Broken material control optimization method and system for cement batching station

Abstract

The invention discloses a cement batching station material interruption control method and system, and the method comprises the steps: obtaining a feedback value fed back by each batching scale in a cement batching station, determining whether the cement batching station has potential material interruption or not according to the feedback value and a preset ratio value, and when the cement batching station has potential material interruption, determining whether the cement batching station has potential material interruption or not. The vibrating control unit drives the vibrating motor to vibrate the cone part of the stock bin in the cement batching station, so that the problem of material breakage of the system is solved, vibration effect feedback is monitored in real time after vibrating, and vibrating parameters are dynamically adjusted, so that the vibrating effect is optimized, and the working efficiency is improved. The system solves the technical problems of feedback lagging, fixed rapping parameters and low judgment precision of traditional material breaking control, is suitable for intelligent material breaking control in a cement production batching link, and has important industrial application value.

Description

Technical Field

[0001] This invention relates to the field of automatic control technology in cement production, and in particular to an optimization method and system for controlling material shortage in cement batching stations. Background Technology

[0002] In the automated batching process of the cement industry, the continuity of raw material transportation is crucial to ensuring the quality of clinker calcination. High-moisture-content raw materials (such as clay materials with a moisture content >12%) are prone to causing crusting and scaling at the cone-shaped part of the silo, a major cause of material interruption accidents. Currently, the industry commonly uses mechanical material interruption switches (such as rotary paddle level gauges or tuning fork detectors) to monitor material status. However, these devices can only output a binary switch signal (on / off) when the material flow is completely interrupted, and are completely unresponsive to gradual changes in flow regime such as thinning of the material layer and decreasing flow velocity.

[0003] When material properties change, causing non-uniform blockage in the silo wall area (loose flow on the surface and hardening at the bottom), the material cut-off switch, fixed at the discharge port, cannot detect early signs of hardening in the high-risk area of ​​the cone, leading to a high system misjudgment rate. For these reasons, the rapping motor often starts prematurely when the material layer is only slightly thinner, causing ineffective idling; or it delays response after the material is completely hardened, forcing a several-fold increase in operation time for forced clearing, significantly increasing energy consumption. Summary of the Invention

[0004] In view of this, this application proposes an optimization scheme for material interruption control in cement batching stations, which can improve batching stability, optimize production efficiency and reduce energy consumption, and is applicable to material interruption control in cement production batching process.

[0005] Based on one aspect of this application, an optimization method for material shortage control in a cement batching plant is provided. The method includes: Obtain the feedback value from each batching scale in the cement batching station, wherein the feedback value is the actual measured weight of material per unit time; Based on the feedback value and the preset ratio value, determine whether the cement batching station has a potential material shortage; When a potential material shortage is detected at the cement batching station, the vibration control unit drives the vibration motor to vibrate the cone-shaped part of the silo in the cement batching station.

[0006] Optionally, the specific method for determining potential material shortage is as follows: calculate the feedback value in real time and compare it with the preset ratio value; when the feedback value is lower than the ratio value... Furthermore, if the duration reaches a preset threshold, it is determined to be a potential material shortage; Where N is the deviation threshold, and its value ranges from 85 to 95.

[0007] In one implementation, the proportion is calculated by the automatic batching system of the cement batching station and synchronized to the control unit of the central control and batching scale via a one-to-two TI capacitor isolation device to ensure data synchronization and electrical safety.

[0008] When a potential material shortage is detected at the cement batching station, the vibration control unit drives the vibration motor to vibrate the cone-shaped part of the silo in the cement batching station.

[0009] According to a preferred embodiment of this application, during the vibration process, the current humidity of the material is also acquired, and the vibration motor is controlled to vibrate the cone part of the hopper in combination with the current humidity.

[0010] Specifically, controlling the vibrating motor in conjunction with the current humidity of the material includes: obtaining the current humidity value of the material at the cone part of the hopper; and controlling the vibrating motor to vibrate according to the current humidity value and a preset mapping relationship between humidity value and vibration duration.

[0011] Optionally, after the vibration operation is performed, the process also includes real-time monitoring of the batching scale feedback value and executing a secondary vibration or triggering a manual warning according to preset logic.

[0012] In addition, the vibration control unit can interact with the central control system via a wireless communication module to achieve remote monitoring and control functions.

[0013] Based on another aspect of this application, a material shortage control optimization system for a cement batching plant is provided. The system includes: a data acquisition module for acquiring feedback values ​​from each batching scale in the cement batching plant, wherein the feedback values ​​are the actual measured weight values ​​of materials per unit time; a material shortage judgment module connected to the data acquisition module for determining whether a potential material shortage has occurred based on the actual measured weight values ​​of the materials and a preset proportion value; and a vibration execution module connected to the material shortage judgment module, which includes a vibration control unit and a vibration motor driven by it; when a potential material shortage is determined to have occurred, the vibration control unit drives the vibration motor to perform a vibration operation on the cone-shaped portion of the silo.

[0014] In one possible implementation, the vibration control unit can also dynamically adjust the vibration parameters based on real-time monitored vibration feedback during the vibration process to optimize the vibration effect.

[0015] Optionally, the system also includes a data storage module for storing historical batching data and vibration records of the cement batching station, providing support for subsequent data analysis and strategy optimization.

[0016] Based on another aspect of this application, a material shortage control optimization device for a cement batching plant is provided. The device includes: a processor; and a memory for storing processor-executable instructions; wherein the processor is configured to implement the method described in any of the preceding claims when executing the executable instructions.

[0017] This invention effectively improves the material supply stability of cement batching plants, reduces the probability of material shortages, increases production efficiency, and reduces manual intervention by real-time monitoring of material weight, intelligent judgment of material shortage situations, and automatic vibration control. It has high practical value and promising prospects for promotion. Attached Figure Description

[0018] The accompanying drawings, which are included in and form part of this specification, illustrate exemplary embodiments, features, and aspects of this disclosure together with the specification and serve to explain the principles of this disclosure.

[0019] Figure 1 This is a first flowchart illustrating the optimization method for material shortage control in a cement batching plant according to an embodiment of this application. Figure 2 This is a second flowchart illustrating the optimization method for material shortage control in a cement batching plant according to an embodiment of this application. Figure 3 This is a third flowchart illustrating the optimization method for material shortage control in a cement batching plant according to an embodiment of this application; Figure 4 This application shows a schematic diagram of the specific connection circuit of a one-to-two TI capacitor isolation device according to an embodiment of the present application. Figure 5 This diagram illustrates the feedback fluctuation of the batching scale before the automatic material breaking and feeding according to an embodiment of this application. Figure 6 This diagram shows the feedback fluctuation of the batching scale after the automatic vibration input of material interruption according to an embodiment of this application. Figure 7 The material humidity and vibration motor operation status monitoring trend curves of this application embodiment are shown. Detailed Implementation

[0020] This invention relates to the field of automated control technology in cement production, and in particular to a method, system, and equipment for optimizing material shortage control in cement batching stations. The technical solution for which this invention is claimed will be clearly and completely described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can fully understand and implement the technical solution of this invention.

[0021] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0022] Furthermore, to better illustrate this application, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that this application can be implemented without certain specific details. In some instances, methods, means, components, and circuits well-known to those skilled in the art have not been described in detail in order to highlight the main points of this application.

[0023] In this embodiment, the automatic batching system can be a gamma analysis automatic batching system produced by Dandong Dongfang Measurement and Control. This system has the characteristics of high precision and fast response, and can automatically adjust the ratio based on real-time detection of material composition to ensure the uniformity and stability of batching.

[0024] Figure 1 This diagram illustrates a first flowchart of a method for optimizing material shortage control at a cement batching plant according to an embodiment of this application. Figure 1 As shown, the method includes: step S100, obtaining the feedback values ​​from each batching scale in the cement batching station; S200, determining whether the cement batching station has a potential material shortage based on the feedback values ​​and a preset proportion value; S300, when it is determined that the cement batching station has a potential material shortage, the vibration control unit drives the vibration motor to vibrate the cone part of the silo in the cement batching station. The above processes and methods can reduce the probability of material interruption in actual production and improve production efficiency. The material interruption control optimization method of this application includes intelligent material interruption judgment and adaptive vibration control, and supports online parameter adjustment and optimization, ensuring the adaptability of the control method in different operating environments.

[0025] The material breakage control optimization method of this application first performs intelligent material breakage judgment, including steps S100 and S200.

[0026] For details, see Figure 1 Step S100 is executed to obtain the feedback values ​​from each batching scale in the cement batching station. These feedback values ​​are the actual measured weight of materials per unit time. To ensure the real-time performance and accuracy of data acquisition, this invention relies on a high-precision electronic batching scale and a data acquisition module to obtain the actual measured weight data per unit time, i.e., the feedback values, at a fixed sampling period. The sampling period can be set to 100-500ms, and automatic retransmission is performed when the network latency exceeds 200ms, ensuring that the transmission latency is less than or equal to 200ms.

[0027] It should be understood that the feedback value, also known as the actual weight of material per unit time, is derived from the actual weight of material fed per unit time detected by the batching scale.

[0028] The batching scale mainly uses two types of sensors to detect operating parameters in real time: a load cell and a speed sensor. The load cell is used to detect the weight of the material per unit length of the belt (unit: kg / m), and the speed sensor is used to detect the actual running speed of the belt (unit: m / s).

[0029] The acquisition module receives analog voltage signals from the weighing sensor and pulse signals from the speed sensor. It filters, amplifies, and performs analog-to-digital conversion on the acquired analog and pulse signals to eliminate noise interference and ensure signal stability. Then, using the digitized weight value and the actual operating speed value, it calculates the feedback value, i.e., the measured weight of material per unit time, typically in t / h (tons per hour).

[0030] Further, see Figure 1 Step S200 is executed to determine whether a potential material shortage has occurred at the cement batching station based on the feedback value and the preset proportion value.

[0031] It should be understood that in the cement production control system involved in this patent, the "ratio value" is a key basic parameter. It specifically refers to the theoretical feed weight set value of a certain material per unit time, which is calculated in real time by the automatic batching system of the cement batching station based on the current production process formula.

[0032] In this patent, "potential material shortage" describes a non-complete material shortage state, referring to an abnormal state where the material feed rate continuously falls below a preset threshold for the set proportion for more than a specified time (e.g., three consecutive sampling cycles), but the flow has not completely stopped. In this state, the material flow is not completely interrupted, but due to abnormal conditions such as bulging, wall adhesion, or material arching within the silo, the actual feed rate is significantly and continuously lower than the theoretical requirement set by the proportion. The "batching scale" is a belt scale corresponding to each raw material, installed on the feeding belt. It is used to measure and provide feedback on the instantaneous flow rate of a single material in real time and continuously. As a belt scale corresponding to each raw material, it can acquire the measured weight value and belt running speed value in real time, and calculate the measured weight value of the material per unit time, i.e., the feedback value, to achieve precise proportion control.

[0033] Furthermore, the proportioning value is calculated in real time by the automatic batching system based on the production formula and process parameters, and synchronously transmitted to the batching scale control unit and central control unit on-site via a one-to-two TI capacitor isolation device. This device employs electrical isolation technology to ensure the stability and accuracy of the proportioning value signal transmission in complex industrial electromagnetic environments, avoiding signal interference. For example, in actual production, a one-to-two TI capacitor isolation device (model DF-2000) can be used to achieve synchronous signal transmission with one input and two outputs, significantly improving the system's anti-interference capability.

[0034] Specifically, the automatic batching system calculates the batching ratio in real time and transmits it synchronously to the batching scale control unit and central control unit on site via a one-to-two TI capacitor isolation device, including the following steps: In the specific implementation of this system, the calculation of the proportioning value is completed by the automatic batching system. The automatic batching system first sets the total output target according to the production plan and calls the preset fixed process formula. This formula defines the target percentage of each raw material in the mixture. The system then automatically calculates the initial flow rate setpoint (i.e., the initial proportioning value) of each material according to the formula "single material proportioning value = total output × formula percentage", and then transmits the proportioning value of each raw material to the batching scale control unit and the central control unit on site.

[0035] Taking the actual operation of a cement batching plant as an example, when the automatic batching system receives a production plan instruction and determines the total output setpoint to be 200 tons / hour, the system calls the preset fixed process formula for "PO 42.5 cement". This formula specifies: limestone proportion: 85%, clay proportion: 10%, iron powder proportion: 5%. Then, the complete proportion value is calculated based on the formula, specifically, according to the formula... The automatic batching system automatically calculates the initial batching ratios: limestone ratio = 200t / h × 85% = 170t / h; clay ratio = 200t / h × 10% = 20t / h; iron powder ratio = 200t / h × 5% = 10t / h.

[0036] After calculating the proportions of each raw material, in order to ensure that the proportions can be accurately transmitted to the batching scale control unit and the central control, the digital value of the proportion is first converted into an analog signal suitable for transmission by the internal digital-to-analog converter circuit of the system, namely the first analog signal. The magnitude of the analog signal has a strict linear relationship with the proportion.

[0037] The first analog signal is transmitted to a 1-to-2 TI capacitor isolation device. The core of this TI capacitor isolation device lies in its internal dedicated isolation circuit built upon the ISO1540 dual-channel analog isolation chip. The circuit topology and component configuration of this TI capacitor isolation device are as follows: Figure 4 As shown, it includes an input-side signal drive circuit, an ISO1540 dual-channel analog isolation chip, and a first-channel output amplifier circuit (i.e., Figure 4 The first output circuit and the second output amplifier circuit (i.e.) Figure 4 The second output circuit in the circuit). The specific working principle is as follows: the signal conditioning circuit on the input side (i.e. Figure 4The input-side signal drive circuit converts the received first analog signal into a standard analog current signal and inputs the standard analog current to the dual-channel analog isolation chip. The dual-channel analog isolation chip converts the standard analog current into two independent initial electrical signals and uses silicon dioxide (SiO2) gates with TI capacitor isolation technology to safely isolate the input standard analog current from the two output initial electrical signals. Subsequently, the two initial electrical signals output by the dual-channel analog isolation chip are processed by high-precision operational amplifiers through a precision-calibrated first and second output amplifier circuits, respectively, and finally output two high-precision analog output signals that are electrically completely isolated and numerically highly consistent with the input signals, namely, the second analog signal and the third analog signal.

[0038] Because the electromagnetic environment in industrial sites, especially in batching stations where high-power equipment is frequently started and stopped, is extremely complex, there are ground loop interference and electromagnetic interference between the central control system and the field equipment. Direct transmission can lead to problems such as setpoint drift, setpoint reading jumps, and ambiguity, affecting the operator's judgment.

[0039] This application utilizes a one-to-two TI capacitor isolation device to achieve the conversion process from electrical signal to electrical signal after isolation, fundamentally cutting off the direct electrical connection between the input and output circuits, thereby achieving ideal electrical isolation.

[0040] After isolation, the one-to-two TI capacitor isolation device synchronously generates two independent analog signals with values ​​completely consistent with the input signal, namely the second analog signal and the third analog signal.

[0041] The second analog signal is sent to the control unit of the on-site batching scale. The control unit uses the analog signal as the batching target value and performs feeding control according to this target, including adjusting the operating parameters of the feeding mechanism according to the ratio value to ensure that the actual feeding amount is close to the set value.

[0042] The third analog signal is sent to the central control system. The central control system needs the ratio value as a benchmark reference value, compares the feedback value of the batching scale with the ratio value in real time, calculates the deviation, and determines whether there is a potential material shortage. The central control system can also drive the vibrating motor according to the material shortage status and combined with the real-time humidity, and call the adaptive vibrating logic to achieve intelligent vibrating and achieve precise material shortage control.

[0043] Therefore, the one-to-two TI capacitor isolation device effectively blocks potential electrical interference or faults (such as short circuits) from affecting the stable operation of the central control system, ensuring the accuracy and integrity of the ratio signal during transmission, and also protecting the safety of the control core.

[0044] Optionally, the isolation device used for the transmission of the proportion value signal can be a DF-2000 one-to-two TI capacitor isolation device. This device has an isolation voltage of up to 4KV and a dual-output function, which can ensure that the proportion value is transmitted to the central control system and the batching scale control unit simultaneously and accurately, thereby effectively avoiding signal interference.

[0045] Furthermore, when determining whether a potential material shortage has occurred at the cement batching station based on the feedback value and the preset proportion value, the specific method for determining whether a potential material shortage has occurred is as follows: the feedback value is calculated in real time and compared with the preset proportion value; when the feedback value is lower than the proportion value... When the duration reaches a preset threshold, it is determined to be a potential material shortage. The value of N ranges from 85 to 95. The preset threshold is set to three consecutive sampling cycles. The preset threshold can be adjusted according to the actual working conditions.

[0046] In this application, a value of N of 90 is preferably used, meaning that when the feedback value is lower than 10% of the proportion value, the silo is determined to be in a potential material shortage state. This 10% threshold, determined based on extensive industrial field experiments and data analysis, balances the false alarm rate and false negative rate of the system at a high confidence level, avoiding unnecessary equipment actions while ensuring accurate detection of genuine abnormal states. For example, when a limestone proportion is 28 t / h and the sampling period is set to 200 ms, if the feedback value is lower than 2.8 t / h (i.e., 10% of 28 t / h) for 600 ms (three consecutive sampling periods), the system determines that the silo has experienced a potential material shortage.

[0047] If it is determined that there is a potential material shortage in the discharge bin, the material shortage control optimization method of this application performs adaptive vibration control, including steps S300 and S400.

[0048] Specifically, see Figure 1 In step S300, once the system determines that a potential material shortage has occurred in a silo, the rapping control unit will quickly drive the rapping motor installed in the cone part of the silo to start targeted rapping operations. The purpose is to effectively break up the material arches formed in the silo and shake off the material adhering to the silo wall through mechanical vibration, thereby restoring the smooth flow of material and preventing a complete material shortage.

[0049] Optionally, the vibrating motor can be a YZO-10-6 model with a power of 10kW and a vibration frequency of 1500 times / minute, installed in the conical part of each hopper to ensure that sufficient excitation force can be generated in the event of material interruption.

[0050] Traditional rapping control uses fixed parameters, which cannot adapt to changes in material properties and environmental conditions. This invention develops an adaptive rapping control strategy based on material moisture content.

[0051] In one optimized implementation, see [link to implementation details]. Figure 2 When the rapping control program starts, it also executes the following steps: S310, acquiring the current humidity value of the material in the cone-shaped part of the hopper; S320, based on the current humidity value and according to the mapping relationship between humidity value and rapping duration, controlling the rapping motor to rappe the cone-shaped part of the hopper. The current humidity value can be obtained by monitoring a humidity sensor. Optionally, the humidity sensor can be a capacitive humidity sensor, with a measurement accuracy of ±2% and a response time of less than 10 seconds, enabling real-time and accurate detection of material humidity.

[0052] It should also be noted that the adaptive rapping strategy based on material humidity specifically refers to the mapping relationship between humidity value and rapping duration. This mapping relationship is stored in an intelligent mapping relationship library built into the rapping control unit. After obtaining a specific humidity value, the corresponding rapping parameters are directly extracted from the library according to the corresponding relationship. It should be noted that this intelligent mapping relationship library defines the optimal rapping parameters corresponding to different humidity levels, and the rapping parameters include at least one of the following: single rapping time and rapping interval.

[0053] In one possible implementation, the mapping relationship is as follows: The mapping relationship between rapping time t and material moisture content H: Mapping relationship between rapping interval d and material moisture content H: In the formula, s is the unit of seconds, t is the rapping time (s), H is the material moisture content (%), and d is the rapping interval (s).

[0054] Practical application verification shows that this strategy improves rapping efficiency by 35% under high humidity raw material conditions, while reducing rapping motor energy consumption by 25%. For example, when an online humidity sensor integrated into the silo wall measures the current material humidity to be 14%, the rapping control unit queries its built-in intelligent mapping database. When the humidity is detected to be higher than 12%, the system automatically sets the rapping time to 8 seconds and the rapping interval to 2 seconds to enhance the unblocking effect. This achieves adaptive rapping control for materials with different humidity levels.

[0055] It is important to understand that after a single vibration, the feedback value is used to determine whether the vibration was successful. If the vibration was successful, the vibration program is stopped; if it was unsuccessful, a second vibration is performed after an interval.

[0056] That is, after a single vibration operation is completed, step S400 is also included, namely, real-time monitoring and dynamic feedback adjustment of the vibration effect. After the first vibration is completed, the central control system immediately checks the feedback value of the batching scale. It also compares the feedback value of the batching scale with the proportioning value to comprehensively evaluate the vibration effect.

[0057] In one optimized implementation, see [link to implementation details]. Figure 3 Specifically, this includes: S410, if the feedback value significantly rises to above 80% of the mixing ratio, the vibration is deemed successful and subsequent vibrations are stopped; S420, if the value does not rise to above 80% of the mixing ratio after the first vibration, a second vibration is initiated after an interval; S430, if the feedback value is still below 60% of the mixing ratio after two vibrations, a manual warning is triggered, and a manual check is initiated based on the material level gauge data.

[0058] In addition, if the feedback value after two vibrations is between 60% and 80%, the system enters a continuous monitoring state, continues to monitor the changes in the feedback value with the original sampling cycle, and sets the monitoring time according to the inertia of the actual material flow.

[0059] If the feedback value gradually rises and reaches above 80% within the monitoring period, the system will automatically resume normal operation. If the feedback value remains between 60% and 80% or further drops below 60% within the monitoring period, a manual warning will be triggered.

[0060] It should be noted that the threshold (80%) used to determine the success of the vibration in the above process is an optimal value. In practical applications, this threshold can be flexibly configured according to the specific material characteristics, equipment operating conditions, or production experience, and can also be adjusted to 90% or other more suitable values ​​to ensure that the system has good adaptability.

[0061] For example, in the case of a limestone batching plant, the batching ratio was 28 t / h. The feedback values ​​for three consecutive sampling cycles were all below 2.8 t / h, leading the system to determine a potential material shortage. The system detected a humidity sensor reading of 13% and automatically set the rapping time to 8 seconds and the rapping interval to 2 seconds.

[0062] After the initial 8-second vibration, the feedback value rose to 15 t / h, which was an improvement over the initial value, but still below 80% of the set ratio of 28 t / h (i.e., 22.4 t / h), failing to meet the criteria for effective unblocking. Therefore, the system initiated a second vibration after a 2-second interval, with the vibration duration remaining at 8 seconds. After the second vibration, the feedback value quickly rebounded to 26 t / h, accounting for 92.8% of the set value, exceeding the 80% threshold. The system then determined the vibration was successful and resumed normal operation. The entire process took approximately 25 seconds, while traditional manual processing typically takes 5 to 10 minutes, demonstrating a significant improvement in efficiency.

[0063] Furthermore, the vibration control unit in this system integrates advanced wireless communication capabilities. This unit maintains continuous data interaction with the factory's central control system via a built-in wireless communication module. This wireless communication module is a multi-mode adapter unit integrating 4G, 5G, or Wi-Fi communication protocols. Its core components include a wireless communication module, an embedded SIM card unit, a data encryption transmission unit, and signal processing circuitry. In the example above, all process data is transmitted to the central control room via the 4G / 5G wireless DTU module for remote monitoring and recording.

[0064] Optionally, the rapping motor control system is connected to the central control unit, supporting independent control by the central control unit. It uses the Modbus protocol for communication and has CRC check function to ensure accurate transmission of commands.

[0065] Optionally, the communication protocol can be Profinet to ensure stable and reliable data interaction with field devices.

[0066] With the help of this module, the field control unit can upload high-value data such as real-time equipment status, vibration operation records, fault codes, and alarm information to the central control room server. At the same time, operators of the central control system can also send remote commands, such as manually starting vibration, setting parameters, or querying detailed status, thereby greatly improving the convenience of equipment management, system transparency, and fault response speed.

[0067] The technical solution of this invention brings technological improvements compared to the prior art and achieves good beneficial effects. Specifically, based on real-time data sampling and deviation calculation, it can detect material shortage trends in advance and dynamically adjust the rapping time and frequency according to the material moisture content. Under the same working conditions, compared with traditional rotary paddle level gauges, the false alarm rate is reduced by 40%, the response time is improved by 35%, and the motor energy consumption is reduced by 25%. In addition, zero error in the transmission of the proportioning value is ensured through capacitive isolation and CRC verification, establishing a real-time closed loop of "setting-feedback-control".

[0068] After implementing the technical solution of this invention, experiments showed that the batching stability of the cement batching station was significantly improved. The incidence of material shortages decreased, and the production interruption time caused by material shortages was reduced by 75%. The fluctuation range of the batching scale feedback value decreased from ±13t / h to ±3t / h, with a stability improvement of 77%. As a result, the standard deviation of the 28-day compressive strength of cement clinker decreased from 2.3MPa to 1.5MPa, and the quality fluctuation was reduced by 35%. The raw material mill operated more smoothly, with grinding efficiency increasing by 18%, system energy consumption decreasing by 12%, and annual electricity savings of approximately 120,000 kWh per unit. The effective operating time of the equipment increased from 95.2% to 98.5%, and production continuity was significantly improved.

[0069] In terms of adaptability, the system can adapt to a variety of raw materials such as limestone, clay, and iron powder. Even under extreme working conditions with humidity as high as 15%, it can still maintain stable feeding and precise proportion control.

[0070] In terms of continuous optimization, the system further incorporates machine learning algorithms to continuously refine the material breakage judgment threshold and rapping parameters based on historical operating data. It also incorporates considerations of factors such as ambient temperature and atmospheric pressure, improving the algorithm's predictive accuracy. Simultaneously, a material characteristic database has been established, enabling personalized control strategies for different materials. Regarding functional expansion, the system has added preventative maintenance capabilities, capable of predicting maintenance needs based on equipment operating data. It integrates an energy management module for real-time monitoring and optimization of energy consumption and has developed a mobile application for remote monitoring and control.

[0071] This application also includes a cement batching plant material shortage control optimization system. This system, through the collaborative work of multiple functional modules, achieves accurate identification and intelligent handling of potential material shortage states. The core of this system mainly includes three modules: a data acquisition module, a material shortage judgment module, and a vibration execution module.

[0072] The system includes a data acquisition module for obtaining the actual weight values ​​of materials from each batching scale in the cement batching station; a material breakage judgment module connected to the data acquisition module for determining whether a potential material breakage has occurred based on the actual weight values ​​and preset proportions; and a vibration execution module connected to the material breakage judgment module, including a vibration control unit and a vibration motor driven by it. When the material breakage judgment module determines that a potential material breakage has occurred, the vibration control unit drives the vibration motor to perform a vibration operation on the cone-shaped part of the hopper. During the vibration process, the vibration control unit dynamically adjusts the vibration parameters based on real-time monitoring of the vibration effect to optimize the vibration effect.

[0073] The modules are tightly connected and exchange data at high speed through a highly reliable industrial network. The system uses an industrial bus or industrial Ethernet as the communication bus, which not only ensures the real-time and deterministic transmission of control commands and status data between modules, but also ensures communication stability in complex industrial electromagnetic environments due to its inherent anti-interference capabilities.

[0074] The system can also be further integrated with a data storage module. This module is used for persistent storage of all critical data during system operation, and its stored content extensively covers historical batching data, detailed records of each rapping operation, all alarm event logs, and system status snapshots. The accumulation of massive amounts of historical data provides a solid data foundation for subsequent in-depth big data analysis, continuous optimization of production process parameters, and the implementation of predictive maintenance strategies. For example, by analyzing the relationship between rapping frequency and specific material humidity and seasonal variations, the control algorithm can be further optimized, thereby improving production efficiency and reducing maintenance costs.

[0075] This invention also protects a physical device for implementing the above-described method. This device is a dedicated industrial computing and control unit, whose hardware includes a high-performance processor and a large-capacity memory. The memory is typically composed of non-volatile memory chips, which store pre-written computer-executable instructions. When the device is powered on, the processor reads these instructions from the memory and executes them sequentially, thereby precisely completing a series of automated operations such as real-time data acquisition, material cut-off logic judgment, intelligent vibration control, and early warning information generation, ultimately realizing the aforementioned material cut-off optimization control function of the cement batching station in the physical world.

[0076] The technical effects of this invention are further disclosed in the accompanying drawings. Figure 5 The figure shows the drastic fluctuations and long interruptions in the feedback value of the batching scale when material shortage occurs before the application of this invention. As can be seen from the figure, the fluctuation amplitude of the feedback value is large and the fluctuation frequency is high, indicating poor batching stability. Figure 6 The invention demonstrates that after applying this invention, the system responds quickly and restores the feeding to a stable state rapidly through adaptive vibration. The fluctuation amplitude of the feed value is significantly reduced, and the fluctuation frequency is also significantly lowered, indicating that the stability of the batching is significantly improved. Figure 7 The figure shows the monitoring trend curve of material temperature and rapping motor operation status in industrial production. It can be seen from the figure that the embodiment of this application achieves good material cut-off control effect, which is an intuitive display of practical application in actual engineering.

[0077] Finally, it should be noted that the system and method described in this invention are not only applicable to batching stations in the cement industry, but also, based on the core concept of intelligent judgment and adaptive control according to real-time data and material characteristics, can be widely applied to industrial fields such as metallurgy, chemical industry, and food industry that require continuous and stable batching. The specific embodiments described above are only for explaining this invention and are not intended to limit the scope of protection of this invention. Other technical solutions that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experiments based on the technical solutions of this invention should also be considered within the scope of protection defined by the appended claims.

Claims

1. An optimization method for material shortage control in a cement batching plant, characterized in that, include: Obtain the feedback value from each batching scale in the cement batching station, wherein the feedback value is the actual measured weight of material per unit time; Based on the feedback value and the preset ratio value, determine whether the cement batching station has a potential material shortage; When a potential material shortage is detected at the cement batching station, the vibration control unit drives the vibration motor to vibrate the cone-shaped part of the silo in the cement batching station.

2. The method according to claim 1, characterized in that, The specific method for determining potential material shortages is as follows: The feedback value is calculated in real time and compared with the preset ratio value. When the feedback value is lower than the ratio value... Furthermore, when the duration reaches a preset threshold, it is determined to be a potential material shortage, where N is the deviation threshold.

3. The method according to claim 1, characterized in that, The proportion is calculated by the automatic batching system of the cement batching station and synchronized to the control unit of the central control and batching scale through a one-to-two TI capacitor isolation device.

4. The method according to claim 1, characterized in that, When the vibration control unit drives the vibration motor to vibrate the cone-shaped part of the silo in the cement batching station, it also includes: The current humidity of the material is obtained, and the vibration motor is controlled to vibrate the cone part of the hopper based on the current humidity of the material.

5. The method according to claim 1, characterized in that, After the vibration control unit drives the vibration motor to vibrate the cone part of the silo in the cement batching station, it also includes the steps of real-time monitoring of the feedback value of the batching scale and executing secondary vibration or triggering manual warning according to preset logic.

6. The method according to claim 1, characterized in that, The vibration control unit interacts with the central control system via a wireless communication module to achieve remote monitoring and control.

7. The method according to claim 4, characterized in that, When the vibrating motor is used to vibrate the cone-shaped part of the hopper in accordance with the current humidity of the material, the following steps are included: Obtain the current humidity of the material at the cone-shaped part of the hopper; Based on the current humidity, and according to the mapping relationship between humidity value and vibration duration, the vibration motor is controlled to vibrate the cone-shaped part of the hopper.

8. A cement batching station material shortage control optimization system, characterized in that, include: The data acquisition module is used to obtain the actual weight values ​​of materials fed back by each batching scale in the cement batching station; The material shortage judgment module is connected to the data acquisition module and is used to determine whether a potential material shortage has occurred based on the measured weight value of the material and the preset ratio value. A rapping execution module is used to connect to the material breakage judgment module, including a rapping control unit and a rapping motor driven by it; When the material breakage judgment module determines that a potential material breakage has occurred, the vibration control unit drives the vibration motor to perform vibration operation on the cone part of the hopper; During the vibration process, the vibration control unit dynamically adjusts the vibration parameters based on real-time monitoring feedback of the vibration effect to optimize the vibration effect.

9. The system according to claim 8, characterized in that, Also includes: The data storage module is used to store the historical batching data and vibration records of the cement batching station for subsequent analysis and optimization.

10. A material shortage control and optimization device for a cement batching station, characterized in that, include: processor; Memory used to store processor-executable instructions; The processor is configured to implement the method of any one of claims 1 to 7 when executing the executable instructions.

Images