Method and device for controlling an on-line metering device for bulk materials

Abstract

The application relates to a control method and device of a bulk material online metering device, and relates to the field of bulk material online metering, which comprises the following steps: conveying the bulk material to a shunt metering device according to conveying parameters by controlling a conveying device; conveying the bulk material to a material car by controlling the shunt metering device, and detecting the bulk material by the shunt metering device to generate a real-time material flow; collecting a target loading weight, a cumulative loading amount and a single loading time; calculating the product of the real-time material flow and the single loading time to generate a single loading amount; calculating the sum of the single loading amount and the cumulative loading amount to generate a current total loading amount; judging whether the current total loading amount is not less than the target loading weight; if yes, stopping the conveying device and the shunt metering device; if not, continuing to control the conveying device to convey the bulk material to the shunt metering device, and controlling the shunt metering device to convey the bulk material to the material car. The application has the advantages of guaranteeing good bulk material online metering effect.

Description

Technical Field

[0001] This application relates to the technical field of online metering of bulk materials, and in particular to control methods and apparatus for online metering devices for bulk materials. Background Technology

[0002] Online metering of bulk materials refers to a technical means of collecting parameters such as flow rate and weight of materials in real time through a dedicated metering device during the continuous conveying of bulk materials without interrupting the material transmission process, and outputting accurate metering results after data processing and error correction.

[0003] In related technologies, when bulk materials are metered online, manual online measurement is performed by capturing the bulk material flow within a fixed time period, and the real-time material flow rate is calculated by weighing the captured bulk material mass. The cumulative loading volume is estimated, and based on the cumulative loading volume and the target loading volume, the loading time of the target material is calculated. The bulk material is then transported to the material truck according to the loading time of the target material.

[0004] Regarding the aforementioned technologies, in the process of diverting and transporting bulk materials into material trucks, if the target loading time is obtained by measuring the flow rate of bulk materials within a fixed time period and then calculating the target loading volume, the calculated target loading time will be inaccurate because the flow rate of bulk materials is not constant. This results in poor conveying efficiency of diverting and transporting bulk materials into material trucks, and there is still room for improvement. Summary of the Invention

[0005] In order to improve the accuracy of online metering of bulk materials and ensure good conveying effect of bulk materials diverted and transported to material trucks, this application provides a control method and device for online metering of bulk materials.

[0006] Firstly, this application provides a control method for an online metering device for bulk materials, employing the following technical solution:

[0007] Control methods for online metering devices for bulk materials include:

[0008] According to the preset conveying parameters, the preset conveying device is controlled to convey the preset bulk materials to the preset diversion and metering device.

[0009] The control diversion and metering device diverts and transports bulk materials to preset material carts, and controls the diversion and metering device to detect the bulk materials in order to generate real-time material flow rate.

[0010] Collect the target material loading weight, cumulative loading volume, and real-time material flow rate of the material truck, and the corresponding single bulk material loading time.

[0011] Calculate the product of real-time material flow rate and single bulk material loading time to generate single material loading quantity;

[0012] Calculate the sum of the single material loading quantity and the cumulative loading quantity to generate the current total loading quantity;

[0013] Determine whether the current total loading quantity is not less than the target material loading weight;

[0014] If so, then the control conveying device and the diversion metering device shall be stopped;

[0015] If not, continue to control the conveying device to transport the bulk material to the diversion metering device, and control the diversion metering device to divert and transport the bulk material to the material cart.

[0016] By adopting the above technical solution, in the process of controlling the diversion and metering device to divert and transport bulk materials to the preset material car, the diversion and metering device is first controlled to detect the bulk materials to determine the real-time material flow rate. After calculating the real-time material flow rate and the loading time of a single batch of bulk materials, the loading quantity of a single batch of materials is obtained. The current total loading quantity is determined based on the loading quantity of a single batch of materials and the cumulative loading quantity. When it is determined that the current total loading quantity is not less than the target loading weight of materials, the conveying device and the diversion and metering device are stopped, thereby dynamically improving the accuracy of the current total loading quantity and ensuring accurate online metering of bulk materials.

[0017] Optionally, the step of controlling the diversion metering device to detect bulk materials to generate real-time material flow includes:

[0018] The control diversion metering device detects bulk materials to generate an initial real-time material flow rate;

[0019] The arc of the landing area of ​​bulk materials on the diversion metering device is collected;

[0020] Determine whether the arc of the landing area is consistent with the preset baseline arc of the landing area;

[0021] If so, the initial real-time material flow rate is defined as the real-time material flow rate;

[0022] If not, the initial real-time material flow rate and the curvature of the landing area are analyzed to generate the real-time material flow rate.

[0023] By adopting the above technical solution, the control diversion metering device detects the bulk material to determine the initial real-time material flow rate. When the arc of the landing area and the reference arc of the landing area are inconsistent, the real-time material flow rate is determined based on the initial real-time material flow rate and the arc of the landing area, thereby improving the accuracy of the real-time material flow rate.

[0024] Optionally, the step of controlling the diversion metering device to detect bulk materials to generate an initial real-time material flow rate includes:

[0025] Collect the no-load measurement values ​​of the diversion metering device;

[0026] The difference between the no-load measurement value and the preset reference no-load value is calculated to generate the real-time measurement drift of the shunt metering device;

[0027] Determine whether the real-time measured drift amount is greater than the preset adhesion judgment threshold;

[0028] If so, the diversion metering device should be pre-processed;

[0029] The control diversion metering device directly detects bulk materials to generate an initial real-time material flow rate;

[0030] If not, the control diversion metering device directly detects the bulk material to generate the initial real-time material flow rate.

[0031] By adopting the above technical solution, the real-time measurement drift of the diversion metering device is obtained after calculating the no-load measurement value and the reference no-load value. When it is determined that the real-time measurement drift is greater than the adhesion judgment threshold, considering that the high humidity of the bulk material itself will cause it to adhere to the diversion metering device, it is necessary to preprocess the diversion metering device and then control the diversion metering device to directly detect the bulk material to determine the initial real-time material flow rate, thereby ensuring the accuracy of the initial real-time material flow rate.

[0032] Optionally, the pretreatment steps for the diversion metering device include:

[0033] Collect the adhesive friction and contact area of ​​the diversion metering device;

[0034] Adhesive friction and contact area are analyzed to generate airflow velocity;

[0035] The pretreatment device controls the blowing speed to blow air into the diversion metering device to obtain a diversion metering device without material adhesion.

[0036] By adopting the above technical solution, the blowing speed is determined based on the adhesion friction and contact area. Then, the pretreatment device is controlled to blow air onto the diversion metering device based on the blowing speed, thereby ensuring that there is no material adhering to the diversion metering device and improving the accuracy of the diversion metering device in measuring the initial real-time material flow rate.

[0037] Optionally, before the control diversion metering device directly detects the bulk material to generate the initial real-time material flow rate, a pretreatment step for the bulk material is also included. Specific steps include:

[0038] Collect the initial humidity of bulk materials;

[0039] Determine whether the initial humidity is not greater than the preset humidity threshold;

[0040] If so, the control diversion metering device directly detects the bulk material to generate the initial real-time material flow rate;

[0041] If not, calculate the difference between the initial humidity and the humidity threshold to generate the current amount of water removed;

[0042] The current water removal rate and preset thermal efficiency are analyzed to generate the target heating power;

[0043] The pretreatment device is controlled according to the target heating power to dehumidify the bulk material, so as to generate dehumidified bulk material.

[0044] The control diversion metering device directly detects bulk materials to generate an initial real-time material flow rate.

[0045] By adopting the above technical solution, when the initial humidity of the bulk material is determined to be greater than the humidity threshold, the current dehumidification amount is obtained after calculating the initial humidity and the humidity threshold. The target heating power is determined based on the current dehumidification amount and thermal efficiency. Considering the influence of excessively high humidity of the bulk material, it will re-adhere to the diversion metering device during the online metering process. Therefore, the pretreatment device is controlled to dehumidify the bulk material according to the target heating power to obtain dehumidified bulk material. The diversion metering device is then controlled to detect the dehumidified bulk material to determine the initial real-time material flow rate, thereby ensuring that the dehumidified bulk material does not adhere during the detection process and ensuring a good online metering effect for bulk materials.

[0046] Optionally, the steps of analyzing the initial real-time material flow rate and the curvature of the landing area to generate the real-time material flow rate include:

[0047] Determine the segment points of the landing point and the corresponding actual radian value based on the radian of the landing area;

[0048] The corresponding reference radian value is found in the preset segmented radian relationship based on the landing point segmentation point;

[0049] The actual radian value and the reference radian value are analyzed to generate the flow correction coefficient;

[0050] Calculate the product of the flow correction factor and the initial real-time material flow rate to generate the real-time material flow rate.

[0051] By adopting the above technical solution, the landing point segment and the corresponding actual arc value are determined according to the arc of the landing area. Considering that different landing point segment corresponds to different arc changes, the corresponding reference arc value is found in the preset segment arc relationship based on the landing point segment, thus laying the foundation for the subsequent calculation of the flow correction coefficient. The flow correction coefficient is determined based on the actual arc value and the reference arc value. After calculating the flow correction coefficient and the initial real-time material flow, the real-time material flow is obtained, thereby improving the accuracy of the real-time material flow.

[0052] Optionally, the step of analyzing the actual radian value and the reference radian value to generate the flow correction factor includes:

[0053] Calculate the difference between the actual radian value and the reference radian value to generate the radian change.

[0054] The percentage of material mass at each landing point segment;

[0055] The change in radii is weighted and summed based on the mass ratio of the material landing point to generate the total change in radii.

[0056] The total change in radians and the preset linear correction coefficient are analyzed to generate the linear correction coefficient.

[0057] The total change in radians and the preset nonlinear correction coefficients are analyzed to generate the nonlinear correction coefficients.

[0058] The sum of the nonlinear coefficient correction, the linear coefficient correction, and the preset baseline correction coefficient is calculated to generate the flow correction coefficient.

[0059] By adopting the above technical solution, the arc change is obtained by calculating the actual arc value and the reference arc value. The arc change is then weighted and summed according to the mass ratio of the material landing point to determine the total arc change. Considering that the arc change values ​​of different landing point segments have different impacts on the real-time material flow rate, the linear coefficient correction is obtained by calculating the total arc change and the linear correction coefficient. The nonlinear coefficient correction is obtained by calculating the total arc change and the nonlinear correction coefficient. Finally, the flow rate correction coefficient is obtained by calculating the nonlinear coefficient correction, the linear coefficient correction, and the reference correction coefficient, thereby improving the accuracy of the flow rate correction coefficient.

[0060] Secondly, this application provides a control device for an online metering device for bulk materials, which adopts the following technical solution:

[0061] The control device for the online metering device for bulk materials includes:

[0062] The data acquisition module is used to collect the loading weight, cumulative loading volume, and real-time material flow rate of the target material, corresponding to the loading time of a single bulk material loading operation.

[0063] A memory for storing a program for a control method of an online metering device for bulk materials as described in any of the preceding claims;

[0064] The processor and the program in the memory can be loaded and executed by the processor to implement the control method of the online metering device for bulk materials as described in any of the above.

[0065] By adopting the above technical solution, the control processor loads and executes the control method program of the online metering device for bulk materials stored in the memory. In the process of controlling the diversion metering device to divert and transport bulk materials to the preset material cart, the diversion metering device first detects the bulk materials to determine the real-time material flow rate. After calculating the real-time material flow rate and the loading time of a single batch of bulk materials, the loading quantity of a single batch of materials is obtained. Based on the loading quantity of a single batch of materials and the cumulative loading quantity, the current total loading quantity is determined. The acquisition module collects the loading weight of the target material. When it is determined that the current total loading quantity is not less than the loading weight of the target material, the conveying device and the diversion metering device are stopped, thereby dynamically improving the accuracy of the current total loading quantity and ensuring accurate online metering of bulk materials.

[0066] In summary, this application includes at least one of the following beneficial technical effects:

[0067] 1. By controlling the diversion and metering device to divert and transport bulk materials to the preset material carts, the diversion and metering device is first controlled to detect the bulk materials to determine the real-time material flow rate. After calculating the real-time material flow rate and the loading time of a single batch of bulk materials, the loading quantity of a single batch of materials is obtained. The current total loading quantity is determined based on the loading quantity of a single batch of materials and the cumulative loading quantity. When it is determined that the current total loading quantity is not less than the target loading weight of the material, the conveying device and the diversion and metering device are stopped, thereby dynamically improving the accuracy of the current total loading quantity and ensuring accurate online metering of bulk materials.

[0068] 2. The initial real-time material flow rate is determined by controlling the diversion metering device to detect bulk materials. When the arc of the landing area and the reference arc of the landing area are inconsistent, the real-time material flow rate is determined based on the initial real-time material flow rate and the arc of the landing area, thereby improving the accuracy of the real-time material flow rate.

[0069] 3. The real-time measurement drift of the diversion metering device is obtained by calculating the no-load measurement value and the reference no-load value. When the real-time measurement drift is determined to be greater than the adhesion judgment threshold, considering the influence of the high humidity of the bulk material itself on the diversion metering device, it is necessary to pre-process the diversion metering device and then control the diversion metering device to directly detect the bulk material to determine the initial real-time material flow rate, thereby ensuring the accuracy of the initial real-time material flow rate. Attached Figure Description

[0070] Figure 1 This is a flowchart of the control method for the online metering device for bulk materials in the embodiments of this application.

[0071] Figure 2 This is a flowchart of the steps in this application embodiment to control the diversion metering device to detect bulk materials in order to generate real-time material flow rate.

[0072] Figure 3 This is a flowchart of the steps in this application embodiment to control the diversion metering device to detect bulk materials in order to generate an initial real-time material flow rate.

[0073] Figure 4 This is a flowchart of the preprocessing steps for the diversion metering device in the embodiments of this application.

[0074] Figure 5 In this embodiment of the application, before the control diversion metering device directly detects the bulk material to generate the initial real-time material flow, a pre-processing step for the bulk material is also included, as shown in the flowchart of the specific steps.

[0075] Figure 6 This is a flowchart of the steps in this application embodiment to analyze the initial real-time material flow rate and the curvature of the landing area to generate the real-time material flow rate.

[0076] Figure 7 This is a flowchart of the steps in this application embodiment to analyze the actual radian value and the reference radian value to generate the flow correction coefficient. Detailed Implementation

[0077] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figures 1 to 7 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0078] This application discloses a control method for an online metering device for bulk materials, wherein a bulk material conveying pipeline is sequentially connected to a data acquisition device, a pretreatment device, and a diversion metering device. The specific operating steps are as follows: First, the conveying device is controlled to transport bulk materials to the pre-treatment device and the diversion metering device according to the conveying parameters. After the pre-treatment device pre-treats the bulk materials, the diversion metering device is controlled to detect the real-time material flow rate. Finally, the diversion metering device is controlled to divert and transport the bulk materials to the material cart. The target material loading weight, cumulative loading amount, and real-time material flow rate of the material cart are obtained by the acquisition device, and the single bulk material loading time is obtained by calculating the product of the real-time material flow rate and the single bulk material loading time. Then, the current total loading amount is obtained by calculating the sum of the single material loading amount and the cumulative loading amount. If the current total loading amount is not less than the target material loading weight, the conveying device and the diversion metering device are controlled to stop. If the current total loading amount is less than the target material loading weight, the conveying device continues to transport bulk materials to the diversion metering device, and the diversion metering device is controlled to divert and transport the bulk materials to the material cart.

[0079] Reference Figure 1This application discloses a control method for an online metering device for bulk materials, comprising the following steps:

[0080] Step S100: Control the preset conveying device to convey the preset bulk material to the preset diversion metering device according to the preset conveying parameters.

[0081] Among them, conveying parameters refer to the general term for the pre-set operating control parameters and performance parameters that ensure the stable and accurate conveying of bulk materials by the conveying device. They are the core basis for achieving precise control of the conveying device. Conveying parameters include the rated operating speed of the conveyor belt.

[0082] A conveying device is a general term for equipment used to stably transport bulk materials from a storage unit or the previous process unit to a diversion and metering device. It includes a feed hopper, a drive unit, a discharge chute, and a conveyor belt. Bulk materials enter the conveyor belt controlled by the drive unit from the feed hopper, are transported to the discharge chute, and then enter the diversion and metering device. As a carrier for material transfer, it stably transports bulk materials from the storage end to the diversion and metering device, providing a continuous source of materials for subsequent diversion and metering.

[0083] The diversion metering device is the core functional component that realizes material diversion and real-time flow detection. It is a general term for equipment that integrates a diversion device, a flow detection unit, an arc acquisition unit, and a pre-treatment execution unit. One end of the device is connected to the discharge end of the conveying device, and the other end is connected to the inlet of the material cart. As an intermediate hub connecting the conveying device and the material cart, the pre-treatment execution unit uses a high-pressure airflow purging module and an infrared heating and dehumidification module to pre-treat the bulk materials remaining on the inner wall of the diversion device and the surface of the arc-shaped guide plate to ensure the accuracy of the initial material flow. The flow detection unit collects the material conveying speed and the mass of material per unit length in real time through sensors to obtain the initial real-time material flow. Then, the arc acquisition unit collects the arc to determine whether deformation has occurred during the detection process. Finally, the arc-shaped guide plate of the diversion device adopts a streamlined curved surface structure. When the material flows through the guide plate, it slides down along a preset trajectory under the guidance of the curved surface to avoid splashing and spillage of bulk materials.

[0084] Step S101: Control the diversion metering device to divert and transport the bulk materials to the preset material cart, and control the diversion metering device to detect the bulk materials to generate real-time material flow rate.

[0085] In this process, after the bulk materials are conveyed to the diversion and metering device by the conveying device, the diversion and metering device is controlled to detect the bulk materials and obtain the real-time material flow rate. Then, the diversion and metering device is controlled to divert and convey the bulk materials to the material truck.

[0086] Real-time material flow rate refers to the mass or volume of bulk material passing through the diversion and metering device per unit time. By controlling the diversion and metering device to detect the bulk material flow rate in real time, the accuracy of online metering of bulk materials is improved, ensuring a good conveying effect of bulk materials diverted and transported to the material cart. Specific methods are described in [reference needed]. Figure 2 The steps.

[0087] Step S102: Collect the target material loading weight, cumulative loading volume, and real-time material flow rate of the material truck, and the time for loading bulk materials in a single transaction.

[0088] The target loading weight refers to the total weight of bulk materials that need to be loaded into a single material truck. It is the target threshold for loading operations. By setting a reasonable target value, overloading of material trucks can be avoided, thus reducing traffic safety risks.

[0089] Cumulative loading volume refers to the total weight of bulk materials loaded into the material truck during this loading operation, based on the total flow rate before this material flow rate. It is obtained by the control device accumulating the real-time flow rate at different time intervals. Operators can intuitively understand the current loading completion status through the cumulative loading volume, providing a direct data source for obtaining the current total loading volume later.

[0090] The loading time for a single batch of bulk materials is the time length during a continuous loading process, which is multiplied by the real-time material flow rate to estimate the mass of material loaded in one batch. This time is not the total time of the entire loading task, but a dynamically updated time parameter that corresponds one-to-one with the real-time material flow rate. When the real-time material flow rate detected by the diversion metering device changes, the timer restarts to obtain the loading time for a single batch of bulk materials corresponding to the changed material flow rate, providing data support for obtaining the loading quantity of a single batch of materials.

[0091] Step S103: Calculate the product of real-time material flow rate and single bulk material loading time to generate single material loading quantity.

[0092] Among them, the single material loading quantity refers to the weight of bulk materials loaded into the material truck through the diversion metering device within a continuous single bulk material loading time cycle. It is necessary to calculate the product of the real-time material flow rate and the single bulk material loading time to obtain the single material loading quantity, which provides a basis for obtaining the current total loading quantity and is also the basis for the dynamic update of the cumulative loading quantity.

[0093] Step S104: Calculate the sum of the single material loading quantity and the cumulative loading quantity to generate the current total loading quantity.

[0094] The current total loading volume refers to the total weight of bulk materials that have been loaded into the material trucks up to the current moment during the bulk material loading operation. It is the sum of the cumulative loading volume and the latest single loading volume. The current total loading volume is obtained by calculating the sum of the single loading volume and the cumulative loading volume. It serves as the core criterion for determining whether the loading operation is completed and can provide real-time feedback on the loading operation progress.

[0095] Step S105: Determine whether the current total loading quantity is not less than the target material loading weight.

[0096] Specifically, by determining whether the current total loading volume is not less than the target material loading weight, it is determined whether the loading task has been completed, and further, whether to control the conveying device and the diversion metering device to stop.

[0097] Step S1051: If so, then control the conveying device and the diversion metering device to stop.

[0098] If the current total loading volume is not less than the target material loading weight, it indicates that the bulk material loading task has been completed. Therefore, it is not necessary to continue controlling the conveying device to transport the bulk material to the diversion metering device. The conveying device and the diversion metering device can be stopped directly.

[0099] Step S1052: If not, continue to control the conveying device to transport the bulk material to the diversion metering device, and control the diversion metering device to divert and transport the bulk material to the material cart.

[0100] If the current total loading volume is less than the target material loading weight, it means that the current total loading volume has not yet reached the target material loading weight, and the task of loading bulk materials has not been completed. Therefore, it is necessary to continue to control the conveying device to transport the bulk materials to the diversion metering device, and control the diversion metering device to divert and transport the bulk materials into the material car.

[0101] Reference Figure 2 The steps for controlling the diversion metering device to detect bulk materials and generate real-time material flow rates include:

[0102] Step S200: Control the diversion metering device to detect the bulk material to generate an initial real-time material flow rate.

[0103] The initial real-time material flow rate refers to the material mass or volume per unit time directly collected by the flow detection unit of the diversion metering device. This provides the calculation basis for the subsequent curvature correction of the diversion metering device. Obtaining the initial real-time material flow rate requires subsequent preprocessing and direct detection by the diversion metering device. Specific methods are detailed in [reference needed]. Figure 3 The steps.

[0104] Step S201: Collect the arc of the landing area of ​​the bulk material on the diversion metering device.

[0105] The landing area arc refers to the central angle of the guide plate corresponding to the area of ​​bulk material falling from the discharge end of the conveying device and impacting the material coverage area on the arc-shaped guide plate of the diversion metering device. By arranging multiple weighing sensor units along the circumference on the arc-shaped guide plate of the diversion metering device, the load signals of each point are collected in real time based on the identified effective material coverage area. The starting and ending angles of the material impact area are accurately located using interpolation fitting, and the difference between the two is calculated to obtain the dynamic landing area arc. Since the landing area arc may deform with the flow of bulk material, only by obtaining the true dynamic landing area arc can the subsequent arc change be calculated. The arc change is the core input variable that triggers the real-time material flow correction. Based on the fact that the arc change of different landing point segments within the landing area arc has different degrees of influence on the real-time material flow, the accuracy of online metering of bulk material can be improved by correcting the real-time material flow, thereby ensuring a good conveying effect of bulk material diversion and transportation to the material cart.

[0106] Step S202: Determine whether the arc of the landing area is consistent with the preset reference arc of the landing area.

[0107] Among them, the reference radian of the landing area refers to the standard value of the central angle of the guide plate corresponding to the area covered by the landing point of the bulk material when it passes through the arc-shaped guide plate of the diversion metering device under ideal working conditions. The reference radian of the landing area directly determines the triggering condition and correction accuracy of the flow correction, and is the threshold basis for judging whether to trigger the flow correction.

[0108] By determining whether the curvature of the landing area is consistent with the reference curvature of the landing area, it can be determined whether the curvature of the landing area has been deformed and whether the initial real-time material flow rate needs to be corrected before obtaining the real-time material flow rate.

[0109] Step S2021: If so, define the initial real-time material flow rate as the real-time material flow rate.

[0110] If the arc of the landing area is consistent with the reference arc of the landing area, it indicates that the arc of the landing area of ​​the diversion metering device has not changed and will not affect the detection of real-time material flow. Therefore, the initial real-time material flow is directly defined as the real-time material flow.

[0111] Step S2022: If not, analyze the initial real-time material flow rate and the curvature of the landing area to generate the real-time material flow rate.

[0112] If the curvature of the landing area is inconsistent with the reference curvature of the landing area, it indicates that the curvature of the diversion metering device has been deformed, which will affect the subsequent detection of real-time material flow by the diversion metering device. Therefore, it is necessary to analyze the initial real-time material flow and the curvature of the landing area to obtain the real-time material flow. The specific method is as follows: Figure 6 The steps.

[0113] Reference Figure 3 The steps for controlling the diversion metering device to detect bulk materials to generate an initial real-time material flow rate include:

[0114] Step S300: Collect the no-load measurement value of the diversion metering device.

[0115] Among them, the no-load measurement value refers to the real-time measurement data output by the flow detection unit when no bulk material passes through the diversion metering device under no-load operation. It reflects the inherent operating state of the diversion metering device when it is no-load and provides a basis for subsequent calculation of the real-time measurement drift of the diversion metering device.

[0116] Step S301: Calculate the difference between the no-load measurement value and the preset reference no-load value to generate the real-time measurement drift of the shunt metering device.

[0117] Among them, the reference no-load value refers to the theoretical measurement value output by the flow detection unit of the diversion metering device under ideal and interference-free no-load conditions. The reference no-load value needs to be calibrated at the factory. The reference no-load value is the core reference for judging whether the equipment is normal under no-load conditions. Without this value, it is impossible to quantify the degree of deviation of the no-load measurement value.

[0118] Real-time measurement drift refers to the systematic measurement offset of the diversion metering device caused by material adhesion and residue when no material is passing through. It is obtained by calculating the difference between the actual no-load measurement value collected by the diversion metering device and the reference no-load value. It reflects the degree of deviation between the current no-load state of the equipment and the ideal state, and triggers the core threshold of subsequent material adhesion pretreatment.

[0119] Step S302: Determine whether the real-time measured drift amount is greater than the preset adhesion determination threshold.

[0120] Among them, the adhesion judgment threshold is a pre-set critical drift value used to determine whether there is material adhesion in the detection area of ​​the diversion metering device. The adhesion judgment threshold is the core control threshold that triggers the pretreatment of the diversion metering device and directly determines whether the pretreatment device is started.

[0121] By determining whether the real-time drift is greater than the adhesion threshold, it can be determined whether there is material adhesion on the diversion metering device, and whether the diversion metering device needs to be pre-processed before it can be controlled to directly detect the bulk material to obtain the initial real-time material flow.

[0122] Step S3021: If so, preprocess the diversion metering device.

[0123] If the real-time drift measurement exceeds the adhesion threshold, it indicates material adhesion on the diversion metering device. This will cause the initial real-time material flow rate measurement by the diversion metering device to be too high, affecting the conveying effect of bulk materials to the material cart. Therefore, it is necessary to control the pre-treatment device to pre-treat the diversion metering device before controlling the diversion metering device to detect the bulk materials and obtain the initial real-time material flow rate. The specific method is as follows: Figure 4 The steps.

[0124] Step S30211: Control the diversion metering device to directly detect bulk materials to generate initial real-time material flow.

[0125] In this process, after preprocessing the diversion metering device, the diversion metering device is controlled to directly detect the bulk material to obtain the initial real-time material flow rate, thereby ensuring the accuracy of the initial real-time material flow rate.

[0126] Step S3022: If not, control the diversion metering device to directly detect the bulk material to generate an initial real-time material flow rate.

[0127] If the real-time drift amount is not greater than the adhesion judgment threshold, it indicates that there is no material adhesion on the diversion metering device. Therefore, it is not necessary to control the pre-treatment device to pre-process the diversion metering device. The diversion metering device can be directly controlled to detect the bulk material to obtain the initial real-time material flow rate, providing data support for obtaining the real-time material flow rate in the future.

[0128] Reference Figure 4 The pretreatment steps for the diversion metering device include:

[0129] Step S400: Collect the adhesive friction force and contact area of ​​the diversion metering device.

[0130] Among them, the adhesion friction force refers to the friction force that hinders relative motion between the material and the device contact surface when bulk material particles adhere to the detection area of ​​the diversion metering device. First, the adhesion strength of the bulk material in this batch is obtained by looking up the table, and then the adhesion friction force is obtained by calculating the product of the contact area and the adhesion strength, which provides a calculation basis for obtaining the blowing wind speed in the future.

[0131] The contact area refers to the actual contact area between the adhering bulk material and the detection area of ​​the diversion metering device. It is different from the overall surface area of ​​the device. This area only applies to the local area where the material adheres. The contact area is obtained by calculating the product of the radius of curvature of the diversion metering device's guide plate, the arc of the landing area, and the width of the guide plate. The contact area can be combined with the adhesion friction of the diversion metering device to obtain the subsequent blowing air velocity.

[0132] Step S401: Analyze the adhesive friction and contact area to generate the blowing velocity.

[0133] The blowing velocity refers to the airflow velocity output by the blowing component of the pretreatment device when material adheres to the detection area of ​​the diversion metering device. The blowing velocity is not a fixed value and needs to be calculated based on the collected adhesion friction and contact area. The specific calculation formula is as follows:

[0134] .

[0135] in, To determine the airflow speed, For adhesive friction, For contact area, Air density is a physical property of air, obtained by looking up a table. It serves as a bridge between airflow impact force and wind speed, improving the accuracy of blowing wind speed. The wind force coefficient is a parameter that corrects the influence of airflow pattern on impact force. It is obtained through experimental calibration and allows the calculated wind speed to better reflect the actual desiccation scenario.

[0136] Step S402: The pretreatment device is purged with air according to the air blowing speed to obtain a flow metering device without material adhesion.

[0137] Among them, after determining the blowing speed, the wind force intensity required to remove bulk materials adhering to the diversion metering device is determined. By controlling the pretreatment device to perform air blowing pretreatment on the diversion metering device, it is ensured that no material adheres to the diversion metering device, thereby improving the accuracy of the initial real-time material flow rate.

[0138] Reference Figure 5 Before the control and diversion metering device directly detects bulk materials to generate the initial real-time material flow rate, a pre-treatment step for the bulk materials is also included. Specific steps include:

[0139] Step S500: Collect the initial humidity of the bulk material.

[0140] Initial humidity refers to the percentage of water content in the bulk material before it enters the diversion metering device, relative to the total mass of the material. The initial humidity of the bulk material is directly measured by a humidity sensor and is the core basis for triggering the dehumidification pretreatment of the bulk material. By pre-treating the bulk material by dehumidification, it is possible to prevent the bulk material from adhering to the diversion metering device again during the online metering process, thereby improving the accuracy of the real-time material flow rate and ensuring a good conveying effect of the bulk material diverted and transported to the material cart.

[0141] Step S501: Determine whether the initial humidity is not greater than the preset humidity threshold.

[0142] Among them, the humidity threshold refers to the pre-set critical moisture content value used to determine whether bulk materials need to undergo dehumidification pretreatment. The humidity threshold is the core control threshold for triggering material dehumidification pretreatment and directly determines whether the dehumidification process is started.

[0143] By determining whether the initial humidity is greater than the humidity threshold, it can be determined whether the bulk material will adhere to the diversion metering device again during the online metering process, and whether it is necessary to perform a water removal pretreatment step on the bulk material before controlling the diversion metering device to directly detect the bulk material to obtain the initial real-time material flow.

[0144] Step S502: If so, control the diversion metering device to directly detect the bulk material to generate an initial real-time material flow rate.

[0145] If the initial humidity is less than or equal to the humidity threshold, it indicates that the bulk material will not adhere to the diversion metering device again during the online metering process, and will not affect the accuracy of the real-time material flow. Therefore, the diversion metering device can be directly controlled to detect the bulk material and obtain the initial real-time material flow.

[0146] Step S503: If not, calculate the difference between the initial humidity and the humidity threshold to generate the current water removal amount.

[0147] If the initial humidity is greater than the humidity threshold, it indicates that the bulk material will adhere to the diversion metering device again during the online metering process, which will affect the accuracy of the real-time material flow rate measurement. Therefore, the bulk material needs to be dehydrated.

[0148] The current water removal amount refers to the amount of water that needs to be removed from a unit mass or batch mass of material in order to reduce the moisture content of bulk materials with excessive humidity to a preset humidity threshold. The current water removal amount is obtained by calculating the difference between the initial humidity and the humidity threshold, and it is the direct data source for subsequent calculations to obtain the target heating power.

[0149] Step S504: Analyze the current water removal rate and the preset thermal efficiency to generate the target heating power.

[0150] The target heating power refers to the constant power output required by the dehumidification pretreatment device to remove the current amount of moisture within a set time. The dehumidification device will automatically adjust its output power according to the target heating power to ensure accurate removal of the current amount of moisture within the set time, reducing the material humidity below the threshold. The specific formula is as follows:

[0151] .

[0152] in, For the target heating power, The mass of the material to be dehumidified, measured directly by a weighing sensor, is a fundamental parameter for determining the target heating power. The specific heat capacity of bulk materials can be directly obtained by looking up a table, reflecting the heat absorption capacity of the bulk materials. This is the temperature change of the material from its initial temperature to the moisture evaporation temperature, obtained by calculating the difference between the initial temperature and the moisture evaporation temperature. It directly affects the target heating power required for dehumidification. For the current water removal volume, The heat required for a unit mass of water to change from a liquid to a gaseous state is a fixed value and serves as the benchmark constant for calculating the heat of vaporization of water. Thermal efficiency refers to the ratio of the effective heat utilized by the dehumidifier to the total input heat. The preset thermal efficiency is read from the control system's memory to compensate for the energy loss of the dehumidifier. The preset time required to complete dehumidification determines the heat output intensity per unit time.

[0153] Step S505: Control the pretreatment device to dehumidify the bulk material according to the target heating power to generate dehumidified bulk material.

[0154] After determining the target heating power, the heating power required to remove the current amount of moisture from the bulk material is determined. The bulk material is dehumidified by controlling the pretreatment device to obtain dehumidified bulk material. This ensures that the dehumidified bulk material does not adhere during the online metering process, thereby improving the accuracy of the online metering results of the bulk material.

[0155] The pretreatment unit is a specialized equipment module designed specifically for reducing the moisture content of bulk materials. It is integrated between the conveying device and the diversion and metering device. It includes heating and dehumidifying the bulk materials by an electric heater that supplies heat energy to ensure the dehumidification effect. Then, the completion of the dehumidification process is determined by inlet and outlet humidity sensors that detect the moisture content of the bulk materials. Finally, the moisture content that needs to be removed from the bulk materials is discharged outside the device by a dehumidifying fan. The pretreatment unit is the core execution unit for realizing material moisture control. By reducing the moisture content of the materials, it ensures the accuracy of the initial real-time material flow rate detection.

[0156] Step S506: Control the diversion metering device to directly detect bulk materials to generate initial real-time material flow rate.

[0157] In this step, the initial real-time material flow rate is the same as that in step S200. The real-time material flow rate is obtained by directly detecting the dehumidified bulk material through the control of the diversion metering device.

[0158] Reference Figure 6 The steps for generating real-time material flow rate by analyzing the initial real-time material flow rate and the curvature of the landing area include:

[0159] Step 600: Determine the landing segment points and corresponding actual radian values ​​based on the radian of the landing area.

[0160] Among them, the landing point segmentation point refers to the geometric boundary point set on the arc-shaped guide plate of the diversion metering device to accurately divide the actual landing point coverage area of ​​the material. These segmentation points are evenly arranged along the arc direction of the guide plate. They are obtained by dividing the continuous material landing point area into several independent and quantifiable arc sub-regions. Since the influence of material impact on flow detection is different in the guide plate area corresponding to different segmentation points, the average error of the real-time material flow rate obtained due to the overall arc change can be avoided. This provides data support for quantifying the correction of the real-time material flow rate by the arc change corresponding to different segmentation points.

[0161] The actual radian value refers to the size of the central angle corresponding to the arc sub-region defined by each landing point segment. Based on the radian of the landing point region, the overlapping part of the landing point segment and the actual coverage area of ​​the current material is obtained to obtain the starting angle and ending angle of each overlapping part on the arc. The actual radian value is obtained by calculating the difference between the starting and ending angles, which is the core data basis for subsequent calculations to obtain the flow correction coefficient.

[0162] Step 601: Based on the landing point segmentation point, find the corresponding reference radian value in the preset segmentation radian relationship.

[0163] Among them, the segmented radian relationship refers to the one-to-one correspondence rule between the landing point segment and the reference radian value of each segment, which is pre-calibrated and stored in the control system under ideal working conditions. Based on the landing point segment and the reference radian value corresponding to each segment, the segment boundary is optimized through calibration experiments to obtain the segmented radian relationship, which can realize segmented query and segmented correction, and improve the accuracy of subsequent flow correction.

[0164] The baseline radian value refers to the standard radian value of the arc sub-region defined by each landing point in the segmented radian relationship under ideal working conditions. It is obtained by the processing terminal by looking up the landing point in the mapping table corresponding to the segmented radian relationship, and provides basic data for subsequent weighted calculation of the total radian change.

[0165] Step 602: Analyze the actual radian value and the reference radian value to generate the flow correction coefficient.

[0166] The flow correction coefficient reflects the degree of flow detection error caused by material landing point offset. Its value is positively correlated with the curvature deviation. It is a proportional coefficient used to correct real-time material flow rate, calculated based on the deviation between the actual curvature of the material landing point area and the reference curvature. The flow correction coefficient is a core parameter for improving the accuracy of online metering of bulk materials and directly determines the correction effect of real-time material flow rate. The specific formula is as follows:

[0167] .

[0168] in, This is the flow correction factor. The basic flow correction coefficient is a fixed coefficient for the inherent systematic error of the compensation device under ideal operating conditions. It is obtained at the factory by calculating the quotient of the actual material flow rate and the detected flow rate under ideal operating conditions. It serves as the benchmark anchor point for flow correction. The preset linear correction coefficient, quantified experimentally, quantifies the linear impact of the total arc change on the flow rate and is the core parameter for correcting linearity errors. To quantify the overall offset of the material's landing point by calculating the total change in radian based on the actual radian value, Using the baseline radian value, the standard total radian of the material landing area under ideal working conditions serves as a reference standard for radian offset. The preset nonlinear correction coefficient is an empirical coefficient that compensates for nonlinear factors. Through experimental calibration, it corrects the nonlinear error when there is a large arc offset, thereby improving the measurement accuracy of real-time material flow.

[0169] Step 603: Calculate the product of the flow correction factor and the initial real-time material flow to generate the real-time material flow.

[0170] In this step, the real-time material flow rate is the same as that in step S2022. It is obtained by multiplying the flow correction coefficient and the initial real-time material flow rate by the processing terminal. By quantifying the impact of the deformation of the arc-shaped guide plate on the detection accuracy, the accuracy of online metering of bulk materials is improved, and the good conveying effect of bulk materials being diverted and transported to the material vehicle is guaranteed.

[0171] Reference Figure 7 The steps for analyzing the actual radian value and the reference radian value to generate the flow correction coefficient include:

[0172] Step 700: Calculate the difference between the actual radian value and the reference radian value to generate the radian change.

[0173] Among them, the arc change refers to the degree of deviation of the material landing point area. It is obtained by calculating the difference between the segment arc value of the actual landing point of the bulk material on the arc-shaped guide plate of the diversion metering device and the segment reference arc value, which provides data support for subsequent calculation to obtain the total arc change.

[0174] Step 701: Collect the percentage of material mass at each landing point segment.

[0175] Among them, the material landing point mass ratio refers to the proportion of the mass of the material in a certain landing point segment of the arc-shaped guide plate of the diversion metering device to the total mass of the material in all landing point areas. By summing the load signals of all sensors in each segment and dividing the sum of the signals in that segment by the sum of the total signals, the material landing point mass ratio is obtained, which quantifies the distribution concentration of the material in different segments of the guide plate. The material mass ratio of different segments is different, and the degree of influence of the arc change on the flow detection is also different. It is the core weight for the subsequent weighted calculation of the total arc change.

[0176] Step 702: Calculate the weighted sum of the arc change based on the mass ratio of the material landing point to generate the total arc change.

[0177] The total arc change refers to a comprehensive parameter obtained by weighting and summing the arc changes of each segment, using the proportion of material landing mass in each segment as the weight. It is the core indicator for quantifying the overall landing point offset of the material on the arc-shaped guide plate. The specific formula is as follows:

[0178] .

[0179] in, This represents the total change in radians. The effective segmentation count refers to the number of segmented sub-regions actually covered by the material. By identifying the segmentation points covered by the material using a sensor array and counting the effective segments, the range of segments participating in the weighted calculation can be determined, ensuring that deviation statistics are only performed on areas containing material. This is a numerical constant, indicating the number of segments representing the arc of the landing area. For the first The percentage of material landing point quality in each segment is used as a weighting factor to reflect the degree of impact of material quality in different segments on flow detection. For the first The difference between the actual radian value of each segment and the reference radian value is the basic data for calculating the total radian change.

[0180] Step 703: Analyze the total change in radians and the preset linear correction coefficient to generate the linear correction coefficient.

[0181] The linear correction factor is obtained by calculating the product of the total change in radians and the linear correction factor.

[0182] .

[0183] in, The linear coefficient correction amount is the linear adjustment part of the flow correction coefficient, which quantifies the linear impact of the total curvature change on the material flow rate.

[0184] Step 704: Analyze the total change in radians and the preset nonlinear correction coefficients to generate the nonlinear correction coefficient.

[0185] The nonlinear coefficient correction is the nonlinear adjustment part of the flow correction coefficient, and the specific formula is as follows:

[0186] .

[0187] in, This is a correction term for the nonlinear coefficient, obtained by weighting the square of the total radian change. It compensates for the nonlinear flow error under large radian offset and provides data support for obtaining the flow correction coefficient in the future.

[0188] Step 705: Calculate the sum of the nonlinear coefficient correction, the linear coefficient correction, and the preset baseline correction coefficient to generate the flow correction coefficient.

[0189] The reference correction factor refers to the fixed systematic compensation factor that needs to be applied under standard operating conditions to ensure that the output of the diversion metering device is consistent with the actual flow rate. It is obtained through factory calibration and provides data support for subsequent calculations to obtain the flow correction factor.

[0190] By calculating the sum of the nonlinear coefficient correction, the linear coefficient correction, and the baseline correction coefficient, the flow correction coefficient is obtained, which improves the accuracy of the real-time material flow rate of the diversion metering device in detecting bulk materials and ensures the accuracy of obtaining the current total loading volume.

[0191] Based on the same inventive concept, embodiments of this application provide an apparatus for a control method of an online metering device for bulk materials, comprising:

[0192] The data acquisition module is used to collect the curvature of the landing area of ​​bulk materials on the diversion metering device, the no-load measurement value of the diversion metering device, the adhesive friction and contact area of ​​the diversion metering device, the initial humidity of the bulk materials, and the mass ratio of the material landing at the landing segment points.

[0193] A memory used to store the control method program for an online metering device for bulk materials;

[0194] A processor is a method for controlling an online metering device for bulk materials, where programs in memory can be loaded and executed by the processor.

[0195] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0196] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed to control a method for an online metering device for bulk materials.

[0197] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0198] Based on the same inventive concept, embodiments of this application provide a smart terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed to control a method for an online metering device for bulk materials.

[0199] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0200] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A control method for an online metering device for bulk materials, characterized in that, include: According to the preset conveying parameters, the preset conveying device is controlled to convey the preset bulk materials to the preset diversion and metering device. The control diversion and metering device diverts and transports bulk materials to preset material carts, and controls the diversion and metering device to detect the bulk materials in order to generate real-time material flow rate. Collect the target material loading weight, cumulative loading volume, and real-time material flow rate of the material truck, and the corresponding single bulk material loading time. Calculate the product of real-time material flow rate and single bulk material loading time to generate single material loading quantity; Calculate the sum of the single material loading quantity and the cumulative loading quantity to generate the current total loading quantity; Determine whether the current total loading quantity is not less than the target material loading weight; If so, then the control conveying device and the diversion metering device shall be stopped; If not, continue to control the conveying device to transport the bulk material to the diversion metering device, and control the diversion metering device to divert and transport the bulk material to the material cart; The steps of controlling the diversion metering device to detect bulk materials and generate real-time material flow rates include: The control diversion metering device detects bulk materials to generate an initial real-time material flow rate; The arc of the landing area of ​​bulk materials on the diversion metering device is collected; Determine whether the arc of the landing area is consistent with the preset baseline arc of the landing area; If so, the initial real-time material flow rate is defined as the real-time material flow rate; If not, the initial real-time material flow rate and the curvature of the landing area are analyzed to generate the real-time material flow rate; The steps of controlling the diversion metering device to detect bulk materials to generate an initial real-time material flow rate include: Collect the no-load measurement values ​​of the diversion metering device; Calculate the difference between the no-load measurement value and the preset reference no-load value to generate the real-time measurement drift of the shunt metering device; Determine whether the real-time measured drift amount is greater than the preset adhesion judgment threshold; If so, the diversion metering device should be pre-processed; The control diversion metering device directly detects bulk materials to generate an initial real-time material flow rate; If not, the flow metering device is controlled to directly detect the bulk material to generate an initial real-time material flow rate; The pretreatment steps for the diversion metering device include: Collect the adhesive friction and contact area of ​​the diversion metering device; Adhesive friction and contact area are analyzed to generate airflow velocity; The pretreatment device controls the blowing speed to blow air into the diversion metering device to obtain a diversion metering device without material adhesion.

2. The control method for the online metering device for bulk materials according to claim 1, characterized in that, Before the control diversion metering device directly detects bulk materials to generate the initial real-time material flow rate, a pretreatment step for the bulk materials is also included. Specific steps include: Collect the initial humidity of the bulk materials; Determine whether the initial humidity is not greater than the preset humidity threshold; If so, the control diversion metering device directly detects the bulk material to generate the initial real-time material flow rate; If not, calculate the difference between the initial humidity and the humidity threshold to generate the current amount of water removed; The current water removal rate and preset thermal efficiency are analyzed to generate the target heating power; The pretreatment device is controlled according to the target heating power to dehumidify the bulk material, so as to generate dehumidified bulk material. The control diversion metering device directly detects bulk materials to generate an initial real-time material flow rate.

3. The control method for the online metering device for bulk materials according to claim 1, characterized in that, The steps for generating real-time material flow rate by analyzing the initial real-time material flow rate and the curvature of the landing area include: Determine the segment points of the landing point and the corresponding actual radian value based on the radian of the landing area; The corresponding reference radian value is found in the preset segmented radian relationship based on the landing point segmentation point; The actual radian value and the reference radian value are analyzed to generate the flow correction coefficient; Calculate the product of the flow correction factor and the initial real-time material flow rate to generate the real-time material flow rate.

4. The control method for the online metering device for bulk materials according to claim 3, characterized in that, The steps for analyzing the actual radian value and the reference radian value to generate the flow correction factor include: Calculate the difference between the actual radian value and the reference radian value to generate the radian change. The percentage of material mass at each landing point segment; The change in radii is weighted and summed based on the mass ratio of the material landing point to generate the total change in radii. The total change in radians and the preset linear correction coefficient are analyzed to generate the linear correction coefficient. The total change in radians and the preset nonlinear correction coefficients are analyzed to generate the nonlinear correction coefficients. The sum of the nonlinear coefficient correction, the linear coefficient correction, and the preset baseline correction coefficient is calculated to generate the flow correction coefficient.

5. A control device for an online metering device for bulk materials, characterized in that, include: The data acquisition module is used to collect the target material loading weight, cumulative loading volume, and single loading time of bulk materials. A memory for storing a program for controlling a bulk material online metering device as described in any one of claims 1 to 4; The processor and the program in the memory can be loaded and executed by the processor to implement the control method of the online metering device for bulk materials as described in any one of claims 1 to 4.

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