Automatic control method and control system for concrete mixing plant

Abstract

The invention relates to an automatic control method and system for a concrete mixing plant, and belongs to the technical field of concrete production control, and the method comprises the steps: collecting the operation state data of key equipment in a mixing plant production line in real time; inputting the operation state data into a preset equipment health prediction model to generate predictive maintenance information for the key equipment; when the early warning key equipment meets the condition that the corresponding predictive maintenance information meets a preset early warning condition, a production scheduling plan is dynamically adjusted based on the predicted fault time point corresponding to the early warning key equipment, and a planned maintenance window before the corresponding predicted fault time point is planned for the early warning key equipment; the maintenance personnel are reminded to maintain the early warning key equipment during the planned maintenance window; wherein in the planned maintenance window, other parts except the early warning key equipment normally operate on the production line of the mixing plant. The device has the effect of improving the production efficiency under the abnormal condition of the stirring station equipment.

Description

Technical Field

[0001] This application relates to the field of concrete production control technology, and in particular to an automatic control method and control system for a concrete mixing plant. Background Technology

[0002] The production process of a concrete mixing plant typically includes a series of sequential steps such as batching, weighing, conveying, and mixing. Currently, most mixing plants use a centralized, serial control system. The equipment in each process (such as batching scales, conveyor belts, powder scales, and mixing hosts) is tightly coupled to form a rigid production chain. This means that dry materials (such as sunflower seed shells, manufactured sand, coarse sand, and gravel) are weighed and batched; powder materials (such as mineral powder and fly ash) are weighed; additives and water are added and weighed again; then, the weighed batching materials are fed into the mixing host using a conveyor belt; and then the mixing host is started to mix the dry materials, batching materials, water, and additives. After a preset mixing time, the material can be discharged, thus realizing the mixing process.

[0003] However, the traditional control model has a significant drawback: when any equipment in any stage of the production line (such as weighing equipment) malfunctions, in order to avoid producing defective products, prevent equipment damage, or ensure safety, the entire mixing process is usually shut down immediately, and then restarted after the faulty equipment is repaired. This approach directly leads to low production efficiency and therefore needs to be improved. Summary of the Invention

[0004] To address the problem of low production efficiency under abnormal conditions of batching plant equipment, this application provides an automatic control method and control system for concrete batching plants.

[0005] Firstly, this application provides an automatic control method for a concrete mixing plant, employing the following technical solution: Real-time acquisition of operating status data of key equipment in the mixing plant production line; The operating status data is input into a preset equipment health prediction model to generate predictive maintenance information for the key equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability; When a critical device for early warning meets the following conditions: the corresponding predictive maintenance information meets the preset early warning conditions, the production schedule is dynamically adjusted based on the expected failure time point corresponding to the critical device for early warning. A planned maintenance window is planned for the critical device for early warning before the corresponding expected failure time point, reminding maintenance personnel to perform maintenance on the critical device for early warning during the planned maintenance window; wherein the following conditions are met: the mixing plant production line and other parts except the critical device for early warning operate normally within the planned maintenance window.

[0006] By adopting the above technical solution, the operating status of key equipment is monitored in real time, and its health status and development trend are judged using an equipment health prediction model. When a failure risk is predicted, the production schedule is proactively and intelligently adjusted, and preventive measures are arranged for potentially faulty equipment (i.e., critical equipment with early warning). These preventive measures include at least scheduling planned maintenance windows (i.e., maintenance periods) for critical equipment with early warning. This effectively solves the drawback of low production efficiency caused by complete shutdowns for maintenance, achieving uninterrupted or minimized production interruptions. It realizes a fundamental shift from "post-failure response" to "pre-failure early warning and planning," transforming unplanned shutdowns into planned shutdowns, significantly improving the reliability of production planning and the proactivity of equipment management.

[0007] Optionally, the dynamic adjustment of the production scheduling plan, which plans a scheduled maintenance window for the critical equipment under early warning before the corresponding expected failure time, includes: Identify all idle periods of the critical early warning equipment prior to the early warning failure time point; If there is a target idle period with a duration not less than the estimated maintenance time, then the target idle period is determined as the planned maintenance window; If the target idle period does not exist, the production schedule is adjusted, and a backup device is selected from all preset backup devices to replace the warning critical device in performing the work tasks of the warning critical device in the mixing plant production line, so as to adjust the idle period of the warning critical device and make the target idle period exist in the adjusted idle period.

[0008] By adopting the above technical solution, a deterministic scheduling method is provided, progressing from simple to complex and from partial to overall. It prioritizes exploring the idle potential of existing equipment and utilizes the flexible approach of backup equipment to create planned maintenance windows that meet requirements, minimizing disruption to the overall production plan. The scheduling logic is clear and efficient.

[0009] Optionally, if the target idle period does not exist, the production schedule is adjusted by selecting a backup device from all preset backup devices to replace the critical warning device in performing its work tasks on the mixing plant production line, thereby adjusting the idle period of the critical warning device and ensuring that the target idle period exists within the adjusted idle period. This includes: If the target idle period does not exist, the longest idle period is selected, and the adjustable periods adjacent to the longest idle period are determined in order from nearest to farthest, until the total duration of the longest idle period and all the determined adjustable periods is not less than the estimated maintenance time. From all the preset backup devices, match backup devices for the adjustable time periods; determine whether a corresponding backup device has been matched for all adjustable time periods; If so, the successfully matched backup device will replace the critical early warning device in performing its work tasks during the corresponding adjustable time period; the adjustable time period of the matched backup device will be used as the idle time period of the critical early warning device, and the idle time period of the critical early warning device will be updated so that the idle time period of the critical early warning device contains a target idle time period; wherein, the same backup device can be successfully matched with multiple adjustable time periods; If not, the preset chain advance plan is executed, and the execution time of the work tasks in the mixing plant production line that have a time-series dependency relationship with the work tasks performed by the early warning key equipment is adjusted together to free up supplementary time periods. This allows the supplementary time periods to be spliced ​​together with the already determined idle time periods and the successfully matched adjustable time periods of the early warning key equipment to form the planned maintenance window with a total duration not less than the estimated maintenance time.

[0010] By adopting the above technical solution, this application provides one mode of replacement execution (distributed replacement: the same backup device can be successfully matched with multiple adjustable time periods), which enhances the flexibility of resource scheduling. The control system can select the optimal replacement strategy according to the idle status and capacity of the backup device to improve the utilization rate of the backup device and the feasibility of the replacement scheme. When it is impossible to make up the maintenance window through backup device replacement, the necessary maintenance time for the critical equipment is freed up by determining and adjusting the execution time of the task chain in a way that minimizes the impact scope, so that: maintenance time + successfully matched adjustable time periods + existing idle time periods ≥ estimated maintenance time.

[0011] Optionally, matching a backup device from all the preset backup devices for the adjustable time period includes: The available time slots are matched sequentially according to the order of proximity to the longest available time slot. If an available time slot cannot be matched, the matching process is stopped. The pre-defined chain-like advance plan adjusts the execution time of tasks in the mixing plant production line that have a time-dependent relationship with the tasks performed by the critical early warning equipment, in order to free up supplementary time periods, including: All adjustable time periods that have been successfully matched with backup equipment are spliced ​​together with the longest idle time period to form a core maintenance segment. The adjustable time periods that fail to match are defined as boundary unmatched segments. The boundary unmatched segments are adjacent to the core maintenance segment and located at one end of the core maintenance segment. The work tasks required by the early warning device in the boundary mismatch section, and all work tasks in the mixing plant production line that have a temporal dependency relationship with the work tasks in the boundary mismatch section, constitute a process task chain. The time period for executing all work tasks corresponding to the process task chain is shifted away from the core maintenance section to free up a supplementary time period that is adjacent to and continuous with the core maintenance section. The duration of the time period formed by splicing the supplementary time period and the core maintenance section is not less than the estimated maintenance time.

[0012] By adopting the above technical solution and using the concept of a "core maintenance segment," it is ensured that the successful matching results in the early stage will not be destroyed by subsequent adjustments, avoiding repeated optimization processes and resource waste. The complex global scheduling problem is simplified into a local translation problem for a single "unmatched boundary segment," which greatly reduces the computational complexity and decision-making difficulty of the algorithm. The "one-way translation" strategy has clear logic and reliable execution, perfectly solving the core contradiction caused by the interweaving of unmatched and matched time periods, and ensuring that feasible maintenance window solutions can be generated under various complex conditions.

[0013] Optionally, the sequential matching of adjustable time periods with backup time periods includes: The system sequentially matches the adjustable time period with the backup time period. During the matching process, if multiple backup devices can be successfully matched with the same adjustable time period, the system calculates the stability evaluation coefficient of each backup device based on its historical fault data. The system prioritizes the backup device with the higher stability evaluation coefficient to achieve the matching with the adjustable time period, and reduces the calling frequency of backup devices with stability evaluation coefficients lower than the preset threshold. This ensures that the time interval between two consecutive activations of backup devices with stability evaluation coefficients lower than the preset threshold is not less than the preset value.

[0014] By adopting the above technical solution, an intelligent decision-making layer based on equipment reliability is introduced. This not only optimizes the quality of a single scheduling (selecting more reliable equipment), but also avoids overuse and accelerated degradation of weak links from the perspective of long-term system operation. It achieves synergy between preventive maintenance and production resource optimization, thereby improving the overall robustness and sustainability of the system.

[0015] Optionally, the method further includes: Whenever the current time falls within the planned maintenance window of any critical early warning device, maintenance feedback information from maintenance personnel regarding the critical early warning device is obtained, wherein the maintenance feedback information includes at least the actual maintenance time. Regularly collect maintenance feedback information for each critical early warning device, and adjust and update the specific values ​​of the estimated maintenance time for the critical early warning device based on the actual maintenance time collected.

[0016] By adopting the above technical solutions and driven by historical data, the system can continuously learn and correct itself, making the estimated maintenance time infinitely close to the actual value, thus solving the inaccuracy problem caused by relying on fixed experience values. More accurate estimated time means that the planned maintenance window is neither too short (leading to incomplete maintenance or rushed work) nor too long (resulting in wasted valuable production time), thereby significantly improving the reliability and success rate of production scheduling. By optimizing the maintenance window duration, unplanned production interruptions or equipment waiting time caused by inaccurate estimates are reduced, thereby improving equipment utilization and overall production efficiency, and reducing overall operating costs.

[0017] Optionally, the maintenance feedback information may also include early warnings of critical equipment malfunctions and corresponding maintenance solutions for resolving those malfunctions; The method further includes: The system receives a maintenance plan retrieval command from maintenance personnel, retrieves and displays maintenance feedback information from historical storage that matches the warning key equipment and fault problems included in the maintenance plan retrieval command, and displays the corresponding maintenance plan for maintenance personnel to refer to.

[0018] By adopting the above technical solutions and using historical maintenance plans as a reference for maintenance personnel, maintenance personnel can improve their maintenance efficiency.

[0019] Secondly, this application provides an automatic control system for a concrete mixing plant, which adopts the following technical solution: The equipment operation status monitoring module is used to collect real-time operation status data of key equipment in the mixing plant production line; The equipment health prediction and maintenance module is used to input the operating status data into a preset equipment health prediction model to generate predictive maintenance information for the key equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability; The early warning equipment maintenance execution module is used to dynamically adjust the production schedule based on the expected failure time point corresponding to the early warning key equipment when the corresponding predictive maintenance information meets the preset early warning conditions. It plans a scheduled maintenance window for the early warning key equipment before the corresponding expected failure time point, and reminds maintenance personnel to maintain the early warning key equipment during the scheduled maintenance window. The module is configured to ensure that the equipment operates normally on the mixing plant production line, except for the early warning key equipment, within the scheduled maintenance window.

[0020] Thirdly, this application provides an automatic control device for a concrete mixing plant, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any of the first aspects.

[0021] Fourthly, this application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and execute the method described in any of the first aspects.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. In this application, by real-time monitoring of the operating status of key equipment, a health prediction model is used to determine its health status and development trend. When a failure risk is predicted, the production schedule is proactively and intelligently adjusted, and preventive measures are arranged for potentially faulty equipment (i.e., early warning key equipment). These preventive measures include at least scheduling planned maintenance windows (i.e., maintenance periods) for the early warning key equipment. This effectively solves the drawback of low production efficiency caused by complete shutdowns for maintenance, achieving uninterrupted or minimized production interruptions. It realizes a fundamental shift from "post-failure response" to "pre-failure early warning and planning," transforming unplanned shutdowns into planned shutdowns, significantly improving the reliability of production planning and the proactiveness of equipment management. 2. Furthermore, this application provides a deterministic scheduling method that progresses from simple to complex and from partial to overall. It prioritizes exploring the idle potential of equipment and uses the flexible means of backup equipment to create planned maintenance windows that meet the requirements, minimizing disruption to the overall production plan, and achieving clear and efficient scheduling logic. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a flowchart illustrating an automatic control method for a concrete mixing plant disclosed in an embodiment of this application.

[0025] Figure 2 This is a structural block diagram of an automatic control system for a concrete mixing plant disclosed in an embodiment of this application.

[0026] Explanation of reference numerals in the attached diagram: 201, Equipment operation status monitoring module; 202, Equipment health prediction and maintenance module; 203, Early warning equipment maintenance execution module. Detailed Implementation

[0027] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0028] This application discloses an automatic control method for a concrete batching plant (hereinafter referred to as the automatic control method), the execution subject of which is the automatic control system of the concrete batching plant (hereinafter referred to as the automatic control system). The following will refer to... Figure 1 This section details the specific steps and procedures by which an automatic control system executes its automatic control methods.

[0029] S101, real-time acquisition of operating status data of key equipment in the mixing plant production line; S102, input the operating status data into the preset equipment health prediction model to generate predictive maintenance information for key equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability; S103, when a critical device for early warning meets the following conditions: the corresponding predictive maintenance information meets the preset early warning conditions, the production schedule is dynamically adjusted based on the expected failure time point corresponding to the critical device for early warning, and a planned maintenance window is planned for the critical device for early warning before the corresponding expected failure time point, reminding maintenance personnel to maintain the critical device for early warning during the planned maintenance window; wherein the following conditions are met: normal operation is maintained within the planned maintenance window, on the mixing plant production line, and in other parts except for the critical device for early warning.

[0030] Specifically, S103's "dynamically adjusting the production schedule to plan a maintenance window for critical equipment before the corresponding expected failure time" includes the following steps: S1031, Identify all idle periods of critical equipment before the warning failure time point; S1032, If there is a target idle period with a duration not less than the estimated maintenance time, then the target idle period is determined as the planned maintenance window; S1033, if there is no target idle period, select the longest idle period and determine the adjustable periods adjacent to the longest idle period in order from nearest to farthest, until the total duration of the longest idle period and all determined adjustable periods is not less than the estimated maintenance time. S1034, Match backup devices for adjustable time periods from all preset backup devices; Determine whether all adjustable time periods have matched the corresponding backup devices; S1035, if so, the successfully matched backup device will replace the warning key device in performing the work tasks of the warning key device during the corresponding adjustable time period; the adjustable time period of the matched backup device will be used as the idle time period of the warning key device, and the idle time period of the warning key device will be updated so that the idle time period of the warning key device contains the target idle time period; wherein, the same backup device can be successfully matched with multiple adjustable time periods. S1036, if not, then execute the preset chain advance plan, adjust the execution time of the work tasks in the mixing plant production line that have a time sequence dependency with the work tasks performed by the early warning key equipment, so as to free up supplementary time periods. This allows the supplementary time periods to be combined with the already determined idle time periods and the successfully matched adjustable time periods of the early warning key equipment to form a planned maintenance window with a total duration not less than the estimated maintenance time.

[0031] Specifically, S1034, "matching backup equipment from all preset backup equipment for adjustable time periods," includes the following sub-steps: S10341, in order of proximity to the longest idle time period, the adjustable time periods are matched with backup time periods in sequence. During the matching process, if multiple backup devices can be successfully matched with the same adjustable time period, the stability evaluation coefficient of each backup device is calculated based on its historical fault data. The backup device with the higher stability evaluation coefficient is selected first to match the adjustable time period, and the calling frequency of backup devices with stability evaluation coefficients lower than a preset threshold is reduced so that the time interval between two consecutive activations of backup devices with stability evaluation coefficients lower than the preset threshold is not less than a preset value. If an adjustable time period cannot be matched, the matching is stopped.

[0032] S1035's "Execute the preset chain advance plan, and adjust the execution time of the work tasks in the mixing plant production line that have a time dependency relationship with the work tasks performed by the early warning key equipment, so as to free up supplementary time periods" specifically includes the following sub-steps: S10351, All adjustable time periods that have been successfully matched with the backup equipment are spliced ​​together with the longest idle time period to form a core maintenance segment. Adjustable time periods that fail to match are defined as boundary unmatched segments. Boundary unmatched segments are adjacent to the core maintenance segment and located at one end of the core maintenance segment. S10352, the work tasks required by the early warning equipment in the boundary mismatch section, and all work tasks in the mixing plant production line that have a time sequence dependency with the work tasks in the boundary mismatch section, constitute a process task chain. The time period of all work tasks corresponding to the process task chain is translated along the direction away from the core maintenance section to free up a supplementary time period that is adjacent to and continuous with the core maintenance section. The duration of the time period formed by splicing the supplementary time period and the core maintenance section is not less than the estimated maintenance time.

[0033] In implementation, key equipment refers to equipment with a probability of failure during the operation of the mixing plant production line. Specifically, key equipment includes: the mixing host, inclined belt conveyor (i.e., conveyor), powder weighing screw conveyor, water pump, additive pump, air compressor, etc. Physical sensors are pre-installed at specific detection points of the aforementioned key equipment, such as: vibration sensors (installed on the bearing housings of the motor and gearbox to collect vibration acceleration and velocity signals, and monitor mechanical imbalance, misalignment, bearing wear, etc.), temperature sensors (installed on the motor windings, bearing housings, and hydraulic system to monitor overheating), current / power sensors (integrated in the motor driver to collect three-phase current signals and monitor electrical and mechanical faults such as load changes, broken bars, and eccentricity through current spectrum analysis), and pressure sensors (used to monitor the hydraulic and pneumatic pressures of the hydraulic and pneumatic systems).

[0034] The analog signals collected by the aforementioned physical sensors are converted into digital signals through the I / O module of a preset PLC (Programmable Logic Controller) or a dedicated data acquisition card, and then transmitted in real time to the automatic control system via an industrial fieldbus (such as Profinet, EtherCAT) or industrial Ethernet at a fixed acquisition frequency (e.g., 1kHz for vibration signals and 1Hz for temperature signals).

[0035] The automatic control system is used to preprocess the received data, such as filtering out abnormal jump points caused by signal interference. It also extracts representative features from the raw data, for example: extracting RMS, peak value, taper, and envelope spectrum features from vibration signals; extracting moving average temperature and temperature rise rate from temperature signals; and extracting total harmonic distortion (THD) from current signals.

[0036] The extracted features constitute the operational status data. The automatic control system inputs the extracted features of each key piece of equipment into a pre-set equipment health prediction model, enabling the model to output predictive maintenance information for each key piece of equipment. This equipment health prediction model is a machine learning model trained in advance using a large amount of historical operational data (including operational status data of the key equipment throughout its entire lifecycle from normal to failure). Each piece of historical operational data consists of two parts: input and output. Input includes the features of the key equipment at a specific historical point in time (i.e., the operational status data mentioned above). Output includes two parts: a Boolean value (1 or 0, indicating whether the key equipment has failed within the next N hours, where N can be 24 hours) and remaining useful life (RIL, i.e., how many hours until the final failure). It should be noted that the time difference between the time point corresponding to each status data and the time point of the final failure is extracted from the feature operational status data of the entire lifecycle of the equipment from the start of operation to the final failure, and this is used as the remaining useful life (RUL) corresponding to the corresponding status data.

[0037] Specifically, the equipment health prediction model includes a random forest classification model. This model takes a large amount of historical operational data (i.e., operational status data) as input and uses the Boolean values ​​from the historical operational data as the target value to train the random forest classification model. The trained model outputs a value between 0 and 1, for example, 0.85. This value represents the probability that the equipment will fail within the next N hours, i.e., failure probability = 0.85 (85%).

[0038] The equipment health prediction model also includes the XGBoost regression model. The input content (i.e., operating status data) from a large amount of historical operating data is input into the regression model, and the remaining service life from the output content of the historical operating data is used as the target value to train the XGBoost regression model. This allows the XGBoost regression model to output the remaining service life (RUL) based on the input operating status data.

[0039] The corresponding predictive maintenance information includes: failure probability (a value between 0% and 100%, representing the likelihood of critical equipment failing within a specific time period (e.g., 24 hours)); predicted failure time point T_f = current time + remaining service life.

[0040] Next, the automatic control system determines whether preset warning conditions are met based on predictive maintenance information; that is, it compares the predictive maintenance information with the warning conditions, where the warning conditions are logical expressions, such as: failure probability > 80% or predicted failure time point - current time < 24 hours. Once met, the corresponding critical equipment is marked as "warning critical equipment" and the subsequent process S103 is triggered.

[0041] For critical equipment identified in the early warning system, the automatic control system accesses a pre-set production plan database. It's important to note that the production plan database stores the work tasks for all processes on the entire mixing plant production line, the corresponding work time slots for each process, and the critical equipment for each process to perform its tasks. The automatic control system, when any work time slot is reached, controls the critical equipment corresponding to that work time slot to start operating and execute the corresponding work task. Furthermore, since concrete mixing plant production is generally batch production, meaning the entire mixing plant production line typically needs to repeat the same complete production operation (i.e., all process tasks) multiple times, the production plan database records all processes included in each complete production operation, the critical equipment for each process, and the work time slot for each process; essentially, the production plan database stores the concrete production operation plan for the current and future periods. It is worth mentioning that the automatic control system can calculate the single operation time required to execute a complete production operation (i.e., the sum of the working time of all processes), and display the concrete production operation plan, current and future periods, and single operation time in the production plan database through a preset display. At this time, the staff can add new production operation requests by using the touch function on the display and enter the start time of the new production operation request. The automatic control system can then calculate the operation time of the current new production operation request (i.e., [start time, start time + single operation time]) based on the aforementioned start time and the aforementioned single operation time. Then, based on all processes on the mixing plant production line, the key equipment corresponding to each process (i.e., key equipment that is idle during the corresponding operating period and can perform the work tasks of the corresponding process), and the working time of each process, the working time of each process can be determined. Then, the operation time of the current new production operation request is broken down to obtain the working time corresponding to each process, and key equipment is assigned to each process. Finally, the broken working time, the corresponding process, and the corresponding assigned key equipment are added to the production plan database as a new complete production operation to realize the update.

[0042] The automatic control system accesses a preset production plan database and retrieves the work schedule of the critical equipment for the period [current time, predicted failure time T_f]. Specifically, it checks whether there are corresponding work tasks and work periods for the critical equipment within the production plan database for the period [current time, predicted failure time T_f]. The system then uses this retrieval to find the idle periods (i.e., non-working periods within [current time, predicted failure time T_f]) of the critical equipment and records the start time, end time, and duration of each idle period.

[0043] For all idle time periods retrieved for critical equipment under early warning, the automatic control system iterates through all idle time periods to check if there is any idle time period whose duration is greater than or equal to the preset estimated maintenance time (hereinafter referred to as ΔT_m, where ΔT_m refers to the duration set in advance according to the maintenance procedures or historical periods for critical equipment under early warning, and by default the actual maintenance time for critical equipment under early warning is not greater than the estimated maintenance time). If such a period exists, the idle time period with the shortest duration among all idle time periods that is greater than or equal to the preset estimated maintenance time is taken as the target idle time period, and the target idle time period is directly used as the planned maintenance window.

[0044] For planned maintenance windows, the automatic control system will send maintenance information to the maintenance personnel's smart terminal, which includes the planned maintenance window, the unique ID number preset for the critical equipment, and the current operating status data of the critical equipment. This will remind the maintenance personnel to perform troubleshooting and maintenance work on the critical equipment within the time period corresponding to the planned maintenance window.

[0045] If, among all the idle time slots retrieved for the critical equipment under early warning, there is no target idle time slot ≥ the estimated maintenance time, then the longest idle time slot (hereinafter referred to as the longest idle time slot, FreeSlot_max) is found from all the idle time slots. The automatic control system establishes a time axis containing the longest idle time slot, and on this time axis, with the longest idle time slot as the anchor point, scans the working time slots of the critical equipment before and after the longest idle time slot (i.e., the working time slots of the critical equipment under early warning in the production plan database within the time slot of [current time, predicted fault time point T_f]) in order from near to far from the longest idle time slot. The duration of the working time slot is determined. If the working time slot duration + the duration of the longest idle time slot < the estimated maintenance time (ΔT_m), then the working time slot is defined as an adjustable time slot, and the scanning continues until the duration of the latest scanned working time slot + the duration of all previously defined adjustable time slots + the duration of the longest idle time slot ≥ ΔT_m. At this point, the latest scanned working time slot is also defined as an adjustable time slot, and the scanning is terminated, thus completing the determination of the adjustable time slot for the critical equipment under early warning, which corresponds to step S1033.

[0046] Next, the automatic control system uses the longest idle period as an anchor point on the aforementioned time axis, and sequentially matches backup equipment to the adjustable time periods before and after the longest idle period in order of increasing distance. Regarding backup equipment, it should be noted that backup equipment refers to key equipment that has the same function as the critical equipment under warning (i.e., can perform the work tasks of the critical equipment under warning). In other words, by default, each process on the mixing plant production line corresponds to multiple key pieces of equipment capable of performing the work tasks of that process (such as key equipment A, key equipment B, and key equipment C). When key equipment A is identified as the critical equipment under warning, the corresponding key equipment B and key equipment C become backup equipment for that critical equipment under warning. Accordingly, the automatic control system can pre-cluster the key equipment performing the work tasks of a unified process, forming an equipment pool for each process based on the process. Different key pieces of equipment within the same equipment pool serve as backup equipment for each other.

[0047] The matching logic for backup equipment in the automatic control system for adjustable time periods is as follows: First, all corresponding backup equipment is found from the equipment pool of critical equipment corresponding to the adjustable time period, and backup equipment that is idle during the adjustable time period is selected (i.e., backup equipment whose working period and adjustable time period do not overlap, and which itself is not marked as a predicted critical equipment during the adjustable time period). Then, the automatic control system maintains a stability evaluation coefficient S for the selected backup equipment. This coefficient is calculated based on the number of historical failures and the mean time between failures (MTBF) of the backup equipment within a specified period (e.g., 30 days) before the current time (where MTBF = the sum of the remaining useful life (RUL) predicted by the equipment health prediction model each day within the specified period / the number of days included in the specified period). For example, S = 1 / (1 + number of failures) * Mean Time Between Failures (MTBF); For standby equipment with a stability evaluation coefficient lower than a preset threshold (0.5) (hereinafter referred to as the equipment to be evaluated), the automatic control system will check the period during which the equipment to be evaluated was last activated before the current time (i.e., the period during which it was powered on and running). If the interval between this period and the current time is less than a preset value, and there is a standby equipment with a stability evaluation coefficient not lower than the preset threshold that can participate in the matching with the current adjustable period, then the execution restriction system will be triggered (i.e., the standby equipment is not allowed to participate in the matching operation with the current adjustable period to be matched). Finally, the standby equipment with the highest stability evaluation coefficient is selected as the standby equipment that successfully matches the adjustable period. This content corresponds to S1034 and S10341.

[0048] If all adjustable time periods are matched with backup equipment, the critical equipment corresponding to the adjustable time period is replaced with the successfully matched backup equipment in the production plan database. This allows the automatic control system to control the backup equipment to perform the work tasks corresponding to the adjustable time period when the current time reaches the adjustable time period, thus enabling the critical equipment to be idle during the adjustable time period. The critical equipment is "released" during these adjustable time periods, which are transformed from "working time periods" to "idle time periods". The automatic control system uses this to naturally connect all successfully matched adjustable time periods with the original longest idle time period FreeSlot_max. Since the adjustable time periods are working time periods found sequentially before and after the longest idle time period FreeSlot_max, after the adjustable equipment is successfully matched and released to become an idle time period, it can be spliced ​​with the longest idle time period FreeSlot_max to form a new, continuous target idle time period with a total duration ≥ ΔT_m. Correspondingly, the automatic control system determines this time period as a planned maintenance window, which corresponds to the content of S1035.

[0049] In the aforementioned matching logic, following the matching order, if a backup device cannot be matched (e.g., there is no backup device with an adjustable time slot in an idle state), the matching of all adjustable time slots corresponding to the critical device in the warning is stopped. The adjustable time slots that have been successfully matched before the current time are concatenated with the longest idle time slot, FreeSlot_max, to form the core maintenance segment. Adjustable time slots that failed to match at the current time, as well as those that have not yet started matching, are all used as boundaries for the matching degree segment. The automatic control system analyzes the work tasks corresponding to the boundary unmatched segments and identifies the work tasks with a time-dependent relationship (i.e., time-dependent tasks). These include predecessor tasks (i.e., tasks that must be completed before the work task corresponding to the boundary unmatched segment, such as the material weighing task before the material conveying task) and successor tasks (i.e., tasks that must start after the task, such as the mixing task after the material conveying task). The time-dependent tasks and the work tasks corresponding to the boundary unmatched segments together constitute a time-ordered process task chain.

[0050] The automatic control system is used to translate the working time periods (including boundary mismatch segments and time-dependent task periods) of all work tasks included in the process task chain away from the core maintenance segment, until a supplementary time period is created that is adjacent to and continuous with the core maintenance segment, satisfying: core maintenance time period duration + supplementary time period duration ≥ ΔT_m. Finally, the core maintenance segment and the supplementary time period are joined to form the final planned maintenance window. Specifically, the translation method is as follows: the boundary mismatch segments and time-dependent task periods before the core maintenance segment are translated forward, making them earlier on the time axis and increasing their distance from the core segment; the boundary mismatch segments and time-dependent task periods after the core maintenance segment are translated backward, making them later on the time axis and increasing their distance from the core segment. The supplementary time period is the time period between the boundary mismatch segment closest to the core maintenance segment after translation and the core maintenance segment. The automatic control system will use the working time period corresponding to the time-dependent task after the shift to replace the working time period corresponding to the time-dependent task before the shift in the production plan database, thereby realizing the update of the production plan database.

[0051] Optionally, the automatic control method may also include the following steps: Whenever the current time falls within the planned maintenance window of any critical early warning device, the maintenance feedback information of the maintenance personnel on the critical early warning device is obtained. The maintenance feedback information includes at least the actual maintenance time, as well as the faults of the critical early warning device and the corresponding maintenance solutions adopted to resolve the faults.

[0052] Regularly collect maintenance feedback information for each critical early warning device, and adjust and update the specific values ​​of the estimated maintenance time for the critical early warning device based on the actual maintenance time collected.

[0053] The system receives maintenance plan retrieval commands from maintenance personnel, retrieves and displays maintenance feedback information from historical storage that matches the critical equipment warnings and faults mentioned in the maintenance plan retrieval command, and displays the corresponding maintenance plan for maintenance personnel to refer to.

[0054] In implementation, whenever the current time enters any planned maintenance window, the automatic control system reminds maintenance personnel on a preset display to input maintenance feedback information using the touch panel of the preset display upon completion of maintenance. The system then acquires and stores this maintenance feedback information. Specifically, the maintenance feedback information includes a maintenance identifier (a unique ID used to associate with this maintenance event, which can be defined using the critical equipment being maintained and the maintenance time); actual maintenance time (ΔT_actual): this refers to the actual time elapsed from when the maintenance personnel confirm the start of maintenance in the system to when they confirm its completion; the fault problem corresponding to the critical equipment being maintained; and the maintenance solution adopted to resolve the fault problem. The automatic control system periodically (e.g., monthly) extracts historically stored maintenance feedback information and calculates the average of all actual maintenance times based on the actual maintenance time extracted from the maintenance feedback information for each critical equipment within the period. This average is then used as the estimated maintenance time for that critical equipment, enabling updates to the estimated maintenance time. When executing S103, the latest updated maintenance estimate for the critical equipment under warning is used to execute the specific steps of S103, thus determining the planned maintenance window. Within each planned maintenance window, maintenance personnel can also use the touch panel on the display to trigger a maintenance plan retrieval command. This allows the automatic control system to use the critical equipment ID and fault problem contained in the maintenance plan retrieval command as keywords to search for historical maintenance feedback information containing those keywords. The system then displays the maintenance plan contained in the retrieved maintenance feedback information for maintenance personnel to use as a maintenance reference, thereby improving maintenance efficiency.

[0055] This application also discloses an automatic control system for a concrete mixing plant. (See attached embodiments.) Figure 2 ,include: The equipment operation status monitoring module 201 is used to collect real-time operation status data of key equipment in the mixing plant production line; The equipment health prediction and maintenance module 202 is used to input operating status data into a preset equipment health prediction model to generate predictive maintenance information for critical equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability. The early warning equipment maintenance execution module 203 is used to dynamically adjust the production schedule based on the expected failure time of the early warning key equipment when the corresponding predictive maintenance information meets the preset early warning conditions. It plans a planned maintenance window for the early warning key equipment before the corresponding expected failure time and reminds maintenance personnel to maintain the early warning key equipment during the planned maintenance window. The early warning key equipment is normal operating within the planned maintenance window, on the mixing plant production line, and in other parts except for the early warning key equipment.

[0056] Optionally, the early warning equipment maintenance execution module 203 is also used to identify all idle periods of the early warning critical equipment before the early warning failure time point; if there is a target idle period with a duration not less than the estimated maintenance time, then the target idle period is determined as the planned maintenance window; if there is no target idle period, then the production schedule is adjusted, and a backup device is selected from all preset backup devices to replace the early warning critical equipment in performing the work tasks of the early warning critical equipment in the mixing plant production line, so as to adjust the idle period of the early warning critical equipment and make sure that the target idle period exists in the adjusted idle period.

[0057] Optionally, the early warning equipment maintenance execution module 203 is further configured to: if no target idle time period exists, select the longest idle time period and determine the adjustable time periods adjacent to the longest idle time period in order from nearest to furthest, until the total duration of the longest idle time period and all determined adjustable time periods is not less than the estimated maintenance time; match backup equipment for the adjustable time periods from all preset backup equipment; determine whether all adjustable time periods have matched corresponding backup equipment; if so, use the successfully matched backup equipment to replace the early warning critical equipment in performing the work tasks of the early warning critical equipment in the adjustable time period; and adjust the adjustable time of the matched backup equipment. The time period is designated as the idle time period for critical early warning equipment. The idle time period of critical early warning equipment is updated to ensure that there is a target idle time period within the idle time period of critical early warning equipment. Among these, the same backup equipment can be successfully matched with multiple adjustable time periods. If not, a preset chain advance plan is executed to adjust the execution time of the work tasks in the mixing plant production line that have a time dependency relationship with the work tasks performed by the critical early warning equipment, so as to free up supplementary time periods. Thus, after the supplementary time period is combined with the already determined idle time period of the critical early warning equipment and the successfully matched adjustable time periods, a planned maintenance window with a total duration not less than the estimated maintenance time is formed.

[0058] Optionally, the early warning equipment maintenance execution module 203 is also used to match the adjustable time periods with the backup time periods in order of proximity to the longest idle time period. If an adjustable time period fails to match, the matching is stopped. It is also used to splice all the adjustable time periods that have been successfully matched with the backup equipment with the longest idle time period to form a core maintenance segment. The adjustable time periods that fail to match are defined as boundary unmatched segments. The boundary unmatched segments are adjacent to the core maintenance segment and located at one end of the core maintenance segment. It is also used to form a process task chain by combining the work tasks that the early warning equipment needs to perform in the boundary unmatched segment and all the work tasks in the mixing plant production line that have a time sequence dependency with the work tasks in the boundary unmatched segment. The time period of all the work tasks corresponding to the process task chain is shifted in the direction away from the core maintenance segment to free up a supplementary time period that is adjacent to and continuous with the core maintenance segment. The duration of the time period formed by splicing the supplementary time period and the core maintenance segment is not less than the estimated maintenance time.

[0059] Optionally, the early warning equipment maintenance execution module 203 is also used to sequentially match the adjustable time period with the backup time period. During the matching process, if multiple backup devices can be successfully matched with the same adjustable time period, the stability evaluation coefficient of each backup device is calculated based on the historical fault data of each backup device. The backup device with the higher stability evaluation coefficient is selected first to achieve matching with the adjustable time period, and the calling frequency of backup devices with stability evaluation coefficients lower than the preset threshold is reduced, so that the time interval between two adjacent activations of backup devices with stability evaluation coefficients lower than the preset threshold is not less than the preset value.

[0060] Optionally, it also includes a maintenance estimated time adjustment module, which is used to obtain maintenance feedback information of maintenance personnel on the critical equipment whenever the current time is within the planned maintenance window of any critical equipment, wherein the maintenance feedback information includes at least the actual maintenance time; periodically collect maintenance feedback information of each critical equipment, and adjust and update the specific value of the estimated maintenance time of the critical equipment based on the collected actual maintenance time.

[0061] Optionally, it also includes a maintenance plan retrieval module, which is used to receive maintenance plan retrieval instructions from maintenance personnel, retrieve and display maintenance feedback information that is consistent with the warning key equipment and fault problems contained in the maintenance plan retrieval instructions from historical storage, and display the corresponding maintenance plan for maintenance personnel to know and refer to.

[0062] This application also discloses an automatic control device for a concrete batching plant. The automatic control device for a concrete batching plant includes a memory and a processor. The memory stores a computer program that can be loaded by the processor and executed as described above for the automatic control method of the concrete batching plant.

[0063] This application also discloses a computer-readable storage medium that stores a computer program that can be loaded by a processor and executed as described above for the automatic control method of a concrete mixing plant. The computer-readable storage medium includes, for example, various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0064] It should be noted that in this paper, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0065] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit the scope of protection of the application. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

Claims

1. An automatic control method for a concrete mixing plant, characterized in that, include: Real-time acquisition of operating status data of key equipment in the mixing plant production line; The operating status data is input into a preset equipment health prediction model to generate predictive maintenance information for the key equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability; When a critical device for early warning meets the following conditions: the corresponding predictive maintenance information meets the preset early warning conditions, the production schedule is dynamically adjusted based on the expected failure time point corresponding to the critical device for early warning. A planned maintenance window is planned for the critical device for early warning before the corresponding expected failure time point, reminding maintenance personnel to perform maintenance on the critical device for early warning during the planned maintenance window; wherein the following conditions are met: the mixing plant production line and other parts except the critical device for early warning operate normally within the planned maintenance window.

2. The automatic control method for a concrete mixing plant according to claim 1, characterized in that, The dynamic adjustment of the production scheduling plan, which allocates a planned maintenance window for the critical equipment under early warning before the corresponding expected failure time, includes: Identify all idle periods of the critical early warning equipment prior to the early warning failure time point; If there is a target idle period with a duration not less than the estimated maintenance time, then the target idle period is determined as the planned maintenance window; If the target idle period does not exist, the production schedule is adjusted, and a backup device is selected from all preset backup devices to replace the warning critical device in performing the work tasks of the warning critical device in the mixing plant production line, so as to adjust the idle period of the warning critical device and make the target idle period exist in the adjusted idle period.

3. The automatic control method for a concrete mixing plant according to claim 2, characterized in that, If the target idle period does not exist, the production schedule is adjusted by selecting a backup device from all preset backup devices to replace the critical warning device in performing its work tasks on the mixing plant production line, thereby adjusting the idle period of the critical warning device so that the target idle period exists within the adjusted idle period, including: If the target idle period does not exist, the longest idle period is selected, and the adjustable periods adjacent to the longest idle period are determined in order from nearest to farthest, until the total duration of the longest idle period and all the determined adjustable periods is not less than the estimated maintenance time. From all the preset backup devices, match backup devices for the adjustable time periods; determine whether a corresponding backup device has been matched for all adjustable time periods; If so, the successfully matched backup device will replace the critical early warning device in performing its work tasks during the corresponding adjustable time period; the adjustable time period of the matched backup device will be used as the idle time period of the critical early warning device, and the idle time period of the critical early warning device will be updated so that the idle time period of the critical early warning device contains a target idle time period; wherein, the same backup device can be successfully matched with multiple adjustable time periods; If not, the preset chain advance plan is executed, and the execution time of the work tasks in the mixing plant production line that have a time-series dependency relationship with the work tasks performed by the early warning key equipment is adjusted together to free up supplementary time periods. This allows the supplementary time periods to be spliced ​​together with the already determined idle time periods and the successfully matched adjustable time periods of the early warning key equipment to form the planned maintenance window with a total duration not less than the estimated maintenance time.

4. The automatic control method for a concrete mixing plant according to claim 3, characterized in that, The step of matching backup devices from all the preset backup devices for the adjustable time period includes: The available time slots are matched sequentially according to the order of proximity to the longest available time slot. If an available time slot cannot be matched, the matching process is stopped. The pre-defined chain-like advance plan adjusts the execution time of tasks in the mixing plant production line that have a time-dependent relationship with the tasks performed by the critical early warning equipment, in order to free up supplementary time periods, including: All adjustable time periods that have been successfully matched with backup equipment are spliced ​​together with the longest idle time period to form a core maintenance segment. The adjustable time periods that fail to match are defined as boundary unmatched segments. The boundary unmatched segments are adjacent to the core maintenance segment and located at one end of the core maintenance segment. The work tasks required by the early warning device in the boundary mismatch section, and all work tasks in the mixing plant production line that have a temporal dependency relationship with the work tasks in the boundary mismatch section, constitute a process task chain. The time period for executing all work tasks corresponding to the process task chain is shifted away from the core maintenance section to free up a supplementary time period that is adjacent to and continuous with the core maintenance section. The duration of the time period formed by splicing the supplementary time period and the core maintenance section is not less than the estimated maintenance time.

5. The automatic control method for a concrete mixing plant according to claim 4, characterized in that, The sequence of adjustable time periods matching backup time periods includes: The system sequentially matches the adjustable time period with the backup time period. During the matching process, if multiple backup devices can be successfully matched with the same adjustable time period, the system calculates the stability evaluation coefficient of each backup device based on its historical fault data. The system prioritizes the backup device with the higher stability evaluation coefficient to achieve the matching with the adjustable time period, and reduces the calling frequency of backup devices with stability evaluation coefficients lower than the preset threshold. This ensures that the time interval between two consecutive activations of backup devices with stability evaluation coefficients lower than the preset threshold is not less than the preset value.

6. The automatic control method for a concrete mixing plant according to claim 2, characterized in that, The method further includes: Whenever the current time falls within the planned maintenance window of any critical early warning device, maintenance feedback information from maintenance personnel regarding the critical early warning device is obtained, wherein the maintenance feedback information includes at least the actual maintenance time. Regularly collect maintenance feedback information for each critical early warning device, and adjust and update the specific values ​​of the estimated maintenance time for the critical early warning device based on the actual maintenance time collected.

7. The automatic control method for a concrete mixing plant according to claim 1, characterized in that, The maintenance feedback information also includes early warnings of critical equipment malfunctions and corresponding maintenance solutions for resolving these malfunctions. The method further includes: The system receives a maintenance plan retrieval command from maintenance personnel, retrieves and displays maintenance feedback information from historical storage that matches the warning key equipment and fault problems included in the maintenance plan retrieval command, and displays the corresponding maintenance plan for maintenance personnel to refer to.

8. An automatic control system for a concrete mixing plant, characterized in that, include, The equipment operation status monitoring module (201) is used to collect real-time operation status data of key equipment in the mixing plant production line; The equipment health prediction and maintenance module (202) is used to input the operating status data into a preset equipment health prediction model to generate predictive maintenance information for the key equipment; wherein, the predictive maintenance information includes at least the predicted failure time point and / or failure probability; The early warning equipment maintenance execution module (203) is used to dynamically adjust the production schedule based on the expected failure time point corresponding to the early warning key equipment when the corresponding predictive maintenance information meets the preset early warning conditions. It plans a planned maintenance window for the early warning key equipment before the corresponding expected failure time point and reminds maintenance personnel to maintain the early warning key equipment during the planned maintenance window. The early warning key equipment is maintained normally within the planned maintenance window, on the mixing plant production line, and in other parts except for the early warning key equipment.

9. An automatic control device for a concrete mixing plant, 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 as described in any one of claims 1 to 7.

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

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