is the specific heat capacity of the motor material (unit: J / kg·℃). This formula shows that the temperature rise of the motor is proportional to the loss power it generates, and is related to the mass and material properties of the motor. Through this formula, the temperature rise of the motor under different loads and working conditions can be preliminarily estimated, providing data support for whether a cooling system needs to be added.

[0150] According to the calculation results of the temperature rise of the motor, the system needs to evaluate whether a cooling system is needed to keep the operating temperature of the motor within a safe range. The maximum operating temperature of the motor is usually specified by the design of the motor, and exceeding this temperature will cause the insulation material of the motor to age, affecting the long-term operation stability of the motor. Generally, the rated operating temperature range of the motor is 70℃ to 90℃, and the specific value varies depending on the design of the motor and the application environment.

[0151] If the temperature of the motor calculated by the temperature rise analysis is close to or exceeds its safe working temperature threshold, it is necessary to consider adding a cooling system in the transmission structure. The role of the cooling system is to remove the heat generated by the motor through heat exchange, keeping the working temperature of the motor within a safe range. The design of the cooling system needs to be optimized according to the following factors:

[0152] Common motor cooling methods include natural cooling, forced air cooling, liquid cooling, etc. Each cooling method has different effects and applicability. Liquid cooling system is suitable for high-power motors, which can efficiently remove the heat generated by the motor; while the air cooling system is suitable for small and medium power motors, which is easy to operate and has lower cost.

[0153] The flow and temperature control of the cooling medium is an important factor affecting the cooling efficiency. The flow rate and temperature of the cooling medium (such as water or oil) determine the heat transfer capacity. By reasonably controlling the flow and temperature of the cooling medium, the motor can always be kept within the safe working temperature range under the condition of large load fluctuation.

[0154] Analyzing the temperature and heat distribution of the motor and determining whether to add a cooling system can significantly improve the stability and reliability of the flotation machine. An effective cooling system can maintain the stable temperature of the motor under high load and long-time operation, avoiding damage or performance degradation caused by overheating. Especially in the high load working condition of the flotation machine, the addition of the cooling system can ensure the continuous operation of the motor, prolong the service life of the equipment, and reduce the probability of failure.

[0155] In addition, the design and implementation of the cooling system can also help to improve the energy efficiency of the motor, because the motor works at a suitable temperature, its efficiency will be higher, thereby reducing energy consumption and improving the overall production efficiency of the flotation machine.

[0156] By analyzing the heat distribution of the motor during operation, the system can determine whether to add a cooling system in the transmission structure. The role of the cooling system is to ensure that the motor maintains a stable working temperature under high load, thereby improving the stability, long-term reliability and energy utilization efficiency of the flotation machine. An optimized cooling system not only reduces the risk of motor overheating, but also prolongs the service life of the equipment, ensuring the efficient operation of the flotation machine under various working conditions.

[0157] Example 3: Flotation machines are commonly used in the beneficiation process of ores, where agitation and bubble contact in the slurry facilitate the attachment and separation of minerals from bubbles. In this process, the performance of the motor and transmission structure is crucial for the working efficiency and stability of the flotation machine. There is an ore flotation machine with the following working parameters and motor physical parameters: flotation machine working load: 100 N; flotation machine agitation speed: 30 RPM; permanent magnet synchronous motor power: 50 kW; motor torque output: 200 N m; motor efficiency curve: at different speeds, the motor efficiency is 90% (at full load working condition), 80% (at low load working condition); reducer type: 2-stage reduction ratio 5:1; transmission shaft type: rigid transmission shaft.

[0158] First, the physical parameters of the transmission structure of the flotation machine are obtained through the API interface of the flotation machine management platform, including: motor power: 50 kW, motor torque output: 200 N m, motor efficiency curve: according to different speed and load conditions, the maximum efficiency of the motor is 90%. Reducer and coupling parameters: reduction ratio 5:1, coupling friction coefficient 0.05, in the simulation platform, the physical parameters of the motor are loaded to the simulation platform, combined with the working requirements of the flotation machine (such as working load and agitation speed), the matching analysis of the motor drive system and the flotation machine is carried out. Matching model formula:

[0159] Motor output power ;

[0160] Motor speed and flotation machine speed matching: through the power and torque matching between the motor and the flotation machine, it is ensured that the motor can meet the load demand of the flotation machine. According to the model, assuming that the motor speed is 1500 RPM, the output power is:

[0161] , assuming that the flotation machine needs 12 kW of driving force, the motor output power is enough to meet the demand.

[0162] In the simulation process, based on the motor and flotation machine matching model, energy efficiency analysis is carried out, and several adjustment schemes are automatically generated.

[0163] Assuming that through analysis, the efficiency of the motor is 90% (full load working condition), then: , according to the energy efficiency analysis result, the adjustment scheme is proposed:

[0164] Adjust the motor speed: optimize the motor speed to keep it at the best efficiency point.

[0165] Optimize the reduction ratio of the reducer: the reduction ratio is optimized to 4:1 to reduce energy loss.

[0166] After each simulation adjustment, the system analyzes the motor vibration. Assuming that through finite element analysis, the simulation results show that the motor vibration amplitude is 0.3 mm, and during the adjustment process, the cooperation between the motor and the transmission shaft of the flotation machine is optimized several times, and finally the motor vibration amplitude is 0.15 mm, which meets the expected requirements.

[0167] By comparing multiple adjustment schemes, the optimal scheme is selected. Assuming that the vibration amplitude of scheme 1 is 0.3 mm, the vibration amplitude of scheme 2 is 0.15 mm, and the vibration amplitude of scheme 3 is 0.1 mm, the optimal scheme is scheme 3, the motor vibration is the smallest, and the energy efficiency optimization reaches the best state. Finally, it is determined to apply this scheme and apply it to the transmission system of the flotation machine.

[0168] On the adjusted transmission structure, the variable frequency control algorithm is used to accurately control the motor speed to meet the speed requirements of the flotation machine under different load conditions. Variable frequency control can realize rapid start and stop, maintain stable operation of the motor under high and low loads, and through dynamic adjustment algorithm, the motor can automatically adjust the speed and output power according to the real-time changes of the flotation machine working load (such as pulp concentration, mineral quality, etc.), improve the adaptability and response speed of the system, and through the analysis of the heat distribution of the motor, if the temperature exceeds the preset threshold when the motor operates under high load, the simulation platform will automatically suggest adding a cooling system. Assuming that the cooling system can reduce the motor temperature by 10°C, ensuring that the motor maintains a stable working temperature under high load. The optimization result comparison is shown in Table 1:

[0169] Table 1 Optimization result comparison

[0170]

[0171] The parameters of the permanent magnet synchronous motor direct drive flotation machine transmission structure have been effectively adjusted, which can meet the efficient and stable operation requirements of the flotation machine. The optimized system not only improves the energy efficiency and reduces the energy consumption, but also reduces the motor vibration and prolongs the service life of the equipment. In addition, the application of variable frequency control algorithm and dynamic adjustment algorithm enables the motor to adjust in real time according to the changes of the flotation machine working load, further improving the adaptability and response speed of the system.

[0172] In the description of the present specification, the description of the terms "one embodiment", "example", "specific example" and the like means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the described specific features, structures, materials or characteristics can be combined in any one or more embodiments or examples in a suitable manner.

[0173] The preferred embodiments of the application disclosed above are only to facilitate the elucidation of the application. The preferred embodiments do not describe all the details of the application and limit the application to the specific embodiments. Obviously, many modifications and variations can be made in light of the teachings above. The description is chosen and described in order to provide the best illustration of the application and its practical application to those skilled in the art and to enable those skilled in the art to best utilize the application. The application is limited only by the claims and their full scope and equivalents.

Claims

1. A method for optimizing the transmission structure of a direct-drive flotation machine using a permanent magnet synchronous motor, characterized in that: The optimization method includes the following steps: S1: Obtain the physical parameters of the flotation machine's transmission structure through the API interface of the flotation machine management platform; S2: Load the physical parameters of the permanent magnet synchronous motor into the simulation platform, combine them with the working requirements of the flotation machine, perform a matching analysis between the motor drive system and the flotation machine, and construct a matching model between the permanent magnet synchronous motor and the transmission structure of the flotation machine; S3: Perform energy efficiency analysis on the transmission structure based on the matching model, and automatically generate several adjustment schemes based on the energy efficiency analysis results; S4: In each simulation, the transmission structure of the flotation machine is optimized and adjusted according to several adjustment schemes, and the motor vibration is analyzed during the simulation. S5: Based on the motor vibration analysis results, the drive shafts of the motor and the flotation machine are adjusted multiple times. When convergence is achieved, the optimal adjustment scheme is selected and applied to the transmission structure of the flotation machine. S6: When the flotation machine is running based on the adjusted transmission structure, the motor speed is automatically controlled by the frequency conversion control algorithm; Constructing a matching model for the permanent magnet synchronous motor and the flotation machine transmission structure includes the following steps: The operational requirements of a flotation machine include workload and stirring speed; The motor's output power is compared with the flotation machine's operating requirements to verify whether the motor can meet the flotation machine's operating requirements. If they do not match, the simulation platform adjusts the motor's output parameters until the motor output matches the flotation machine's operating requirements. When the motor output matches the working requirements of the flotation machine, a matching model is constructed between the permanent magnet synchronous motor and the transmission structure of the flotation machine. The matching model optimizes the working state of the motor based on the working load and stirring speed of the flotation machine.

2. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 1, characterized in that: Based on the matching model, an energy efficiency analysis of the transmission structure is performed, and several adjustment schemes are automatically generated according to the energy efficiency analysis results, including the following steps: The efficiency of each step in the energy transfer process affects the performance of the transmission structure. The formula for calculating energy transfer efficiency is: ,in, The total energy transfer efficiency of the entire transmission structure. Let be the energy transfer efficiency of the i-th transmission component, and n be the total number of transmission components; Several adjustment schemes are automatically generated based on the energy efficiency analysis results. The adjustment schemes include adjusting motor parameters, optimizing the reduction ratio of the reducer, and optimizing the configuration of transmission components.

3. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 2, characterized in that: The transmission structure of the flotation machine was optimized and adjusted according to several adjustment schemes, and the motor vibration was analyzed during simulation. The steps included: Several simulations were performed based on different adjustment schemes, and the transmission structure of the flotation machine was adjusted during each simulation. The adjustment schemes included adjusting motor parameters, optimizing the reduction ratio of the reducer, and optimizing the configuration of transmission components. In each simulation, the motor vibration is analyzed using the finite element method to obtain the motor vibration amplitude.

4. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 3, characterized in that: Based on the motor vibration analysis results, the drive shafts of the motor and flotation machine were adjusted multiple times. When convergence was achieved, the optimal adjustment scheme was selected and applied to the transmission structure of the flotation machine, including the following steps: After each adjustment, the simulation platform will adjust the motor and the drive shaft of the flotation machine based on the vibration analysis results of the motor and the drive shaft, and recalculate the vibration amplitude of the motor after each adjustment; The adjustment should be stopped when the maximum number of adjustments is reached, or when the mechanical loss is less than or equal to the loss threshold and the motor vibration is less than or equal to the vibration threshold. When convergence occurs, the mechanical losses and motor vibrations are normalized, and the weighted calculation of the normalized mechanical losses and motor vibrations is used to obtain the inferior selection index. The adjustment scheme with the smallest inferior selection index is selected as the optimal adjustment scheme and applied to the transmission structure of the flotation machine.

5. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 4, characterized in that: The physical parameters of the transmission structure of the existing flotation machine can be obtained through the API interface of the flotation machine management platform, including the power, torque output, and efficiency curve of the permanent magnet synchronous motor, as well as the parameters of the reducer and coupling transmission components.

6. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 1, characterized in that: The optimization method further includes: S7: Through a dynamic adjustment algorithm, the motor automatically adjusts its speed and output power according to the real-time changes in the working load of the flotation machine.

7. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 6, characterized in that: The motor automatically adjusts its speed and output power based on real-time changes in the flotation machine's workload using a dynamic adjustment algorithm, including the following steps: The dynamic adjustment algorithm monitors the real-time load changes of the flotation machine, inputs these load changes into the control system, and automatically adjusts the motor output power. The adjustment algorithm expression is as follows: ,in, The adjusted motor output power, This refers to the rated power of the motor. This is the scaling factor for load changes. This represents the change in load.

8. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 1, characterized in that: The optimization method further includes: S8: Analyze the heat distribution during the operation of the permanent magnet synchronous motor, and determine whether a cooling system needs to be added to the transmission structure based on the analysis results.

9. The method for optimizing the transmission structure of a permanent magnet synchronous motor direct-drive flotation machine according to claim 8, characterized in that: The heat distribution during the operation of a permanent magnet synchronous motor is analyzed, and based on the analysis results, it is determined whether a cooling system needs to be added to the transmission structure. This includes the following steps: The expression for calculating the internal temperature rise of the motor is: Where ΔW is the motor temperature rise. Let m be the total power loss of the motor, m be the mass of the motor, and c be the specific heat capacity of the motor material. If the motor temperature calculated through temperature rise analysis exceeds its safe operating temperature threshold, it is determined that a cooling system needs to be added to the transmission structure.

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