Metallurgical electric furnace feeding control method and system based on array type dynamic scheduling

Abstract

The application discloses a kind of based on array dynamic scheduling's metallurgical electric furnace feeding control method and system, it is related to industrial automation control technical field, method includes receiving the feeding request of target furnace top stock bin, corresponding formula array is called based on array scheduling algorithm;According to the production unit of target furnace top stock bin belongs to automatically determine corresponding transport path;Determine the set of discharge port participating in batching and select target discharge port as reference zero point, the spatial difference of each discharge port in discharge port set relative to reference zero point is mapped as dynamic time series by the running speed of belt based on the synchronous trigger mechanism of space-time mapping, generate the start time interval of each discharge port corresponding;According to dynamic time series, discharge port and corresponding quantitative belt are started in turn, quantitative belt is controlled to run using subtraction discharge strategy, through the combination of collaborative control of space-time mapping and adaptive discharge strategy, realize the intelligentization, high accuracy and high reliability operation of whole process of feeding.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, and in particular to a method and system for controlling the feeding of metallurgical electric furnaces based on array-type dynamic scheduling. Background Technology

[0002] Existing electric arc furnace charging systems typically employ sequential control or fixed-delay control strategies. The core problem lies in the fundamental contradiction between the rigidity of control and the flexibility and precision required by production processes. Specifically, the system cannot adapt to changes in the formula combination at each batching, leading to temporal and spatial asynchrony among different raw materials during long-distance, multi-node transport. This results in head-to-tail separation and poor uniformity of the mixture, severely impacting the quality and stability of the smelted product. Furthermore, traditional feeding control strategies, such as "additive feeding" or fixed-speed "subtractive feeding," struggle to balance batching accuracy, efficiency, and adaptability to different operating conditions, often resulting in compromises.

[0003] Furthermore, for large-scale systems with multiple electric furnaces, numerous silos, and complex conveyor belt paths, the lack of an intelligent and collaborative scheduling method to optimize resource allocation and operational processes leads to low overall system efficiency, and the silo discharge port is prone to off-center loading problems due to fixed use.

[0004] In summary, while current technologies have achieved automation of material feeding to some extent, their inherent rigid control characteristics prevent them from fundamentally solving the aforementioned technical problems, particularly in balancing mixing uniformity, batching accuracy, and efficiency. Therefore, there is an urgent need for a metallurgical electric furnace material feeding control method capable of intelligent scheduling and precise control to meet the high standards of raw material handling required by modern metallurgical production. Summary of the Invention

[0005] The purpose of this invention is to provide a metallurgical electric furnace charging control method and system based on array-type dynamic scheduling. By combining spatiotemporal mapping collaborative control with an adaptive feeding strategy, the entire charging process can be made intelligent, highly precise and highly reliable.

[0006] This invention provides a method for controlling the charging of a metallurgical electric furnace based on array-based dynamic scheduling, comprising:

[0007] Upon receiving a feeding request from the target furnace top hopper, the corresponding formula array is invoked based on an array-based scheduling algorithm to obtain the raw material data required for feeding and the target weight of the corresponding raw material; the corresponding conveying path is automatically determined according to the production unit to which the target furnace top hopper belongs, and the conveying path includes at least a batching belt, a moving reversible belt, and an inclined conveyor belt;

[0008] The set of feeding ports participating in the batching is determined and the target feeding port is selected as the reference zero point. Based on the time-space mapping synchronization triggering mechanism, the spatial difference of each feeding port in the feeding port set relative to the reference zero point is mapped into a dynamic time series through the belt running speed, and the start time interval corresponding to each feeding port is generated.

[0009] The feed inlet and the corresponding quantitative conveyor belt are started sequentially according to the dynamic time sequence. The operation of the quantitative conveyor belt is controlled by a subtractive feeding strategy to complete the raw material conveying and mixing.

[0010] Preferably, the array-based scheduling algorithm includes:

[0011] A mapping table between pre-stored material bin numbers and formula array indices;

[0012] Upon receiving the feeding request, the mapping table is queried using the number of the target furnace top hopper as an index to obtain the corresponding recipe array index, and the recipe array is called according to the index;

[0013] Each furnace top hopper number uniquely corresponds to a recipe array index, and the mapping table is pre-stored in the control core memory.

[0014] Preferably, the synchronization triggering mechanism of the spatiotemporal mapping includes:

[0015] Determine the corresponding silos based on the required raw material specifications in the formula array;

[0016] From the available discharge ports of the same silo, discharge ports participating in the current batching are selected according to a preset balanced usage strategy, forming the discharge port set; the physical distance from each discharge port in the discharge port set to the target inclined conveyor belt inlet is obtained, and the discharge port with the farthest, closest, or intermediate physical distance is selected as the reference zero point; the physical distance difference between each discharge port in the discharge port set (excluding the reference zero point) and the reference zero point is calculated as the spatial difference; based on the preset belt running speed V, and the path distance difference ΔS between each discharge port and the reference zero point to the inclined conveyor belt inlet, the dynamic start time interval ΔT of each discharge port relative to the reference zero point is calculated using the formula ΔT=ΔS / V.

[0017] By adjusting the start time of different discharge ports, the material flows can be synchronously merged at the target inclined conveyor belt convergence point.

[0018] Preferably, before sequentially activating the feed inlet and the corresponding quantitative conveyor belt according to the dynamic time sequence, the method further includes a step of matching the optimal operating frequency based on a pre-stored flow rate-frequency relationship curve:

[0019] For each feeding port, the target flow rate Vrequired of the quantitative belt corresponding to each feeding port is calculated based on the target weight W of each raw material in the formula array and the preset feeding time T, where Vrequired = W / T;

[0020] The system queries the pre-stored flow rate-frequency relationship curve and matches the optimal operating frequency F of the quantitative belt motor according to the target flow rate Vrequired. The optimal operating frequency F is then sent to the frequency converter of the corresponding quantitative belt to control the quantitative belt to run at a constant frequency F, ensuring that the batch of raw materials is discharged within the preset discharge time T.

[0021] Preferably, the step of sequentially activating the feed inlet and the corresponding quantitative conveyor according to the dynamic time sequence, and controlling the operation of the quantitative conveyor using a subtractive feeding strategy, includes:

[0022] Taking the start time of the reference zero point as the starting point, the corresponding feed port and quantitative belt are triggered sequentially according to the dynamic start time interval calculated for each feed port. For each started feed port, the following subtractive feeding strategy is executed: the residual material amount of the corresponding weighing hopper is monitored in real time. When the residual material amount is lower than the preset high material level threshold, the vibrating feeder is started to replenish the material until it is restored to the high material level.

[0023] The quantitative belt is started to operate at the optimal operating frequency F to discharge material, and the discharge amount of the weighing hopper is monitored in real time. When the discharge amount reaches the target weight of the corresponding formula, the quantitative belt and vibrating feeder are stopped.

[0024] Preferably, the step also includes a layered mixing and conveying process:

[0025] Raw materials of the same type but different specifications are conveyed on their respective batching belts and undergo initial mixing.

[0026] The similar raw materials after the initial mixing are transferred from the batching belt to the inclined conveyor belt, where different types of raw materials from different batching belts are mixed a second time to form the final mixture.

[0027] The final mixture is received by the moving reversible belt and transported to the target furnace top hopper that issued the feeding request.

[0028] Preferably, the step of automatically determining the corresponding conveying path based on the production unit to which the target furnace top silo belongs includes:

[0029] When the target furnace top silo belongs to the first production unit, the first batching belt, the first movable reversible belt, and either the A inclined conveyor belt or the B inclined conveyor belt are selected to form the conveying path; when the target furnace top silo belongs to the second production unit, the second batching belt, the second movable reversible belt, and either the C inclined conveyor belt or the B inclined conveyor belt are selected to form the conveying path; wherein, the B inclined conveyor belt is a shared spare belt for the A inclined conveyor belt and the C inclined conveyor belt.

[0030] This invention also provides a metallurgical electric furnace charging control system based on array-based dynamic scheduling, realizing the metallurgical electric furnace charging control method based on array-based dynamic scheduling as described above, including:

[0031] The request parsing module is used to receive the feeding request of the target furnace top hopper and call the corresponding formula array based on the array scheduling algorithm to obtain the raw material data and the target weight of the corresponding raw material for feeding; the path planning module is used to automatically determine the corresponding conveying path according to the production unit to which the target furnace top hopper belongs, and the conveying path includes at least a batching belt, a moving reversible belt and an inclined conveyor belt.

[0032] The timing synchronization calculation module is used to determine the set of feeding ports participating in the batching and select the target feeding port as the reference zero point. Based on the time-space mapping synchronization triggering mechanism, the spatial difference of each feeding port in the feeding port set relative to the reference zero point is mapped into a dynamic time series through the belt running speed, generating the start time interval corresponding to each feeding port.

[0033] The collaborative execution module is used to sequentially start the feed port and the corresponding quantitative belt according to the dynamic time sequence, and control the operation of the quantitative belt using a subtractive feeding strategy to complete the raw material conveying and mixing.

[0034] The present invention also provides an electronic device, comprising:

[0035] The memory is used to store the processing program;

[0036] The processor, when executing the processing program, implements the metallurgical electric furnace charging control method based on array-type dynamic scheduling as described in the embodiments of the present invention.

[0037] The present invention also provides a computer-readable storage medium for storing computer instructions, which, when executed by a processor, complete the metallurgical electric furnace charging control method based on array-based dynamic scheduling as described in the embodiments of the present invention.

[0038] Compared with the prior art, the present invention has the following beneficial effects:

[0039] This invention proposes a metallurgical electric furnace charging control method based on array-based dynamic scheduling. It establishes a mapping relationship between "bin number - recipe index" to form an array-based scheduling algorithm. When a charging request is received from any top bin, the system uses the bin number as an index and queries a pre-stored mapping table to instantly and error-free retrieve the corresponding recipe array. It also parses out the required raw materials and their precise target weights, achieving rapid and accurate recipe retrieval. This provides a precise data foundation for all subsequent control steps and is a prerequisite for the system's high efficiency and flexibility. It can easily handle the complex concurrent recipe requirements of multiple electric furnaces and multiple bins.

[0040] This invention, based on the production unit to which the target furnace top silo belongs, automatically matches the optimal conveyor path from a pre-set path library (including selecting which batching belt, which inclined conveyor belt, which reversible conveyor belt, etc.). Simultaneously, when determining the set of discharge ports participating in batching, a pre-set balanced usage strategy is adopted, automatically selecting the discharge port to be used from multiple available discharge ports in the same silo. This avoids the inefficiency and errors of manual path selection, ensures the orderly operation of the equipment, and prevents path conflicts. More importantly, the automatic alternation of discharge ports effectively avoids material segregation and arching problems caused by long-term single-point feeding within the silo, ensuring smooth feeding and significantly improving the long-term reliability of the equipment.

[0041] The dynamic reference time interval algorithm employed in this invention, a synchronous triggering mechanism based on spatial-temporal mapping, automatically selects the discharge port with the longest physical distance to the convergence point from the set of discharge ports participating in the batching process as the "reference zero point." It calculates the physical distance difference between each other discharge port and this "reference zero point," and uses a preset belt speed to precisely map the spatial difference into a start-up time interval using a formula. With the start-up time of the "reference zero point" as the time zero point, other discharge ports are started sequentially according to the calculated time interval ΔT. This compensation mechanism of "using time difference to compensate for spatial difference" ensures that all material flows, regardless of their starting point or path length, are precisely aligned at the convergence point of the main conveyor belt. This fundamentally solves the persistent problem of uneven material mixing, achieving thorough physical mixing during the conveying process and providing a fundamental guarantee for obtaining extremely high raw material mixing uniformity, thereby directly improving the quality stability of the final product.

[0042] This invention abandons the traditional fixed-speed mode and establishes a "fixed-time-variable-speed" control model. The system presets a standard feeding time T. For each raw material in each batch, based on its formula weight W, the target flow rate required by the quantitative belt is dynamically calculated using the formula Vrequired=W / T. Subsequently, the system queries a pre-stored "flow rate-frequency relationship curve" calibrated through numerous physical experiments, precisely matches the target flow rate Vrequired to the optimal operating frequency F of the quantitative belt motor, and sends this information to the driver. Through the above methods, regardless of the quantity of each batch of materials, it can be completed within the same standard time T, establishing a stable and predictable cycle time for the entire production line, significantly improving system throughput and overall efficiency. With large quantities of materials, the belt runs at high speed, and with small quantities, it runs at low speed, ensuring that the material load on the belt is always maintained within the optimal range. This optimizes belt load, avoids waste from "overloading with large quantities and idling with small quantities," and improves equipment lifespan and energy efficiency. Combined with the subsequent "subtractive feeding" strategy, at the end of the feeding process, a speed reduction and precision feeding can be performed based on this dynamic speed, improving batching accuracy compared to a fixed speed mode.

[0043] This invention deeply integrates the aforementioned automatic equalization strategy for the feed inlet with dynamic time interval calculation and dynamic control of quantitative belt speed, forming a closed-loop, self-optimizing system that maximizes equipment utilization, balances equipment wear, and improves overall reliability and fault-free operation time at the system level.

[0044] This invention does not simply employ "addition" or "subtraction" feeding, but rather organically combines dynamic time interval adjustment, dynamic control of quantitative belt speed, and the "subtraction feeding" strategy. Through this comprehensive strategy, it utilizes the high precision advantage of "subtraction feeding" while overcoming its efficiency bottleneck under harsh working conditions through dynamic speed control, thus achieving the goal of significantly improving accuracy and system stability while ensuring efficiency. Attached Figure Description

[0045] Figure 1 This is a flowchart of the metallurgical electric furnace charging control method based on array-type dynamic scheduling in an embodiment of the present invention;

[0046] Figure 2 This is an overall flowchart of the metallurgical electric furnace charging control method based on array-type dynamic scheduling in an embodiment of the present invention. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0048] The term "comprising" and its variations as used herein are open-ended inclusion, meaning "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments". Definitions of other terms will be given in the description below.

[0049] It should be noted that the concepts of "first" and "second" mentioned in this application are only used to distinguish different devices, modules or units, and are not used to limit the order of functions performed by these devices, modules or units or their interdependencies.

[0050] It should be noted that the terms "a" and "a plurality of" used in this application disclosure are illustrative rather than restrictive, and those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0051] like Figures 1-2 As shown, this invention provides a method for controlling the charging of a metallurgical electric furnace based on array-based dynamic scheduling, comprising the following steps:

[0052] S1: Receive the feeding request from the target furnace top silo. Based on the array-based scheduling algorithm, call the corresponding formula array to obtain the raw material data and target weight of the corresponding raw materials required for feeding. The first step is request reception and formula parsing: The system receives the feeding request (including the target furnace top silo number) from the upper-level system. The control core uses the array-based scheduling algorithm to quickly retrieve and lock the formula data corresponding to the silo from the stored 20 formula arrays. The formula data includes the specifications and target weights of the various required raw materials. The array-based scheduling used in this embodiment refers to treating multiple requests (such as feeding requests) and multiple resources (such as feeding ports and conveyor belts) as a multi-dimensional array, and using a specific algorithm (such as calculating the time interval based on the farthest feeding port) for unified, efficient, and collaborative scheduling control. The furnace top silo is located at the top of the electric furnace and is used to store mixed raw materials prepared according to a specific formula.

[0053] S2: The corresponding conveying path is automatically determined based on the production unit to which the target furnace top silo belongs. The conveying path includes a batching belt, an inclined conveyor belt, and a mobile reversible belt. The batching belt is a mobile belt used to receive raw materials of the same type but different specifications (such as silica 1, silica 2, etc.) and perform initial mixing. Its end can move above different inclined conveyor belts for unloading. The inclined conveyor belt is used to perform final mixing and lifting of pre-mixed raw materials from multiple batching belts. The mobile reversible belt is a belt conveyor that can move along a track and operate in both directions, used to receive the mixture from the inclined conveyor belt and transport it to the designated furnace top silo. Multiple batching conveyor belts operate in parallel, performing initial longitudinal mixing according to raw material type. They then converge on an inclined conveyor belt for secondary transverse mixing according to the formula, bringing together all types of raw materials into the final product. The inclined conveyor belts operate sequentially, finally distributing the material to a mobile reversible conveyor belt for final distribution according to production needs, precisely delivering the mixture to the target furnace top silo. In this embodiment, there are three belts: A, B, and C, with belt B serving as a shared backup for belts A and C. The second step involves path selection and resource allocation: based on the unit (unit 1 or unit 2) to which the target silo belongs, the system automatically determines which batching conveyor belt and mobile reversible conveyor belt to use, and further determines the available inclined conveyor belts (unit 1 selects A or B, unit 2 selects C or B). The system schedules the corresponding batching conveyor belt to its designated position. Based on the target address (to which production unit) and preset, optimized path rules, the system automatically plans a complete logistics path from the raw material source to the destination, and pre-locks the necessary equipment resources to avoid subsequent operational conflicts. During implementation, the system inputs a known target unit (Unit 1) and makes decisions based on predefined rules: Rule: IF target unit == Unit 1 THEN reversible conveyor belt = 1; inclined conveyor belt = A or B; batching conveyor belt = 1; Rule: IF target unit == Unit 2 THEN reversible conveyor belt = 2; batching conveyor belt = 2; inclined conveyor belt = C or B. The system automatically selects "reversible conveyor belt 1" and prioritizes "inclined conveyor belt A" from A and B, assuming B is a spare and A is in good condition. Simultaneously, the system sends instructions to the batching conveyor belts responsible for silica 1, semi-coke 2, and iron products 3, instructing them to move to a work position where they can feed materials onto inclined conveyor belt A. A clear logistics path is determined: discharge port - batching conveyor belt - inclined conveyor belt A - reversible conveyor belt 1 - top hopper 1. Here, a unit is a production unit consisting of two electric furnaces and their auxiliary feeding systems; in this embodiment, it includes units 1 and 2.

[0054] S3: Determine the set of feeding ports participating in the batching and select the target feeding port as the reference zero point. Based on the time-space mapping synchronous triggering mechanism, the spatial difference of each feeding port in the feeding port set relative to the reference zero point is mapped into a dynamic time series through the belt running speed, generating the start time interval corresponding to each feeding port; the spatial difference here is the distance difference ΔS between other feeding ports and the "reference zero point".

[0055] S4: Start the feeding port and the corresponding quantitative belt in sequence according to the dynamic time sequence, and use the subtractive feeding strategy to control the operation of the quantitative belt to complete the raw material conveying and mixing.

[0056] Through the above methods, this embodiment achieves the following functions: precise formula management and timing control: It can quickly and accurately call up the corresponding formula array based on the feeding request of any furnace top hopper, and parse out the required raw materials and their precise weights; intelligent path planning and resource scheduling: It can automatically select the optimal conveying path (including which batching belt, which inclined belt, and which moving reversible belt) based on formula requirements and the current system status, and coordinate the orderly operation of each device to avoid conflicts; excellent mixing uniformity guarantee: Through the innovative "dynamic reference time interval algorithm," it calculates and adjusts the start-up sequence of each feeding port in real time, ensuring that different raw materials can achieve head-to-tail alignment when converging on the main belt, thereby ensuring excellent mixing uniformity during conveying. The process achieves thorough physical mixing; adaptive discharge speed control: through a "fixed time-variable speed" model, the optimal operating speed of each quantitative belt in each batch is dynamically calculated, ensuring that different batches of raw materials can be discharged within the same time, which not only guarantees the batching rhythm but also optimizes the belt load, improving overall efficiency and accuracy; reliable equipment management and optimization: through the automatic alternation function of the discharge port, material segregation in the silo is avoided, ensuring smooth discharge and improving the long-term reliability of the equipment; high efficiency in adapting to working conditions: by selecting the "subtractive discharge" strategy and combining it with the above dynamic control, the problem of material sticking to the hopper in cold seasons is overcome, and the system stability and throughput efficiency are significantly improved while ensuring discharge accuracy.

[0057] Traditional systems typically handle multiple silos and multiple formulas using manual input, menu selection, or database queries. These methods are either inefficient and error-prone, or slow in response, failing to meet the demands of modern large-scale, fast-paced production. When multiple electric furnaces simultaneously request feeding, the system is prone to response delays or logical inconsistencies. To address this issue, the array-based scheduling algorithm used in step S1 of this implementation treats all furnace top silos and their corresponding formulas as a structured data matrix (array). When a request targeting a silo number is received, the system does not sequentially traverse the search but instead directly locates the corresponding formula data block using an "index," much like looking up a dictionary. This achieves a fast and accurate mapping from "physical requests" to "digital formulas." Specifically, this includes the following:

[0058] A mapping table is pre-stored between silo numbers and formula array indices. Upon receiving the feeding request, the system queries the mapping table using the target silo number as the index to obtain the corresponding formula array index, and then calls the formula array based on the index. Each silo number uniquely corresponds to a formula array index, and the mapping table is pre-stored in the control core memory. For example, when the system receives the instruction "feed to silo number 1", a mapping table is pre-stored in the control core memory, similar to: silo numbers: 1, 2..., formula indices P1, P2... The system immediately locks index P1 and calls the formula array it points to, for example, P1: {"raw material specifications":"silica 1","target weight":500}, {"raw material specifications":"semi-coke 2","target weight":300}, {"raw material specifications":"limestone 3","target weight":200}. The system clearly indicates that this task requires three raw materials and their precise weight targets. The formula data used in this embodiment is pre-configured and centrally managed, avoiding errors that may arise from manual input. This ensures that each batch has a unique and accurate data basis, eliminating product quality problems caused by formula errors at the source and improving production reliability and consistency. Adding a new silo or modifying the formula only requires adding or modifying a record in the mapping table, without altering the core control logic. When the production line needs expansion or the product process needs adjustment, the system can adapt quickly, greatly reducing system maintenance and upgrade costs and extending the life cycle of the technical solution. The array-based scheduling algorithm can efficiently handle complex formulas and parallel tasks; the automatic feeding port switching function avoids silo overloading, reduces maintenance needs, and improves the long-term reliability of the system.

[0059] To address emergency situations during equipment failures, step S2, which automatically determines the corresponding conveying path based on the production unit to which the target furnace top silo belongs, includes:

[0060] When the target furnace top hopper belongs to the first production unit, the conveying path is formed by the first batching belt, the first movable reversible belt, and either the A inclined conveyor belt or the B inclined conveyor belt. When the target furnace top hopper belongs to the second production unit, the conveying path is formed by the second batching belt, the second movable reversible belt, and either the C inclined conveyor belt or the B inclined conveyor belt. The B inclined conveyor belt is a shared backup belt for both the A and C inclined conveyor belts. For example, if the A inclined conveyor belt serving the first production unit suddenly fails, the system can automatically or manually switch the path to "first batching belt, first movable reversible belt + B inclined conveyor belt". Production in the first production unit can continue, avoiding downtime. Similarly, if the C inclined conveyor belt fails, the second production unit can seamlessly switch to the B inclined conveyor belt.

[0061] During implementation, in normal operating mode, the task is: the No. 1 furnace top hopper of electric furnace No. 1 issues a feeding request. Execution flow: Request parsing: The control system receives the request and identifies the target hopper, "No. 1 furnace top hopper," as belonging to "First Production Unit." Path planning: The system queries the equipment status according to the preset rule "First Production Unit - No. 1 movable reversible conveyor belt + (A or B) inclined conveyor belt + batching conveyor belt." Status judgment: The system detects that the current status of inclined conveyor belt A is "idle" and "fault-free." Path determination and execution: The system automatically selects the optimal path and issues the command: Start the No. 1 movable reversible conveyor belt and move it to the unloading point of hopper No. 1. Start inclined conveyor belt A. Subsequent materials will be transported along the path "batching conveyor belt - inclined conveyor belt A - No. 1 movable reversible conveyor belt - No. 1 furnace top hopper." Result: Without manual intervention, the system selects its dedicated and most efficient conveying path for the First Production Unit, achieving automated operation.

[0062] In automatic fault switching mode, the system is operating as described in the above embodiment. If the motor of the inclined conveyor belt A trips due to overheating, a fault signal is sent to the control system. Task: The feeding task of electric furnace No. 1 cannot be interrupted and needs to be resumed immediately. The execution process is as follows:

[0063] Fault Detection: The control system receives a "fault" alarm from the A inclined conveyor belt. Automatic Diagnosis and Replanning: The system logic is immediately triggered, determining that the main conveyor belt A serving the first production unit is unavailable. According to preset rules, it begins searching for a backup solution. Backup Resource Query: The system finds that the B inclined conveyor belt (the backup for A) is "idle" and "fault-free". Path Switching and Execution: The system automatically switches the conveyor path of Unit 1 to the backup path and issues the following instructions: keep the No. 1 movable reversible belt in place, stop operating the A belt, and start the B inclined conveyor belt. The system displays an alarm message on the HMI, indicating that "Unit 1 has automatically switched to the B inclined conveyor belt." Production Resumption: The material flow seamlessly switches to the new path "batch conveyor belt - B inclined conveyor belt - No. 1 movable reversible conveyor belt - No. 1 furnace top hopper," and the feeding task quickly resumes after a brief interruption. Result: Due to the redundant design of the B belt, a critical equipment failure did not cause the entire first production unit to shut down. The system's availability and robustness were fully demonstrated, avoiding significant economic losses.

[0064] To address the issue of uneven mixing and achieve head-to-tail alignment, the spatiotemporal mapping synchronization triggering mechanism employed in step S3 of this implementation includes: determining the corresponding silo based on the required raw material specifications in the formula array; selecting the discharge port participating in the batching process from the available discharge ports of the same silo according to a preset balanced usage strategy, forming the discharge port set; and automatically selecting or switching one of the two discharge ports under the same silo for the current operation based on historical usage data to achieve balanced usage and avoid unbalanced loading. Obtain the physical distance from each discharge port in the set of discharge ports to the inlet of the target inclined conveyor belt, and select the discharge port with the farthest physical distance as the reference zero point; calculate the physical distance difference between each discharge port in the set of discharge ports other than the reference zero point and the reference zero point, as the spatial difference; based on the preset belt running speed V, and the path distance difference ΔS between each discharge port and the reference zero point to the inlet of the inclined conveyor belt, calculate the dynamic start time interval ΔT of each discharge port relative to the reference zero point using the formula ΔT=ΔS / V; the distance difference ΔS between the discharge port and the convergence point can be measured directly, or an encoder can be installed on the belt to indirectly calculate the relative displacement of the material conveying by pulse counting, thereby achieving the same time control purpose.

[0065] One approach involves adjusting the start times of different discharge ports to ensure that all material flows converge synchronously at the target inclined conveyor belt convergence point. By using the farthest point as a reference and delaying the start of the nearest points, the head and tail of all material flows are aligned at the convergence point, fundamentally solving the problem of uneven mixing. This allows different raw materials to achieve sufficient and uniform physical mixing during the conveying process, rather than passive mixing after entering the electric furnace. This directly leads to the stability and consistency of the final product quality, and is a decisive factor in improving product qualification rate and reducing scrap rate. Another approach allows for the selection of the reference point not only using the "farthest discharge port" as the zero point, but also the "nearest discharge port" or the "middle-position discharge port." For example, using the nearest discharge port as the reference, other discharge ports start at a corresponding time in advance. Essentially, this still relies on dynamically calculating the time interval based on distance differences, employing the same mathematical principles, and represents different strategies to achieve the same goal.

[0066] In traditional systems, quantitative conveyor belts typically operate at a fixed, empirically determined speed. This results in two problems: large quantities require long processing times (e.g., when a formula requires 1000 kg of raw material, discharging at a fixed speed (e.g., 5 kg / s) takes 200 seconds); small quantities require short processing times (e.g., when another formula requires only 200 kg of raw material, discharging at the same speed takes only 40 seconds). This "uncertain discharging time" makes the entire feeding system's cycle time chaotic and unpredictable. Subsequent mixing, conveying, and feeding processes can only passively wait, failing to form an efficient and coordinated production line, resulting in overall low efficiency. To address these shortcomings, in various embodiments of this application, step S4, before sequentially starting the discharge port and corresponding quantitative conveyor belt according to the dynamic time sequence, further includes a step of matching the optimal operating frequency based on a pre-stored flow rate-frequency relationship curve.

[0067] For each feeding port, the target flow rate Vrequired of the quantitative belt corresponding to each feeding port is calculated based on the target weight W of each raw material in the formula array and the preset feeding time T, where Vrequired = W / T;

[0068] The system queries the pre-stored velocity-frequency relationship curve and, based on the target velocity Vrequired, determines the optimal operating frequency F of the quantitative belt motor. The velocity-frequency relationship curve can be generated through actual testing and fitting, or it can be generated by installing a weighing instrument on the quantitative belt motor to provide feedback on the material feeding speed, thereby constructing a simple closed-loop control system to fine-tune the frequency in real time to approximate the target velocity. Through real-time feedback from the online weighing instrument, the system can automatically compensate for speed deviations caused by factors such as belt slippage and slight changes in material characteristics.

[0069] The optimal operating frequency F is sent to the frequency converter of the corresponding quantitative belt to control the quantitative belt to run at a constant frequency F, ensuring that the batch of raw materials is discharged within the preset discharge time T. The core of this solution is to preset a standard feeding time T, such as 60 seconds. Regardless of the quantity of material dispensed in a single batch, the system dynamically calculates the required target flow rate using the formula Vrequired=W / T, and ensures that all batches are completed within 60 seconds by matching the frequency. This significantly improves the throughput and overall efficiency of the entire production line. Because the feeding time is constant, the system can precisely plan the feeding tasks for different silos and electric furnaces, enabling parallel and off-peak operations. This avoids idle or conflicting equipment resources. The system can precisely schedule feeding from silo A at T=0s, silo B at T=60s, and silo C at T=120s, allowing for seamless connection between the three lines and maximizing equipment utilization. This solution optimizes belt load, achieving energy saving, reduced consumption, and extended equipment lifespan. Variable speed means on-demand allocation; the belt runs at high speed for large quantities and at low speed for small quantities, effectively extending the service life of the conveyor equipment. Compared to determining the endpoint at a fixed speed, controlling at the optimal speed F tailored to this formula offers greater control margin, stronger anti-interference capabilities, and ultimately higher batching accuracy. This advantage is even more pronounced when combined with the "closed-loop control" alternative mentioned in the solution.

[0070] The current typical solution uses a "subtractive feeding" combined with a fixed-delay start strategy. After receiving the feeding command, the system starts the feeding ports one by one according to the formula. A preset fixed delay is used between the feeding ports to attempt to align the materials. The quantitative conveyor belt runs at a fixed empirical speed, or is fine-tuned by slowing down at the end of the feeding process. The disadvantages are as follows: 1) Poor mixing uniformity: The fixed-delay strategy cannot adapt to changes in the combination of feeding ports selected for each formula. Due to the different physical distances from different feeding ports to the convergence point, the fixed time difference cannot guarantee perfect overlap of all materials on the belt, leading to separation at the beginning and end and uneven mixing. 2) Conflict between batching efficiency and accuracy: "Additive feeding" has high accuracy but is easily affected by operating conditions; "Subtractive feeding" has high efficiency but the feeding flow rate is greatly affected by the material level, making it difficult to balance accuracy and uniformity. If the running speed of the quantitative conveyor belt is fixed, it cannot adapt to changes in the amount of different formulas, either resulting in excessively long feeding time affecting efficiency, or resulting in an excessively thick or thin material layer on the belt. 3) Poor system flexibility: The rigid scheduling logic cannot efficiently handle the complex needs of two electric furnaces with 20 silos of different formulas and two unit batching lines that may work in parallel, easily leading to resource conflicts or waiting. 4) Reliability issues: Using only one silo discharge port can easily cause material segregation within the silo, forming rat holes or arching, affecting the smoothness of material discharge. Subtractive Discharging is a discharge control strategy where the hopper is always kept at a high material level, and a quantitative belt discharges material, stopping when the target weight is reached. Discharging is complete when the weight reduction in the hopper reaches the target value. Additive Discharging is a discharge control strategy where a vibrator adds material to the empty hopper to the target weight, and the quantitative belt empties the hopper in one go. Discharging is complete when the hopper weight approaches zero. The quantitative belt is a device located below the weighing hopper that discharges raw materials to the batching belt at a precisely controlled speed and flow rate. Ingredient Conveyor Belt: A moving belt used to receive raw materials of the same type but different specifications (such as silica 1, silica 2, etc.) and perform initial mixing. Its end can be moved above different inclined conveyor belts for unloading.

[0071] To address the aforementioned issues, this embodiment perfectly combines the dynamic time-series startup (ensuring uniform mixing) with the subtractive feeding strategy (ensuring metering accuracy). Specifically, in step S4, the feeding port and the corresponding metering conveyor are started sequentially according to the dynamic time sequence. The subtractive feeding strategy is used to control the operation of the metering conveyor, including:

[0072] Starting from the reference zero point, the system sequentially triggers the corresponding feeding port and quantitative conveyor belt according to the calculated dynamic start time interval for each feeding port. The system starts each feeding port sequentially according to the calculated dynamic time interval. First, the "reference zero point" feeding port is started, then the second is started at an interval of ΔT1, the third at an interval of ΔT2, and so on. For each started feeding port, the following subtractive feeding strategy is implemented: The remaining material in the corresponding weighing hopper is monitored in real time. When the remaining material is lower than the preset high material level threshold, the vibrating feeder is started to replenish the material until it returns to the high material level.

[0073] The quantitative conveyor belt is activated to operate at the optimal frequency F for material feeding, and the feeding amount from the weighing hopper is monitored in real time. When the feeding amount, i.e., the reduced weight, reaches the target weight of the corresponding formula, the quantitative conveyor belt and vibrating feeder are stopped. This "subtractive feeding" method controls the endpoint by monitoring the reduced weight, avoiding the influence of belt vibration on weighing in the "additive feeding" method, resulting in higher accuracy. Simultaneously, feeding is initiated when the hopper is at a high level, ensuring stable material supply and efficiency. This combination overcomes the drawbacks of a single strategy, enabling the system to maintain stable operation and high-precision output even under harsh conditions such as cold and humid environments. This significantly enhances the system's environmental adaptability and robustness, reducing production interruptions caused by environmental issues.

[0074] This embodiment also includes a layered mixing and conveying step when performing collaborative execution and material feeding control:

[0075] Raw materials of the same type but different specifications are conveyed on their respective batching belts and undergo initial mixing.

[0076] The similar raw materials after the initial mixing are transferred from the batching belt to the inclined conveyor belt, where different types of raw materials from different batching belts are mixed a second time to form the final mixture.

[0077] The final mixture is received by the movable reversible belt and transported to the target furnace top hopper that issued the feeding request. This technical solution combines dynamic time interval adjustment, dynamic control of the quantitative belt speed, and a "subtractive feeding" strategy, supplemented by an automatic feed port switching function, to comprehensively improve the uniformity, efficiency, and reliability of the batching. Alternatively, within the core framework of dynamic time interval and dynamic speed control, this embodiment can also re-emphasize the "additive feeding" strategy. Although the efficiency may be slightly lower than subtractive feeding, its high precision, combined with other strategies in this embodiment, still constitutes a high-performance solution, especially in situations where hopper insulation is well-maintained.

[0078] Based on the same concept, this invention provides a metallurgical electric furnace charging control system based on array-type dynamic scheduling, realizing the metallurgical electric furnace charging control method based on array-type dynamic scheduling as described in the above embodiments, including:

[0079] The request parsing module is used to receive the feeding request of the target furnace top hopper and call the corresponding formula array based on the array scheduling algorithm to obtain the raw material data and the target weight of the corresponding raw material for feeding; the path planning module is used to automatically determine the corresponding conveying path according to the production unit to which the target furnace top hopper belongs, and the conveying path includes at least a batching belt, a moving reversible belt and an inclined conveyor belt.

[0080] The timing synchronization calculation module is used to determine the set of feeding ports participating in the batching and select the target feeding port as the reference zero point. Based on the time-space mapping synchronization triggering mechanism, the spatial difference of each feeding port in the feeding port set relative to the reference zero point is mapped into a dynamic time series through the belt running speed, generating the start time interval corresponding to each feeding port.

[0081] The collaborative execution module is used to sequentially start the feed port and the corresponding quantitative belt according to the dynamic time sequence, and control the operation of the quantitative belt using a subtractive feeding strategy to complete the raw material conveying and mixing.

[0082] It should be noted that the division of the various modules in this device / system embodiment is merely a logical functional division. In actual implementation, they can be fully or partially integrated into a single physical entity, or they can be physically separated. Furthermore, these modules can be implemented entirely in software through processing element calls; they can also be implemented entirely in hardware; or some units can be implemented by processing element calls to software, while others can be implemented in hardware.

[0083] The implementation principle of the above modules has been described in the foregoing method embodiments, so it will not be repeated here.

[0084] Based on the same concept, an electronic device is also provided in some embodiments of this application. This electronic device includes a memory and a processor, wherein the memory stores a processing program, and the processor executes the processing program according to instructions. When the processor executes the processing program, the array-based dynamic scheduling-based metallurgical electric furnace charging control method described in the foregoing embodiments is realized.

[0085] In some embodiments of this application, a readable storage medium is also provided. This readable storage medium can be a non-volatile readable storage medium or a volatile readable storage medium. The readable storage medium stores instructions that, when executed on a computer, cause an electronic device containing this readable storage medium to perform the aforementioned array-based dynamic scheduling-based metallurgical electric furnace charging control method.

[0086] It is understood that, for the aforementioned array-based dynamic scheduling-based metallurgical electric furnace charging control method, if all of them are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of the present invention. The aforementioned storage medium includes: USB flash drive, mobile hard drive, read-only memory (ROM), random access memory (RAM), magnetic disk, or optical disk, and other media capable of storing program code.

[0087] Computer-readable storage media may include data signals propagated in baseband or as part of a carrier wave, carrying readable program code. Such propagated data signals may take various forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination thereof. A readable storage medium may also be any readable medium other than a readable storage medium that can transmit, propagate, or transfer a program for use by or in connection with an instruction execution system, apparatus, or device. The program code contained on the readable storage medium may be transmitted using any suitable medium, including but not limited to wireless, wired, optical fiber, RF, etc., or any suitable combination thereof.

[0088] The program code for executing the technical solutions disclosed in this application can be written in any combination of one or more programming languages. These programming languages ​​include object-oriented programming languages—such as Python and C++—and conventional procedural programming languages—such as C or similar languages. The program code can be executed entirely on the user's computing device, partially on the user's computing device, as a standalone software package, partially on the user's computing device and partially on a remote computing device, or entirely on a remote computing device or server. In cases involving remote computing devices, the remote computing device can be connected to the user's computing device via any type of network, including a local area network (LAN) or a wide area network (WAN), or it can be connected to an external computing device (e.g., via the Internet using an Internet service provider).

[0089] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for charge control of a metallurgical furnace based on array dynamic scheduling, characterized in that, The method comprises the following steps: receiving a feeding request of a target top bin, calling a corresponding formula array based on an array scheduling algorithm to obtain raw material data required for feeding and target weights of corresponding raw materials, and automatically determining a corresponding conveying path according to a production unit to which the target top bin belongs, wherein the conveying path at least comprises a batching belt, a mobile reversible belt and an inclined conveying belt; determining a set of discharge ports participating in batching and selecting a target discharge port as a reference zero point, and based on a time-space mapping synchronous triggering mechanism, mapping spatial differences of each discharge port in the set of discharge ports relative to the reference zero point into dynamic time sequences through the running speed of the belt to generate a starting time interval corresponding to each discharge port; starting the discharge ports and corresponding quantitative belts in sequence according to the dynamic time sequences, adopting a subtraction discharging strategy to control the running of the quantitative belts, and completing raw material conveying and mixing; the time-space mapping synchronous triggering mechanism comprises: determining a corresponding silo according to the required raw material specifications in the formula array; from the available discharge ports of the same silo, selecting the discharge ports participating in batching this time according to a preset balanced use strategy to form the set of discharge ports, obtaining the physical distance from each discharge port in the set of discharge ports to the inlet of the target inclined conveying belt, and selecting the discharge port with the farthest or closest or intermediate physical distance as the reference zero point, calculating the physical distance difference between each discharge port in the set of discharge ports except the reference zero point and the reference zero point as the spatial difference, and calculating the dynamic starting time interval ΔT of each discharge port relative to the reference zero point based on the path distance difference ΔS of each discharge port and the reference zero point to the inlet of the inclined conveying belt according to a preset belt running speed V through the formula ΔT=ΔS / V; wherein, by adjusting the starting time of different discharge ports, the material flows are synchronized at the target inclined conveying belt convergence point; before starting the discharge ports and corresponding quantitative belts in sequence according to the dynamic time sequences, there is still a step of matching the best running frequency according to the pre-stored flow rate-frequency relationship curve: for each discharge port, according to the target weight W of each raw material in the formula array and the preset discharging time T, the target flow rate Vrequired of the quantitative belt corresponding to each discharge port is calculated, wherein Vrequired=W / T; querying the pre-stored flow rate-frequency relationship curve of the system, matching the best running frequency F of the quantitative belt motor according to the target flow rate Vrequired, and delivering the best running frequency F to the variable frequency driver of the corresponding quantitative belt to control the quantitative belt to run at a constant frequency F, ensuring that the batch of raw materials is discharged within the preset discharging time T.

2. The array-based dynamic dispatch-based metallurgical furnace charging control method of claim 1, wherein, the array scheduling algorithm comprises: a mapping table of pre-stored bin numbers and formula array indexes; after receiving the feeding request, taking the number of the target top bin as an index, querying the mapping table to obtain the corresponding formula array index, and calling the formula array according to the index; wherein, each top bin number uniquely corresponds to one formula array index, and the mapping table is pre-stored in the control core memory.

3. The array-based dynamic dispatch-based metallurgical furnace charging control method of claim 1, wherein, The dynamic time sequence is used to start the discharge port and the corresponding quantitative belt in turn, and a subtraction feeding strategy is used to control the operation of the quantitative belt, which comprises: Taking the starting time of the reference zero point as the time origin, the corresponding discharge port and quantitative belt are triggered in turn according to the dynamic starting time interval calculated for each discharge port; for each started discharge port, the following subtraction feeding strategy is executed: Real-time monitoring of the residual material amount of the corresponding weighing hopper is performed, and when the residual material amount is lower than the preset high material level threshold, the vibrating feeder is started to supplement the material until the high material level is restored; The quantitative belt is started to run at the optimal running frequency F to discharge the material, and the discharge amount of the weighing hopper is monitored in real time, and when the discharge amount reaches the target weight of the corresponding formula, the quantitative belt and the vibrating feeder are stopped.

4. The array-based dynamic dispatch-based metallurgical furnace charging control method of claim 1, wherein, It also includes a layered mixing and conveying step: Different specifications of the same raw materials are conveyed on the respective batching belts and primary mixing is performed; The primary mixed raw materials of the same kind are transferred from the batching belt to the inclined conveying belt, and different kinds of raw materials from different batching belts are subjected to secondary mixing to form the final mixed material; The final mixed material is received by the movable reversible belt and conveyed to the target stock bin that issues the feeding request.

5. The array-based dynamic dispatch-based metallurgical furnace charging control method of claim 1, wherein, The corresponding conveying path is automatically determined according to the production unit to which the target stock bin belongs, which comprises: When the target stock bin belongs to the first production unit, the first batching belt, the first movable reversible belt, and the A inclined conveying belt or the B inclined conveying belt are selected to form the conveying path; when the target stock bin belongs to the second production unit, the second batching belt, the second movable reversible belt, and the C inclined conveying belt or the B inclined conveying belt are selected to form the conveying path; wherein the B inclined conveying belt is a shared standby belt of the A inclined conveying belt and the C inclined conveying belt.

6. A metallurgical furnace feeding control system based on array dynamic scheduling, characterized in that, The metallurgical electric furnace feeding control method based on array-type dynamic scheduling as claimed in any one of claims 1 to 5 is implemented, which comprises: A request analysis module is configured to receive a feeding request of a target stock bin, call a corresponding formula array based on an array-type scheduling algorithm to obtain raw material data required for feeding and target weights of the corresponding raw materials; a path planning module is configured to automatically determine a corresponding conveying path according to the production unit to which the target stock bin belongs, wherein the conveying path at least comprises a batching belt, an inclined conveying belt, and a movable reversible belt; A time sequence synchronization calculation module is configured to determine a set of discharge ports participating in batching and select a target discharge port as a reference zero point, map the spatial differences of each discharge port in the set of discharge ports relative to the reference zero point into a dynamic time sequence through the running speed of the belt based on a time-space mapping synchronization triggering mechanism, and generate a starting time interval corresponding to each discharge port; A cooperative execution module is configured to start the discharge port and the corresponding quantitative belt in turn according to the dynamic time sequence, control the operation of the quantitative belt by using a subtraction feeding strategy, and complete raw material conveying and mixing.

7. An electronic device, comprising: It comprises: A memory is configured to store a processing program; A processor is configured to implement the metallurgical electric furnace feeding control method based on array-type dynamic scheduling as claimed in any one of claims 1 to 5 when executing the processing program.

8. A computer-readable storage medium, characterized in that, Computer program product for storing computer instructions which, when executed by a processor, implement the method for controlling the loading of a metallurgical furnace based on array dynamic scheduling according to any one of claims 1 to 5.

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