Intelligent driving control system and method for crusher
By installing cutter shaft sensors and material detection modules inside the crusher, combined with load balancing algorithms and frequency converter control, the number and frequency of cutter shafts are dynamically adjusted, solving the problem of motor load fluctuation in traditional crushers and achieving a highly efficient and energy-saving crushing process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- GUANGZHOU LEI MENG MASCH EQUIP CO LTD
- Filing Date
- 2025-12-15
- Publication Date
- 2026-04-21
AI Technical Summary
The fixed number of cutter shafts in traditional crushers leads to fluctuations in motor load, resulting in energy waste and equipment wear. Furthermore, it is difficult to adapt to changes in material properties, affecting the crushing effect.
By installing first and second cutter shaft sensors inside the crusher, combined with load balancing algorithms and material characteristic detection, the number of cutter shafts and the output frequency of the frequency converter are dynamically adjusted to form a grouping strategy, thereby realizing the dynamic increase, decrease and allocation of cutter shafts, generating torque control parameters, and using the frequency converter for intelligent control.
It achieves efficient crushing of different materials, reduces energy consumption, improves crushing efficiency, reduces equipment wear, and enhances system stability and energy efficiency.
Smart Images
Figure CN121892274A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of crusher control technology, and in particular to an intelligent drive control system and method for crushers. Background Technology
[0002] In traditional crushers, if the number of cutter shafts is fixed, changes in material properties can easily lead to excessive or insufficient motor load. These drastic load fluctuations result in wasted energy and increased equipment wear. Furthermore, the traditional fixed-parameter control method in crushers is ill-suited to adapting to these drastic changes in cutter shaft load, easily causing incomplete or excessive crushing. This not only affects product quality, but also leads users to repeatedly start and stop the crusher until the desired degree of crushing is achieved. Frequent starts, stops, and load changes subject the motor to significant impacts, further increasing energy consumption and equipment wear.
[0003] Therefore, the technical problem of this application is how to achieve dynamic setting and allocation of the number of cutter shafts so that the crusher can effectively utilize braking energy, reduce energy loss, and improve crushing efficiency. Summary of the Invention
[0004] This application provides an intelligent drive control system and method for a crusher, which can support users to add or remove cutter shafts according to the different characteristics of the crushed material, and reduce and balance the output frequency of each frequency converter.
[0005] In a first aspect, embodiments of this application provide an intelligent drive control system for a crusher, including: The system includes a control module, a first cutter axis sensor, a second cutter axis sensor, a relay module, multiple frequency converters, multiple cutter axis motors, and cutter axes that are connected one-to-one with each cutter axis motor. The first cutter shaft sensor is located inside the primary crusher and is used to collect the first pulse signal and send it to the control module. The second cutter shaft sensor is located inside the secondary crusher and is used to collect the second pulse signal and send it to the control module. The relay module is connected to each frequency converter via contacts; each frequency converter is connected to each cutter shaft motor via contacts. The control module is used to determine the number of primary tool axes based on the first pulse signal; determine the number of secondary tool axes based on the second pulse signal; generate a grouping strategy based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes; generate grouping control commands based on the grouping strategy and send them to the relay module. The relay module is used to connect to the contacts of the frequency converter according to the group control command, and to send the group control command to the corresponding frequency converter so that the frequency converter connects to the contacts of the cutter shaft motor according to the group control command.
[0006] Furthermore, the system also includes a material detection module and a current detection module; The material detection module and the current detection module are respectively connected to the control module; The material detection module is located on the inner wall of the crusher and is used to detect material characteristic data and send it to the control module; The current detection module is connected to each cutter shaft motor to detect motor current data and send it to the control module; The control module is also used to generate torque control parameters based on material characteristic data and motor current data, and send them to the corresponding frequency converter through the relay module so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
[0007] Furthermore, the multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; the multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft, and the control module is specifically used for: If the number of primary cutter shafts is greater than or equal to the number of secondary cutter shafts, then the target number of secondary cutter shafts is used. The first frequency converter is connected to the target number of primary cutter shaft motors, and the second frequency converter is connected to each of the secondary cutter shaft motors. The redundant frequency converter is connected to the remaining primary cutter shaft motors. If the number of primary cutter shafts is less than the number of secondary cutter shafts, then the target number of primary cutter shafts is used. The first frequency converter is connected to each of the primary cutter shaft motors, and the second frequency converter is connected to the target number of secondary cutter shaft motors. The redundant frequency converter is connected to the remaining secondary cutter shaft motors.
[0008] Furthermore, the material characteristic data includes first hardness data, second hardness data, first humidity data, and second humidity data; the material detection module includes a first pressure sensor, a second pressure sensor, a first capacitive sensor, and a second capacitive sensor, which are respectively connected to the control module. The first pressure sensor is installed on the inner wall of the primary crusher to collect the first hardness data. The second pressure sensor is installed on the inner wall of the secondary crusher to collect the second hardness data; The first capacitive sensor is installed on the inner wall of the primary crusher to collect the first humidity data; The second capacitive sensor is located on the inner wall of the secondary crusher and is used to collect the second humidity data.
[0009] Furthermore, the motor current data includes primary motor current data and secondary motor current data; The control module is specifically used for: The first hardness data, the first humidity data, and the first motor current data are fuzzified to obtain the first fuzzy level data; the first fuzzy level data is matched with a preset control database to obtain the first torque threshold and the first reversal time parameter, which are then sent to the first frequency converter as the first torque control parameter. The second hardness data, second humidity data, and secondary motor current data are fuzzified to obtain second fuzzy level data. The second fuzzy level data is matched with a preset control database to obtain the second torque threshold and the second reversal time parameter, which are then sent to the second frequency converter as the second torque control parameter.
[0010] Furthermore, the control module is also used to acquire the speed data of each secondary cutter shaft motor and calculate the speed fluctuation; Determine whether the speed fluctuation exceeds the preset fluctuation threshold; if so, calculate the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm, and send them to the first frequency converter. The first frequency converter is used to control the speed of each primary cutter shaft motor according to the cutter shaft rotation control parameters.
[0011] Furthermore, the first frequency converter is also used to obtain the real-time torque of any one of the first-stage cutter shaft motors; Determine whether the real-time torque is greater than the first torque threshold. If so, switch to regenerative braking mode and start energy recovery to obtain DC bus voltage and capacitor voltage monitoring data; and determine whether to stop energy recovery based on DC bus voltage, capacitor voltage monitoring data and voltage comparison algorithm.
[0012] Furthermore, the first frequency converter is also used to input the stored electrical energy obtained from energy recovery into the DC / DC converter when starting the first-stage cutter shaft motor to obtain the release current data; to acquire the grid input current data, and to combine the release current data and the grid input current data to obtain the input peak current data; and to provide reactive power compensation using a bidirectional inverter based on the input peak current data.
[0013] Furthermore, the control module is also used to acquire historical operating condition data; Historical operating data includes motor operating parameters and material property variation curves; Calculate crushing efficiency based on historical operating data; The preset control database is updated based on historical operating data and corresponding crushing efficiency.
[0014] Furthermore, the control module is specifically used to extract the feature mapping relationship between historical operating condition data and crushing efficiency; Determine whether the interval since the last update of the preset control database has reached the preset period; If so, the preset control database is updated based on the self-learning algorithm and feature mapping relationship.
[0015] Secondly, embodiments of this application provide an intelligent drive control method for a crusher, applied to a control module in an intelligent drive control system for a crusher as described in any of the above embodiments, the method comprising: Acquire the first pulse signal from the first tool axis sensor and the second pulse signal from the second tool axis sensor; The number of primary tool shafts is determined based on the first pulse signal; The number of secondary cutter shafts is determined based on the second pulse signal; A grouping strategy is generated based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes. Group control commands are generated according to the grouping strategy and sent to the relay module, so that the relay module connects to the contacts of the frequency converter according to the group control commands, and the frequency converter connects to the contacts of the cutter shaft motor according to the group control commands.
[0016] Furthermore, the method also includes: Acquire material characteristic data detected by the material detection module; the material detection module is located on the inner wall of the crusher; Acquire motor current data detected by the current detection module; the current detection module is connected to each cutter shaft motor. Torque control parameters are generated based on material characteristic data and motor current data; and sent to the corresponding frequency converter through the relay module so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
[0017] Furthermore, the grouping strategy generated above based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes includes: Determine whether the number of primary tool shafts is greater than or equal to the number of secondary tool shafts; If so, then the number of secondary cutter shafts is taken as the target number, and the first frequency converter is connected to the target number of primary cutter shaft motors; Connect the second frequency converter to each of the secondary cutter shaft motors; Connect the redundant frequency converter to each of the remaining primary cutter shaft motors; Among them, the multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; the multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft; If not, then take the number of primary cutter shafts as the target number and connect the first frequency converter to each primary cutter shaft motor; Connect the second frequency converter to the target number of secondary cutter shaft motors; Connect the redundant frequency converter to each of the remaining secondary cutter shaft motors.
[0018] Furthermore, the material characteristic data includes first hardness data, second hardness data, first humidity data, and second humidity data; the motor current data includes first-stage motor current data and second-stage motor current data. The torque control parameters include a first torque control parameter and a second torque control parameter; The torque control parameters generated above based on material characteristic data and motor current data include: The first hardness data, the first humidity data, and the first motor current data are fuzzified to obtain the first fuzzy level data; the first fuzzy level data is matched with a preset control database to obtain the first torque threshold and the first reversal time parameter, which are then sent to the first frequency converter as the first torque control parameter. The second hardness data, second humidity data, and secondary motor current data are fuzzified to obtain second fuzzy level data. The second fuzzy level data is matched with a preset control database to obtain the second torque threshold and the second reversal time parameter, which are then sent to the second frequency converter as the second torque control parameter.
[0019] Furthermore, the method also includes: Obtain the speed data of each secondary cutter shaft motor and calculate the speed fluctuation; Determine whether the speed fluctuation exceeds a preset fluctuation threshold; if so, calculate the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm, and send them to the first frequency converter; so that the first frequency converter controls the speed of each primary cutter shaft motor according to the cutter shaft rotation control parameters.
[0020] Furthermore, the above calculation of the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm includes: The average speed change curve is calculated based on the speed data of each secondary cutter shaft motor; The average speed change curve is compared with the preset speed threshold to obtain the secondary speed deviation curve; Calculate the first-level speed adjustment curve based on the PID control algorithm and the second-level speed deviation curve; The primary speed adjustment curve is used as the control parameter for the cutter shaft rotation.
[0021] Furthermore, the method also includes: Acquire historical operating data; historical operating data includes motor operating parameters and material property change curves; Calculate the corresponding crushing efficiency based on historical operating data; The preset control database is updated based on historical operating data and corresponding crushing efficiency.
[0022] Furthermore, the above-mentioned updating of the preset control database based on historical operating data and corresponding crushing efficiency includes: Extract the feature mapping relationship between historical operating condition data and crushing efficiency; Determine whether the interval since the last update of the preset control database has reached the preset period; If so, the preset control database is updated based on the self-learning algorithm and feature mapping relationship.
[0023] Thirdly, embodiments of this application provide a computer device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it performs the steps of a crusher intelligent drive control method as described in any of the above embodiments.
[0024] Fourthly, embodiments of this application provide a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of a crusher intelligent drive control method as described in any of the above embodiments.
[0025] In summary, compared with the prior art, the beneficial effects of the technical solution provided in this application include at least the following: This application provides an intelligent drive control system for a crusher. Firstly, within a two-stage crusher, a first cutter shaft sensor located in the first-stage crusher detects the number of primary cutter shafts; a second cutter shaft sensor located in the second-stage crusher detects the number of secondary cutter shafts. Then, a load balancing algorithm and a grouping strategy are formed by allocating the number of cutter shafts to each frequency converter, controlling a specific number of cutter shafts for each type of crusher. This grouping strategy is implemented through contact connections between a control relay module, the frequency converter, and the cutter shaft motor. The system enables dynamic addition, reduction, and allocation of crusher cutter shafts, allowing users to add or remove cutter shafts based on the different characteristics of the crushed material, reducing and balancing the output frequency of each frequency converter, and maximizing energy savings while ensuring crushing performance. Attached Figure Description
[0026] Figure 1 This is a structural diagram of an intelligent drive control system for a crusher, provided as an exemplary embodiment of this application.
[0027] Figure 2 A flowchart illustrating an exemplary embodiment of this application provides a method for intelligent drive control of a crusher.
[0028] Figure 3 A flowchart illustrating the torque control parameter generation steps provided in an exemplary embodiment of this application.
[0029] Figure 4 A flowchart illustrating the steps for generating tool shaft rotation control parameters, provided as an exemplary embodiment of this application. Detailed Implementation
[0030] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.
[0031] Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0032] Please see Figure 1 This application provides an intelligent drive control system for a crusher, including a control module, a first cutter shaft sensor, a second cutter shaft sensor, a relay module, multiple frequency converters, multiple cutter shaft motors, and cutter shafts connected one-to-one with each cutter shaft motor. The multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; the multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft.
[0033] The first cutter shaft sensor is located inside the primary crusher and is used to collect the first pulse signal and send it to the control module.
[0034] The second cutter shaft sensor is located inside the secondary crusher and is used to collect the second pulse signal and send it to the control module.
[0035] Specifically, this application is an improvement on an electrically driven two-stage crusher. Therefore, the crusher is divided into a primary crusher and a secondary crusher. The material is first fed into the primary crusher and is initially crushed by the blades on each primary cutter shaft. Then it enters the secondary crusher and is further crushed by the blades on each secondary cutter shaft.
[0036] Both the first and second cutter shaft sensors are Hall effect sensors. After the user installs the cutter shaft blades, they start the crusher to rotate the cutter shaft. The Hall effect sensors can detect the pulse signals generated by the rotation of the magnets and send them to the control module.
[0037] The control module will count the first / second pulse signals using a high-speed counter of the programmable logic controller to determine the total number of pulses for each tool axis, i.e., the corresponding number of tool axes.
[0038] The relay module is connected to each frequency converter via contacts; each frequency converter is connected to each cutter shaft motor via contacts.
[0039] It should be noted that the aforementioned contacts are controllable switches in electronic devices. The controllable switch between the relay module and the frequency converter is controlled by the relay module, while the controllable switch between the frequency converter and the cutter shaft motor is controlled by the frequency converter.
[0040] The control module is used to determine the number of primary tool axes based on the first pulse signal; determine the number of secondary tool axes based on the second pulse signal; generate a grouping strategy based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes; generate grouping control commands based on the grouping strategy and send them to the relay module.
[0041] The control module is specifically used for the following: if the number of primary cutter shafts is greater than or equal to the number of secondary cutter shafts, then with the number of secondary cutter shafts as the target number, the first frequency converter is connected to the target number of primary cutter shaft motors, and the second frequency converter is connected to each of the secondary cutter shaft motors; the redundant frequency converter is connected to the remaining primary cutter shaft motors; if the number of primary cutter shafts is less than the number of secondary cutter shafts, then with the number of primary cutter shafts as the target number, the first frequency converter is connected to each of the primary cutter shaft motors, and the second frequency converter is connected to the target number of secondary cutter shaft motors; the redundant frequency converter is connected to the remaining secondary cutter shaft motors.
[0042] In another embodiment, multiple frequency converters can be divided into a main frequency converter group and a redundant frequency converter. The control module can also be used to start a target number of frequency converters in the main frequency converter group when the number of primary cutter shafts is greater than or equal to the number of secondary cutter shafts, with the number of secondary cutter shafts as the target number. Each frequency converter adopts a dual-drive method, connecting one primary cutter shaft motor and one secondary cutter shaft motor respectively; the extra, remaining primary cutter shaft motors are connected by the redundant frequency converter.
[0043] When the number of primary cutter shafts is less than the number of secondary cutter shafts, the target number of primary cutter shafts is used as the target number, and the target number of frequency converters in the main frequency converter group are started. Each frequency converter adopts a dual-drive method, connecting one primary cutter shaft motor and one secondary cutter shaft motor respectively; the extra, remaining secondary cutter shaft motors are connected by redundant frequency converters.
[0044] The relay module is used to connect to the contacts of the frequency converter according to the group control command, and to send the group control command to the corresponding frequency converter so that the frequency converter connects to the contacts of the cutter shaft motor according to the group control command.
[0045] Specifically, the relay module stores which output interface corresponds to which frequency converter. Therefore, when a closing signal is sent out through the output interface, the controllable switch receives the closing signal and closes the corresponding path, thus completing the connection with the corresponding frequency converter.
[0046] The process of connecting the frequency converter and each cutter shaft motor is similar.
[0047] The above embodiment provides an intelligent drive control system for a crusher. Firstly, within the two-stage crusher, a first cutter shaft sensor located in the first-stage crusher detects the number of first-stage cutter shafts; a second cutter shaft sensor located in the second-stage crusher detects the number of second-stage cutter shafts. Then, a load balancing algorithm and a grouping strategy are formed by allocating the number of cutter shafts to each frequency converter, controlling a specific number of cutter shafts for each type of crusher. This grouping strategy is implemented through contact connections between the control relay module, the frequency converter, and the cutter shaft motor. The system enables dynamic addition, reduction, and allocation of crusher cutter shafts, allowing users to add or remove cutter shafts based on the different characteristics of the crushed material, reducing and balancing the output frequency of each frequency converter, and maximizing energy savings while ensuring crushing performance.
[0048] In practice, when crushers process different materials, the material characteristics vary greatly, such as hardness, moisture content, and particle size, which leads to drastic fluctuations in the load on the cutter shaft during the crushing process. Traditional fixed parameter control methods are also difficult to adapt to such dynamic changes in material characteristics, and are also prone to insufficient or excessive crushing of materials.
[0049] Therefore, in some embodiments, the system further includes a material detection module and a current detection module.
[0050] The material detection module and the current detection module are respectively connected to the control module.
[0051] The material detection module is located on the inner wall of the crusher and is used to detect material characteristic data and send it to the control module.
[0052] The current detection module is connected to each cutter shaft motor to detect motor current data and send it to the control module.
[0053] The control module is also used to generate torque control parameters based on material characteristic data and motor current data, and send them to the corresponding frequency converter through the relay module so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
[0054] Specifically, the material characteristic data includes first hardness data, second hardness data, first humidity data, and second humidity data; the motor current data includes first-stage motor current data and second-stage motor current data; the material detection module includes a first pressure sensor, a second pressure sensor, a first capacitive sensor, and a second capacitive sensor, which are respectively connected to the control module.
[0055] The first pressure sensor is located on the inner wall of the primary crusher and is used to collect the first hardness data.
[0056] The second pressure sensor is located on the inner wall of the secondary crusher and is used to collect the second hardness data.
[0057] The first capacitive sensor is located on the inner wall of the primary crusher and is used to collect the first humidity data.
[0058] The second capacitive sensor is located on the inner wall of the secondary crusher and is used to collect the second humidity data.
[0059] The control module is specifically used for: The first hardness data, first humidity data, and first-stage motor current data are fuzzified to obtain first fuzzy level data. A preset control database is matched based on the first fuzzy level data to obtain a first torque threshold and a first reversal time parameter, which are then sent to the first frequency converter as first torque control parameters. The second hardness data, second humidity data, and second-stage motor current data are fuzzified to obtain second fuzzy level data. A preset control database is matched based on the second fuzzy level data to obtain a second torque threshold and a second reversal time parameter, which are then sent to the second frequency converter as second torque control parameters.
[0060] Specifically, the fuzzification process divides the hardness data, humidity data, and motor current data into low, medium, and high fuzziness levels, and outputs fuzzy level data; the preset control database contains torque control parameters set for different levels.
[0061] For example, the primary motor current data I=45A, the first pressure sensor detects the first hardness data H=82 (0-100 division), and the first capacitance sensor measures the first humidity data S=15, which are then input into the fuzzy controller. The fuzzy controller sets H≥70 as high hardness, S≤20 as low humidity, and I in the 40-50A range as medium current, triggering the preset rule: "When hardness is high and humidity is low, the first torque threshold is increased by 18% to 129% of the rated value, and the first reversal time parameter is extended by 8%."
[0062] If the detected second hardness data, second humidity data, and secondary motor current data are H=50, S=30, and I=45, respectively, the data is input into the fuzzy controller. The fuzzy levels are then determined using trigonometric membership functions: hardness H<40 is low, 40≤H≤70 is medium, and H>70 is high; humidity S<30 is low, 30≤S≤60 is medium, and S>60 is high; and current I<40A is low, 40A≤I≤60A is medium, and I>60A is high. Based on the preset control database, the conditions of "medium hardness, low humidity, and medium current" are matched, and the center-of-gravity method is used to calculate the second torque threshold K=1.15 (increased by 15%) and the second reversal time parameter T=1.05 (extended by 5%).
[0063] The first / second reversal time parameter is the duration for which the inverter controls the cutter shaft motor to reverse when it detects that the torque of the cutter shaft motor it controls exceeds the limit. Exceeding the torque limit means that the real-time torque of the cutter shaft motor exceeds the corresponding first / second torque threshold.
[0064] It is worth noting that if the above control module enables each frequency converter to connect to each cutter shaft motor in a dual-drive manner, then the first torque control parameter and the second torque control parameter here must be sent to each frequency converter separately.
[0065] The above embodiments adaptively generate torque thresholds and reversal time output parameters for each cutter shaft motor based on material effect data of materials at different stages of the crushing process and current conditions of the cutter shaft motor, thereby achieving a high-efficiency, energy-saving, and stable crushing process.
[0066] In some embodiments, the control module is further configured to acquire the speed data of each secondary cutter shaft motor and calculate the speed fluctuation; determine whether the speed fluctuation is greater than a preset fluctuation threshold; if so, calculate the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm, and send them to the first frequency converter.
[0067] The preset fluctuation threshold can be 5%. When the speed fluctuation is greater than 5%, it indicates that the material output from the primary crusher is not crushed evenly, which may be due to the primary cutter shaft motor not being synchronized. Therefore, it needs to be adjusted.
[0068] Specifically, the control module calculates the average speed change curve based on the speed data of each secondary cutter shaft motor; compares the average speed change curve with the preset speed threshold to obtain the secondary speed deviation curve; calculates the primary speed adjustment curve based on the PID control algorithm and the secondary speed deviation curve; and uses the primary speed adjustment curve as the cutter shaft rotation control parameter.
[0069] It can be assumed that the speed data is real-time and continuous. Therefore, the processing is all about processing continuous data (curves). The above comparison with the preset speed threshold means that the average speed change curve is subtracted from the preset speed threshold.
[0070] The process of calculating the first-stage speed adjustment curve using the PID control algorithm is as follows: in, This is the first-stage speed adjustment curve, representing the adjustment amount by which the first frequency converter regulates the speed of the first-stage cutter shaft motor. This is the second-level speed deviation curve. , and These are the coefficients of the PID algorithm, which will not be discussed in detail here.
[0071] The first frequency converter is used to control the speed of each primary cutter shaft motor according to the cutter shaft rotation control parameters.
[0072] It is worth noting that if the above control module enables each frequency converter to connect to each cutter shaft motor in a dual-drive manner, then the cutter shaft rotation control parameters here must be sent to each frequency converter separately.
[0073] The above embodiment adjusts the primary cutter shaft motor based on the speed feedback of the secondary cutter shaft motor, which solves the problem of uneven material crushing or even equipment failure caused by the asynchronous operation of multiple cutter shaft motors, and improves crushing efficiency.
[0074] In some embodiments, the first frequency converter is further configured to acquire the real-time torque of any one of the primary cutter shaft motors; determine whether the real-time torque is greater than a first torque threshold; if so, switch to regenerative braking mode and initiate energy recovery to obtain DC bus voltage and capacitor voltage monitoring data; and determine whether to stop energy recovery based on the DC bus voltage, capacitor voltage monitoring data, and voltage comparison algorithm. Similarly, the second frequency converter processes the secondary cutter shaft motor in the same way as the first frequency converter.
[0075] Specifically, if the real-time torque exceeds the first torque threshold, it indicates that the primary cutter shaft motor has exceeded its torque limit. In this case, switching to regenerative braking mode will cause the corresponding primary cutter shaft motor to switch from motoring to generating mode. At this time, the cutter shaft motor generates a braking torque (reverse torque) in the opposite direction of rotation, actively counteracting the inertial kinetic energy of the mechanical load, thereby reducing the actual mechanical load of the motor and preventing damage to the rotor and stator due to overload.
[0076] Meanwhile, in regenerative braking mode, the inverter converts mechanical energy into electrical energy and feeds it back to the DC bus. Excess electrical energy is transferred to a supercapacitor bank for storage via a DC / DC converter, or dissipated through a braking resistor, quickly stabilizing the bus voltage (preventing overvoltage from causing device breakdown). This process indirectly controls the motor's energy output, ensuring it operates within a safe torque range.
[0077] The voltage comparison algorithm determines whether the supercapacitor bank has reached its storage limit; if so, energy recovery is stopped.
[0078] Furthermore, the first frequency converter is also used to input the stored electrical energy obtained from energy recovery into the DC / DC converter when starting the first-stage cutter shaft motor to obtain the release current data; to acquire the grid input current data, and to combine the release current data and the grid input current data to obtain the input peak current data; and to provide reactive power compensation using a bidirectional inverter based on the input peak current data.
[0079] It should be noted that the operation of the second frequency converter when starting the secondary cutter shaft motor is the same as that of the first frequency converter.
[0080] The bidirectional inverter is characterized by supporting bidirectional energy flow (grid → motor, motor → grid) and can independently control active and reactive power. By adjusting the reactive current component of the inverter output, it offsets the inductive / capacitive reactive power demand of the load, making the grid-side current and voltage in phase (power factor ≈ 1), thus reducing grid losses.
[0081] Specifically, the reactive current component of the bidirectional inverter is orthogonal to the input peak current data.
[0082] If the control module enables each frequency converter to connect to each cutter shaft motor in a dual-drive manner, then the operation of each frequency converter for the primary cutter shaft motor and the secondary cutter shaft motor when the torque exceeds the limit is the same as the above process.
[0083] The above embodiments utilize the energy recovery of the frequency converter to actively improve the power grid supply quality, enhance the overall energy efficiency and stability of the crusher system, and indirectly reduce the required electrical energy consumption.
[0084] In some embodiments, the control module is further configured to acquire historical operating condition data; calculate crushing efficiency based on the historical operating condition data; and update the preset control database based on the historical operating condition data and the corresponding crushing efficiency.
[0085] The control module is specifically used to extract the feature mapping relationship between historical operating condition data and crushing efficiency; determine whether the interval since the last update of the preset control database has reached the preset period; if so, it updates the preset control database according to the self-learning algorithm and the feature mapping relationship. The historical operating condition data includes motor operating parameters and material characteristic change curves.
[0086] The preset cycle can be 10 hours or 24 hours.
[0087] Specifically, the crushing efficiency is a percentage figure, and the feature mapping relationship includes the correlation between material hardness, moisture content and torque, reversal time and crushing efficiency. For example, the linear relationship between hardness and torque can be obtained through regression analysis (e.g., torque = 10 × hardness + 50), and then the preset control database is updated using a self-learning algorithm.
[0088] Please see Figure 2 Another embodiment of this application provides a crusher intelligent drive control method, applied to the control module in the crusher intelligent drive control system as described in any of the above embodiments, the method comprising: Step S11: Obtain the first pulse signal from the first tool axis sensor and the second pulse signal from the second tool axis sensor.
[0089] Step S12: Determine the number of primary tool shafts based on the first pulse signal.
[0090] Step S13: Determine the number of secondary tool shafts based on the second pulse signal.
[0091] Step S14: Generate a grouping strategy based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes.
[0092] Step S15: Generate group control commands according to the grouping strategy and send them to the relay module, so that the relay module connects to the contacts of the frequency converter according to the group control commands, and the frequency converter connects to the contacts of the cutter shaft motor according to the group control commands.
[0093] Furthermore, the method also includes: Step S21: Obtain material characteristic data detected by the material detection module; the material detection module is located on the inner wall of the crusher.
[0094] Step S22: Obtain motor current data detected by the current detection module; the current detection module is connected to each cutter shaft motor.
[0095] Step S23: Generate torque control parameters based on material characteristic data and motor current data; and send them to the corresponding frequency converter through the relay module so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
[0096] Furthermore, the grouping strategy generated above based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes includes: Determine whether the number of primary tool shafts is greater than or equal to the number of secondary tool shafts.
[0097] If so, then the number of secondary cutter shafts is taken as the target number, and the first frequency converter is connected to the target number of primary cutter shaft motors.
[0098] Connect the second frequency converter to each of the secondary cutter shaft motors.
[0099] Connect the redundant frequency converter to each of the remaining primary cutter shaft motors.
[0100] The multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; the multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft.
[0101] If not, then use the number of primary cutter shafts as the target number and connect the first frequency converter to each primary cutter shaft motor.
[0102] Connect the second frequency converter to the target number of secondary cutter shaft motors.
[0103] Connect the redundant frequency converter to each of the remaining secondary cutter shaft motors.
[0104] Furthermore, the material characteristic data includes first hardness data, second hardness data, first humidity data, and second humidity data; the motor current data includes first-stage motor current data and second-stage motor current data.
[0105] The torque control parameters include the first torque control parameter and the second torque control parameter.
[0106] Please see Figure 3 The torque control parameters generated based on material characteristic data and motor current data include: Step S231: The first hardness data, the first humidity data, and the first motor current data are fuzzified to obtain the first fuzzy level data.
[0107] Step S232: Match the first fuzzy level data with the preset control database to obtain the first torque threshold and the first reversal time parameter, and send them to the first frequency converter as the first torque control parameter.
[0108] Step S233: The second hardness data, the second humidity data, and the secondary motor current data are fuzzified to obtain the second fuzzy level data.
[0109] Step S234: Match the second fuzzy level data with the preset control database to obtain the second torque threshold and the second reversal time parameter, and send them to the second frequency converter as the second torque control parameter.
[0110] Furthermore, the method also includes: Step S31: Obtain the speed data of each secondary cutter shaft motor and calculate the speed fluctuation.
[0111] Step S32: Determine whether the speed fluctuation is greater than the preset fluctuation threshold.
[0112] Step S33: If yes, calculate the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm, and send them to the first frequency converter; so that the first frequency converter controls the speed of each primary cutter shaft motor according to the cutter shaft rotation control parameters.
[0113] Please see Figure 4 Furthermore, the above calculation of the cutter shaft rotation control parameters based on the speed data of each secondary cutter shaft motor and the PID control algorithm includes: Step S331: Calculate the average speed change curve based on the speed data of each secondary cutter shaft motor.
[0114] Step S332: Compare the average speed change curve with the preset speed threshold to obtain the secondary speed deviation curve.
[0115] Step S333: Calculate the first-level speed adjustment curve based on the PID control algorithm and the second-level speed deviation curve.
[0116] Step S334: Use the first-stage speed adjustment curve as the control parameter for the cutter shaft rotation.
[0117] Furthermore, the method also includes: Step S41: Obtain historical operating data; historical operating data includes motor operating parameters and material characteristic change curves.
[0118] Step S42: Calculate the corresponding crushing efficiency based on historical operating data.
[0119] Step S43: Update the preset control database based on historical operating data and corresponding crushing efficiency.
[0120] Furthermore, the above-mentioned updating of the preset control database based on historical operating data and corresponding crushing efficiency includes: Step S431: Extract the feature mapping relationship between historical operating data and crushing efficiency.
[0121] Step S432: Determine whether the interval between the last update of the preset control database and the previous update has reached the preset period.
[0122] Step S433: If yes, update the preset control database according to the self-learning algorithm and feature mapping relationship.
[0123] The specific limitations of the intelligent drive control method for a crusher provided in this embodiment can be found in the embodiment of an intelligent drive control system for a crusher described above, and will not be repeated here.
[0124] This application provides a computer device that may include a processor, memory, network interface, and database connected via a system bus. The processor provides computing and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system, computer programs, and a database. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The network interface communicates with external terminals via a network connection. When the computer program is executed by the processor, it causes the processor to perform the steps of a crusher intelligent drive control method as described in any of the above embodiments.
[0125] The working process, working details and technical effects of the computer equipment provided in this embodiment can be found in the embodiment of a crusher intelligent drive control method described above, and will not be repeated here.
[0126] This application provides a computer-readable storage medium storing a computer program thereon. When executed by a processor, the computer program implements the steps of a crusher intelligent drive control method as described in any of the above embodiments. The computer-readable storage medium refers to a data storage carrier, which may include, but is not limited to, floppy disks, optical disks, hard disks, flash memory, USB flash drives, and / or memory sticks. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The working process, details, and technical effects of the computer-readable storage medium provided in this embodiment can be found in the embodiments of a crusher intelligent drive control method described above, and will not be repeated here.
[0127] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), RAMbus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and RAMbus dynamic RAM (RDRAM).
[0128] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0129] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.
Claims
1. A smart drive control system for a crusher, characterized in that, include: The system includes a control module, a first cutter axis sensor, a second cutter axis sensor, a relay module, multiple frequency converters, multiple cutter axis motors, and cutter axes that are connected one-to-one with each of the cutter axis motors. The first cutter shaft sensor is located inside the primary crusher and is used to collect the first pulse signal and send it to the control module; The second cutter shaft sensor is located inside the secondary crusher and is used to collect the second pulse signal and send it to the control module; The relay module is connected to each frequency converter via contacts; each frequency converter is connected to each cutter shaft motor via contacts. The control module is used to determine the number of primary tool axes based on the first pulse signal; and to determine the number of secondary tool axes based on the second pulse signal. A grouping strategy is generated based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes; a grouping control command is generated based on the grouping strategy and sent to the relay module; The relay module is used to connect to the contacts of the frequency converter according to the group control command, and to send the group control command to the corresponding frequency converter so that the frequency converter connects to the contacts of the cutter shaft motor according to the group control command.
2. The intelligent drive control system for crushers according to claim 1, characterized in that, It also includes a material detection module and a current detection module; the material detection module and the current detection module are respectively connected to the control module; The material detection module is located on the inner wall of the crusher and is used to detect material characteristic data and send it to the control module; The current detection module is connected to each cutter shaft motor and is used to detect motor current data and send it to the control module. The control module is also used to generate torque control parameters based on the material characteristic data and the motor current data, and send them to the corresponding frequency converter through the relay module, so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
3. The intelligent drive control system for crushers according to claim 2, characterized in that, Multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft, and the control module is specifically used for: If the number of primary cutter shafts is greater than or equal to the number of secondary cutter shafts, then the number of secondary cutter shafts is taken as the target number, and the first frequency converter is connected to the target number of primary cutter shaft motors, and the second frequency converter is connected to each secondary cutter shaft motor. Connect the redundant frequency converter to each of the remaining primary cutter shaft motors; If the number of primary cutter shafts is less than the number of secondary cutter shafts, then the number of primary cutter shafts is taken as the target number, and the first frequency converter is connected to each primary cutter shaft motor, and the second frequency converter is connected to the target number of secondary cutter shaft motors; Connect the redundant frequency converter to each of the remaining secondary cutter shaft motors.
4. The intelligent drive control system for a crusher according to claim 3, characterized in that, The material characteristic data includes first hardness data, second hardness data, first humidity data, and second humidity data; the material detection module includes a first pressure sensor, a second pressure sensor, a first capacitive sensor, and a second capacitive sensor, which are respectively connected to the control module. The first pressure sensor is installed on the inner wall of the primary crusher and is used to collect the first hardness data; The second pressure sensor is installed on the inner wall of the secondary crusher to collect the second hardness data; The first capacitive sensor is installed on the inner wall of the primary crusher and is used to collect the first humidity data; The second capacitive sensor is installed on the inner wall of the secondary crusher and is used to collect the second humidity data.
5. The intelligent drive control system for a crusher according to claim 4, characterized in that, The motor current data includes primary motor current data and secondary motor current data; the control module is specifically used for: The first hardness data, the first humidity data, and the first-stage motor current data are fuzzified to obtain the first fuzzy level data; the first torque threshold and the first reversal time parameter are obtained by matching the first fuzzy level data with a preset control database, and then sent to the first frequency converter as the first torque control parameter. The second hardness data, the second humidity data, and the secondary motor current data are fuzzified to obtain the second fuzzy level data. The second fuzzy level data is matched with a preset control database to obtain the second torque threshold and the second reversal time parameter, which are then sent to the second frequency converter as the second torque control parameter.
6. The intelligent drive control system for a crusher according to claim 5, characterized in that, The control module is also used to acquire the rotational speed data of each of the secondary cutter shaft motors and calculate the rotational speed fluctuation; Determine whether the speed fluctuation is greater than a preset fluctuation threshold; if so, calculate the cutter shaft rotation control parameters based on the speed data of each of the secondary cutter shaft motors and the PID control algorithm, and send them to the first frequency converter; The first frequency converter is used to control the speed of each of the first-stage cutter shaft motors according to the cutter shaft rotation control parameters.
7. The intelligent drive control system for a crusher according to claim 6, characterized in that, The first frequency converter is also used to acquire the real-time torque of any first-stage cutter shaft motor; determine whether the real-time torque is greater than the first torque threshold; if so, switch to regenerative braking mode and start energy recovery to obtain DC bus voltage and capacitor voltage monitoring data; and determine whether to stop energy recovery based on the DC bus voltage, the capacitor voltage monitoring data and voltage comparison algorithm.
8. The intelligent drive control system for a crusher according to claim 7, characterized in that, The first frequency converter is also used to input the stored electrical energy obtained from energy recovery into the DC / DC converter when starting the first-stage cutter shaft motor to obtain release current data; to obtain grid input current data, and to combine the release current data and grid input current data to obtain input peak current data; Based on the input peak current data, a bidirectional inverter is used to provide reactive power compensation.
9. The intelligent drive control system for a crusher according to claim 5, characterized in that, The control module is also used to acquire historical operating condition data, which includes motor operating parameters and material characteristic change curves; calculate crushing efficiency based on historical operating condition data; and update the preset control database based on the historical operating condition data and the corresponding crushing efficiency.
10. The intelligent drive control system for a crusher according to claim 9, characterized in that, The control module is specifically used to extract the feature mapping relationship between the historical operating condition data and the crushing efficiency; determine whether the interval between the last update of the preset control database and the previous update has reached a preset period; if so, update the preset control database according to the self-learning algorithm and the feature mapping relationship.
11. A method for intelligent drive control of a crusher, characterized in that, The method, applied to the control module in the intelligent drive control system for a crusher as described in any one of claims 1-10, comprises: Acquire the first pulse signal from the first tool axis sensor and the second pulse signal from the second tool axis sensor; The number of primary tool shafts is determined based on the first pulse signal; The number of secondary cutter shafts is determined based on the second pulse signal; A grouping strategy is generated based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes; Group control commands are generated according to the grouping strategy and sent to the relay module, so that the relay module connects to the contacts of the frequency converter according to the group control commands, and the frequency converter connects to the contacts of the cutter shaft motor according to the group control commands.
12. The intelligent drive control method for a crusher according to claim 11, characterized in that, Also includes: Acquire material characteristic data detected by the material detection module; the material detection module is located on the inner wall of the crusher; Acquire motor current data detected by the current detection module; The current detection module is connected to each cutter shaft motor; Torque control parameters are generated based on the material characteristic data and the motor current data; and sent to the corresponding frequency converter through the relay module so that the frequency converter controls the cutter shaft motor to work according to the torque control parameters.
13. The intelligent drive control method for a crusher according to claim 12, characterized in that, The generation of a grouping strategy based on the load balancing algorithm, the number of primary tool axes, and the number of secondary tool axes includes: Determine whether the number of primary tool shafts is greater than or equal to the number of secondary tool shafts; If so, then the number of secondary cutter shafts is taken as the target number, and the first frequency converter is connected to the target number of primary cutter shaft motors; Connect the second frequency converter to each of the secondary cutter shaft motors; Connect the redundant frequency converter to each of the remaining primary cutter shaft motors; Among them, the multiple frequency converters include a first frequency converter, a second frequency converter, and a redundant frequency converter; the multiple cutter shaft motors include a first-stage cutter shaft motor connected to a first-stage cutter shaft and a second-stage cutter shaft motor connected to a second-stage cutter shaft; If not, then take the number of first-stage cutter shafts as the target number and connect the first frequency converter to each first-stage cutter shaft motor; Connect the second frequency converter to the target number of secondary cutter shaft motors; Connect the redundant frequency converter to each of the remaining secondary cutter shaft motors.
14. The intelligent drive control method for a crusher according to claim 13, characterized in that, The material property data includes first hardness data, second hardness data, first humidity data, and second humidity data; The motor current data includes primary motor current data and secondary motor current data; The torque control parameters include a first torque control parameter and a second torque control parameter; The step of generating torque control parameters based on the material characteristic data and the motor current data includes: The first hardness data, the first humidity data, and the first-stage motor current data are fuzzified to obtain the first fuzzy level data; the first torque threshold and the first reversal time parameter are obtained by matching the first fuzzy level data with a preset control database, and then sent to the first frequency converter as the first torque control parameter. The second hardness data, the second humidity data, and the secondary motor current data are fuzzified to obtain the second fuzzy level data. The second fuzzy level data is matched with a preset control database to obtain the second torque threshold and the second reversal time parameter, which are then sent to the second frequency converter as the second torque control parameter.
15. The intelligent drive control method for a crusher according to claim 14, characterized in that, Also includes: Obtain the rotational speed data of each of the secondary cutter shaft motors and calculate the rotational speed fluctuation; Determine whether the speed fluctuation exceeds the preset fluctuation threshold; If so, the cutter shaft rotation control parameters are calculated based on the speed data of each of the secondary cutter shaft motors and the PID control algorithm, and sent to the first frequency converter; so that the first frequency converter controls the speed of each of the primary cutter shaft motors according to the cutter shaft rotation control parameters.
16. The intelligent drive control method for a crusher according to claim 15, characterized in that, The calculation of the cutter shaft rotation control parameters based on the speed data of each of the secondary cutter shaft motors and the PID control algorithm includes: The average speed change curve is calculated based on the speed data of each of the secondary cutter shaft motors; The average speed change curve is compared with a preset speed threshold to obtain a secondary speed deviation curve; The first-level speed adjustment curve is calculated based on the PID control algorithm and the second-level speed deviation curve. The first-level speed adjustment curve is used as the control parameter for the cutter shaft rotation.
17. The intelligent drive control method for a crusher according to claim 14, characterized in that, Also includes: Acquire historical operating condition data; the historical operating condition data includes motor operating parameters and material characteristic change curves; The corresponding crushing efficiency is calculated based on the historical operating data. The preset control database is updated based on the historical operating data and the corresponding crushing efficiency.
18. The intelligent drive control method for a crusher according to claim 17, characterized in that, The step of updating the preset control database based on the historical operating data and the corresponding crushing efficiency includes: Extract the feature mapping relationship between the historical operating data and the crushing efficiency; Determine whether the interval since the last update of the preset control database has reached the preset period; If so, the preset control database is updated according to the self-learning algorithm and the feature mapping relationship.
19. A computer device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the intelligent drive control method for the crusher as described in any one of claims 11 to 18.
20. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the intelligent drive control method for the crusher as described in any one of claims 11 to 18.