Uniform blanking device and method for stock bin based on discrete element optimization

Abstract

According to the device and method, a material characteristic-bin body structure-arch breaking device collaborative design system is constructed, discrete element simulation and orthogonal tests are combined, the influence of all factors on the flowing property is quantified, optimal parameters are determined, and the uniform discharging device of the stock bin is designed and comprises a conical stock bin body, an arc breaking device, an arc breaking device, an arc breaking device, an arc breaking device, an arc breaking device and an arc breaking device. A double-flange arch breaking device is arranged in the conical stock bin, the double-flange arch breaking device is composed of an upper circular flange plate and a lower circular flange plate which are coaxially arranged and are large in upper portion and small in lower portion, the double-flange arch breaking device is rigidly connected through at least two sets of symmetrical scrapers, the curvature of the scrapers is matched with the bin wall of the conical stock bin, and the edges of the scrapers can be tightly attached to the bin wall to rotate. The problems of arching of dry bulk materials, wall hanging of wet materials, dead zones of particles and the like are solved in a targeted mode, continuous flowing of the materials is guaranteed, residues are reduced, and bin cleaning shutdown is achieved; the subjectivity of empirical design is avoided, it is ensured that device design is highly matched with material characteristics, and practicability and reliability are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of bulk material storage and conveying equipment, in particular to a material bin uniform discharging device and method based on discrete element optimization. BACKGROUND

[0002] In the loading station operation of coal, ore and other bulk materials, the material bin as the core equipment for material storage and transfer, its discharging efficiency and stability are directly related to the continuous operation ability of the loading system. There are still many technical problems in the design and application of the current loading station material bin, which is difficult to meet the efficient and stable production demand.

[0003] From the actual operation, the most prominent problems are poor material flow and arching and blocking. The bulk materials (such as coal, iron ore, etc.) handled by the loading station often have complex physical properties: dry bulk materials are easy to form "bridges" due to the friction between particles, and accumulate into stable arches above the discharge port, causing discharging to be interrupted; wet and sticky materials will be adsorbed on the wall due to surface tension, forming a thick wall-hanging layer, which not only reduces the effective volume of the bin, but also may cause a sudden drop in the discharging amount due to the sudden shedding of the wall-hanging material, affecting the loading accuracy; Large particle materials are easy to form "dead zones" in the corners of the bin, only the materials in the center area can flow, resulting in a high residual rate of materials in the bin, which requires frequent shutdown for cleaning. These problems cause the daily downtime for cleaning and blocking to be longer, and in severe cases, may even cause equipment overload, material leakage and other safety accidents, causing considerable economic losses.

[0004] Although the prior art attempts to alleviate the above problems by using arch breaking devices, the adaptability and effect are not ideal. For example, the spiral arch breaking device pushes the material by rotating blades, which has a certain effect on dry and small particle materials, but when facing sticky materials, it is easy to fail due to material winding and caking; the electromagnetic vibrator relies on the vibration of the bin wall to break the arch, but it is difficult to control the frequency and amplitude of the vibration, and the effect on high-density materials is weak, and high-frequency vibration may cause fatigue damage to the bin structure; the chain plate arch breaker has a complex transmission structure, and the failure rate is high in a dusty environment, with high maintenance costs.

[0005] The deeper problem is that the industry often uses empirical design methods to determine the parameters of the material bin, but the density and particle size of different materials differ greatly, and the empirical design cannot accurately match the parameters, cannot meet the dual requirements of uniformity and efficiency of discharging, and lacks quantitative design basis, and cannot be optimized according to the characteristics of the material, making it difficult to fundamentally solve the problem of arching and blocking. SUMMARY

[0006] In view of the above defects, the present application provides a kind of based on discrete element optimization's uniform material bin discharging device, constructs the collaborative design system of material characteristics-bin structure-arch breaking device, based on discrete element simulation and orthogonal test, quantitatively analyze the influence of each factor on flow performance, determine the optimal parameter combination, innovative design adaptive arch breaking device, solve the problem of uneven discharge, low efficiency and poor adaptability of existing device, realize efficient and uniform discharge in a variety of coal and iron ore scene.

[0007] The purpose of the present application is achieved as follows: The present application includes two aspects, the first aspect: A method of a uniform material bin discharging device based on discrete element optimization, comprising the following steps: Step 1, establish a simulation model: 1) Data collection: including geometric parameters of bin type, physical parameters of material, auxiliary simulation parameters, and clear core indicators; 2) Model establishment: establish the simulation model of the bin and the material by using the discrete element method, considering the properties, stress and boundary conditions; Step 2, design orthogonal test: Design a four-factor three-level orthogonal test, including bin type, material density, material radius and material adhesion energy parameters, and comprehensively investigate the influence of each factor on material flowability through orthogonal test; Step 3, perform discrete element simulation: Use discrete element simulation software to simulate each group of parameters in the orthogonal test, analyze the key indicators such as material descending speed, flow pattern change law and discharge flow rate; Step 4, analyze simulation results and determine optimal level combination: According to the simulation results, determine the influence degree of each factor on material flow rate by using range analysis method, and select the optimal bin design parameter combination; Step 5, install arch breaking device: For the optimal bin type, install arch breaking device to improve material flowability; Step 6, manufacture physical bin according to optimized parameters; Manufacture physical bin according to optimized bin design parameters; Step 7, actual test and optimization verification: Perform actual test, compare simulation results, verify optimization effect, and adjust and optimize to form final scheme.

[0008] Further, in step 4, the following discharge flow rate fluctuation less than 5%, no obvious blocking phenomenon is the comprehensive evaluation standard of flowability, and the optimal bin design parameter combination is selected as a conical bin, the density of the treated material is 3000 kg / m³, the material radius is 20 mm, and the adhesion energy of the material and the bin material is 25 J / m².

[0009] The second aspect: A silo uniform feeding device based on discrete element method optimization includes a conical silo. The conical silo has an overall axially symmetrical inverted cone structure with a large-diameter circular inlet at the top and a small-diameter circular outlet at the bottom. A rotatable double-flange arch-breaking device is coaxially arranged inside the conical silo. The double-flange arch-breaking device is driven to rotate by a drive motor. The double-flange arch-breaking device includes two circular upper flanges and a lower flange arranged coaxially, which are larger at the top and smaller at the bottom. They are rigidly connected by at least two sets of symmetrical scrapers. The curvature of the scrapers matches the silo wall of the conical silo. When rotating, the edges of the scrapers are in close contact with the silo wall.

[0010] Furthermore, an upper constraint guide ring is fixedly provided on the inner wall of the conical hopper, and multiple bearing connecting seats are symmetrically installed on the upper flange of the double flange arch breaking device, which are rolledly connected to the upper constraint guide ring through guide bearings.

[0011] Furthermore, a lower constraint guide ring is fixedly provided on the inner wall of the conical silo, and the lower flange of the double flange arch-breaking device is fixedly connected to the driven gear ring. The lower flange cooperates with the lower constraint guide ring with a guide structure to ensure the coaxiality of the lower part of the device. A drive motor is fixedly installed on the side wall of the bottom of the conical silo, and its output shaft is connected to the drive gear. The drive gear meshes with the driven gear ring to provide low-speed rotation power for the double flange arch-breaking device.

[0012] Furthermore, the drive motor is a geared motor with adjustable speed, and its output shaft is connected to the drive gear via a coupling.

[0013] Furthermore, a speed sensor and a humidity sensor are installed inside the conical hopper. The speed sensor is used to monitor the flange speed in real time, and the humidity sensor is used to check the humidity of the material, so that the speed of the double flange arch breaking device can be adjusted in real time.

[0014] Furthermore, the connection between the scraper and the upper and lower flanges is provided with an elastic buffer assembly. The scraper is thin on both sides and thick in the middle, with the outer wall curvature matching the conical silo wall. The inner wall is a long strip scraper formed by two arcs. The edges of the scraper are provided with replaceable hard alloy teeth at intervals to enhance the ability to crush agglomerated materials.

[0015] Furthermore, the upper and lower flanges of the double-flange arch-breaking device are rigidly connected by three sets of scrapers evenly distributed at 120°.

[0016] Furthermore, reinforcing ribs are provided between the scrapers.

[0017] The beneficial effects of this invention are as follows: Addressing the core problems of existing loading station silos, such as low material unloading efficiency, poor stability, frequent arching and blockage, high material residue rate, and insufficient adaptability of arch-breaking devices, this invention achieves precise adaptation design based on the differences in the physical properties of bulk materials, resulting in the following beneficial effects: 1. Achieve precise matching of silo parameters: Abandoning traditional experience-based design methods, this approach provides quantitative design basis based on the physical characteristics (density, particle size, viscosity, etc.) of different bulk materials, and optimizes key silo parameters in a targeted manner. This achieves precise matching between material characteristics and silo structure and anti-bridging mechanism, taking into account both the uniformity and efficiency of material feeding, fundamentally solving the problem of bridging and silo blockage, and ensuring the continuous and stable operation of the loading system.

[0018] 2. Enhanced flow performance: Core parameters are optimized through discrete element simulation, and an arch-breaking device is added to precisely break up bridging arches in dry bulk materials and wall-mounted accumulations in wet viscous materials. This solves industry pain points such as material arching, wet material wall adhesion, bridging, and particle dead zones. It effectively expands the uniform flow zone, enabling materials to present an ideal first-in-first-out flow pattern, ensuring continuous and stable material flow, reducing material residue in the silo, and lowering the frequency of silo cleaning and downtime.

[0019] 3. Improved production efficiency: The coordinated operation of the arch-breaking device and the optimized silo design reduces downtime caused by blockages and material shortages, enhances the continuity of loading and unloading operations, and shortens the material transfer cycle; the design method that combines simulation and actual measurement verification ensures that the device is accurately matched with the material characteristics of different types of coal and iron ore, and its adaptability covers a variety of working conditions, ensuring stable operation without frequent equipment adjustments.

[0020] 4. Reduced maintenance costs and high reliability: The optimized silo structure reduces the impact and adhesion of materials to the silo walls. Combined with a suitable arch-breaking device, it effectively reduces wear on the silo body and components, extending the service life of the equipment. It reduces costs incurred due to fault maintenance and component replacement, while avoiding production capacity losses caused by downtime during silo clearing. Based on the dual guarantee of four-factor three-level orthogonal discrete element simulation and actual measurement verification, it avoids the subjectivity of experience-based design, ensuring that the device design is highly compatible with material characteristics, and significantly improving practicality and reliability.

[0021] The present invention will be further explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the conical silo and double-flange arch-breaking device of the present invention; Figure 2 This is a schematic diagram of the flange arch-breaking device of the present invention; Figure 3 This is a partial enlarged view of the scraper structure at point B of the double-flange arch-breaking device of the present invention; Figure 4 This is a schematic diagram of the uniform feeding device for the hopper of the present invention; Figure 5 This is a partial enlarged view of point A in the uniform feeding device of the hopper of the present invention; Figure 6 This is a comparison diagram of the flow patterns of tracer particles in the discrete element simulation of this invention; Figure 7 This is a distribution diagram of the particle descent velocity field in the discrete element simulation of this invention; Figure 8 This is a flowchart illustrating the design method of the uniform feeding device for a silo based on discrete element optimization according to the present invention.

[0023] In the diagram: 1-conical hopper, 2-double flange arch-breaking device, 3-upper restraint guide ring, 4-guide bearing, 5-bearing connecting seat, 6-drive motor, 7-drive gear, 8-driven gear ring, 9-lower restraint guide ring, 21-upper flange, 22-lower flange, 23-scraper, 24-reinforcing rib. Detailed Implementation

[0024] Example 1: A design method for a uniform feeding device for silos based on discrete element method optimization, such as... Figure 8 As shown, it includes the following steps: Step 1, establish a simulation model: 1. Data Collection: 1.1 The orthogonal experiment involved three types of silos: circular, square, and hyperbolic. The necessary geometric parameters for modeling each silo type were collected: circular silo (diameter of the straight section, height of the straight section, half-apex angle of the conical section, and discharge port diameter); square silo (side length of the straight section, height of the straight section, inclination angle of the conical sidewall, and side length of the discharge port); and hyperbolic silo (diameter of the straight section, height of the straight section, starting / ending diameter of the hyperbolic section, and discharge port diameter). This ensured that the models of the three silo types could be accurately implemented. 1.2 Identify the key physical parameters of the target material (such as lignite, bituminous coal, iron ore, coal gangue, etc.), including density, particle size distribution, and adhesion energy parameters between the material and the silo wall. For the mainstream silo wall materials involved in the experiment, such as steel and concrete, collect the measured adhesion energy data corresponding to the three levels of the orthogonal experiment as key parameters of the contact model.

[0025] 1.3 Supplementing auxiliary simulation parameters: Collect basic auxiliary parameters to support the implementation of the four-factor parameters, including particle elastic modulus, Poisson's ratio, and internal friction angle (to ensure that particle contact and flow behavior are consistent with reality).

[0026] 1.4 Clearly define the impact of four factors on material flowability as the core objective, focusing on three key indicators: average outflow velocity, arching rate, and maximum stress on the silo wall, to ensure that the collected parameters are highly compatible with the target.

[0027] 2. Model building: A discrete element method (DEM) is used to establish a simulation model of the silo and the material. The silo model needs to accurately reproduce its geometric parameters, including key dimensions such as silo height, diameter, and cone angle. The material model needs to define the physical properties of the particles based on the actual material characteristics, including density, radius, and elastic modulus. During the simulation, the gravity acting on the particles, the contact forces between particles, and the torque generated by particle rotation need to be considered. Boundary conditions are set, including fixed silo walls, outlet size, and simulation time step, to simulate the flow behavior of the material within the silo.

[0028] Step 2, Design an orthogonal experiment: A four-factor, three-level orthogonal experiment was designed, including parameters such as silo type (e.g., conical silo, square silo, hyperbolic silo), material density (three gradients are set according to the actual material value range, such as 1000 kg / m³, 2000 kg / m³, and 3000 kg / m³), material radius (three representative values ​​are selected according to the particle size distribution characteristics, such as 20 mm, 25 mm, and 30 mm), and adhesion energy between the material and the silo (e.g., 5 J / m², 25 J / m², and 45 J / m²). The orthogonal experiment comprehensively examines the influence of each factor on the material flowability.

[0029] Step 3: Perform discrete element simulation. Simulations were conducted sequentially according to the parameter combinations of the orthogonal experimental design. During the simulation, key indicators needed to be monitored and recorded in real time, including the distribution of the material's descent velocity at different cross-sections, the dynamic changes in the overall flow pattern (such as funnel flow or overall flow), the discharge flow rate per unit time, and its fluctuation coefficient. It was essential to ensure that the boundary conditions (such as the initial filling volume of the silo and the outlet size) remained consistent for each simulation group to improve the comparability of the experimental results.

[0030] Based on the nine parameter combinations of the orthogonal experimental design in Table 1 (silo type: square silo / conical silo / hyperbolic silo; material density: 1000 / 2000 / 3000 kg / m³; material radius: 20 / 25 / 30 mm; adhesion energy: 5 / 25 / 45 J / m²), simulations were conducted sequentially. Uniform boundary conditions were set for each simulation group: initial silo filling volume was 80% of the silo capacity, outlet diameter was 300 mm, and simulation duration was 15 minutes, ensuring that the experimental variables were unique and the results were comparable.

[0031] During the simulation, three key indicators were collected in real time: ① Velocity indicators: the average descent velocity and standard deviation of particles at 1 / 4, 1 / 2, and 3 / 4 height sections of the hopper; ② Flow pattern indicators: the flow pattern type (funnel flow / overall flow) and the frequency of blockage were determined by tracing the particle trajectory; ③ Flow rate indicators: the mass of material fed per unit time and the flow rate fluctuation coefficient (fluctuation coefficient = standard deviation / average value). All data were sampled at a frequency of 10Hz.

[0032] Step 4: Analyze the simulation results and determine the optimal combination of levels: Based on the key indicator data obtained from simulation, the range and contribution rate of each factor are calculated using range analysis to determine the degree of influence of different factors on the stability of material flow (e.g., silo type may be the main influencing factor). Combined with the comprehensive flowability evaluation criteria (feed flow fluctuation less than 5% and no obvious blockage), the combination of silo design parameters that makes the material flow most uniform and the feeding efficiency highest is selected.

[0033] Based on the simulation results, the range analysis method was used to determine the degree of influence of each factor on the material flow rate, and the optimal combination of silo design parameters was selected. Based on the key indicator data obtained from simulation, range analysis was used to determine the degree of influence of each factor on material flow rate and stability. The steps are as follows: 1. Organize the data corresponding to the experimental group, factor level, and index: Clarify the influencing factors in the experiment (such as silo type, cone angle, and discharge port size), the level settings of each factor, and the index results corresponding to each experimental group.

[0034] Calculate the core flow indicators for each set of parameters (with flow fluctuation coefficient as the core, combined with cross-sectional velocity standard deviation and blockage frequency), and compile them into a data table corresponding to "experimental group - factor level - indicator". Clarify the four factors and their levels, namely, silo type, material density, material radius, and adhesion energy, and the results of indicators such as flow fluctuation coefficient for each set of experiments.

[0035] 2. Calculate the average level (K value) for each factor: For each factor, calculate the average value of all experimental indicators at the same level, i.e., K. ij This represents the mean value of the indicator at the j-th level of the i-th factor, reflecting the average influence of this factor at this level on the indicator.

[0036] For example, the average flow fluctuation coefficient of three sets of tests under the conical silo level in the silo type factor is calculated to reflect the average influence of this level on the index.

[0037] 3. Calculate the range (R-value) and rank them to determine the order of influence: the range R-value for each factor. i= The maximum value of the factor's average values ​​minus the minimum value. The larger the R value, the more significant the factor's impact on the indicator. Arrange the factors in descending order of R value to determine the order of influence (e.g., the warehouse type has the largest R value, which is the main influencing factor). At the same time, calculate the contribution rate of each factor to assist in the verification.

[0038] 4. Based on comprehensive evaluation criteria such as material flow fluctuation of less than 5% and no obvious blockage, and referring to the average value of each factor (e.g., a better K value at a certain level indicates better performance of that level), candidate parameter combinations are initially screened out; the initially screened combination of "conical silo + 3000kg / m³ + 20mm + 25J / m²" is subjected to three repeated simulation verifications to confirm that it meets the evaluation criteria, and is finally determined as the optimal silo design parameters.

[0039] 5. Step 5: Install the arch-breaking device: Based on the selected silo type, a double-flange anti-bridging device was installed, and the effect of the anti-bridging device on improving material flowability was analyzed; for example... Figures 6-7 As shown, Figure 6 The flow process of tracer particles within a silo over 15 minutes was demonstrated: The upper silo, without an arch-breaking device, showed tracer particles gradually forming a "V"-shaped collapse flow from an initially uniform distribution, resulting in rapid material discharge; the lower silo, equipped with an arch-breaking device, showed a smoother flow of tracer particles, without concentrated collapse, and more uniform and stable material discharge. This demonstrates that the arch-breaking device can improve the particle flow state within the silo, preventing localized sudden flows and making material discharge more controllable and uniform.

[0040] Figure 7 The comparison shows the velocity distribution of particles falling through silos: In the left image, silo A without the anti-bridging device, only the bottom A2 area has a high particle velocity (red), while the upper A1 area is mostly low-velocity (blue-green), resulting in uneven velocity distribution. In the right image, after the anti-bridging device is installed, a large area of ​​silo B shows high-velocity particles (red), with a more uniform velocity distribution. The anti-bridging device effectively improves the velocity distribution of particles within the silo, allowing particles in more areas to maintain a higher flow velocity, thus improving overall discharge efficiency and uniformity.

[0041] Step 6: Construct the physical silo based on the optimized parameters; Based on the optimal parameter combination determined in step 4 (including bin type, size, and adhesion energy between material and bin) and the parameters of the arch-breaking device selected in step 5, the solid bin is processed and manufactured.

[0042] Step 7, Actual testing and optimization verification: An actual feeding test platform was built, and the same materials as in the simulation were used for testing. Indicators such as actual feeding flow rate, flow uniformity, and the operational stability of the arch-breaking device were measured and compared with the simulation results. If significant deviations were found (e.g., actual flow rate fluctuations exceeding simulation values), the causes needed to be traced (e.g., errors in material physical property testing, insufficient device processing precision). Further adjustments and improvements were made to the design parameters or the arch-breaking device to ultimately form a uniform feeding device design scheme that meets the requirements of practical applications.

[0043] Silos optimized using the Discrete Element Method (DEM) can precisely determine parameters suitable for specific material scenarios through relevant experiments, demonstrating high specificity and adaptability to the density, radius, viscosity, and other characteristics of different materials. This optimization method effectively solves problems such as arching of dry bulk materials, adhesion of wet materials to the walls, and dead zones caused by large particles, ensuring continuous and stable material flow and reducing material residue and downtime for cleaning. It enables precise control of the feeding process, stabilizing the feeding volume and thus improving the accuracy and efficiency of related operations. Based on DEM optimization, it can achieve intelligent adjustment of equipment operation, adaptively adjusting parameters according to different material states to optimize energy consumption and efficiency. It provides a scientific and quantitative optimization path for silos with different material characteristics, reduces maintenance costs, and provides efficient and reliable design support for material handling.

[0044] Example 2: This embodiment is a silo uniform feeding device based on discrete element optimization designed according to the method of embodiment 1. The parameter optimization of the feeding device is based on the four-factor, three-level orthogonal discrete element simulation test conditions: silo type, material density, material radius, and material adhesion energy to silo body are used as test factors. The range and contribution rate of each factor are calculated by range analysis to clarify the degree of influence of each factor on the stability of material flow rate. The comprehensive evaluation standard of flow rate fluctuation of less than 5% and no obvious blockage phenomenon is adopted.

[0045] After testing and screening, the optimal design parameters for the silo were finally obtained: the best combination of silo design parameters is a conical silo, which is suitable for a material density of 3000 kg / m³, a material radius of 20 mm, and a material adhesion energy to the silo body of 25 J / m². This combination can achieve the most uniform material flow and the highest material discharge efficiency.

[0046] Its optimal parameter combination has been verified for adaptability in multiple scenarios and can be widely applied to various coal and iron ore scenarios. The coal scenario includes feeding different types of coal materials such as anthracite, bituminous coal, and lignite; the iron ore scenario includes feeding different types of iron ore materials such as magnetite, hematite, and limonite, and can adapt to the material requirements of different particle size levels in various scenarios.

[0047] A hopper uniform feeding device based on discrete element method optimization includes a conical hopper 1, such as... Figures 1-5As shown, the conical silo 1 is made of stainless steel, and its design parameters are determined through a four-factor, three-level orthogonal experiment.

[0048] The conical silo 1 has an axially symmetrical inverted conical structure, with a large-diameter circular inlet at the top and a small-diameter circular outlet at the bottom. A rotatable double-flange arch-breaking device 2 is coaxially installed inside the conical silo 1. The double-flange arch-breaking device 2 consists of two circular flanges arranged coaxially, with the upper flange 21 and the lower flange 22 being larger at the top and smaller at the bottom. They are rigidly connected by two sets of scrapers 23 distributed at 180°. Reinforcing ribs 24 are provided between the scrapers 23, and an elastic buffer component (such as a disc spring) is added to the connection between the scrapers 23 and the flanges. When the instantaneous pressure of the material is too high, the scrapers can slightly retract to avoid rigid damage, and automatically reset when the pressure decreases, ensuring that the gap with the silo wall remains stable within the design range and adapting to the impact fluctuations of particulate materials.

[0049] The scraper 23 is a long strip structure that is thin on both sides and thick in the middle. The curvature of the outer wall matches the wall of the conical silo 1. The inner wall is formed by two smooth arcs. The edge maintains a small gap with the silo wall. Replaceable hard alloy teeth are set at intervals on the scraper edge. The high hardness characteristics are used to cope with the compression of high-density particles and enhance the crushing ability of agglomerated materials. The scraper edge is equipped with a detachable wear-resistant rubber strip to ensure the scraping effect against the wall and reduce the wear of the silo wall.

[0050] An upper constraint guide ring 3 is fixedly installed on the inner wall of the conical silo 1. The guide ring is machined with an annular groove, the size of which matches the outer ring of the guide bearing 4. The outer ring of the guide bearing 4 is fixed in the annular groove by an interference fit. Multiple bearing connecting seats 5 are symmetrically installed on the edge of the upper flange 21 of the double flange arch breaking device 2. The bearing connecting seats 5 are connected to the inner ring of the guide bearing 4 by a tight fit, so that the upper flange 21 forms a rolling connection with the upper constraint guide ring 3 through the guide bearing 4. That is, the upper constraint guide ring 3 is fixed to the silo wall, the outer ring of the guide bearing 4 remains stationary, and the inner ring rotates synchronously with the upper flange 21, realizing the rotational guidance of the upper part of the arch breaking device 2.

[0051] A lower constraint guide ring 9 is fixedly installed at a corresponding position on the lower inner wall of the conical hopper 1. Both the upper constraint guide ring 3 and the lower constraint guide ring 9 are made of high-strength alloy material. The inner side of the lower constraint guide ring 9 is provided with an annular guide surface that is adapted to the lower flange 22. The edge of the lower flange 22 slides with the guide surface, and a labyrinth-type sealing structure is added to the mating part. It is formed by the annular boss extending from the outer wall of the lower flange 22 and the annular groove on the inner wall of the lower constraint guide ring 9. At the same time, a lip seal ring is added to the end of the mating surface to prevent material particles from entering the guide gap through double protection.

[0052] A drive motor 6 is fixedly installed on the bottom side wall of the conical silo 1. The drive motor 6 is a geared motor with an output torque that is 20%-30% higher than that of conventional specifications to match the load requirements of high-density materials. The output shaft is connected to the drive gear 7 through a coupling. The drive gear 7 is meshed with the driven gear ring 8 to provide low-speed rotation power for the double flange arch breaking device 2. The speed of the geared motor is adjustable.

[0053] The conical silo 1 is equipped with a speed sensor and a humidity sensor. The speed sensor is used to monitor the flange speed in real time, and the humidity sensor is used to detect the material humidity. The speed of the double flange arch-breaking device 2 can be adjusted in real time. Microwave level gauges (to monitor changes in material accumulation height) and strain gauges (to detect changes in silo wall stress) are also arranged at different heights in the conical silo 1. When a sudden drop in material height or abnormal stress on the silo wall is detected (determined as a precursor to arching), the double flange arch-breaking device 2 can be activated in advance.

[0054] A silo uniform feeding device based on discrete element method (DEM) uses a double flange combined with symmetrical scrapers and reinforcing ribs as the core framework of the arch-breaking device. Combined with upper and lower constraint guide rings, this forms an integrated arch-breaking structure that balances rigidity and stability. An elastic buffer component at the connection between the scraper and the flange enables adaptive gap adjustment. A speed regulation mechanism linked to multiple sensors (humidity, pressure, etc.) allows the device to dynamically adapt to material impact fluctuations and humidity changes. Hard alloy teeth are integrated into the scraper edges, and a labyrinth seal combined with a lip seal ring is used at the junction of the lower flange and the guide ring for protection. This design is specifically reinforced for high-density, medium-to-high viscosity materials.

[0055] It effectively ensures uniform material feeding from the hopper, avoids problems such as arching and blockage, reduces material residue and downtime for cleaning, ensures continuous and stable material flow, and the stable feeding volume can improve the accuracy and efficiency of related operations. In addition, the structure is durable and has a low failure rate, which can reduce maintenance costs and provide efficient and reliable equipment support for the material handling process.

[0056] The uniform feeding device for the silo described in this invention is used to load anthracite coal with a density of 3000 kg / m³ and a radius of 20 mm. Surface treatment ensures the adhesion energy between the anthracite coal and the silo body remains at 25 J / m². After starting the feeding device, the feeding flow rate is monitored in real time. The results show a flow rate fluctuation of 3.2%, with no blockage. The feeding efficiency is 35% higher than that of traditional square silo devices and 28% higher than that of traditional hyperbolic silo devices.

[0057] The magnetite ore being loaded has a density of 3000 kg / m³ and a radius of 20 mm. By adjusting the silo material, the adhesion energy between the magnetite and the silo body is set to 25 J / m². During the feeding process, the flow rate fluctuates by 4.5%, with no blockages. The feeding efficiency is 32% higher than that of traditional square silos and 28% higher than that of traditional hyperbolic silos.

[0058] Example 3: This embodiment is another implementation of embodiment 2. The difference is that the upper flange 21 and the lower flange 22 of the double flange arch breaking device 2 are rigidly connected by three sets of scrapers 23 evenly distributed at 120°. Reinforcing ribs 24 are provided between the scrapers 23. The reinforcing ribs 24 are "T" shaped ribs connected to the adjacent scrapers 23.

[0059] Compared to two sets of 180° symmetrically distributed scrapers, the three sets of 120° evenly distributed scrapers with "T"-shaped reinforcing ribs have a more balanced structural stress distribution: the 120° evenly distributed scrapers cause the force on the bin wall during device rotation to be distributed symmetrically in a ring, reducing wear caused by concentrated stress on local bin walls; the "T"-shaped reinforcing ribs enhance the scraper's own deformation resistance through the transverse section and strengthen the overall rigidity of the flange and scraper through the longitudinal section, which can reduce the deflection of the scraper caused by excessive force on one side when handling high-density agglomerated materials.

[0060] More comprehensive arch breaking coverage: The three sets of scrapers divide the circumferential area inside the bin into three uniform sectors. During the rotation process, they can simultaneously shear and break up material arches at different angles, reducing the local arching residue caused by excessive gaps in traditional double scrapers. This is especially suitable for ore materials with high viscosity that are prone to forming large-area adhesion layers on the bin wall.

[0061] Improved operational stability: The support structure reduces the vibration amplitude of the device by 15%-20% when it is subjected to material impact. Combined with the elastic buffer components, it can further reduce the load fluctuation of the drive system caused by instantaneous impact and extend the service life of the geared motor and gear transmission mechanism.

[0062] Finally, it should be noted that the above is only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for a silo uniform feeding device based on discrete element method optimization, characterized in that, Includes the following steps: Step 1, establish a simulation model: 1) Data acquisition: including warehouse geometric parameters, material physical parameters, and auxiliary simulation parameters, to clarify core indicators; 2) Model building: A simulation model of the silo and materials is built using the discrete element method (DEM), taking into account properties, forces, and boundary conditions; Step 2, Design an orthogonal experiment: A four-factor, three-level orthogonal experiment was designed, including silo type, material density, material radius, and adhesion energy parameters between the material and the silo. The orthogonal experiment comprehensively examined the impact of each factor on the material flowability. Step 3: Perform discrete element simulation. Discrete element simulation software was used to simulate the parameters of each group in the orthogonal experiment and analyze key indicators such as material descent speed, flow pattern change law and feed flow rate. Step 4: Analyze the simulation results and determine the optimal combination of levels: Based on the simulation results, the range and contribution rate of each factor were calculated using the range analysis method to clarify the degree of influence of each factor on the stability of material flow and to select the optimal combination of silo design parameters. Step 5, install the arch-breaking device: For optimal silo design, the addition of an arch-breaking device can improve material flowability. Step 6: Construct the physical silo based on the optimized parameters; Based on the optimized silo design parameters, construct the physical silo. Step 7, Actual testing and optimization verification: Conduct actual tests, compare the simulation results, verify the optimization effect, and adjust and optimize to form the final solution.

2. The method for a uniform material feeding device for a silo based on discrete element optimization according to claim 1, characterized in that, In step 4, the flow rate fluctuation is less than 5% and there is no obvious blockage as the comprehensive evaluation standard for flowability. The optimal combination of silo design parameters is selected as a conical silo with a material density of 3000 kg / m³, a material radius of 20 mm, and an adhesion energy between the material and the silo material of 25 J / m².

3. A silo uniform feeding device based on discrete element optimization according to the method of claim 2, characterized in that, The device includes a conical silo (1), which is an axially symmetrical inverted cone structure with a large-diameter circular inlet at the top and a small-diameter circular outlet at the bottom. A rotatable double-flange arch-breaking device (2) is coaxially arranged inside the conical silo (1). The double-flange arch-breaking device (2) is driven to rotate by a drive motor (6). The double-flange arch-breaking device (2) includes two circular upper flanges (21) and lower flanges (22) arranged coaxially, which are larger at the top and smaller at the bottom. They are rigidly connected by at least two sets of symmetrical scrapers (23). The curvature of the scrapers (23) matches the wall of the conical silo (1). When rotating, the edge of the scrapers (23) is close to the wall of the silo.

4. The silo uniform feeding device based on discrete element optimization according to claim 3, characterized in that, The inner wall of the conical silo (1) is fixed with an upper constraint guide ring (3), and the upper flange (21) of the double flange arch breaking device (2) is symmetrically equipped with multiple bearing connecting seats (5), which are rolledly connected to the upper constraint guide ring (3) through the guide bearing (4).

5. The silo uniform feeding device based on discrete element optimization according to claim 3, characterized in that, The inner wall of the conical silo (1) is fixedly provided with a lower constraint guide ring (9). The lower flange (22) of the double flange arch breaking device (2) is fixedly connected to the driven gear ring (8), and the lower flange (22) cooperates with the lower constraint guide ring (9) with a guide structure to ensure the coaxiality of the lower part of the device. The bottom side wall of the conical silo (1) is fixedly installed with a drive motor (6), whose output shaft is connected to the drive gear (7). The drive gear (7) meshes with the driven gear ring (8) to provide low-speed rotation power for the double flange arch breaking device (2).

6. The silo uniform feeding device based on discrete element optimization according to claim 3, characterized in that, The drive motor (6) is a geared motor, and its output shaft is connected to the drive gear (7) via a coupling.

7. The silo uniform feeding device based on discrete element optimization according to claim 3, characterized in that, The conical hopper (1) is equipped with a speed sensor and a humidity sensor. The speed sensor is used to monitor the flange speed in real time, and the humidity sensor is used to check the humidity of the material. The speed of the double flange arch breaking device can be adjusted in real time.

8. The uniform feeding device for silos based on discrete element optimization according to claim 3, characterized in that, The connection between the scraper (23) and the upper and lower flanges is provided with an elastic buffer assembly. The scraper (23) has an outer wall curvature that matches the conical hopper (1) wall, which is thin on both sides and thick in the middle. The inner wall is a long strip scraper formed by two arcs. The scraper (23) is provided with replaceable hard alloy teeth at intervals along its edges to enhance its ability to crush agglomerated materials.

9. The silo uniform feeding device based on discrete element optimization according to claim 3, characterized in that, The upper flange (21) and lower flange (22) of the double flange arch breaking device (2) are rigidly connected by three sets of scrapers (23) evenly distributed at 120°.

10. The silo uniform feeding device based on discrete element optimization according to claim 9, characterized in that, The scraper blades (23) are provided with reinforcing ribs (24).

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