Centralized dust removal system for multiple capacitor roll nailing machines and cooperative control method of centralized dust removal system

Abstract

The invention provides a centralized dust removal system for multiple capacitor roll nailing machines, and the system comprises a distributed precise dust collection unit which comprises differential dust collection hoods installed at multiple dust production stations of each capacitor roll nailing machine in a production workshop; the multi-stage safety monitoring unit comprises a flow meter and a dynamic pressure sensor which are arranged on an equipment dust collection branch pipe, an infrared temperature measurement array arranged on a regional dust removal main pipe, and a spark detector and a dust concentration monitor which are arranged on a system dust removal main pipe; the self-adaptive power conveying unit comprises a dust removal pipe network connected with each equipment branch pipe, a pneumatic control valve arranged in the dust removal pipe network, and a dual-mode centrifugal fan which is driven by a frequency converter and is provided with a bypass return valve; the efficient purification and recovery unit comprises a spray tower with a built-in explosion suppression type coagulant adding system, and a dust resource recovery module linked with a slurry outlet of the spray tower; and an intelligent cooperative control unit. And the risk identification speed and the positioning precision are improved.

Description

Technical Field

[0001] This invention relates to the field of capacitive nailing machine technology, and in particular to a centralized dust removal system for multiple capacitive nailing machines and its collaborative control method. Background Technology

[0002] With the development of the new energy industry, the production scale of capacitor nailing machines is constantly expanding, with dozens of machines often operating in workshops. These machines continuously generate large amounts of fine aluminum dust at multiple workstations, such as nailing, foil pulling, foil brushing, and foil support, posing an extremely high risk of flammability and explosion.

[0003] Chinese patent application publication number CN109065378A, published on December 21, 2018, discloses an aluminum foil removal device and a capacitor nailing machine. The aluminum foil removal device includes dust collection boxes located at the foil strip of each capacitor nailing machine, aluminum foil removal mechanisms located inside each dust collection box for removing foil powder or dust from the surface of the foil strip, a drive device for driving each aluminum foil removal mechanism, and an exhaust device connected to each dust collection box for uniformly extracting the collected foil powder or dust to the outside. The exhaust device includes suction nozzles on the dust outlets of each dust collection box, various suction pipes connected to each suction nozzle, a converging pipe connecting the various suction pipes, and an exhaust fan connected to the converging pipe. The aluminum foil removal device and capacitor nailing machine provided by this invention have a simple structure, excellent dust removal effect, and improve the working environment. The shortcomings of the prior art are:

[0004] 1. Primarily designed for foil strip cleaning, with limited dust capture capabilities for other dust-generating workstations such as nail pressing;

[0005] 2. The decentralized design of "one machine and one box" has limited processing capacity, and directly discharging dust outdoors may cause secondary pollution and waste of resources.

[0006] 3. Lacks system operation status monitoring and security early warning functions;

[0007] 4. The recycling and reuse of dust was not considered.

[0008] While existing technologies also include dust removal equipment, they generally suffer from the following drawbacks:

[0009] 1. Incomplete safety monitoring: Traditional centralized dust removal systems often set up a single safety monitoring point (such as spark detection) in the main pipe, which cannot locate specific risky equipment and is insufficient in responding to initial hidden dangers such as local blockage and abnormal flow, resulting in weak early warning capabilities.

[0010] 2. Inefficient energy control: The system fans often operate at a fixed power, and cannot dynamically adjust the air volume and negative pressure according to the actual number of dust-generating equipment, resulting in energy waste due to "overpowered power."

[0011] 3. Lack of collaborative control logic: The dust collection, conveying, purification and recycling units operate independently, lacking intelligent collaborative and optimized scheduling strategies based on global status (such as safety risks, energy consumption, equipment load).

[0012] 4. Incomplete dust recovery: The sludge treatment unit after wet dust removal is separated from the front-end dust removal system, failing to form a closed-loop management and resource recovery control from "gaseous dust" to "solid recyclables".

[0013] Therefore, there is an urgent need for a dust removal system that can systematically solve the above problems and achieve integrated intelligent control of safety, energy efficiency, and recycling. Summary of the Invention

[0014] Based on this, the purpose of the present invention is to provide a centralized dust removal system and its collaborative control method for multiple capacitor nailing machines, so as to solve the problems of inaccurate safety monitoring, serious energy waste, poor coordination of each unit, and non-closed-loop dust recycling in the prior art.

[0015] This invention provides a centralized dust removal system for multiple capacitive nailing machines, comprising:

[0016] The distributed precision dust collection unit includes differentiated dust collection hoods installed at multiple dust-generating stations of each capacitor nailing machine in the production workshop, as well as an equipment-level integrated valve group connecting each dust collection hood; the dust-generating stations include nailing stations, foil pulling or brushing stations, and foil holding stations;

[0017] The multi-level safety monitoring unit includes a flow meter and dynamic pressure sensor installed on the equipment's dust suction branch pipe, an infrared temperature measurement array installed on the area dust removal main pipe, and a spark detector and dust concentration monitor installed on the system's dust removal main pipe.

[0018] The adaptive power delivery unit includes a dust removal pipe network connecting the branch pipes of each device, a pneumatic regulating valve installed in the dust removal pipe network, and a dual-mode centrifugal fan driven by a frequency converter and equipped with a bypass return valve.

[0019] The high-efficiency purification and recovery unit includes a spray tower with a built-in explosion-suppressing coagulant dosing system, and a dust resource recovery module that is linked to the spray tower's slurry discharge port.

[0020] The intelligent collaborative control unit is used to run a multi-objective optimization collaborative control algorithm and is electrically connected to the multi-level safety monitoring unit, adaptive power transmission unit and high-efficiency purification and recycling unit to achieve collaborative optimization control of safety, energy efficiency and recycling objectives.

[0021] Preferably, the differentiated dust cover includes:

[0022] A ring-shaped slit dust hood for use in nailing stations;

[0023] Slotted or umbrella-shaped dust hoods for foil pulling or brushing stations;

[0024] Low-profile, box-type dust collection hood with a bottom flow equalization plate for use in foil handling stations.

[0025] Preferably, the equipment-level integrated valve group includes a quick-shut-off valve, an electrically regulating valve, and a manually isolating valve connected in sequence.

[0026] Preferably, the dynamic pressure sensor is a high-frequency pressure transmitter with a response frequency higher than 1kHz, used to capture pressure wave signals caused by sparks or initial combustion in the pipeline.

[0027] Preferably, the dual-mode centrifugal fan includes:

[0028] In the high-efficiency energy-saving mode, the control system adjusts the fan speed and the opening of the bypass return valve according to the number of online devices and the required air volume, so that the system operates at the optimal efficiency point.

[0029] In the safety boost mode, when the multi-level safety monitoring unit issues an early warning, the control system increases the fan speed and / or adjusts the pipeline valves to increase the airflow velocity in the risky pipeline.

[0030] Preferably, the explosion-suppressing coagulant dosing system is used to automatically add an agent with phosphate and high molecular polymer as the main components to the circulating water tank of the spray tower, so as to reduce the explosion hazard of dust in the washing liquid and promote particle agglomeration and sedimentation.

[0031] Preferably, the dust resource recovery module includes an intelligent slurry discharge system, a thickening sedimentation tank, and a plate and frame filter press; the intelligent slurry discharge system automatically controls the slurry discharge operation based on the turbidity and pH parameters of the spray tower circulating water tank.

[0032] Preferably, the intelligent collaborative control unit includes an industrial PLC, an edge computing gateway, and a host computer monitoring platform; the edge computing gateway is used to perform real-time spectrum analysis on the signal of the dynamic pressure sensor to identify early spark characteristics.

[0033] A collaborative control method for a centralized dust removal system for multiple capacitor nail rolling machines includes the following steps:

[0034] 1) Real-time acquisition of operating data from multi-level safety monitoring units, all flow meters, and fans;

[0035] 2) Assess the system's safety risk level based on spectrum analysis of dynamic pressure signals and fusion of multi-level monitoring data;

[0036] 3) Calculate the system's baseline air volume requirement based on the current operating equipment and its workstation requirements, and make corrections according to the safety risk level;

[0037] 4) Taking the minimization of total system energy consumption as the optimization objective, and taking the corrected air volume requirements of each branch pipe and the safe negative pressure of the main pipe as constraints, solve for the optimal fan frequency setting value and the opening setting value of each branch pipe regulating valve.

[0038] 5) Execute control commands and synchronously adjust the operating parameters of the purification and recovery unit.

[0039] Preferably, the safety risk levels include at least normal, early warning, alarm, and emergency stop; when the risk level is early warning, the control method includes increasing the opening of the regulating valve of the branch pipe where the risk source is located to enhance airflow dilution, while fine-tuning the total air volume of the system, and keeping the quick shut-off valve of the branch pipe in the open state.

[0040] The beneficial effects of this invention are as follows: early spark detection is performed by the dynamic pressure sensor of the equipment branch pipe, forming a dual early warning in time and space with the spark detector of the main pipe, which significantly improves the speed of risk identification and positioning accuracy; the control objective of the dust removal system is expanded from a single "safety interlock" to a multi-objective collaborative optimization of "safety-energy efficiency-recovery", and the optimal operating point is solved in real time by the algorithm, which realizes a leap in overall performance; the introduction of explosion-suppressing coagulant in the wet dust removal process extends the safety measures from the airflow system to the liquid phase, forming an explosion-proof barrier for the entire process. Attached Figure Description

[0041] Figure 1 This is a structural view of the present invention.

[0042] Figure 2 This is a schematic diagram of the pipeline structure of the present invention.

[0043] Figure 3 This is a block diagram showing the logical connections for monitoring and control (information flow and control flow).

[0044] Figure 4 This is a flowchart of the system control method.

[0045] The attached figures are labeled as follows: 10. Capacitor nailing machine; 11. Infrared temperature measurement array; 12. Intelligent collaborative control unit; 15. Spark detector; 16. Dust concentration monitor; 17. Dual-mode centrifugal fan; 18. Spray tower; 19. Dust resource recovery module; 20. Dynamic pressure sensor; 21. Flow meter; 13. Integrated valve group. Detailed Implementation

[0046] To further understand the features, technical means, and specific objectives and functions achieved by the present invention, the present invention will be described in further detail below with reference to specific embodiments and accompanying drawings.

[0047] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0048] Please refer to Figure 1-4 As shown, a centralized dust removal system for multiple capacitive nailing machines includes:

[0049] The distributed precision dust collection unit includes differentiated dust collection hoods installed at more than 10 dust-generating stations on each capacitor nailing machine in the production workshop, as well as equipment-level integrated valve assemblies connecting each dust collection hood. The dust-generating stations include nailing stations, foil pulling or brushing stations, and foil holding stations. The differentiated dust collection hoods include: an annular narrow slit dust collection hood for the nailing station, the hood body is usually annular, with a narrow slit around the inside or bottom, the slit width is usually 5-15mm, to achieve a low air volume and high air velocity capture effect; a slotted or umbrella-shaped dust collection hood for the foil pulling or brushing station, in actual use, the slotted dust collection hood can be found in the "slotted dust collection hood" or "groove side exhaust hood" series products, while the umbrella-shaped dust collection hood can be an umbrella-shaped exhaust hood; and a low-profile air collection box dust collection hood with a bottom air distribution plate for the foil holding station, which can be a low-profile air collection box hood with an internal airflow distribution plate. The equipment-level integrated valve group includes a quick-shut-off valve, an electrically controlled regulating valve, and a manually isolated valve connected in sequence.

[0050] The multi-level safety monitoring unit includes a flow meter 21 and a dynamic pressure sensor 20 installed on the equipment's dust suction branch pipe, an infrared temperature measurement array 11 installed on the area dust removal main pipe, and a spark detector 15 and a dust concentration monitor 16 installed on the system's dust removal main pipe.

[0051] The adaptive power delivery unit includes a dust removal pipe network connecting the branch pipes of each equipment, a pneumatic regulating valve installed in the dust removal pipe network, and a dual-mode centrifugal fan 17 driven by a frequency converter and equipped with a bypass return valve.

[0052] The high-efficiency purification and recycling unit includes a spray tower 18 with a built-in explosion-suppressing coagulant dosing system, and a dust resource recovery module 19 that is linked to the slurry discharge port of the spray tower 18.

[0053] The intelligent collaborative control unit 12 is used to run a multi-objective optimization collaborative control algorithm and is electrically connected to the multi-level safety monitoring unit, the adaptive power transmission unit and the high-efficiency purification and recycling unit to achieve collaborative optimization control of safety, energy efficiency and recycling objectives.

[0054] The dynamic pressure sensor 20 is a high-frequency pressure transmitter with a response frequency higher than 1kHz, used to capture pressure wave signals caused by sparks or initial combustion in the pipeline.

[0055] The dual-mode centrifugal fan 17 includes the following dual modes:

[0056] In the high-efficiency energy-saving mode, the control system adjusts the fan speed and the opening of the bypass return valve according to the number of online devices and the required air volume, so that the system operates at the optimal efficiency point.

[0057] In the safety boost mode, when the multi-level safety monitoring unit issues an early warning, the control system increases the fan speed and / or adjusts the pipeline valves to increase the airflow velocity in the risky pipeline.

[0058] An explosion-suppressing coagulant dosing system is used to automatically add agents mainly composed of phosphates and high molecular polymers to the circulating water tank of the spray tower 18 to reduce the explosion hazard of dust in the washing liquid and promote particle agglomeration and sedimentation.

[0059] The dust resource recovery module 19 includes an intelligent slurry discharge system, a thickening sedimentation tank, and a plate and frame filter press; the intelligent slurry discharge system automatically controls the slurry discharge operation based on the turbidity and pH parameters of the circulating water tank of the spray tower 18.

[0060] The intelligent collaborative control unit includes an industrial PLC, an edge computing gateway, and a host computer monitoring platform; the edge computing gateway is used to perform real-time spectrum analysis on the signal of the dynamic pressure sensor 20 to identify early spark characteristics.

[0061] A collaborative control method for a centralized dust removal system for multiple capacitor nail rolling machines includes the following steps:

[0062] 1) Real-time acquisition of operating data from multi-level safety monitoring units, all flow meters 21, and fans;

[0063] 2) Assess the system's safety risk level based on spectrum analysis of dynamic pressure signals and fusion of multi-level monitoring data;

[0064] 3) Calculate the system's baseline air volume requirement based on the current operating equipment and its workstation requirements, and make corrections according to the safety risk level;

[0065] 4) Taking the minimization of total system energy consumption as the optimization objective, and taking the corrected air volume requirements of each branch pipe and the safe negative pressure of the main pipe as constraints, solve for the optimal fan frequency setting value and the opening setting value of each branch pipe regulating valve.

[0066] 5) Execute control commands and synchronously adjust the operating parameters of the purification and recovery unit.

[0067] In this embodiment, a production workshop equipped with 24 capacitive nailing machines is provided.

[0068] The system is constructed as follows:

[0069] Dust collection unit: Each machine is equipped with a dedicated dust collection hood at each of its four workstations, with a designed airflow of 15m³ / h for the nail press position. 3 / h, foil pulling position 50m 3 / h, foil brushing position 30m 3 / h, foil position 20m 3 / h. An integrated valve group 13 is installed on the main branch pipe of each piece of equipment, which includes a manual ball valve, an electric regulating valve, and a quick pneumatic shut-off valve. Specifically, the manual ball valve can be a Q41F-16C type flange-connected floating ball valve, the electric regulating valve can be a Q941F-16C type intelligent electric regulating ball valve, and the quick pneumatic shut-off valve can be a ZSPQ-40B type pneumatic piston shut-off valve.

[0070] Monitoring Units: Each branch pipe is equipped with a vortex flow meter and a dynamic pressure transmitter with a range of 0-10 kPa and a response frequency >1 kHz. The workshop is divided into 4 areas, and a 6-point infrared temperature array 11 is installed on the main pipe for every 6 pieces of equipment. A spark detector 15 with a response time <1 ms and a dust concentration monitor 16 are installed on the main pipe. The dust concentration monitor 16 is set as a laser backscattering dust concentration meter.

[0071] Power unit: One unit with a rated air volume of 50,000 m³ / h 3 The double-suction centrifugal fan is driven by a 160kW frequency converter and equipped with a DN400 electric reflux valve, which is a valve with a nominal diameter of 400 mm (DN400) driven by an electric actuator to realize the function of media reflux or prevent backflow.

[0072] Purification and recovery unit: A 0.5‰ concentration of explosion-suppressing coagulant (mainly composed of phosphates and high-molecular polymers) is continuously added to the circulating water tank of the spray tower. The plate and frame filter press is an automatic plate-pulling type, with a filter cake moisture content of approximately 22%.

[0073] Control Unit: A Siemens S7-1500 PLC is used as the master station, connected to the I / O slave stations, frequency converters, and instruments on each branch pipe via a PROFINET network. The host computer monitoring system runs data services based on OPC UA. The control algorithm is executed in the PLC's Cyclic Interrupt, with an optimization cycle of 1 second.

[0074] Work process:

[0075] Assume the system currently has 18 devices operating. The control unit first aggregates the set flow rates of all operating branches (summing up to -2000m³).3 The system reads data from all safety sensors ( / h). If everything is normal, the algorithm, with minimum energy consumption as the objective, determines that the fan should operate at 38Hz and the opening of the regulating valves in each branch pipe should be between 40% and 70%. At this time, the system is in "high-efficiency energy-saving mode".

[0076] Suddenly, the dynamic pressure sensor of device number 5 in zone 3 detected a pressure pulse with an abnormal amplitude and a duration of 10ms. The spectrum analysis module of the edge computing gateway determined that it was a suspected spark feature (possibly related to metal friction). The control unit immediately raised the system risk level to "warning".

[0077] Coordinated control response:

[0078] Safety Response: The host computer displays an alert, locating "Equipment No. 5 in Zone 3". The quick-cut-off valve of the branch pipe of this equipment remains open (to avoid downtime affecting production), but the opening of its electric regulating valve is temporarily increased by 20% to enhance the airflow velocity in the pipeline, dilute and transport any potential sparks.

[0079] Energy efficiency response: If the system's required air volume increases by 5% (i.e., the increased flow rate of the branch pipe), the optimization calculation is re-performed, and the fan frequency and the opening of other valves are fine-tuned.

[0080] Monitoring and linkage: The system focuses on the infrared temperature measurement array data on the No. 3 main pipe and the spark detector data on the main pipe.

[0081] If subsequent infrared thermography shows that the temperature of the main pipe is normal, and no spark is confirmed in the main pipe within 2 seconds, the warning is lifted, and the system returns to its original optimized operating state. If the spark detector in the main pipe confirms a spark, the system immediately enters the "emergency stop" state, shuts off the main pipe shut-off valve and fan in Zone 3, and initiates the emergency procedure.

[0082] At the same time, the purification and recycling unit operates automatically based on dust concentration data to ensure that emissions meet standards and resources are recycled.

[0083] The above-described embodiments are merely one implementation of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A centralized dust removal system for multiple capacitor nailing machines, characterized in that, include: The distributed precision dust collection unit includes differentiated dust collection hoods installed at multiple dust-generating stations of each capacitor nailing machine (10) in the production workshop, and an equipment-level integrated valve group connecting each dust collection hood; the dust-generating stations include nailing stations, foil pulling or brushing stations, and foil holding stations; The multi-level safety monitoring unit includes a flow meter (21) and a dynamic pressure sensor (20) installed on the equipment dust suction branch pipe, an infrared temperature measurement array (11) installed on the area dust removal main pipe, and a spark detector (15) and a dust concentration monitor (16) installed on the system dust removal main pipe. The adaptive power delivery unit includes a dust removal pipe network connecting the branch pipes of each equipment, a pneumatic regulating valve installed in the dust removal pipe network, and a dual-mode centrifugal fan (17) driven by a frequency converter and equipped with a bypass return valve. The high-efficiency purification and recycling unit includes a spray tower (18) with a built-in explosion-suppressing coagulant dosing system, and a dust resource recovery module (19) linked to the slurry discharge port of the spray tower (18); The intelligent collaborative control unit (12) is used to run a multi-objective optimization collaborative control algorithm and is electrically connected to the multi-level safety monitoring unit, the adaptive power transmission unit and the high-efficiency purification and recycling unit to achieve collaborative optimization control of safety, energy efficiency and recycling objectives.

2. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The differentiated vacuum hood includes: A ring-shaped slit dust hood for use in nailing stations; Slotted or umbrella-shaped dust hoods for foil pulling or brushing stations; Low-profile, box-type dust collection hood with a bottom flow equalization plate for use in foil handling stations.

3. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The equipment-level integrated valve group includes a quick-shut-off valve, an electrically controlled regulating valve, and a manually isolated valve connected in sequence.

4. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The dynamic pressure sensor (20) is a high-frequency pressure transmitter with a response frequency higher than 1kHz.

5. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The dual-mode centrifugal fan (17) includes the following dual modes: In the high-efficiency energy-saving mode, the control system adjusts the fan speed and the opening of the bypass return valve according to the number of online devices and the required air volume, so that the system operates at the optimal efficiency point. In the safety boost mode, when the multi-level safety monitoring unit issues an early warning, the control system increases the fan speed and / or adjusts the pipeline valves to increase the airflow velocity in the risky pipeline.

6. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The explosion-suppressing coagulant dosing system is used to automatically add agents with phosphate and high molecular polymer as the main components to the circulating water tank of the spray tower (18).

7. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The dust resource recovery module (19) includes an intelligent slurry discharge system, a thickening sedimentation tank and a plate and frame filter press; the intelligent slurry discharge system automatically controls the slurry discharge operation according to the turbidity and pH value parameters of the circulating water tank of the spray tower (18).

8. A centralized dust removal system for multiple capacitor nailing machines according to claim 1, characterized in that: The intelligent collaborative control unit includes an industrial PLC, an edge computing gateway, and a host computer monitoring platform.

9. A cooperative control method based on the system according to any one of claims 1-8, characterized in that, Includes the following steps: 1) Real-time acquisition of operating data from multi-level safety monitoring units, all flow meters (21), and fans; 2) Assess the system's safety risk level based on spectrum analysis of dynamic pressure signals and fusion of multi-level monitoring data; 3) Calculate the system's baseline air volume requirement based on the current operating equipment and its workstation requirements, and make corrections according to the safety risk level; 4) Taking the minimization of total system energy consumption as the optimization objective, and taking the corrected air volume requirements of each branch pipe and the safe negative pressure of the main pipe as constraints, solve for the optimal fan frequency setting value and the opening setting value of each branch pipe regulating valve. 5) Execute control commands and synchronously adjust the operating parameters of the purification and recovery unit.

10. The cooperative control method according to claim 9, characterized in that, The safety risk levels include at least normal, warning, alarm, and emergency stop. When the risk level is warning, the control method includes increasing the opening of the regulating valve of the branch pipe where the risk source is located to enhance airflow dilution, while fine-tuning the total air volume of the system, and keeping the quick shut-off valve of the branch pipe in the open state.

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