High-efficiency powder airflow homogenizing device and control system

Abstract

The invention discloses a high-efficiency powder airflow homogenizing device and a control system thereof. The high-efficiency powder airflow homogenizing device comprises a compressed gas supply system, a storage homogenizing device, an intelligent detection control system and a degassing and dust recycling system. The storage homogenizing device comprises a stock bin and a multi-layer airflow guide pipe arranged in the stock bin, the multi-layer airflow guide pipe comprises 3-5 layers of annular airflow guide pipes and a middle main airflow pipe, all the layers are arranged in a concentric circle mode, and a plurality of nozzles are distributed on planes with different heights. The intelligent detection control system comprises a PLC control cabinet and a DCS interface, airflow parameters and powder states are collected in real time through a sensor, the intelligent detection control system has a timing control mode and a constant-pressure control mode, and the air injection pressure or the valve opening degree is adjusted in real time through a PID algorithm in the constant-pressure control mode. According to the invention, through combination of multi-layer airflow conduit three-dimensional air injection and intelligent control, the problems of non-uniform homogenization, high energy consumption and poor adaptability in the prior art are solved, the powder is uniformly mixed in the whole space, the energy consumption and the cost are reduced, and the device is suitable for multi-industry application scenes.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of solid bulk powder airflow homogenization, and particularly relates to a high-efficiency powder airflow homogenization device and a control system. BACKGROUND

[0002] In the industrial fields of building materials, metallurgy, chemical industry, food and heat treatment, the uniformity of solid bulk powder or fluid material directly determines the quality of the final product, process stability and production efficiency. Whether it is the mixing preparation of industrial raw materials such as alpha alumina powder or the precise regulation of the atmosphere in a pit-type carburizing furnace, the homogenization technology is needed to eliminate material stratification, segregation or airflow turbulence. With the upgrading of industrial production to scale and high precision, the efficiency, adaptability and impurity control requirements of homogenization technology have significantly improved. Mechanical homogenization and airflow homogenization, as two main types of homogenization technology, have become the core direction of industry technology optimization.

[0003] The current homogenization technology scheme applied in the industrial field mainly includes mechanical homogenization and airflow homogenization. Both types of technology have formed a relatively mature patent technology system, and the specific representative schemes are as follows:

[0004] The mechanical homogenization represented by patent CN221965189U uses a servo motor to control the movement of a baffle through a threaded rod to achieve continuous intermittent feeding. At the same time, a stirring motor drives a stirring shaft to rotate at high speed to mechanically stir and homogenize the powder entering the homogenization cavity. The airflow homogenization represented by patent CN222019398U allows the material to enter the mixing tank through the feeding pipe, and the gas source is sprayed from the uniformly arranged aeration holes through the aeration pipeline to form uniform airflow disturbance, so that the material realizes airflow homogenization in the tank.

[0005] However, the present inventors found at least the following technical problems in the process of implementing the technical scheme of the present application:

[0006] (1) The traditional airflow homogenization scheme has a limited homogenization coverage. The stratification and segregation of the powder due to differences in particle size and density result in incomplete homogenization.

[0007] (2) The mechanical homogenization has high energy consumption and the mechanical parts are prone to wear. The traditional airflow homogenization has low gas utilization rate and energy waste.

[0008] (3) The existing homogenization technology is operated with fixed parameters and cannot be dynamically adjusted according to the characteristics of the powder or the production conditions, which has poor adaptability. SUMMARY

[0009] To address the shortcomings of the aforementioned technologies, the present invention aims to provide a high-efficiency powder airflow homogenization device to solve the problems of uneven airflow distribution, high energy consumption, homogenization dead zones, complex system structures, and poor adaptability in existing homogenization technologies. By optimizing the airflow distribution, improving energy utilization efficiency, simplifying the system structure, and implementing intelligent detection and control, the invention achieves more efficient, energy-saving, stable, reliable, and adaptable powder homogenization.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0011] This invention provides a high-efficiency powder airflow homogenization device, comprising a compressed gas supply system, a storage homogenization device, an intelligent detection and control system, and a degassing and dust recovery system.

[0012] The compressed gas supply system is connected to the storage homogenization device via a pipeline to provide stable, clean compressed gas with sufficient flow rate.

[0013] The storage and homogenization device includes a silo, a multi-layered airflow duct installed inside the silo, a pneumatic shut-off valve, and a bottom fluidization control device. The number of layers in the multi-layered airflow duct is determined according to the volume of the silo and the characteristics of the material. Each layer of the annular airflow duct is arranged in a concentric circle structure at different heights and is connected to the central main airflow duct through branch pipes. The central main airflow duct is connected to the compressed gas supply system through a top interface. The multi-layered airflow duct has multiple nozzles arranged at different heights for injecting compressed gas into the powder in the silo. The pneumatic shut-off valve is located at the connection between each layer of the annular airflow duct and the branch pipes to control the gas flow in each layer of the airflow duct. The bottom fluidization control device has a fluidizing plate or breathable cloth installed at the bottom of the cone and supplies compressed gas to the bottom of the cone through an externally installed air passage ring pipe. It is equipped with pressure gauges and flow meters to assist in material feeding, prevent powder bridging, and ensure smooth discharge.

[0014] The intelligent detection and control system includes a PLC control cabinet, a human-machine interface (HMI), sensors, and a DCS system interface. The sensors collect airflow parameters (pressure, flow rate, temperature), powder status (material level, bed differential pressure), and equipment safety signals (valve status, compressor load). The PLC control cabinet realizes closed-loop control based on the collected data. The human-machine interface (HMI) supports parameter setting, mode switching, and operation monitoring.

[0015] The intelligent detection and control system has a timing control mode and a constant pressure control mode;

[0016] In timed control mode, the opening and closing of pneumatic shut-off valves on each floor are controlled according to a preset time cycle to achieve time-sharing and layered air jetting.

[0017] In constant pressure control mode, the pressure inside the chamber is set as the target value, and the jet pressure or valve opening is adjusted in real time through PID algorithm to keep the pressure inside the chamber stable within the set range.

[0018] The degassing and dust recovery system specifically includes a silo top dust collector and a recovery pipeline. The silo top dust collector is installed on the top of the solid silo and is equipped with a pulse jet cleaning device and pressure difference detection devices.

[0019] Furthermore, the degassing and dust recovery system is used to filter dust-laden gas, periodically clean the dust, and discharge or centrally recover the clean gas after powder filtration.

[0020] Furthermore, the vertical spacing between two adjacent annular airflow ducts is 1 / 4 to 1 / 6 of the effective height of the silo;

[0021] Furthermore, the intelligent detection and control system also includes a touch screen HMI for displaying real-time monitoring images, setting control parameters, and switching control modes;

[0022] Furthermore, the sensors include a pressure transmitter (PT-01), a temperature transmitter (TT-01), a flow meter (FT-01), a level gauge (LT-01), a load cell (WT-01), and a differential pressure transmitter (DPT-01);

[0023] Furthermore, the compressed gas supply system includes an air compressor, an air tank, a safety valve, a pressure reducing valve, and a compressed gas delivery pipeline;

[0024] Furthermore, the pulse jet cleaning device of the degassing and dust recovery system is linked with the intelligent detection and control system, and adopts timed and pressure-based control logic to ensure dust removal efficiency.

[0025] This invention provides a method for controlling powder airflow homogenization, comprising the following steps:

[0026] S1: Initialization settings: Based on the characteristics of the powder material and the capacity of the silo, set the control mode, jet pressure, jet time and number of cycles;

[0027] S2: Start the compressed gas supply system to supply compressed gas to the multi-layer airflow duct in the silo;

[0028] S3: Real-time acquisition of airflow parameters and powder state through sensors. The airflow parameters include pressure P, flow rate Q, and temperature T. The powder state includes material level H and weight W.

[0029] S4: Execute the corresponding control strategy according to the set control mode:

[0030] If it is in the timing control mode, the pneumatic cut-off valves of each layer are controlled to open and close according to a preset time period. In the initial stage of homogenization, short-period high-frequency jetting is used to break the initial stratification, and in the later stage of homogenization, long-period low-frequency jetting is used to maintain uniformity. After cycling to the set number of times, the homogenization ends.

[0031] If it is in the constant pressure control mode, with the set pressure P_target as the target value, the pressure P_actual in the bin is collected in real time, and the pressure deviation ΔP = P_target - P_actual is calculated. According to the deviation, the air supply pressure or valve opening is adjusted through the PID algorithm:

[0032] When P_actual < P_min, increase the air supply pressure;

[0033] When P_actual > P_max, decrease the air supply pressure;

[0034] When P_min ≤ P_actual ≤ P_max, maintain the current pressure;

[0035] Continue to run until the set homogenization time, and then the homogenization ends;

[0036] S5: Close all pneumatic cut-off valves, stop the air supply, and the homogenization process ends.

[0037] Further, in the timing control mode, the jetting time T1 is 10 - 30 seconds, the gas stop time T2 is 5 - 15 seconds, and the number of cycles N is 5 - 20 times.

[0038] Further, the method also includes a safety protection step:

[0039] When the pressure in the bin exceeds the safety upper limit P_safe, automatically close all start-up cut-off valves and start the safety relief device;

[0040] When the gas flow Q is lower than the set lower limit Q_min or the compressor load is abnormal, give an alarm prompt and link to stop the machine; when the bed differential pressure exceeds the normal range, trigger an alarm prompt.

[0041] The present invention sets the association relationship between P_safe and P_max, based on the working pressure characteristics of the air flow homogenization system: the normal working pressure (P_target) is usually 0.05 - 0.08 MPa, P_max = P_target + ΔP (ΔP = 0.01 - 0.02 MPa), and the absolute pressure upper limit is 0.1 MPa, which conforms to the safety design specifications of powder tanks in the industry and ensures the safe operation of the equipment.

[0042] The working principle of this invention is as follows: a compressed gas supply system provides clean gas to the storage homogenization device. Under the control of an intelligent detection and control system, based on the selected control mode (timed and pressure controlled) and real-time monitored multi-dimensional parameters, the opening and closing of pneumatic shut-off valves and the jet pressure of each layer are adaptively adjusted. This causes compressed gas to be injected into the silo from the nozzles of the multi-layered airflow duct, forming a three-dimensional circulating airflow field. This drives the powder particles to mix thoroughly under the combined action of "convective diffusion" and "shear diffusion," achieving efficient homogenization. Simultaneously, a degassing and dust recovery system ensures clean operation. The entire process is highly automated and requires no manual intervention.

[0043] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0044] 1. Because the present invention adopts a multi-layer airflow duct structure and arranges multiple nozzles at different heights to form vertical multi-layer and radial multi-directional airflow disturbance, it effectively solves the problems of limited airflow coverage and powder segregation caused by homogenization blind zones in the prior art. As a result, the powder homogenization uniformity reaches ±1.5%, which is 70% higher than the traditional single-layer structure, and eliminates the homogenization dead zones at the bottom and top of the silo.

[0045] 2. Due to the adoption of an intelligent control system, the problem of energy waste has been effectively solved, thereby reducing energy consumption;

[0046] 3. Due to the adoption of an integrated PLC and DCS control system and a PID closed-loop control algorithm, the homogenization process is made intelligent and automated, reducing the labor intensity of operators by 40%, increasing the system response speed by 60%, and reducing the equipment failure rate by 50%. Attached Figure Description

[0047] The following figures are schematic diagrams of embodiments of the present invention.

[0048] Figure 1 This is a block diagram of the overall structure of the high-efficiency powder airflow homogenization device of the present invention, showing the four major subsystems and their connection relationships.

[0049] Figure 2 This is a schematic diagram of the storage homogenization device of the present invention, showing the overall structure of the silo and the three-dimensional arrangement of the multi-layer airflow ducts;

[0050] Figure 3 This is a control architecture diagram of the intelligent detection and control system of the present invention, which shows the logical control relationship of the system;

[0051] Figure 4 This is a hardware architecture diagram of the intelligent detection and control system of the present invention, showing the connection relationship between the PLC, sensors and actuators;

[0052] Figure 5 The control flowchart of the timing control mode of the present invention illustrates the control logic of time-division and layered jet injection.

[0053] Figure 6 The control flowchart of the constant pressure control mode of this invention shows the execution flow of PID closed-loop control;

[0054] In the diagram: 1-Compressed gas supply system; 1-1-Air compressor; 1-2-Air tank; 1-3-Pressure transmitter PT-01; 1-4-Temperature transmitter TT-01; 1-5-Pressure reducing valve; 2-Storage homogenization device; 2-1-Hill; 2-2-Multi-layer airflow duct; 2-3-Pneumatic shut-off valves 2-3-1, 2-3-2, 2-3-3 (corresponding to each layer); 2-4-Level gauge LT-01; 2-5-Weighing sensor WT-01; 3-Intelligent detection and control system; 3-1-PLC control cabinet; 3-2-Touch screen HMI (Hardware Interface); 3-3-DCS System Interface; 3-4-Profinet Communication Network; 4-Degassing and Dust Recovery System; 4-1-Binary Top Dust Collector; 4-2-Differential Pressure Transmitter DPT-01; 4-3-Pulse Jet Control Valve; 101-Inlet; 102-Binary Side Wall; 103-Conical Discharge Structure; 104-Outlet; 105-Outlet Valve; 6-Sampling Device; 7-Safety Relief Device; 2-2-1-First Layer Airflow Conduit; 2-2-2-Second Layer Airflow Conduit; 2-2-3-Third Layer Airflow Conduit; Detailed Implementation

[0055] To enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings, so as to help those skilled in the art understand the content of the present invention.

[0056] HMI (Human Machine Interface)

[0057] DCS (Distributed Control System)

[0058] PID algorithm (Proportional-Integral-Derivative Algorithm)

[0059] Profinet (ProcessFieldNet)

[0060] PLC (Programmable Logic Controller)

[0061] This invention provides a high-efficiency powder airflow homogenization device, solving problems such as uneven airflow distribution, high energy consumption, homogenization dead zones, complex system structure, and poor adaptability in existing technologies. By optimizing the airflow distribution, improving energy utilization efficiency, simplifying the system structure, and implementing intelligent detection and control, it achieves more efficient, energy-saving, stable, reliable, and adaptable powder homogenization.

[0062] Example 1

[0063] like Figure 1 and Figure 3 As shown, the high-efficiency powder airflow homogenization device of the present invention comprises four subsystems: a compressed gas supply system 1, a storage homogenization device 2, an intelligent detection and control system 3, and a degassing and dust recovery system 4. The connection relationships of each subsystem are as follows: Figure 1 As shown, the control logic is as follows Figure 3 As shown.

[0064] The compressed gas supply system 1 is connected to the storage and homogenization device via a gas delivery pipeline, providing dry and clean compressed air. The storage and homogenization device 2 adopts an innovative multi-layer airflow duct structure, including multiple layers of annularly arranged airflow ducts, with micro-orifice nozzles 3 evenly distributed on each layer of ducts to form a three-dimensional airflow distribution. The intelligent detection and control system 3 connects the sensors and actuators of each system through a cable network to achieve real-time monitoring and intelligent control. The degassing and dust recovery system 4 is installed on the top of the silo, treating the dust-laden gas through a dust collector 4-1 and ensuring it meets emission standards. The four subsystems work together through pipeline connections and electrical control. The air compressor 1-1 and air storage tank 1-2 of the compressed gas supply system 1 provide a stable air source, which enters the multi-layer airflow ducts of the storage and homogenization device 2 after being regulated by the pressure reducing valve 1-5. The PLC control cabinet 3-1 of the intelligent detection and control system 3 collects data from sensors such as pressure transmitter PT-01 (1-3), flow meter FT-01, and level gauge LT-01. Human-machine interaction is achieved through the touchscreen HMI 3-2, and the system employs both timed and pressure-controlled modes to precisely control the opening of pneumatic shut-off valves 2-3-1, 2-3-2, and 2-3-3. The pulse jet cleaning device of the degassing and dust recovery system 4 periodically cleans dust to maintain dust removal efficiency. Through modular design and intelligent control, the entire system achieves high efficiency, energy saving, and safety in the powder homogenization process.

[0065] Example 2

[0066] The compressed gas supply system 1 provides dry, clean, and pressure-stable compressed gas for the entire homogenization process. It mainly includes an air compressor 1-1, an air tank 1-2, a pressure transmitter PT-01 (1-3), a temperature transmitter TT-01 (1-4), and a pressure reducing valve 1-5. The air compressor 1-1 is a screw compressor with a rated discharge pressure of 0.8 MPa and a discharge capacity of 10 m³ / s. 3 / min, equipped with variable frequency drive, the speed can be adjusted according to gas demand, energy saving and high efficiency. Gas storage tank 1-2, 5m³ / min 3 The operating pressure is 0.7 MPa, serving as a gas source buffer to ensure stable gas supply. The pressure transmitter PT-01(1-3) has a range of 0-1.0 MPa and an accuracy of 0.5% FS, monitoring the outlet pressure of the gas tank in real time. The temperature transmitter TT-01(1-4) has a range of 0-100℃ and an accuracy of 0.2% FS, monitoring gas temperature to prevent overheating. The pressure reducing valve 1-5 is an electrically adjustable type with an output pressure range of 0.1-0.6 MPa; its opening is adjusted by the PLC in constant pressure control mode. The gas supply pressure is preferably stabilized within the range of 0.5-0.7 MPa, and the gas mass should achieve solid particle density ≤5 mg / m³. 3 Water content ≤ -40℃ pressure dew point, oil content ≤ 1mg / m³ 3 To avoid contaminating powder materials.

[0067] Example 3

[0068] The homogenization device 2, as the core equipment of the powder homogenization system, adopts an innovative three-dimensional airflow distribution design to achieve efficient and uniform mixing of powders. This device mainly consists of a cylindrical vertical silo 2-1 and an innovative multi-layer airflow duct system 2-2. The silo adopts a standardized design with an inner diameter of 3 meters and an effective height of 12 meters, with a volume of approximately 85 cubic meters. A 65° conical discharge structure 103 is configured at the bottom to ensure smooth powder discharge. Figure 2As shown, the core innovation of the multi-layer air duct system lies in its three-layer three-dimensional distribution structure: the three-layer annular air ducts are arranged in concentric circles, connected to the main air duct through DN50 branch pipes, and flanges and sealing rings are used at the interfaces to ensure airtightness. In this embodiment, 12 micro-nozzles 3 are evenly arranged on each layer of the annular duct, the nozzle aperture is 10 mm, and the spraying angle is 3°0. In other embodiments, the number of nozzles can be 8 - 16, the nozzle aperture can be 8 - 15 mm, and the spraying angle can be 20 - 45°, forming a three-dimensional cross airflow network. The nozzle aperture d is set based on the average particle size d_p of the powder: when d_p ≤ 50μm, d = 6 - 8mm; when 50μm < d_p ≤ 100μm, d = 8 - 12mm; when d_p > 100μm, d = 12 - 15mm. The pneumatic cut-off valve system 2 - 3 consists of three valves 2 - 3 - 1, 2 - 3 - 2, and 2 - 3 - 3, which respectively and precisely control the gas on and off of the three-layer air ducts. DN50 pneumatic cut-off valves are used, with a response time less than 1 second, and position feedback switches are equipped to monitor the valve status in real time. This innovative multi-layer structure design uses the lower layer 2 - 3 - 1 air flow (nozzle spraying obliquely upward at 45°) to push the powder at the lower part of the silo upward for fluidization; the middle layer 2 - 3 - 2 air flow (nozzle spraying horizontally radially) forms a shear force to achieve uniform radial mixing of the powder; the upper layer 2 - 3 - 3 air flow (nozzle spraying obliquely downward at 30°) forms a pressing air curtain to prevent the powder from rising excessively and avoid secondary stratification, completely eliminating the fluidization blind zone of the traditional single-layer structure, making the homogenization uniformity reach ±1.5%, a 70% improvement compared to the traditional structure, while reducing energy consumption by 35% and shortening the homogenization time by 50%. The entire system adopts a modular design, with the main air duct connected by segmented flanges, and the annular ducts arranged in split sections for easy installation and maintenance; key components adopt wear-resistant designs, the inner wall of the air duct is sprayed with a tungsten carbide coating, and the nozzles are made of cemented carbide to ensure long-term stable operation. The specific implementation method of the bottom fluidization control device is as follows: an air-permeable cloth or a porous fluidization plate is installed at the lowest point of the conical bottom 103 of the silo. The air-permeable cloth is made of wear-resistant polyester fiber, and the air permeability ≥ 100L / 2 ·min); the external air circuit ring pipe uses a DN25 stainless steel pipe, with 4 air inlets evenly distributed along the circumference of the conical bottom, and each air inlet is equipped with a pressure gauge (range 0 - 1.0MPa) and a manual regulating valve; the fluidization air pressure is set at 0.1 - 0.2MPa, and the flow rate is dynamically adjusted according to the discharging speed.

[0069] Example 4

[0070] It should be noted that there seems to be an incorrect unit "壮志m" in the original text which is likely a typo and is translated as it is in the above translation. You may want to correct it for a more accurate technical description.Unlike Embodiment 3, this embodiment employs a four-layer airflow duct system. The silo adopts a standardized design with an inner diameter of 3.5 meters and an effective height of 15 meters, with a volume of approximately 144 cubic meters. A 62° conical discharge structure 103 is configured at the bottom, with wear-resistant ceramic lining plates on the conical surface to further reduce powder flow resistance and ensure smooth powder discharge. The core innovation of the four-layer airflow duct system lies in its four-layer three-dimensional distribution structure: the pipe diameter is upgraded to DN80 to accommodate the flow requirements of the four air paths; the four annular airflow ducts are arranged concentrically, with the diameters of each annular duct being 80%, 65%, 50%, and 35% of the silo's inner diameter, respectively. They are connected to the main airflow pipe via DN50 branch pipes, with reinforced flanges and sealing rings at the interfaces to ensure airtightness under high-pressure airflow.

[0071] In this embodiment, 16 micro-orifice nozzles 3 are evenly arranged on each layer of the annular guide tube. The nozzle orifice diameter is 9 mm, and the spray angle is 35°. The nozzles of the bottom and top layers adopt a "35° upward angle" spray angle, while the nozzles of the lower middle and upper middle layers adopt a "35° horizontal angle" spray angle, forming a three-dimensional cross-flow network of "upward and downward lifting + radial diffusion in the middle". In other embodiments, the number of nozzles can be adjusted to 12-20 according to the powder characteristics, with nozzle orifice diameters of 7-12 mm and spray angles of 25-40° to ensure airflow coverage under different working conditions.

[0072] The pneumatic shut-off valve system 2-3 consists of four valves: 2-3-1 (bottom layer), 2-3-2 (lower middle layer), 2-3-3 (upper middle layer), and V4 (top layer). These valves precisely control the gas flow in and out of the four airflow ducts. The system uses DN50 high-performance pneumatic shut-off valves with a response time of ≤0.8 seconds. It is equipped with explosion-proof position feedback switches and pressure sensors to monitor the valve status and the airflow pressure in the pipes in real time.

[0073] This optimized four-layer structure design achieves efficient homogenization through synergistic action: the bottom 2-3-1 airflow provides strong thrust, pushing the powder in the lower part of the hopper upwards to fluidize; the airflow in the lower middle layer 2-3-2 and the upper middle layer 2-3-3 forms radial shear force, breaking the powder layering interface and achieving uniform mixing in the horizontal direction.

[0074] Example 5

[0075] Unlike Example 3, Example 5 employs a five-layer airflow duct system. The silo features a standardized design with an inner diameter of 4.2 meters and an effective height of 18 meters, with a volume of approximately 249 cubic meters. A 60° conical discharge structure 103 is configured at the bottom, with a fluidizing plate at the bottom of the cone to assist discharge and prevent powder compaction and arching at the bottom of the large silo. The core innovation of the five-layer airflow duct system lies in its five-layer three-dimensional distribution structure: bottom layer - lower middle layer 1 - middle middle layer - upper middle layer 2 - top layer. The pipe diameter is upgraded to DN100 to meet the total flow requirements of the five air paths. The five annular airflow ducts are arranged concentrically, with the diameters of each annular duct being 85%, 72%, 58%, 45%, and 32% of the silo's inner diameter, respectively. They are connected to the main airflow pipe via DN50 branch pipes, with flanges and pressure monitoring points at the interfaces to detect leak risks in real time.

[0076] In this embodiment, 20 micro-orifice nozzles 3 are evenly arranged on each layer of the annular duct. The nozzle orifice diameter is 8 mm, and the spray angle is 32°. The bottom layer nozzles are angled upward at 32°, the top layer nozzles are angled downward at 32°, and the three middle layers of nozzles are arranged horizontally, forming a full-space coverage airflow network of "bottom lifting + middle radial diffusion + top pressing", ensuring that there are no dead zones in the airflow within the large silo. In other embodiments, the number of nozzles can be adjusted to 16-24, the nozzle orifice diameter is 6-10 mm, and the spray angle is 28-38°. The nozzle distribution is optimized using airflow simulation software to achieve an airflow velocity uniformity of ≥90% within the silo.

[0077] The pneumatic shut-off valve system consists of five valves: 2-3-1 (bottom layer), 2-3-2 (lower middle layer 1), 2-3-3 (middle middle layer), V4 (upper middle layer 2), and V5 (top layer). These valves precisely control the gas flow in and out of the five airflow ducts. The system uses DN50 intelligent pneumatic shut-off valves with a response time of ≤0.7 seconds. It integrates valve positioners and temperature sensors to achieve three-parameter linkage monitoring of "pressure-temperature-position" and is suitable for the complex working conditions of large silos.

[0078] This sophisticated five-layer structure design achieves ultimate homogenization through multi-dimensional collaboration: the bottom 2-3-1 airflow provides strong fluidization thrust, solving the problem of powder compaction at the bottom of large silos; the lower middle layer 1 (2-3-2) and upper middle layer 2 (V4) airflows form bidirectional radial shear, breaking the stratification gradient of powder along the height direction; the middle middle layer (2-3-3) airflow serves as the core mixing layer, enhancing the turbulent mixing effect of powder in the middle; the top V5 airflow forms a flexible pressing air curtain, balancing the pressure distribution within the silo and preventing powder from flying off the top.

[0079] The selection criteria for the number of layers in a multi-layer airflow duct are as follows: 1. When the effective height of the silo is ≤10m, a 3-layer structure (layer spacing 2.5-3.3m) is preferred; 2. When the effective height of the silo is 10-15m, a 4-layer structure (layer spacing 2.5-3.75m) is preferred; 3. When the effective height of the silo is ≥15m, a 5-layer structure (layer spacing 3-3.6m) is preferred. The layer spacing is controlled within 1 / 4-1 / 6 of the effective height of the silo to ensure that the airflow coverage is without dead angles.

[0080] Example 6

[0081] like Figure 3 and Figure 4 As shown, the intelligent detection and control system 3 is responsible for real-time monitoring and intelligent control of the entire powder airflow homogenization process. The intelligent detection and control system 3 includes a PLC control cabinet 3-1, a touchscreen HMI (3-2), and a DCS system interface 3-3. The PLC control cabinet 3-1 is the core of the entire control system, using a high-performance PLC from a mainstream brand, such as the S7-1500 series or an equivalent PLC. The PLC control cabinet's module configuration includes a CPU, AI, AO, DI, DO, and Profinet communication modules; the HMI supports mode switching, parameter setting, real-time curve display, and fault alarm pop-ups, and exchanges data with the DCS system to achieve remote monitoring and centralized management.

[0082] The touchscreen HMI (3-2) uses a 10.1-inch color industrial touchscreen, installed on the panel of PLC control cabinet 3-1, for displaying real-time monitoring screens, setting control parameters, and switching control modes. The touchscreen interface includes the following functional areas: real-time monitoring screen, control mode selection, parameter setting area, alarm display area, and historical curves. The real-time monitoring screen displays the positions of the hopper, airflow duct, and various sensors in animated form, and displays real-time values ​​for parameters such as pressure P, flow rate Q, temperature T, material level H, weight W, and differential pressure ΔP. The control mode selection provides "manual / automatic" and "timed / constant pressure" switching buttons. The parameter setting area allows setting the jet time T1, gas stop time T2, number of cycles N (timed mode) or target pressure P_target and pressure upper and lower limits (constant pressure mode). The alarm display area displays current alarm information, such as pressure exceeding limits and abnormal flow. The historical curves display historical change curves of parameters such as pressure, flow rate, and material level, facilitating analysis and optimization. In this embodiment, the dust collector on the silo top uses bag filter material, therefore ΔP_low = 200Pa, ΔP1 = 1600Pa, and ΔP_high = 2000Pa; the timed dust cleaning cycle is set to 15 minutes (suitable for inlet dust concentrations of 5-10 g / m³). 3(The system operates under the following conditions); when ΔP_dust≤200Pa, the system immediately stops the compressed gas supply and homogenization process, and the HMI interface displays 'Filter Bag Damage Alarm'; when ΔP_dust≥2000Pa, 'Filter Bag Blockage Alarm' is displayed, and the timed cleaning cycle is shortened to 5 minutes, while the blowing pressure is increased to 0.6MPa to enhance the cleaning effect. The DCS system interface 3-3 connects to the factory's DCS system via the Profinet communication network 3-4 to achieve data upload and remote control. The PLC uploads all parameters collected in real time to the DCS system and simultaneously receives control commands issued by the DCS system.

[0083] In this embodiment, P_target = 0.06MPa, ΔP = 0.015MPa, therefore P_max = 0.075MPa, P_safe = 0.075MPa + 0.025MPa = 0.1MPa (reaching the upper limit of the safety of the atmospheric pressure vessel); when the sensor detects that the pressure inside the chamber is ≥0.1MPa for 3 seconds, the safety relief valve on the top of the chamber automatically opens, with a pressure relief rate ≥0.01MPa / s. At the same time, the PLC control cabinet triggers a red audible and visual alarm, the HMI interface displays 'Overpressure relief in progress', and the fault signal is uploaded to the central control room through the DCS interface.

[0084] like Figure 5 As shown, the control logic for the timed control mode is as follows:

[0085] Step S1: Initialization Setup. The operator sets the following parameters via the touchscreen HMI (3-2):

[0086] Jet time T1: The duration for which the pneumatic shut-off valve is open at each layer, set according to the powder characteristics, typically 10-30 seconds. In this embodiment, T1 = 15 seconds.

[0087] Gas shut-off time T2: The duration for which all pneumatic shut-off valves are closed, allowing the powder to settle, typically 5-15 seconds. In this embodiment, T2 = 10 seconds.

[0088] Number of cycles N: The number of times the entire jet cycle is repeated, set according to the homogenization requirements, usually 5-20 times. In this embodiment, N = 10 times.

[0089] Confirm that all other parameters are normal.

[0090] Step S2: Start the homogenization process. The operator clicks the "Start" button on the touch screen, and PLC control cabinet 3-1 begins executing the timing control program.

[0091] Step S3: First-layer air injection. The PLC sends a control signal to open the first-layer pneumatic shut-off valve 2-3-1 (2-3). Compressed gas is injected from the nozzle of the first-layer airflow duct into the powder at the bottom of the hopper, causing the powder in this area to fluidize and tumble upwards. At the same time, the PLC monitors the value of the flow meter FT-01 (2-4) in real time to confirm normal gas flow.

[0092] Step S4: Delay for T1 seconds. The PLC's internal timer counts for 15 seconds.

[0093] Step S5: Switch to the second layer. After the timer reaches its set time, the PLC shuts off 2-3-1 and simultaneously opens the second-layer pneumatic shut-off valve 2-3-2, allowing compressed gas to be injected from the nozzle of the second-layer airflow duct into the powder in the center of the hopper.

[0094] Step S6: Delay for T1 seconds. The PLC internal timer starts counting down again for 15 seconds.

[0095] Step S7: Switch to the third layer. After the timer reaches its set time, the PLC shuts off 2-3-2 and simultaneously opens the third-layer pneumatic shut-off valve 2-3-3, allowing compressed gas to be sprayed from the nozzle of the third-layer airflow duct onto the powder in the upper part of the hopper.

[0096] Step S8: Delay for T1 seconds. The PLC's internal timer starts counting down again for 15 seconds.

[0097] Step S9: Stop all gas supply. After the timer expires, PLC shuts down 2-3-3, all pneumatic shut-off valves are closed, and the powder settles under gravity.

[0098] Step S10: Delay for T2 seconds. The PLC internal timer counts for 10 seconds to allow the powder to settle completely.

[0099] Step S11: Cycle counting. The PLC's internal cycle counter is incremented by 1, and it is determined whether the set number of cycles N = 10 has been reached.

[0100] Step S12: Determine if the loop is complete. If the loop count has not reached 10, return to step S3 and start the next loop; if the loop count has reached 10, proceed to step S13.

[0101] Step S13: Homogenization complete. The PLC sends a homogenization complete signal, displays "Homogenization complete" on the touch screen, and records the relevant data for this homogenization.

[0102] In the above process, each cycle is T1×3+T2=15×3+10=55 seconds, and 10 cycles require a total of 550 seconds.

[0103] To further optimize energy consumption, the timed control mode can also adopt a segmented timed strategy:

[0104] In the initial stage of homogenization: short-cycle high-frequency jetting is used, with T1 = 10 seconds and T2 = 5 seconds, to quickly break up the initial stratification of the powder;

[0105] In the later stage of homogenization: long-cycle low-frequency jetting is adopted, with T1=20 seconds and T2=15 seconds set to maintain the uniformity of the powder and reduce energy consumption.

[0106] like Figure 6 As shown, the constant pressure control mode uses a closed-loop PID control algorithm to achieve precise pressure regulation. Its control logic includes three core components: First, the pressure transmitter PT-01 (1-3) collects the chamber pressure P_actual in real time and compares it with the setpoint P_target to generate a deviation signal ΔP; second, the PID controller calculates the control quantity based on the deviation, where the proportional coefficient Kp quickly responds to pressure changes, the integral coefficient Ki eliminates steady-state errors, and the derivative coefficient Kd suppresses pressure fluctuations; finally, the actuator adjusts the pressure reducing valve opening and valve combination based on the output signal. Parameter setting adopts a tiered strategy. Basic parameters include the target pressure P_target (adjustable from 0.05-0.5MPa) and the pressure band P_max / min (±0.05MPa). During system initialization, the target pressure P_target is set to 0.3MPa, the upper pressure limit P_max to 0.35MPa, and the lower limit P_min to 0.25MPa. The PID parameters are set to Kp = 1.0, Ki = 0.3, and Kd = 0.1. During operation, the PLC collects the chamber pressure P_actual in real time and calculates the deviation ΔP = P_target - P_actual. The PLC then outputs control signals using a PID algorithm: When P_actual < 0.25 MPa, the pressure-reducing valve opening is increased, and the lower-level valve 2-3-1 is opened first, with each valve opening for 10 seconds in the sequence 2-3-1 → 2-3-2 → 2-3-3; when 0.25 MPa ≤ P_actual ≤ 0.35 MPa, the current valve opening is maintained, employing a balanced jetting strategy of 2-3-1:2-3-2:2-3-3 = 3:3:3; when P_actual > 0.35 MPa, the pressure-reducing valve opening is decreased, and some valves are closed. The proportional term (Kp) of the PID algorithm quickly responds to pressure changes, the integral term (Ki) eliminates steady-state errors, and the derivative term (Kd) suppresses pressure fluctuations, stabilizing the system pressure within ±0.02 MPa. For easily dusty powders (such as fly ash), when P_target = 0.3MPa is set, the system can automatically adjust the air supply pressure between 0.25-0.35MPa, ensuring both fluidization effect and preventing dust dispersion, achieving 25% energy savings compared to open-loop control. The pressure regulation response time is less than 3 seconds, and the overshoot is controlled within 5%, demonstrating excellent dynamic performance.

[0107] Calculation Example

[0108] Given: Alpha alumina powder dp = 45 μm, ρp = 3960 kg / m3; compressed air at 25℃ ρg = 1.2 kg / m3; εmf = 0.45.

[0109] Substituting into the Ergun equation and iteratively calculating, we obtain Umf = 0.8 m / s;

[0110] Real-time airflow velocity Ureal = 0.7 m / s (lower than 0.9·Umf = 0.72 m / s);

[0111] The system automatically increases the jet pressure from 0.4MPa to 0.48MPa, restoring Ureal to 0.82 m / s, ensuring the powder is in a stable fluidized state.

[0112] This module enables adaptive control of the fluidization rate of different powders (such as ultrafine calcium carbonate, alpha alumina, etc.), solving the problems of "poor adaptability and high energy consumption" in the traditional constant pressure / time mode, improving homogenization uniformity by 15-20%, and reducing energy consumption by 10-15%.

[0113] Example 7: Application of Timed Control Mode

[0114] A cement plant needs to homogenize alpha alumina powder and perform the following initialization settings:

[0115] S1: Based on the silo capacity of 85m 3 Based on powder characteristics, the control parameters are set as follows:

[0116] - Control Mode: Timed Control

[0117] - Jet pressure: 0.4 MPa

[0118] - Initial homogenization phase: Jet time T1 = 10 seconds, gas stop time T2 = 5 seconds

[0119] - Later stage of homogenization: Jet time T1 = 25 seconds, gas stop time T2 = 15 seconds

[0120] - Number of cycles: N = 10

[0121] S2: Start the compressed gas supply system 1, start the air compressor 1-1, the pressure in the air tank 1-2 rises to 0.7MPa, and the pressure reducing valve 1-5 adjusts the output pressure to 0.4MPa.

[0122] S3: The intelligent detection and control system 3 collects initial parameters before homogenization starts:

[0123] - Pressure P = 0.39 MPa (Gas storage tank pressure)

[0124] - Material level H = 10.2m (hopper 80% full)

[0125] - Weight W = 76 tons (corresponding to a bulk density of approximately 0.9 t / m³ for Alpha alumina powder) 3 )

[0126] S4: PLC control cabinet 3-1 determines that the current mode is timed control and executes step S5.

[0127] S5: Execute according to segmented timing strategy

[0128] Example 8: Application of Constant Pressure Control Mode

[0129] A chemical plant needs to homogenize ultrafine calcium carbonate powder, which is prone to dust generation. The powder has a large fluctuation in particle size distribution (d50 = 5-15 μm) and significant batch-to-batch differences. To prevent dust generation and ensure homogenization effectiveness, the operators selected a constant pressure control mode.

[0130] S1: Initialization Settings:

[0131] - Control mode: Constant pressure control

[0132] - Target pressure: P_target = 0.15 MPa

[0133] - Upper pressure limit: P_max = 0.20 MPa

[0134] - Lower pressure limit: P_min = 0.10 MPa

[0135] - Homogenization time: 15 minutes

[0136] S2: Start the compressed gas supply system 1, and set the initial gas supply pressure to 0.15MPa.

[0137] S3: Intelligent detection and control system 3 collects parameters in real time, with a sampling period of 1 second.

[0138] S4: PLC control cabinet 3-1 determines that the current mode is constant pressure control and executes step S5.

[0139] S5: Constant pressure control process:

[0140] [0-60 seconds] The pressure P_actual in the warehouse rises rapidly.

[0141] ① The compressed gas is oil-free, water-free, and dry (dew point ≤ -40℃); ② The powder loading in the silo is 60% of the effective volume; ③ The valve opening adjustment rate is ≤ 5% / s to avoid airflow impact and dust generation; ④ Distributed data acquisition is achieved using pressure transmitters in the upper, middle, and lower layers of the silo, and the data is averaged (measurement accuracy ±0.001MPa).

[0142] The pressure change and control logic are as follows:

[0143] -t=0s: P_actual=0.02MPa, ΔP=0.13MPa, PLC increases the gas supply pressure to 0.25MPa

[0144] -t=15s: P_actual=0.07MPa, ΔP=0.08MPa, PLC reduces the gas supply pressure to 0.22MPa.

[0145] -t=30s: P_actual=0.12MPa, ΔP=0.03MPa, PLC adjusts the air supply pressure to 0.18MPa

[0146] -t=45s: P_actual=0.14MPa, ΔP=0.01MPa, PLC maintains gas supply pressure at 0.18MPa

[0147] -t=60s: P_actual=0.15MPa, ΔP=0, entering steady-state control

[0148] [60-900 seconds] Steady-state control phase

[0149] -Intra-warehouse pressure fluctuation range: 0.14-0.16MPa

[0150] - The PLC uses a PID algorithm to fine-tune the opening degree of the pressure reducing valve (1-5) to maintain stable pressure.

[0151] - The three-layer valves 2-3-1, 2-3-2, and 2-3-3 employ an alternating opening strategy, with each layer opening for 30 seconds.

[0152] After running for 15 minutes, proceed to step S6.

[0153] S6: Close all valves, start the dust collector to clean the dust, and the homogenization process ends.

[0154] Example 9

[0155] The degassing and dust recovery system 4 is a key subsystem ensuring clean operation during the powder airflow homogenization process. It mainly consists of a silo top dust collector (4-1) and a pulse jet cleaning device. The silo top dust collector is installed on the top of the silo and adopts a high-efficiency filter bag design. When dust-laden gas passes through the filter bag, the dust is trapped on the outer surface of the filter bag, and the clean gas is discharged through the filter bag. As filtration proceeds, the dust layer on the surface of the filter bag thickens. The system monitors the pressure difference ΔP across the filter bag in real time through a differential pressure transmitter DPT-01. When the pressure difference exceeds the set value, the dust removal program is automatically triggered. When the pressure difference ΔP_dust across the filter media of the dust collector reaches the cleaning trigger threshold (1600Pa for bag filters / 900Pa for cartridge filters), the pulse jet cleaning program is automatically triggered: compressed air pressure 0.4–0.6MPa, cleaning time 15–18 seconds, cleaning in separate compartments (to avoid system pressure fluctuations); if ΔP_dust is still ≥ ΔP_high (2000Pa for bag filters / 1200Pa for cartridge filters) after cleaning, a 'cleaning invalid' alarm is triggered, prompting a check of the filter media or the pulse jet cleaning device; if ΔP_dust ≤ ΔP_low (200Pa for bag filters / 150Pa for cartridge filters), it is determined that the filter media is damaged, the system automatically shuts down the fan and alarms to prevent dust from escaping and polluting the environment. The pulse jet cleaning device uses compressed air pulse cleaning technology, which controls the compressed air to be sprayed in reverse instantaneously through a solenoid valve, causing the filter bags to vibrate violently and achieve dust removal. The system employs a timed and pressure-controlled joint control logic: the timed cleaning cycle is set to 15 minutes, while the differential pressure of the filter media is monitored in real time; when the differential pressure is greater than or equal to the cleaning threshold, constant pressure jet cleaning is immediately triggered. After cleaning is completed, the timed cycle resumes, achieving coordinated control of 'timed cycle guarantee and constant pressure response to sudden blockage'. The two work together to ensure that the dust removal efficiency remains stable at over 99%. During the cleaning process, the PLC controls the opening and closing sequence of pulse valves 4-3 through the DO module and adopts a segmented jet cleaning strategy (such as sequential cleaning of each row of filter bags) to avoid secondary dust generation. The recovered dust is returned to the silo by gravity settling, achieving a closed-loop circulation. This system is linked with the intelligent detection and control system 3, which automatically alarms when abnormal differential pressure or air source failure is detected, ensuring safe system operation.

[0156] Example 10

[0157] like Figure 5As shown, the timed control mode achieves powder homogenization through precise time control. Its workflow consists of seven key stages: Initialization stage, where the operator sets the jetting time T1 = 10-30 seconds, the gas stop time T2 = 5-15 seconds, and the number of cycles N = 5-20 via the touchscreen; Gas supply start-up stage, where the compressed gas system starts working, and the air compressor supplies gas to the storage tank; Layered jetting control stage, where the system sequentially opens three layers of pneumatic shut-off valves (2-3-1 / 2-3-2 / 2-3-3), with each layer of jetting lasting for T1 seconds, creating a three-dimensional airflow disturbance; Gas stoppage and settling stage, where all valves are closed to allow the powder to settle for T2 seconds; Cyclic control stage, where the PLC counter accumulates the number of cycles until the set value N is reached; System termination stage, where the air source is shut off and the dust collector is started for cleaning; Data recording stage, where operating parameters are stored and uploaded to the DCS system. This mode ensures uniform mixing of powder within the silo through strict time control and a layered jetting strategy.

[0158] like Figure 6 As shown, the constant pressure control mode uses PID closed-loop control to achieve precise pressure regulation. Its workflow includes seven core steps: Initialization phase: setting the target pressure P_target = 0.05-0.5MPa, pressure upper and lower limits ±0.05MPa; Constant pressure control process: setting the target pressure P_target and upper and lower limits P_max = P_target + 0.05MPa, P_min = P_target - 0.05MPa; real-time acquisition of the chamber pressure; increasing the opening of the pressure reducing valve when the pressure is lower than P_min, and decreasing the opening when the pressure is higher than P_max, stabilizing the pressure. The system maintains the current valve status periodically and monitors the compressor load synchronously. Pressure fine-tuning is triggered when the load is abnormal. After system startup, all pneumatic shut-off valves open simultaneously, and the pressure transmitter PT-01(1-3) monitors the chamber pressure in real time at a frequency of 1Hz. During the PID control phase, the pressure reducing valve opening is dynamically adjusted according to the pressure deviation ΔP = P_target - P_actual. If the pressure is too low, the supply pressure is increased (e.g., 0.3 → 0.35 MPa); if the pressure is too high, the pressure is decreased or some valves are closed. When the system ends, the supply of gas is stopped and pulse cleaning is initiated. During the data recording phase, operating data such as pressure curves and adjustment records are saved. This mode maintains the chamber pressure control accuracy within ±0.01 MPa through real-time pressure feedback and intelligent adjustment, making it particularly suitable for the homogenization treatment of easily dusty and easily oxidized powders.

[0159] Example 11

[0160] like Figure 2 , Figure 4 , Figure 5 and Figure 6As shown, this invention achieves a highly flexible configuration through an innovative multi-layered airflow duct structure. A modular design of 3-5 layers can be selected based on the silo size and powder characteristics. The 5-layer configuration is particularly suitable for large silos, significantly improving homogenization by optimizing layer spacing and increasing the bottom disturbance zone. The system employs intelligent parameter adjustment technology. The timed control mode automatically adjusts the jetting and stopping times according to the powder density, while the constant pressure control mode supports precise adjustment within the range of 0.05-0.5 MPa.

[0161] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0162] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "connected" should be interpreted broadly, for example, they can be fixed connections, detachable connections, or integral connections; they can be mechanical connections or electrical connections; they can be direct connections or indirect connections through an intermediate medium; they can be internal connections between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0163] The above description is merely one specific embodiment of this application, and not all embodiments. Therefore, the scope of protection of this application is not limited thereto. All other embodiments obtained by those skilled in the art without inventive effort, and any modifications, equivalent substitutions, and improvements within the spirit and principles of this invention, should be included within the scope of protection of this invention.

Claims

1. A high-efficiency powder airflow homogenization device, comprising a compressed gas supply system, a storage homogenization device, an intelligent detection and control system, and a degassing and dust recovery system, characterized in that... : The compressed gas supply system (1) is connected to the storage homogenization device (2) through a pipeline to provide stable, clean, and flow-sufficient compressed gas; The storage homogenization device (2) includes a silo (2-1), a multi-layer air duct (2-2) arranged inside the silo, a pneumatic cut-off valve, and a bottom fluidization control device. The multi-layer air duct (2-2) includes 3-5 layers of annular air ducts and a central main air duct. The number of layers is set according to the volume of the silo and the characteristics of the material. When H≤10m, 3 layers are used, and the layer spacing is (1 / 4-1 / 6)H; when 10m<H≤15m, 4 layers are used; when H>15m, 5 layers are used. Each layer of annular air duct is arranged in a concentric circle structure on different height planes and is connected to the central main air duct through a branch pipe. The multi-layer air duct is provided with a plurality of nozzles on different height planes for injecting compressed gas into the powder in the silo. The pneumatic cut-off valve is arranged at the connection of each layer of annular air duct and the branch pipe to control the gas on and off of each layer of air duct; the bottom fluidization control device installs a fluidization component at the conical bottom and installs an air circuit ring pipe outside and configures corresponding instruments; The intelligent detection and control system (3) includes a PLC control cabinet (3-1), a human-machine interface HMI, sensors, and a DCS system interface (3-3). The sensors collect air flow parameters (pressure, flow rate, temperature), powder state (material level, bed differential pressure), and equipment safety signals (valve state, compressor load). The PLC control cabinet (3-1) realizes closed-loop control based on the collected data. The human-machine interface HMI supports parameter setting, mode switching, and operation monitoring. In the constant pressure control mode of the intelligent detection and control system (3), the PLC first calculates the target gas supply pressure through the PID algorithm according to the pressure deviation ΔP and outputs a signal to adjust the opening of the pressure reducing valve; if the pressure still does not return to the set range within the preset response time (for example, 3 seconds), the switch combination strategy of the pneumatic cut-off valve is further executed to quickly intervene in the pressure in the silo. The intelligent detection and control system (3) has a timing control mode and a constant pressure control mode; In the timing control mode, the opening and closing of the pneumatic cut-off valves of each layer are controlled according to a preset time period to achieve time-sharing and layer-by-layer jetting; In the constant pressure control mode, with the set pressure in the silo as the target value, the jetting pressure or the valve opening is adjusted in real time through the PID algorithm to keep the pressure in the silo stable within the set range; The degassing and dust recovery system (4) includes a dust collector on the top of the silo and a recovery pipeline. The dust collector on the top of the silo is installed on the top of the solid silo and is provided with a pulse jetting device and detection devices such as differential pressure.

2. The high-efficiency powder airflow homogenization device according to claim 1, characterized in that: It is used to filter the dust-containing gas, clean the ash regularly, and discharge the clean gas after filtering the powder into the air or collect it centrally.

3. The apparatus according to claim 1, characterized in that: The vertical distance between adjacent two layers of annular air ducts is 1 / 4-1 / 6 of the effective height of the silo.

4. The apparatus according to claim 1, characterized in that: The sensor includes a pressure transmitter (PT-01) (1-3), a temperature transmitter (TT-01) (1-4), a flow meter (FT-01), a level gauge (LT-01) (2-4), a load cell (WT-01) (2-5), and a differential pressure transmitter (DP-01) (4-2).

5. The apparatus according to claim 1, characterized in that: The compressed gas supply system (1) includes an air compressor (1-1), a gas storage tank (1-2), a safety valve, a pressure reducing valve (1-5), and a compressed gas delivery pipeline.

6. The apparatus according to claim 1, characterized in that: The pulse jet device of the degassing and dust recovery system (4) is linked with the intelligent detection and control system, and adopts a timing and pressure-based control logic to ensure the dust removal efficiency.

7. A method for controlling powder airflow homogenization, applicable to the high-efficiency powder airflow homogenization device described in claims 1-6, characterized in that, It includes the following steps: S1: Initialization settings. According to the characteristics of the powder material and the capacity of the silo, set the control mode, jet pressure, jet time, and cycle number; If it is a timing control mode, set the total cycle number N, where N includes the cycle number N1 in the disturbance strengthening stage and the cycle number N2 in the uniform maintenance stage, that is, N = N1 + N2, and set the jet time T1-1 and the gas stop time T2-1 in the N1 stage, and the jet time T1-2 and the gas stop time T2-2 in the N2 stage respectively; If it is a constant pressure control mode, set the target pressure P_target, the pressure upper limit P_max = P_target + ΔP, and the pressure lower limit P_min = P_target - ΔP; S2: Start the compressed gas supply system and supply compressed gas to the multi-layer air flow conduit in the silo; S3: Real-time collect the air flow parameters and powder state through the sensor. The air flow parameters include pressure P, flow rate Q, and temperature T, and the powder state includes the level H and weight W; S4: Execute the corresponding control strategy according to the set control mode: If it is a timing control mode, control the opening and closing of each layer of pneumatic cut-off valves according to the preset time period, and end the homogenization after cycling to the set number of times; If it is a constant pressure control mode, take the set pressure P_target as the target value, real-time collect the pressure P_actual in the silo, calculate the pressure deviation ΔP = P_target - P_actual, and adjust the gas supply pressure or valve opening through the PID algorithm according to the deviation: When P_actual < P_min,优先开启底层阀门以快速提升仓压;间隔时间根据料仓高度设定:H≤10m时取5秒,H>10m时取10秒,每层开启间隔时间为5-15秒,直至仓内压力恢复至P_min以上;(When P_actual < P_min, preferentially open the bottom layer valve to quickly increase the silo pressure; the interval time is set according to the height of the silo: take 5 seconds when H ≤ 10m, take 10 seconds when H > 10m, and the opening interval time for each layer is 5 - 15 seconds until the pressure in the silo recovers above P_min;) When P_actual > P_max, reduce the gas supply pressure and close in the order of "upper layer pneumatic cut-off valve → middle layer pneumatic cut-off valve → bottom layer pneumatic cut-off valve"; When P_min ≤ P_actual ≤ P_max, maintain the current pressure and adopt an equalized jet strategy of "bottom layer: middle layer: upper layer pneumatic cut-off valve = 1:1:1"; Continue to operate until the set homogenization time and then end the homogenization; S5: Close all pneumatic cut-off valves, stop the gas supply, and the homogenization process ends.

8. In the control method according to claim 8, in the timing control mode, the jetting time T1 is 10-30 seconds, the gas stop time T2 is 5-15 seconds, and the number of cycles N is 5-20 times.

9. The control method according to claim 7, characterized in that: The method also includes security protection steps: When the pressure inside the silo reaches or exceeds the safety limit P_safe for a duration of ≥3 seconds, all pneumatic shut-off valves are automatically closed and the safety relief device (7) is activated; the safety limit P_safe = P_max + ΔP_safe, where ΔP_safe is the safety redundancy pressure, ΔP_safe is fixed at 0.02MPa, or set according to the powder flowability: when the flowability is poor, ΔP_safe = 0.03MPa, when the flowability is good, ΔP_safe = 0.01MPa; when the pressure inside the silo drops below P_max, the safety relief device (7) is automatically closed, and at the same time, an audible and visual alarm is triggered and the fault is uploaded to the DCS system; When the gas flow rate Q is lower than the set lower limit Q_min or the compressor load is abnormal, an alarm will be triggered and the machine will be shut down. When the bed differential pressure exceeds the normal range, an alarm will be triggered.

10. The apparatus according to claim 1, characterized in that: Each layer of the multi-layered airflow duct has 8-20 nozzles evenly distributed on it. The nozzle orifice diameter is 6-15 mm and the spray angle is 20-45°.

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