Self-adaptive control device and method for in-situ rapid stirring and curing of sludge

Abstract

The invention discloses a self-adaptive control device and method for in-situ rapid stirring and solidification of sludge, the self-adaptive control device comprises an execution unit and an intelligent control system, the execution unit comprises an excavator bucket, and fixing holes are respectively formed in two side panels close to a rear side panel; two mounting holes are formed in the positions, close to the bent hopper, of the two side panels; a water content sensor is arranged in the excavator bucket; the two ends of the curing agent spraying device are fixed in the fixing holes, and the curing agent spraying device comprises a spraying pipe with one end serving as an inlet end and a plurality of spraying heads; the inlet end is connected with an input pipe; the controllable metering pump is connected with the input pipe to pump the curing agent; the stirring device comprises a stirring shaft, a stirring coulter and a controllable motor, two ends of the stirring shaft are fixed in the mounting holes through bearings, and one end of the stirring shaft extends out of the side panel and is connected with the controllable motor; the controllable motor sends a working current signal; and the intelligent control system is installed in a computer, and the intelligent control system receives the working current signal and the water content and controls the controllable metering pump and the controllable motor.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sludge solidification, and particularly relates to a self-adaptive control device and method for in-situ rapid mixing and solidification of sludge. BACKGROUND

[0002] In a river dredging project, a large amount of sludge to be treated is often generated. Sludge solidification treatment is to use a solidifying agent to have a series of complex physical and chemical reactions with the sludge, fix the toxic and harmful substances in the network chain formed by solidification, reduce the water content of the sludge, and improve the strength and density of the sludge, so as to achieve the purpose of treatment. According to different working conditions, the sludge solidification process is generally divided into in-situ solidification and ex-situ solidification. In-situ solidification treatment generally uses a shovel mixer or a cement mixing pile-like device to save space, but needs to pump out river water to create construction conditions, has a complex process and affects the water ecology. The addition of the solidifying agent of the existing in-situ solidification device depends on manual experience or simple mechanical feeding, and has the problems of poor mixing uniformity, inaccurate solidifying agent dosage, and difficulty in adapting to the spatial variation of sludge composition and water content. The fundamental reason is that the solidifying agent feeding system cannot sense the real-time change of the physical state of the sludge. Therefore, it is impossible to dynamically adjust the feeding amount, resulting in unstable solidification effect and serious material waste. Ex-situ sludge solidification treatment excavates and transports the sludge to a fixed treatment plant for centralized treatment using a special mixing station, a solidified soil production line and the like, and does not need to pump out river water, but has the problems of high cost and large occupied area, and the device needs to be fixed on the ground and cannot be conveniently moved, which limits its application range.

[0003] Therefore, in order to have the advantages of in-situ treatment and ex-situ treatment, overcome the problems of unstable solidification effect and serious material waste, and improve the operability of sludge solidification treatment, it becomes an urgent problem to be solved. SUMMARY

[0004] The purpose of the present application is to provide a self-adaptive control device and method for in-situ rapid mixing and solidification of sludge, especially to intelligently optimize the solidifying agent feeding system, so as to solve the problems of strict construction conditions of in-situ solidification equipment, unstable solidification effect depending on manual experience, serious material waste, and inability to dynamically adjust the input amount of the solidifying agent.

[0005] To achieve the above purpose, the present application provides the following technical solutions: The application discloses a quick in-situ sludge stirring and solidifying self-adaptive control device, which comprises an execution unit and an intelligent control system, wherein the execution unit comprises a bucket, two side panels of which are respectively provided with a fixing hole near a rear side panel; two mounting holes are arranged on the two side panels near the bucket; a water content sensor is arranged in the bucket and used for sensing the water content of sludge in the bucket; a solidifying agent spraying device is fixed in the fixing hole through a fixing ring at two ends, the solidifying agent spraying device comprises a spray pipe provided with an inlet end and a plurality of nozzles arranged on the spray pipe; the inlet end is connected with an input pipe; a controllable metering pump is connected with the input pipe to pump the solidifying agent; a stirring device comprises a stirring shaft, a stirring plough arranged on the stirring shaft and a controllable motor, two ends of the stirring shaft are fixed in the mounting holes through bearings, and one end of the stirring shaft is connected with the controllable motor and extends out of the side panel; the controllable motor sends a working current signal; the intelligent control system is installed in a computer, receives the working current signal and the water content and controls the controllable metering pump and the controllable motor.

[0006] Preferably, the controllable motor is provided with a sealed motor protection cover outside.

[0007] Preferably, the rear side panel of the bucket is provided with two concave supports, and a side tooth extends out of each side panel at a lower side; one end of a grid plate is fixed to the concave supports through a connecting piece, and the two sides of the grid plate are locked through fixing pieces.

[0008] Preferably, the grid plate comprises a shielding part at an upper part and a grid hole part at a lower part, and the shielding part shields the stirring device and the solidifying agent spraying device.

[0009] Preferably, the grid hole part of the grid plate is arranged from dense to sparse from top to bottom.

[0010] Preferably, the controllable metering pump is a pneumatic powder diaphragm pump.

[0011] Preferably, the stirring plough is in an arc shape and is fixed on the stirring shaft at equal intervals.

[0012] The application also discloses a quick in-situ sludge stirring and solidifying self-adaptive control method, which is applied to the quick in-situ sludge stirring and solidifying self-adaptive control device and comprises the following steps. Obtain the state parameters related to the work, which include the water content of the sludge in the excavator bucket obtained by the built-in water content sensor, and the real-time working current signal reflecting the stirring resistance obtained by monitoring the controllable motor, and transmit the state parameters to the intelligent control system; the intelligent control system queries the working condition-control mapping relationship table preset in the intelligent control system according to the combination of the water content and the working current signal, generates the flow control and motor control instructions for the controllable metering pump; the intelligent control system drives the controllable metering pump to pump the curing agent at a corresponding flow according to the generated flow control instruction; the intelligent control system controls the speed and torque of the controllable motor according to the generated motor control instruction; during the work process, the above steps are continuously repeated, and the flow control instruction and the motor control instruction are dynamically adjusted according to the feedback water content and current signal until the single treatment is completed.

[0013] Due to the adoption of the above technical scheme, the advantages of the present application are as follows: 1. The spraying device integrated inside the excavator bucket can atomize or spray the curing agent in multiple fine jets, greatly increasing the contact area with the sludge; 2. The internal special stirring device (especially the arc-shaped stirring plow) can fully break and stir the sludge; the external adjustable grid plate can effectively block large debris and protect the internal mechanism.

[0014] 3. The device is equipped with an adaptive control system based on multiple source information such as "water content-current signal", which intelligently judges the physical state of the sludge, thereby dynamically and accurately adjusting the curing agent dosage. This fundamentally solves the industry pain points of unstable curing effect and serious material waste, and realizes efficient, uniform, low-consumption and controllable sludge curing treatment. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a structural schematic diagram of an embodiment of the present application; Figure 2 is a structural schematic diagram of a curing agent spraying device of the present application; Figure 3 is a structural schematic diagram of a stirring device of the present application.

[0016] Figure 4 is a self-adaptive control flow chart of the present application. DETAILED DESCRIPTION

[0017] The technical scheme of the present application will be further specifically described below through embodiments and in combination with the drawings.

[0018] Referring to Figure 1 , the sludge in-situ rapid stirring and curing self-adaptive control device of the embodiment of the present application includes an execution unit and an intelligent control system. As shown inFigure 1 As shown, the execution unit includes components such as: bucket 1, curing agent spraying device 2, controllable metering pump, and stirring device 3.

[0019] Each of the two side panels 11 of the bucket 1 has a fixing hole near the rear side panel 12 for installing a curing agent spraying device 2. Two mounting holes are also provided on the two side panels 11 near the curved part of the bucket for installing a mixing device. A moisture content sensor is installed inside the bucket 1.

[0020] like Figure 2 As shown, the curing agent spraying device 2 is fixed at both ends to the fixing holes by fixing rings 21. The curing agent spraying device 2 includes a spray pipe 22 with one end designated as the inlet end 24 and several nozzles 23 mounted on the spray pipe 22. The inlet end 24 is connected to an input pipe, which is connected to a controllable metering pump to pump in the curing agent. The number and spatial distribution of the nozzles 23 can be optimized according to the bucket volume and mixing requirements. The power source of the curing agent spraying device 2 is a controllable metering pump with precise flow control to adapt to the spraying requirements of different working conditions. As one of the key execution units of the system, this pump can achieve precise control of the curing agent addition flow rate and start / stop sequence through the curing agent spraying device 2 based on received electronic control commands.

[0021] A controllable metering pump can be installed on a carrier (neither the pump body nor the carrier is shown in the figure), and pumps the powdered or liquid curing agent to the spraying device 2 through an input pipe. In this embodiment, the curing agent is in powder form, and the curing agent spraying device 2 is powered by a pneumatic powder diaphragm pump, so that the curing agent enters the curing agent spraying device 2 under the action of high-pressure airflow, and is then uniformly sprayed out by the nozzle 23.

[0022] The stirring device 3 includes a stirring shaft 31, stirring blades 32 mounted on the stirring shaft 31, and a controllable motor 33. Both ends of the stirring shaft 31 are fixed in the mounting holes by bearings, and one end of the stirring shaft 31 extends out of the side panel and is connected to the controllable motor 33.

[0023] The mixing blades 32 are arc-shaped and are equidistantly mounted on the mixing shaft 31. Compared with straight blades, arc-shaped blades are more conducive to crushing and mixing silt.

[0024] The controllable motor 33 is a low-speed, high-torque power unit, and its specific selection can be made according to the properties of the silt. It can be configured as hydraulically driven or electrically driven depending on the carrier conditions. Its drive system has the ability to receive external speed adjustment commands and feed back real-time working current, torque, or speed signals to the upper-level control system (intelligent control system).

[0025] A sealed motor protective cover 4 is provided on the outside of the controllable motor 33. The motor protective cover 6 can effectively protect the controllable motor 41, and the streamlined shape of the motor protective cover 6 (composed of an upper cuboid and a lower triangular prism) effectively reduces the resistance during the digging process.

[0026] In this embodiment, the carrier is an excavator or other equipment with its own drive capability and robotic arm, and the carrier controls the present invention to excavate, solidify and transport river silt.

[0027] The intelligent control system is installed in a computer. The intelligent control system receives the operating current signal and the moisture content, and generates instructions to control the controllable motor and the controllable metering pump based on the operating current-motor operating status mapping table and the moisture content-curing agent dosage mapping table, so as to control the controllable metering pump and the controllable motor 33.

[0028] The core function of the intelligent control system is to jointly determine the state of the sludge based on the moisture content data obtained from the moisture content sensor. The real-time operating current data fed back by the controllable motor 33 is proportional to the motor output torque, directly reflecting the resistance torque on the stirring shaft. The intelligent control system has pre-stored mapping tables based on experimental calibration (including a mapping table of operating current-motor operating status and a mapping table of moisture content-solidifying agent dosage).

[0029] The intelligent control system determines the physical state of the silt by analyzing the range of the operating current signal fed back by the controllable motor, thereby generating a motor control command to adjust the motor control mode and the speed / torque of the controllable motor. The specific operating current-motor operating state mapping table is as follows: Current state interval Corresponding sludge physical state Determination condition Motor control mode Low current interval Loose / over-dry state Real-time current continuously below 60% of rated current Keep constant rotational speed, or slightly increase rotational speed (increment ≤ 10%), enhance the stirring effect on loose sludge Medium current interval Normal flow plastic state Real-time current stable at 60%-100% of rated current Keep constant rotational speed mode, maintain the designed stirring speed, ensure uniform mixing of the curing agent and sludge High current interval Viscous / hardening state Real-time current exceeds 100% of rated current, or current rising rate ≥ 20% / s in a short time Switch to constant torque mode, appropriately reduce the motor speed (decrement recommended 10%-20%), avoid motor overload due to excessive load Overload current threshold Severe hardening / blockage Current exceeds 150% of rated current, duration ≥ 3s Immediately trigger the load shedding protection program, first reduce the speed to 0, then reverse the motor (for 1-2s), disperse the hardened sludge Before construction, input physical parameters such as sludge plastic limit, bulk density, and organic matter content, as well as a moisture content-solidifier dosage mapping table. During construction, the natural moisture content of the sludge is obtained through a moisture content sensor. Combined with parameters such as hopper capacity and bulk density, and the preset dosage, the amount of solidifier is obtained and fed back to the flow pump to start adding solidifier.

[0030] Due to the differences in the physicochemical properties of silt and the significant differences in the curing effect of curing agents, at least three sets of tests need to be completed before on-site construction. The optimal dosage needs to be determined through indoor compaction tests and unconfined compressive strength tests, thereby determining the calibrated moisture content-curing agent dosage mapping table.

[0031] Taking lime-based curing agents as an example, the moisture content-curing agent dosage mapping table is as follows: In addition, two concave supports 13 are provided on the rear side panel 12 of the bucket 1, and a protruding side tooth 14 is provided on the lower part of the side panel 11. One end of the grating plate 5 is fixed to the concave support 13 by a pin, and the two sides of the grating plate 5 are locked to the side tooth 14 by fasteners, thereby the grating plate 5 covers the interior of the bucket 1.

[0032] like Figure 1 As shown, the grating plate 5 includes an upper shielding part 51 and a lower grating hole part 52. The shielding part shields the mixing device 3 and the curing agent spraying device 2. The grating hole part 52 of the grating plate 5 is arranged from dense to sparse from top to bottom. This effectively prevents larger stones or plastic waste from entering the bucket 1 and avoids damage to the mixing device 3. The grating hole part 52 is composed of multiple grating bars 521, and the density of the grating bars 521 can be adjusted according to the properties of the dredged silt to adapt to different types of silt.

[0033] This invention also proposes an adaptive control method for on-site rapid mixing and solidification of sludge, such as... Figure 4 As shown, its application in the aforementioned adaptive control device for on-site rapid mixing and solidification of sludge includes the following steps: S1: Acquire status parameters related to the operation, including the moisture content of the silt in the bucket obtained by the built-in moisture content sensor, and the real-time operating current signal reflecting the stirring resistance obtained by monitoring the controllable motor, and transmit the status parameters to the intelligent control system.

[0034] S2: The intelligent control system queries the preset working condition-control mapping relationship based on the combination of the moisture content signal and the current signal, and generates a flow control command for the controllable metering pump; S3: The intelligent control system drives the controllable metering pump to pump the curing agent at a corresponding flow rate according to the generated flow control command; S4: During the operation, continuously repeat the above steps, continuously collect moisture content and operating current signals, and determine whether it is stable within the optimal range; if not, adjust the flow control command according to the above steps; if yes, continue to maintain the current flow control command. Once the moisture content of the cured soil meets the requirements for on-site backfill or other uses (due to the reaction time difference of the curing agent, the moisture content of the on-site cured soil needs to be about 3% above the design moisture content to meet the requirements), then the single curing treatment operation is complete.

[0035] In practice, the carrier is driven to the appropriate location for operation, and the robotic arm operates the bucket 1 to excavate silt. The grating 5 prevents larger stones or debris from entering the bucket 1. When the bucket 1 excavates silt, the system automatically or the operator triggers an adaptive solidification program. The intelligent control system begins to synchronously collect two key status parameters in real time: the silt moisture content obtained through the moisture content sensor and the real-time operating current of the controllable motor 33. Based on this combination of dual parameter signals, the system immediately queries the pre-stored working condition-control strategy mapping table and directly generates the current optimal collaborative control instruction set. The instruction set precisely adjusts the controllable motor 33 to drive the stirring device 3 to rotate and stir. During stirring, the instruction set synchronously adjusts the flow rate of the controllable metering pump and controls the start of the solidifying agent spraying device 2. The solidifying agent delivery pipeline directly delivers the solidifying agent to the spray pipe 23, and then sprays it out from the nozzle 23, realizing the synchronous addition of solidifying agent during the stirring process, improving the efficiency of silt stirring and solidification, and achieving rapid on-site solidification of silt inside the bucket 1.

[0036] When the system detects that the parameters have stabilized within the preset threshold range for a certain period of time, or have reached the preset optimal processing cycle, it determines that the mixing of the sludge in a single bucket has been sufficient and uniform, and the solidification reaction conditions have been optimized and created. Operations are then stopped. The solidified sludge can be directly backfilled on-site via short-haul transport within the site or transported to other sites requiring backfilling for reuse.

[0037] The embodiments described above are for illustrative purposes only and are not intended to limit the scope of the invention. All equivalent changes and modifications made to the invention by those skilled in the art should fall within the scope of the appended claims.

Claims

1. An adaptive control device for on-site rapid mixing and solidification of sludge, characterized in that, Includes execution units and intelligent control systems, among which: The execution unit includes: The bucket has a fixing hole on each of its two side panels near the rear side panel; two mounting holes are provided on the two side panels near the curved bucket; a moisture content sensor is provided inside the bucket to sense the moisture content of the silt inside the bucket; A curing agent spraying device, the two ends of which are respectively fixed in the fixing hole by fixing rings, the curing agent spraying device includes a spray pipe with one end set as the inlet end and a plurality of spray nozzles provided on the spray pipe; the inlet end is connected to an input pipe; A controllable metering pump is connected to the input pipe to pump in the curing agent; A stirring device includes a stirring shaft, stirring blades mounted on the stirring shaft, and a controllable motor. Both ends of the stirring shaft are fixed in the mounting holes by bearings, and one end of the stirring shaft extends out of the side panel and is connected to the controllable motor. The controllable motor sends a working current signal. The intelligent control system is installed in a computer. The intelligent control system receives the working current signal and the moisture content and controls the controllable metering pump and the controllable motor.

2. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 1, characterized in that, The controllable motor is equipped with a sealed motor protective cover on its outside.

3. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 1, characterized in that, The rear side panel of the bucket is provided with two concave supports, and a protruding side tooth is provided on the lower part of the side panel; one end of a grid plate is fixed to the concave support by a connector, and the two sides of the grid plate are locked to the side tooth by a fastener.

4. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 3, characterized in that, The grating plate includes an upper shielding portion and a lower grating hole portion, the shielding portion shielding the stirring device and the curing agent spraying device.

5. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 4, characterized in that, The grid holes of the grid plate are arranged from dense to sparse from top to bottom.

6. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 1, characterized in that, The controllable metering pump is a pneumatic powder diaphragm pump.

7. The adaptive control device for on-site rapid mixing and solidification of sludge according to claim 1, characterized in that, The stirring blades are arc-shaped and fixed at equal intervals on the stirring shaft.

8. An adaptive control method for on-site rapid mixing and solidification of sludge, characterized in that, The adaptive control device for on-site rapid mixing and solidification of sludge, as described in any one of claims 1 to 7, comprises the following steps: The system acquires operation-related status parameters, including the moisture content of the silt in the bucket obtained by the built-in moisture content sensor, and the real-time operating current signal reflecting the stirring resistance obtained by monitoring the controllable motor, and transmits the status parameters to the intelligent control system. The intelligent control system queries the pre-set operating condition-control mapping table within the system based on the combination of the moisture content and the operating current signal, and generates flow control commands and motor control commands for the controllable metering pump. The intelligent control system drives the controllable metering pump to pump the curing agent at a corresponding flow rate according to the generated flow control command; the intelligent control system controls the speed and torque of the controllable motor according to the generated motor control command; During the operation, the above steps are repeated continuously, and the flow control command and the motor control command are dynamically adjusted according to the feedback moisture content and current signal until the single processing is completed.

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