Tile raw material feeding machine group control method and system based on intelligent sorting of aging time

Abstract

The invention discloses a ceramic tile raw material feeder group control method and system based on intelligent sorting of aging time, and relates to the technical field of ceramic production automation control, the method comprises the following steps: S1, data structure establishment and initialization: establishing a full-field data model of a feeder group in an intelligent automation control unit; s2, state monitoring and time accumulation: performing real-time statistics on the stale accumulation time after each stale bin is full; s3, an intelligent sorting and optimization strategy based on aging time; s4, automatically selecting the feeder corresponding to the first-stage stale bin for discharging, and triggering the feeder corresponding to the next-stage stale bin for discharging by a current bin empty signal; and S5, PID variable frequency speed regulation is carried out according to the total flow feedback in the discharging process. The system is reasonable in design, tedious meter reading, timing and startup and shutdown operations are completely given to the intelligent automatic control unit, and the labor intensity of workers and the misoperation risk are greatly reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic control of ceramic production, and more particularly to a tile raw material feeder group control method and system based on stale time intelligent sequencing. BACKGROUND

[0002] In the process of tile production, the stale (homogenization) of raw materials is a key link to determine product quality. In the prior art, the number of stale warehouses is large (usually dozens), and the traditional control method has the following disadvantages: 1) Relies on manual recording and scheduling: which warehouse is full first, how long has it been stale, and which warehouse should be discharged, often relies on manual statistics, which can easily result in "last in, first out" or insufficient stale time, affecting the performance of the mud.

[0003] 2) Poor continuity of supply: during the switching process between warehouses, material breakage or flow fluctuations can occur; manual adjustment of the feeder speed is difficult to follow the real-time needs of the downstream preparation process, resulting in unstable production line load.

[0004] 3) Low automation: lack of global monitoring and intelligent optimization mechanism for multiple warehouse positions. SUMMARY

[0005] The purpose of the present application is to solve the above technical problems, and the present application provides a tile raw material feeder group control method and system based on stale time intelligent sequencing.

[0006] In order to achieve the above purpose, the present application specifically adopts the following technical solutions: The first aspect of the present application provides a tile raw material feeder group control system based on stale time intelligent sequencing, comprising a warehouse detection unit, a feeder material detection unit, a raw material storage unit, a material flow metering unit, a feeder variable frequency control unit, a material feeding conveying unit, a material discharging conveying unit and an intelligent automation control unit arranged in sequence. The warehouse detection unit, the feeder material detection unit, the raw material storage unit, the material flow metering unit, the feeder variable frequency control unit, the material feeding conveying unit, the material discharging conveying unit are all signal connected with the intelligent automation control unit.

[0007] The second aspect of the present application provides a tile raw material feeder group control method based on stale time intelligent sequencing, which adopts the above-mentioned tile raw material feeder group control system based on stale time intelligent sequencing, comprising the following steps: S1, data structure establishment and initialization: a full-field data model of the feeder group is established in the intelligent automation control unit; a self-defined data format array Array[i] is defined, i is the corresponding number of stale warehouses, i∈(1,...,N); S2. Status monitoring and time accumulation: Real-time statistics of the cumulative aging time after each aging warehouse is full; S3. Intelligent sorting and optimization strategy based on aging time: Use a sorting algorithm to sort all full-capacity aging warehouses in descending order according to the cumulative aging time. S4. Automatically select the feeder corresponding to the first-ranked aging bin for material discharge; the current bin empty signal triggers the feeder corresponding to the next-level aging bin for material discharge. S5. PID variable frequency speed regulation is performed based on the total flow feedback during the feeding process.

[0008] In one implementation, in step S1, each array element i contains the following status bits and process variables: Status indicators include full position signals. Short position signal Feeder operating status Material flow detection signal ; Process variables include drive signal, speed setpoint, and current aging cumulative time T. aging The cumulative time of empty warehouses after the air raid shelter is filled, and the cumulative time of material aging after the warehouse is full.

[0009] In one implementation, the specific method for status monitoring and time accumulation in step S2 is as follows: The intelligent automated control unit scans the sensor signals of each aging chamber in real time and performs independent state transition logic processing for each aging chamber i: S21, Feeding stage: When the aging bin i is detected to be empty and the upstream requests feeding, the feeding conveyor is started; S22, Timing Phase: When the bin detection unit detects that the aging bin i is full, it stops feeding. The intelligent automation control unit automatically starts the aging timer for the intelligent automation control unit and updates the aging cumulative time of Array[i] in real time. S23, Standby Stage: When the aging time in aging chamber i reaches the preset process threshold. Then, mark the bin as "ready to be loaded".

[0010] In one implementation, the intelligent sorting and optimization strategy based on staleness in step S3 is specifically implemented as follows: The intelligent automation control unit executes an optimization algorithm to determine the start-up sequence of the feeder: S31. Traverse the array Array[0..27] and filter out all aging bins marked as "ready to be filled". S32. For the selected aging warehouses, automatically sort them from largest to smallest according to the "cumulative aging time" (BubbleSort or QuickSort algorithm). S33. The intelligent automation control unit always prioritizes the feeder corresponding to the aging bin i with the longest aging time (ranked first) as the current operating equipment, so as to achieve strict "first-in, first-out" process control.

[0011] In one implementation, the seamless switching and relay of the feeder group in step S4 is specifically handled as follows: S41. When the material detection unit of the running feeder detects no material, or the bin level detection unit detects an empty bin signal: S42. The intelligent automation control unit automatically stops the feeder and, based on the sorting result of step S3, immediately and automatically starts the feeder with the next priority (second longest aging time). S43. At the same time, a "empty hopper awaiting feeding" request signal is sent to the upstream of the feeder to form a closed loop.

[0012] In one implementation, the specific steps of the PID dynamic current stabilization control based on flow feedback in step S5 are as follows: During the operation of the feeder, the intelligent automated control unit performs closed-loop flow control: S51, Setting Value : Receives the feed rate setting value required by downstream processes; S52, Feedback Value : Real-time reading of the material flow rate metering unit on the main conveyor belt; S53. Deviation Calculation: Calculate the deviation. ; S54, PID control: The output frequency is calculated using the PID algorithm, and the motor speed of the variable frequency control unit of the currently running feeder is dynamically adjusted.

[0013] In one implementation, in step S54, when When (flow is insufficient), automatically increase the feeder frequency; when When the flow rate is too high, the feeder frequency is automatically reduced to ensure that the actual flow rate always closely tracks the set value, thus achieving stable and continuous feeding.

[0014] The beneficial effects of this invention are as follows: 1. This invention establishes a data model that includes the status of storage silos and the cumulative time, uses an intelligent sorting algorithm to automatically select the best material silo, and combines it with PID closed-loop control to achieve stable output of material flow, thereby replacing manual calculation and improving production efficiency and product quality.

[0015] 2. Improved process quality: Through data array recording and intelligent sorting algorithms, the principle of "prioritizing the discharge of materials with the longest aging time" is enforced, completely eliminating the mixing of raw materials caused by manual operation and ensuring the consistency of ceramic tile raw materials.

[0016] Increased production efficiency: 3. It achieves fully automated and seamless rotation of 28 warehouses, eliminating downtime caused by manual warehouse changes and significantly improving equipment utilization.

[0017] Energy conservation and emission reduction: 4. PID variable frequency control avoids long-term operation of the motor at the power frequency or frequent start-stop, while precise flow control reduces material overflow or idling waste in downstream processes.

[0018] 5. Labor Liberation: The tedious meter reading, timing, and power on / off operations are completely handed over to the intelligent automated control unit, which greatly reduces the labor intensity of workers and the risk of misoperation. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a flowchart of a control system for a ceramic tile raw material feeder group based on intelligent sorting of aging time, according to the present invention.

[0021] Figure 2 This is the block diagram of the intelligent sorting logic for the stale warehouse; Attached reference numerals: 1. Bin position detection unit; 2. Feeder material detection unit; 3. Raw material storage unit; 4. Material flow metering unit; 5. Feeder frequency conversion control unit; 6. Material feeding and conveying unit; 7. Material discharging and conveying unit; 8. Intelligent automation control unit. Detailed Implementation

[0022] To make the technical problems, technical solutions, and technical effects of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0023] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0024] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0025] In the description of the embodiments of the present invention, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0026] Example 1 like Figure 1 As shown, this embodiment provides a control system for a ceramic tile raw material feeder group based on intelligent sorting of aging time, including a bin detection unit 1, a feeder material detection unit 2, a raw material storage unit 3, a material flow metering unit 4, a feeder frequency conversion control unit 5, a material feeding and conveying unit 6, a material discharging and conveying unit 7, and an intelligent automation control unit 8 arranged sequentially. The silo detection unit 1, feeder material detection unit 2, raw material storage unit 3, material flow metering unit 4, feeder frequency conversion control unit 5, material feeding and conveying unit 6, and material discharging and conveying unit 7 are all connected to the intelligent automation control unit 8 via signals.

[0027] Example 2 like Figure 2 As shown, this embodiment provides a control method for a ceramic tile raw material feeder group based on intelligent sorting of aging time. It adopts a ceramic tile raw material feeder group control system based on intelligent sorting of aging time disclosed in Embodiment 1, and includes the following steps: S1. Data Structure Establishment and Initialization: Establish the full-field data model of the feeder group in the intelligent automation control unit 8; define a custom data format array Array[i] (N=27 in this embodiment, corresponding to 28 bins), i is the corresponding number of the aging bin, i∈(1,...,N); S2. Status monitoring and time accumulation: Real-time statistics of the cumulative aging time after each aging warehouse is full; The intelligent automation control unit 8 scans the sensor signals of each aging chamber in real time and performs independent state transition logic processing for each aging chamber i: S21, Feeding stage: When the aging bin i is detected to be empty and the upstream requests feeding, the feeding conveyor is started; S22, Timing Stage: When the bin detection unit 1 detects that the aging bin i is full, it stops feeding. The intelligent automation control unit 8 automatically starts the aging timer for the intelligent automation control unit 8 and updates the aging cumulative time of Array[i] in real time. S23. Standby stage: When the aging time of aging bin i reaches the process preset threshold Tset, the bin is marked as "material discharge state".

[0028] S3. Intelligent sorting and optimization strategy based on aging time: Use a sorting algorithm to sort all full-capacity aging warehouses in descending order according to the cumulative aging time. The intelligent automation control unit 8 executes an optimization algorithm to determine the start-up sequence of the feeder: S31. Traverse the array Array[0..27] and filter out all aging bins marked as "ready to be filled". S32. For the selected aging warehouses, automatically sort them from largest to smallest according to the "cumulative aging time" (BubbleSort or QuickSort algorithm). S33, the intelligent automation control unit 8 always prioritizes the feeder corresponding to the aging bin i with the longest aging time (ranked first) as the current operating equipment, to achieve strict "first-in, first-out" process control.

[0029] S4. Automatically select the feeder corresponding to the first-ranked aging bin for material discharge; the current bin empty signal triggers the feeder corresponding to the next-level aging bin for material discharge. S41. When the material detection unit 2 of the running feeder detects no material, or the bin detection unit 1 detects an empty bin signal: S42. The intelligent automation control unit 8 automatically stops the feeder and, based on the sorting result of step S3, immediately and automatically starts the feeder with the next priority (second longest aging time). S43. At the same time, a "empty hopper awaiting feeding" request signal is sent to the upstream of the feeder to form a closed loop.

[0030] S5. During the feeding process, PID variable frequency speed regulation is performed based on the total flow feedback. During the operation of the feeder, the intelligent automation control unit 8 executes closed-loop flow control. S51, Setpoint Qsp: Receives the feed rate setpoint required by the downstream process; S52, Feedback value Qpv: Real-time reading of the value of the material flow metering unit 4 on the main conveyor belt; S53. Deviation Calculation: Calculate the deviation. ; S54, PID control: The output frequency is calculated using the PID algorithm, and the motor speed of the current feeder frequency conversion control unit 5 is dynamically adjusted.

[0031] S55, when When (flow is insufficient), automatically increase the feeder frequency; when When the flow rate is too high, the feeder frequency is automatically reduced to ensure that the actual flow rate always closely tracks the set value, thus achieving stable and continuous feeding.

[0032] Taking 28 storage locations as an example, the cumulative aging time of the storage locations before sorting and the cumulative aging time of the storage locations after sorting are shown in Table 1. This achieves fully automatic and seamless rotation of the 28 storage locations, eliminating the downtime caused by manual storage changes and significantly improving equipment utilization.

[0033] Table 1. Cumulative storage time before and after sorting

Claims

1. A control system for a ceramic tile raw material feeder group based on intelligent sorting of aging time, characterized in that, It includes, in sequence, a hopper detection unit, a feeder material detection unit, a raw material storage unit, a material flow metering unit, a feeder frequency conversion control unit, a material feeding and conveying unit, a material discharging and conveying unit, and an intelligent automation control unit; The silo detection unit, feeder material detection unit, raw material storage unit, material flow metering unit, feeder frequency conversion control unit, material feeding and conveying unit, and material discharging and conveying unit are all connected to the intelligent automation control unit via signals.

2. A method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time, employing the control system for a group of ceramic tile raw material feeders based on intelligent sorting of aging time as described in claim 1, characterized in that... Includes the following steps: S1. Data Structure Establishment and Initialization: Establish the full-field data model of the feeder group in the intelligent automation control unit; define a custom data format array Array[i], where i is the corresponding numbered aging bin, i∈(1,...,N); S2. Status monitoring and time accumulation: Real-time statistics of the cumulative aging time after each aging warehouse is full; S3. Intelligent sorting and optimization strategy based on aging time: Use a sorting algorithm to sort all full-capacity aging warehouses in descending order according to the cumulative aging time. S4. Automatically select the feeder corresponding to the first-ranked aging bin for material discharge; the current bin empty signal triggers the feeder corresponding to the next-level aging bin for material discharge. S5. PID variable frequency speed regulation is performed based on the total flow feedback during the feeding process.

3. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 2, characterized in that, In step S1, each array element i contains the following status bits and process variables: Status indicators include full position signals. Short position signal Feeder operating status Material flow detection signal ; Process variables include drive signal, speed setpoint, and current aging cumulative time T. aging The cumulative time of empty warehouses after the air raid shelter is filled, and the cumulative time of material aging after the warehouse is full.

4. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 2, characterized in that, The specific methods for status monitoring and time accumulation in step S2 are as follows: The intelligent automated control unit scans the sensor signals of each aging chamber in real time and performs independent state transition logic processing for each aging chamber i: S21, Feeding stage: When the aging bin i is detected to be empty and the upstream requests feeding, the feeding conveyor is started; S22, Timing Stage: When the silo detection unit (1) detects that the aging silo i is full, it stops feeding. The intelligent automation control unit automatically starts the aging timer for the intelligent automation control unit and updates the aging cumulative time of Array[i] in real time. S23, Standby Stage: When the aging time in aging chamber i reaches the preset process threshold. Then, mark the bin as "ready to be filled".

5. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 2, characterized in that, The specific method of the intelligent sorting and optimization strategy based on staleness in step S3 is as follows: The intelligent automation control unit executes an optimization algorithm to determine the start-up sequence of the feeder: S31. Traverse the array Array[0..27] and filter out all aging bins marked as "ready to be put out"; S32. The selected aging warehouses are automatically sorted from largest to smallest based on their "cumulative aging time"; S33. The intelligent automation control unit always prioritizes the feeder corresponding to the aging bin i with the longest aging time as the current operating equipment, so as to achieve strict "first-in, first-out" process control.

6. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 2, characterized in that, In step S4, the seamless switching and relay of the feeder group is carried out in the following manner: S41. When the feeder material detection unit (2) of the running feeder detects no material, or the bin detection unit (1) detects an empty bin signal: S42. The intelligent automation control unit automatically stops the feeder and, based on the sorting result of step S3, immediately and automatically starts the feeder of the next priority. S43. At the same time, a "empty hopper waiting to be fed" request signal is sent to the upstream of the feeder to form a closed loop.

7. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 2, characterized in that, In step S5, the specific steps of the PID dynamic steady-flow control based on flow feedback are as follows: During the operation of the feeder, the intelligent automated control unit performs closed-loop flow control: S51, Setting Value : Receives the feed rate setting value required by downstream processes; S52, Feedback Value : Real-time reading of the material flow metering unit (4) on the main conveyor belt; S53. Deviation Calculation: Calculate the deviation. ; S54, PID regulation: The output frequency is calculated using the PID algorithm, and the motor speed of the current feeder frequency converter control unit (5) is dynamically adjusted.

8. The method for controlling a group of ceramic tile raw material feeders based on intelligent sorting of aging time according to claim 7, characterized in that, In step S54, when When, automatically increase the feeder frequency; when When the feeder frequency is reduced, the actual flow rate is always closely tracked by the set value, thus achieving stable and continuous feeding.

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