Pelletizing disc large ball automatic processing device and method based on visual guidance

Abstract

The invention discloses a pelletizing disc large ball automatic processing device and method based on visual guidance, and belongs to the technical field of pellet production. Comprising a fixed base, a rotating device, a lifting positioning device, a fishing and crushing assembly, a visual monitoring system and an electrical control system. Wherein the lifting positioning device is provided with a counterweight mechanism which is used for balancing the eccentric torque of the executing mechanism and improving the operation stability; and the rotation range of the rotation device covers an operation area and a non-operation area, so that foreign matters which cannot be crushed can be thoroughly removed. According to the invention, the image of the pelletizing disc is analyzed in real time through the visual monitoring system so as to identify and position a large ball, and then the electrical control system drives the rotating device and the lifting positioning device to move the fishing and crushing assembly to a target position for automatic fishing and crushing. The problems that in the prior art, large ball fishing equipment is unstable in operation, and foreign matter cannot be thoroughly removed are solved, full automation and intellectualization of the operation process are achieved, and production efficiency and safety are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of pellet production, and particularly relates to a visual guidance-based automatic large ball processing device for a balling disc and an automatic processing method thereof. BACKGROUND

[0002] Pellet production is an important link in the steel and iron metallurgical industry, and balling is a key process. In the rotation process of the balling disc, fine ground material rolls into balls under the action of water and mechanical force. However, due to fluctuations in material properties, uneven water control, or equipment operation, etc., it is inevitable that large-diameter balls, i.e., "large balls", will be produced in the balling disc.

[0003] The existence of these large balls will cause a series of negative impacts on production: first, their larger mass will damage qualified green balls through rolling, reducing the balling rate; second, they will block the normal discharge path of qualified green balls, affecting production efficiency and load; finally, in order to handle these large balls, manual intervention is often required, which is labor-intensive and poses a serious safety hazard when working near high-speed rotating equipment.

[0004] To solve this problem, some automatic ball fishing devices have appeared in the prior art. However, these devices generally have defects: one type of device only fishes without breaking, or only breaks without taking out, and cannot completely remove large balls or mixed foreign objects (such as stone blocks, refractory material falling blocks) from the production system. The broken return material also interferes with the water balance in the balling disc, affecting the balling quality. Another type of device that can achieve fishing, breaking, and taking out often has mechanical design defects, and is unstable in operation when facing harsh working conditions with large dust and fluctuating material surface height, and cannot meet the requirements of continuous production. In addition, the automation and intelligence levels of existing devices are generally low, and they mostly use open-loop control methods such as fixed-time or fixed-point fishing, which cannot dynamically adjust the operation strategy according to the actual situation of large balls in the disc, and the processing efficiency and effect need to be improved.

[0005] Therefore, it is a technical problem to be solved in the field to develop an automatic large ball fishing device that can intelligently identify, stably operate, efficiently process, and completely remove foreign objects. SUMMARY

[0006] The present application aims to solve the above-mentioned problems in the prior art and provides a visual guidance-based automatic large ball processing device for a balling disc and a method thereof, to solve the problems of single function, unstable operation, inability to completely remove foreign objects, and low automation and intelligence level of existing large ball fishing devices.

[0007] Technical solution: A kind of based on visual guidance's automatic processing device of big ball of pelletizing disc, comprising: a fixed base;Rotary device, rotatably installed on the fixed base, and the rotary range covers the work area located above pelletizing disc and the non-work area located outside pelletizing disc;Lifting positioning device, one end is connected with the rotary device, the lifting positioning device has lifting arm moving along vertical direction, and including counterweight mechanism connected with the lifting arm;A broken assembly is fished, is installed at the other end of the lifting positioning device;Visual monitoring system, including camera and industrial control unit, the camera is installed on the fixed base, and field of view covers pelletizing disc;Electrical control system, electrically connected with the visual monitoring system, rotary device, lifting positioning device and broken assembly fished, for receiving the image analysis result of the visual monitoring system and outputting control signal, respectively control the action of the rotary device, lifting positioning device and the broken assembly fished.

[0008] The principle of the scheme is: by combining rotary device, lifting positioning device with counterweight mechanism, broken assembly fished, visual monitoring system and electrical control system, a complete automatic closed-loop operation system capable of realizing "visual identification-three-dimensional positioning-fishing broken" is constructed, which provides a solid hardware platform foundation for realizing unmanned and intelligent operation of big ball processing of pelletizing disc, and solves the problems of high labor intensity and high risk.

[0009] Further, the camera is a high-definition barrel camera, and the industrial control unit is configured with visual identification management software, which allows input or issuance of ball diameter threshold, quantity threshold and fishing time interval. Thus, flexible and accurate visual identification and process parameter configuration capabilities are provided.

[0010] Further, the broken assembly fished includes: fixed support, rotary drive, rotary shaft, fixed tooth, rotary tooth;The fixed tooth and rotary tooth are respectively arranged in at least one column transversely, and are staggered with each other to form a broken channel in the working interval of the fixed support;The fixed tooth is fixedly arranged on the fixed support, the rotary tooth is arranged with a ball hooking portion at the end portion, the rotary shaft is installed on the fixed support, and the rotary shaft is driven to rotate by the rotary drive.

[0011] Further, the fixed tooth and rotary tooth form a pincer type broken channel in space, the minimum gap of the broken channel is smaller than the characteristic size of the big ball corresponding to the target diameter threshold, and the rotary tooth moves in the tangential direction of the pelletizing disc pellet when working. Thus, the efficiency and effect of the broken operation are further optimized.

[0012] Further, the rotating device comprises a rotating support, a rotating column and a rotating drive, the rotating support is installed on the fixed base and rotates relative to the fixed base, the rotating column connects the rotating support and the lifting positioning device, so that the salvaging and crushing assembly can be switched between the working area and the non-working area.

[0013] Further, the rotating teeth and the fixed teeth are made of high-strength wear-resistant steel material after quenching treatment, so as to ensure the durability and reliability of the core working components.

[0014] The application also relates to a visual guidance-based automatic processing method for large balls of a balling disc, which is applied to the device and comprises the following steps: S1, a visual detection step: continuously collecting balling disc images through a visual monitoring system and analyzing the images to determine whether large balls exist; S2, a work execution step: if it is determined that large balls exist, sequentially performing the following steps: S2.1, determining the planar position coordinates and target height of the large balls to be crushed based on the image analysis result of the visual monitoring system; S2.2, controlling the rotating device and the lifting positioning device to move a salvaging and crushing assembly from a standby area to a target positioning area; S2.3, starting the salvaging and crushing assembly to perform a crushing operation; S3, a normal end step: after the crushing operation reaches a preset time length, sequentially performing the following steps: S3.1, controlling the lifting positioning device to lift the salvaging and crushing assembly; S3.2, stopping the work of the salvaging and crushing assembly; S3.3, controlling the rotating device to rotate the salvaging and crushing assembly back to the standby area and returning to step S1.

[0015] Further, during the crushing operation in step S2.3, an abnormal processing step is further included: real-time monitoring the motor running state of the salvaging and crushing assembly, and when an overload alarm is detected, interrupting the normal crushing operation and performing the following steps: controlling the lifting positioning device to lift the salvaging and crushing assembly and stopping the work thereof; controlling the rotating device to rotate the salvaging and crushing assembly to a maintenance area; controlling the salvaging and crushing assembly to reversely rotate at a low speed to perform a foreign matter removing action; controlling the salvaging and crushing assembly to positively rotate at a low speed and detecting whether an overload alarm exists, if the overload alarm is removed, returning to step S2.2, and if the overload alarm continues, sending an alarm signal requesting manual processing.

[0016] Further, the analysis in step S1 further comprises counting the number and / or size distribution of the large balls, and dynamically adjusting the starting frequency or operation time length of the crushing operation according to the statistical result.

[0017] Beneficial Effects: Compared with existing technologies, the beneficial effects of this invention are as follows: 1. By automatically identifying large balls through a visual monitoring system and combining it with an electrical control system, the entire process is automated, requiring no manual intervention, significantly reducing labor intensity and eliminating safety hazards. 2. It possesses intelligent fault handling capabilities for motor overload, automatically attempting to remove foreign objects and resume operation, greatly reducing downtime caused by equipment jams. The rotary device can transfer the entire assembly to the maintenance area, greatly facilitating daily maintenance and foreign object handling. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the installation position of the present invention; Figure 2 This is a three-dimensional structural diagram of the present invention; Figure 3 This is a schematic diagram of the rotary device. Figure 4 This is a schematic diagram of the lifting and positioning device. Figure 5 A schematic diagram of the crushing assembly structure is provided for retrieval. Figure 6 This is a flowchart of an automated method for handling large balls. Detailed Implementation

[0019] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. These embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0020] This embodiment provides a vision-guided automated ball-forming disc processing device for large balls, such as... Figure 1 As shown, the device 100 is installed on the pelletizing platform 101 and is used for the automated processing of large pellets in the pelletizing tray 102. The device is as follows... Figure 2 As shown, it includes: a fixed base 1, a rotary device 2, a lifting and positioning device 3, a retrieval and crushing assembly 4, a vision monitoring system 5, and an electrical control system.

[0021] The fixed base 1 is installed on the ball-making platform 101 to provide stable support for the entire device.

[0022] The rotating device 2 is rotatably mounted on the fixed base 1. Specifically, as follows... Figure 3As shown, it comprises a slewing support 11, a slewing column 12 and a slewing drive 13 (such as an electric cylinder or a motor). The slewing support 11 is installed on the fixed base 1 and rotates relative to the fixed base 1, and the slewing column 12 connects the slewing support 11 and the lifting positioning device 3. Under the action of the slewing drive 13, the entire upper structure (the lifting positioning device 3 and the salvaging and crushing assembly 4) can rotate in the horizontal plane. The slewing range covers at least the working area above the balling disc 102 and the non-working area outside the balling disc. The non-working area can be used as a standby area or a maintenance area of the device.

[0023] The lifting positioning device 3 is used to realize the accurate positioning of the salvaging and crushing assembly 4 in three-dimensional space. As shown, Figure 4 one end thereof is connected with the slewing device 2, and the other end thereof is installed with the salvaging and crushing assembly 4. The device has a lifting arm 31 that can move vertically, and the extension and retraction of the salvaging and crushing assembly 4 are realized through a driving mechanism 32 such as an electric cylinder. One key design of the present embodiment is that the lifting positioning device 3 further comprises a counterweight mechanism 33. The weight and position of the counterweight mechanism 33 are calculated mechanically, and are used to balance the eccentric moment generated when the lifting arm and the salvaging and crushing assembly 4 are extended, to ensure the stability of the device during lifting and slewing, and to effectively resist the impact from the material in the balling disc, which is one of the core structures to ensure the stable operation of the device. Specifically, the counterweight mechanism 33 comprises a counterweight body 33a, a roller 33b and a cable 33c. The roller 33b is installed on the slewing column 12 through an ear seat, one end of the cable 33c is fixedly connected with the lifting arm 31, the middle part thereof is wound around the roller 33b, and the other end thereof lifts the counterweight body 33a.

[0024] The salvaging and crushing assembly 4 is the core component for performing the final task. As shown, Figure 5 it mainly comprises a fixed support 41, a rotary drive 42 (such as a variable frequency reduction motor), a rotary shaft 43, a fixed tooth 44 and a rotary tooth 45. The fixed tooth 44 and the rotary tooth 45 are the keys to realize salvaging and crushing. They are both made of high-strength wear-resistant steel (such as 45# steel) and are subjected to surface quenching treatment, so as to cope with high-strength impact and wear. The fixed tooth 44 is fixedly arranged on the fixed support 41, the rotary tooth 45 has a ball hooking portion 46 arranged at the end portion thereof and is penetrated through the rotary shaft 43 arranged in the middle part thereof, and the rotary shaft 43 is installed on the fixed support 41 and is driven to rotate by the rotary drive 42. The fixed tooth 44 and the rotary tooth 45 are both arranged in a row in the transverse direction and are staggered with each other in working state, so as to form a broken channel in the form of a fence or a clamp. The minimum gap of the broken channel is designed to be smaller than the minimum size of the large ball to be processed, so as to ensure that the large ball can be effectively crushed. When the rotary tooth 45 rotates, the ball hooking portion 46 can effectively hook the large ball from the material layer and bring it into the broken channel. In order to achieve the best salvaging effect, the linear speed direction of the rotary tooth in working state is set to move along the tangential direction of the balling disc, so as to form a working mode of salvaging along the direction of the ball rolling.

[0025] The visual monitoring system 5 includes a camera (preferably a high-definition bullet camera capable of clear imaging in dusty or water-mist environments) and an industrial control unit, both mounted on or near the fixed base 1. The camera's field of view completely covers the critical area of ​​the pelletizing tray 102. The industrial control unit is equipped with visual recognition management software. This software, based on image processing algorithms (such as edge detection and deep learning models), can analyze images captured by the camera in real time, accurately identify the outline of large pellets, calculate their actual diameter, and locate their position coordinates on the two-dimensional plane of the pelletizing tray. Operators can flexibly input or remotely issue key process parameters through the software's human-machine interface, such as the pellet diameter threshold (a pellet larger than this value is considered a large pellet), the quantity threshold (the operation is triggered only when the number of large pellets in the tray reaches this value), and the retrieval time interval, to adapt to different production needs.

[0026] The electrical control system uses a PLC (Programmable Logic Controller) as its core. It is electrically connected to all drive components of the vision monitoring system 5, the rotary device 2, the lifting and positioning device 3, and the retrieval and crushing assembly 4. It receives image analysis results (such as "large ball detected, coordinates (X, Y)") from the industrial control unit of the vision monitoring system 5, and outputs precise control signals according to the preset control logic to command each mechanical component to coordinate its actions according to a predetermined sequence, completing the entire automated operation process.

[0027] The present invention also provides a corresponding automated processing method, such as... Figure 6 As shown, the specific steps of this method are as follows: S1: Visual Inspection Step: After system startup, the visual monitoring system 5 continuously captures real-time images of the pelletizing disc. The industrial control unit analyzes the images to determine if there are large balls with a diameter exceeding a preset threshold. This step may further include statistically analyzing the number and size distribution of large balls. Based on the statistical results, the electrical control system can dynamically adjust the start frequency or single operation duration of subsequent crushing operations. For example, if the number of large balls surges in a short period, the retrieval interval can be shortened, increasing the operation frequency.

[0028] S2: Job execution steps: Once it is determined that there is a large ball that needs to be processed, the system starts the job.

[0029] S2.1 Positioning: The electrical control system calculates the target three-dimensional spatial position that the retrieval and crushing assembly 4 needs to reach, based on the planar position coordinates (X, Y) of the target ball given by the industrial control unit and in combination with the preset or measured material surface height by the sensor.

[0030] S2.2 Movement: Control the rotation device 2 and the lifting and positioning device 3 to move the scooping and crushing assembly 4 quickly and smoothly from the non-operation area (standby area) to the target positioning area above the pelletizing plate.

[0031] S2.3 Breaking: Start the rotating drive of the fishing and breaking assembly 4, and the rotating teeth start to rotate to fish up the large ball and break it with the fixed teeth.

[0032] S3: Normal end step: When the breaking operation reaches the preset time length, the system considers that the task is completed.

[0033] S3.1 Lifting: Control the lifting positioning device 3 to lift the fishing and breaking assembly 4 away from the material surface.

[0034] S3.2 Stopping: Stop the rotation of the fishing and breaking assembly 4.

[0035] S3.3 Returning: Control the rotating device 2 to rotate the fishing and breaking assembly 4 back to the standby area, complete a working cycle, and return to execute step S1 to continue monitoring the task.

[0036] In particular, the method of the present application also includes an intelligent abnormal processing process, which is run in real time during the breaking operation in step S2.3: The system will monitor the motor current or torque of the fishing and breaking assembly 4 in real time. When a hard foreign object such as an iron block causes a jam, the motor will have an overload alarm. At this time, the system will interrupt the normal breaking operation and automatically execute the following fault self-recovery sequence: Safety avoidance: Immediately control the lifting positioning device 3 to lift the fishing and breaking assembly 4 and stop its operation, and then control the rotating device 2 to rotate it to a safe maintenance area (equivalent to a non-operation area in this embodiment).

[0037] Obstacle removal attempt: Control the fishing and breaking assembly 4 to rotate in reverse at low speed. This action aims to use the reverse force to "spit out" the stuck foreign object.

[0038] State verification: After reversing, control the fishing and breaking assembly 4 to rotate forward at low speed, and detect whether the motor still has an overload alarm.

[0039] Decision judgment: If the overload alarm is removed, the system determines that the fault has been eliminated, and will automatically return to execute step S2.2 to reattempt operation on the next target. If the overload alarm persists, the system determines that it is a serious fault that cannot be solved automatically, at which time an audible and visual alarm signal will be issued to request manual intervention.

[0040] This abnormal processing process greatly improves the automation level and operation reliability of the equipment.

[0041] The above merely provides the preferred embodiments of the present application, and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modifications, equivalent replacements, improvements, etc. made within the principles and technical scope of the present application shall fall into the scope of the present application.

Claims

1. A vision-guided automated ball-forming disc processing device for large balls, characterized in that, include: A fixed base; A rotary device is rotatably mounted on the fixed base, and its rotation range covers the working area above the pelletizing tray and the non-working area outside the pelletizing tray. A lifting and positioning device, one end of which is connected to the rotary device, the lifting and positioning device having a lifting arm that moves vertically, and including a counterweight mechanism connected to the lifting arm; A crushing assembly is retrieved and installed at the other end of the lifting and positioning device; A visual monitoring system includes a camera and an industrial control unit. The camera is mounted on the fixed base and its field of view covers the sphere-forming disk. An electrical control system is electrically connected to the visual monitoring system, the rotary device, the lifting and positioning device, and the retrieval and crushing assembly. It is used to receive the image analysis results of the visual monitoring system and output control signals to control the actions of the rotary device, the lifting and positioning device, and the retrieval and crushing assembly, respectively.

2. The apparatus according to claim 1, characterized in that, The camera is a high-definition bullet camera, and the industrial control unit is equipped with visual recognition management software, which allows input or output of pellet diameter thresholds, quantity thresholds, and retrieval time intervals.

3. The apparatus according to claim 1, characterized in that, The retrieval and crushing assembly includes: a fixed support, a rotary drive, a rotary shaft, fixed teeth, and rotary teeth; the fixed teeth and rotary teeth are arranged in at least one row in a transverse manner, and intersect each other to form a crushing channel within the working area of ​​the fixed support; the fixed teeth are fixed on the fixed support, the rotary teeth have the rotary shaft passing through their middle and hook ball parts at their ends, the rotary shaft is mounted on the fixed support and is driven to rotate by the rotary drive.

4. The apparatus according to claim 3, characterized in that, The fixed teeth and the rotating teeth form a clamp-type crushing channel in space. The minimum gap of the crushing channel is smaller than the characteristic size of the large ball corresponding to the target diameter threshold, and the rotating teeth move along the tangential direction of the pellets in the pelletizing disc during operation.

5. The apparatus according to claim 1, characterized in that, The rotary device includes a rotary support, a rotary column, and a rotary drive. The rotary support is mounted on the fixed base and rotates relative to the fixed base. The rotary column connects the rotary support and the lifting and positioning device, so that the retrieval and crushing assembly can switch between the working area and the non-working area.

6. The apparatus according to claim 4, characterized in that, The rotating teeth and the fixed teeth are made of high-strength, wear-resistant steel that has been hardened.

7. A vision-guided automated method for processing large balls in a ball-forming disc, applied to the apparatus described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Visual inspection step: Continuously collect and analyze images of the ball-forming tray using a visual monitoring system to determine whether large balls are present; S2: Job execution steps: If a large ball is determined to exist, then execute the following steps in sequence: S2.1 Based on the image analysis results of the visual monitoring system, determine the planar position coordinates and target height of the large ball to be broken; S2.2 Control the rotary device and the lifting and positioning device to move a retrieval and crushing assembly from the standby area to the target positioning area; S2.3 Start the retrieval and crushing assembly to perform the crushing operation; S3: Normal termination procedure: After the crushing operation reaches the preset time, the following steps are executed sequentially: S3.1 Control the lifting and positioning device to raise the retrieval and crushing assembly; S3.2 Stop the operation of retrieving the crushed assembly; S3.3 Control the rotary device to rotate the retrieval and crushing assembly back to the standby area and return to the execution step S1.

8. The method according to claim 7, characterized in that, The crushing operation in step S2.3 also includes an abnormal handling step: real-time monitoring of the motor operating status of the retrieval and crushing assembly, and interrupting the normal crushing operation when an overload alarm is detected, and executing: Control the lifting and positioning device to raise the retrieval and crushing assembly and stop its operation; The rotary device is controlled to rotate the retrieval and crushing assembly to a maintenance area; The retrieval and crushing assembly is controlled to rotate in reverse at a low speed to perform the action of removing foreign objects; Control the low-speed forward rotation of the scooping and crushing assembly and detect if there is an overload alarm. If the overload alarm is cleared, return to step S2.

2. If the overload alarm continues, issue an alarm signal requesting manual handling.

9. The method according to claim 7, characterized in that, The analysis in step S1 also includes statistically analyzing the number and / or size distribution of large balls, and dynamically adjusting the start frequency or duration of the crushing operation based on the statistical results.

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