A multi-stage circulating crushing and particle size precise control system for processing coarse cereals

Abstract

The application relates to the technical field of coarse grain processing, and discloses a multi-stage circulation smashing and particle size precision regulation and control system for coarse grain processing. The system comprises a smashing execution module, a particle size monitoring module, a regulation and control processing module, a central control module and an early warning feedback unit. The primary smashing unit, the secondary smashing unit and the material circulation reflux mechanism of the smashing execution module are used to realize the step-by-step refinement of particle size. Meanwhile, the particle size distribution of the smashed material is monitored in real time by the particle size monitoring module, and the particle size abnormal area including the deviation of excessively coarse and excessively fine particles is identified, so that the particle size uniformity of the smashing process is ensured, and the precision of particle size control is improved. According to the real-time data, the regulation and control processing module executes regulation and control measures, including adjusting the speed of the smashing machine, controlling the feeding rate, adjusting the circulation flow and adding an additive, correcting the particle size deviation in real time, optimizing the smashing efficiency and ensuring that the particle size meets the preset requirements.

Description

Technical Field

[0001] This invention relates to the field of coarse grain processing technology, specifically to a multi-stage circulating crushing and precise particle size control system for coarse grain processing. Background Technology

[0002] Coarse grains generally refer to grain and legume crops other than the five major crops: rice, wheat, corn, soybeans, and potatoes. They mainly include: sorghum, millet, buckwheat, oats, barley, foxtail millet, foxtail millet, Job's tears, amaranth, as well as kidney beans, mung beans, adzuki beans, broad beans, peas, cowpeas, lentils, and black beans. They are characterized by a short growing season, limited planting area, specific growing regions, and lower yields, but generally contain rich nutritional components.

[0003] Currently, due to the diverse material characteristics and complex crushing process in the processing of miscellaneous grains, existing crushing systems cannot monitor particle size distribution and identify abnormal particle size areas in real time when performing multi-stage crushing of miscellaneous grains. If the deviation of particles being too coarse or too fine is not corrected in time, it may result in low crushing efficiency and unstable product quality, and cannot guarantee the consistency of particle size and processing accuracy.

[0004] Therefore, a multi-stage circulating crushing and precise particle size control system for coarse grain processing is proposed to solve the above problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a multi-stage circulating crushing and precise particle size control system for grain processing, which solves the problems of low crushing efficiency and unstable product quality mentioned in the background technology, and the inability to guarantee particle size consistency and processing accuracy.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a multi-stage circulating crushing and particle size precise control system for processing miscellaneous grains, the system comprising a crushing execution module, a particle size monitoring module, a control processing module and a central control module;

[0007] The crushing execution module is used to perform multi-stage cyclic crushing of grain materials, and the particle size is gradually refined through the primary crushing unit, the secondary crushing unit and the material circulation and reflux mechanism.

[0008] The particle size monitoring module is used to monitor the particle size distribution of the crushed material in real time. It acquires particle size data through a laser particle size analyzer, image processing sensor, and sieving device, and identifies abnormal particle size areas, including deviations such as particles that are too coarse or too fine.

[0009] The control and processing module is used to execute corresponding control measures based on particle size monitoring data, including adjusting the pulverizer speed, controlling the feed rate, adjusting the circulation flow rate, and adding additives;

[0010] The central control module is used to coordinate the operation of various modules of the system, receive monitoring data and analyze and process it, control the operation of the control and processing module according to the preset control strategy, and provide a human-machine interface to support the setting of processing parameters, real-time data display and historical query.

[0011] The system also integrates an early warning feedback unit, which automatically triggers audible and visual alarms and pushes messages when the particle size distribution exceeds the set safety threshold or the control measures fail. It also records processing data, including particle size curves and operation logs, for subsequent evaluation and optimization, forming a closed-loop control.

[0012] Preferably, the crushing execution module includes a primary crushing unit, a secondary crushing unit, a circulation and recirculation unit, and a material conveying unit;

[0013] The primary crushing unit controls the crushing force through an adjustable speed drive device to adapt to the hardness and moisture content of different types of grains.

[0014] The secondary crushing unit is equipped with a classifier and a cyclone separator to separate particles by size, output qualified particles and recycle unqualified particles.

[0015] The circulating reflux unit adjusts the reflux ratio through pneumatic conveying pipelines and mechanical valve groups to uniformly process materials in multi-stage crushing.

[0016] The material conveying unit uses a screw conveyor and a belt conveyor to continuously supply and discharge materials.

[0017] Preferably, the primary crushing unit also integrates a pretreatment component for washing, drying and removing impurities from the grains;

[0018] The secondary crushing unit includes a multi-stage classifying wheel and a dynamic adjustment mechanism, which controls the particle fineness in real time by changing the rotation speed of the classifying wheel.

[0019] The circulating recirculation unit is equipped with a flow sensor and a feedback controller, which dynamically adjusts the recirculation rate based on real-time granular data.

[0020] The material conveying unit is equipped with a weighing sensor and a speed monitoring device to stabilize the feed rate and flow rate and reduce fluctuations.

[0021] Preferably, the particle size monitoring module includes a sensor array, a data acquisition unit, and a state analysis unit;

[0022] The sensor array consists of a laser particle size analyzer, an image acquisition camera, and a vibrating sieve sensor arranged at the crushing outlet, circulation pipeline, and finished product bin, covering key processing nodes.

[0023] The data acquisition unit is used to collect sensor data in real time and perform preliminary filtering, and uses a moving average algorithm to suppress noise.

[0024] The state analysis unit determines whether the particle size is abnormal based on the particle size distribution model and real-time data, and determines the particle size change trend, including calculating the average particle size, particle size dispersion and deviation index.

[0025] Preferably, the sensor array is arranged in a mesh pattern, covering typical cross-sections of the crushing process: the feed inlet, the crushing chamber, and the discharge outlet;

[0026] The data acquisition unit supports multi-channel synchronous acquisition and has the functions of redundant data storage and automatic outlier removal.

[0027] The state analysis unit uses time series analysis to identify the dynamic process of granularity change, including using an autoregressive model to predict future granularity trends and comparing them with historical processing data.

[0028] Preferably, the control and processing module includes a parameter adjustment unit, a circulation control unit, and an additive addition unit;

[0029] The parameter adjustment unit adjusts the speed, pressure, and gap of the pulverizer through a frequency converter and a servo motor to control the pulverizing force.

[0030] The circulation control unit uses electric valves and pump sets to regulate the material return path and flow rate, thereby optimizing circulation efficiency.

[0031] The additive addition unit adds additives uniformly through a metering pump and a spraying device, thereby improving material flowability and particle size consistency.

[0032] Preferably, the parameter adjustment unit has pressure and temperature compensation functions, and dynamically corrects and controls the parameters according to the material characteristics;

[0033] The circulation control unit integrates a flow meter and a concentration sensor to monitor the particle concentration and distribution of the reflux material in real time.

[0034] The additive addition unit is equipped with a mixing and stirring mechanism and a liquid level control device to ensure that the additives are evenly dispersed and added in precise amounts.

[0035] Preferably, the central control module includes a main control unit, a data analysis unit, and a human-computer interaction unit;

[0036] The main control unit is used to schedule the coordinated operation and timing control of various modules of the system, and adopts a distributed architecture to support modular expansion;

[0037] The data analysis unit integrates and analyzes the monitoring data, and evaluates the effectiveness of the control measures based on the granularity control model;

[0038] The human-machine interaction unit provides a graphical user interface that supports processing scheme design, real-time monitoring, alarm log export, and remote access.

[0039] Preferably, the main control unit uses a PLC or industrial computer to achieve multi-task parallel processing and has a communication interface to connect to external devices;

[0040] The data analysis unit integrates multiple prediction algorithms and dynamically adjusts the control strategy based on real-time data.

[0041] The human-computer interaction unit supports touch screen operation and data visualization, including granular distribution curves, historical control charts, and report generation functions.

[0042] Preferably, the early warning feedback unit includes an abnormal alarm subunit and a data management subunit;

[0043] The abnormal alarm subunit automatically triggers graded alarms based on the granularity deviation threshold and the control effect, including mild warning and emergency shutdown;

[0044] The data management subunit is used to store all processing data and operation logs, and provides retrieval and comparative analysis functions based on time, material type and control type, and supports data export and cloud platform integration.

[0045] Compared with the prior art, the present invention provides a multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains, which has the following beneficial effects:

[0046] 1. In this invention, when performing multi-stage circulating crushing and particle size control of miscellaneous grains, the particle size is gradually refined through the primary crushing unit, secondary crushing unit and material circulation reflux mechanism of the crushing execution module. At the same time, the particle size monitoring module monitors the particle size distribution of the crushed material in real time and identifies abnormal particle size areas, including deviations of particles that are too coarse or too fine, to ensure the uniformity of particle size in the crushing process and improve the accuracy of particle size control.

[0047] 2. In this invention, when abnormal particle size monitoring data occurs, the control and processing module executes control measures based on real-time data, including adjusting the pulverizer speed, controlling the feed rate, adjusting the circulation flow rate, and adding additives, to correct particle size deviation in real time, optimize pulverization efficiency, and ensure that the particle size meets the preset requirements.

[0048] 3. In this invention, the operation of each module of the system is coordinated by the central control module, and the operation of the control processing module is controlled according to the preset control strategy. Combined with the early warning feedback unit, an alarm is automatically triggered when the granularity distribution exceeds the safety threshold, and the processing data, including granularity curves and operation logs, are recorded to form a closed-loop control, thereby improving the automation level and reliability of the system. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the architecture of a multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to the present invention. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] Specific embodiment: A multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains, the system includes a crushing execution module, a particle size monitoring module, a control processing module and a central control module;

[0052] The crushing execution module is used to perform multi-stage circulating crushing of grain materials, and the particle size is gradually refined through the primary crushing unit, the secondary crushing unit and the material circulation and reflux mechanism.

[0053] The particle size monitoring module is used to monitor the particle size distribution of the crushed material in real time. It acquires particle size data through a laser particle size analyzer, image processing sensor, and sieving device, and identifies abnormal particle size areas, including deviations such as particles that are too coarse or too fine.

[0054] The control and processing module is used to execute corresponding control measures based on particle size monitoring data, including adjusting the pulverizer speed, controlling the feed rate, adjusting the circulation flow rate, and adding additives;

[0055] The central control module is used to coordinate the operation of various modules in the system, receive and analyze monitoring data, control the operation of the control and processing module according to the preset control strategy, and provide a human-machine interface to support the setting of processing parameters, real-time data display and historical query.

[0056] The system also integrates an early warning feedback unit, which automatically triggers audible and visual alarms and pushes messages when the particle size distribution exceeds the set safety threshold or the control measures fail. It also records processing data, including particle size curves and operation logs, for subsequent evaluation and optimization, forming a closed-loop control.

[0057] The crushing execution module includes a primary crushing unit, a secondary crushing unit, a circulation and recirculation unit, and a material conveying unit;

[0058] The primary crushing unit controls the crushing force through an adjustable speed drive device to adapt to the hardness and moisture content of different types of grains.

[0059] The secondary crushing unit is equipped with a classifier and a cyclone separator to separate particles according to size, outputting qualified particles and recycling unqualified particles.

[0060] The recirculation unit adjusts the recirculation ratio through pneumatic conveying pipes and mechanical valve groups to uniformly process materials in multi-stage crushing.

[0061] The material conveying unit uses screw conveyors and belt conveyors to continuously supply and discharge materials, avoiding blockages and waste.

[0062] The primary crushing unit also integrates a pre-treatment component for washing, drying, and removing impurities from grains.

[0063] The secondary crushing unit includes a multi-stage classifying wheel and a dynamic adjustment mechanism, which controls the particle fineness in real time by changing the rotation speed of the classifying wheel;

[0064] Firstly, for the cleaning, drying, and impurity removal steps in the pretreatment components, the cleaning operation is achieved through a high-pressure spray system installed in a water tank. The spray water pressure is adjustable from 0.5 to 2.0 MPa, and the water flow covers the surface of the grain materials to remove dust and impurities. The drying operation uses a hot air circulating dryer, with the hot air temperature controlled at 50-80°C and the wind speed at 1-3 m / s. The drying time is automatically adjusted according to the moisture content of the material to ensure that the moisture content of the material is reduced to below 12%. The impurity removal operation is completed through a vibrating screen and a magnetic separator. The vibrating screen has a mesh size of 10-20, and the magnetic separator uses permanent magnets to adsorb metallic impurities. The impurity level is monitored by sensors throughout the process and fed back to the central control module in real time.

[0065] Secondly, regarding the multi-stage classifying wheel and dynamic adjustment mechanism, the multi-stage classifying wheel consists of multiple concentric discs with an adjustable spacing of 1-10mm. It is driven to rotate by a servo motor at a speed of 100-1000rpm. The dynamic adjustment mechanism includes a linear actuator and a position sensor, which adjusts the gap and speed of the classifying wheel based on real-time particle size data. When the particle size is too coarse, the gap is reduced and the speed is increased to enhance classification accuracy. In practice, the classifying wheel works in conjunction with the airflow; coarse particles are thrown towards the wall and collected, while fine particles pass through the central outlet, achieving continuous classification. The dynamic adjustment mechanism also integrates an adaptive algorithm that automatically optimizes parameters based on material flow rate to ensure classification efficiency.

[0066] The recirculation unit is equipped with a flow sensor and a feedback controller to dynamically adjust the recirculation rate based on real-time granular data;

[0067] The material conveying unit is equipped with weighing sensors and speed monitoring devices to stabilize the feed rate and flow rate, and reduce fluctuations.

[0068] The particle size monitoring module includes a sensor array, a data acquisition unit, and a status analysis unit;

[0069] The sensor array consists of laser particle size analyzers, image acquisition cameras, and vibrating screen sensors arranged at the crushing outlet, circulation pipeline, and finished product bin, covering key processing nodes;

[0070] The data acquisition unit is used to collect sensor data in real time and perform preliminary filtering, and uses a moving average algorithm to suppress noise;

[0071] The formula for the moving average algorithm is expressed as:

[0072] ;

[0073] in Indicates a point in time Filtered data points, Indicates a point in time The original granularity data points, Indicates the size of the movable window. Indicates a time index. Indicates the summation index, from 0 to... ;

[0074] The algorithm smooths out random fluctuations and improves data stability. In implementation, the data acquisition unit samples at a frequency of 10 times per second, and the window size n is dynamically adjusted according to the data variation coefficient.

[0075] The state analysis unit determines whether the particle size is abnormal based on the particle size distribution model and real-time data, and determines the particle size change trend, including calculating the average particle size, particle size dispersion and deviation index;

[0076] The particle size distribution model uses a normal distribution for fitting, and the formula is:

[0077] ;

[0078] in Indicates particle size as The probability density function value of the particles. Indicates the particle size. The average particle size, representing the particle size distribution, The standard deviation represents the particle size distribution;

[0079] The average particle size is calculated using the volume average formula:

[0080] ;

[0081] in Indicates the volume average particle size. Indicates particle size as The number of particles, Indicates the first The median particle size of each particle size range;

[0082] Particle size distribution:

[0083] ;

[0084] in Indicates particle size distribution;

[0085] Deviation index:

[0086] ;

[0087] in Indicates the deviation index. Indicates the target particle size;

[0088] During implementation, the system updates these metrics every 5 seconds. >5% or If the value exceeds the preset range, an anomaly flag will be triggered, and control measures will be initiated.

[0089] The sensor array is arranged in a mesh pattern, covering typical cross-sections of the crushing process: the feed inlet, the crushing chamber, and the discharge outlet;

[0090] The data acquisition unit supports multi-channel synchronous acquisition and has the functions of redundant data storage and automatic outlier removal;

[0091] Redundant data storage is achieved through a multi-backup mechanism in the data acquisition unit. Raw data is simultaneously written to both local SSDs and cloud servers, stored in timestamp-labeled CSV files to ensure data integrity. The automatic outlier removal function employs statistical methods, first calculating the Z-score of the dataset using the formula:

[0092] ;

[0093] in Represents the Z-score value. Represents a single data point. This represents the arithmetic mean of the dataset. Indicates standard deviation;

[0094] when If a point is found to be an outlier, it will be automatically removed, and the gap will be filled using linear interpolation. In practice, this function runs during each batch of data processing to reduce the impact of noise.

[0095] The state analysis unit uses time series analysis to identify the dynamic process of granularity change, including using an autoregressive model to predict future granularity trends and comparing them with historical processing data;

[0096] Time series analysis is used to identify trends in granularity changes. It employs an autoregressive integral moving average model, with the general formula being:

[0097] ;

[0098] in Represents an autoregressive polynomial. Indicates the backoff operator. Indicates the difference order. Indicates a point in time Granular time series data, Represents the moving average polynomial. The white noise error term is assumed to be a random variable with a mean of 0 and a constant variance. In practice, the model parameters are estimated by the least squares method. The system fits the data once per minute, predicts the particle size trend for the next 30 seconds, and compares it with historical data. When the prediction deviation exceeds the threshold, the crushing parameters are adjusted. The method also integrates a rolling window mechanism, which uses the most recent 100 data points for modeling to adapt to data non-stationarity.

[0099] The control and processing module includes a parameter adjustment unit, a circulation control unit, and an additive addition unit;

[0100] The parameter adjustment unit adjusts the speed, pressure, and gap of the pulverizer through a frequency converter and a servo motor to control the pulverizing force.

[0101] The circulation control unit uses electric valves and pump sets to regulate the material return path and flow rate, thereby optimizing circulation efficiency;

[0102] Optimization of circulation efficiency is achieved through a circulation control unit, which monitors the flow rate and concentration of the reflux material. A PID controller is used to adjust the opening of the electric valve. The valve opening and flow rate are linearly proportional, and the formula can be simplified as follows:

[0103]

[0104] in Indicates material flow rate; Represents system constants; Indicates the valve opening degree;

[0105] During implementation, the controller uses particle size distribution as a setpoint and adjusts the return path in real time to ensure that unqualified particles are quickly returned to the crushing unit, reducing energy consumption; simultaneously, the system calculates the circulation ratio:

[0106] ;

[0107] in Indicates the circulation ratio, optimizing reflux efficiency;

[0108] The goal is to Maintain the value between 0.2 and 0.5 to avoid excessive cycling;

[0109] The additive addition unit uniformly adds additives through a metering pump and a spray device to improve material flowability and particle size consistency.

[0110] Improving material flowability and particle size consistency is achieved through an additive addition unit. Additives, such as silica anti-caking agents, are added via spraying, with the addition rate controlled by a metering pump. The formula is as follows:

[0111] ;

[0112] in Indicates the amount of additives added. Indicates the concentration coefficient. Indicates the mass flow rate of the material;

[0113] During implementation, the additives and materials are uniformly stirred in a mixer at a speed of 200-500 rpm for 10-30 seconds to reduce inter-particle friction and improve flowability. Particle size consistency is verified by real-time monitoring of the dispersion index. If the value is greater than the specified value, the amount of additive will be increased to ensure a concentrated particle size distribution.

[0114] The parameter adjustment unit has pressure and temperature compensation functions, and dynamically corrects and controls the parameters according to the material characteristics;

[0115] Pressure and temperature compensation functions are achieved through sensors integrated into the pulverizer. The pressure sensor measures the pressure inside the pulverizing chamber, and the temperature sensor monitors the material temperature. The compensation algorithm dynamically corrects the control parameters based on empirical formulas. The pulverizer speed correction formula is as follows:

[0116] ;

[0117] in This indicates the corrected pulverizer speed. Indicates the reference speed. This indicates the real-time measured material temperature. Indicates reference temperature. This indicates the real-time measured pressure in the grinding chamber. Indicates reference pressure. Indicates the temperature compensation coefficient. This represents the pressure compensation coefficient. During implementation, the system collects sensor data every second, automatically calculates correction values, and adjusts the inverter output to ensure stable crushing force.

[0118] The circulation control unit integrates a flow meter and a concentration sensor to monitor the particle concentration and distribution of the reflux material in real time.

[0119] The additive addition unit is equipped with a mixing and stirring mechanism and a liquid level control device to ensure that the additives are evenly dispersed and added in precise amounts.

[0120] The central control module includes a main control unit, a data analysis unit, and a human-computer interaction unit;

[0121] The main control unit is used to schedule the coordinated operation and timing control of various modules in the system, and adopts a distributed architecture to support modular expansion;

[0122] The distributed architecture is implemented through a main control unit and adopts a multi-node design. Each node is controlled by an independent PLC, and the nodes communicate with each other via Ethernet and exchange information using the Modbus protocol. In implementation, the system supports modular expansion. When adding a new crushing unit, only the node address needs to be configured for integration. The main control unit coordinates the timing of each node to ensure data synchronization.

[0123] The data analysis unit integrates and analyzes the monitoring data, and evaluates the effectiveness of the control measures based on the granular control model;

[0124] Integrated analysis was performed by the data analysis unit, which aggregated data from various modules and applied a granularity control model for evaluation. The granularity control model, based on physical equations and machine learning, uses a population equilibrium model to describe the pulverizing process; the formula is:

[0125] ;

[0126] in Indicates particle size as Particles in time The number density function, Indicates the rate of new particle formation. Indicates the rate of particle breakage and disappearance. This represents the flux term; during implementation, the model parameters are learned from historical data, and the system runs a simulation every minute to evaluate the effectiveness of the current control measures. When the simulation results deviate from the actual measurements by more than 10%, the evaluation is marked as failed, triggering a strategy adjustment.

[0127] The human-machine interaction unit provides a graphical user interface that supports processing scheme design, real-time monitoring, alarm log export, and remote access.

[0128] The main control unit uses a PLC and an industrial computer to achieve multi-task parallel processing and has a communication interface to connect to external devices;

[0129] The data analysis unit integrates multiple prediction algorithms and dynamically adjusts control strategies based on real-time data.

[0130] Multiple prediction algorithms, including Support Vector Machines and Neural Networks, are used to predict granular changes; the SVM algorithm is based on kernel functions, and its formula is the decision function:

[0131] ;

[0132] in Indicates the predicted output. This represents the input feature vector. This indicates the number of support vectors. Represents the Lagrange multipliers. Indicates the class labels of the training data. Represents the kernel function. Indicates the bias term;

[0133] The neural network uses a three-layer perceptron with ReLU activation function and backpropagation algorithm for training. In practice, the system retrains the model every 5 minutes using historical data to predict future granularity distribution and calculate confidence intervals.

[0134] The dynamic adjustment and control strategy is based on prediction results: when the prediction indicates that the particle size will deviate from the target, the strategy engine modifies the parameters in real time, adjusting the pulverizer speed setpoint by the following amount:

[0135] ;

[0136] in Indicates the amount of speed adjustment. Indicates the error signal. Represents the proportionality coefficient. Represents the integral coefficient. The integral representing the error. Represents a time variable;

[0137] During implementation, the adjustment strategy is stored in the form of a rule base, supporting IF-THEN logic to ensure rapid response to changes;

[0138] The human-computer interaction unit supports touch screen operation and data visualization, including granular distribution curves, historical control charts, and report generation functions.

[0139] The early warning feedback unit includes an abnormal alarm subunit and a data management subunit;

[0140] The abnormal alarm subunit automatically triggers graded alarms based on the granularity deviation threshold and the control effect, including mild warning and emergency shutdown;

[0141] The granularity deviation threshold is set based on statistical control principles, and the upper and lower control limits are calculated as follows:

[0142] ;

[0143] ;

[0144] in Indicates the upper control limit. Indicates the lower control limit. Indicates the target particle size. The standard deviation of historical data;

[0145] During implementation, the threshold is dynamically adjusted based on the material type, and the system is updated for each batch. The effectiveness of the control is evaluated by comparing granular indicators before and after the control, with an effectiveness index:

[0146] ;

[0147] in Indicates the effectiveness index. Indicates the average particle size before regulation. Indicates the average particle size after regulation;

[0148] when If the deviation is less than 50%, the control is considered to have failed. Automatic tiered alarms are triggered through the abnormal alarm subunit: mild warning is triggered when the deviation threshold exceeds UCL or LCL, and an SMS notification is sent to the operator; emergency shutdown is triggered when the control fails or the equipment malfunctions, and the power is immediately cut off and the event is recorded.

[0149] The data management subunit is used to store all processing data and operation logs, and provides retrieval and comparative analysis functions based on time, material type and control type, and supports data export and cloud platform integration.

[0150] The operating steps of this system are as follows:

[0151] The grain material first enters the crushing execution module, where it is initially crushed by the primary crushing unit. Then, it passes through the classifier and cyclone separator in the secondary crushing unit to separate the particles according to size. Qualified particles are output, while unqualified particles are re-entered into the crushing process through the pneumatic conveying pipeline and mechanical valve group of the circulation return unit to adjust the return ratio, thereby achieving multi-stage circulation crushing and gradual refinement.

[0152] During this process, the sensor array of the particle size monitoring module monitors the particle size distribution of materials at key nodes such as the crushing outlet and circulation pipeline in real time. The data acquisition unit performs preliminary filtering on the sensor data, while the status analysis unit determines whether the particle size is abnormal based on the particle size distribution model and calculates the average particle size, particle size dispersion, and deviation index to identify the trend of change.

[0153] The central control module's main control unit schedules the coordinated operation of all modules within the system. Its data analysis unit integrates and analyzes the monitoring data and assesses the current state based on the particle size control model. Subsequently, the control and processing module executes precise control according to instructions: the parameter adjustment unit adjusts the crusher's speed and gap via frequency converters and servo motors; the circulation control unit regulates the material return path and flow rate using electric valves and pump sets; and the additive addition unit adds additives via metering pumps to improve material properties when necessary. Throughout the process, the early warning feedback unit continuously monitors particle size distribution and control effects. Once the deviation exceeds the safety threshold, a graded alarm is automatically triggered. Simultaneously, the data management subunit records all processing data and operation logs, forming a complete closed-loop control system, thereby achieving precise control of the particle size of processed grains.

[0154] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0155] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains, characterized in that: The system includes a crushing execution module, a particle size monitoring module, a control and processing module, and a central control module; The crushing execution module is used to perform multi-stage cyclic crushing of grain materials, and the particle size is gradually refined through the primary crushing unit, the secondary crushing unit and the material circulation and reflux mechanism. The particle size monitoring module is used to monitor the particle size distribution of the crushed material in real time. It acquires particle size data through a laser particle size analyzer, image processing sensor, and sieving device, and identifies abnormal particle size areas, including deviations such as particles that are too coarse or too fine. The particle size monitoring module includes a sensor array, a data acquisition unit, and a status analysis unit; The sensor array consists of a laser particle size analyzer, an image acquisition camera, and a vibrating sieve sensor arranged at the crushing outlet, circulation pipeline, and finished product bin, covering key processing nodes. The data acquisition unit is used to collect sensor data in real time and perform preliminary filtering, and uses a moving average algorithm to suppress noise. The state analysis unit determines whether the particle size is abnormal based on the particle size distribution model and real-time data, and determines the particle size change trend, including calculating the average particle size, particle size dispersion and deviation index. The particle size distribution model uses a normal distribution for fitting, and the formula is: ； in Indicates particle size as The probability density function value of the particles. Indicates the particle size. The average particle size, representing the particle size distribution, The standard deviation represents the particle size distribution; The average particle size is calculated using the volume average formula: ； in Indicates the volume average particle size. Indicates particle size as The number of particles, Indicates the first The median particle size of each particle size range; Particle size distribution: ； in Indicates particle size distribution; Deviation index: ； in Indicates the deviation index. Indicates the target particle size; when >5% or If the value exceeds the preset range, an anomaly flag will be triggered, and control measures will be initiated. The control and processing module is used to execute corresponding control measures based on particle size monitoring data, including adjusting the pulverizer speed, controlling the feed rate, adjusting the circulation flow rate, and adding additives; The control and processing module includes a parameter adjustment unit, which adjusts the speed, pressure and gap of the crusher through a frequency converter and a servo motor to control the crushing force. The formula for correcting the speed of the crusher is: ； in This indicates the corrected pulverizer speed. Indicates the reference speed. This indicates the real-time measured material temperature. Indicates reference temperature. This indicates the real-time measured pressure in the grinding chamber. Indicates reference pressure. Indicates the temperature compensation coefficient. Indicates the pressure compensation coefficient; The parameter adjustment unit has pressure and temperature compensation functions, and dynamically corrects and controls the parameters according to the material characteristics. The central control module is used to coordinate the operation of various modules of the system, receive monitoring data and analyze and process it, control the operation of the control and processing module according to the preset control strategy, and provide a human-machine interface to support the setting of processing parameters, real-time data display and historical query. The system also integrates an early warning feedback unit, which automatically triggers audible and visual alarms and pushes messages when the particle size distribution exceeds the set safety threshold or the control measures fail. It also records processing data, including particle size curves and operation logs, for subsequent evaluation and optimization, forming a closed-loop control.

2. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 1, characterized in that: The crushing execution module includes a primary crushing unit, a secondary crushing unit, a circulation and reflux unit, and a material conveying unit; The primary crushing unit controls the crushing force through an adjustable speed drive device to adapt to the hardness and moisture content of different types of grains. The secondary crushing unit is equipped with a classifier and a cyclone separator to separate particles by size, output qualified particles and recycle unqualified particles. The circulating reflux unit adjusts the reflux ratio through pneumatic conveying pipelines and mechanical valve groups to uniformly process materials in multi-stage crushing. The material conveying unit uses a screw conveyor and a belt conveyor to continuously supply and discharge materials.

3. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 2, characterized in that: The primary crushing unit also integrates a pretreatment component for washing, drying and removing impurities from the grains. The secondary crushing unit includes a multi-stage classifying wheel and a dynamic adjustment mechanism, which controls the particle fineness in real time by changing the rotation speed of the classifying wheel. The circulating recirculation unit is equipped with a flow sensor and a feedback controller, which dynamically adjusts the recirculation rate based on real-time granular data. The material conveying unit is equipped with a weighing sensor and a speed monitoring device to stabilize the feed rate and flow rate and reduce fluctuations.

4. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 1, characterized in that: The sensor array is arranged in a mesh pattern, covering typical cross-sections of the crushing process: the feed inlet, the crushing chamber, and the discharge outlet. The data acquisition unit supports multi-channel synchronous acquisition and has the functions of redundant data storage and automatic outlier removal. The state analysis unit uses time series analysis to identify the dynamic process of granularity change, including using an autoregressive model to predict future granularity trends and comparing them with historical processing data.

5. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 1, characterized in that: The regulation and processing module includes a circulation control unit and an additive addition unit; The circulation control unit uses electric valves and pump sets to regulate the material return path and flow rate, thereby optimizing circulation efficiency. The additive addition unit adds additives uniformly through a metering pump and a spraying device, thereby improving material flowability and particle size consistency.

6. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 5, characterized in that: The circulation control unit integrates a flow meter and a concentration sensor to monitor the particle concentration and distribution of the reflux material in real time. The additive addition unit is equipped with a mixing and stirring mechanism and a liquid level control device to ensure that the additives are evenly dispersed and added in precise amounts.

7. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 1, characterized in that: The central control module includes a main control unit, a data analysis unit, and a human-computer interaction unit; The main control unit is used to schedule the coordinated operation and timing control of various modules of the system, and adopts a distributed architecture to support modular expansion; The data analysis unit integrates and analyzes the monitoring data, and evaluates the effectiveness of the control measures based on the granularity control model; The human-machine interaction unit provides a graphical user interface that supports processing scheme design, real-time monitoring, alarm log export, and remote access.

8. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 7, characterized in that: The main control unit uses a PLC and an industrial computer to achieve multi-task parallel processing and has a communication interface to connect to external devices. The data analysis unit integrates multiple prediction algorithms and dynamically adjusts the control strategy based on real-time data. The human-computer interaction unit supports touch screen operation and data visualization, including granular distribution curves, historical control charts, and report generation functions.

9. The multi-stage circulating crushing and precise particle size control system for processing miscellaneous grains according to claim 1, characterized in that: The early warning feedback unit includes an abnormal alarm subunit and a data management subunit; The abnormal alarm subunit automatically triggers graded alarms based on the granularity deviation threshold and the control effect, including mild warning and emergency shutdown; The data management subunit is used to store all processing data and operation logs, and provides retrieval and comparative analysis functions based on time, material type and control type, and supports data export and cloud platform integration.

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