Water supply stirring system of refractory material stirrer and water supply stirring control method

Abstract

The invention relates to the technical field of refractory material preparation, in particular to a refractory material stirrer water supply stirring system and a water supply stirring control method.The refractory material stirrer water supply stirring system comprises a stirring device, a water supply device, a process state sensing unit, a central controller and a human-computer interaction interface; and the central controller performs first closed-loop control on the water pump based on the target water supply parameter and a feedback signal of the flowmeter, and performs second closed-loop control on the water supply process of the water pump based on a feedback signal of the process state sensing unit. Unification of water supply precision and process adaptability is achieved, basic precision is guaranteed through first closed-loop control, the system can deal with complex working conditions through second closed-loop control, and the laboratory-level control effect can be achieved in real industrial production. Through high automation and intelligence, dependence on skilled operators is remarkably reduced, personal errors are reduced, and production efficiency and process reliability are improved.

Description

Technical Field

[0001] This invention relates to the field of refractory material preparation technology, and in particular to a water supply and stirring system for a refractory material mixer and a water supply and stirring control method. Background Technology

[0002] Refractory materials are key basic materials for high-temperature industries such as steel, cement, and ceramics. In the wet production process of refractory materials, the uniform mixing of powdered or granular raw materials with water (or binder solution) is a crucial step. The precise control of moisture in the mixture is a core factor affecting key indicators such as the material's molding performance, drying shrinkage, density and strength after sintering.

[0003] Currently, the water supply methods for refractory material mixers commonly used in the industry are mostly manual valve control or simple timed / frequency water pump start-stop. This water supply method relies on the operator's experience, requiring multiple manual operations from setting, starting, to stopping, resulting in low production efficiency and susceptibility to human error. This leads to large fluctuations in water volume, causing inconsistencies in the water-to-material ratio between different batches of the mixture, which in turn causes fluctuations in product performance and a decrease in yield. Although some automated mixing equipment uses flow meters for metering, their control logic is simple, mostly open-loop or single closed-loop control, lacking multi-dimensional perception and decision-making regarding the mixing process status. This makes it difficult to achieve truly stable, reliable, and precise water supply in complex refractory material production scenarios.

[0004] Therefore, there is an urgent need in this field for a water supply and mixing system that can achieve real-time precise water supply and intelligent regulation in order to improve the product quality and production stability of refractory materials. Summary of the Invention

[0005] This invention provides a water supply and mixing system and a water supply and mixing control method for a refractory material mixer, which solves the defects of the existing water supply methods for refractory material mixers, which rely heavily on manual experience and are prone to product performance fluctuations and reduced yield. The system can intelligently sense the material status, dynamically adjust the water supply strategy, and deeply coordinate with the mixing action to improve the product quality and production stability of refractory materials.

[0006] This invention provides a water supply and mixing system for a refractory material mixer, comprising a mixing device, a water supply device, a process status sensing unit, a central controller, and a human-machine interface. The mixing device includes a mixing container and a mixing drive mechanism located within the mixing container. The water supply device includes a water supply pipeline connecting a water source and the mixing container, and a water pump and a flow meter are installed on the water supply pipeline. The process status sensing unit is located within the mixing container and is used to acquire the status parameters of the materials being mixed in the mixing container in real time. The central controller is connected to the water pump, the flow meter, and the process status sensing unit via signal connections. The human-machine interface is connected to the central controller and is used to set target water supply parameters and display the status of the materials being mixed in the mixing container. The central controller is configured to perform a first closed-loop control of the water pump based on the target water supply parameters and the feedback signal from the flow meter; and a second closed-loop control of the water pump's water supply process based on the feedback signal from the process status sensing unit.

[0007] According to the present invention, a water supply and mixing system for a refractory material mixer is provided. The process status sensing unit includes a current sensor, which is used to monitor the load current of the drive motor of the mixing drive mechanism. The central controller is configured to: determine the mixing uniformity and wet / dry state of the mixing material in the mixing container according to the changing trend of the load current, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

[0008] According to the present invention, a water supply and mixing system for a refractory material mixer is provided. The process status sensing unit includes an infrared moisture sensor, which is used to acquire infrared moisture data of the material being mixed in the mixing container. The central controller is configured to: compare and verify the infrared moisture data detected by the infrared moisture sensor with the theoretical value calculated based on the cumulative water supply of the flow meter, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

[0009] According to the present invention, a water supply and mixing system for a refractory material mixer is provided, wherein the infrared moisture sensor is a non-contact infrared moisture sensor, and there are multiple sensors distributed in different spatial positions of the mixing container to obtain spatial distribution information of infrared moisture data of the mixed material.

[0010] According to the present invention, a water supply and mixing system for a refractory material mixer is provided, wherein the process state sensing unit further includes an acoustic sensing module, which is used to collect the mixing sound signal of the mixing material in the mixing container; the central controller is further configured to perform spectrum analysis on the mixing sound signal to identify changes in the material viscosity or agglomeration state, and calculate the actual water requirement of the material in combination with the infrared moisture data.

[0011] According to the present invention, a water supply and mixing system for a refractory material mixer is provided. The water supply and mixing system for the refractory material mixer further includes a weighing sensor, which is disposed in the mixing container and is used to measure the total weight of the mixing container and its contents in real time. The central controller is further configured to cross-validate and calibrate the measurement value of the flow meter based on the weight difference before and during the water supply process.

[0012] According to the present invention, a water supply and mixing system for a refractory material mixer is provided, wherein the central controller has a built-in adaptive compensation model; the human-machine interface is also used to input material formula information; the central controller is further configured to: dynamically compensate and correct the target water supply parameters according to the material formula information through the adaptive compensation model.

[0013] The present invention also provides a water supply and mixing control method for a refractory material mixer, applicable to the water supply and mixing system of the refractory material mixer described in any of the above-mentioned methods, comprising the following steps S1 to S4.

[0014] S1. Set the target water supply parameters through the human-computer interaction interface.

[0015] S2. The central controller starts the water pump to supply water, obtains the cumulative water supply in real time through the flow meter, and performs the first closed-loop flow control on the water pump based on the difference between the target water supply parameter and the cumulative water supply.

[0016] S3. The state parameters of the material being stirred in the mixing container are obtained in real time through the process state sensing unit.

[0017] S4. Based on the real-time status parameters obtained by the process status sensing unit, the central controller performs a second closed-loop dynamic adjustment of the water supply strategy of the water pump until the stirring process is completed.

[0018] According to the present invention, a water supply and stirring control method for a refractory material mixer is provided, wherein the state parameters of the material being stirred in the stirring container include the load current of the drive motor of the stirring drive mechanism.

[0019] The second closed-loop dynamic adjustment of the water supply strategy of the water pump includes: analyzing the change curve of the load current during the water supply process; if the current value reaches and stabilizes in the preset uniform wet mixing current range in advance, it is determined that the material has been uniformly mixed in advance, and the water supply is reduced or stopped in advance; if the load current still does not enter the preset uniform wet mixing current range after the target water supply parameter is reached, it is determined that the material is too dry, and an alarm is triggered or the water pump is adjusted to supplement water supply according to the preset strategy.

[0020] According to the present invention, a water supply and stirring control method for a refractory material mixer is provided, wherein the state parameters of the material being stirred in the stirring container include online moisture detection values.

[0021] The second closed-loop dynamic adjustment of the water supply strategy of the water pump includes: comparing the real-time acquired online moisture detection value with the theoretical value calculated based on the cumulative water supply of the flow meter in real time; if the online moisture detection value is continuously lower than the theoretical value and the deviation increases, then the water supply rate of the water pump is increased or the water supply time of the water pump is extended; if the online moisture detection value is higher than the theoretical value, then the water supply rate of the water pump is reduced.

[0022] The refractory material mixer water supply and mixing system provided by this invention constructs a dual-closed-loop collaborative control architecture with a central controller as the decision-making core, realizing intelligent and precise water supply throughout the entire process from target setting to final mixing completion. The refractory material mixer water supply and mixing system includes a mixing device, a water supply device, a process status sensing unit, a central controller, and a human-machine interface. The central controller performs a first closed-loop control of the water pump based on the target water supply parameters and feedback signals from the flow meter, and a second closed-loop control of the water pump's water supply process based on feedback signals from the process status sensing unit. The first closed-loop control ensures basic accuracy, while the second closed-loop control enables the system to cope with complex working conditions, achieving laboratory-level control effects in real industrial production. This invention, through high automation and intelligence, significantly reduces reliance on skilled operators, reduces human error, and improves production efficiency and process reliability. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic flowchart of the water supply and mixing control method for the refractory material mixer of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0026] This invention provides a water supply and mixing system for a refractory material mixer, comprising a mixing device, a water supply device, a process status sensing unit, a central controller, and a human-machine interface. The mixing device includes a mixing container and a mixing drive mechanism located within the mixing container. The water supply device includes a water supply pipeline connecting a water source and the mixing container, and a water pump and a flow meter are installed on the water supply pipeline. The process status sensing unit is located inside the mixing container and is used to acquire the status parameters of the mixed material in the mixing container in real time. The central controller is connected to the water pump, the flow meter, and the process status sensing unit via signal connections. The human-machine interface is connected to the central controller and is used to set target water supply parameters and display the status of the mixed material in the mixing container. The central controller is configured to perform a first closed-loop control of the water pump based on the target water supply parameters and the feedback signal from the flow meter, and a second closed-loop control of the water pump's water supply process based on the feedback signal from the process status sensing unit.

[0027] It is understood that the refractory material mixer water supply and mixing system of this embodiment constructs a dual closed-loop collaborative control architecture with a central controller as the decision-making core, realizing intelligent and precise water supply throughout the entire process from target setting to final mixing completion. The refractory material mixer water supply and mixing system includes actuators (mixing device, water supply device), sensing units (process status sensing units), a decision-making core (central controller), and an interactive terminal (human-machine interface).

[0028] When the system is in operation, the operator first sets the desired target water supply parameters (such as total water volume, water supply curve, etc.) through the human-machine interface. After the water supply is started, the central controller immediately performs the first closed-loop control of the water pump based on the target parameters and the actual water supply feedback from the flow meter in real time, ensuring that the total water supply accurately matches the preset benchmark. The first closed-loop control of the water pump solves the problems of inaccurate total water supply and large fluctuations in traditional manual or simple automation methods.

[0029] However, the actual water requirement for refractory material mixing is affected by material characteristics, environmental factors, and the mixing process; a fixed water volume may not correspond to the ideal material state. Therefore, this embodiment introduces a second closed-loop control. Through a process state sensing unit, key state parameters of the material within the mixing container (such as moisture content and mixing uniformity) are continuously and in real-time acquired. Based on this real-time material state feedback, the central controller dynamically judges and adjusts the ongoing water supply process (e.g., adjusting the water supply rate, terminating the water supply earlier or later). Once a deviation is detected between the actual material state and the expected target state (derived from the target water supply parameters), the first closed-loop control ensures the water volume meets the target while dynamically intervening to adjust the water supply strategy (e.g., changing the water supply rhythm, performing minor compensation, or terminating the process earlier). In this way, even if the actual water requirement deviates from the preset target due to batch differences in materials, changes in environmental temperature and humidity, or fluctuations in equipment status, the system can proactively sense and correct it in real-time, ultimately achieving the actual and optimal wettability and mixing state of the material.

[0030] It is important to understand that this embodiment, by sensing the material state in real time and dynamically adjusting accordingly, can automatically adapt to changes in different formulations, batches, and environments, ensuring a stable water-to-material ratio, thereby improving the consistency of refractory material product performance and yield. The refractory material mixer water supply and mixing system in this embodiment achieves a balance between water supply accuracy and process adaptability. The first closed loop ensures basic accuracy, while the second closed loop enables the system to handle complex operating conditions, achieving laboratory-level control effects in real industrial production. This embodiment, through high automation and intelligence, significantly reduces reliance on skilled operators, lowers human error, and improves production efficiency and process reliability.

[0031] In some embodiments of the refractory material mixer water supply and mixing system of the present invention, the process status sensing unit includes a current sensor, which is used to monitor the load current of the drive motor of the mixing drive mechanism. The central controller is configured to: determine the mixing uniformity and dry / wet state of the mixing material in the mixing container according to the changing trend of the load current, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

[0032] It is understood that the process state sensing unit in this embodiment indirectly but with high sensitivity senses the material state by monitoring the load current of the stirring drive motor. The specific implementation process is as follows: At the start of water supply and stirring, the material is in a dry powder or semi-dry state, with low stirring resistance and a low load current for the drive motor. As water supply continues, the material gradually becomes wet, and its adhesion, cohesion, and overall viscosity change, causing a regular change in the resistance experienced by the stirring blades, which is directly reflected in the increase of the motor load current. The central controller collects and analyzes this current change curve in real time. When the current value rises and eventually stabilizes within a preset "uniform wet mixing current range," it indicates that the material has reached the ideal state of moisture saturation and uniform mixing. Based on this judgment, the central controller can immediately issue a command to stop water supply or switch to a micro-volume maintenance mode.

[0033] It is important to understand that this embodiment transforms the conventional operating parameter of motor load into a precise criterion for process status, achieving visualization of the process and intelligent determination of the endpoint. Compared to traditional control methods that rely solely on fixed times or fixed water volumes, this embodiment can automatically adapt to subtle differences in the initial humidity, ambient temperature, and material formulation of different batches of materials. For example, when the material itself has a high moisture content, the amount of water required to reach the "uniform wet mixing current range" will be reduced, and the system will terminate the water supply early, effectively avoiding the degradation of material performance due to excessive moisture. Conversely, if the material is abnormally dry, the system will extend the water supply until the current reaches a stable state, ensuring thorough mixing.

[0034] Furthermore, the central controller can not only determine the water supply endpoint but also make predictions and fine adjustments based on the rate and trajectory of current rise during the water supply process. For example, if the current rises too slowly, the controller can determine that the material is absorbing water slowly or is clumping, and thus appropriately reduce the water supply rate to allow time for water penetration, preventing the surface from becoming too wet while the interior remains dry. If the current stabilizes too early before reaching the target water volume, it can slow down in advance for a refined water supply finish. This combination of real-time feedback and proactive adjustment in this embodiment ensures that the water supply process is deeply synchronized with the actual needs of the material, significantly improving the stability of product quality and the level of intelligence in the production process.

[0035] In some other embodiments of the refractory material mixer water supply and mixing system of the present invention, the process status sensing unit includes an infrared moisture sensor, which is used to acquire infrared moisture data of the material being mixed in the mixing container. The central controller is configured to: compare and verify the infrared moisture data detected by the infrared moisture sensor with the theoretical value calculated based on the cumulative water supply of the flow meter, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

[0036] Understandably, this embodiment establishes a direct, in-situ measurement capability for the moisture content of materials by integrating an infrared moisture sensor. During the stirring process, the infrared moisture sensor continuously emits infrared light of a specific wavelength onto the material surface and receives the reflected signal. By analyzing the absorption characteristics of the material to the infrared spectrum, the instantaneous moisture content data of the stirred material is calculated in real time. Simultaneously, the central controller, based on the cumulative reading of the high-precision flow meter and combined with known information such as the dry weight of the material, synchronously calculates the theoretical moisture content of the current material.

[0037] This embodiment compares and cross-verifies directly measured infrared moisture data with indirectly calculated theoretical moisture values ​​in real time, constructing a self-verifying measurement system that greatly improves the reliability and fault tolerance of moisture control. For example, if the infrared sensor experiences instantaneous reading drift or distortion due to dust contamination, window smudges, or sudden changes in material surface conditions (such as severe crusting), the central controller can detect abnormal deviations between the readings and the stable, accumulated theoretical values. In this case, the system can automatically trigger an alarm or temporarily switch to a "degraded" control mode based primarily on the flow meter's theoretical values, ensuring uninterrupted production while simultaneously indicating maintenance needs. Conversely, if the flow meter develops minor calibration deviations due to long-term use or if there are minor leaks in the pipeline, the direct measurement values ​​from the infrared sensor will serve as the "truth source" for correction, allowing the central controller to dynamically adjust the water supply target or initiate a calibration procedure accordingly.

[0038] Furthermore, this real-time comparison in this embodiment can not only be used for fault diagnosis but also achieve dynamic compensation control. For example, in the initial stage of mixing, when the infrared detection value lags significantly behind the theoretical calculation value (indicating that moisture has not yet diffused evenly in the material), the central controller can intelligently slow down the increase in water supply rate to avoid local over-wetting; in the later stage of mixing, if the infrared value stably reaches the target while the theoretical value shows that there is still water supply margin, the controller can determine that the moisture has been efficiently absorbed and utilized, and thus decisively end the water supply in advance. This intelligent decision-making based on data fusion enables the system to no longer mechanically rely on a single data source, achieving in-depth control over the moisture migration and equilibrium state during the mixing process of complex, heterogeneous refractory materials, thereby ensuring that each batch of material reaches a precise and uniform moisture content at the molecular level.

[0039] In some specific examples, the infrared moisture sensors are non-contact infrared moisture sensors, and there are multiple sensors distributed in different spatial locations in the mixing container to obtain spatial distribution information of infrared moisture data of the mixed material.

[0040] Understandably, this example employs an array deployment scheme of non-contact infrared moisture sensors. Multiple (e.g., three or more) non-contact infrared moisture sensor probes are installed at specific spatial angles on the top, side walls, or internal support structure of the mixing vessel. Each probe is responsible for monitoring the material surface in a specific area within the mixing vessel. During the mixing process, as the material is continuously agitated, scattered, and mixed by the mixing mechanism, each sensor periodically captures the infrared reflectance spectrum of material segments flowing through its detection field of view, thereby acquiring real-time moisture data at multiple local points. The central controller synchronously collects and processes this set of spatially distributed moisture signals. It not only calculates the overall average moisture value, but more importantly, it analyzes the differences between the data points (i.e., statistical characteristics such as the standard deviation and range of moisture distribution). This allows the system to construct a real-time spatial distribution map of the moisture content of the mixed materials. This enables the system to accurately identify moisture dead zones or uneven wetting phenomena that cannot be detected by traditional single-point measurements. Based on this, the central controller can dynamically adjust the water supply strategy. For example, when it is determined that there is a local dry area, it can instruct the water pump to briefly increase the water supply pressure or adjust the operating parameters of the mixing mechanism (such as briefly changing the speed or direction) to enhance the spatial diffusion and mixing efficiency of moisture until the readings of each sensor converge and the preset uniformity threshold is reached.

[0041] Furthermore, long-term accumulated spatial moisture distribution data can reveal the degradation trend of mixer performance. For example, if the reading in a certain area is consistently different from other areas, it may indicate wear of the mixing blades, nozzle blockage, or material adhesion to the liner in that area, allowing the system to provide early warnings. Simultaneously, by analyzing the time and trajectory required for moisture to achieve spatial uniformity under different formulations and water addition strategies, the water supply curve and mixing parameters can be optimized in reverse.

[0042] Furthermore, the process state sensing unit also includes an acoustic sensing module, which is used to collect the stirring sound signal of the stirring material in the stirring container; the central controller is also configured to perform spectrum analysis on the stirring sound signal to identify changes in the material viscosity or agglomeration state, and calculate the actual water requirement of the material in combination with infrared moisture data.

[0043] Understandably, the process state sensing unit in this embodiment incorporates an acoustic sensing module, constructing a multi-dimensional sensing system integrating vision (infrared), touch (current), and hearing. Specifically, one or more high-sensitivity acoustic sensors (such as microphones or vibration accelerometers) are installed on the outer wall or at specific locations inside the mixing container to collect the rich sound signals generated during the mixing process, including the impact sound of blades cutting materials, the flow sound of materials rubbing and rolling, and the background noise of equipment operation. The spectrum analysis unit built into the central controller processes these raw sound signals in real time, extracting key acoustic features, such as the energy distribution of specific frequency bands, the dominant frequency shift, and the chaos of the sound signal. During the water supply process, as the material gradually changes from dry powder to wet mud, its physical properties (such as viscosity, cohesion, and interparticle lubrication) undergo drastic changes, and these changes are precisely mapped to the characteristic evolution of the sound spectrum. For example, dry materials produce high-frequency, crisp, discrete impact sounds, while as moisture increases and viscosity rises, the sound shifts towards low-frequency, dull, and continuous sounds; when abnormal clumping occurs, it may produce low-frequency, periodic, heavy impact characteristic sounds.

[0044] The central controller, through multimodal data fusion, correlates the viscosity / agglomeration state inferred from acoustics with the moisture content measured by infrared spectroscopy, enabling more accurate calculation of the actual process water requirements of materials. For example, for specific materials with slow water absorption and a tendency to agglomerate, the system will detect that even if the infrared moisture value is below the standard, the acoustic spectrum already shows that the viscosity has reached its upper limit. At this point, it will determine that the moisture is saturated but not uniform, thus stopping the water supply and transitioning to an extended mixing stage. This embodiment, combining stirring sound signals with infrared moisture data, allows the system to not only determine the amount of moisture but also the hardness and viscosity of the material, providing precise control for the preparation of high-performance, highly consistent special refractory materials.

[0045] In some embodiments of the refractory material mixer water supply and mixing system of the present invention, the refractory material mixer water supply and mixing system further includes a weighing sensor, which is installed in the mixing container and used to measure the total weight of the mixing container and its contents in real time; the central controller is also configured to cross-validate and calibrate the flow meter reading based on the weight difference before and during the water supply process.

[0046] Understandably, this embodiment incorporates a high-precision load cell as a crucial redundancy verification and benchmark calibration unit. The load cell (such as a tension sensor or weighing module) is integrated beneath the support structure of the mixing vessel, enabling real-time and continuous measurement of the total weight, including the mixing vessel itself, all internal materials, and added water. At the start of each mixing operation, the system records the initial total weight after the addition of dry materials. As the water supply process proceeds, the central controller simultaneously acquires two independent data streams: one is the cumulative volumetric water supply from the flow meter. (The theoretical weight gain can be calculated by converting the density of water) The second is the real-time total weight directly measured by the weighing sensor. And calculate the actual difference between its weight and the initial total weight. The central controller will continuously compare... and These two weight increments should theoretically be equal.

[0047] Weighing measurement is independent of the water flow pipeline and is minimally affected by pipeline pressure, air bubbles, and water quality changes, directly reflecting the total amount of substance actually entering the container. Its primary function is to achieve high-frequency online calibration and error diagnosis of the flow meter. For example, if the system detects... consistently and steadily below The central controller can accurately detect potential pipeline leaks, gas injection due to pump cavitation, or positive drift of the flow meter itself due to wear or dirt. The controller can immediately and dynamically correct the water supply target based on this information, ensuring accurate final water volume, and simultaneously generate maintenance warnings to prompt inspection of the pipeline or calibration of the flow meter.

[0048] Even when the infrared moisture sensor is temporarily interfered with or the motor current signal is uncertain due to voltage fluctuations, the absolute mass information provided by the weighing data can serve as a reliable anchor point for control decisions, preventing system misjudgments. Furthermore, through long-term accumulation... and Based on the deviation data, the system can establish an error model for the flow meter, enabling predictive maintenance and adaptive calibration—automatically compensating for known system errors in subsequent control without manual intervention. This allows the water supply mixing system to not only be accurate in a single operation but also maintain factory-grade metering accuracy throughout a month or a year of continuous operation, solving the problem of slow batch-to-batch quality degradation caused by equipment drift in industrial settings and providing long-term quality assurance for large-scale continuous production.

[0049] In some embodiments of the refractory material mixer water supply and mixing system of the present invention, the central controller has a built-in adaptive compensation model; the human-machine interface is also used to input material formula information; the central controller is also configured to: dynamically compensate and correct the target water supply parameters according to the material formula information through the adaptive compensation model.

[0050] It is understood that this embodiment, through the integration of an adaptive compensation model, enables personalized water supply tailored to specific formulations. Specifically, before starting the mixing process, the operator not only sets the basic target water supply volume or moisture content but also inputs or selects the material formulation information for the current batch via a human-machine interface. This includes information such as the type of aggregate (e.g., bauxite, corundum, magnesia), particle size distribution, binder type and content, and the type of functional additives. This formulation information is input into the adaptive compensation model built into the central controller. This model is an algorithm core trained on extensive historical process data or built based on materials science principles, capable of analyzing the comprehensive impact of different material components' water absorption characteristics, surface energy, bulk density, and other physicochemical parameters on water demand. During water supply, the adaptive compensation model dynamically calculates a real-time compensation correction based on real-time operating conditions (e.g., current cumulative water supply volume, mixing time) and the input formulation information. The central controller then superimposes or integrates the compensation correction output from the model into the control commands in real time, thereby dynamically and precisely adjusting the water pump's supply rate, rhythm, and even the final total water volume to match the formulation.

[0051] Through the adaptive compensation model of the central controller, the water supply and mixing system of the refractory material mixer in this embodiment has the ability to deeply understand and adapt to the inherent differences of the process object. For example, for lightweight aggregate formulations with high water absorption and porous particles, the adaptive compensation model will suggest a gentler water addition curve at the beginning of water supply to prevent the surface from becoming too saturated and forming a water film, which would affect internal wetting. For raw material formulations with high density and strong hydrophobicity, the adaptive compensation model may recommend a higher initial water supply pressure or use a specific mixing mode to ensure effective water penetration.

[0052] In another aspect, the present invention provides a water supply and mixing control method for a refractory material mixer, which can be applied to the water supply and mixing system of the refractory material mixer in any of the above embodiments or examples. For some specific embodiments, see [link to specific embodiments]. Figure 1 As shown, the water supply and stirring control method for refractory material mixers decomposes the goal of precise water supply into a dynamic process involving the coordinated action of water quantity closed loop and state closed loop, specifically including the following steps S1~S4.

[0053] S1. Set the target water supply parameters through the human-computer interaction interface.

[0054] This step involves parameter setting and process target initialization. Specifically, the operator sets the target water supply parameters for this mixing operation through a human-machine interface (such as a touchscreen). The target water supply parameters are not simply the total water volume target; in a more preferred embodiment, they can be the target moisture content, a water addition curve based on a specific formulation, etc. The system can also receive or retrieve pre-stored material formulation information. This step completes the transformation from "experience-based instructions" to "digitalized process targets," providing a clear quantitative benchmark for subsequent intelligent control and replacing the traditional fuzzy start / stop mode of manually operating valves or buttons based on experience.

[0055] S2. The central controller starts the water pump to supply water, obtains the cumulative water supply in real time through the flow meter, and performs the first closed-loop flow control of the water pump based on the difference between the target water supply parameters and the cumulative water supply.

[0056] This step performs the first closed-loop flow control to achieve precise delivery of macroscopic water volume. Specifically, the central controller starts the water pump and opens the water supply pipeline according to the target set in step S1. During this process, the high-precision flow meter, as the core feedback element, continuously sends the cumulative water supply data to the central controller. The central controller uses the target water supply parameter (such as the target total water volume) as the setpoint and the real-time cumulative value of the flow meter as the feedback value, forming a typical negative feedback closed-loop control system. Through control algorithms such as PID, the speed or start / stop of the water pump is dynamically adjusted to ensure that the cumulative water supply quickly, smoothly, and accurately approaches the target value.

[0057] S3. The state parameters of the material being stirred in the mixing container are obtained in real time through the process state sensing unit.

[0058] This step involves process status sensing, which is performed in parallel with step S2. Specifically, the process status sensing unit performs in-depth monitoring of the actual process progress within the mixing vessel. According to different embodiments of the refractory material mixer water supply and mixing system described above, the process status sensing unit may include: a current sensor (monitoring the load current of the mixing motor, indirectly sensing changes in material viscosity and mixing resistance), an infrared moisture sensor (directly and in-situ measuring the real-time moisture content of the material surface), an acoustic sensing module (collecting mixing sounds and identifying material agglomeration, adhesion to walls, etc., through spectrum analysis), and a weighing sensor (providing an absolute measurement of the total weight of the container), etc. These sensors convert state parameters reflecting material wet-dry uniformity, moisture distribution, rheological properties, etc., into electrical signals in real time and upload them to the central controller.

[0059] S4. Based on the real-time status parameters obtained by the process status sensing unit, the central controller performs a second closed-loop dynamic adjustment of the water pump's water supply strategy until the stirring process is completed.

[0060] This step involves a second closed-loop dynamic adjustment, based on intelligent decision-making and execution of material status. Specifically, the central controller processes water quantity information from step S2 and material status information from step S3 in parallel, and executes advanced decisions: dynamically adjusting the preset water supply strategy based on the real-time material status (second closed loop).

[0061] In some embodiments of the refractory material mixer water supply and mixing control method of the present invention, the state parameters of the mixing material in the mixing container include the load current of the drive motor of the mixing drive mechanism. The second closed-loop dynamic adjustment of the water pump's water supply strategy includes: analyzing the change curve of the load current during the water supply process; if the current value reaches and stabilizes within the preset uniform wet mixing current range ahead of schedule, it is determined that the material has been uniformly mixed ahead of schedule, and the water supply is reduced or stopped ahead of schedule; if the load current still does not enter the preset uniform wet mixing current range after reaching the target water supply parameters, it is determined that the material is too dry, and an alarm is triggered or the water pump is adjusted to supplement water supply according to the preset strategy.

[0062] Understandably, in this embodiment, the central controller continuously samples the motor's load current throughout the water supply process, plotting a dynamic curve of current change over time (or with cumulative water supply). The system pre-stores or learns a uniform wet mixing current range for a specific type of material (this is an empirically or theoretically determined range of current values, representing an ideal process state where the material is fully wetted, uniformly mixed, and the stirring resistance reaches dynamic equilibrium). The central control unit analyzes the current curve's trend in real time. Once it detects that the current value has prematurely entered and stabilized within this preset range, even if the preset target water supply has not been fully added, the central controller immediately determines that the material has reached its optimal process state. Subsequently, exceeding the flow control command of the first closed loop, it decisively issues a deceleration or stop command to the water pump, achieving precise early termination of water supply, thereby avoiding over-wetting of the material due to mechanically adding the preset water volume.

[0063] This embodiment ensures strict synchronization between the water supply endpoint and the actual physical state of the materials, effectively resolving issues of over-wetting or under-mixing caused by variables such as initial material humidity, ambient temperature and humidity, and differences in the water absorption characteristics of batch raw materials. For example, when the material itself has a certain level of humidity or the ambient humidity is extremely high, the amount of additional water required to achieve the ideal mixing state will decrease. This embodiment can detect this change and terminate the water supply in advance via a current signal, ensuring product quality. Conversely, if the current curve remains in the lower dry mixing range or is in a rapid rise phase after reaching the target water supply volume without entering a stable platform, the central controller accurately determines that the material is too dry and the water absorption demand is higher than expected. In this case, the system will not only issue an audible and visual alarm to alert the operator, but also automatically initiate a small-flow supplementary water supply program based on a preset safety compensation strategy (such as continuing to supply water at a lower flow rate until the current reaches the target, or making a comprehensive judgment based on other sensor data) to ensure the final mixing quality. This adaptive endpoint control based on physical signal feedback in this embodiment can enhance the robustness of the production process to fluctuations in incoming materials and environmental changes, and improve the consistency of product quality.

[0064] In some other embodiments of the refractory material mixer water supply and stirring control method of the present invention, the state parameters of the stirred material in the stirring container include online moisture detection values. The second closed-loop dynamic adjustment of the water pump's water supply strategy includes: comparing the real-time acquired online moisture detection values ​​with the theoretical values ​​calculated based on the cumulative water supply from the flow meter in real time; if the online moisture detection values ​​are consistently lower than the theoretical values ​​and the deviation widens, then increasing the water pump's water supply rate or extending the water pump's water supply time; if the online moisture detection values ​​are higher than the theoretical values, then decreasing the water pump's water supply rate.

[0065] Understandably, in this embodiment, during the water supply and mixing process, the central controller receives two independent moisture-related data streams in parallel. One stream is a direct measurement value, obtained in real time by an online moisture sensor (such as a near-infrared sensor), representing the instantaneous moisture content of the material surface; the other stream is an indirect calculation value, calculated from the cumulative water supply data of a high-precision flow meter, combined with information such as the dry weight of the material, representing the theoretically desirable moisture content of the material. The central controller compares these two values ​​in real time at an extremely high frequency (e.g., several times per second), focusing not only on the absolute difference but, more importantly, on analyzing the trend of the difference (i.e., whether the deviation is stable, decreasing, or increasing).

[0066] The changing trend of the difference between the online moisture detection value and the theoretical value can diagnose the dynamic efficiency of moisture migration and absorption in materials, and adjust the water supply accordingly. When the online detection value is consistently lower than the theoretical calculation value, and the deviation between the two shows an increasing trend, the controller determines that the current water supply rate cannot meet the actual absorption needs of the material, and there may be moisture lag or uneven distribution. At this time, the system actively increases the water pump's water supply rate, or compensates for the apparent moisture loss caused by slow material water absorption, rapid evaporation due to dry environment, etc. by extending the effective water supply time. Conversely, if the online detection value is consistently higher than the theoretical value, it indicates that the surface enrichment rate of moisture exceeds the absorption and diffusion rate of the material, and there is a risk of local over-humidification. The central controller will immediately reduce the water pump's water supply rate, slow down the humidification process, and give moisture more time to penetrate into the material and distribute evenly, thereby preventing the formation of a water film or slurry on the surface.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A water supply and mixing system for a refractory material mixer, characterized in that, include: A stirring device, comprising a stirring container and a stirring drive mechanism located within the stirring container; A water supply device includes a water supply pipeline connecting a water source and the stirring container, and a water pump and a flow meter are installed on the water supply pipeline; A process status sensing unit is installed inside the stirring container to acquire the status parameters of the stirring material inside the stirring container in real time. The central controller is connected to the water pump, the flow meter, and the process status sensing unit via signals. A human-machine interface, connected to the central controller, is used to set target water supply parameters and display the status of the materials being stirred in the mixing container; The central controller is configured to perform a first closed-loop control of the water pump based on the target water supply parameters and the feedback signal from the flow meter; and to perform a second closed-loop control of the water pump's water supply process based on the feedback signal from the process status sensing unit.

2. The water supply and mixing system for the refractory material mixer according to claim 1, characterized in that, The process status sensing unit includes a current sensor, which is used to monitor the load current of the drive motor of the stirring drive mechanism. The central controller is configured to: determine the mixing uniformity and dry / wet state of the stirring material in the stirring container according to the changing trend of the load current, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

3. The water supply and mixing system for the refractory material mixer according to claim 1, characterized in that, The process status sensing unit includes an infrared moisture sensor, which is used to acquire infrared moisture data of the material being stirred in the stirring container. The central controller is configured to: compare and verify the infrared moisture data detected by the infrared moisture sensor with the theoretical value calculated based on the cumulative water supply of the flow meter, and dynamically adjust the water supply rate of the water pump or trigger a water supply termination command.

4. The water supply and mixing system for the refractory material mixer according to claim 3, characterized in that, The infrared moisture sensor is a non-contact infrared moisture sensor, and there are multiple sensors distributed in different spatial locations in the mixing container to obtain spatial distribution information of infrared moisture data of the mixed material.

5. The water supply and mixing system for the refractory material mixer according to claim 3, characterized in that, The process state sensing unit also includes an acoustic sensing module, which is used to collect the stirring sound signal of the stirring material in the stirring container; the central controller is also configured to perform spectrum analysis on the stirring sound signal to identify changes in the material viscosity or agglomeration state, and calculate the actual water requirement of the material in combination with the infrared moisture data.

6. The water supply and mixing system for a refractory material mixer according to any one of claims 1 to 5, characterized in that, The refractory material mixer water supply and mixing system also includes a weighing sensor, which is installed in the mixing container to measure the total weight of the mixing container and its contents in real time; the central controller is also configured to cross-validate and calibrate the flow meter's measurement value based on the weight difference before and during water supply.

7. The water supply and mixing system for a refractory material mixer according to any one of claims 1 to 5, characterized in that, The central controller has a built-in adaptive compensation model; the human-machine interface is also used to input material formula information; the central controller is also configured to dynamically compensate and correct the target water supply parameters according to the material formula information through the adaptive compensation model.

8. A method for controlling the water supply and mixing of a refractory material mixer, characterized in that, A water supply and mixing system for a refractory material mixer according to any one of claims 1 to 7, comprising: Set the target water supply parameters through the human-computer interaction interface; The central controller starts the water pump to supply water, obtains the cumulative water supply in real time through the flow meter, and performs the first closed-loop flow control on the water pump based on the difference between the target water supply parameter and the cumulative water supply. The process status sensing unit acquires the status parameters of the material being stirred in the mixing container in real time. The central controller performs a second closed-loop dynamic adjustment of the water supply strategy of the water pump based on the real-time status parameters obtained by the process status sensing unit until the stirring process is completed.

9. The water supply and mixing control method for a refractory material mixer according to claim 8, characterized in that, The state parameters of the material being stirred in the stirring container include the load current of the drive motor of the stirring drive mechanism. The second closed-loop dynamic adjustment of the water supply strategy of the water pump includes: analyzing the change curve of the load current during the water supply process; if the current value reaches and stabilizes in the preset uniform wet mixing current range in advance, it is determined that the material has been uniformly mixed in advance, and the water supply is reduced or stopped in advance; if the load current still does not enter the preset uniform wet mixing current range after the target water supply parameter is reached, it is determined that the material is too dry, and an alarm is triggered or the water pump is adjusted to supplement water supply according to the preset strategy.

10. The water supply and mixing control method for a refractory material mixer according to claim 8, characterized in that, The state parameters of the material being stirred in the stirring container include online moisture detection values; The second closed-loop dynamic adjustment of the water supply strategy of the water pump includes: comparing the real-time acquired online moisture detection value with the theoretical value calculated based on the cumulative water supply of the flow meter in real time; if the online moisture detection value is continuously lower than the theoretical value and the deviation increases, then the water supply rate of the water pump is increased or the water supply time of the water pump is extended; if the online moisture detection value is higher than the theoretical value, then the water supply rate of the water pump is reduced.

Images