Quality control system for full-flow mixing operation of stacker-reclaimer

Abstract

This invention relates to the field of automatic control technology for stacker-reclaimers, specifically a quality control system for the entire process of mixing operations of a stacker-reclaimer. It overcomes the shortcomings of existing mixing operations, which are prone to material mixing errors. This system allows remote control personnel to start and stop the mixing process with a single button, eliminating the need for continuous close monitoring of the mixing process by staff. Instead, the automated system dynamically monitors the belt scale accuracy, automatically adjusts the operating flow according to the mixing ratio requirements, and spreads any single materials generated during automatic reversal or layer changing. Simultaneously, it minimizes the occurrence of single materials, better controls the mixing operation, and improves mixing quality and operational efficiency.

Description

Technical Field

[0001] This invention relates to the field of automatic control technology for stacker-reclaimer, specifically a quality control system for the entire process of mixing operations of a stacker-reclaimer. Background Technology

[0002] Due to the high cost of silo construction, and considering the scale and investment costs of port construction in the water transport industry, ports generally use open-air storage yards to store materials. Ports are usually large in scale and have relatively complex processes, and often need to mix different materials in a certain proportion. For example, coal ports often need to mix raw coal with large differences in quality in a certain proportion, i.e., to carry out blending operations. When two material handling equipment are working during coal blending operations, the blending ratio is difficult to control due to factors such as the collapse of the material stack and the asynchronous operation of the two machines, resulting in poor blending accuracy.

[0003] With the continuous advancement of smart port construction, heavy machinery and equipment in bulk cargo ports have gradually achieved automated and intelligent operation, with centralized control personnel remotely monitoring and operating multiple machines, gradually replacing the traditional manual operation mode where drivers operate the machines on-site.

[0004] In existing technology, the control of mixed materials is described in invention patent 201810200767.7. The reclaimer and ground conveyor are equipped with cantilevered mobile belt scales and ground fixed belt scales, respectively, for dynamic weighing of single items and mixed materials. The stacker and reclaimer are equipped with intelligent operation systems, featuring overall machine attitude positioning and stack shape monitoring. Radar rangefinders are installed on both sides of the reclaimer's bucket wheel, or a lidar is placed on the top of the cantilever front end to monitor whether the bucket wheel has reached the edge of the stack. The reclaimer's bucket wheel is hydraulically driven, and the hydraulic system can track the working pressure of the bucket wheel when it is feeding material in real time. Due to space limitations, the distance and path length from the bucket wheel of each reclaimer to the merging point of the ground conveyor vary. The conveyor uses a fixed speed, and the arrival times of the various materials requiring mixing in each reclaimer at the merging point differ. The material from the reclaimer with the shorter conveying path arrives at the merging point first. Different materials are taken from the stockpile by a bucket wheel reclaimer and transported to the auxiliary ground conveyor belt. After being dispersed and mixed by the transfer funnel on the auxiliary ground conveyor belt, they are transported to the stacker for storage, thereby realizing large-scale continuous mixing operations.

[0005] Existing operational control systems still have shortcomings: during mixing operations, there are problems such as material leakage from belt conveyors or inaccurate belt scales, resulting in a difference between the amount of material picked up by the reclaimers and the actual amount of material reaching the merging point. The existing technology lacks monitoring and analysis of the amount of material reaching the merging point on each conveyor line and the specific difference; the material picking of each reclaimer lacks dynamic control, resulting in each reclaimer operating independently and unable to communicate with each other in real time, thus causing the material ratio of the mixed stockpile to not meet the requirements. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the purpose of this invention is to provide a quality control system for the entire mixing operation of a stacker-reclaimer.

[0007] The technical solution adopted by this invention to solve its technical problem is:

[0008] A quality control system for the whole-process mixing operation of a stacker-reclaimer includes a first reclaimer, a second reclaimer, and a stacker. Both the first and second reclaimers are equipped with cantilever belt scales. The first reclaimer is connected to a merging point via a first ground belt conveyor. A first ground belt scale is installed on the first ground belt conveyor near the merging point. The second reclaimer is connected to the merging point via a second ground belt conveyor. The merging point is connected to the stacker via a third ground belt conveyor. A third ground belt scale is installed on the third ground belt conveyor.

[0009] During the mixing process, the control system executes automated dynamic monitoring logic for the belt scale accuracy and automated control logic for the material handling flow rate.

[0010] Automated dynamic monitoring logic for belt scale accuracy:

[0011] T11. Store the cumulative amount of each ground belt scale in real time at a set frequency, and record the cumulative amount of the cantilever belt scale of the first reclaimer and the second reclaimer respectively;

[0012] T12. Based on the time it takes for the material flow in the first reclaimer to be transported from the cantilever belt scale to the first ground belt scale, match the cumulative amount D1 of the first ground belt scale corresponding to the cumulative amount Q1 of the cantilever belt scale;

[0013] T13. Based on the time it takes for the material flow in the second reclaimer to be transported from the cantilever belt scale to the third ground belt scale, match the cumulative amount D3 of the third ground belt scale corresponding to the cumulative amount Q2 of the cantilever belt scale. At the same time, based on the time it takes for the material flow to be transported from the first ground belt scale to the third ground belt scale, match the cumulative amount D1´ of the first ground belt scale corresponding to the cumulative amount D3.

[0014] T14. Calculate the conveying deviation of the first and second reclaimers based on the cumulative quantities Q1, Q2 and D1, D1', D3 of the arm belt scale, and issue an over-limit alarm if the conveying deviation exceeds the deviation threshold.

[0015] Automated control logic for material handling flow rate:

[0016] T21. The time that the material in the first reclaimer takes from the start of conveying until it reaches the merging point is T0 compared with the time that the material in the second reclaimer takes from the start of conveying until it reaches the merging point.

[0017] T22. Obtain the mixing ratio B1:B2 of the first and second material fetching machines, and determine the mixing control threshold based on the mixing ratio.

[0018] T23. Set the operating flow rate V1 of the first material fetching machine and start the first material fetching machine. After T0 time, set the operating flow rate Vc of the second material fetching machine according to the operating flow rate V1 and the mixing ratio and start the second material fetching machine. Thereafter, adjust the operating flow rate V1 or the operating flow rate Vc through the comparison relationship of the cumulative ratio of the first and second material fetching machines, so that the comparison relationship of the cumulative ratio between the first and second material fetching machines is within the mixing control threshold.

[0019] As a preference, a further technical solution of the present invention is:

[0020] Preferably, T14 specifically includes:

[0021] Calculate the cumulative amount D2 of the material transported to the confluence point by the second ground belt conveyor, D2 = D3 - D1´;

[0022] In the initial stage of the mixing operation, calculate the transportation difference E3 = Q1 - D1 of the first material fetching machine and the transportation difference E4 = Q2 - D2 of the second material fetching machine, and issue an overlimit alarm when the transportation difference E3 or E4 exceeds the allowable deviation amount.

[0023] In the operation stage of the mixing operation, calculate the transportation error rate E1 = (Q1 - D1) / D1 of the first material fetching machine and the transportation error rate E2 = (Q2 - D2) / D2 of the second material fetching machine, and issue an error overlimit alarm when E1 or E2 exceeds ±1%.

[0024] Preferably, the process of determining the mixing control threshold based on the mixing ratio in T22 includes:

[0025] Set B1:B2 = r, and the allowable fluctuation range of r is ±2%; set the dynamic mixing ability J. Correspondingly, calculate the upper limit Rmax of the mixing control threshold = J×(r + 2%), and the lower limit Rmin of the mixing control threshold = J×(r - 2%).

[0026] Preferably, the design rated values of the operating flow rates of the first and second material fetching machines are both V0, and the time duration for the bucket wheel to rotate two circles is both Td. Correspondingly, T23 specifically includes:

[0027] T23-1. If B1≥B2, then set the operating flow rate V1 = V0; if B1 < B2, then set the operating flow rate V1 = (V0×B1) / B2; after the first material fetching machine is started, calculate the average operating flow rate of the first material fetching machine every Td time step with Td as the time step, and obtain the average operating flow rate sequence Vz (Vz1, Vz2, Vz3... Vzn);

[0028] T23-2. Using the average operating flow rate Vz1 corresponding to the first time step, the first operating flow rate of the second reclaimer is determined based on the formula Vc=Vz×B2 / B1=Vz / r, and the second reclaimer is controlled to start operation with the first operating flow rate after time T0.

[0029] T23-3. During the operation of the second reclaimer, the operating flow rate Vc is adjusted every Td interval with Td as the time step. During the adjustment, the operating flow rate Vc of the second reclaimer is calculated using Vz corresponding to the same number of time steps.

[0030] Preferably, T23 also includes:

[0031] T23-4. After the second reclaimer operates, record the cumulative amount of the cantilever belt scale of the second reclaimer every 1 second to obtain the cumulative amount sequence Q2 (Q2.1, Q2.2, Q2.3...Q2.n).

[0032] T23-5. After the first reclaimer starts operating, record the cumulative amount of the cantilever belt scale of the first reclaimer every 1 second to obtain the cumulative amount sequence Q1 (Q1.1, Q1.2, Q1.3...Q1.n, Q1.n+1, Q1.n+2...Q1.n+T0); where n represents the number of records as an integer value, and (Q1.n+1, Q1.n+2...Q1.n+T0) are the additional data recorded compared to the second reclaimer because the first reclaimer starts T0 time earlier.

[0033] T23-6. Using the cumulative amounts of the first and second reclaimers under the same number of records, calculate the difference in the cumulative amount of the proportion between the first and second reclaimers (Q1.n / r-Q2.n).

[0034] When (Q1.n / r-Q2.n)>Rmax, the cumulative amount of material to be reclaimed by the second reclaimer is calculated using the latest recorded cumulative amount of the cantilever belt scale of the first and second reclaimers. The total amount of material to be reclaimed by the second reclaimer is Mcb=Q1.n+T0 / r-Q2.n, and the operating flow rate Vc of the second reclaimer is increased according to the set ratio.

[0035] After time Td, if Mcb shows a decreasing trend, keep the operating flow rate Vc of the second reclaimer unchanged until (Q1.n / r-Q2.n)≤Rmax, then use process T23-3 to adjust the operating flow rate Vc of the second reclaimer; if Mcb does not decrease, set the operating flow rate Vc of the second reclaimer to V0, and reduce the operating flow rate V1 of the first reclaimer according to the set ratio.

[0036] After another Td time, if Mcb shows a decreasing trend, keep the current operating flow rates of the first and second reclaimers unchanged until (Q1.n / r-Q2.n)≤Rmax, then use process T23-3 to adjust the operating flow rate Vc of the second reclaimer; if Mcb does not decrease, stop the first reclaimer until Mcb decreases, then restart the first reclaimer, and at the same time reduce the operating flow rate V1 according to the set ratio;

[0037] T23-7. When the ratio difference between the second and first reclaimers (Q2.n-Q1.n / r) > Rmin, reduce the operating flow rate Vc of the second reclaimer according to the set ratio. After time Td, if Mcb shows an increasing trend, keep the current operating flow rate Vc of the second reclaimer unchanged; otherwise, stop the second reclaimer until (Q2.n-Q1.n / r) ≤ Rmin. Then, use the T23-3 process to set the operating flow rate Vc of the second reclaimer and restart the second reclaimer.

[0038] Preferably, it also includes material continuity control logic during the reversing of the cantilever of the reclaimer:

[0039] To improve the continuity of material proportioning while ensuring safety, the automatic switching of the cantilever rotation direction before the bucket wheel of the reclaimer reaches the protection threshold of the material stack boundary requires the following three conditions to be met simultaneously:

[0040] 1) Based on the reclaimer's attitude positioning data and the radar data at the front end of the cantilever, it was determined that the bucket wheel was located at the edge of the stack;

[0041] 2) The rotational speed of the reclaimer's cantilever towards the outside of the stack reaches more than 5% of the rated speed;

[0042] 3) The working pressure value of the bucket wheel of the reclaimer is lower than the set value F;

[0043] The setting value F has two sources: the reference value Fm and the correction value Fmx;

[0044] The baseline value Fm originates from the baseline parameters set during the commissioning of the control system. It represents the working reversing pressure of the bucket wheel at 20% of the rated flow rate when the rotation direction is automatically switched at the edge of the material stack. The baseline parameters also include the no-load working pressure F0 of the bucket wheel and the rated working pressure Fn of the bucket wheel when the reclaimer operates at the rated flow rate for different material types. When the reclaimer starts operating, the default setting is F=Fm.

[0045] When the fluctuation range between the actual flow rate and the rated flow rate of the feeder is stable within ±5%, and the fluctuation of the working pressure of the matching bucket wheel is also less than 10%, and the system runs continuously for two bucket wheel rotation cycles, the control system automatically records the average working pressure of the bucket wheel at the rated flow rate, Fnx. If the deviation between Fnx and Fn exceeds ±10%, the correction value Fmx of F is calculated based on the deviation between Fnx and Fn, and F=Fmx is set to control the switching of the cantilever rotation direction. If the deviation between Fnx and Fn exceeds ±20%, it is marked as abnormal data, but F is still set as the reference value Fm.

[0046] Preferably, this also includes a strategy for ensuring the quality of the mix proportions during layer changing at the reclaimer's working surface:

[0047] The bucket wheel of the reclaimer rotates from the outer edge of the stack to the inner edge with the cantilever, then moves forward with the reclaimer to feed material, and then returns to the outer edge with the cantilever; this is one rotation cycle. The reclaimer operates on the stack layer by layer in a rotating feeding manner. The cooperative material handling control of the first and second reclaimers is as follows:

[0048] Based on the cumulative amount of the cantilever belt scales of the first and second reclaimers, the amount of material Mzt that the first reclaimer takes up more material due to prioritizing material taking over time difference T0 is calculated in real time; during the rotation of the first reclaimer, the amount of material taken up MTd in the two most recent bucket wheel rotation cycles is recorded in real time.

[0049] Determine the material collection area and corresponding material collection amount of the second reclaimer in the last three bucket wheel rotation cycles, then calculate the remaining material collection amount Mcs corresponding to the remaining area of ​​the current working layer of the second reclaimer, and calculate the corresponding material collection amount Mzs of the first reclaimer based on Mcs and the mixing ratio.

[0050] If Mzt > Mzs + MTd, the first reclaimer enters a paused reclaiming state until the second reclaimer reaches the starting point of the next working surface and sends a start reclaiming signal, after which the first reclaimer resumes reclaiming.

[0051] Preferably, a single-material automatic spreading control strategy for the stacker is also included:

[0052] Based on the instantaneous flow data of the third ground belt scale, the instantaneous flow data of the cantilever belt scales of the first and second reclaimers are matched to realize the detection of material type. If it is determined that only a single type of material from the first or second reclaimer arrives at the stacker and continues to exceed Td, the automatic single material spreading control mode of the stacker is activated.

[0053] During the single-material automatic spreading control mode of the stacker, the stacker transitions from automatic stacking mode to automatic continuous point-changing mode. The point-changing path is consistent with the original stacking path, and the maximum number of points changed in a single operation does not exceed the number of stacking points in a single row of the material pile. During the point-changing process...

[0054] 1) When the material section of a single material ends, the stacker will automatically return to the original stacking point corresponding to the single material automatic spreading control mode of the stacker when it is activated;

[0055] 2) When the maximum number of relocation points is reached, the stacker will automatically return to the original stacking point;

[0056] 3) If the source of a single material is switched to another reclaimer, the stacker will automatically return to the original stacking point;

[0057] After returning to the original stockpile point, another material reclaimer replenishes the mixing ratio according to the single material automatic spreading control mode of the stockpile machine.

[0058] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art:

[0059] It overcomes the operational control defects of existing mixing operations that are prone to material mixing errors, enabling remote centralized control personnel to start and stop the mixing operation process with one click. Instead of requiring staff to continuously and closely monitor the mixing process, the automated system dynamically monitors the belt scale accuracy, automatically adjusts the operation flow according to the mixing ratio requirements, and spreads any single materials generated during automatic reversal or layering. At the same time, it minimizes the occurrence of single materials, better controls the mixing operation, and improves the mixing quality and operation efficiency. Attached Figure Description

[0060] Figure 1 This is a schematic diagram of the arrangement of two material handling machines in a mixing operation scenario according to an embodiment of the present invention;

[0061] Figure 2 This is a schematic diagram of the material reclaimer operating at the edge of the material stack in an embodiment of the present invention;

[0062] Figure 3 This is a schematic diagram of the automatic stacking path of the stacker in an embodiment of the present invention;

[0063] Figure 4 This is a schematic diagram of a single material spreading path of the stacker in an embodiment of the present invention. Detailed Implementation

[0064] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0065] This embodiment presents a quality control system for the entire mixing operation of a stacker-reclaimer, such as... Figure 1As shown, the system includes a first reclaimer, a second reclaimer, and a stacker. Both the first and second reclaimers are equipped with cantilever belt scales. The first reclaimer is connected to the merging point via a first ground belt conveyor. A first ground belt scale is installed on the first ground belt conveyor near the merging point. The second reclaimer is connected to the merging point via a second ground belt conveyor. The merging point is connected to the stacker via a third ground belt conveyor. A third ground belt scale is installed on the third ground belt conveyor.

[0066] During the blending process, automated operation control is achieved through a control system. The system calculates the path of material from the bucket wheel of the reclaimer to the merging point of the ground conveyor belt. Specifically, the reclaimer farther away is designated as the first reclaimer, and the one closer is designated as the second reclaimer. Using the path length to the merging point, the material drop height in the hopper, and the fixed rotational speed of the conveyor belt, the time difference T0 between the arrival of material at the merging point by the first and second reclaimers is calculated. Both reclaimers feed material at a fixed bucket wheel speed. Combined with the weighing data from the cantilever belt scale, the material flow rate is adjusted by controlling the cantilever's rotational speed. After the centralized control personnel initiate the fully automated blending process, the control system controls the first reclaimer to begin feeding material, and the second reclaimer begins feeding material after a delay of T0. After completing the predetermined blending volume, the first reclaimer stops feeding material first, and the second reclaimer stops feeding material after completing the remaining proportion.

[0067] During implementation, the control system executes automated dynamic monitoring logic for belt scale accuracy and automated control logic for material handling flow during the mixing process.

[0068] Automated dynamic monitoring logic for belt scale accuracy:

[0069] T11. Store the cumulative amount of each ground belt scale in real time at a set frequency, and record the cumulative amount of the cantilever belt scale of the first reclaimer and the second reclaimer respectively;

[0070] T12. Based on the time it takes for the material flow in the first reclaimer to be transported from the cantilever belt scale to the first ground belt scale, match the cumulative amount D1 of the first ground belt scale corresponding to the cumulative amount Q1 of the cantilever belt scale;

[0071] T13. Based on the time it takes for the material flow in the second reclaimer to be transported from the cantilever belt scale to the third ground belt scale, match the cumulative amount D3 of the third ground belt scale corresponding to the cumulative amount Q2 of the cantilever belt scale. At the same time, based on the time it takes for the material flow to be transported from the first ground belt scale to the third ground belt scale, match the cumulative amount D1´ of the first ground belt scale corresponding to the cumulative amount D3.

[0072] T14. Calculate the conveying deviation of the first and second reclaimers based on the cumulative quantities Q1, Q2 and D1, D1', D3 of the arm belt scale, and issue an over-limit alarm if the conveying deviation exceeds the deviation threshold.

[0073] Automated control logic for material handling flow rate:

[0074] T21. The time that the material in the first reclaimer takes from the start of conveying until it reaches the merging point is T0 compared with the time that the material in the second reclaimer takes from the start of conveying until it reaches the merging point.

[0075] T22. Obtain the mixing ratio B1:B2 of the first feeder and the second feeder, and determine the mixing control threshold based on the mixing ratio;

[0076] T23. Set the operating flow rate V1 of the first reclaimer and start the first reclaimer. After time T0, set the operating flow rate Vc of the second reclaimer according to the operating flow rate V1 and the mixing ratio and start the second reclaimer. Thereafter, adjust the operating flow rate V1 or the operating flow rate Vc by comparing the cumulative mixing ratio between the first reclaimer and the second reclaimer, so that the comparison of the cumulative mixing ratio between the first reclaimer and the second reclaimer is within the mixing control threshold.

[0077] During implementation, both the cantilever belt and the ground belt operate at a fixed speed. The time it takes for the material flow from the first reclaimer to be transported from the cantilever belt scale to the first ground belt scale, the time it takes for the material flow from the second reclaimer to be transported from the cantilever belt scale to the third ground belt scale, and the time it takes for the material flow to be transported from the first ground belt scale to the third ground belt scale are all fixed values. To ensure the accuracy of the early warning, when verifying whether there is a conveying deviation based on the data of the belt scale, it is necessary to synchronously compare the data based on the difference in material transportation time.

[0078] For example, if the material flow from the first reclaimer to the first ground belt scale takes 5 seconds (meaning the material flow at the first reclaimer's cantilever belt scale needs 5 seconds to reach the first ground belt scale), then when comparing, the cumulative amount Q1 recorded at the 10th second is recorded at the cantilever belt scale, and the corresponding cumulative amount D1 recorded at the 15th second is used for the first ground belt scale. Similarly, if the material flow from the second reclaimer to the third ground belt scale takes 3 seconds, and the material flow from the first ground belt scale to the third ground belt scale takes 1 second, then the cumulative amount Q2 recorded at the 10th second is recorded at the 13th second. Furthermore, since the cumulative amount Q2 recorded at the 10th second merges with the cumulative amount D1' recorded at the 12th second at the third ground belt scale to form D3, the corresponding cumulative amount D3 is recorded at the 12th second at the first ground belt scale.

[0079] In implementation, the cantilever belt weigher of the second belt conveyor should correspond to a second ground belt weigher. To reduce costs, the second ground belt weigher can be set as a virtual device, and its value is calculated based on the first ground belt weigher and the third ground belt weigher. Correspondingly, T14 specifically includes:

[0080] Calculate the cumulative amount of material D2 transported to the confluence point by the second ground belt conveyor. D2 = D3 - D1´.

[0081] In the initial stage of the blending operation, calculate the transportation difference E3 = Q1 - D1 of the first reclaimer and the transportation difference E4 = Q2 - D2 of the second reclaimer. When the transportation difference E3 or E4 exceeds the allowable deviation amount, an overlimit alarm is issued. The allowable deviation amount can be ±2 tons.

[0082] In the operation stage of the blending operation, calculate the transportation error rate E1 = (Q1 - D1) / D1 of the first reclaimer and the transportation error rate E2 = (Q2 - D2) / D2 of the second reclaimer. When E1 or E2 exceeds ±1%, an error overlimit alarm is issued.

[0083] Based on the existing stacking and reclaiming machine blending unit, when the reclaimer continuously reclaims 200 tons of materials, the system reaches a stable operation state. Therefore, it can be set that: when the cumulative material amount of a single reclaimer in the blending operation is within 200 tons, it is the initial stage of the blending operation; in the blending operation, after the cumulative material amount of the reclaimer exceeds 200 tons, it is the operation stage of the blending operation.

[0084] The process of determining the blending control threshold based on the blending ratio in T22 includes:

[0085] Set B1:B2 = r, and the allowable fluctuation range of r is ±2%; set the dynamic blending ability J. Correspondingly, calculate the upper limit Rmax of the blending control threshold = J×(r + 2%), and the lower limit Rmin of the blending control threshold = J×(r - 2%). Optionally, J = 200 tons.

[0086] The designed rated values of the operation flow rates of the first reclaimer and the second reclaimer are both V0, and the time duration for the bucket wheel to rotate two circles is both Td. Correspondingly, T23 specifically includes:

[0087] T23-1. If B1≥B2, set the operation flow rate V1 = V0; if B1 < B2, set the operation flow rate V1 = (V0×B1) / B2. After the first reclaimer starts, calculate the average operation flow rate of the first reclaimer every interval of Td with Td as the time step, and obtain the average operation flow rate sequence Vz (Vz1, Vz2, Vz3... Vzn).

[0088] T23-2. Using the average operating flow rate Vz1 corresponding to the first time step, the first operating flow rate of the second reclaimer is determined based on the formula Vc=Vz×B2 / B1=Vz / r for calculating the operating flow rate of the second reclaimer, and the second reclaimer is controlled to start operation with the first operating flow rate after time T0.

[0089] T23-3. During the operation of the second reclaimer, the operating flow rate Vc is adjusted at intervals Td, with Td as the time step. During the adjustment, the operating flow rate Vc of the second reclaimer is calculated using Vz corresponding to the same time step. Specifically, the second reclaimer, which starts later, is used to complete the mixing ratio with the first reclaimer. The Vc value at each time step needs to be sequentially matched with the average operating flow rate sequence Vz (Vz1, Vz2, Vz3...Vzn). That is, Vz1 is used to calculate Vc (first operating flow rate) corresponding to the first time step, Vz2 is used to calculate Vc corresponding to the second time step, and so on, to ensure the accuracy and timeliness of Vc adjustment.

[0090] T23 also includes:

[0091] T23-4. After the second reclaimer operates, record the cumulative amount of the cantilever belt scale of the second reclaimer every 1 second to obtain the cumulative amount sequence Q2 (Q2.1, Q2.2, Q2.3...Q2.n).

[0092] T23-5. After the first reclaimer starts operating, record the cumulative amount of the cantilever belt scale of the first reclaimer every 1 second to obtain the cumulative amount sequence Q1 (Q1.1, Q1.2, Q1.3...Q1.n, Q1.n+1, Q1.n+2...Q1.n+T0); where n represents the number of records as an integer value, and (Q1.n+1, Q1.n+2...Q1.n+T0) are the data that are recorded more than the second reclaimer because the first reclaimer starts T0 time earlier.

[0093] T23-6. Using the cumulative values ​​of the first and second reclaimers' cantilever belt scales under the same number of recordings, calculate the difference in cumulative mixing ratio between the first and second reclaimers (Q1.n / r - Q2.n). As mentioned earlier, the second reclaimer, which starts later, is to make up for the mixing ratio with the first reclaimer. Therefore, if the cumulative values ​​of the cantilever belt scales recorded at the same time interval can sequentially satisfy the mixing ratio, i.e., Q2.1 corresponds to Q1.1, Q2.2 corresponds to Q1.2, and so on, then the precise control of the mixing ratio between the first and second reclaimers is achieved.

[0094] When (Q1.n / r-Q2.n)>Rmax, that is, when the first reclaimer is over-supplied, the cumulative amount of the cantilever belt scale currently recorded by the first and second reclaimers is used to calculate the total amount of material that the second reclaimer should replenish, Mcb=Q1.n+T0 / r-Q2.n, and the operating flow rate Vc of the second reclaimer is increased according to the set ratio, such as adjusting it to 1.5 times the current operating flow rate Vc.

[0095] After time Td, if Mcb shows a decreasing trend, keep the operating flow rate Vc of the second reclaimer unchanged until (Q1.n / r-Q2.n)≤Rmax, then use process T23-3 to adjust the operating flow rate Vc of the second reclaimer; if Mcb does not decrease, set the operating flow rate Vc of the second reclaimer to V0, and reduce the operating flow rate V1 of the first reclaimer according to the set ratio, such as setting the operating flow rate V1 to 0.7 times the current value.

[0096] After time Td, if Mcb shows a decreasing trend, keep the current operating flow rates of the first and second reclaimers unchanged until (Q1.n / r-Q2.n)≤Rmax, then use process T23-3 to adjust the operating flow rate Vc of the second reclaimer; if Mcb does not decrease, stop the first reclaimer until Mcb decreases, then restart the first reclaimer, and at the same time reduce the operating flow rate V1 according to the set ratio, such as setting it to 0.7 times the operating flow rate V1 when stopped.

[0097] T23-7. When the ratio difference between the second and first reclaimers (Q2.n-Q1.n / r) > Rmin, the second reclaimer is over-proportioned. The operating flow rate Vc of the second reclaimer is reduced according to the set ratio. For example, if the operating flow rate Vc is set to 0.5 times the current value, after time Td, if Mcb shows an increasing trend, the current operating flow rate Vc of the second reclaimer remains unchanged. Otherwise, the second reclaimer is stopped until (Q2.n-Q1.n / r) ≤ Rmin. Then, the operating flow rate Vc of the second reclaimer is set using the T23-3 procedure and the second reclaimer is restarted.

[0098] This enables automatic adjustment of the material flow rates of the first and second material feeders in the mixing process, ensuring that the mixing ratio is met. In practice, if the first material feeder malfunctions and stops, the second material feeder automatically replenishes the required amount and then stops feeding. If the second material feeder malfunctions and stops, the first material feeder stops feeding within the Td cycle, and resumes feeding automatically according to the aforementioned automated material flow rate control logic after the malfunction is resolved.

[0099] In implementation, the first and second reclaimers retrieve materials from their respective stacks. The conventional method in existing technology involves reclaiming material in a straight line from the first side of the stack to the opposite second side, then reversing the cantilever to return from the second side to the first side, repeating this process. However, due to equipment inertia and the control method, the reclaimer cantilever may fail to switch direction in time during reversal, causing the bucket wheel to exceed the stack's range and resulting in discontinuous reclaiming. To address the material ratio deviation caused by discontinuous reclaiming during the cantilever rotation and reversal, the control system also executes material continuity control logic during the cantilever rotation and reversal process in the mixing operation.

[0100] See Figure 2 To improve the continuity of material proportioning while ensuring safety, the automatic switching of the cantilever rotation direction before the bucket wheel of the reclaimer reaches the protection threshold of the material stack boundary requires the following three conditions to be met simultaneously:

[0101] 1) Based on the reclaimer's attitude positioning data and the radar data at the front end of the cantilever, it was determined that the bucket wheel was located at the edge of the stack;

[0102] 2) The rotational speed of the reclaimer's cantilever towards the outside of the stack reaches more than 5% of the rated speed;

[0103] 3) The working pressure value of the bucket wheel of the reclaimer is lower than the set value F;

[0104] The setting value F has two sources: the reference value Fm and the correction value Fmx;

[0105] The baseline value Fm originates from the baseline parameters set during the commissioning of the control system. It represents the working reversing pressure of the bucket wheel at 20% of the rated flow when the rotation direction is automatically switched at the edge of the material stack. The baseline parameters also include the no-load working pressure F0 of the bucket wheel and the rated working pressure Fn of the bucket wheel when the reclaimer operates at the rated flow for different material types. When the reclaimer starts operating, the default setting is F=Fm.

[0106] When the fluctuation range between the actual flow rate and the rated flow rate of the feeder is stable within ±5%, and the fluctuation of the working pressure of the matching bucket wheel is also less than 10%, and the system runs continuously for two bucket wheel rotation cycles, the control system automatically records the average working pressure Fnx of the bucket wheel under the rated flow rate. If the deviation between Fnx and Fn exceeds ±10%, the correction value Fmx of F is calculated based on the deviation between Fnx and Fn. For example, if the deviation between Fnx and Fn is 10%, then Fmx is 110%F, and F=Fmx is set to control the switching of the cantilever rotation direction. If the deviation between Fnx and Fn exceeds ±20%, it is marked as abnormal data, but F is still set as the reference value Fm.

[0107] During implementation, to further ensure safe operation, after the reclaimer switches the cantilever rotation direction and enters the traveling feed stage, if the bucket wheel working pressure reaches 80%Fn, the reclaimer will immediately stop traveling and send an alarm to the central control personnel. Simultaneously, to reduce the number of reversals, the material layer height on the reclaimer's working surface should be consistent with the maximum radius of the bucket wheel.

[0108] During implementation, the material reclaimer picks up material sequentially from the top layer of the stack to the bottom layer, specifically: "first row top layer, first row middle layer, first row bottom layer, second row top layer, second row middle layer, second row bottom layer, third row...". During layer changes, the width of each layer of material in the stack varies, resulting in differences in the amount of material picked up by the bucket wheel, which ultimately affects the proportion of the stacked material. To mitigate the defects caused by this, the control system also implements a proportioning quality assurance strategy during layer changes on the reclaimer's working surface during the mixing process:

[0109] The bucket wheel of the reclaimer rotates from the outer edge of the stack to the inner edge with the cantilever, then moves forward with the reclaimer to feed material, and then returns to the outer edge with the cantilever; this is one rotation cycle. The reclaimer operates on the stack layer by layer in a rotating feeding manner. The cooperative material handling control of the first and second reclaimers is as follows:

[0110] Based on the cumulative amount of the cantilever belt scales of the first and second reclaimers, the amount of material Mzt that the first reclaimer takes up more material due to prioritizing material taking over time difference T0 is calculated in real time; during the rotation of the first reclaimer, the amount of material taken up MTd in the two most recent bucket wheel rotation cycles is recorded in real time.

[0111] Determine the material collection area and corresponding material collection amount of the second reclaimer in the last three bucket wheel rotation cycles, then calculate the remaining material collection amount Mcs corresponding to the remaining area of ​​the current working layer of the second reclaimer, and calculate the corresponding material collection amount Mzs of the first reclaimer based on Mcs and the mixing ratio.

[0112] If Mzt > Mzs + MTd, the first reclaimer enters a paused reclaiming state until the second reclaimer reaches the starting point of the next working face and sends a signal to resume reclaiming. The core logic of this judgment is whether the existing over-allocation Mzt of the first reclaimer exceeds the maximum amount Mzs that the second reclaimer can replenish in the current layer plus the system's allowed buffer amount MTd. This is to avoid long-term imbalance in the material ratio caused by the first reclaimer's "priority reclaiming + layer change difference". By quantifying the relationship between "the first reclaimer's over-allocation" and "the upper limit of the amount the second reclaimer can replenish during layer change", it ensures that the material ratio of the two reclaimers is always controlled within the allowable fluctuation range. Mzt quantifies the "over-allocation scale" of the first reclaimer, and the remaining reclaiming amount Mcs is used to calculate the corresponding reclaiming amount Mzs, which clarifies the "maximum reasonable amount" that the second reclaimer can support the first reclaimer to continue reclaiming in the remaining work of the current layer. MTd reserves "buffer amount" to play a redundancy role.

[0113] In practice, multiple reclaimers operate simultaneously. However, due to various reasons, the materials from the reclaimers do not arrive at the merging point at the same time for some periods. Occasionally, only one type of material is reclaimed at the merging point, and the stacker continuously reclaims material from the merging point. Therefore, the stacker spends part of its time transporting a single material. Traditional stacker unloading involves continuous point-changing operations, moving according to location without distinguishing the current material conditions. This results in uneven material distribution and significant differences in material ratios at different locations within the stack, leading to inaccurate quality inspections later on. To address this deficiency, the control system also implements an automatic single-material spreading control strategy for the stacker during the mixing process.

[0114] Based on the instantaneous flow data of the third ground belt scale, the instantaneous flow data of the cantilever belt scales of the first and second reclaimers are matched to realize the detection of material type. If it is determined that only a single type of material from the first or second reclaimer arrives at the stacker and continues to exceed Td, the single material automatic spreading control mode of the stacker is activated.

[0115] During the single-material automatic spreading control mode of the stacker, the stacker transitions from automatic stacking mode to automatic continuous point-changing mode. The point-changing path remains the same as the original stacking path, but the maximum number of points changed at one time does not exceed the number of stacking points in a single row of the material pile. During the point-changing process,

[0116] 1) When the material section of a single material ends, the stacker will automatically return to the original stacking point corresponding to the single material automatic spreading control mode of the stacker when it is activated;

[0117] 2) When the maximum number of relocation points is reached, the stacker will automatically return to the original stacking point;

[0118] 3) If the source of a single material is switched to another reclaimer, the stacker will automatically return to the original stacking point;

[0119] After returning to the original stockpile point, another material reclaimer replenishes the mixing ratio according to the single material automatic spreading control mode of the stockpile machine.

[0120] See Figure 3 and Figure 4 For example, when the automatic material stacking reaches point 18, the second material reclaimer malfunctions and stops operating. At this time, it enters the single material automatic spreading control mode. The material section of the single material of the first material reclaimer is relatively long, and the material stacking point will be switched from point 18 to point 24 one by one. The second material reclaimer resumes normal operation. After that, the stacker returns to point 18, and the second material reclaimer replenishes the mixing ratio according to the single material automatic spreading control mode.

[0121] The solution provided by this invention overcomes the operational control defects of existing mixing operations, which are prone to material mixing errors. It enables remote centralized control personnel to start and stop the mixing operation process with one click, eliminating the need for staff to continuously and closely monitor the mixing process. Instead, the automated system dynamically monitors the belt scale accuracy, automatically adjusts the operation flow according to the mixing ratio requirements, and spreads any single materials generated during automatic reversal or layering. At the same time, it minimizes the occurrence of single materials, better controls the mixing operation, and improves the mixing quality and operational efficiency.

[0122] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A quality control system for a full-flow blending operation of a stacker-reclaimer, characterized in that, It includes a first reclaimer, a second reclaimer, and a stacker. Both the first and second reclaimers are equipped with cantilever belt scales. The first reclaimer is connected to the merging point via a first ground belt conveyor. A first ground belt scale is installed on the first ground belt conveyor near the merging point. The second reclaimer is connected to the merging point via a second ground belt conveyor. The merging point is connected to the stacker via a third ground belt conveyor. A third ground belt scale is installed on the third ground belt conveyor. During the mixing process, the control system executes automated dynamic monitoring logic for belt scale accuracy and automated control logic for material handling flow. Automated dynamic monitoring logic for belt scale accuracy: T11. Store the cumulative amount of each ground belt scale in real time at a set frequency, and record the cumulative amount of the cantilever belt scale of the first reclaimer and the second reclaimer respectively. T12. Based on the time it takes for the material flow in the first reclaimer to be transported from the cantilever belt scale to the first ground belt scale, match the cumulative amount D1 of the first ground belt scale corresponding to the cumulative amount Q1 of the cantilever belt scale; T13. Based on the time it takes for the material flow in the second reclaimer to be transported from the cantilever belt scale to the third ground belt scale, match the cumulative amount D3 of the third ground belt scale corresponding to the cumulative amount Q2 of the cantilever belt scale. At the same time, based on the time it takes for the material flow to be transported from the first ground belt scale to the third ground belt scale, match the cumulative amount D1´ of the first ground belt scale corresponding to the cumulative amount D3. T14. Calculate the conveying deviation of the first and second reclaimers based on the cumulative quantities Q1, Q2 and D1, D1', D3 of the arm belt scale, and issue an over-limit alarm if the conveying deviation exceeds the deviation threshold. Automated control logic for material handling flow rate: T21. The time that the material in the first reclaimer takes from the start of conveying until it reaches the merging point is compared with the time that the material in the second reclaimer takes from the start of conveying until it reaches the merging point, is defined as T0. T22. Obtain the mixing ratio B1:B2 of the first feeder and the second feeder, and determine the mixing control threshold based on the mixing ratio; T23. Set the operating flow rate V1 of the first reclaimer and start the first reclaimer. After time T0, set the operating flow rate Vc of the second reclaimer according to the operating flow rate V1 and the mixing ratio and start the second reclaimer. Thereafter, adjust the operating flow rate V1 or the operating flow rate Vc by comparing the cumulative mixing ratio between the first reclaimer and the second reclaimer, so that the comparison of the cumulative mixing ratio between the first reclaimer and the second reclaimer is within the mixing control threshold. T14 specifically includes: Calculate the cumulative amount of material D2 transported to the confluence point via the second ground conveyor belt, where D2 = D3 - D1'; In the initial stage of the mixing operation, the transport difference of the first reclaimer is calculated as E3=Q1-D1, and the transport difference of the second reclaimer is calculated as E4=Q2-D2. When the transport difference E3 or E4 exceeds the allowable deviation, an over-limit alarm is issued. During the mixing operation phase, the transport error rate of the first material reclaimer is calculated as E1 = (Q1 - D1) / D1, and the transport error rate of the second material reclaimer is calculated as E2 = (Q2 - D2) / D2. When E1 or E2 exceeds ±1%, an error over-limit alarm is issued.

2. The reclaimer full-flow blending operation quality control system of claim 1, wherein, The process of determining the mixing control threshold based on the mixing ratio in T22 includes: Set B1:B2 = r, and the allowable fluctuation range of r is ±2%; set the dynamic mixing capacity J. Accordingly, calculate the upper limit Rmax of the mixing control threshold as Rmax = J×(r + 2%), and the lower limit Rmin of the mixing control threshold as Rmin = J×(r - 2%).

3. The reclaimer full-flow blending operation quality control system of claim 2, wherein, The rated values of the operation flow rates of the first reclaimer and the second reclaimer are both V0, and the time taken for the bucket wheel to rotate two circles is both Td. Accordingly, T23 specifically includes: T23-1: If B1≥B2, set the operation flow rate V1 = V0; if B1 < B2, set the operation flow rate V1 = (V0×B1) / B2; after the first reclaimer starts, calculate the average operation flow rate of the first reclaimer every Td as the time step, and obtain the average operation flow rate sequence Vz (Vz1, Vz2, Vz3... Vzn); T23-2: Based on the average operation flow rate Vz1 corresponding to the first time step, calculate the first operation flow rate of the second reclaimer using the second reclaimer operation flow rate calculation formula Vc = Vz×B2 / B1 = Vz / r, and control the second reclaimer to start operating with the first operation flow rate after T0 time; T23-3: During the operation of the second reclaimer, adjust the operation flow rate Vc every Td as the time step. During the adjustment process, use Vz corresponding to the same number of time steps to calculate the operation flow rate Vc of the second reclaimer.

4. The reclaimer full-flow blending operation quality control system of claim 3, wherein, T23 also includes: T23-4: After the second reclaimer operates, record the cumulative amount of the second reclaimer's cantilever belt scale every 1 second, and obtain the cantilever belt scale cumulative amount sequence Q2 (Q2.1, Q2.2, Q2.3... Q2.n); T23-5: After the first reclaimer operates, record the cumulative amount of the first reclaimer's cantilever belt scale every 1 second, and obtain the cantilever belt scale cumulative amount sequence Q1 (Q1.1, Q1.2, Q1.3... Q1.n, Q1.n + 1, Q1.n + 2... Q1.n + T0); where n represents the recording times as an integer value, and (Q1.n + 1, Q1.n + 2... Q1.n + T0) are the data recorded more by the first reclaimer than the second reclaimer due to the first reclaimer starting T0 time in advance; T23-6: Use the cantilever belt scale cumulative amounts of the first reclaimer and the second reclaimer at the same recording times to calculate the ratio cumulative amount difference (Q1.n / r - Q2.n) between the first reclaimer and the second reclaimer in turn; When (Q1.n / r - Q2.n) > Rmax, use the most recently recorded cantilever belt scale cumulative amounts of the first reclaimer and the second reclaimer to calculate the total amount of material Mcb that the second reclaimer should supplement currently as Mcb = Q1.n + T0 / r - Q2.n, and increase the operation flow rate Vc of the second reclaimer according to the set ratio; After Td time, if Mcb shows a decreasing trend, keep the operation flow rate Vc of the second reclaimer unchanged until (Q1.n / r - Q2.n) ≤ Rmax, and then adjust the operation flow rate Vc of the second reclaimer using the T23-3 process; if Mcb does not decrease, set the operation flow rate Vc of the second reclaimer = V0 and reduce the operation flow rate V1 of the first reclaimer according to the set ratio; After another Td time, if Mcb shows a decreasing trend, keep the current operating flow rates of the first and second reclaimers unchanged until (Q1.n / r-Q2.n)≤Rmax, then use process T23-3 to adjust the operating flow rate Vc of the second reclaimer; if Mcb does not decrease, stop the first reclaimer until Mcb decreases, then restart the first reclaimer, and at the same time reduce the operating flow rate V1 according to the set ratio; T23-7. When the ratio difference between the second and first reclaimers (Q2.n-Q1.n / r) > Rmin, reduce the operating flow rate Vc of the second reclaimer according to the set ratio. After time Td, if Mcb shows an increasing trend, keep the current operating flow rate Vc of the second reclaimer unchanged; otherwise, stop the second reclaimer until (Q2.n-Q1.n / r) ≤ Rmin. Then, use the T23-3 process to set the operating flow rate Vc of the second reclaimer and restart the second reclaimer.

5. The reclaimer full-process blending operation quality control system of claim 1, wherein, It also includes the material continuity control logic during the reversal of the cantilever of the reclaimer: To improve the continuity of material proportioning while ensuring safety, the automatic switching of the cantilever rotation direction before the bucket wheel of the reclaimer reaches the protection threshold of the material stack boundary requires the following three conditions to be met simultaneously: 1) Based on the reclaimer's attitude positioning data and the radar data at the front end of the cantilever, it was determined that the bucket wheel was located at the edge of the stack; 2) The rotational speed of the reclaimer's cantilever towards the outside of the stack reaches more than 5% of the rated speed; 3) The working pressure value of the bucket wheel of the reclaimer is lower than the set value F; The setting value F has two sources: the reference value Fm and the correction value Fmx; The baseline value Fm originates from the baseline parameters set during the commissioning of the control system. It represents the working reversing pressure of the bucket wheel at 20% of the rated flow rate when the rotation direction is automatically switched at the edge of the material stack. The baseline parameters also include the no-load working pressure F0 of the bucket wheel and the rated working pressure Fn of the bucket wheel when the reclaimer operates at the rated flow rate for different material types. When the reclaimer starts operating, the default setting is F=Fm. When the fluctuation range between the actual flow rate and the rated flow rate of the feeder is stable within ±5%, and the fluctuation of the working pressure of the matching bucket wheel is also less than 10%, and the system runs continuously for two bucket wheel rotation cycles, the control system automatically records the average working pressure of the bucket wheel at the rated flow rate, Fnx. If the deviation between Fnx and Fn exceeds ±10%, the correction value Fmx of F is calculated based on the deviation between Fnx and Fn, and F=Fmx is set to control the switching of the cantilever rotation direction. If the deviation between Fnx and Fn exceeds ±20%, it is marked as abnormal data, but F is still set as the reference value Fm.

6. The reclaimer full-process compounding operation quality control system according to claim 1, characterized in that, This also includes a mix proportioning quality assurance strategy during layer changeover at the reclaimer's working surface: The bucket wheel of the reclaimer rotates from the outer edge of the stack to the inner edge with the cantilever, then moves forward with the reclaimer to feed material, and then returns to the outer edge with the cantilever; this is one rotation cycle. The reclaimer operates on the stack layer by layer in a rotating feeding manner. The cooperative material handling control of the first and second reclaimers is as follows: Based on the cumulative amount of the cantilever belt scales of the first and second reclaimers, the amount of material Mzt that the first reclaimer takes up more material due to prioritizing material taking over time difference T0 is calculated in real time; during the rotation of the first reclaimer, the amount of material taken up MTd in the two most recent bucket wheel rotation cycles is recorded in real time. Determine the material collection area and corresponding material collection amount of the second reclaimer in the last three bucket wheel rotation cycles, then calculate the remaining material collection amount Mcs corresponding to the remaining area of ​​the current working layer of the second reclaimer, and calculate the corresponding material collection amount Mzs of the first reclaimer based on Mcs and the mixing ratio. If Mzt > Mzs + MTd, the first reclaimer enters a paused reclaiming state until the second reclaimer reaches the starting point of the next working surface and sends a start reclaiming signal, after which the first reclaimer resumes reclaiming.

7. The reclaimer full-flow blending operation quality control system of claim 3, wherein, It also includes automatic single-material spreading control strategies for stackers: Based on the instantaneous flow data of the third ground belt scale, the instantaneous flow data of the cantilever belt scales of the first and second reclaimers are matched to realize the detection of material type. If it is determined that only a single type of material from the first or second reclaimer arrives at the stacker and continues to exceed Td, the automatic single material spreading control mode of the stacker is activated. During the single-material automatic spreading control mode of the stacker, the stacker transitions from automatic stacking mode to automatic continuous point-changing mode. The point-changing path is consistent with the original stacking path, and the maximum number of points changed in a single operation does not exceed the number of stacking points in a single row of the material pile. During the point-changing process... 1) When the material section of a single material ends, the stacker will automatically return to the original stacking point corresponding to the single material automatic spreading control mode of the stacker when it is activated; 2) When the maximum number of relocation points is reached, the stacker will automatically return to the original stacking point; 3) If the source of a single material is switched to another reclaimer, the stacker will automatically return to the original stacking point; After returning to the original stockpile point, another material reclaimer replenishes the mixing ratio according to the single material automatic spreading control mode of the stockpile machine.

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