Workpiece sanding mechanism, sanding method and system based on state intelligent monitoring

Abstract

The application relates to the technical field of sanding equipment, in particular to a workpiece sanding mechanism based on state intelligent monitoring, a sanding method and a system, which method comprises the following steps: conveying a workpiece to a sanding station in a sanding chamber, and pausing the conveying; driving the workpiece to rotate axially; starting a plurality of shot blasting machines to perform omnibearing shot blasting treatment on the surface of the workpiece; steel sand falls into a steel sand circulating system and is conveyed into a hopper of the shot blasting machine to be reused; the running state of the steel sand circulating system is monitored in real time through a state monitoring system, and corresponding control instructions are output when abnormal working conditions are identified. The application has the effects of improving the automation level and operation reliability of the workpiece sanding process and realizing real-time monitoring of the running state of the steel sand circulating system.

Description

Technical Field

[0001] This application relates to the technical field of sandblasting equipment, and in particular to a workpiece sandblasting mechanism, sandblasting method and system based on intelligent status monitoring. Background Technology

[0002] Sandblasting is a key process in metal surface pretreatment. It involves high-speed blasting of steel shot to impact the workpiece surface, removing oxide scale, rust, and impurities, and achieving a certain surface roughness. This provides a good base for subsequent coating and corrosion protection processes. Sandblasting technology is widely used in the manufacturing and maintenance of containers, steel structures, and construction machinery.

[0003] In related technologies, the steel shot circulation system of sand-making equipment typically consists of a screw conveyor, a bucket elevator, and a separator. The screw conveyor is generally powered by a belt drive. In actual operation, due to instantaneous fluctuations in steel shot flow, obstruction by foreign objects, or aging and loosening of the belt itself, the drive belt is prone to slippage. Related technologies handle such problems relatively passively, mainly relying on operators to conduct regular inspections, judging the equipment status through listening and touching, or troubleshooting and restoring the equipment after a motor overload trip.

[0004] The aforementioned technologies, relying on post-incident handling and manual experience for maintenance, cannot provide early warning and precise location of gradual belt slippage faults. By the time operators discover the abnormality, it has often progressed to severe slippage or even belt breakage, causing production interruptions and potential equipment damage. Furthermore, they cannot distinguish between slippage and actual overload (such as blockage), making it difficult to achieve differentiated control based on the root cause of the fault, thus hindering the improvement of automation and intelligence levels in sand making equipment. Summary of the Invention

[0005] To improve the automation level and operational reliability of the workpiece sandblasting process and to monitor the operating status of the steel sand circulation system in real time, this application provides a workpiece sandblasting mechanism, sandblasting method and system based on intelligent status monitoring.

[0006] Firstly, this application provides a workpiece sandblasting mechanism based on intelligent state monitoring, employing the following technical solution: A workpiece sandblasting mechanism based on state-based intelligent monitoring includes: A shot blasting chamber is used to hold workpieces and perform shot blasting treatment. The shot blasting chamber is provided with a workpiece inlet and a workpiece outlet. The overhead conveyor system is used to sequentially transport workpieces from the workpiece inlet to the sandblasting station, suspend the workpieces at the sandblasting station and drive them to rotate axially, and output the processed workpieces from the workpiece outlet. Multiple shot blasters are arranged circumferentially in the sandblasting chamber to perform shot blasting on the surface of a rotating workpiece from different directions. A steel shot recycling system is used to recover, sort and reuse the steel shot after blasting. The steel shot recycling system includes a transverse screw conveyor located below the bottom grid of the sand-blasting chamber, a longitudinal screw conveyor connected to the discharge end of the transverse screw conveyor, a bucket elevator connected to the discharge end of the longitudinal screw conveyor, and a separator located at the discharge end of the bucket elevator. The status monitoring system includes a multi-source sensing unit for real-time acquisition of operating data characterizing the conveying load and equipment health status, and a control unit for identifying overload or fault risks based on the operating data and outputting control commands. The multi-source sensing unit is located in the drive section of the transverse screw conveyor and the longitudinal screw conveyor, and there is a signal connection between the control unit and the multi-source sensing unit.

[0007] By adopting the above technical solutions, the equipment's condition monitoring system can collect multi-source operating data from the screw conveyor drive unit in real time, enabling early warning and precise location of gradual faults such as belt slippage, transforming passive maintenance into proactive intervention. The condition monitoring system can effectively distinguish between actual overload and belt slippage, outputting differentiated control commands to avoid production interruptions and equipment damage, thereby improving the automation level, operational reliability, and intelligent operation and maintenance capabilities of the sandblasting process.

[0008] Secondly, this application provides a workpiece sandblasting method based on intelligent state monitoring, employing the following technical solution: A workpiece sandblasting method based on state-based intelligent monitoring, applicable to the workpiece sandblasting mechanism as described in the first aspect, comprising: S1, the workpiece is transported to the sandblasting station in the sandblasting chamber by the overhead conveyor system, and the conveying is paused; S2 drives the workpiece to rotate axially. S3, simultaneously starts multiple sets of shot blasters to perform all-round shot blasting treatment on the surface of the workpiece; S4. After the current batch of workpieces has finished sandblasting, the overhead conveyor system resumes conveying and transports the next batch of workpieces to the sandblasting station. S4. The blasted steel shot falls into the steel shot circulation system through the bottom grid of the sand blasting chamber. It is then conveyed to the bucket elevator by the transverse screw conveyor and the longitudinal screw conveyor. The bucket elevator lifts the steel shot to the separator, and the steel shot is then conveyed to the hopper of the shot blaster for reuse. S5 monitors the operating status of the steel sand circulation system in real time through the status monitoring system, and outputs corresponding control commands when abnormal operating conditions are detected.

[0009] By adopting the above technical solution, the method integrates a status monitoring system into the sand-making process, enabling real-time perception and intelligent decision-making of the steel sand circulation system's operating status. This proactively identifies abnormal operating conditions during the conveying process (such as belt slippage or material blockage) and outputs differentiated control commands, transforming traditional passive fault handling into proactive early warning and precise intervention. This not only effectively avoids production interruptions and equipment damage caused by sudden failures but also significantly improves the continuity and reliability of the steel sand recycling process and the overall intelligence level of the sand-making system.

[0010] Furthermore, S5 also includes: The operation data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor are collected in real time by a multi-source sensing unit. The operation data includes the output torque of the drive motor, the speed difference between the drive shaft and the driven shaft, the vibration spectrum of the drive unit, and the three-phase current and voltage data of the drive motor. The control unit performs dynamic feature extraction and fusion analysis on the operating data to identify the overload risk of the conveying system or the decline in the health status of the equipment. Dynamic feature extraction includes calculating real-time load intensity, transmission slip rate and characteristic frequency band vibration energy. When a momentary overload is detected, the conveyor system is triggered to reduce load or shut down in an orderly manner. When a decline in the health status of the equipment is detected, a maintenance alarm containing the identifier of the specific faulty component is generated; When the load is consistently low, adjust the shot blasting machine's operating parameters to optimize energy efficiency.

[0011] By adopting the above technical solutions, and through multi-source data fusion and dynamic feature analysis, we can achieve deep perception and intelligent decision-making of the state of the conveying system, accurately distinguish different working conditions such as instantaneous overload, equipment health decline, and low load, and execute differentiated responses: avoid production interruption through load reduction protection, improve maintenance efficiency through accurate location of faulty components, and reduce operating costs through energy efficiency optimization, thereby comprehensively improving the reliability, economy and intelligent operation and maintenance level of the system.

[0012] Furthermore, methods for identifying overload risks in conveyor systems include: Based on the rotational speed data of the drive shaft and driven shaft, the real-time transmission slip ratio η is calculated. slip η slip =(1-N driven / N drive ) × 100%, where N drive N is the drive shaft speed. driven The driven shaft speed; Based on the vibration spectrum of the drive unit, the characteristic frequency band energy E specific to belt drive faults is extracted. blet The characteristic frequency band is the harmonic region of the belt's natural frequency; Construct a joint criterion for belt slippage risk, based on the real-time transmission slip rate η. slip The characteristic frequency band energy E continuously exceeds the first threshold T1 blet When the synchronization exceeds the second threshold T2, it is judged as a serious slippage or belt slippage risk; Real-time transmission slip ratio η slip If the risk of belt breakage is continuously exceeded by the higher third threshold T3, it is directly determined as a risk of belt breakage.

[0013] By adopting the above technical solution and integrating transmission slip rate and vibration spectrum characteristics, a precise joint criterion for belt slippage risk was constructed. Its core benefit lies in achieving quantitative and multi-dimensional diagnosis of belt health status: through slip rate threshold grading (T1, T3), it can effectively distinguish between slight slippage, severe slippage, and breakage risk, combined with characteristic frequency band energy (E... belt Analysis improves the accuracy of slippage detection, avoids misjudgment based on a single parameter, provides graded early warning of fault severity for the system, and enables differentiated intelligent responses from emergency shutdown to planned maintenance, thereby improving the accuracy of risk identification and the reliability of equipment protection.

[0014] Furthermore, graded response strategies for belt slippage include: When a risk of belt slippage is identified, a Level 1 alarm is generated; The load reduction protection strategy is implemented synchronously. The load reduction protection strategy is to reduce the operating speed of the transverse screw conveyor or the longitudinal screw conveyor and increase the working power of the shot blaster to maintain the sandblasting intensity. When a serious risk of slippage or belt breakage is detected, a Level 2 emergency alarm is generated. The orderly shutdown strategy is executed synchronously. The orderly shutdown strategy is as follows: stop the shot blaster feeding, stop the shot blaster after a first preset time delay, stop the bucket elevator after a second preset time delay, and finally stop the screw conveyor.

[0015] By adopting the above technical solutions, risk levels and response measures are precisely matched to achieve intelligent and proactive operation and maintenance. In the event of a Level 1 alarm, speed reduction and power compensation protect the conveyor equipment while maintaining production continuity and preventing unplanned downtime. In the event of a Level 2 alarm, an orderly shutdown is triggered to prevent steel shot blockage and cascading damage to equipment, ensuring the safety and controllability of the shutdown process. This enhances the system's fault tolerance for belt failures and overall operational reliability.

[0016] Furthermore, belt health trend prediction methods based on historical data include: Continuously record real-time transmission slip ratio η slip With characteristic frequency band energy E blet Historical data sequences; Based on historical data sequences, a regression algorithm is used to fit the trend curve of transmission slip ratio as a function of working time t. The trend curve indicates the transmission slip ratio η slip The predicted value will exceed the maintenance threshold T within a predetermined time period ΔT in the future. m Generate predictive maintenance alerts at that time; Predictive maintenance alerts include the faulty component identifier "drive belt", the maintenance recommendation "tension or replace", and a recommended maintenance time window calculated based on the trend curve.

[0017] By adopting the above technical solutions and through continuous monitoring and trend analysis, we can achieve a leap from post-failure maintenance to predictive maintenance. Based on historical data, we can accurately predict the performance degradation trajectory of belts and generate early warnings with clear maintenance content and time windows before failures occur. This allows maintenance personnel to plan ahead and intervene at the best time, minimizing unplanned downtime, improving equipment availability, reducing maintenance costs, and optimizing spare parts management.

[0018] Furthermore, methods for dynamic feature extraction and fusion analysis of operational data through control units also include: Based on three-phase current and voltage data, the real-time active power P of the drive motor is calculated. motor and the effective value of current I rms And construct multi-source data fusion criteria; Real-time transmission slip ratio η slip The increase, and the real-time active power P motor With the effective value of current I rms When the load intensity increases synchronously, the output judgment conclusion is "the conveying system is overloaded or blocked". Real-time transmission slip ratio η slip Increased, but real-time active power P motor With the effective value of current I rms If the output does not rise synchronously or even decreases, the conclusion is "the drive belt is slipping or aging". Real-time active power P motor The volatility exceeds a preset threshold, and the characteristic frequency band vibration energy E blet When an abnormality occurs, the output judgment conclusion is "the mechanical connection of the drive unit is loose or the bearing is short of oil".

[0019] By adopting the above technical solution and fusing and cross-validating multi-source data (slip rate, power, current, vibration), the root causes of faults can be accurately diagnosed and differentiated. This clearly identifies different fault modes such as overload / blockage, belt slippage, and mechanical loosening, providing the system with differentiated control strategies based on the root causes of the faults. This fundamentally avoids misjudgments, achieving a leap from general overload alarms to precise root cause analysis, thus improving the targeted nature of maintenance and the system's intelligence level.

[0020] Thirdly, this application provides a batch sandblasting system for workpieces based on intelligent status monitoring, which adopts the following technical solution: A batch sandblasting system for workpieces based on state-based intelligent monitoring includes: The acquisition module is used to acquire the operating data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor, as well as the three-phase current and voltage data of the drive motor; A memory for storing the program of the control method for any of the above-mentioned workpiece sandblasting methods; The processor and the program in the memory can be loaded and executed by the processor to implement the control method of any of the above-mentioned workpiece sandblasting methods.

[0021] By adopting the above technical solution and constructing a system architecture including an acquisition module, memory, and processor, the workpiece sandblasting method is solidified into an executable system program, achieving systematic intelligent control of the sandblasting process. Fault diagnosis, risk warning, and differentiated control strategies based on multi-source data fusion are transformed into stable and repeatable system functions, systematically improving the automation level, operational reliability, and intelligent operation and maintenance level of batch workpiece sandblasting operations, ensuring the efficient, accurate, and consistent implementation of the process method.

[0022] Fourthly, this application provides a smart terminal, which adopts the following technical solution: A smart terminal includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed by any of the methods described above.

[0023] Fifthly, this application provides a computer storage medium capable of storing corresponding programs, employing the following technical solution: A computer-readable storage medium storing a computer program that can be loaded by a processor and executed in any of the above-described workpiece sandblasting methods.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. By using a status monitoring system to perform real-time multi-source sensing and intelligent fusion analysis of key parameters, early warning, accurate diagnosis and root cause differentiation of faults such as belt slippage and overload blockage are provided, and graded response strategies (such as load reduction operation and orderly shutdown) are implemented to effectively avoid unplanned shutdowns and production interruptions, and ensure the continuity and stability of the production process. 2. Upon detecting an anomaly, this solution accurately identifies different fault modes such as overload, slippage, and mechanical loosening through cross-validation of multi-dimensional data (e.g., slip rate, power, current, vibration), and outputs differentiated control commands based on the root cause of the fault. Simultaneously, based on trend prediction using historical data, predictive maintenance is achieved, transforming maintenance work from on-demand or reactive to on-demand, optimizing maintenance resources and spare parts management. 3. Solidify the sandblasting method into a system program consisting of an acquisition module, a processor, and a memory, and build a complete intelligent sandblasting system. Transform monitoring, diagnosis, control, and optimization strategies into stable and repeatable system functions, thereby systematically improving the automation level, operational reliability, and overall efficiency of batch sandblasting operations for workpieces, and achieving a comprehensive intelligent upgrade of processes, equipment, and management. Attached Figure Description

[0025] Figure 1 This is a flowchart of a workpiece sandblasting method based on state intelligent monitoring according to an embodiment of this application.

[0026] Figure 2 This is a flowchart of step S5 in a workpiece sandblasting method based on state intelligent monitoring according to an embodiment of this application.

[0027] Figure 3 This is a flowchart of the method for identifying overload risk of a conveying system in an embodiment of this application.

[0028] Figure 4 This is a flowchart of the graded response strategy for belt slippage in the embodiments of this application.

[0029] Figure 5 This is a flowchart of a belt health trend prediction method based on historical data in an embodiment of this application.

[0030] Figure 6 This is a flowchart of a method for dynamic feature extraction and fusion analysis of operational data through a control unit in an embodiment of this application.

[0031] Figure 7 This is a module diagram of a batch sandblasting system for workpieces based on intelligent status monitoring. Detailed Implementation

[0032] The present application will be further described in detail below with reference to the accompanying drawings.

[0033] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the appendices in the embodiments of this application will be described below. Figure 1-7 The technical solutions in the embodiments of this application are clearly and completely described. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0034] This application discloses a workpiece sandblasting mechanism based on intelligent state monitoring. The workpiece sandblasting mechanism based on intelligent state monitoring includes a sandblasting chamber, a overhead conveyor system, multiple sets of shot blasters, a steel shot circulation system, and a state monitoring system.

[0035] The shot blasting chamber is a closed cavity structure used to hold workpieces and perform shot blasting. Workpiece inlets and outlets are located on the front and rear sides of the chamber, respectively, facilitating continuous workpiece loading and unloading. A grating plate is installed at the bottom of the chamber to allow the shot to fall and to block larger pieces of waste or workpiece fragments.

[0036] The overhead conveyor system runs through the workpiece inlet and outlet of the sandblasting chamber. The system includes a drive motor, chain, lifting device, and control system. The lifting device is used to suspend the workpieces. During operation, the overhead conveyor system sequentially transports the suspended workpieces from the workpiece inlet to the sandblasting station within the sandblasting chamber. Upon arrival at the sandblasting station, the conveying pauses, and the rotary drive device (with a motor-driven hook) in the overhead conveyor system activates, driving the workpiece to rotate uniformly around its own axis to ensure uniform surface treatment. After processing, the overhead conveyor system resumes operation, outputting the workpiece through the workpiece outlet and simultaneously transporting the next workpiece to be processed to the sandblasting station.

[0037] Multiple shot blasters are arranged circumferentially on the inner sidewall of the sandblasting chamber. Each shot blaster includes an impeller, a motor, and a directional sleeve, used for high-speed shot blasting. Through the circumferential arrangement of multiple shot blasters, the surface of a rotating workpiece can be impacted simultaneously from different directions, achieving shot blasting treatment without dead angles.

[0038] The steel shot recycling system is used to recover, sort, and reuse steel shot after blasting. The system includes a transverse screw conveyor located below the grid at the bottom of the shot blasting chamber, a longitudinal screw conveyor connected to the discharge end of the transverse screw conveyor, a bucket elevator connected to the discharge end of the longitudinal screw conveyor, and a separator located at the discharge end of the bucket elevator. After blasting, the steel shot falls through the grid into the transverse screw conveyor, where it is collected and conveyed to the longitudinal screw conveyor, and then centrally conveyed to the feed inlet of the bucket elevator. The bucket elevator vertically lifts the steel shot to the separator at the top. The separator is a magnetic separator that separates reusable qualified steel shot from dust, resin, etc. The steel shot is then conveyed to the hoppers of each shot blaster for reuse, achieving automatic steel shot recycling.

[0039] The condition monitoring system is used to monitor the real-time operating status of the steel shot circulation system, especially the health and load status of the screw conveyor. It includes multi-source sensing units and control units.

[0040] The multi-source sensing unit includes various sensors installed in the drive section (i.e., the drive motor and reducer) of the transverse and longitudinal screw conveyors. Specifically, it includes: a torque sensor for monitoring the output torque of the drive motor; encoders installed on the drive shaft and driven shaft respectively to monitor the rotational speed and calculate the speed difference; a vibration sensor for acquiring the vibration spectrum signal of the drive section; and a current / voltage sensor for acquiring the three-phase current and voltage data of the drive motor.

[0041] The control unit is a programmable logic controller (PLC) that connects to all the aforementioned multi-source sensing units to receive and process operational data in real time. The control unit has pre-installed algorithms that can identify potential faults in the conveyor system, such as overload, slippage, or belt breakage, based on this fused operational data, and can output control commands. These commands include adjusting the speed, triggering alarms, and orderly shutdown.

[0042] This sandblasting mechanism not only automates, batches, and homogenizes workpiece processing, improving processing efficiency and quality, but also enhances the reliability and safety of equipment operation through an intelligent status monitoring system. It can predictively detect potential faults, avoid unplanned downtime, and reduce maintenance costs.

[0043] This application discloses a workpiece sandblasting method based on intelligent state monitoring. (Refer to...) Figure 1 The method includes: Step S1: The workpiece is transported to the sandblasting station in the sandblasting chamber via a overhead conveyor system, and the conveying is paused.

[0044] A catenary conveyor system is used for continuous transport of workpieces and includes a drive motor, chain, lifting devices, and control system. A shot blasting station refers to a specific area within the shot blasting chamber surrounded by multiple sets of shot blasters, used for centralized shot blasting treatment of workpieces.

[0045] Step S2: Drive the workpiece to rotate axially.

[0046] Axial rotation refers to the rotational motion of a workpiece around its own central axis, which allows the entire outer surface of the workpiece to be uniformly shot-blasted.

[0047] Step S3: Simultaneously start multiple sets of shot blasters to perform all-round shot blasting treatment on the workpiece surface.

[0048] Multiple shot blasters are arranged circumferentially within the shot blasting chamber to simultaneously blast steel shot from different angles. Synchronous startup ensures that all surfaces of the workpiece begin treatment at the same time, avoiding localized over-treatment or under-treatment and achieving comprehensive coverage.

[0049] Step S4: After the current batch of workpieces has finished sandblasting, the overhead conveyor system resumes conveying and transports the next batch of workpieces to the sandblasting station.

[0050] The current batch of workpieces has finished shot blasting, meaning the preset shot blasting time for that workpiece has elapsed. The controller first stops the shot blaster and closes the shot blasting gate, then starts the overhead conveyor drive motor. The motor-driven chain moves the processed workpieces towards the workpiece exit, while simultaneously, the next workpiece to be processed, suspended on the subsequent hoist, is transported to the now-empty shot blasting station.

[0051] In step S4, the blasted steel shot falls into the steel shot circulation system through the bottom grid of the shot blasting chamber. It is then conveyed to the bucket elevator by the transverse screw conveyor and the longitudinal screw conveyor, and then lifted to the separator by the bucket elevator. The steel shot is then conveyed to the hopper of the shot blaster for reuse.

[0052] After being blasted, the steel shot passes through the bottom grid and first falls into the spiral groove of the transverse screw conveyor. The rotating blades of the transverse screw conveyor push the steel shot to one end, from its outlet into the vertically arranged longitudinal screw conveyor. The longitudinal screw conveyor then collects the steel shot and conveys it to the bottom inlet of the bucket elevator. The bucket elevator scoops up the steel shot and lifts it to the top of the equipment, pouring it into the separator. The separator separates the intact, usable steel shot and reintroduces it into the hopper of the shot blaster, ready to be blasted again.

[0053] Step S5: Monitor the operating status of the steel shot circulation system in real time through the status monitoring system, and output corresponding control commands when abnormal operating conditions are detected.

[0054] The status monitoring system is the core of the intelligentization of the workpiece sandblasting method. It collects data in real time through sensors, identifies anomalies through algorithm models, and finally outputs instructions to intervene.

[0055] For example, the control unit analyzes and detects a sharp increase in the drive current and a decrease in the drive shaft speed of the longitudinal screw conveyor, indicating a possible blockage. It then outputs the following instructions: first, stop feeding material to the relevant shot blasting unit; then, trigger an audible and visual alarm to notify the operator; and simultaneously, briefly reverse the screw conveyor to attempt self-clearing, thereby preventing equipment damage.

[0056] Reference Figure 2 Step S5 also includes: Step S501: Real-time acquisition of operating data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor through the multi-source sensing unit. The operating data includes the output torque of the drive motor, the speed difference between the drive shaft and the driven shaft, the vibration spectrum of the drive unit, and the three-phase current and voltage data of the drive motor.

[0057] Multi-source sensing units are the fundamental data source for condition monitoring systems. They integrate various types of sensors to comprehensively perceive the mechanical and electrical status of the drive unit of the conveyor system. The drive unit typically includes key components such as drive motors, reducers, transmission belts, and couplings.

[0058] Physical sensors are installed on the drive motors and transmission mechanisms of the transverse and longitudinal screw conveyors, and the measurement data is transmitted to the control unit in real time via signal lines. The specific data collected includes: The output torque of the drive motor is directly measured by a torque sensor mounted on the motor output shaft, directly reflecting the current load size.

[0059] Speed ​​difference between drive shaft and driven shaft: The real-time speeds of both shafts are measured by installing rotary encoders on both shafts. The control unit reads the pulse signals from the two encoders and calculates the speed difference and ratio.

[0060] Vibration spectrum of the drive unit: Raw vibration signals are collected by installing vibration acceleration sensors on the bearing housings of the drive motor or reducer. After the signals are transmitted to the control unit, they are converted into time and frequency using a built-in algorithm to obtain the vibration spectrum characterizing the mechanical state of the equipment.

[0061] Three-phase current and voltage data of the drive motor: collected from the motor's power line through current transformers and voltage sensors, used to calculate the motor's real-time power, efficiency and other electrical characteristics.

[0062] Step S502: The control unit performs dynamic feature extraction and fusion analysis on the operating data to identify the overload risk of the conveying system or the decline in the health status of the equipment. Dynamic feature extraction includes calculating the real-time load intensity, transmission slip rate and characteristic frequency band vibration energy.

[0063] Dynamic feature extraction refers to calculating high-level feature values ​​that can directly characterize a specific state of a device from raw sensor data. Fusion analysis refers to associating and comprehensively judging multiple feature values ​​of different types to improve the accuracy and reliability of state recognition.

[0064] The microprocessor within the control unit executes a pre-set algorithm program to calculate real-time load intensity. Based on the output torque and active power of the drive motor, combined with its rated values, it calculates a normalized percentage load rate for intuitively judging the load magnitude. It also calculates the transmission slip ratio ηslip, which directly reflects the slippage efficiency of the belt drive. Finally, it extracts the vibration energy E in the characteristic frequency band. blet For belt drive systems, the algorithm focuses on a specific high-frequency band in the vibration spectrum that is related to the natural frequency of the belt, and calculates the sum of vibration energy in that band. This value is sensitive to belt wear and loosening.

[0065] The fusion analysis process involves cross-validating the aforementioned characteristic values ​​with electrical parameters such as current and power. If the slip ratio η... slip Increase, and at the same time, the motor current I rms If η also increases significantly, it is determined to be an overload; slip Increase and I rms If the belt does not rise or even falls, it is determined that the belt is slipping (see step S5021 for details).

[0066] For example, the control unit's calculation program displays the η of the transverse screw conveyor in real time. slip The slippage rate jumped from 5% to 20%, while the motor current increased from 30A to 45A. The algorithm, through fusion analysis, determined that this was not a simple slippage, but rather a possible material blockage inside the screw conveyor, leading to an overload risk.

[0067] Step S503: When a momentary overload is detected, the conveyor system is triggered to reduce load or shut down in an orderly manner.

[0068] Instantaneous overload refers to the sudden and rapid increase in load on the auger caused by the steel shot sprayed onto the workpiece surface by the shot blaster, or the possibility of accumulation of steel shot or workpiece fragments falling onto the auger in a short period of time, far exceeding the normal bearing capacity of the equipment. If not dealt with immediately, it may lead to motor burnout or damage to mechanical parts.

[0069] The control unit is equipped with threshold logic for various operating conditions. When the fusion analysis determines that there is an "instantaneous overload," the controller immediately executes the preset protective control command: Load reduction protection: Immediately reduce the operating frequency of the relevant screw conveyor motor (achieved through a frequency converter), causing its speed to decrease and its conveying capacity to be reduced, thereby slowing down the blockage process. At the same time, the shot blaster can be controlled in conjunction with the motor to appropriately reduce its shot volume, thereby reducing the inflow of steel shot from the source and indirectly reducing the load on the conveying system.

[0070] Orderly shutdown: If load reduction measures are ineffective or the overload is extremely severe (e.g., the instantaneous torque value exceeds the safety limit), an orderly shutdown procedure will be triggered. The controller will follow the principle of "stopping the upstream first, then stopping the machine," first closing the sand supply gate of the corresponding shot blaster, then stopping the main motor of the shot blaster after a delay of several seconds, and then stopping the screw conveyor of this machine, in order to avoid the equipment from hard-starting under heavy load or causing more serious blockage.

[0071] For example, if the system detects a severe overload on the longitudinal screw conveyor, the PLC immediately outputs a command: reduce the conveyor's speed from 50Hz to 30Hz, and simultaneously reduce the shot blasting volume of the two associated shot blasters by 20%. If the torque value does not decrease after 5 seconds, the PLC immediately initiates an orderly shutdown to prevent potential shaft breakage.

[0072] Step S504: When a decline in the health status of the equipment is detected, a maintenance alarm containing a specific faulty component identifier is generated.

[0073] Equipment health degradation refers to the gradual decline in equipment performance, not a sudden failure, but it will eventually lead to failure if left unaddressed. Specific fault component identifiers are unique codes or names pre-defined for each monitored component, used to accurately locate problems.

[0074] The trend analysis module of the control unit will record and analyze data such as vibration energy E over a long period of time. blet slip ratio η slip The system tracks the slow changing trend of characteristic values. When the trend of a certain characteristic value indicates that its health has declined to a preset maintenance threshold, the system determines that the component's condition has deteriorated.

[0075] The controller then generates a structured maintenance alarm message, which includes the alarm level and content, clearly indicating the "faulty component identifier," such as "transverse screw conveyor - drive belt," and includes maintenance suggestions, such as "check tension; estimated remaining service life 2 weeks." The alarm can be sent to the host computer monitoring system.

[0076] Step S505: When the load is found to be consistently low, adjust the working parameters of the shot blaster to optimize energy efficiency.

[0077] A persistently low load refers to a screw conveyor's load rate being significantly lower than its rated capacity for an extended period, indicating that the current workload of the shot blaster may be too high, resulting in energy waste.

[0078] The energy management module of the control unit continuously monitors the load rate of the delivery system. If the load rate is found to be consistently below a certain set low threshold for a period of time, such as being below 30% of the rated load for more than 10 minutes, the system is determined to be operating in an inefficient zone.

[0079] Subsequently, the controller sends optimization commands to the shot blasting system controller. This is achieved by adjusting the frequency of the shot blasting motor (controlling the speed of the shot blasting wheel) or adjusting the opening of the sand supply gate. The aim is to reduce the shot blasting intensity to match the actual amount of steel shot being delivered, thereby saving energy while ensuring process requirements are met.

[0080] For example, during lighter nighttime production periods, the system monitored that the load rate of the longitudinal screw conveyor remained around 25%. Based on this, the control unit determined that the current steel shot circulation volume was low, and automatically switched the operating mode of all shot blasters from "enhanced" to "standard," reducing their motor operating frequency from 50Hz to 40Hz. This reduced the overall power consumption of the system while maintaining the cleaning effect.

[0081] Reference Figure 3 Methods for identifying overload risks in conveyor systems include: Step S5021: Calculate the real-time transmission slip ratio η based on the rotational speed data of the drive shaft and driven shaft. slip η slip =(1-N driven / N drive ) × 100%, where N drive N is the drive shaft speed. driven For the driven shaft speed, Transmission slip ratio η slip The slip ratio is a core technical indicator characterizing the efficiency and health of a belt drive system. It is defined as the relative percentage difference between the speed of the drive shaft and the speed of the driven shaft. This value directly reflects the degree of belt slippage during power transmission. Ideally, the slip ratio of a belt drive should be maintained within a stable, low range.

[0082] The control unit continuously reads the pulse signals from two rotary encoders mounted on the drive shaft and driven shaft, respectively, via a high-speed counter module. By calculating the number of pulses per unit time, the drive shaft speed N is accurately obtained. drive and driven shaft speed N driven The algorithm program built into the control unit follows the formula η. slip =(1-N driven / N drive The calculation is performed in real time at a rate of 100%, and the result is stored in the storage area and used for subsequent logical judgments.

[0083] Step S5022: Based on the vibration spectrum of the drive unit, extract the characteristic frequency band energy E specific to belt drive faults. blet The characteristic frequency band is the harmonic region of the belt's natural frequency.

[0084] Characteristic band energy E blet These are quantitative indicators extracted from equipment vibration signals, and are highly correlated with specific belt failure modes (such as wear, looseness, and misalignment). The "characteristic frequency band" is set around the belt's natural frequency and its harmonic frequency range, and the vibration energy in these frequency bands is most sensitive to abnormal changes in the belt's dynamics.

[0085] A vibration acceleration sensor installed in the drive unit collects raw time-domain vibration signals and transmits them to the control unit via signal lines. The signal processing algorithm within the control unit converts the time-domain signal into a frequency-domain spectrum. The algorithm focuses on a pre-defined characteristic frequency range. For example, if the natural frequency calculated based on the belt model is 40Hz, the characteristic frequency band can be set to the second harmonic region of 75-85Hz and the third harmonic region of 115-125Hz. The algorithm calculates the sum of the squares of the amplitudes corresponding to all spectral lines within this frequency band to obtain the vibration energy value E of that characteristic frequency band. blet .

[0086] Step S5023: Construct a joint criterion for belt slippage risk, based on the real-time transmission slip rate η. slip The characteristic frequency band energy E continuously exceeds the first threshold T1 blet When the synchronization exceeds the second threshold T2, it is judged as a serious slippage or belt slippage risk.

[0087] Joint criteria is a multi-parameter fusion decision logic used to improve the accuracy of state recognition and avoid erroneous actions caused by false alarms due to a single parameter. It requires two or more related feature parameters to simultaneously exceed their respective thresholds before triggering the final decision.

[0088] In the control unit, the logic program of the joint criterion continuously monitors the real-time calculated η. slip Value and E blet Value. The first threshold T1 is for η. slip A threshold value is set, for example, T1=10%. This indicates that a slip rate below this value is within the normal fluctuation range, while exceeding it warrants attention. The second threshold T2 is for E. blet A set threshold value, such as T2 = 20 m / s², indicates that belt vibration below this energy level is normal, while exceeding it indicates abnormal belt dynamics.

[0089] When the system detects η slip For a sustained period of time (e.g., 5 seconds) greater than T1, and within the same time period, E bletWhen the value is consistently greater than T2, the joint criterion is established. The control unit then determines that the transmission system has a "serious risk of slippage" or a "risk of belt slippage".

[0090] Step S5024, based on the real-time transmission slip ratio η slip If the risk of belt breakage is continuously exceeded by the higher third threshold T3, it is directly determined as a risk of belt breakage.

[0091] The third threshold, T3, is an emergency threshold with a set value much higher than T1 (e.g., T3 = 40%). This criterion is an independent, highest-priority risk assessment rule. When the slip ratio abnormally rises to T3, it indicates that the driven shaft almost no longer rotates with the drive shaft, the belt is likely to have severely slipped or is about to break or has already broken, the situation is extremely critical, there is no need to wait for other parameter verification, the most urgent measures must be taken immediately.

[0092] Reference Figure 4 The graded response strategies for belt slippage include: Step 5025: When a risk of belt slippage is determined, a Level 1 alarm is generated.

[0093] A Level 1 alarm is a primary warning signal issued by the status monitoring system in response to potential risks. Its purpose is to promptly remind operators to pay attention to the equipment status, but it does not require immediate shutdown and is a preventative warning.

[0094] When the diagnostic algorithm in the control unit is based on the real-time acquired transmission slip ratio η slip and characteristic frequency band vibration energy E blet When data such as η is comprehensively used to determine that the current state is "risk of belt slippage", then... slip It remains above the first threshold T1 but below the emergency threshold T3, and E blet Upon synchronous elevation, the control unit's CPU sends an alarm message to the host computer monitoring system via its communication interface. The alarm message includes the alarm level ("Level 1"), alarm source (e.g., "Longitudinal screw conveyor drive"), alarm content ("Belt slippage risk"), and a timestamp. On the host computer interface, the alarm is displayed as a flashing icon or a list of text, accompanied by a low-priority audible alert.

[0095] Step 5026: Simultaneously execute the load reduction protection strategy, which involves reducing the operating speed of the transverse or longitudinal screw conveyor and increasing the working power of the shot blaster to maintain the sandblasting intensity.

[0096] The load reduction protection strategy is a set of active control commands that mainly reduces the load on the slipping belt to curb the slipping trend, while striving to maintain the final sandblasting intensity and process effect basically unchanged through compensatory adjustments.

[0097] While generating a Level 1 alarm, the control unit simultaneously outputs a control signal to the corresponding actuator: Reducing conveyor speed: Through the built-in logic control of the control unit, a command is sent to the frequency converter responsible for driving the screw conveyor to reduce the output frequency, thereby reducing the conveyor motor speed. Lower speed directly reduces the torque that the belt needs to transmit, thus reducing the load and alleviating slippage.

[0098] To increase the working power of the shot blasting machine: To compensate for the temporary reduction in steel shot circulation volume that may be caused by the conveyor speed reduction, the control unit sends a command to the main motor inverter of the shot blasting machine through the control loop to appropriately increase its speed (i.e., increase the speed of the shot blasting wheel), and / or sends a command to the pneumatic or electric sand supply gate to fine-tune the opening to maintain the steel shot flow rate. This ensures that the kinetic energy and quantity of steel shot impacting the workpiece per unit time do not decrease, thereby maintaining the shot blasting intensity.

[0099] For example, after the system determines that the transverse screw conveyor has a risk of slippage, the PLC immediately reduces the frequency of its drive motor from 50Hz to 35Hz. Simultaneously, the PLC increases the frequency of the main motor of the associated shot blasting unit (No. 2) from 45Hz to 48Hz and fine-tunes the sand supply gate opening from 70% to 75%. This reduces the belt load, suppresses slippage, and the shot blasting intensity is not weakened by the reduced conveyor speed.

[0100] Step 5027: When a serious risk of slippage or belt breakage is determined, a Level 2 emergency alarm is generated.

[0101] Level 2 emergency alerts are the highest level of warnings issued for high-risk malfunctions that could cause serious equipment damage or production disruptions, requiring immediate attention and emergency measures.

[0102] When the diagnostic algorithm determines the current state as "severe slippage" or "risk of belt breakage", such as η slip If the value rises sharply and exceeds the higher third threshold T3, the control unit will immediately trigger the highest priority alarm output, regardless of other parameters.

[0103] Step 5028: Simultaneously execute the orderly shutdown strategy, which is to stop the shot blaster from feeding, stop the shot blaster after a first preset time delay, stop the bucket elevator after a second preset time delay, and finally stop the screw conveyor.

[0104] An orderly shutdown strategy is a shutdown process executed in a specific time sequence. It can clear the steel sand being processed in the system as much as possible while protecting the equipment, avoiding heavy-load shutdowns, preventing blockages, and creating safe conditions for subsequent maintenance.

[0105] Upon triggering the Level 2 emergency alarm, the control unit immediately executes the following shutdown sequence according to a preset logical timing. This sequence is precisely delayed and controlled by a timer within the PLC: Immediately stop the shot blasting machine's feed: Send a shut-off command to the solenoid valve that controls the shot blasting machine's sand supply to cut off the source of steel shot.

[0106] Stop the shot blasting machine after a first preset time delay (e.g., t1=10 seconds): Wait about 10 seconds to allow the small amount of remaining steel shot that has entered the shot blasting machine to be ejected, preventing it from remaining inside the shot blasting machine.

[0107] Stop the bucket elevator after a second preset time delay (e.g., t2=20 seconds): After the shot blaster stops, wait for about 20 seconds to ensure that the remaining steel shot in the screw conveyor and at the bottom of the elevator has enough time to be lifted up and emptied.

[0108] Finally, stop the screw conveyor: After all upstream equipment has stopped and its internal materials have been confirmed to be largely emptied, send a stop command to the frequency converter of the malfunctioning screw conveyor. Ensure the conveyor stops in a near-unloaded state to maximize the protection of the motor and transmission mechanism.

[0109] Reference Figure 5 Methods for predicting belt health trends based on historical data include: Step S50211: Continuously record the real-time transmission slip ratio η slip With characteristic frequency band energy E blet Historical data sequence.

[0110] Historical data sequences are data sets arranged chronologically to reflect the changes in equipment status characteristic parameters. Establishing such sequences captures the gradual changes in equipment performance, thus providing a data foundation for trend prediction.

[0111] The control unit is equipped with a data storage module. This module is configured as a cyclic database, automatically updating the real-time calculated transmission slip ratio η at fixed time intervals. slip Value and characteristic frequency band vibration energy η slip The data is packaged and stored together with the timestamp. The system sets a storage capacity (e.g., storing data from the most recent 90 days) and manages it using a first-in, first-out (FIFO) principle to ensure that the latest and most relevant historical data is stored for trend analysis.

[0112] Step S50212: Based on the historical data sequence, fit the trend curve of the transmission slip ratio with working time t using a regression algorithm.

[0113] Regression algorithms are mathematical methods used to find a best-fit curve to describe the independent variable t and the dependent variable η. slipA predictive model for the correlation between η and other variables. The trend curve can visually demonstrate the relationship between η and other variables. slip The direction and speed of evolution over time.

[0114] The control unit's trend prediction module periodically (e.g., every morning) retrieves stored historical data. The algorithm uses time t as the x-axis and the corresponding η... slip The values ​​are used as the ordinate, forming a scatter plot in the coordinate system. The algorithm then uses linear regression to fit the scatter plot, obtaining a straight line or curve equation representing the trend, such as η. slip (t) = a + b × t (linear model), where the slope b represents η. slip The average rate of deterioration.

[0115] For example, the system extracts the average η of each day over the past 30 days. slip Value. The trend line equation is obtained through linear regression calculation as η. slip (t) = 4.5 + 0.1 × t, the intercept a = 4.5% represents the initial value about 30 days ago, the slope b = 0.1% / % represents that the ηslip value increases by an average of 0.1 percentage points per day, and the upward slope indicates that the health condition of the belt continues to deteriorate.

[0116] Step S50213, the trend curve shows the transmission slip ratio η slip The predicted value will exceed the maintenance threshold T within a predetermined time period ΔT in the future. m At that time, predictive maintenance alerts are generated.

[0117] Predictive maintenance alerts are warnings based on predictions of future conditions rather than current faults. The preset time period ΔT is a preparation window (e.g., 2 weeks) allowing for planned maintenance, and the maintenance threshold T... m These are verified critical state values ​​that require maintenance intervention (such as η). slip =15%).

[0118] The control unit extrapolates the trend line equation obtained in step S50212 to the future, adds ΔT (e.g., 14 days) to the current time point, substitutes it into the trend line equation, and calculates η. slip Predicted value. Compare this predicted value with the preset maintenance threshold T. m Compare. η slip (current time + ΔT) ≥ T m If the belt reaches or exceeds the required maintenance state within the planned maintenance time window, it is determined that the belt will be in a state that requires maintenance.

[0119] For example, based on the trend equation η slip (t) = 4.5 + 0.1 × t, currently t = 30 days, predict η 14 days (ΔT) later, i.e., when t = 44. slip(44) = 4.5 + 0.1 × 44 = 8.9%. Assume a maintenance threshold T. m =10%, 8.9% < 10%, no alarm is triggered at this time. As time goes on, when t=50, the predicted value after 14 days will be η. slip (64) = 4.5 + 0.1 × 64 = 10.9% > 10%. At this point, the condition is met, and the system immediately generates an early warning and sends it to the upper management system.

[0120] Step S50214, the predictive maintenance alarm includes the faulty component identifier "drive belt", the maintenance recommendation "tension or replacement", and the recommended maintenance time window calculated based on the trend curve.

[0121] When generating an alarm, the control unit calls a predefined alarm template and fills in specific data: the faulty component identifier is used to directly and clearly indicate the problem object, such as "drive belt"; the maintenance suggestion can give the most likely operation based on the fault mode library, such as "tighten or replace"; the recommended maintenance time window is based on core predictive information calculated from trends.

[0122] Algorithm calculates trend curve and maintenance threshold T m The intersection point is taken as the earliest time when maintenance may be needed. Based on this point and in conjunction with the production plan, a reasonable execution time range is recommended (e.g., "It is recommended to schedule maintenance between [date] and [date]").

[0123] For example, the predictive maintenance alert generated by the system displays: "[Predictive Maintenance Alert] Component: Longitudinal Screw Conveyor - Drive Belt. Status: Health trending downwards. Prediction: Expected to reach maintenance threshold in 15 days. Recommendation: Tension or replace the belt. Recommended maintenance time window: 2025-12-20 to 2025-12-27." This enables equipment administrators to order spare parts in advance and schedule downtime, achieving an intelligent upgrade from "preventive maintenance" to "predictive maintenance."

[0124] Reference Figure 6 The method of dynamically extracting and fusing operational data through the control unit also includes: Step S5011: Based on the three-phase current and voltage data, calculate the real-time active power P of the drive motor. motor and the effective value of current I rms And construct a multi-source data fusion criterion.

[0125] Real-time active power P motor This refers to the electrical power actually consumed by the drive motor and converted into mechanical energy, directly reflecting the motor's load. Current RMS value I rmsIt is an indicator for measuring the magnitude of motor current and is closely related to load and torque. Multi-source data fusion criterion is a decision-making logic that improves the accuracy of state identification conclusions by comprehensively analyzing feature parameters from multiple different sources and of different types.

[0126] The control unit uses a dedicated power measurement module to collect the three-phase voltage (U) of the drive motor in real time. a U b U c ) and three-phase current (I a ,I b ,I c The instantaneous value of the current. The algorithm program built into the control unit calculates the effective value of the current I. rms and real-time active power P motor： RMS current value I rms The root mean square value of the three-phase current; real-time active power P motor =√3×U×I×cosφ, where U is the effective value of the line voltage, I is the effective value of the line current, and cosφ is the power factor, which is calculated by the phase difference between the voltage and the current.

[0127] Calculated electrical parameter P motor ,I rms With the parameter η obtained from the mechanical sensor slip E blet They are all fed into the fusion analysis logic and participate in decision-making together.

[0128] In step S5012, when the real-time transmission slip ratio ηslip increases and the real-time active power Pmotor and the effective value of current Irms increase synchronously, it is confirmed that the load intensity has increased, and the output judgment conclusion is "the conveying system is overloaded or blocked".

[0129] This criterion is used to distinguish between a genuine increase in load and drivetrain slippage. When the drive shaft needs to output more torque to overcome the load, this manifests as an increase in motor current and power. If the drivetrain is effective, the driven shaft should also be able to keep up, and the slip ratio will only fluctuate slightly. If the slip ratio increases significantly and the electrical parameters increase simultaneously, it indicates that excessive load may cause a decrease in drivetrain efficiency, which is a clear signal of overload or blockage.

[0130] The fault diagnosis module of the control unit continuously monitors η slip P motor and I rms The real-time value and its changing trend. The algorithm includes comparison logic; if η is detected... slip If the fluctuation consistently exceeds the normal range (e.g., >5%), and within the same time period, P... motor and I rmsIf the values ​​of both values ​​increase significantly compared to their baseline values ​​(e.g., both increase by more than 15%), then the fusion criterion is met. At this point, the control unit will output a diagnostic conclusion: "Conveyor system overload or blockage," which is used to trigger an alarm or automatic control process.

[0131] For example, steel shot blockage occurs inside the screw conveyor. The system monitors η slip From 5% to 18%, while P motor From 15kW to 22kW, I rms The system was upgraded from 28A to 38A. All parameters increased significantly and simultaneously, and the system immediately identified this as "overload / blockage," automatically triggering load reduction or backflushing strategies.

[0132] Step S5013, based on the real-time transmission slip ratio η slip Increased, but real-time active power P motor With the effective value of current I rms If the output does not increase synchronously or even decreases, the conclusion is "the drive belt is slipping or aging".

[0133] This criterion is crucial for diagnosing faults in the transmission system itself. When the belt slips or ages, the drive shaft rotates but cannot effectively drive the driven shaft. Therefore, the actual load on the drive motor does not increase; in fact, due to friction and efficiency loss during slippage, its current and power may decrease slightly or remain essentially unchanged. In this case, the abnormal increase in slip ratio is purely caused by transmission failure.

[0134] The fault diagnosis module also monitors these three parameters. When the algorithm detects η... slip Significantly elevated (e.g., >12%) but P motor and I rms If there is no synchronous increase trend, and the value is even lower than normal, the fusion criterion is established. Based on this, the control unit draws a different conclusion than in step S5012: "The drive belt is slipping or aging." This indicates that the problem lies in the power transmission link, not the load end.

[0135] For example, the belt may stretch due to aging, causing slippage. The system monitors η. slip It rose sharply from 5% to 25%, however P motor However, it decreased slightly from 15kW to 14kW. rms The voltage also decreased from 28A to 26A. The characteristic pattern of "increased slip rate but decreased electrical parameters" was accurately diagnosed by the system as "belt slippage".

[0136] Step S5014, based on the real-time active power P motor The volatility exceeds a preset threshold, and the characteristic frequency band vibration energy E blet When an abnormality occurs, the output judgment conclusion is "the mechanical connection of the drive unit is loose or the bearing is short of oil".

[0137] Volatility refers to the degree of variation in active power values, quantified by calculating its standard deviation or the ratio of peak-to-peak value to average value over a certain period. Loose mechanical connections, such as loose anchor bolts, misaligned couplings, or poor bearing lubrication, can cause abnormal fluctuations in load torque and trigger specific high-frequency vibrations.

[0138] The control unit's calculation program calculates P in real time. motor The short-term volatility (e.g., calculating the standard deviation of data points over the past 10 seconds). Simultaneously, monitor the characteristic frequency band vibration energy E. blet Does it exceed its normal threshold? When the algorithm identifies P... motor The volatility consistently exceeds the preset stability threshold (e.g., volatility > 10%), and E blet When the value remains abnormal (e.g., >18 m / s²), the fusion criterion is established. The control unit then outputs the judgment conclusion as "loose mechanical connection of the drive unit or insufficient lubrication of the bearing," clearly indicating the specific location and nature of the possible fault.

[0139] For example, when the bearings of the drive motor begin to lack lubrication, the system detects P. motor The vibration fluctuated violently around 12kW, with a volatility of 20% (normal is <5%). Simultaneously, the vibration sensor detected energy E in the characteristic frequency band. blet The value remained stable at a high level of 25 m / s². The system comprehensively analyzed abnormal indicators from both electrical and mechanical sources to accurately diagnose a "bearing lubrication shortage" fault, rather than a simple load change.

[0140] Based on the same inventive concept, embodiments of this application provide a batch sandblasting system for workpieces based on intelligent status monitoring, comprising: The acquisition module is used to acquire the operating data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor, as well as the three-phase current and voltage data of the drive motor; A memory for storing the program of the control method for any of the above-mentioned workpiece sandblasting methods; The processor and the program in the memory can be loaded and executed by the processor to implement the control method of any of the above-mentioned workpiece sandblasting methods.

[0141] By constructing a system architecture that includes an acquisition module, memory, and processor, the workpiece sandblasting method is solidified into an executable system program, enabling systematic intelligent control of the sandblasting process. Fault diagnosis, risk warning, and differentiated control strategies based on multi-source data fusion are transformed into stable and repeatable system functions, systematically improving the automation level, operational reliability, and intelligent operation and maintenance level of batch workpiece sandblasting operations, ensuring the efficient, accurate, and consistent implementation of the process method.

[0142] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0143] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as a batch sandblasting method for workpieces based on state-based intelligent monitoring.

[0144] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0145] Based on the same inventive concept, embodiments of this application provide an intelligent terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded and executed by the processor for a batch sandblasting method for workpieces based on state-based intelligent monitoring.

[0146] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0147] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A workpiece sandblasting method based on state-based intelligent monitoring, characterized in that, The method is applied to a sandblasting mechanism, the sandblasting mechanism comprising: A shot blasting chamber is used to hold workpieces and perform shot blasting treatment. The shot blasting chamber is provided with a workpiece inlet and a workpiece outlet. The overhead conveyor system is used to sequentially transport workpieces from the workpiece inlet to the sandblasting station, suspend the workpieces at the sandblasting station and drive them to rotate axially, and output the processed workpieces from the workpiece outlet. Multiple shot blasters are arranged circumferentially in the sandblasting chamber to perform shot blasting on the surface of a rotating workpiece from different directions. A steel shot recycling system is used to recover, sort and reuse the steel shot after blasting. The steel shot recycling system includes a transverse screw conveyor located below the bottom grid of the sand-blasting chamber, a longitudinal screw conveyor connected to the discharge end of the transverse screw conveyor, a bucket elevator connected to the discharge end of the longitudinal screw conveyor, and a separator located at the discharge end of the bucket elevator. The status monitoring system includes a multi-source sensing unit for real-time acquisition of operating data characterizing the conveying load and equipment health status, and a control unit for identifying overload or fault risks based on the operating data and outputting control commands. The multi-source sensing unit is located in the drive unit of the transverse screw conveyor and the longitudinal screw conveyor, and there is a signal connection between the control unit and the multi-source sensing unit. Workpiece sandblasting methods based on state-based intelligent monitoring include: S1, the workpiece is transported to the sandblasting station in the sandblasting chamber by the overhead conveyor system, and the conveying is paused; S2 drives the workpiece to rotate axially. S3, simultaneously starts multiple sets of shot blasters to perform all-round shot blasting treatment on the surface of the workpiece; S4. After the current batch of workpieces has finished sandblasting, the overhead conveyor system resumes conveying and transports the next batch of workpieces to the sandblasting station. S4. The blasted steel shot falls into the steel shot circulation system through the bottom grid of the sand blasting chamber. It is then conveyed to the bucket elevator by the transverse screw conveyor and the longitudinal screw conveyor. The bucket elevator lifts the steel shot to the separator, and the steel shot is then conveyed to the hopper of the shot blaster for reuse. S5 monitors the operating status of the steel shot circulation system in real time through the status monitoring system, and outputs corresponding control commands when abnormal operating conditions are detected. S5 also includes: The operation data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor are collected in real time by a multi-source sensing unit. The operation data includes the output torque of the drive motor, the speed difference between the drive shaft and the driven shaft, the vibration spectrum of the drive unit, and the three-phase current and voltage data of the drive motor. The control unit performs dynamic feature extraction and fusion analysis on the operating data to identify the overload risk of the conveying system or the decline in the health status of the equipment. Dynamic feature extraction includes calculating real-time load intensity, transmission slip rate and characteristic frequency band vibration energy. When a momentary overload is detected, the conveyor system is triggered to reduce load or shut down in an orderly manner. When a decline in the health status of the equipment is detected, a maintenance alarm containing the identifier of the specific faulty component is generated; When a persistently low load is detected, adjust the shot blasting machine's operating parameters to optimize energy efficiency. Methods for identifying overload risks in conveyor systems include: Based on the rotational speed data of the drive shaft and driven shaft, the real-time transmission slip ratio η is calculated. slip η slip =(1-N driven / N drive ) × 100%, where N drive N is the drive shaft speed. driven The driven shaft speed; Based on the vibration spectrum of the drive unit, the characteristic frequency band energy E specific to belt drive faults is extracted. blet The characteristic frequency band is the harmonic region of the belt's natural frequency; Construct a joint criterion for belt slippage risk, based on the real-time transmission slip rate η. slip The characteristic frequency band energy E continuously exceeds the first threshold T1 blet When the synchronization exceeds the second threshold T2, it is judged as a serious slippage or belt slippage risk; Real-time transmission slip ratio η slip If the risk of belt breakage is continuously exceeded by the higher third threshold T3, it is directly determined as a risk of belt breakage.

2. The workpiece sandblasting method based on intelligent state monitoring according to claim 1, characterized in that, Graded response strategies for belt slippage include: When a risk of belt slippage is identified, a Level 1 alarm is generated; The load reduction protection strategy is implemented synchronously. The load reduction protection strategy is to reduce the operating speed of the transverse screw conveyor or the longitudinal screw conveyor and increase the working power of the shot blaster to maintain the sandblasting intensity. When a serious risk of slippage or belt breakage is detected, a Level 2 emergency alarm is generated. The orderly shutdown strategy is executed synchronously. The orderly shutdown strategy is as follows: stop the shot blaster feeding, stop the shot blaster after a first preset time delay, stop the bucket elevator after a second preset time delay, and finally stop the screw conveyor.

3. The workpiece sandblasting method based on intelligent state monitoring according to claim 1, characterized in that, Methods for predicting belt health trends based on historical data include: Continuously record real-time transmission slip ratio η slip With characteristic frequency band energy E blet Historical data sequences; Based on historical data sequences, a regression algorithm is used to fit the trend curve of transmission slip ratio as a function of working time t. The trend curve indicates the transmission slip ratio η slip The predicted value will exceed the maintenance threshold T within a predetermined time period ΔT in the future. m Generate predictive maintenance alerts at that time; Predictive maintenance alerts include a faulty component identifier "drive belt", a maintenance recommendation "tension or replace", and a recommended maintenance time window calculated based on a trend curve.

4. The workpiece sandblasting method based on intelligent state monitoring according to claim 1, characterized in that, The method of dynamically extracting and fusing operational data through the control unit also includes: Based on three-phase current and voltage data, the real-time active power P of the drive motor is calculated. motor and the effective value of current I rms And construct multi-source data fusion criteria; Real-time transmission slip ratio η slip The increase, and the real-time active power P motor With the effective value of current I rms When the load intensity increases synchronously, the output judgment conclusion is "the conveying system is overloaded or blocked". Real-time transmission slip ratio η slip Increased, but real-time active power P motor With the effective value of current I rms If the output does not rise synchronously or even decreases, the judgment conclusion is "the drive belt is slipping or aging". Real-time active power P motor The volatility exceeds a preset threshold, and the characteristic frequency band vibration energy E blet When an abnormality occurs, the output judgment conclusion is "the mechanical connection of the drive unit is loose or the bearing is short of oil".

5. A batch sandblasting system for workpieces based on intelligent status monitoring, characterized in that, include: The acquisition module is used to acquire the operating data of the drive units of the transverse screw conveyor and the longitudinal screw conveyor, as well as the three-phase current and voltage data of the drive motor; A memory for storing a program for controlling the workpiece sandblasting method as described in any one of claims 1 to 4; The processor and the program in the memory can be loaded and executed by the processor to implement the control method of the workpiece sandblasting method as described in any one of claims 1 to 4.

6. A smart terminal, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed according to any one of claims 1 to 4.

7. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and executed according to any one of claims 1 to 4.

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