Anti-blocking system of weighing feeder and control method of anti-blocking system

Abstract

The invention discloses a weighing feeder anti-blocking system and a control method thereof.The weighing feeder anti-blocking system comprises a raw material supply module, a discharging pipeline, a monitoring module, a dredging module and a control module, and the monitoring module comprises an audio collection unit, a visual collection unit and a thickness detection unit which are arranged around the discharging pipeline; the control module judges whether the materials are blocked or not based on the multi-source monitoring signals and controls the dredging module to execute dredging operation when abnormal conditions are recognized. By fusing multi-dimensional data such as sound, image, thickness and the like, advanced judgment and accurate recognition of the blockage state are realized, the defects that a traditional blockage rotator can only detect single-point blockage and the false alarm and missing alarm rate is high are overcome, and the hysteresis problem that an alarm is given after serious blockage is effectively avoided; through automatic dredging control, the manual blockage removal frequency is reduced, the operation reliability and safety of the system are improved, the probability of shutdown, belt damage and raw material waste caused by blockage is remarkably reduced, and the weighing and feeding continuity and automation level are improved.

Description

Technical Field

[0001] This application relates to the field of automation control technology, and in particular to a weighing feeder anti-blocking system and its control method. Background Technology

[0002] Currently, desulfurization systems commonly use traditional rotary gauges as alarm devices for material blockage at the discharge port. These devices can only detect blockages at a fixed location at the discharge port, resulting in a limited detection range. Furthermore, alarms typically occur when the blockage is already severe, making timely warnings and early intervention difficult. In addition, the rotary gauges are installed near the material impact area, making them susceptible to jamming or malfunctions due to raw material erosion during long-term operation, leading to frequent false alarms and missed alarms. With increasing demands for reliability in desulfurization equipment, traditional blockage monitoring methods relying on single-point mechanical detection are no longer sufficient to meet the needs of modern industrial automation for early identification, accurate judgment, and highly reliable alarms. Summary of the Invention

[0003] The purpose of this application is to overcome the above-mentioned problems and provide a weighing feeder anti-blocking system and its control method, storage medium, electronic equipment and computer program product.

[0004] The technical solution of this application provides a material blocking system for a weighing feeder, including a raw material supply module, a feeding pipe, a monitoring module, a clearing module, and a control module for controlling the raw material supply module and the clearing module; The raw material supply module is connected to the discharge pipe and is used to supply raw materials to the discharge pipe; The monitoring module includes an audio acquisition unit, a visual acquisition unit, and a thickness detection unit, which are respectively communicatively connected to the control module. The audio acquisition unit is located at the feeding pipe, the visual acquisition unit is located above the feeding pipe and arranged in the direction of the pipe diameter, and the thickness detection unit is located on the outer wall of the feeding pipe and faces the feeding pipe. The unblocking module is installed at the discharge pipe, and the control module controls the unblocking module to perform unblocking operations based on the monitoring signal from the monitoring module.

[0005] Furthermore, the unblocking module includes a water supply pipe, an electric valve, and a nozzle; One end of the water supply pipe is connected to an external water source, and the other end of the water supply pipe is connected to the nozzle. The electric valve is installed inside the water supply pipe and communicates with the control module. The nozzle is installed above the discharge pipe and is arranged facing the inside of the discharge pipe.

[0006] Furthermore, the raw material supply module includes a raw material storage bin, an inlet valve, and a belt conveyor; The discharge port of the raw material storage silo is connected to the feed end of the belt conveyor through the inlet valve. The discharge end of the belt conveyor is connected to the discharge pipe. The belt conveyor and the inlet valve are respectively connected to the control module.

[0007] Furthermore, the thickness detection unit is an ultrasonic thickness sensor.

[0008] The technical solution of this application also provides a control method for a weighing feeder anti-blocking system as described above, including: acquiring pipeline monitoring signals; Determine whether the blockage alarm conditions are met based on the pipeline monitoring signals; If the blockage alarm conditions are met, a clearing signal is sent to the clearing module.

[0009] Furthermore, the pipeline monitoring signal includes the audio monitoring signal provided by the audio acquisition unit, the video monitoring signal provided by the visual acquisition unit, and the thickness monitoring signal provided by the thickness detection unit; The step of determining whether the blockage alarm condition is met based on the pipeline monitoring signal specifically includes: Determine whether the audio monitoring signal meets the material blockage early warning conditions; If the material blockage warning conditions are met, then determine whether the video monitoring signal and the thickness monitoring signal meet the material blockage alarm conditions.

[0010] Furthermore, the audio monitoring signal includes sound pressure level; The video monitoring signal includes the proportion of the shadowed portion; The thickness monitoring signal includes thickness data; The determination of whether the audio monitoring signal meets the material blockage early warning conditions specifically includes: If the sound pressure level is lower than the first sound pressure threshold, then the material blockage warning condition is met; The determination of whether the video monitoring signal and the thickness monitoring signal meet the material blockage alarm conditions specifically includes: If the proportion of the shaded area is greater than a first shaded proportion threshold and less than a second shaded proportion threshold, and the thickness data is greater than a first thickness threshold, then the material blockage alarm condition is met; or If the proportion of the shaded area is greater than the second shaded proportion threshold, then the material blockage alarm condition is met.

[0011] The technical solution of this application also provides a storage medium that stores computer instructions. When the computer executes the computer instructions, it is used to perform a control method for a weighing feeder anti-blocking system as described above.

[0012] The technical solution of this application also provides an electronic device, including at least one processor; and, A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor, which, when executed, enable the at least one processor to perform the control method for the weighing feeder anti-blocking system as described above.

[0013] The technical solution of this application also provides a computer program product, including a computer program / instruction, which, when executed by a processor, implements the control method of the weighing feeder anti-blocking system as described above.

[0014] The above technical solution has the following beneficial effects: This application discloses a material blocking system and control method for a weighing feeder, comprising a raw material supply module, a feeding pipe, a monitoring module, a clearing module, and a control module. The monitoring module includes an audio acquisition unit, a visual acquisition unit, and a thickness detection unit, respectively deployed around the feeding pipe. The control module determines whether material blockage has occurred based on multi-source monitoring signals and controls the clearing module to perform clearing operations when an anomaly is detected. By integrating multi-dimensional data such as sound, image, and thickness, the system achieves early judgment and accurate identification of blockage status, overcoming the shortcomings of traditional blockage rotary instruments that can only detect single-point blockages and have a high false alarm and false negative rate. This effectively avoids the lag problem of alarming only after severe blockage. Through automatic clearing control, the frequency of manual clearing is reduced, improving the reliability and safety of system operation, significantly reducing the probability of downtime, belt damage, and raw material waste caused by blockage, and improving the continuity and automation level of weighing and feeding. Attached Figure Description

[0015] The disclosure of this application will become more readily understood with reference to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this application. In the drawings: Figure 1 This is a schematic diagram of the structure of the anti-blocking system of the weighing feeder in one embodiment of this application; Figure 2 This is a flowchart of the control method of the anti-blocking system of the weighing feeder in one embodiment of this application; Figure 3 This is a flowchart of the control method for the anti-blocking system of a weighing feeder in one embodiment of this application; Figure 4 This is a schematic diagram of the hardware structure of an electronic device in one embodiment of this application.

[0016] Appendix Label Reference Table: Raw material supply module 1: Raw material storage bin 11, inlet valve 12, belt conveyor 13; Feed pipe 2; Monitoring module 3: audio acquisition unit 31, visual acquisition unit 32, thickness detection unit 33; Unblocking module 4: Water supply pipe 41, electric valve 42, nozzle 43; Control module 5: Weighing feeder control unit 51, blockage alarm and unblocking control unit 52; External water source 6. Detailed Implementation

[0017] The specific embodiments of this application will be further described below with reference to the accompanying drawings.

[0018] It is readily understood that, based on the technical solution of this application, various structural and implementation methods can be interchanged by those skilled in the art without altering the essential spirit of this application. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this application and should not be considered as the entirety of this application or as limitations or restrictions on the technical solution of the application.

[0019] The directional terms such as up, down, left, right, front, back, front, back, top, and bottom mentioned or possibly used in this specification are defined relative to the structures shown in the accompanying drawings. These are relative concepts and may therefore vary depending on their location and usage. Therefore, these or other directional terms should not be interpreted as restrictive. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meanings of the above in this application according to the specific circumstances.

[0021] like Figure 1 As shown, an anti-blocking system for a weighing feeder in one embodiment of this application includes a raw material supply module 1, a discharge pipe 2, a monitoring module 3, a clearing module 4, and a control module 5 for controlling the raw material supply module 1 and the clearing module 4. The raw material supply module 1 is connected to the feeding pipe 2 and is used to supply raw materials to the feeding pipe 2. The monitoring module 3 includes an audio acquisition unit 31, a visual acquisition unit 32, and a thickness detection unit 33, which are respectively connected to the control module 5. The audio acquisition unit 31 is located at the feeding pipe 2, the visual acquisition unit 32 is located above the feeding pipe 2 and is arranged in the direction of the pipe diameter of the feeding pipe 2, and the thickness detection unit 33 is located on the outer wall of the feeding pipe 2 and is arranged in the direction of the pipe diameter of the feeding pipe 2. The unblocking module 4 is installed at the material discharge pipe 2, and the control module 5 controls the unblocking module 4 to perform unblocking operations based on the monitoring signal from the monitoring module 3.

[0022] This embodiment of a weighing feeder anti-clogging system includes a raw material supply module 1, a feeding pipe 2, a monitoring module 3, a clearing module 4, and a control module 5. The raw material supply module 1 supplies raw materials to the feeding pipe 2. The monitoring module 3 includes an audio acquisition unit 31, a visual acquisition unit 32, and a thickness detection unit 33, all communicatively connected to the control module 5. The audio acquisition unit 31 is located at the feeding pipe 2 and is used to collect acoustic characteristics during the feeding process. Specifically, the audio acquisition unit 31 is installed in the middle of the feeding pipe 2. The visual acquisition unit 32 is located above the feeding pipe 2 and faces the pipe diameter direction, and is used to collect the material accumulation morphology and flow state within the pipe. Specifically, the visual acquisition unit 32 is installed at the inlet opening of the feeding pipe 2. The thickness detection unit 33 is located on the outer wall of the feeding pipe 2 and faces the feeding pipe 2, and is used to detect changes in the material layer thickness. Specifically, the thickness detection unit 33 is installed on the outer wall of the middle section of the feeding pipe 2. The unblocking module 4 is installed at the material discharge pipe 2. The control module 5 is connected to the monitoring module 3 and the unblocking module 4 respectively. It judges the material discharge status based on the monitoring signal, that is, whether there is a blockage. When the blockage or blockage trend is identified, the control module 4 is controlled to perform the unblocking operation.

[0023] This embodiment employs monitoring module 3 to perform multi-dimensional monitoring of acoustic features, image features, and material layer thickness during the feeding process. Compared to the traditional method of using only a single material blockage rotary instrument for point-triggered detection, this significantly improves the coverage and recognition accuracy of material blockage detection. It can predict material blockage trends in advance, reducing the risk of severe material blockage, belt jamming, and machine downtime. Through the automatic linkage of control module 5 and unblocking module 4, timely flushing and unblocking are achieved, reducing manual intervention, shortening downtime, and improving production continuity.

[0024] like Figure 1 As shown, in one embodiment, the unblocking module 4 includes a water supply pipe 41, an electric valve 42, and a nozzle 43; One end of the water supply pipe 41 is used to connect to an external water source, and the other end of the water supply pipe 41 is connected to the nozzle 43. The electric valve 42 is installed inside the water supply pipe 41 and is connected to the control module 5. The nozzle 43 is installed above the discharge pipe 2 and is arranged facing the inside of the discharge pipe 2.

[0025] In this embodiment, the unblocking module 4 includes a water supply pipe 41, an electric valve 42, and a nozzle 43. The electric valve 42 is communicatively connected to the control module 5. One end of the water supply pipe 41 is connected to an external water source 6, and the other end is connected to the nozzle 43 for conveying flushing water to the material discharge pipe 2. The electric valve 42 is located inside the water supply pipe 41 and is connected to the control module 5 to achieve intelligent control of the water supply volume and the opening and closing of the water supply. The nozzle 43 is located above the material discharge pipe 2 and faces the inside of the material discharge pipe 2, so that the flushing water can directly act on the material accumulation area and directionally impact the blockage location to achieve efficient unblocking.

[0026] In this embodiment, by setting up the unblocking module 4, when the monitoring module 3 detects a blockage warning or blockage status, the control module 5 controls the electric valve 42 to open in real time and spray flushing water onto the blocked area through the nozzle 43, so that the blockage is quickly flushed and loosened and discharged from the discharge pipe 2, thereby achieving automated unblocking. This avoids the problems of low efficiency, long time and safety hazards of traditional manual cleaning methods, and also avoids the risk of secondary damage that may occur by relying on mechanical beating or disassembly.

[0027] In one preferred embodiment, nozzle 43 is a high-pressure nozzle.

[0028] In this preferred embodiment, the nozzle 43 is a high-pressure nozzle and is connected to the water supply pipe 41. The high-pressure water flow is controlled by the electric valve 42, giving the sprayed water a stronger impact force, which can achieve concentrated impact and rapid unblocking of blockages inside the discharge pipe 2 in a short time. The high-pressure nozzle can be arranged in a conical or fan-shaped spray structure to cover key blockage areas on the inner wall of the discharge pipe 2, achieving both directional and comprehensive flushing.

[0029] This preferred embodiment employs a high-pressure nozzle, which provides more efficient unblocking capabilities when blockages occur. Compared to ordinary nozzles, it has a stronger impact force, which can effectively break up and peel off compacted or agglomerated blockages, improve unblocking efficiency, shorten flushing time, and reduce the impact of blockages on equipment.

[0030] like Figure 1 As shown, in another embodiment, the raw material supply module 1 includes a raw material storage bin 11, an inlet valve 12, and a belt conveyor 13; The discharge port of the raw material storage silo 11 is connected to the feed end of the belt conveyor 13 through the inlet valve 12. The discharge end of the belt conveyor 13 is connected to the discharge pipe 2. The belt conveyor 13 and the inlet valve 12 are respectively connected to the control module 5.

[0031] In this embodiment, the raw material supply module 1 includes a raw material storage bin 11, an inlet valve 12, and a belt conveyor 13. The outlet of the raw material storage bin 11 is connected to the feed end of the belt conveyor 13 through the inlet valve 12 to realize the quantitative feeding and start / stop control of the raw materials. The outlet of the belt conveyor 13 is connected to the discharge pipe 2 to continuously and stably transport the raw materials into the discharge pipe 2. Both the inlet valve 12 and the belt conveyor 13 are communicatively connected to the control module 5, which can automatically start and stop according to the system operating status to ensure that the feeding process is linked with the blockage monitoring and unblocking operation. When the system detects the risk of blockage or performs unblocking operation, it can immediately cut off the material source to prevent the blockage from worsening.

[0032] This embodiment, through the setting of the raw material supply module 1, enables a continuous feeding process from storage and unloading to conveying, which helps ensure the stability and controllability of the raw material supply. The control module 5 can dynamically adjust the opening or start / stop of the inlet valve 12 based on the real-time feedback of the unloading status from the monitoring module 3, and link it with the start / stop of the belt conveyor 13 to control the feeding flow. When initial signs of stagnation are detected, the inlet valve 12 can be closed in advance to reduce the flow. When high-pressure water unblocking is required, the inlet valve 12 can be closed immediately and the belt conveyor 13 can be stopped to create stable conditions for unblocking operations. After unblocking is completed, the feeding can be resumed, thereby avoiding further aggravation of blockage and reducing equipment downtime. This effectively improves the overall safety of the weighing and feeding system, forms a closed-loop control between the raw material conveying process, blockage monitoring, and unblocking operations, improves production efficiency, reduces the need for manual intervention, and ensures long-term stable operation of the system.

[0033] In another embodiment, the thickness detection unit 33 is an ultrasonic thickness sensor.

[0034] In this embodiment, the thickness detection unit 33 is specifically an ultrasonic thickness sensor. The thickness detection unit 33 is installed on the outer wall of the feeding pipe 2 and is arranged facing the inside of the feeding pipe 2. It measures the wall thickness change caused by the accumulation of material inside the feeding pipe 2 by transmitting and reflecting ultrasonic signals. The ultrasonic thickness sensor is communicatively connected to the control module 5 and can obtain the distance change between the inner wall of the feeding pipe 2 and the material interface in real time during system operation, thereby realizing the quantitative judgment of the degree of material blockage.

[0035] This embodiment uses an ultrasonic thickness sensor as the thickness detection unit 33, enabling non-contact monitoring of blockages and improving the safety and applicability of the measurement. Compared to traditional single-point triggering devices such as rotary instruments, ultrasonic thickness measurement is unaffected by material impacts, dust accumulation, or other environmental factors, exhibiting higher stability and anti-interference capabilities. It can identify blockage trends in advance by detecting changes in wall thickness, and its judgment is coordinated with audio monitoring and visual recognition results, improving the accuracy and reliability of blockage detection. This avoids severe blockages leading to downtime and enhances the continuous operation and maintenance efficiency of the weighing and feeding system.

[0036] In one embodiment, the audio acquisition unit 31 is a directional microphone.

[0037] In this embodiment, a directional microphone is used as the audio acquisition unit 31. This is because it can acquire the specific audio level generated by the flow and collision of materials in the feed pipe 2 with a high signal-to-noise ratio. Through its directional sound pickup characteristics, it can effectively suppress the interference of environmental background noise commonly found in the production site, such as equipment vibration, motor operation, and environmental noise. When the material flows smoothly, the continuous collision between the particles and the pipe wall will generate a high and stable sound pressure level signal. Once a blockage occurs or the flow slows down, the sound pressure level will significantly attenuate or even disappear. By continuously comparing the real-time sound pressure level with the preset normal flow threshold, the system can quickly and reliably determine whether there is a blockage or whether a blockage is imminent, thereby providing a key trigger signal for the control module 5.

[0038] like Figure 1 As shown, in one embodiment, the control module 5 includes a weighing feeder control unit 51 and a blockage alarm and unblocking control unit 52; The weighing feeder control unit 51 and the raw material supply module 1 are connected in communication. The blockage alarm and unblocking control unit 52 is connected to the monitoring module 3 and the unblocking module 4 respectively.

[0039] In this embodiment, the control module 5 includes a weighing feeder control unit 51 and a blockage alarm and unblocking control unit 52. The weighing feeder control unit 51 is communicatively connected to the raw material supply module 1 and is used to control the opening and closing of the raw material supply and the adjustment of the supply amount. The blockage alarm and unblocking control unit 52 is communicatively connected to the monitoring module 3 and the unblocking module 4, respectively, and is used to receive monitoring signals from the audio acquisition unit 31, the visual acquisition unit 32 and the thickness detection unit 33, and trigger the unblocking module 4 to perform unblocking operations or issue an alarm signal according to the judgment result.

[0040] In this embodiment, the control module 5 is divided into a weighing feeder control unit 51 and a blockage alarm and unblocking control unit 52, so that the raw material supply module 1 can dynamically adjust the feeding status according to the monitoring situation, and the unblocking operation can be executed in time when blockage occurs, thereby improving the safety, reliability and automation level of the weighing feeder operation and reducing manual intervention and equipment maintenance costs.

[0041] like Figure 2 The flowchart shown illustrates a control method for an anti-blocking system of a weighing feeder according to an embodiment of this application, comprising: S201: Acquire pipeline monitoring signals; S202: Determine whether the blockage alarm conditions are met based on the pipeline monitoring signal; S203: If the blockage alarm conditions are met, send a clearing signal to the clearing module.

[0042] Specifically, in step S201, the pipeline monitoring signal is acquired. The pipeline monitoring signal refers to the data collected by the control module 5 from each sensing unit in the monitoring module 3 in real time or periodically. That is, the sound pressure level signal of the material flow in the pipeline provided by the audio acquisition unit 31 is used as the audio acquisition signal, the image data of the inlet or inside of the discharge pipeline 2 captured by the visual acquisition unit 32 is used as the visual monitoring signal, and the material adhesion thickness data at the pipe wall measured by the thickness detection unit 33 is used as the visual monitoring signal.

[0043] In step S202, determining whether the blockage alarm condition is met based on the pipeline monitoring signal means that the control module 5 judges the acquired multi-source monitoring signals. This can be done by comparing the audio acquisition signal with a preset sound pressure threshold. When the audio acquisition signal is lower than the preset sound pressure threshold, it can be used as one of the blockage alarm conditions, or it can be used as a prerequisite for acquiring visual monitoring signals and thickness data. Subsequently, the visual monitoring signals and thickness data can be combined to determine whether the safety threshold is exceeded and to make a trend judgment, so as to comprehensively determine whether the blockage alarm condition is met.

[0044] In step S203, if the blockage alarm condition is met, a clearing signal is sent. This means that after confirming that the blockage alarm condition is met, the control module 5 sends a control command to the clearing module 4. The control command includes a clearing operation signal and a supply stop signal, that is, it sends a command to the raw material supply module 1, such as the inlet valve 12 and the belt conveyor 13, to reduce the feeding rate or temporarily stop the feeding to create conditions for the clearing operation. Subsequently, a start command is sent to the clearing module 4, that is, the electric valve 42, to execute the clearing operation with a preset duration and mode.

[0045] In one embodiment, the pipeline monitoring signal includes an audio monitoring signal provided by an audio acquisition unit, a video monitoring signal provided by a visual acquisition unit, and a thickness monitoring signal provided by a thickness detection unit; Determine whether the blockage alarm conditions are met based on pipeline monitoring signals, specifically including: Determine whether the audio monitoring signal meets the conditions for material blockage warning; If the material blockage warning conditions are met, then determine whether the video monitoring signal and the thickness monitoring signal meet the material blockage alarm conditions.

[0046] In this embodiment, the pipeline monitoring signals include audio monitoring signals, video monitoring signals, and thickness monitoring signals. The control module 5 determines whether the blockage alarm conditions are met based on the pipeline monitoring signals. First, it determines whether the audio monitoring signal meets the blockage warning conditions. The control module 5 continuously collects the sound pressure level signal and compares it with the preset threshold in real time. When the sound pressure level is detected to be continuously lower than the normal flow threshold and reaches the predetermined time, it is determined that the blockage warning conditions are met.

[0047] Once the material blockage warning conditions are met, the visual monitoring signal and the thickness monitoring signal are analyzed simultaneously. The image recognition algorithm is used to determine whether there are visual features such as material accumulation or flow interruption in the feeding pipe 2, and at the same time, the thickness data is checked to see if it exceeds the safety threshold. Only when the visual signal and the thickness signal simultaneously meet their respective alarm criteria will the system finally determine that the material blockage alarm conditions are met.

[0048] This embodiment employs a tiered judgment mechanism, effectively balancing the sensitivity and accuracy of monitoring. It uses audio to capture early risks and then cross-verifies the information from other sensors, significantly reducing the false alarm rate caused by interference from single factors such as environmental noise. This ensures the reliability of the alarm signal and lays a solid foundation for subsequent accurate and timely dredging operations.

[0049] In one embodiment, the audio monitoring signal includes sound pressure level; The video monitoring signal includes the proportion of the shadowed area; Thickness monitoring signals include thickness data; Determining whether the audio monitoring signal meets the conditions for a material blockage warning includes: If the sound pressure level is lower than the first sound pressure threshold, the blockage warning condition is met. Determining whether the video monitoring signal and thickness monitoring signal meet the material blockage alarm conditions specifically includes: If the proportion of the shaded area is greater than the first shaded proportion threshold and less than the second shaded proportion threshold, and the thickness data is greater than the first thickness threshold, then the material blockage alarm condition is met; or If the proportion of the shaded area is greater than the second shaded proportion threshold, then the material blockage alarm condition is met.

[0050] In this embodiment, the audio monitoring signal includes sound pressure level; the video monitoring signal includes the proportion of the shadowed portion; and the thickness monitoring signal includes thickness data. Determining whether the audio monitoring signal meets the material blockage warning condition involves first judging the audio monitoring signal, and then judging the video monitoring signal and the thickness monitoring signal. Specifically, when the detected sound pressure level is lower than the first sound pressure threshold, it indicates that the material flow in the discharge pipe 2 has weakened or stopped, and the generated normal flow sound waves have decreased, thus determining that the material blockage warning condition is met. Subsequently, the video monitoring signal and the thickness monitoring signal are analyzed to determine whether the material blockage alarm condition is met. Specifically, when the proportion of the shadowed portion in the video image is greater than the first shadow proportion threshold and less than the second shadow proportion threshold, and the thickness data is greater than the first thickness threshold, it indicates that there is a certain degree of material accumulation in the pipe, but it has not yet completely blocked the flow; at this time, the material blockage alarm condition is met. If the proportion of the shadowed portion is greater than the second shadow proportion threshold, it indicates that the material has formed a large area of ​​obstruction in the pipe, almost blocking the discharge channel; the material blockage alarm condition can be determined without combining the thickness data.

[0051] This embodiment distinguishes between initial raw material accumulation and material blockage by classifying and judging early warning and alarm conditions, based on the joint analysis of audio, video and thickness signals. It achieves collaborative judgment through multi-dimensional perception, improves the sensitivity and accuracy of material blockage detection, and can trigger early warning in advance before severe blockage, providing response time for the unblocking module 4, reducing the risk of equipment downtime and material loss, and improving the stability and reliability of the weighing feeder system.

[0052] In one preferred embodiment, the first sound pressure threshold is calibrated based on the original acoustic characteristics of the equipment under different load conditions: during the initial commissioning phase of the system, the weighing feeder is operated at different feeding rates (20%, 50%, 70%, 100%), and typical audio signals in the feed pipe 2 are collected by an audio sensor; the lowest value of the collected audio signal sound pressure is set as the alarm threshold, serving as the first sound pressure threshold; when the real-time sound pressure level is lower than this threshold during operation, the blockage warning condition is met. When the equipment is actually running, if the monitored sound pressure level is lower than the first sound pressure threshold, it indicates that the normal material flow sound is significantly attenuated, thus meeting the blockage warning condition.

[0053] In one preferred embodiment, the first thickness threshold is the wall thickness of the conventional feeding pipe 2. When the thickness data is greater than the first thickness threshold, it indicates that there is obvious material accumulation in the feeding port, which makes the thickness measurement path longer, and can be used as one of the conditions for material blockage alarm.

[0054] Using the original image of the equipment in a non-blocked state as a reference, the first shadow ratio threshold is when the area of ​​the current shadow part exceeds 20% of the area of ​​the reference image, which can be used as one of the conditions for material blockage alarm.

[0055] The second shadow ratio threshold is when the area of ​​the current shadow part exceeds 50% of the area of ​​the reference image. At this point, it can be directly determined that the material blockage alarm condition is met without combining other signals.

[0056] In one embodiment, after sending the unblocking signal, the unblocking module 4 performs an unblocking operation according to the unblocking signal, specifically including: Control the electric valve 42 to open and maintain it for a preset time; After a preset time, the electric valve 42 is closed to obtain the pipeline monitoring signal; Determine whether the blockage alarm conditions are met based on pipeline monitoring signals; If the blockage alarm conditions are met, send the unblocking signal again until the pipeline monitoring signal no longer meets the blockage alarm conditions. If the blockage alarm conditions are not met, a resumption signal will be sent.

[0057] In this embodiment, after sending a clearing signal, the clearing module 4 receives the signal and performs a clearing operation. Specifically, it controls the raw material supply module 1 to stop supplying / reduce the supply amount and controls the electric valve 42 to open for a preset time, which can be 5 minutes. After the preset time, the electric valve 42 is closed and the pipeline monitoring signal is acquired again. If the proportion of the shaded area is greater than the first shaded area threshold and less than the second shaded area threshold, and the thickness data is greater than the first thickness threshold, or the proportion of the shaded area is greater than the second shaded area threshold, then the blockage alarm condition is met, and the clearing signal is sent again to make the clearing module 4 perform the clearing operation again until the pipeline monitoring signal no longer meets the blockage alarm condition. If the blockage alarm condition is not met, a recovery operation signal is sent, and the raw material supply module 1 resumes supplying / increasing the supply amount to restore the normal operation of the weighing feeder.

[0058] This embodiment achieves closed-loop automatic control of the blockage handling process by setting preset time for the unblocking operation, real-time monitoring, and a cyclic unblocking mechanism. Pausing or reducing material supply during unblocking prevents continuous material accumulation that could lead to ineffective unblocking or worsening of the blockage. By jointly judging the unblocking effect based on video and thickness monitoring signals, it accurately identifies whether the blockage has been cleared, avoiding misjudgments or premature resumption of operation caused by traditional experience-based manual judgment. Simultaneously, cyclic unblocking until the monitoring signal returns to normal ensures complete removal of the blockage, improving unblocking reliability and reducing manual intervention.

[0059] In one preferred embodiment, if the number of times the control module 5 continuously sends the unblocking signal reaches a preset threshold, an alarm signal is sent.

[0060] In this preferred embodiment, if the number of times the control module 5 continuously sends unblocking signals reaches a preset threshold, the control module 5 sends an alarm signal to alert the operator or the upper control system that there is an abnormal blockage that cannot be automatically cleared. The preset threshold can be set according to factors such as the length, diameter, and material characteristics of the feeding pipe 2, for example, 3 or 5 times. When the unblocking operation fails to eliminate the blockage within the preset threshold, the alarm signal triggers the operator to promptly check or take further measures to ensure the safe operation of the feeding pipe 2 and the weighing feeder.

[0061] like Figure 3 The flowchart shown is a control method for an anti-blocking system of a weighing feeder according to one embodiment of this application, including: Step S301: Acquire pipeline monitoring signals; Step S302: If the sound pressure level is lower than the first sound pressure threshold, the blockage warning condition is met, and step S303A or step S303B is executed; otherwise, step S301 is executed again to continue monitoring. Step S303A: If the proportion of the shaded area is greater than the first shaded proportion threshold and less than the second shaded proportion threshold, and the thickness data is greater than the first thickness threshold, then the material blockage alarm condition is met. Step S303B: If the proportion of the shaded area is greater than the second shaded proportion threshold, the blockage alarm condition is met; Step S304: If the blockage alarm conditions are met, send a clearing signal; Step S305: Control the electric valve to open and maintain it for a preset time; Step S306: After a preset time, control the electric valve to close and acquire the pipeline monitoring signal; Step S307: Determine whether the blockage alarm conditions are met based on the pipeline monitoring signal; Step S308A: If the blockage alarm conditions are met, send the unblocking signal again until the pipeline monitoring signal no longer meets the blockage alarm conditions; Step S308B: If the blockage alarm conditions are not met, send a resumption signal; Step S309A: If the number of times the control module continuously sends the unblocking signal reaches the preset threshold, an alarm signal is sent.

[0062] Embodiments of this application also provide a storage medium that stores computer instructions, which, when executed by a computer, are used to perform a control method for a weighing feeder anti-blocking system as described in any of the preceding embodiments.

[0063] Figure 4 An electronic device according to this application is shown, comprising: At least one processor 401; and, Memory 402 is communicatively connected to at least one processor 401; wherein, The memory 402 stores instructions that can be executed by at least one processor 401, which enables the at least one processor 401 to perform all the steps of a control method for a weighing feeder anti-blocking system in any of the foregoing method embodiments.

[0064] Figure 4 Taking a processor 401 as an example: The electronic device may also include an input device 403 and an output device 404.

[0065] The processor 401, memory 402, input device 403 and output device 404 can be connected by a bus or other means. The figure shows an example of connection by bus.

[0066] The memory 402, as a non-volatile computer-readable storage medium, can be used to store non-volatile software programs, non-volatile computer-executable programs, and modules, such as the program instructions / modules corresponding to the control method of a weighing feeder anti-blocking system in an embodiment of this application. Figure 2 and Figure 3 The method flow is shown. The processor 401 executes various functional applications and data processing by running non-volatile software programs, instructions, and modules stored in the memory 402, thereby realizing a control method for a weighing feeder anti-blocking system in the above embodiment.

[0067] The memory 402 may include a program storage area and a data storage area. The program storage area may store the operating system and application programs required for at least one function. The data storage area may store data created during the use of a control method for a weighing feeder anti-blocking system. Furthermore, the memory 402 may include high-speed random access memory and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other non-volatile solid-state storage device. In some embodiments, the memory 402 may optionally include memory remotely located relative to the processor 401, and these remote memories may be connected via a network to means of performing a control method for a weighing feeder anti-blocking system. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0068] The input device 403 can receive user clicks and generate signal inputs related to user settings and function control of the control method for the anti-blocking system of the weighing feeder. The output device 404 may include a display screen or other display device.

[0069] One or more modules are stored in memory 402. When run by one or more processors 401, they execute a control method for a weighing feeder anti-blocking system in any of the above method embodiments.

[0070] Embodiments of this application also provide a computer program product, including a computer program / instruction that, when executed by a processor, implements a control method for a weighing feeder anti-blocking system as described in any of the preceding embodiments.

[0071] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0072] The above description is merely the principle and preferred embodiment of this application. It should be noted that for those skilled in the art, implementation methods obtained by appropriately combining the technical solutions disclosed in different embodiments are also included within the technical scope of this invention. Based on the principle of this application, several other modifications can also be made, which should also be considered within the protection scope of this application.

Claims

1. A material blocking prevention system for a weighing feeder, characterized in that, It includes a raw material supply module, a feeding pipe, a monitoring module, a dredging module, and a control module for controlling the raw material supply module and the dredging module; The raw material supply module is connected to the discharge pipe and is used to supply raw materials to the discharge pipe; The monitoring module includes an audio acquisition unit, a visual acquisition unit, and a thickness detection unit, which are respectively communicatively connected to the control module. The audio acquisition unit is located at the feeding pipe, the visual acquisition unit is located above the feeding pipe and arranged in the direction of the pipe diameter, and the thickness detection unit is located on the outer wall of the feeding pipe and faces the feeding pipe. The unblocking module is installed at the discharge pipe, and the control module controls the unblocking module to perform unblocking operations based on the monitoring signal from the monitoring module.

2. The anti-blocking system for a weighing feeder according to claim 1, characterized in that, The unblocking module includes a water supply pipe, an electric valve, and a nozzle; One end of the water supply pipe is connected to an external water source, and the other end of the water supply pipe is connected to the nozzle. The electric valve is installed inside the water supply pipe and communicates with the control module. The nozzle is installed above the discharge pipe and is arranged facing the inside of the discharge pipe.

3. The anti-blocking system for a weighing feeder according to claim 1, characterized in that, The raw material supply module includes a raw material storage bin, an inlet valve, and a belt conveyor; The discharge port of the raw material storage silo is connected to the feed end of the belt conveyor through the inlet valve. The discharge end of the belt conveyor is connected to the discharge pipe. The belt conveyor and the inlet valve are respectively connected to the control module.

4. The anti-blocking system for a weighing feeder according to claim 1, characterized in that, The thickness detection unit is an ultrasonic thickness sensor.

5. A control method for the anti-blocking system of a weighing feeder as described in any one of claims 1-4, characterized in that, include: Acquire pipeline monitoring signals; Determine whether the blockage alarm conditions are met based on the pipeline monitoring signals; If the blockage alarm conditions are met, a clearing signal is sent to the clearing module.

6. The control method for an anti-blocking system of a weighing feeder according to claim 5, characterized in that, The pipeline monitoring signal includes the audio monitoring signal provided by the audio acquisition unit, the video monitoring signal provided by the visual acquisition unit, and the thickness monitoring signal provided by the thickness detection unit; The step of determining whether the blockage alarm condition is met based on the pipeline monitoring signal specifically includes: Determine whether the audio monitoring signal meets the material blockage early warning conditions; If the material blockage warning conditions are met, then determine whether the video monitoring signal and the thickness monitoring signal meet the material blockage alarm conditions.

7. The control method for the anti-blocking system of the weighing feeder according to claim 6, characterized in that, The audio monitoring signal includes sound pressure level; The video monitoring signal includes the proportion of the shadowed portion; The thickness monitoring signal includes thickness data; The determination of whether the audio monitoring signal meets the material blockage early warning conditions specifically includes: If the sound pressure level is lower than the first sound pressure threshold, then the material blockage warning condition is met; The determination of whether the video monitoring signal and the thickness monitoring signal meet the material blockage alarm conditions specifically includes: If the proportion of the shaded area is greater than a first shaded proportion threshold and less than a second shaded proportion threshold, and the thickness data is greater than a first thickness threshold, then the material blockage alarm condition is met; or If the proportion of the shaded area is greater than the second shaded proportion threshold, then the material blockage alarm condition is met.

8. A storage medium, characterized in that, The storage medium stores computer instructions, which, when executed by the computer, are used to perform the control method of the weighing feeder anti-blocking system as described in any one of claims 5-7.

9. An electronic device, characterized in that, Includes at least one processor; and, A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor, which, when executed by the at least one processor, enables the at least one processor to perform the control method of the weighing feeder anti-blocking system as described in any one of claims 5-7.

10. A computer program product comprising a computer program / instructions, characterized in that, When the computer program / instruction is executed by the processor, it implements the control method of the anti-blocking system for the weighing feeder as described in any one of claims 5-7.

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