A fixed-crusher material self-adaptive processing method

Abstract

The application provides a fixed crusher material self-adaptive processing method, comprising: collecting powder particle images from the discharge flow of the fixed crusher, identifying the boundary features of the powder region and the overall particle region in the images, and extracting the proportion of the powder region in the total discharge area as the discharge powder content; comparing the discharge powder content with the powder control line meeting the process requirements, identifying the exceeding value of the powder content exceeding the control line as the powder exceeding amplitude, and extracting the difference value of the powder content collected continuously twice as the powder generation rate; and adjusting the impact strength of the rotor blade corresponding to the concentrated position of the brittle material according to the rotor blade number and the impact strength reduction amplitude, identifying the rotation frequency reduction amount corresponding to the adjusted impact strength, and obtaining a rotor operation setting scheme.

Description

Technical Field

[0001] This invention relates to the field of information technology, and in particular to an adaptive material handling method for a stationary crusher. Background Technology

[0002] In industrial production, the material handling technology of stationary crushers is a crucial link in ensuring production efficiency and product quality. Its core lies in how to efficiently and accurately crush materials with different properties to meet subsequent processing needs. Research in this area directly relates to resource utilization and production costs, and is of key significance to the sustainable development of the manufacturing industry. The operating performance of crushers not only affects the particle size distribution of materials but is also closely related to energy consumption, equipment lifespan, and many other aspects, thus becoming a key direction for industrial technological innovation. However, current methods often struggle to cope with the complex challenges posed by the differences in material properties when processing mixed materials. Theoretically, materials with higher brittleness require fewer crushing cycles and consume less energy. However, when brittle and tough materials are fed together, the crushing process is prone to getting out of control, leading to over-crushing of fragile materials while tough materials may not achieve the desired crushing effect. This imbalance not only reduces the quality of the output but also increases energy consumption and equipment wear. The root of the problem lies in the crushing system's lack of precise perception and targeted adjustment capabilities for dynamic changes in materials, making it difficult to achieve differentiated processing of different materials under complex operating conditions. More importantly, it lies in how to effectively control the core factor of material crushing depth during the crushing process. The crushing depth directly determines the final particle size distribution of the material. If it cannot be adjusted in real time according to the material properties, brittle materials will be over-crushed during multiple impacts, forming a large amount of fine powder. This fine powder will further affect the material flow within the crushing chamber and the operating efficiency of the equipment. For example, when processing a mixture of limestone and rubber, limestone, as a brittle material, should ideally be crushed with fewer impacts. However, because rubber is tough and requires stronger impact force, the limestone is often ground into excessively fine powder due to the accompanying effect. This powder not only reduces the product value but may also clog the equipment, affecting the overall production process. Therefore, how to accurately control the crushing depth of brittle materials during the crushing process of mixed materials, avoiding over-crushing, while also considering the crushing requirements of tough materials, has become a key issue in the adaptive material handling of stationary crushers. Solving this problem will directly affect the improvement of output quality and the optimization of production efficiency. Summary of the Invention

[0003] This invention provides a method for adaptive material handling in a fixed crusher, mainly comprising: Identify the boundary features between the powder region and the overall particle region in the powder particle image of the discharge flow of a fixed crusher, and extract the proportion of the powder region to the total discharge area as the discharge powder content. The powder content of the output is compared with the powder control line that meets the process requirements. The excess value of the powder content exceeding the control line is identified as the powder excess range. The difference in powder content collected from two consecutive times is extracted as the powder generation rate. Obtain the suspended particle concentration values ​​of each monitoring area in the crushing chamber, obtain the brittleness index of the feed material from the material detection, assess the synchronicity between the increase in suspended concentration and the powder generation rate in areas where the suspended concentration exceeds the preset concentration threshold, and mark the areas where the concentration and rate increase synchronously as areas where the impact strength needs to be adjusted. Obtain the material accumulation thickness at each location in the crushing chamber within the area where the impact strength needs to be adjusted. Combine the brittleness index of the material at each location to determine the concentration location of brittle material and the proportion of excessive accumulation. Evaluate the reduction in impact strength based on the proportion of excessive accumulation and the extent of excessive powder. The impact intensity of the blades at the location of concentrated brittle material is adjusted according to the rotor blade number and the reduction in impact intensity. The amount of reduction in rotational frequency corresponding to the adjusted impact intensity is identified to obtain the rotor operation setting scheme. The rotor operation setting scheme is applied to the stationary crusher to monitor the output particle size distribution, identify the proportion of particles in each particle size range, and evaluate the deviation between the proportion of each particle size range and the target distribution ratio required by the process. If the deviation exceeds the allowable range, the output powder content is re-collected for adjustment. If the deviation is within the allowable range, the current rotor operation setting scheme is maintained and the output particle size distribution is continuously monitored.

[0004] Furthermore, the step of identifying the boundary features between the powder region and the overall particle region in the powder particle image of the fixed crusher discharge flow, and extracting the proportion of the powder region to the total discharge area as the discharge powder content, includes: A high-speed camera is installed below the discharge port of a fixed crusher to capture continuous frame images of the material flow process. The captured images are converted to grayscale, and histogram equalization is used to enhance the contrast between powder particles and larger particles, resulting in an enhanced grayscale image. An adaptive threshold segmentation method is applied to the enhanced grayscale image. The segmentation threshold is calculated based on the local pixel grayscale mean, and powder regions with particle sizes smaller than a preset particle size threshold are identified. Morphological closing operations are used to fill the voids inside the powder regions, resulting in a filled powder connected region. The total number of pixels in the filled powder connected region is counted. Binarization is used to identify all regions in the image containing particulate material as effective particle regions. The total number of pixels in the effective particle regions is counted, and the ratio of the total number of pixels in the powder connected region to the total number of pixels in the effective particle regions is calculated to obtain the percentage of powder content in the discharge.

[0005] Furthermore, the step of comparing the output powder content with the powder control line that meets the process requirements, identifying the excess value of the powder content exceeding the control line as the powder excess range, and extracting the difference in powder content from two consecutive collections as the powder generation rate includes: Obtain the current percentage of powder content in the output material and the preset powder control threshold. Calculate the difference between the powder content exceeding the control threshold and record this difference as the powder exceedance range. Store the powder content data at the current moment in the monitoring record. Extract the powder content at the current moment and the powder content at the previous acquisition moment from the monitoring record. Calculate the difference between the powder content at the current moment and the powder content at the previous acquisition moment. Obtain the timestamp difference between the two acquisition moments as the time interval. Divide the powder content difference by the time interval to obtain the powder generation rate.

[0006] Furthermore, the process of acquiring the suspended particle concentration values ​​in each monitoring area within the crushing chamber, assessing the synchronicity between the increase in suspended concentration and the powder generation rate in areas where the suspended concentration exceeds a preset concentration threshold, and marking areas where the concentration and rate increase synchronously as areas where the impact intensity needs adjustment includes: The concentration of suspended particles in each monitoring area is continuously collected by laser scattering sensors arranged in the crushing chamber. The brittleness index of the feed material is obtained from the material hardness testing device at the feed inlet. The corresponding concentration threshold is found in a pre-established brittleness-concentration mapping table based on the brittleness index. The monitoring area where the concentration of suspended particles exceeds the concentration threshold is identified. The difference between the concentration value of the current moment and the concentration value of the previous moment in the area is calculated as the concentration rise rate. The concentration rise rates of multiple consecutive moments are combined into a concentration change time series. The concentration change time series is extracted to obtain the rate time series of powder generation rate formed at the same moment. The Pearson correlation coefficient is used to calculate the correlation between the values ​​of corresponding moments in the two time series to obtain the correlation value. The monitoring area with the correlation value greater than the preset synchronization threshold is marked as the impact intensity adjustment area. The spatial coordinates of the area and the corresponding concentration excess ratio are recorded. The position coordinates of all impact intensity adjustment areas are summarized to obtain the impact intensity adjustment area distribution map.

[0007] Furthermore, the material accumulation thickness at each location within the crushing chamber of the area to be adjusted for impact strength is obtained. Combined with the brittleness index of the material at each location, the concentrated location of brittle material and the proportion exceeding the accumulation limit are determined. The reduction in impact strength is evaluated based on the proportion exceeding the accumulation limit and the extent of powder exceeding the limit, including: The impact intensity adjustment area is scanned by an ultrasonic ranging sensor array within the crushing chamber, acquiring distance data from each measuring point to the material surface. The material accumulation thickness is calculated by subtracting the measured distance from the known distance from the sensor to the bottom plate of the crushing chamber, yielding accumulation thickness distribution data. The arithmetic mean of this accumulation thickness distribution data is calculated as the regional accumulation mean. Locations with accumulation thicknesses greater than the regional accumulation mean are identified. Concentration values ​​at these locations are extracted from suspended concentration monitoring data, and locations exceeding a concentration threshold are selected as evaluation locations. The material brittleness index at these evaluation locations is obtained, and locations with brittleness indices greater than a preset brittleness threshold are marked as brittle material concentration locations. The difference between the accumulation thickness at these brittle material concentration locations and the regional accumulation mean is calculated, and this difference is divided by the regional accumulation mean to obtain the excess accumulation ratio. The excess accumulation ratio and the powder excess amplitude are used as input parameters, and a weighted calculation method is employed to determine the impact intensity reduction magnitude.

[0008] Furthermore, the step of adjusting the impact intensity of the rotor blade based on the rotor blade number corresponding to the location of concentrated brittle material and the magnitude of the impact intensity reduction, identifying the reduction in rotational frequency corresponding to the adjusted impact intensity, and obtaining the rotor operation setting scheme includes: Based on the spatial coordinates of the concentrated location of brittle materials, a table corresponding to the location and the blade is consulted to determine the rotor blade number corresponding to that location. The current impact strength parameter value of that blade is obtained, and the adjusted impact strength value is calculated. The intensity-frequency mapping table is consulted using the adjusted impact strength value to identify the corresponding target rotational frequency value. The difference between the current rotational frequency and the target rotational frequency is calculated to obtain the reduction in rotational frequency. An operating parameter matrix is ​​constructed based on the reduction in rotational frequency and the rotor blade number. The adjustment parameters of each blade in the matrix are combined to form a control command sequence, resulting in the rotor operation setting scheme.

[0009] Furthermore, the rotor operation setting scheme is applied to the stationary crusher to monitor the output particle size distribution, identify the proportion of particles in each particle size range, and evaluate the deviation between the proportion of each particle size range and the target distribution ratio required by the process. If the deviation exceeds the allowable range, the output powder content is re-sampled for adjustment; if the deviation is within the allowable range, the current rotor operation setting scheme is maintained and the output particle size distribution is continuously monitored, including: The rotor operation settings are transmitted to the actuator of the fixed crusher. A vibrating screening device is used to screen the output material in real time, and the particle mass in each particle size range is counted. The percentage of the mass of each particle size range to the total output mass is calculated to obtain the actual particle size distribution data. The actual particle size distribution data is obtained, and the preset target particle size distribution data is read. The absolute value of the difference between the actual percentage and the target percentage of each particle size range is calculated. The deviation status is determined based on the absolute value of the difference. If the deviation exceeds the standard, the process returns to the powder content acquisition process to execute the adjustment process. If the deviation does not exceed the standard, the current rotor operation settings are maintained and particle size distribution data is continuously collected and monitored according to the preset cycle.

[0010] The technical solutions provided by the embodiments of the present invention may include the following beneficial effects: This invention discloses an adaptive material handling method for a fixed crusher, addressing business scenarios where excessive powder content, abnormal suspended particle concentration, and uneven material accumulation lead to deviations in the output particle size distribution during crushing. It integrates image analysis, concentration monitoring, and impact intensity adjustment to form a logically interconnected solution. First, the invention extracts the powder percentage in the output material through image recognition, compares it with the process control line to determine the extent of exceeding the limit, and calculates the powder generation rate. Simultaneously, it monitors the suspended particle concentration within the crushing chamber and, combined with the material's brittleness index, identifies areas requiring impact intensity adjustment. Then, it dynamically adjusts the rotor blade impact intensity based on the accumulation thickness and the proportion of exceeding the limit, optimizing the operating scheme. Finally, it monitors the output particle size distribution to ensure deviations remain within acceptable limits. This invention effectively controls powder content, optimizes output particle size distribution, and improves crushing efficiency and process stability through multi-dimensional data collaborative analysis and real-time adjustment. Attached Figure Description

[0011] Figure 1 This is a flowchart of a fixed crusher material adaptive processing method according to the present invention.

[0012] Figure 2 This is a schematic diagram of a fixed crusher material adaptive processing method according to the present invention. Detailed Implementation

[0013] To enable those skilled in the art to better understand the technical solutions in this specification, the technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this specification, and not all embodiments. Based on the embodiments in this specification, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this specification.

[0014] The self-adaptive material processing method using a fixed crusher described in this invention can be widely applied in the fields of solid waste resource utilization and infrastructure construction. The materials processed can be typical solid wastes (hereinafter referred to as "solid waste") such as reinforced concrete blocks generated from building demolition, mine tailings, and waste ore. By efficiently crushing and controlling the particle size of these solid wastes, their reduction, harmlessness, and resource utilization are achieved, thus constituting a complete solid waste treatment process. Furthermore, the recycled stone material obtained by this method, due to its good particle shape, reasonable gradation, and controllable powder content, can be directly used in water conservancy projects, such as dam filling, bridge foundations, embankment slope protection, and the preparation of hydraulic concrete aggregates, thereby realizing the high-value application of recycled solid waste materials in water conservancy projects.

[0015] like Figures 1-2 This embodiment of a fixed crusher material adaptive processing method may specifically include: Step S101: Collect powder particle images from the discharge flow of the fixed crusher, identify the boundary features between the powder area and the overall particle area in the image, and extract the proportion of the powder area to the total discharge area as the discharge powder content.

[0016] A high-speed camera is installed below the discharge port of a fixed crusher to capture continuous frame images of the material flow process. The captured images are converted to grayscale, and histogram equalization is used to enhance the contrast between powder particles and larger particles, resulting in an enhanced grayscale image. An adaptive threshold segmentation method is applied to the enhanced grayscale image. A segmentation threshold is calculated based on the local pixel grayscale mean and a preset offset to obtain initially segmented particle regions. The equivalent diameter D = 2*sqrt(A / pi) is calculated for each connected region, where A is the pixel area of ​​the connected region. If D is less than a preset particle size threshold of 1 mm, it is identified as a powder region. Morphological closing operations are used to fill the voids within the powder region, resulting in a filled powder connected region. The total number of pixels in the filled powder connected region is counted. Binarization is used to identify all regions containing particulate material in the image as effective particle regions. The total number of pixels in the effective particle regions is counted, and the ratio of the total number of pixels in the powder connected region to the total number of pixels in the effective particle region is calculated to obtain the percentage of powder content in the discharge.

[0017] For example, in one embodiment, a high-speed camera installed below the discharge port of the fixed crusher is an industrial CCD camera with a frame rate set to 120 frames per second to ensure that the instantaneous distribution of particulate material during the discharge flow is captured. The grayscale processing uses a weighted average method, converting the image according to the different weight coefficients of the red, green, and blue channels, where the weight of the red channel is 0.299, the weight of the green channel is 0.587, and the weight of the blue channel is 0.114, resulting in a single-channel grayscale image.

[0018] Specifically, the histogram equalization process first counts the number of pixels at each gray level in the grayscale image, calculates the cumulative distribution function, and then redistributes the original grayscale values ​​across the entire grayscale range using a grayscale mapping function. This process can stretch the grayscale difference between powder particles and larger broken particles, making smaller powder areas appear darker grayscale values ​​and larger particle areas appear brighter grayscale values, thereby enhancing the contrast between the two.

[0019] It should be noted that in the enhanced grayscale image, the grayscale value distribution of the powder particle region is more concentrated, which is beneficial for subsequent threshold segmentation processing.

[0020] Preferably, the adaptive threshold segmentation method employs the local mean method. For each pixel, an 11×11 pixel neighborhood window is selected, and the average grayscale value of all pixels within this neighborhood is calculated. This average value is then subtracted from a preset offset to obtain the segmentation threshold for the current pixel. When the pixel's grayscale value is below this threshold, it is determined to be a powder region; otherwise, it is determined to be a non-powder region. The preset offset is set according to the characteristics of the crushed material. For brittle materials such as limestone, the offset is set between 5 and 10; for mixtures containing rubber components, the offset is set between 10 and 15.

[0021] In one embodiment, the morphological closing operation uses a circular structuring element with a radius of 3 pixels. The closing operation first performs a dilation operation and then an erosion operation, which can fill small voids inside the powder region caused by uneven lighting or blurred particle edges, making the powder connectivity more complete.

[0022] For example, the identification of effective particle regions is achieved through binarization processing. All pixels in the enhanced grayscale image with grayscale values ​​greater than a background threshold are marked as particle material regions. The background threshold is automatically determined using the Otsu method. This eliminates background regions and equipment edge regions in the image, retaining only the regions that actually contain crushed material as effective particle regions.

[0023] Understandably, the powder content percentage is calculated through pixel statistics. The number of all pixels in the filled powder connected region is divided by the total number of pixels in the effective particle area, and the resulting ratio is the output powder content. This ratio accurately reflects the degree of fine powder generation during the current crushing process.

[0024] Step S102: Compare the output powder content with the powder control line that meets the process requirements, identify the excess value of powder content exceeding the control line as the powder excess range, and extract the difference in powder content collected from two consecutive times as the powder generation rate.

[0025] The system obtains the current percentage of powder content in the output material and a preset powder control threshold. It calculates the difference between the powder content exceeding the control threshold. If the difference is greater than zero, it records this difference as the powder exceedance range, and stores the current powder content data in the monitoring record. From the monitoring record, it extracts the current powder content and the powder content from the previous acquisition time, calculates the difference between the two, obtains the timestamp difference between the two acquisition times as the time interval, and divides the powder content difference by the time interval to obtain the powder generation rate.

[0026] For example, in one implementation, the powder control line threshold is preset according to the specific process requirements of the crushed material. For limestone crushing operations, the powder control line is typically set to 15% of the total output; when processing mixtures containing rubber components, the control line can be adjusted to 10%. The powder exceedance range is obtained through real-time calculation; when the powder content percentage is 18% and the control line is 15%, the exceedance range is 3 percentage points.

[0027] Specifically, the monitoring records are stored using a circular buffer structure, retaining data collected within the most recent 24 hours. Each record includes a timestamp of the collection time and the corresponding percentage of powder content. The time interval is calculated by the difference between the timestamps of two adjacent collections, typically set to a fixed interval of 5 minutes.

[0028] For example, the powder generation rate reflects the dynamic changes in fine powder production during the crushing process. If the powder content is 18% at the current moment and 16% at the previous moment, with a time interval of 5 minutes, then the powder generation rate is 0.4 percentage points per minute. This rate data directly reflects whether the crushing intensity is appropriate.

[0029] Step S103: Obtain the suspended particle concentration values ​​of each monitoring area in the crushing chamber, obtain the brittleness index of the feed material, identify areas where the suspended concentration exceeds the preset concentration threshold, evaluate the synchronicity between the increase in suspended concentration and the powder generation rate in the area, and mark the areas where the concentration and rate increase synchronously as areas where the impact strength needs to be adjusted.

[0030] The concentration of suspended particles in each monitoring area is continuously collected by laser scattering sensors arranged inside the crushing chamber. The brittleness index of the feed material is obtained from the material hardness testing device at the feed inlet. The corresponding concentration threshold is found in a pre-established brittleness-concentration mapping table based on the brittleness index. This mapping table is constructed based on historical crushing data of materials with different brittleness levels. The construction process involves collecting the brittleness index BI and the corresponding post-crushing concentration value C from historical data. BI is divided into three intervals: 0-20 (low brittleness), 21-50 (medium brittleness), and 51-100 (high brittleness). The average C for each interval is calculated as the threshold. The corresponding concentration threshold is then found in the pre-established brittleness-concentration mapping table based on the brittleness index. Monitoring areas where the suspended particle concentration exceeds the concentration threshold are identified. The difference between the current concentration value and the concentration value at the previous collection time in this area is calculated as the concentration increase rate. The concentration increase rates at multiple consecutive times are combined to form a concentration change time series. Extract the concentration change time series to obtain the rate time series of the powder generation rate formed at the same time point. The powder generation rate at multiple time points is continuously calculated and recorded to form this series. The Pearson correlation coefficient is used to calculate the correlation between the values ​​at corresponding time points in the two time series. If the correlation value is greater than a preset synchronization threshold, it is determined to be a synchronous increase. The monitored areas of synchronous increase are marked as impact intensity adjustment areas. The spatial coordinates of these areas and the corresponding concentration exceedance ratio are recorded. The location coordinates of all impact intensity adjustment areas are summarized to obtain an impact intensity adjustment area distribution map.

[0031] For example, in one embodiment, the laser scattering sensors within the crushing chamber are arranged in a multi-point array. Eight sensors are evenly distributed across each of the upper, middle, and lower levels of the crushing chamber, forming 24 monitoring points. The laser scattering sensors emit a red laser beam with a wavelength of 650 nanometers. When the laser passes through air containing suspended particles, the particles scatter the laser light, and the sensors calculate the suspended particle concentration by detecting changes in the intensity of the scattered light. The sensor's acquisition frequency is set to 10 times per second to ensure that rapid changes in suspended particle concentration can be captured. Each monitoring area covers approximately 0.5 cubic meters of space within the crushing chamber, with approximately 10% overlap between adjacent areas to avoid monitoring blind spots.

[0032] Specifically, the brittleness-concentration mapping table was established based on statistical analysis of a large amount of historical crushing data. The brittleness index is characterized by the ratio of Mohs hardness to compressive strength, ranging from 0.1 to 1.0, where 0.1 represents extremely tough materials such as rubber, and 1.0 represents extremely brittle materials such as glass. The mapping table divides the brittleness index into 10 levels, each corresponding to a concentration threshold. When the brittleness index is in the 0.7 to 0.8 range, the corresponding concentration threshold is set at 150 mg / m³; when the brittleness index is in the 0.5 to 0.6 range, the concentration threshold is increased to 200 mg / m³. This differentiated threshold setting reflects the differences in the characteristics of suspended particles generated during the crushing process of different brittle materials. Materials with higher brittleness are more prone to producing fine particles, and therefore have relatively lower corresponding concentration thresholds. The material hardness testing device is installed in the feed channel at the inlet, employing the principle of an indentation hardness tester. The test probe automatically presses into the material surface as it passes through, and the brittleness index is calculated based on the indentation depth and the applied load. The testing frequency is synchronized with the material feeding speed to ensure that each batch of material has corresponding brittleness index data.

[0033] Preferably, the concentration change time series is constructed using a sliding window method with a window length of 30 seconds, containing 300 sampling points. At each sampling moment, the difference between the current concentration value and the concentration value at the previous moment is calculated to obtain the instantaneous concentration change rate. By performing a moving average on all instantaneous change rates within 30 seconds, the influence of random fluctuations is eliminated, resulting in a smooth concentration increase curve. The time series data is stored in a circular buffer, maintaining the latest 5 minutes of historical data for easy time series analysis.

[0034] In one possible implementation, the calculation of the Pearson correlation coefficient involves standardizing two time series. First, the mean and standard deviation of the concentration change time series and the powder generation rate time series are calculated. Then, the values ​​in each series are standardized so that the mean is 0 and the standard deviation is 1. The two standardized series are then multiplied point-by-point. The sum of all products is divided by the series length minus 1 to obtain the correlation coefficient. The correlation coefficient ranges from -1 to 1. A value greater than 0.7 indicates a strong positive correlation, meaning the two series show highly consistent trends. A preset synchronization threshold is typically set to 0.75. When the calculated correlation coefficient exceeds this threshold, the suspended concentration change and powder generation in the monitored area are considered to be synchronous, indicating that the crushing intensity in that area directly affects powder generation. This synchronization determination method can accurately identify the key areas within the crushing chamber that contribute the most to powder generation, avoiding blind adjustments to all areas.

[0035] For example, the spatial coordinates adopt a three-dimensional coordinate system of the crushing chamber, with the center of the crushing chamber as the origin, the horizontal direction as the X and Y axes, and the vertical direction as the Z axis. The center point coordinates of each monitoring area are pre-calibrated and stored in the system. When an area is marked as an area where the impact intensity needs to be adjusted, the system extracts the coordinate information of that area and the corresponding concentration exceedance ratio. The concentration exceedance ratio is calculated by subtracting the threshold from the actual concentration value and then dividing by the threshold, reflecting the severity of the exceedance.

[0036] Understandably, the impact intensity distribution map is presented in the form of a heat map, projecting the three-dimensional space of the crushing chamber onto a two-dimensional plane. Different color depths in the map represent the degree of concentration exceeding the standard in each area; dark red indicates areas with severe exceedances that require priority adjustment; light yellow indicates areas with slight exceedances that can be adjusted moderately. The distribution map is updated every 30 seconds, reflecting the dynamic changes within the crushing chamber in real time.

[0037] For example, when processing a mixture of limestone and a small amount of rubber particles, the suspended concentration often increases first in the upper part of the crushing chamber near the feed inlet. When the concentration in this area rises from 100 mg / m³ to 180 mg / m³, and the powder generation rate increases from 0.3% to 0.5% per minute, the correlation coefficient reaches 0.82, exceeding the synchronization threshold of 0.75. This area is marked as an area for impact intensity adjustment, with spatial coordinates X: 0.3 m, Y: 0.2 m, Z: 1.5 m, and a concentration exceeding the standard by 20%. Furthermore, the information of all marked impact intensity adjustment areas is summarized to form an area adjustment priority list. The list is sorted from highest to lowest concentration exceeding the standard, and those with the same exceeding percentage are sorted from top to bottom by spatial location. This priority sorting mechanism ensures that crushing parameter adjustments can first target the most affected areas for optimization, improving adjustment efficiency.

[0038] Step S104: Obtain the material accumulation thickness at each location in the crushing chamber within the area to be adjusted for impact strength. Combine the brittleness index of the material at locations with accumulation thickness higher than the regional average and high suspension concentration to mark them as concentrated brittle material locations. Extract the proportion of accumulation thickness exceeding the average at these locations as the accumulation excess ratio. Evaluate the reduction in impact strength based on the accumulation excess ratio and the powder excess range.

[0039] An ultrasonic ranging sensor array within the crushing chamber scans the area to be adjusted for impact intensity, acquiring distance data from each measuring point to the material surface. The material accumulation thickness is calculated by subtracting the measured distance from the known distance from the sensor to the bottom plate of the crushing chamber, yielding accumulation thickness distribution data. The arithmetic mean of this accumulation thickness distribution data is calculated as the regional accumulation mean. Locations where the accumulation thickness exceeds 1.2 times the regional accumulation mean are identified. Concentration values ​​at these locations are extracted from the aforementioned suspended concentration monitoring data, and locations with concentration values ​​exceeding the concentration threshold are selected as locations to be evaluated. The brittleness index of the material at the location to be evaluated is obtained through material sampling and laboratory hardness testing. If the brittleness index is greater than 0.7, the material is classified as highly brittle, and this location is marked as a concentrated location of brittle material. The difference between the accumulation thickness at this location and the regional accumulation mean is calculated, and the difference is divided by the regional accumulation mean to obtain the proportion of accumulation exceeding the standard. Using the aforementioned excess accumulation ratio and the previously obtained excess powder magnitude as input parameters, the impact strength reduction value is determined by a weighted calculation method of multiplying the excess accumulation ratio by 0.6 and the excess powder magnitude by 0.4. The weights are based on the assessment that the accumulation contributes 60% to powder generation and the excess magnitude contributes 40% in the crushing test data.

[0040] For example, in one embodiment, the ultrasonic ranging sensor array is arranged in a matrix, with 16 measuring points (4×4) set within the area to be adjusted for impact intensity. Each measuring point is equipped with an ultrasonic sensor with a frequency of 40 kHz. The sensor emits ultrasonic pulse signals, which are reflected when they encounter the material surface. By measuring the time difference between the emitted and received echoes and combining this with the speed of sound in air, the distance from the sensor to the material surface is calculated. The vertical distance from the bottom plate of the crushing chamber to the sensor is calibrated during equipment installation. The material accumulation thickness at that measuring point is obtained by subtracting the calibrated distance from the measured distance. The accumulation thickness data from all measuring points form a 4×4 thickness matrix, reflecting the spatial distribution characteristics of the material accumulation within the area.

[0041] Specifically, the regional average accumulation value is calculated using an arithmetic mean method after removing outliers. First, the accumulation thickness data from 16 measuring points are sorted, and the maximum and minimum values ​​are removed. The arithmetic mean of the remaining 14 data points is then calculated as the regional average accumulation value. This method eliminates the influence of outliers caused by excessively large material particles or measurement errors at individual measuring points. When a location's accumulation thickness exceeds 1.2 times the regional average accumulation value, a point-by-point comparison is used, comparing the actual accumulation thickness at each measuring point with the average. When the accumulation thickness at a measuring point exceeds 1.2 times the average, material accumulation is considered to exist at that location. The concentration values ​​corresponding to these locations are extracted from the aforementioned suspended particle concentration monitoring data. This correspondence is achieved through spatial coordinate mapping, matching the position coordinates of the ultrasonic ranging sensor with the coordinates of the suspended particle concentration monitoring point. When the extracted concentration value exceeds the set concentration threshold for that region, it indicates that not only is there significant material accumulation at that location, but the concentration of suspended particles is also high, requiring close monitoring. A brittleness index of 0.7, used as a criterion for judging highly brittle materials, is an empirical value derived from statistical analysis of extensive crushing experiment data. When the brittleness index of a material exceeds 0.7, it is prone to generating a large number of fine particles upon impact. These particles not only increase the powder content but also form suspended particles that affect the crushing environment. The marking process for concentrated locations of brittle materials involves a comprehensive consideration of multiple criteria: material accumulation thickness exceeding the average, suspension concentration exceeding the threshold, and a brittleness index greater than 0.7. All three conditions must be met simultaneously for a location to be marked as a concentrated location of brittle materials. This multi-criteria mechanism ensures the accuracy of marking and avoids misjudgments that may arise from a single indicator. The calculation of the excess accumulation ratio reflects the degree of excess through specific numerical values. For example, if the accumulation thickness at a certain location is 150 mm and the regional average is 100 mm, then the excess accumulation ratio is 50%. This ratio directly reflects the severity of material accumulation at that location, providing a quantitative basis for subsequent impact strength adjustments.

[0042] Preferably, the weighting coefficients of 0.6 and 0.4 in the weighted calculation method are determined based on the contribution of each factor to powder generation during the crushing process. The excess accumulation ratio reflects the local material accumulation status, which has a direct impact on powder generation, and therefore is assigned a higher weight of 0.6. The excess powder content reflects the overall powder content in the output, which is important but relatively indirect, and is assigned a weight of 0.4. In the calculation, assuming an excess accumulation ratio of 30% and a excess powder content of 20%, the impact strength reduction is 30% × 0.6 + 20% × 0.4 = 26%. This 26% reduction means that the crushing impact force at the corresponding location needs to be reduced by 26% of the original set value.

[0043] In one possible implementation, the determination of the impact strength reduction also takes into account the specific type of material. For highly brittle materials like limestone, the calculated reduction can be directly applied. This reduction ensures that different material types can be properly crushed.

[0044] For example, in a practical application, a measuring point located at the 2nd row and 3rd column within an area where impact strength needs adjustment was detected. Its accumulated thickness was 180 mm, with an area average of 120 mm, indicating an excess accumulation rate of 50%. The suspended concentration at this location was 250 mg / m³, exceeding the threshold of 200 mg / m³. The material's brittleness index was 0.82, classifying it as highly brittle. Simultaneously, the excess powder content was 15%. Based on weighted calculations, the impact strength reduction was 50% × 0.6 + 15% × 0.4 = 36%.

[0045] It is understandable that the magnitude of the impact strength reduction will be converted into specific equipment control parameters in practical applications.

[0046] For example, a 36% reduction might correspond to a 108 rpm decrease in rotor speed or a 1.8 MPa decrease in hydraulic system pressure. This conversion from proportion to specific parameters is achieved through a pre-established parameter mapping table. Furthermore, the assessment results of the impact strength reduction will form an adjustment scheme matrix, where each element corresponds to a location of concentrated brittle material and its required adjustment range.

[0047] Step S105: Adjust the impact intensity of the blade according to the rotor blade number corresponding to the location of the brittle material concentration and the magnitude of the impact intensity reduction, identify the amount of reduction in rotational frequency corresponding to the adjusted impact intensity, and obtain the rotor operation setting scheme.

[0048] Based on the spatial coordinates of the concentrated location of brittle materials, a pre-established table of location-blade correspondence is consulted to determine the rotor blade number corresponding to that location. The current impact strength parameter value of that blade is obtained, and the current strength value is multiplied by one and the difference in impact strength reduction is subtracted to obtain the adjusted impact strength value. The adjusted impact strength value is then used to query a pre-defined strength-frequency mapping table to identify the corresponding target rotational frequency value. The current rotational frequency is obtained from the crusher control system, and the difference between the current rotational frequency and the target rotational frequency is calculated to obtain the rotational frequency reduction. An operating parameter matrix is ​​constructed based on the rotational frequency reduction and the rotor blade number. The adjustment parameters of each blade in the matrix are combined to form a unified control command sequence, resulting in the rotor operation setting scheme.

[0049] For example, in one implementation, the position-blade correspondence table is established based on the cylindrical coordinate system of the crushing chamber. The rotor within the crushing chamber is equipped with 12 blades, evenly distributed around the rotor circumference, with each blade spaced 30 degrees apart. The spatial coordinates of the concentrated location of brittle material are mapped to the corresponding blade number via angle values; for example, a position angle between 0 and 30 degrees corresponds to blade number 1, and 30 to 60 degrees corresponds to blade number 2. The current impact strength parameter value is read from the real-time database of the crusher controller, typically expressed in Newtons (N) as the impact force per unit area. Adjustment calculations use a proportional reduction method; if the current strength is 1000 N / cm², and the impact strength is reduced by 30%, the adjusted strength value is 700 N / cm².

[0050] Specifically, the intensity-frequency mapping table was obtained through experimental calibration. The experimental procedure involved gradually applying different impact intensities under controlled conditions, from 0 to the maximum value, at intervals of 5 Newtons per square centimeter. The corresponding rotor rotation frequency was measured and recorded, and this process was repeated multiple times to obtain the average value. The input data was the impact intensity value in Newtons per square centimeter, and the output was the frequency value in Hertz, accurate to 0.1 Hz. Intensity and rotation frequency exhibited an approximately quadratic relationship, i.e., f = k * sqrt(I), where f is the frequency, I is the intensity, and k is a calibration constant; a 30% decrease in intensity corresponds to an approximately 17% decrease in frequency. The mapping table uses an intensity interval of 5 Newtons per square centimeter, with the corresponding frequency value accurate to 0.1 Hz. Linear interpolation was used to process intermediate values ​​during table lookup to ensure the continuity of frequency adjustment. The current rotation frequency was acquired in real time by an encoder mounted on the rotor shaft, with a sampling frequency of 1000 Hz. The pulse signal output by the encoder was converted into the actual rotational speed value by a frequency counter. The difference between the target rotational frequency and the current frequency is the amount of frequency reduction required. This difference is directly used to set the control parameters of the frequency converter.

[0051] Preferably, the operating parameter matrix adopts a 12-row, 3-column structure, with each row corresponding to one blade, and the three columns storing the blade number, current frequency, and target frequency, respectively. For blades not marked as requiring adjustment, their target frequency remains the same as their current frequency. The parameters in the matrix are transmitted to the crusher's programmable logic controller via a serial communication protocol.

[0052] In one possible implementation, the control command sequence is arranged in blade number order, with each command containing a blade identification code, adjustment type flag, and target parameter value. The command sequence is packaged into data frames after undergoing cyclic redundancy check to ensure reliable transmission. The rotor operation settings are ultimately stored in a configuration file, containing timestamps, adjustment parameters, and execution status flags, facilitating the tracking and review of the effects of each adjustment.

[0053] Step S106: Apply the rotor operation setting scheme to the stationary crusher, monitor the discharge particle size distribution, identify the proportion of particles in each particle size range, and evaluate the deviation between the proportion of each particle size range and the target distribution ratio required by the process. If the deviation exceeds the allowable range, re-collect the discharge powder content for adjustment; if the deviation is within the allowable range, maintain the current rotor operation setting scheme and continuously monitor the discharge particle size distribution.

[0054] The rotor operation settings are transmitted to the actuator of the stationary crusher via a control interface. The vibrating screening device of the stationary crusher performs real-time screening of the output material, statistically analyzing the particle mass within each particle size range and calculating the percentage of each particle size range's mass to the total output mass, thus obtaining the actual particle size distribution data. This actual particle size distribution data is then acquired, and the preset target particle size distribution data is read from the crushing process specifications. The absolute value of the difference between the actual percentage and the target percentage for each particle size range is calculated. If the absolute value of the difference for any particle size range exceeds a preset deviation threshold, it is determined to be a deviation exceeding the standard. Based on this deviation exceeding the standard status, if it is determined to be a deviation exceeding the standard, the process returns to the powder content acquisition process to reacquire the output powder content and execute an adjustment process. If it is determined that the deviation does not exceed the standard, the current rotor operation settings are maintained, and particle size distribution data is continuously acquired and monitored according to a preset cycle.

[0055] For example, in one implementation, the control interface uses the industrial Ethernet communication protocol to transmit the rotor operation settings to the crusher's programmable logic controller (PLC) in the form of data packets. The data packets contain target rotational frequency parameters for each blade. Upon receiving the data, the controller adjusts the speed of the corresponding motor via a frequency converter. The actuator's response time after receiving the control command is within 200 milliseconds, ensuring real-time adjustment.

[0056] Specifically, the vibrating screening device employs a multi-layer screen structure with screen apertures of 10 mm, 5 mm, 2 mm, and 0.5 mm from top to bottom, forming four particle size ranges. A weighing sensor is installed beneath each screen layer to record the cumulative mass of particles within that range in real time. During screening, the vibration frequency is set to 50 Hz and the amplitude to 3 mm to ensure thorough material separation. The statistical period is set to collect data every 30 seconds, calculating the percentage of each particle size range's mass relative to the total output mass.

[0057] For example, particles larger than 10 mm account for 15%, 5-10 mm for 35%, 2-5 mm for 30%, 0.5-2 mm for 15%, and smaller than 0.5 mm for 5%. These percentages constitute the actual particle size distribution.

[0058] It should be noted that the target particle size distribution data is preset according to the intended use of the crushed material. For construction aggregate, the target distribution typically requires a particle size of 5-10 mm to account for more than 40%; for road base materials, the particle size of 2-5 mm needs to account for more than 35%. The deviation threshold is set considering the allowable fluctuation range in production, and is generally set to a deviation of no more than 5 percentage points for the proportion of each particle size range.

[0059] Preferably, the deviation determination adopts a multi-interval comprehensive evaluation method. It not only determines whether the deviation of a single particle size interval exceeds the standard, but also calculates the root mean square (RMS) value of the deviations across all intervals. When the RMS value exceeds a preset threshold or the deviation of any interval exceeds 5 percentage points, it is determined that adjustment is required. This determination method can simultaneously consider both local and overall deviations, improving the accuracy of adjustments.

[0060] In one possible implementation, when returning to the powder content acquisition process, the system automatically records the current operating parameters and deviation data, forming an adjustment log. When the adjustment process is re-executed, it refers to the historical adjustment records and uses an incremental adjustment method to avoid drastic parameter changes. Each adjustment is limited to within 20% of the original parameters.

[0061] For example, the monitoring cycle is dynamically adjusted according to the material type. When handling brittle materials, the monitoring cycle is shortened to once every 15 seconds; when handling tough materials, the monitoring cycle can be extended to once every 60 seconds. The monitoring data is displayed in real time through trend charts, and the operating status is determined to be stable when the particle size distribution is within the allowable range for three consecutive monitoring cycles.

[0062] The above are only some preferred embodiments of the present invention, but the present invention is not limited thereto, and many improvements and modifications can be made. Any improvements and modifications made based on the basic principles of the present invention should be considered to fall within the protection scope of the present invention.

Claims

1. A method for adaptive material handling in a fixed crusher, characterized in that, The method includes: The boundary features between the powder region and the overall particle region in the powder particle image of the fixed crusher discharge flow are identified, and the proportion of the powder region to the total discharge area is extracted as the discharge powder content. The discharge powder content is compared with the powder control line that meets the process requirements, and the excess value of the powder content exceeding the control line is identified as the powder excess range. The difference in powder content between two consecutive collections is extracted as the powder generation rate. The suspended particle concentration values ​​of each monitoring area in the crushing chamber are obtained, and the brittleness index of the feed material is obtained from the material detection. The synchronicity between the increase in suspended concentration and the powder generation rate in areas where the suspended concentration exceeds the preset concentration threshold is evaluated, and areas where the concentration and rate increase synchronously are marked as areas where the impact intensity needs to be adjusted. The material pile at each location in the crushing chamber within the areas where the impact intensity needs to be adjusted is obtained. Based on the thickness of the material and the brittleness index of the material at each location, the location of concentrated brittle material and the proportion of excessive accumulation are determined. The impact strength reduction is evaluated based on the proportion of excessive accumulation and the amount of excessive powder. The impact strength of the blades at the location of concentrated brittle material is adjusted according to the rotor blade number and the impact strength reduction. The reduction in rotational frequency corresponding to the adjusted impact strength is identified to obtain the rotor operation setting scheme. The rotor operation setting scheme is applied to the stationary crusher to monitor the discharge particle size distribution, identify the proportion of particles in each particle size range, and evaluate the deviation between the proportion of each particle size range and the target distribution ratio required by the process. If the deviation exceeds the allowable range, the discharge powder content is re-collected for adjustment. If the deviation is within the allowable range, the current rotor operation setting scheme is maintained and the discharge particle size distribution is continuously monitored.

2. The adaptive material handling method for a fixed crusher according to claim 1, characterized in that, The method of identifying the boundary features between the powder region and the overall particle region in the powder particle image of the fixed crusher discharge flow, and extracting the proportion of the powder region to the total discharge area as the discharge powder content, includes: A high-speed camera is installed below the discharge port of a fixed crusher to capture continuous frame images of the material flow process. The captured images are converted to grayscale, and histogram equalization is used to enhance the contrast between powder particles and larger particles, resulting in an enhanced grayscale image. An adaptive threshold segmentation method is applied to the enhanced grayscale image. The segmentation threshold is calculated based on the local pixel grayscale mean, and powder regions with particle sizes smaller than a preset particle size threshold are identified. Morphological closing operations are used to fill the voids inside the powder regions, resulting in a filled powder connected region. The total number of pixels in the filled powder connected region is counted. Binarization is used to identify all regions in the image containing particulate material as effective particle regions. The total number of pixels in the effective particle regions is counted, and the ratio of the total number of pixels in the powder connected region to the total number of pixels in the effective particle regions is calculated to obtain the percentage of powder content in the discharge.

3. The adaptive material handling method for a fixed crusher according to claim 1, characterized in that, The step of comparing the discharged powder content with the powder control line that meets the process requirements, identifying the excess value of the powder content exceeding the control line as the powder excess range, and extracting the difference in powder content from two consecutive collections as the powder generation rate includes: Obtain the current percentage of powder content in the output material and the preset powder control threshold. Calculate the difference between the powder content exceeding the control threshold and record this difference as the powder exceedance range. Store the powder content data at the current moment in the monitoring record. Extract the powder content at the current moment and the powder content at the previous acquisition moment from the monitoring record. Calculate the difference between the powder content at the current moment and the powder content at the previous acquisition moment. Obtain the timestamp difference between the two acquisition moments as the time interval. Divide the powder content difference by the time interval to obtain the powder generation rate.

4. The adaptive material handling method for a fixed crusher according to claim 1, characterized in that, The process involves acquiring the suspended particle concentration values ​​in each monitoring area within the crushing chamber, assessing the synchronicity between the increase in suspended concentration and the powder generation rate in areas where the suspended concentration exceeds a preset concentration threshold, and marking areas where the concentration and rate increase synchronously as areas where the impact intensity needs adjustment. The concentration of suspended particles in each monitoring area is continuously collected by laser scattering sensors arranged in the crushing chamber. The brittleness index of the feed material is obtained from the material hardness testing device at the feed inlet. The corresponding concentration threshold is found in a pre-established brittleness-concentration mapping table based on the brittleness index. The monitoring area where the concentration of suspended particles exceeds the concentration threshold is identified. The difference between the concentration value of the current moment and the concentration value of the previous moment in the area is calculated as the concentration rise rate. The concentration rise rates of multiple consecutive moments are combined into a concentration change time series. The concentration change time series is extracted to obtain the rate time series of powder generation rate formed at the same moment. The Pearson correlation coefficient is used to calculate the correlation between the values ​​of corresponding moments in the two time series to obtain the correlation value. The monitoring area with the correlation value greater than the preset synchronization threshold is marked as the impact intensity adjustment area. The spatial coordinates of the area and the corresponding concentration excess ratio are recorded. The position coordinates of all impact intensity adjustment areas are summarized to obtain the impact intensity adjustment area distribution map.

5. The adaptive material handling method for a stationary crusher according to claim 1, characterized in that, The material accumulation thickness at each location within the crushing chamber of the area to be adjusted for impact strength is obtained. Combined with the brittleness index of the material at each location, the concentrated location of brittle material and the proportion exceeding the accumulation limit are determined. The reduction in impact strength is assessed based on the proportion exceeding the accumulation limit and the extent of powder exceeding the limit, including: The impact intensity adjustment area is scanned by an ultrasonic ranging sensor array within the crushing chamber, acquiring distance data from each measuring point to the material surface. The material accumulation thickness is calculated by subtracting the measured distance from the known distance from the sensor to the bottom plate of the crushing chamber, yielding accumulation thickness distribution data. The arithmetic mean of this accumulation thickness distribution data is calculated as the regional accumulation mean. Locations with accumulation thicknesses greater than the regional accumulation mean are identified. Concentration values ​​at these locations are extracted from suspended concentration monitoring data, and locations exceeding a concentration threshold are selected as evaluation locations. The material brittleness index at these evaluation locations is obtained, and locations with brittleness indices greater than a preset brittleness threshold are marked as brittle material concentration locations. The difference between the accumulation thickness at these brittle material concentration locations and the regional accumulation mean is calculated, and this difference is divided by the regional accumulation mean to obtain the excess accumulation ratio. The excess accumulation ratio and the powder excess amplitude are used as input parameters, and a weighted calculation method is employed to determine the impact intensity reduction magnitude.

6. The adaptive material handling method for a stationary crusher according to claim 1, characterized in that, The step of adjusting the impact intensity of the rotor blade based on the rotor blade number corresponding to the location of concentrated brittle material and the magnitude of the impact intensity reduction, identifying the reduction in rotational frequency corresponding to the adjusted impact intensity, and obtaining the rotor operation setting scheme includes: Based on the spatial coordinates of the concentrated location of brittle materials, a table corresponding to the location and the blade is consulted to determine the rotor blade number corresponding to that location. The current impact strength parameter value of that blade is obtained, and the adjusted impact strength value is calculated. The intensity-frequency mapping table is consulted using the adjusted impact strength value to identify the corresponding target rotational frequency value. The difference between the current rotational frequency and the target rotational frequency is calculated to obtain the reduction in rotational frequency. An operating parameter matrix is ​​constructed based on the reduction in rotational frequency and the rotor blade number. The adjustment parameters of each blade in the matrix are combined to form a control command sequence, resulting in the rotor operation setting scheme.

7. The adaptive material handling method for a fixed crusher according to claim 1, characterized in that, The process involves applying the rotor operation setting scheme to a stationary crusher, monitoring the discharge particle size distribution, identifying the proportion of particles in each size range, evaluating the deviation between the proportion of each size range and the target distribution ratio required by the process, and if the deviation exceeds the allowable range, re-collecting the discharge powder content for adjustment; if the deviation is within the allowable range, maintaining the current rotor operation setting scheme and continuously monitoring the discharge particle size distribution, including: The rotor operation settings are transmitted to the actuator of the fixed crusher. A vibrating screening device is used to screen the output material in real time, and the particle mass in each particle size range is counted. The percentage of the mass of each particle size range to the total output mass is calculated to obtain the actual particle size distribution data. The actual particle size distribution data is obtained, and the preset target particle size distribution data is read. The absolute value of the difference between the actual percentage and the target percentage of each particle size range is calculated. The deviation status is determined based on the absolute value of the difference. If the deviation exceeds the standard, the process returns to the powder content acquisition process to execute the adjustment process. If the deviation does not exceed the standard, the current rotor operation settings are maintained and particle size distribution data is continuously collected and monitored according to the preset cycle.

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