Online measurement method and device for thickness of sedimentary bed layer of mining thickener

Abstract

The invention discloses an online measurement method and device for the thickness of a sedimentary bed layer of a mining thickener, and aims to solve the problem of inaccurate measurement caused by the fact that an existing ultrasonic wave, optical or pressure method is easily interfered by foam, turbidity, scaling and concentration gradual change. The device comprises an upper computer, a controller, a servo motor, a tension sensor, a meter counter and a special measuring balance weight. The counter weight is made of a hydrophobic anti-scaling material, and the density is calibrated through experiments, so that the counter weight is ensured not to sink when lightly touching the surface of the deposition bed. During measurement, the servo motor accurately lowers the rope, the controller monitors the tension change in real time, the bed is judged to be contacted when the tension suddenly changes, and the thickness of the bed is calculated in combination with data of the meter counter. The device is not influenced by bubbles, medicaments and suspended solids, has self-diagnosis and alarm functions, is high in measurement precision and small in maintenance amount, can realize real-time monitoring and intelligent regulation and control of the running state of the thickener, effectively prevents rake pressing accidents, and optimizes underflow discharge and flocculant addition.

Description

Technical Field

[0001] This invention relates to the field of online measurement technology of thickener bed thickness, and in particular to a method and apparatus for online measurement of the thickness of a mining thickener bed. Background Technology

[0002] Thickeners, as core equipment for solid-liquid separation in mining and metallurgical industries, directly affect underflow concentration control, rake accident prevention, and process optimization through the thickness of their sedimentation bed. Among related technologies, a mainstream bed thickness measurement system has been constructed through the coordinated operation of acoustic / ultrasonic, optical, and pressure / differential pressure methods. Specifically, this system covers the entire process from signal transmission to interface identification, including key aspects such as ultrasonic pulse reflection analysis, light intensity mutation detection, and hydrostatic density estimation. With the development of industrial intelligence, traditional through-beam measurement methods have gradually revealed systemic defects such as strong dependence on media characteristics and poor environmental adaptability.

[0003] However, existing penetration-based measurement methods directly use the speed of sound propagation or sudden changes in light intensity as the basis for judgment, without considering the physical characteristics of the continuous and gradual changes in the concentration of the multi-layered media inside the thickener. This may lead to interface positioning errors (e.g., a 20cm deviation in the ultrasonic method, ΔH=H1-H2), high equipment maintenance costs (optical methods require weekly window cleaning), or data drift (pressure methods have a membrane blockage rate ≥50%). Specifically, ultrasonic interface meters are affected by the density of the medium (±15% error) and are easily affected by foam interference (signal-to-noise ratio decreases by 40%), optical methods have a resolution of only 5cm when the concentration gradient changes slightly, and pressure methods can only measure the average density (insufficient spatial resolution). These technical defects not only affect the real-time monitoring accuracy of bed thickness but may also lead to rake accidents (single losses of hundreds of thousands of yuan) and uncontrolled flocculant addition, severely restricting the improvement of thickener operating efficiency. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the technical problems in the related art.

[0005] Therefore, the first objective of this invention is to provide an online method for measuring the thickness of a sedimentation bed in a mining thickener.

[0006] Another objective of this invention is to provide an online measurement device for the thickness of a mineral thickener bed.

[0007] The third objective of this invention is to provide a computer device.

[0008] A fourth objective of this invention is to provide a non-transitory computer-readable storage medium.

[0009] To achieve the above objectives, a first aspect of the present invention provides a method for online measurement of the thickness of a sedimentation bed in a mining thickener, comprising: S1, Design the critical counterweight of the measuring counterweight according to the slurry settling characteristics, so that the counterweight remains non-penetrating when in contact with the upper layer of the sedimentation bed; S2, through the servo system, controls the precise lowering of the rope, calibrates the vertical height difference between the initial position of the dense machine wall and the counterweight, and establishes a benchmark functional relationship between tension and rope length; S3, real-time acquisition of cable tension data and meter data, detection of tension mutations based on the reference function, and determination of bed contact point position by mutation judgment of three consecutive pulse actions; S4 calculates the thickness of the deposited bed based on the difference between the bed contact point position and the initial calibration position, and dynamically adjusts the measurement position through the servo system to adapt to changes in bed thickness.

[0010] In one embodiment of the present invention, S1 includes: S11, based on slurry settling experiment data, using the formula Calculate the critical counterweight mass of the counterweight, where For transmission power, Let be the thickness of the i-th dielectric layer. For bandwidth, Signal-to-noise ratio; S12 uses hydrophobic materials to make the surface of the counterweight, so that the mass change caused by scaling is controlled within ±0.5%.

[0011] In one embodiment of the present invention, S3 includes: S31, by comparing the current tension in real time With reference function Difference value Determine mutations; S32, when three consecutive pulse actions correspond to All exceeded the preset threshold When the contact point is determined to be an effective bed contact point.

[0012] In one embodiment of the present invention, S4 includes: S41, according to formula Calculate the initial bed thickness, where To calibrate the height, For the first measurement of the contact point height; S42, lifted by a servo motor After the height, according to the formula Dynamically update the bed thickness, among which For the previous thickness measurement, This represents the current measured displacement difference.

[0013] To achieve the above objectives, a second aspect of the present invention provides an online measurement device for the thickness of a mineral thickener bed, comprising: The counterweight design module is used to design the critical counterweight of the counterweight based on the slurry settling characteristics, so that the counterweight remains non-penetrating when in contact with the upper layer of the sedimentation bed. The servo system control and reference function establishment module is used to control the precise lowering of the cable through the servo system, calibrate the vertical height difference between the initial position of the dense machine wall and the counterweight, and establish a reference function relationship between tension and cable length. The tension and meter counting data acquisition and change detection module is used to acquire cable tension data and meter counting data in real time, detect tension changes based on the reference function, and determine the position of the bed contact point by the change judgment of three consecutive pulse actions. The bed thickness calculation and dynamic adjustment module is used to calculate the deposition bed thickness based on the difference between the bed contact point position and the initial calibration position, and dynamically adjust the measurement position through the servo system to adapt to changes in bed thickness.

[0014] The present invention discloses an online measurement method and device for the thickness of a thickener bed in a mine, which can achieve high-precision and stable online measurement of the thickness of the thickener bed, effectively overcome the measurement error problems caused by changes in medium characteristics, suspended matter and bubble interference in the prior art, and significantly improve measurement reliability and maintenance convenience.

[0015] To achieve the above objectives, a third aspect of this application provides a computer device comprising a processor and a memory; wherein the processor runs a program corresponding to the executable program code stored in the memory to implement an online measurement method for the thickness of a mining thickener deposition bed as described in the first aspect embodiment.

[0016] To achieve the above objectives, the fourth aspect of this application provides a non-transitory computer-readable storage medium storing a computer program that, when executed by a processor, implements an online method for measuring the thickness of a mining thickener bed as described in the first aspect embodiment.

[0017] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0018] Figure 1 This is a flowchart of an online method for measuring the thickness of a sedimentation bed in a mining thickener according to an embodiment of the present invention; Figure 2This is a schematic diagram of slurry stratification in a thickener according to an embodiment of the present invention; Figure 3 This is a schematic diagram of an online measurement device for deposition bed thickness according to an embodiment of the present invention; Figure 4 This is a structural diagram of an online measurement device for the thickness of a mineral thickener deposition bed according to an embodiment of the present invention; Figure 5 It is a computer device according to an embodiment of the present invention. Detailed Implementation

[0019] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0021] The following description, with reference to the accompanying drawings, describes an online method and apparatus for measuring the thickness of a sedimentation bed in a mining thickener, according to an embodiment of the present invention.

[0022] Example 1 Figure 1 This is a flowchart of an online measurement method for the thickness of a sedimentation bed in a mining thickener according to an embodiment of the present invention, such as... Figure 1 As shown, it includes: S1, Design the critical counterweight of the measuring counterweight according to the slurry settling characteristics, so that the counterweight remains non-penetrating when in contact with the upper layer of the sedimentation bed.

[0023] Specifically, in some implementations, the critical counterweight of the measuring counterweight is designed based on the settling characteristics of the slurry. The core of this step is to determine the density and mass parameters of the counterweight by combining experimental and theoretical analysis, so that it only contacts the surface of the bed when it settles to the upper layer of the sedimentation bed without penetrating or sinking, thereby ensuring the accuracy and repeatability of the measurement.

[0024] Furthermore, this step first requires a systematic study of the settling characteristics of the slurry, including key parameters such as particle size distribution, density distribution, viscosity, and settling velocity. Through laboratory simulation of the thickening process, the mechanical response characteristics of the slurry under different concentration gradients are obtained, particularly by modeling the relationship between contact force and settling depth.

[0025] Furthermore, the density of the counterweight is typically controlled at... Within this range, the specific values ​​are adjusted based on the average density of solid particles in the slurry and the compressibility of the bed. Its diameter is generally designed to be... This ensures sufficient contact area and measurement stability. Simultaneously, the surface of the counterweight is made of hydrophobic, anti-scaling materials (such as POE or polymer composites) to prevent scale buildup during long-term measurements from causing mass changes and affecting measurement accuracy.

[0026] Furthermore, this step is primarily performed during the initial installation and commissioning phase of the thickener. Tension calibration is conducted within the thickener in a bed-free state to establish a tension function. With cable length The corresponding relationship is as follows. In actual operation, the controller determines whether the counterweight is in contact with the bed by comparing the real-time tension with the calibration curve, thereby achieving non-penetrating measurement. This method is particularly suitable for mineral slurry environments with high concentration, high viscosity, and easy scaling, and can effectively avoid problems such as interface ambiguity and signal interference in traditional acoustic, optical, and pressure methods.

[0027] Furthermore, the technical advantage of this step lies in significantly improving the accuracy and stability of bed thickness measurement. By precisely controlling the counterweight, it generates only a slight tension change upon contact with the bed, rather than sinking or penetrating, thus avoiding errors caused by the interaction between the measuring tool and the bed. Simultaneously, this design enhances the system's adaptability to complex operating conditions, providing a reliable data foundation for subsequent automatic control, underflow regulation, and flocculant optimization.

[0028] Furthermore, S1 includes: S11, based on slurry settling experiment data, using the formula Calculate the critical counterweight mass of the counterweight, where For transmission power, Let be the thickness of the i-th dielectric layer. For bandwidth, This refers to the signal-to-noise ratio.

[0029] Specifically, in some implementations, based on slurry settling experimental data, the formula is used... The critical counterweight mass of the counterweight is calculated. This step, by combining experimental data with a signal transmission model, determines the force characteristics of the counterweight in different media layers, thereby designing a measuring device that can stably conform to the interface of the deposition bed.

[0030] Furthermore, the formula describes the first... Signal transmission loss in layered media With transmission power Medium thickness System bandwidth and signal-to-noise ratio The relationship between these factors is explained in this invention. This formula is used to simulate the resistance variations experienced by the counterweight in different media layers, thereby deriving its critical counterweight mass at the interface of the sedimentation bed. In practice, a slurry settling experiment must first be conducted under laboratory conditions to obtain physical parameters such as density, viscosity, and settling rate of each media layer, and then combined with the transmission power of the wireless communication module used in the actual measurement system. Operating bandwidth and signal-to-noise ratio Substitute the values ​​into the formula and perform iterative calculations to determine the minimum mass at which the counterweight can be stably attached without penetrating the bed.

[0031] Furthermore, transmission power Typically set Within range, bandwidth Generally Signal-to-noise ratio Based on the conductivity of the slurry and the interference situation, Adjust between these parameters. Medium thickness. As measured by experiments, it is usually It is updated in real time based on the dynamic changes of the bed layer.

[0032] Furthermore, this step is mainly used in the design and debugging phase of the counterweight during the initial operation of the thickener. By calculating the signal loss of different media layers, the counterweight mass can be optimized to ensure stable contact with the upper interface of the bed during actual measurement. This avoids the counterweight sinking into the bed due to being too heavy or failing to contact the bed due to being too light, thereby improving measurement accuracy and system stability.

[0033] Furthermore, the technical effect of this step is that, through the combination of theoretical modeling and experimental data, precise control of the counterweight mass of the balance weight in the measuring device is achieved, thereby ensuring that the weight is always at the upper interface of the bed during the measurement process, unaffected by factors such as foam, suspended matter, and concentration gradient, thus improving the robustness and reliability of the measurement system.

[0034] S12 uses hydrophobic materials to make the surface of the counterweight, so that the mass change caused by scaling is controlled within ±0.5%.

[0035] Specifically, in some implementations, hydrophobic materials (such as polyolefin elastomer POE) are used to fabricate the surface of the counterweight. This step effectively inhibits the adhesion and deposition of suspended particles in the slurry on the counterweight surface through the hydrophobic properties of the material surface, thereby avoiding changes in the counterweight mass caused by scaling and ensuring the stability and accuracy of the measurement system.

[0036] Furthermore, as the component in the measurement system that directly contacts the deposition bed, the mass change of the counterweight directly affects the reading of the tension sensor, and thus the calculated bed thickness. POE material possesses excellent hydrophobicity and chemical inertness, with a surface contact angle typically greater than 90°, significantly reducing the deposition of fine particles, colloids, or organic matter in the slurry on the surface. In addition, POE material exhibits good wear resistance and corrosion resistance, making it suitable for high-concentration, high-abrasion slurry environments. In actual processing, the outer layer of the counterweight can be covered with POE material through injection molding, spraying, or coating, with the thickness generally controlled between 1.5 and 3.0 mm to balance surface hydrophobicity and structural strength.

[0037] Furthermore, this invention requires that the mass variation of the counterweight be controlled within ±0.5%, which is achieved through material selection and surface treatment processes. During long-term operation, if scaling on the counterweight surface causes the mass deviation to exceed this threshold, the controller will trigger a calibration mechanism or alarm to ensure the reliability of the measurement data. In addition, the density of the counterweight needs to be designed according to the settling characteristics of the slurry, typically controlled between 1.2 and 1.8 g / cm³, to ensure that it only contacts the upper interface of the bed during measurement without settling.

[0038] Furthermore, this design is particularly suitable for the high-concentration, high-suspended-solids slurry environment in mining thickeners. Because thickeners contain multiple layers of gradually changing concentration zones, traditional measurement methods are susceptible to problems such as interface ambiguity and signal interference. However, this invention achieves high-precision, high-stability online measurement of the deposition bed thickness through a physical contact method using a counterweight, combined with closed-loop control of a servo motor and tension sensor.

[0039] Furthermore, the technical effect of this step is to significantly improve the long-term stability and data reliability of the measurement system. By using hydrophobic materials such as POE, the scaling rate on the surface of the heavy hammer is effectively reduced, thereby avoiding measurement errors caused by mass drift and ensuring that the accuracy of bed thickness calculation is within ±0.5%. This provides a solid data foundation for the automated control of the thickener, optimization of underflow discharge, and early warning of pressure rake.

[0040] S2 controls the precise lowering of the rope through a servo system, calibrates the vertical height difference between the initial position of the dense wall and the counterweight, and establishes a baseline functional relationship between tension and rope length.

[0041] Specifically, in some implementations, the precise lowering of the cable is controlled by a servo system to calibrate the vertical height difference between the initial position of the dense machine wall and the counterweight, and to establish a benchmark function relationship between tension and cable length. This step mainly relies on the high-precision position control capability of the servo motor and the real-time feedback mechanism of the tension sensor to achieve the initialization and benchmark modeling of the measurement system.

[0042] Furthermore, the servo system consists of a controller, a driver, and a servo motor. The controller sends commands to the driver through a preset logic program, and the driver converts these commands into the rotation angle and speed of the servo motor, thereby achieving precise control over the cable lowering length. There is a linear relationship between the servo motor's rotation angle and the cable's advance length, typically determined by a calibration function of pulse count and cable displacement. To describe, among which This refers to the number of pulses output by the servo motor. This represents the actual length of the rope lowered. The meter counter is used to record the cumulative displacement of the rope in real time, ensuring the traceability of the measurement process.

[0043] Furthermore, the calibration process first requires determining the vertical height difference between the thickener wall and the initial position of the counterweight. This value is typically obtained during the installation phase using a laser rangefinder or a high-precision displacement sensor, with the error controlled within ±1mm. Tension sensors are used to collect the tension values ​​of the rope at different lengths. ,in This indicates the length of the cable lowered. In the initial state without bed thickness, the controller collects and records the relationship between tension and cable length to establish a reference function. This is used to determine the point of sudden tension change in subsequent measurements.

[0044] Furthermore, this step is typically performed during the initial installation of the thickener or system restart. Calibration allows the system to adapt to different slurry physical properties, such as particle density and viscosity, ensuring that the counterweight does not sink into the bed or become unstable due to buoyancy. The counterweight is preferably made of hydrophobic, non-fouling plastic or POE material to reduce mass variations and measurement errors caused by surface deposits.

[0045] Furthermore, this step provides a reliable benchmark model for subsequent bed thickness measurement, enabling the controller to accurately identify the bed interface position by comparing real-time tension changes with the benchmark function. Simultaneously, the high-precision control of the servo system ensures the repeatability and stability of the measurement process, significantly improving measurement accuracy and system anti-interference capabilities, and solving problems associated with large concentration gradient changes and susceptibility to environmental interference in traditional acoustic, optical, and pressure methods.

[0046] S3, real-time acquisition of cable tension data and meter data, detection of tension mutations based on the reference function, and determination of bed contact point position by mutation judgment of three consecutive pulse actions.

[0047] Specifically, in some implementations, real-time acquisition of cable tension and meter readings is achieved through the coordinated operation of a tension sensor and a meter counter, combined with a pre-established baseline tension function. This enables high-precision identification of bed contact points, thereby deriving the bed thickness. .

[0048] Furthermore, a tension sensor is installed between the servo motor and the measuring counterweight to monitor the tension changes of the cable in real time during lowering or raising. The meter counter records the cable displacement via an encoder or photoelectric pulse, with an accuracy typically within ±0.1mm to ensure the reliability of the measurement data. The controller acquires the tension through high-speed sampling (sampling frequency recommended to be above 100Hz). With cable length Real-time data, and compared with benchmark functions Perform dynamic comparison. Benchmark function. It is the relationship between cable tension and length obtained through calibration experiments in a bedless state. It has a clear mathematical expression and is used to identify tension abrupt change points.

[0049] Furthermore, the controller employs a three-pulse judgment mechanism when detecting sudden tension changes; that is, when the tension change exceeds a set threshold in three consecutive samplings (e.g., ...), the controller will detect the sudden tension change. When a sudden change occurs, it is considered a valid mutation. This mechanism effectively filters out misjudgments caused by mechanical vibration or transient interference, improving the robustness of the measurement. Meanwhile, the pulse resolution of the servo motor is recommended to be no less than [specified value]. This is to ensure positional accuracy during the lowering and lifting process.

[0050] Furthermore, this step is applicable to online monitoring during continuous operation of the thickener. The controller automatically triggers the measurement process according to the set measurement cycle, controlling the lowering and retrieval of the cable via a servo motor to achieve non-invasive and undisturbed bed thickness measurement. The measuring balance weight is made of hydrophobic, anti-scaling material (such as POE or special plastics) to avoid changes in mass due to surface scaling, which could affect the accuracy of the tension function.

[0051] Furthermore, by using continuous pulse detection based on tension abrupt changes, the contact point between the bed and the slurry can be accurately identified, avoiding the misjudgment problems of traditional acoustic, optical, and pressure methods in the concentration gradient change region. Simultaneously, by combining metering data with a reference function, dynamic online measurement of bed thickness is achieved, providing reliable data support for thickener operation optimization, underflow control, and rake warning, demonstrating significant industrial practical value.

[0052] Furthermore, S3 includes: S31, by comparing the current tension in real time With reference function Difference value Determine mutations.

[0053] Specifically, in some implementations, this is achieved by comparing the current tension in real time. With reference function Difference value To determine the tension change, this step is based on the real-time acquisition of the tension on the measuring rope by the tension sensor, and combined with the pre-calibrated reference tension function, so as to identify the critical point of contact between the measuring balance weight and the bed.

[0054] Furthermore, a tension sensor is installed at the cable connection point between the servo motor and the measuring counterweight to monitor the tension changes of the cable in real time during lowering or lifting. Reference function This is a tension-rope length relationship curve obtained through multiple experiments and fitting when there is no bed or the bed thickness is zero. It reflects the tension distribution characteristics of the system under ideal conditions. Current tension In the actual measurement process, the tension sensor collects data in real time and feeds it back to the controller. The controller then calculates the difference between the two values. And set a threshold. ,when When this occurs, it is determined to be a sudden change in tension, meaning that the measuring balance weight has come into contact with the bed surface.

[0055] Furthermore, the key parameters involved in this step include: tension sampling frequency (recommended to be above 100Hz to ensure real-time performance), fitting accuracy of the benchmark tension function (usually using the least squares method for polynomial fitting, with the fitting error controlled within ±5%), and abrupt change detection threshold. (Set according to experimental data, generally 10%~15% of the maximum reference tension), and pulse control accuracy (the pulse resolution of the servo motor is 0.1mm / pulse, ensuring the measurement accuracy is within ±1mm).

[0056] Furthermore, this step is applicable to continuous online monitoring of bed thickness during thickener operation. The controller automatically triggers the measurement process according to a set measurement cycle (e.g., 1-5 minutes). A servo motor controls the cable lowering, and a tension sensor collects data in real time and compares it with a reference function to determine the bed interface position. This method is particularly suitable for high-concentration, high-suspended-solids, and easily scaling slurry environments, effectively avoiding misjudgments caused by media interference in optical and ultrasonic methods.

[0057] Furthermore, this step achieves high-precision and robust identification of the bed interface through mathematical modeling and comparison with real-time data. Its innovation lies in using changes in physical tension as the judgment criterion, rather than relying on the optical or acoustic properties of the medium, thus significantly improving the stability and accuracy of the measurement. In addition, this method supports dynamic adjustment of measurement parameters, such as threshold, measurement cycle, and pulse step size, enhancing the system's adaptability under different operating conditions and providing reliable data support for the automated control and operational optimization of thickeners.

[0058] S32, when three consecutive pulse actions correspond to All exceeded the preset threshold When the contact point is determined to be an effective bed contact point.

[0059] Specifically, in some implementations, when three consecutive pulse actions correspond to All exceeded the preset threshold When the point is determined to be an effective bed contact point, this step is based on the real-time monitoring of the tension change of the balance weight during the settling process by the tension sensor, combined with the pulse control accuracy of the servo motor, so as to identify whether the balance weight has contacted the upper interface of the sedimentation bed.

[0060] Furthermore, this step utilizes the abrupt tension change caused by the density difference between the sedimentation bed and the overlying slurry. In the absence of a bed or with the bed not in contact, the counterweight settles freely in the slurry, experiencing tension... Depending on the length of the rope It exhibits a linear or near-linear change; however, when the counterweight contacts the bed, due to the bed's high density and low fluidity, the tension... It will suddenly increase in size, forming obvious... Peak value. The controller acquires tension data in real time and compares it with a pre-established... The function compares the results to determine whether contact has occurred.

[0061] Furthermore, the controller is preset with It is the tension mutation threshold obtained from experimental calibration, and is usually set to... The specific value depends on the density and viscosity of the slurry and the counterweight design of the balance weight. The setting of three consecutive pulse actions is to eliminate random errors or noise interference and ensure the reliability of the judgment. The cable displacement corresponding to each pulse action is typically... to The accuracy is determined by the stepping precision of the servo motor, for example, using... High-precision servo motors.

[0062] Furthermore, this step is typically performed periodically during the operation of the thickener, and the measurement frequency can be set to [value missing]. to The specific configuration is determined by the host computer based on process requirements. The controller controls the servo motor's lowering motion via a driver, while simultaneously recording the cable advance data from the meter counter. The bed thickness is then calculated by matching it with the tension abrupt change point. This judgment mechanism effectively avoids misjudgments caused by interference from foam, suspended matter, or bubbles, thus improving the stability and accuracy of the measurement.

[0063] Furthermore, the technical advantage of this step lies in achieving high-precision identification of bed contact points through the combined judgment of continuous pulse action and tension change, thereby ensuring the real-time performance and reliability of bed thickness measurement. Compared with existing acoustic, optical, or pressure measurement methods, this invention, through physical contact, is unaffected by environmental factors such as medium density, turbidity, and temperature, significantly improving the adaptability and anti-interference capability of the measurement system, and has promising prospects for industrial applications.

[0064] S4 calculates the thickness of the deposited bed based on the difference between the bed contact point position and the initial calibration position, and dynamically adjusts the measurement position through the servo system to adapt to changes in bed thickness.

[0065] Specifically, in some implementations, the thickness of the deposition bed is calculated based on the difference between the bed contact point position and the initial calibration position, and the measurement position is dynamically adjusted by a servo system to adapt to changes in bed thickness. This step, based on the combination of physical contact and tension feedback, achieves high-precision, real-time measurement of the deposition layer thickness inside the thickener.

[0066] Furthermore, the system first monitors the tension on the cable in real time using a tension sensor. Combined with the rope advance length recorded by the meter counter Establish the mapping relationship between tension and position. In the initial calibration stage, place the measuring counterweight at a position corresponding to the vertical height difference of the thickener wall. The tension-length baseline curve under no bed disturbance was recorded. During the measurement, the controller drove the servo motor to release the cable, causing the counterweight to fall vertically until it contacted the upper interface of the deposition bed. At this point, the tension sensor detected a sudden tension change, and the controller determined the contact point location accordingly. And calculate the bed thickness. This method, through physical contact rather than non-penetrating measurement, effectively avoids signal interference problems caused by medium concentration, foam, suspended matter, etc., that are present in acoustic and optical methods.

[0067] Furthermore, the control precision of servo motors is typically within... Within this range, the resolution of the tension sensor is... The meter counter's measurement error is less than 0.5%. The controller sets the measurement interval according to actual working conditions and dynamically adjusts the measurement position. This ensures the continuity and accuracy of contact measurements despite changes in bed thickness. During continuous measurement, if the tension suddenly increases, the cable is lowered further; if it suddenly decreases, it is raised in the opposite direction until the contact point is detected again, thus achieving... Dynamic compensation calculation.

[0068] Furthermore, this process is applicable to thickener systems in industries such as mining and metallurgy, especially in high-concentration, high-viscosity, and easily fouling slurry environments, where it exhibits significant anti-interference capabilities and long-term stability. Through closed-loop control of the servo system, the system can adapt to conditions of slow bed growth or periodic fluctuations, achieving continuous, automatic, and non-destructive thickness monitoring.

[0069] Furthermore, this step effectively solves the measurement error problem caused by changes in medium characteristics in existing technologies, improving the accuracy and reliability of bed thickness measurement. Simultaneously, by dynamically adjusting the measurement position, the system can adapt to real-time changes in bed thickness, providing precise data support for underflow control, flocculant addition optimization, and other aspects, thereby improving the overall operating efficiency and safety of the thickener.

[0070] Furthermore, S4 includes: S41, according to formula Calculate the initial bed thickness, where To calibrate the height, This is the first measurement of the contact point height.

[0071] Specifically, in some implementations, according to the formula The initial bed thickness is calculated using a technique based on the coordinated operation of a physical contact measurement principle and a servo control system. This step involves comparing the measured height with the initial thickness. Height of the first measurement contact point This allows for the determination of the initial thickness of the in-middle deposition bed. This provides benchmark data for subsequent dynamic monitoring and thickness change analysis.

[0072] Furthermore, the altitude was calibrated. When the thickener has no bed or the bed is in its initial state, a servo motor lowers the measuring balance weight to the vertical height difference position of the thickener wall (i.e., when the thickener has no bed or the bed is in its initial state). Figure 2 The distance between BC and the center is measured, and the cable length at this point is recorded by a meter counter as a reference value for system calibration. The initial measurement of the contact point height is then performed. After the controller issues a measurement command, the servo motor drives the cable to slowly descend, and the tension sensor monitors the cable tension changes in real time. When the measuring balance weight first contacts the upper layer of the sedimentation bed, due to the difference in physical properties between the bed and the upper slurry, the tension sensor detects a sudden change in tension. The controller determines the contact point position based on this and records the meter reading at this time. ,Right now Figure 2 AC distance.

[0073] Furthermore, the altitude was calibrated. This process is typically completed during the thickener installation and commissioning phase. Its accuracy depends on the positioning accuracy of the servo motor and the resolution of the meter counter. Generally, a millimeter-level resolution (e.g., ±1mm) is required to ensure measurement accuracy. The threshold for determining tension mutations needs to be preset based on the slurry characteristics and the counterweight mass. It is usually set to trigger a stop action when the tension change exceeds a reference value by 10%–15%, avoiding misjudgments or missed judgments.

[0074] Furthermore, this step is applicable during the initial startup of the thickener or after system recalibration, used to obtain the initial thickness of the bed. The measurement process is carried out during the operation of the thickener. The controller sets the measurement cycle (e.g., 1 min, 2 min, etc.) via the host computer and adjusts the measurement frequency and interval according to the actual operating conditions. The measuring balance weight is made of a hydrophobic, non-scaling material to prevent changes in mass due to surface scaling, which could affect the accuracy of tension judgment.

[0075] Furthermore, by directly acquiring the contact point height of the upper layer of the bed through physical contact, measurement errors caused by factors such as medium concentration, foam, and suspended matter, as in traditional acoustic or optical methods, are avoided. Simultaneously, since the measurement process does not depend on the optical or acoustic properties of the medium, it exhibits higher stability and adaptability, making it particularly suitable for high-concentration, high-turbidity slurry environments. Moreover, through the coordinated control of a servo motor and a tension sensor, high-precision, repeatable measurement operations are achieved, providing a reliable data foundation for subsequent analysis of bed thickness variations.

[0076] S42, lifted by a servo motor After the height, according to the formula Dynamically update the bed thickness, among which For the previous thickness measurement, This represents the current measured displacement difference.

[0077] Specifically, in some implementations, when the servo motor completes the initial measurement and raises the cable height... Afterward, the system enters the dynamic bed thickness update stage. This step utilizes precise position control of the servo motor and real-time feedback from the tension sensor, combined with the previous measurement results. Difference from the current measured displacement Using the formula This method enables online updating of bed thickness. Based on the physical properties of the deposition bed, it employs a non-penetrating measurement approach to ensure the stability and accuracy of the measurement results.

[0078] Furthermore, the servo motor receives commands from the controller via a driver and performs the cable lifting operation with a preset step accuracy (typically 0.1~0.5mm / pulse). Lifting height The standard setting is 50-100 mm, but the specific value can be adjusted according to the thickener's operating status, slurry settling rate, and system response time. The meter counter synchronously records the cable displacement changes, with a resolution of 0.01 mm and an accuracy class of ±0.05 mm, meeting the standard requirements of industrial online measurement systems. The tension sensor continuously monitors cable tension changes, with a range of 0-50 N and a sampling frequency of 100 Hz, capable of capturing sudden tension changes caused by the counterweight contacting the bed surface.

[0079] Furthermore, This indicates the vertical thickness of the bed determined in the previous measurement, and its value is stored by the controller and used as a reference for the current measurement. This represents the net displacement of the cable during the current measurement, whether it is descending or ascending. It is calculated based on the current meter reading. Rope position since last measurement The difference between them. The controller judges the tension change trend through logic. If the tension continues to increase, it is judged that the bed interface is in contact; if the tension decreases, it is judged that the interface has been detached, and a reverse action is required to reposition.

[0080] Furthermore, this step is applicable to periodic bed thickness monitoring during continuous operation of a thickener. The controller can set the measurement interval (e.g., 1-5 minutes) according to production needs and perform trend analysis based on historical data, providing real-time basis for adjusting process parameters such as underflow pump control and flocculant addition. This method is particularly suitable for high-concentration, high-viscosity, and easily scaling slurry environments, avoiding measurement distortion problems caused by media interference in traditional acoustic or optical methods.

[0081] Furthermore, this step utilizes high-precision control of the servo motor and tension function. Dynamic comparison enables non-penetrating identification of the bed interface, effectively solving measurement errors caused by density gradients, foam interference, and sensor fouling in existing technologies. Its technological advantages are reflected in improved measurement accuracy, enhanced system stability, reduced maintenance costs, and real-time support for process optimization, demonstrating significant industrial practical value.

[0082] The online measurement method for the deposition bed thickness of a mining thickener according to the present invention can accurately and stably measure the deposition bed thickness of the thickener, avoiding measurement errors caused by changes in medium concentration, pollution or signal interference in the prior art, and improving the reliability and automation level of the thickener operation control.

[0083] Example 2 A thickener operates continuously. Within the thickener, the slurry forms, from top to bottom, a clarification zone, a free settling zone, a transition zone, a compression zone, and a concentrate zone, as shown below. Figure 2 As shown, the operating status of the thickener directly affects the thickness of the layers in several zones; under poor operating conditions, no zones may exist. The thickness of the concentrate zone is the thickness of the thickener's sedimentation bed that we are concerned with. During thickener operation, the thickness of each layer changes. Except for a significant concentration difference between zones A and B, the concentration between zones B and C changes gradually without abrupt changes. Specifically, A is the clarification zone, B is the free settling zone, C is the transition zone, D is the compression zone, and E is the concentrate zone.

[0084] An online measurement system for the thickness of a sedimentation bed in a mining thickener, according to an embodiment of the present invention, comprises the following components: Figure 3 As shown, the system consists of seven parts: 1. Host computer; 2. Controller; 3. Driver; 4. Servo motor; 5. Tension sensor; 6. Measuring counter; 7. Measuring balance weight; 8. Thickener; and 9. Sediment layer. The host computer displays the measurement process, results, and parameter settings (measurement cycle, interval duration, etc.); the controller handles the measurement process logic, calculates bed thickness, and provides alarms for abnormalities; the driver and servo motor form a servo system, providing precise cable position control; the tension sensor detects cable tension in real time; the measuring counter obtains the cable advance; and the measuring balance weight is designed according to the slurry characteristics to ensure it does not sink into the sediment layer during measurement.

[0085] Furthermore, installation and calibration include: studying the settling characteristics of the slurry, determining the concentration range of the sedimentation layer, and then determining the density and size of the counterweight to ensure that the counterweight does not penetrate the sedimentation layer during its descent. The vertical height difference between the servo motor and the thickener wall is calibrated. Figure 3 Distance between BC and center. Initial position of the counterweight at the overflow nozzle (see...) Figure 3 D), meter counter cleared to 0. Obtain the relationship between tension and cable length F(x) when there is no bed thickness, and obtain the relationship between servo motor pulse and cable length L(p).

[0086] Further, the measurement includes: Initial measurement: Set the calibration height BC = H1. The controller issues a command to control the servo motor to lower the cable. The controller collects meter readings and tension data in real time and compares them with F(x). When a sudden tension change occurs, the controller issues a command to stop the servo motor and simultaneously acquires the meter reading H2, i.e. Figure 3 AC = H2. The bed thickness is ΔH = H1 - H2. After obtaining an accurate measurement, the controller locks the bed thickness ΔH and controls the servo motor to raise it by a height Δh. Subsequent measurements: Since the increase or decrease in bed thickness requires time accumulation, the controller can perform measurements at intervals of 1 minute, 2 minutes...5 minutes, etc. The specific parameters are set during debugging according to the actual production situation. When the controller issues a measurement command again, it controls the servo motor to lower the cable. The controller collects metering data and tension data in real time and compares them with F(x). When the servo motor moves for 3 consecutive pulses, the controller obtains a tension change. If the tension change increases, it continues to move; if the tension change decreases, the controller controls the servo motor to move in the opposite direction until another tension change occurs. The controller then issues a command to stop the servo motor and obtains the cable advance data ΔL = L current - L previous - Δh. The bed thickness is ΔH = ΔH previous + ΔL. The measurement is repeated cyclically.

[0087] The measurement method of this invention relies entirely on the physical properties of the deposition bed, ensuring that each measurement does not penetrate the bed. Prior to measurement, a counterweight is designed based on experimental determination of the necessary weights for penetration, ensuring that the counterweight just adheres to the upper layer of the bed during each measurement without sinking, thus guaranteeing measurement accuracy. The entire measurement process is unaffected by the concentration or turbidity of different zones within the thickener.

[0088] Example 3 To achieve the above embodiments, such as Figure 4 As shown, this embodiment also provides an online measurement device 10 for the thickness of a mining thickener bed, comprising: The counterweight design module 100 is used to design the critical counterweight of the counterweight according to the slurry settling characteristics, so that the counterweight remains non-penetrating when it contacts the upper layer of the sedimentation bed. The servo system control and reference function establishment module 200 is used to control the precise lowering of the rope through the servo system, calibrate the vertical height difference between the initial position of the dense machine wall and the counterweight, and establish a reference function relationship between tension and rope length. The tension and meter counting data acquisition and sudden change detection module 300 is used to acquire cable tension data and meter counting data in real time, detect tension sudden changes based on the reference function, and determine the position of the bed contact point by the sudden change judgment of three consecutive pulse actions. The bed thickness calculation and dynamic adjustment module 400 is used to calculate the deposition bed thickness based on the difference between the bed contact point position and the initial calibration position, and dynamically adjust the measurement position through the servo system to adapt to changes in bed thickness.

[0089] Furthermore, the counterweight design module 100 is also used for: Based on slurry settling experiment data, using the formula Calculate the critical counterweight mass of the counterweight, where For transmission power, Let be the thickness of the i-th dielectric layer. For bandwidth, Signal-to-noise ratio; The surface of the counterweight is made of hydrophobic material, so that the mass change caused by scaling is controlled within ±0.5%.

[0090] Furthermore, the tension and metering data acquisition and mutation detection module 300 is also used for: By comparing the current tension in real time With reference function Difference value Determine mutations; When three consecutive pulse actions correspond to All exceeded the preset threshold When the contact point is determined to be an effective bed contact point.

[0091] Furthermore, the bed thickness calculation and dynamic adjustment module 400 is also used for: According to the formula Calculate the initial bed thickness, where To calibrate the height, For the first measurement of the contact point height; Lifting via servo motor After the height, according to the formula Dynamically update the bed thickness, among which For the previous thickness measurement, This represents the current measured displacement difference.

[0092] The present invention discloses an online measurement device for the thickness of a thickener bed in a mine, which can achieve high-precision and stable online measurement of the thickness of the thickener bed, effectively overcoming the measurement error problems caused by changes in medium characteristics, suspended matter and bubble interference in the prior art, and significantly improving measurement reliability and maintenance convenience.

[0093] Example 4 To implement the methods of the above embodiments, the present invention also provides a computer device, such as... Figure 5As shown, the computer device 600 includes a memory 601 and a processor 602; wherein, the processor 602 reads the executable program code stored in the memory 601 to run a program corresponding to the executable program code, so as to implement the various steps of the online measurement method for the thickness of a mining thickener sedimentation bed described above.

[0094] Example 5 To implement the above embodiments, this application also proposes a non-transitory computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements an online measurement method for the thickness of a mining thickener deposition bed as described in the foregoing embodiments.

[0095] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0096] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

Claims

1. A method for online measurement of the thickness of a sedimentation bed in a mining thickener, characterized in that, include: S1, Design the critical counterweight of the measuring counterweight according to the slurry settling characteristics, so that the counterweight remains non-penetrating when in contact with the upper layer of the sedimentation bed; S2, through the servo system, controls the precise lowering of the rope, calibrates the vertical height difference between the initial position of the dense machine wall and the counterweight, and establishes a benchmark functional relationship between tension and rope length; S3, real-time acquisition of cable tension data and meter data, detection of tension mutations based on the reference function, and determination of bed contact point position by mutation judgment of three consecutive pulse actions; S4 calculates the thickness of the deposited bed based on the difference between the bed contact point position and the initial calibration position, and dynamically adjusts the measurement position through the servo system to adapt to changes in bed thickness.

2. The method as described in claim 1, characterized in that, S1 includes: S11, based on slurry settling experiment data, using the formula Calculate the critical counterweight mass of the counterweight, where For transmission power, Let be the thickness of the i-th dielectric layer. For bandwidth, Signal-to-noise ratio; S12 uses hydrophobic materials to make the surface of the counterweight, so that the mass change caused by scaling is controlled within ±0.5%.

3. The method as described in claim 1, characterized in that, The S3 includes: S31, by comparing the current tension in real time With reference function Difference value Determine mutations; S32, when three consecutive pulse actions correspond to All exceeded the preset threshold When the contact point is determined to be an effective bed contact point.

4. The method as described in claim 1, characterized in that, The S4 includes: S41, according to formula Calculate the initial bed thickness, where To calibrate the height, For the first measurement of the contact point height; S42, lifted by a servo motor After the height, according to the formula Dynamically update the bed thickness, among which For the previous thickness measurement, This represents the current measured displacement difference.

5. An online measurement device for the thickness of a sedimentation bed in a mining thickener, characterized in that, include: The counterweight design module is used to design the critical counterweight of the counterweight based on the slurry settling characteristics, so that the counterweight remains non-penetrating when in contact with the upper layer of the sedimentation bed. The servo system control and reference function establishment module is used to control the precise lowering of the cable through the servo system, calibrate the vertical height difference between the initial position of the dense machine wall and the counterweight, and establish a reference function relationship between tension and cable length. The tension and meter counting data acquisition and change detection module is used to acquire cable tension data and meter counting data in real time, detect tension changes based on the reference function, and determine the position of the bed contact point by the change judgment of three consecutive pulse actions. The bed thickness calculation and dynamic adjustment module is used to calculate the deposition bed thickness based on the difference between the bed contact point position and the initial calibration position, and dynamically adjust the measurement position through the servo system to adapt to changes in bed thickness.

6. The apparatus as claimed in claim 5, characterized in that, The counterweight design module is also used for: Based on slurry settling experiment data, using the formula Calculate the critical counterweight mass of the counterweight, where For transmission power, Let be the thickness of the i-th dielectric layer. For bandwidth, Signal-to-noise ratio; The surface of the counterweight is made of hydrophobic material, so that the mass change caused by scaling is controlled within ±0.5%.

7. The apparatus as claimed in claim 5, characterized in that, The tension and metering data acquisition and abrupt change detection module is also used for: By comparing the current tension in real time With reference function Difference value Determine mutations; When three consecutive pulse actions correspond to All exceeded the preset threshold When the contact point is determined to be an effective bed contact point.

8. The apparatus as claimed in claim 5, characterized in that, The bed thickness calculation and dynamic adjustment module is also used for: According to the formula Calculate the initial bed thickness, where To calibrate the height, For the first measurement of the contact point height; Lifting via servo motor After the height, according to the formula Dynamically update the bed thickness, among which For the previous thickness measurement, This represents the current measured displacement difference.

9. A computer device, characterized in that, Including processor and memory; The processor reads executable program code stored in the memory to run a program corresponding to the executable program code, so as to implement the online measurement method for the deposition bed thickness of a mining thickener as described in any one of claims 1-4.

10. A non-transitory computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by the processor, the program implements an online measurement method for the thickness of a mining thickener deposition bed as described in any one of claims 1-4.

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