Multi-stage damping self-adaptive cooling intelligent flow regulating valve and control system

Abstract

The invention discloses a multi-stage damping self-adaptive cooling intelligent flow regulating valve and a control system, and relates to the technical field of air volume regulating valves, the multi-stage damping self-adaptive cooling intelligent flow regulating valve comprises a valve body shell, a regulating unit and a valve plate; an airflow channel is formed in the valve body shell, and a cooling channel structure used for circulating a cooling medium is arranged on the outer side of the valve body shell; the adjusting unit is arranged on the upstream portion of the airflow channel in the valve body shell and used for adjusting the pressure drop and flow field distribution of fluid flowing through the airflow channel by changing the zigzag path of the airflow channel. The valve plate is arranged at the downstream of the adjusting unit, and the sectional area of the airflow channel is continuously adjusted by changing the rotating angle of the valve plate; according to the invention, the linearity and the stability of flow regulation are obviously improved, and the service life of equipment under severe working conditions of the grate cooler is obviously prolonged.

Description

A multi-stage damping adaptive cooling intelligent flow regulating valve and control system Technical Field

[0001] This invention relates to the technical field of airflow regulating valves, specifically to a multi-stage damping adaptive cooling intelligent flow regulating valve and its control system. Background Technology

[0002] The grate cooler is a key cooling device in the cement clinker calcination system. In the high-temperature section air chamber renovation of the fourth-generation cement clinker grate cooler, the grate cooler consists of 13 rows of grate beds, using a segmented assembled air beam structure. The upper part of the grate bed is covered with heat-resistant steel grate plate units with a specification of 400mm×400mm and a gap width of 5mm. The main function of the grate cooler is to rapidly cool the high-temperature clinker (about 1400℃) discharged from the rotary kiln to a temperature that can be transported at ambient temperature. At the same time, it efficiently recovers the sensible heat of the clinker, providing high-temperature secondary and tertiary air for kiln head combustion and waste heat power generation. The flow regulating valve is the core component for controlling the cooling air volume of each grate bed area, and its performance directly affects the clinker cooling rate, heat recovery efficiency, and system resistance.

[0003] In existing technologies, traditional flow control devices often suffer from poor linearity between opening and flow rate when adjusting the cooling air volume of grate coolers. This leads to unstable regulation under low flow conditions and sluggish response under high flow conditions. Furthermore, due to the harsh working environment of grate coolers, the control device is constantly exposed to high-temperature radiation and backflow heat waves, lacking effective heat dissipation integrated with the main body. This makes it highly susceptible to valve body shell thermal deformation and jamming or seal failure. In addition, existing single-loop control modes lack a multi-valve coordination mechanism. When faced with abnormal conditions such as insufficient total air volume or concentrated high-temperature materials, they cannot effectively coordinate and respond to conflicts based on process urgency and equipment stability, making it difficult to achieve optimal system energy consumption control while ensuring equipment safety. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a multi-stage damping adaptive cooling intelligent flow regulating valve and control system.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: The present invention provides a multi-stage damping adaptive cooling intelligent flow regulating valve, comprising: a valve body shell, a regulating unit, and a valve plate; an airflow channel is formed inside the valve body shell, and a cooling channel structure for the flow of cooling medium is provided on the outer side of the valve body shell; the regulating unit is located upstream of the airflow channel inside the valve body shell, and is used to regulate the pressure drop and flow field distribution of the fluid flowing through the airflow channel by changing the tortuous path of the airflow channel; the valve plate is located downstream of the regulating unit, and continuously adjusts the cross-sectional area of ​​the airflow channel by changing its rotation angle.

[0006] The present invention also provides a control system for an intelligent flow regulating valve, comprising: at least one of the intelligent flow regulating valves; a cooling system fluidly connected to the cooling channel structure of the intelligent flow regulating valve for cooling the valve body shell of the intelligent flow regulating valve; a sensor group for acquiring grate pressure, clinker temperature distribution and valve body temperature signals; and a control module communicatively connected to at least one of the intelligent flow regulating valves, the cooling system and the sensor group; the control module is used to execute a conflict coordination process and an operating condition mode management process based on the signals from the sensor group.

[0007] As a preferred technical solution of the present invention, the conflict coordination process is used to calculate the allocation weight of each valve based on the first priority rule and the second priority rule when it is determined that multiple intelligent flow regulating valves simultaneously request an increase in air volume, causing the total air volume demand of the system to exceed the current allocable air volume limit; the working condition mode management process is used to identify preset abnormal working condition modes by analyzing the thermal imaging characteristics of the clinker temperature distribution, and trigger the multi-valve linkage control strategy corresponding to the abnormal working condition mode.

[0008] As a preferred embodiment of the present invention, the conflict coordination process includes: sorting multiple requests according to the temperature deviation of the corresponding area of ​​each intelligent flow regulating valve based on a first priority rule to generate a first sorting sequence, wherein the temperature deviation is proportional to the magnitude of the deviation of the clinker temperature in the current area from the preset cooling curve; and weighting the first sorting sequence according to the adjustment stability coefficient of each intelligent flow regulating valve based on a second priority rule to generate a final allocation sequence, wherein the adjustment stability coefficient is inversely proportional to the valve's opening adjustment frequency within a preset historical time window.

[0009] As a preferred technical solution of the present invention, in the operating condition management process, the abnormal operating condition mode includes a high-temperature material concentration mode; the identification feature of the high-temperature material concentration mode is that a high-temperature area with a temperature exceeding a preset threshold and an area continuously expanding appears in the clinker temperature distribution; triggering the multi-valve linkage control strategy corresponding to the high-temperature material concentration mode includes: generating a first control command to drive the intelligent flow regulating valve corresponding to the high-temperature area to increase its opening and control its regulating unit to switch to a low-damping mode; at the same time, generating a second control command to drive the intelligent flow regulating valve adjacent to the upstream of the high-temperature area to decrease its opening and control its regulating unit to switch to a high-damping mode.

[0010] As a preferred embodiment of the present invention, the control module is further configured with a thermal protection control strategy, which includes: when the valve body temperature is detected to exceed a first safe temperature threshold, generating an instruction to increase the cooling intensity of the cooling system; and when the valve body temperature rise rate is detected to exceed a first rate threshold, increasing the control dead zone of the valve plate.

[0011] As a preferred embodiment of the present invention, the control module further stores a valve characteristic database, which contains data on the correspondence between valve opening degree, flow rate and pressure loss under different damping modes; the control module is used to query the valve characteristic database based on the current damping mode and compensate for the opening command when generating an opening command to drive the valve plate.

[0012] As a preferred technical solution of the present invention, the control module is used to perform system-wide airflow coordinated optimization; the system-wide airflow coordinated optimization includes: taking the reduction of total system energy consumption as the optimization goal, and under the premise of meeting the cooling needs of each area, adjusting the damping mode combination of each intelligent flow regulating valve through iterative calculation.

[0013] As a preferred embodiment of the present invention, the control system further includes an adaptive startup process; the adaptive startup process includes: during the cold start phase of the system, controlling the intelligent flow regulating valve to be in a fully open state and a low-damping mode; monitoring the system exhaust temperature, and adjusting the damping mode level and valve opening based on the trend of the exhaust temperature change, until a steady-state regulation is entered.

[0014] As a preferred embodiment of the present invention, the control module is used to exchange data with the central control system of the cement plant; the data exchange includes: uploading the operating status data of the intelligent flow regulating valve and the execution result data of the collaborative decision-making logic inside the control module, and receiving production target parameters from the central control system.

[0015] The beneficial effects of this invention are: 1. By setting an adjustment unit upstream of the airflow channel inside the valve body shell to change the tortuous path, and cooperating with the downstream valve plate to adjust the opening area, this invention significantly improves the linearity and stability of flow regulation; by combining the valve characteristic database stored in the control module to perform opening command compensation, it effectively solves the technical problems of nonlinear regulation and inaccurate control of traditional valves at small openings.

[0016] 2. This invention achieves active cooling of high-temperature areas by setting a cooling channel structure on the outside of the valve body shell and connecting it to the cooling system. Combined with the thermal protection control strategy of the control module, the cooling intensity of the cooling system is increased when an abnormal increase in valve body temperature is detected, or the control dead zone of the valve plate is increased when the temperature rise rate is too fast. This effectively prevents valve jamming or failure due to high-temperature thermal expansion and significantly extends the service life of the equipment under the harsh working conditions of the grate cooler.

[0017] 3. This invention utilizes a conflict coordination process built into the control module. When the total air volume of the system is limited, it calculates and allocates weights based on the first priority rule (temperature deviation) and the second priority rule (adjustment stability coefficient). This prioritizes the cooling needs of areas that urgently require cooling while also taking into account the mechanical stability of the equipment. It avoids imbalances in air volume allocation caused by disorderly competition among multiple valves and achieves intelligent optimization of air volume resources.

[0018] 4. This invention identifies high-temperature material concentration patterns through a working condition mode management process and triggers a multi-valve linkage control strategy. It controls the valves in the high-temperature area to increase their opening and switch to low-damping mode, while simultaneously controlling the upstream adjacent valves to decrease their opening and switch to high-damping mode. This strengthens the cooling of the target area while building a local high-pressure barrier, effectively dealing with abnormal working conditions such as high-temperature material concentration, and improving the overall operating efficiency and safety of the grate cooler. Attached Figure Description

[0019] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0020] Figure 1 is a schematic diagram of the overall structure of the intelligent flow regulating valve of the present invention; Figure 2 is a cross-sectional schematic diagram of the intelligent flow regulating valve of the present invention; Figure 3 is a schematic diagram of the overall structure of the control system of the intelligent flow regulating valve of the present invention; Figure 4 is a calibration curve of the flow characteristics of the intelligent flow regulating valve of the present invention under different damping modes; Figure 5 is a schematic diagram of the multi-valve linkage control response of the present invention for the high-temperature material concentration mode.

[0021] The components include: 1. Valve body shell; 2. Adjustment unit; 3. Valve plate; 4. Cooling channel structure. Detailed Implementation

[0022] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0023] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0024] As shown in Figures 1 and 2, a multi-stage damping adaptive cooling intelligent flow regulating valve is disclosed. This regulating valve is mainly used in the air supply system of cement clinker grate coolers or other fluid control scenarios in high-temperature dust environments. It includes: a valve body shell 1, a regulating unit 2, and a valve plate 3. An airflow channel is formed inside the valve body shell 1, and a cooling channel structure 4 for the flow of cooling medium is provided on the outer side of the valve body shell 1. The valve body shell 1 serves as the supporting frame and fluid conduit for the entire device, and its internal airflow channel allows for the flow of cooling air, designed to handle temperatures as high as 1000 degrees Celsius under grate cooler operating conditions. To mitigate the intense heat radiation and potential backflow heat waves generated by the clinker, the outer side of the valve body shell 1 is specially equipped with a cooling channel structure 4 for the flow of cooling medium. This cooling channel structure 4 can be implemented as a double-layer jacket, labyrinthine flow channel, or coil structure covering the outer wall of the high-temperature area of ​​the valve body shell 1. By introducing external low-temperature air or other cooling mediums to circulate within the cooling channel structure 4, continuous active heat exchange can be carried out on the valve body shell 1, thereby maintaining the working temperature of the valve body material within a safe range and preventing shell deformation or jamming of internal moving parts due to uneven thermal expansion and contraction.

[0025] The regulating unit 2 is located upstream of the airflow channel inside the valve body shell 1, i.e., at the inlet end after the airflow enters the valve body. Its main function is not to completely cut off the airflow, but to rectify and pre-treat the incoming fluid by reducing pressure. The regulating unit 2 is configured to adjust the pressure drop and flow field distribution of the fluid flowing through the airflow channel by changing the tortuous path of the airflow channel. Specifically, the regulating unit 2 can adopt a rotatable multi-stage blade group or a louvered structure. By changing the angle combination of the blades, different degrees of deflection and obstruction are artificially created in the flow channel, so that the airflow generates controllable pressure loss and eliminates turbulent vortices when passing through this area. This design distinguishes the pressure stabilization function of the airflow from the subsequent flow interception function, ensuring that the airflow flowing downstream has a relatively stable static pressure level.

[0026] The valve plate 3 is located downstream of the regulating unit 2. Its rotation angle is changed to continuously adjust the cross-sectional area of ​​the airflow channel. The valve plate 3 is installed within the valve body flow channel via a drive shaft that passes through or connects to its side. This shaft is connected to an external intelligent electro-hydraulic actuator. When the actuator operates, the drive shaft causes the valve plate 3 to rotate around its axis, thereby changing the angle (i.e., opening) between the valve plate 3 and the airflow direction. A high-stiffness torsion spring is also connected between the valve plate 3 and the valve body. This torsion spring always applies a unidirectional preload torque to the valve plate 3, significantly improving the adjustment accuracy at small openings. Furthermore, the upstream regulating unit... Unit 2 has already pre-handled most of the differential pressure regulation tasks, so that the valve plate 3 exhibits a very high linear correlation between its opening change and the actual flow rate change throughout the entire stroke range, especially under small opening conditions, thereby achieving precise on-demand supply of cooling air volume to the grate cooler; during operation, the cooling air flows sequentially through the regulating unit 2 in a certain damping mode, through the opening formed by the valve plate 3 at a specific opening, and is finally delivered to the designated grate air chamber; while the cooling medium continuously circulating in the cooling channel structure 4 integrated in the valve body shell 1 continuously removes the heat absorbed by the valve body from the high-temperature environment, ensuring continuous and reliable operation.

[0027] It should be noted that, in this embodiment, the hardware manufacturing of the intelligent flow regulating valve adopts a specific high-temperature and wear-resistant material system and precision machining process. First, regarding the manufacturing of the valve body shell 1, considering the high-temperature heat radiation and dust-laden airflow scouring under the working conditions of the cement clinker grate cooler, the valve body shell 1 is made of ZG40Cr25Ni20 heat-resistant steel through an integral precision casting process. This material has excellent high-temperature creep strength. In order to reduce the flow resistance of the airflow inside the valve body and prevent dust from accumulating on the wall, the inner wall of the flow channel after casting has undergone strict shot peening and precision machining treatment, so that its surface roughness Ra is controlled below 3.2μm, thereby ensuring the smoothness of the airflow channel.

[0028] Regarding the valve plate 3, its body material is 310H heat-resistant stainless steel, which can still maintain good mechanical properties at a high temperature of 1100℃. Furthermore, the sealing surface of the valve plate 3 adopts a dual protection process: firstly, Stellite6 or tungsten carbide hard alloy rings are embedded on the sealing surface substrate to resist the physical impact of large particles of clinker using their high hardness characteristics; subsequently, an Al2O3-TiO2 composite ceramic wear-resistant coating with a thickness of 150μm to 200μm is prepared on the surface of the valve plate 3 and the sealing surface using plasma spraying (APS) process. This composite coating structure gives the valve plate 3 extremely strong resistance to erosion and wear.

[0029] Regarding the aforementioned regulating unit 2, it is designed as a rotatable louver structure and is independently driven by a servo motor. The regulating unit 2 is configured to have three damping modes: low, medium, and high. The physical switching time between each mode is less than 5 seconds, and the pressure loss regulation range can cover 200Pa to 1200Pa, thereby meeting the wide-range regulation requirements from low-resistance flow to high-resistance steady flow. Before operation, it is necessary to calibrate the three-dimensional relationship curve family between valve opening, flow rate, and pressure loss under different damping modes (low, medium, and high) through actual flow tests, and solidify the curve family data into the database of the control module as a benchmark for subsequent nonlinear compensation.

[0030] In addition, the present invention also requires static testing. The multi-stage damping adjustment unit 2 and the valve plate 3 with a composite ceramic coating are installed into the valve body, and the deformation resistance test and sealing test are carried out on a high-temperature test bench under the simulated 450°C condition to ensure that the leakage rate at high temperature is less than 0.1%.

[0031] Specifically, as shown in Figure 4, the flow characteristic curve of the intelligent flow regulating valve described in this invention is obtained under a standardized wind tunnel test environment. In the figure, the horizontal axis represents the valve plate opening (0-100%), and the vertical axis represents the air flow rate (Nm³). 3 / h), the three curves correspond to the fluid response characteristics of the regulating unit in low damping mode (solid line), medium damping mode (dashed line) and high damping mode (dotted line), respectively.

[0032] As can be seen from the figure, the present invention significantly expands the effective working area of ​​the valve through the intervention of the adjustment unit.

[0033] Low-damping mode: The curve slope is steeper, and it has the largest flow coefficient at the same opening degree, as shown by the arrow in the figure. This mode is specially used for cold start purging of the system or for conditions that require rapid cooling of high-temperature clinker.

[0034] High-damping mode: The curve slope is gentle and the flow resistance is significantly increased, as shown by the arrow in the figure. This mode creates a high-resistance stable flow region, which is particularly suitable for fine adjustment of small flow rates or for building high-pressure barriers under abnormal operating conditions. It effectively solves the problem that traditional valves are prone to oscillation and nonlinearity at small openings.

[0035] Furthermore, as shown in Figure 3, the present invention also provides a control system for an intelligent flow regulating valve, comprising: at least one of the intelligent flow regulating valves, for installation in each air chamber of the corresponding cement clinker grate cooler.

[0036] The cooling system is fluidly connected to the cooling channel structure 4 of the intelligent flow regulating valve and is used to cool the valve body shell 1 of the intelligent flow regulating valve. The cooling system is an independent external circulation unit, which is usually composed of a fan, pipes and flow regulating components. It is fluidly connected to the cooling channel structure 4 on the valve body shell 1 of the intelligent flow regulating valve through pipes. Its function is to continuously pump cooling medium (low temperature air, cooling water or other heat exchange medium) into the cooling channel structure 4. When the medium flows through the high temperature area of ​​the valve body shell 1, it absorbs heat and is discharged, thereby realizing active forced cooling of the valve body metal structure. This is a key guarantee measure to overcome the extreme high temperature environment inside the grate cooler and prevent the valve body from overheating and deforming.

[0037] The sensor group is used to acquire the clinker pressure, clinker temperature distribution, and valve body temperature signals. It includes pressure sensors arranged below each grate air chamber, an infrared thermal imager for capturing the clinker temperature distribution on the grate, and thermocouples installed in key parts of the valve body shell 1. These sensors work continuously to acquire in real time the grate pressure signal reflecting the clinker layer thickness, the clinker temperature distribution image signal reflecting the uniformity of clinker cooling and the location of abnormal high temperature areas, and the valve body temperature signal directly reflecting the harshness of the valve's working environment.

[0038] The control module is communicatively connected to at least one of the intelligent flow regulating valves, the cooling system, and the sensor group. The control module is used to execute conflict coordination processes and operating mode management processes based on the signals from the sensor group. Based on continuous scanning and analysis of the sensor group signals, the control module autonomously determines the current operating state of the system and calls the corresponding processes to generate the final set of control commands, thereby driving the physical equipment to complete the required actions.

[0039] For example, the control module first reads the grate pressure signal and clinker temperature distribution signal from all associated intelligent flow regulating valve areas, and calculates the initial demand air volume for each area based on the preset air volume demand model. Subsequently, the control module evaluates whether the sum of these demands exceeds the current allocable air volume limit of the fan system. If it does not exceed the limit, it generates the opening command of each valve as needed. If it exceeds the limit, it immediately activates the conflict coordination process, calculates the weight according to the built-in rules, and arbitrates and redistributes the demand. At the same time, the control module continuously analyzes the clinker temperature distribution image to check whether there are abnormal high temperature areas that meet the preset characteristics. Once a high temperature material concentration pattern is identified, the working condition mode management process is triggered, and the corresponding multi-valve linkage control strategy is started for emergency intervention. In addition, the control module also monitors the valve body temperature signal in real time and dynamically adjusts the cooling intensity of the cooling system or the control dead zone of the valve plate 3 through an independent thermal protection control strategy to provide safety protection for the valve body. Through the coordinated operation of the above multiple processes, the system realizes multi-level intelligent control from global resource optimization and rapid response to abnormal working conditions to equipment body protection.

[0040] Furthermore, the conflict coordination process is a resource scheduling mechanism configured by the control module to address the limited air supply resources of the grate cooler. In actual operation, when a large area of ​​high-temperature clinker accumulates in the grate or the system load suddenly increases, the intelligent flow regulating valves in multiple areas often simultaneously send requests to the control system to significantly increase the air volume. If the operating frequency of the system fan has reached its upper limit or the main pipe pressure has dropped to a critical value, that is, when the total air volume demand of the system exceeds the current allocable air volume limit, simply allowing all valves to be fully open will cause the total system pressure to collapse, thereby losing the ability to control the flow field. Therefore, the conflict coordination process is triggered. This process no longer responds to the absolute opening request of a single valve, but instead starts a weight calculation program to comprehensively evaluate all requests based on the preset first priority rule and second priority rule, calculate the allocation weight of each valve, and thus prioritize the allocation of limited air volume resources to the most critical cooling area, ensuring that the system can maintain the stability of core process parameters even under full load.

[0041] The operating mode management process utilizes real-time data collected by the sensor group (especially infrared thermal imaging equipment) to continuously perform image analysis and feature extraction on the thermal imaging characteristics of the clinker temperature distribution. The thermal imaging characteristics include, but are not limited to, the area, shape, location distribution of high-temperature regions, and the rate of change of temperature gradient.

[0042] The control module has a pre-set library of various typical abnormal operating conditions, such as high-temperature patches of a specific shape, with temperatures exceeding a threshold and the area continuously expanding. Once a matching abnormal operating condition is identified, such as a high-temperature material concentration mode, the control module will immediately interrupt or override some regular adjustment commands and instead trigger a multi-valve linkage control strategy that is strictly bound to the identified mode. This strategy is not an independent operation of a single valve, but a set of commands that coordinate with each other in space and execution timing. It aims to systematically respond to sudden process disturbances through the coordinated action of multiple valves.

[0043] Within a complete control cycle, the control module may process the demands from these two processes simultaneously or sequentially: for example, when the total system airflow is sufficient but a certain area experiences concentrated high-temperature material, only the operating mode management process is triggered; when multiple areas simultaneously require more airflow but the total amount is insufficient, the conflict coordination process is activated; and in the most complex scenario, the system may need to prioritize processing a certain identified abnormally high-temperature area under the constraint of insufficient total airflow. In this case, the outputs of the two processes need to be integrated and adjudicated by the control module at a higher level, ultimately generating a unified and conflict-free set of control instructions to be issued to the affected intelligent flow regulating valves.

[0044] Furthermore, the conflict coordination process includes: based on a first priority rule, sorting multiple requests according to the temperature deviation of the area corresponding to each intelligent flow regulating valve to generate a first sorting sequence. The temperature deviation is proportional to the magnitude of the deviation of the clinker temperature in the current area from the preset cooling curve. The temperature deviation is a quantitative indicator, the value of which is obtained by calculating the difference between the clinker temperature in the current area and the target temperature corresponding to the preset ideal cooling curve at that position. The larger the difference, the more serious the cooling lag in the area and the more urgent the need for increased airflow in the process. Therefore, the temperature deviation is proportional to the difference. The control module sorts all concurrent requests in descending order according to the calculated temperature deviation values ​​of each area to generate the first sorting sequence. This sequence reflects the urgency ranking from the perspective of process cooling effect alone.

[0045] Specifically, the control module does not execute the first priority rule solely based on the current static temperature difference, but rather employs a composite calculation logic of static deviation and dynamic trend. In particular, the system calculates the difference between the current clinker temperature and the target value in real time, and simultaneously calculates the slope of the temperature change per unit time. The temperature deviation is defined as the weighted sum of these two values. The advantage of this algorithm is that even if the current temperature has not yet crossed the absolute red line, if the temperature rise rate is extremely high, the system can still calculate a high deviation value, thereby achieving proactive adjustment.

[0046] Next, the control module applies the second priority rule to correct the first sorting sequence. This rule introduces the device-level consideration factor of the adjustment stability coefficient. Specifically, based on the second priority rule, the first sorting sequence is weighted and corrected according to the adjustment stability coefficient of each intelligent flow control valve to generate the final allocation sequence. The adjustment stability coefficient is inversely proportional to the valve's opening adjustment frequency within a preset historical time window. The adjustment stability coefficient is an evaluation value calculated based on the historical operating state of each intelligent flow control valve. Its calculation depends on the valve's opening adjustment frequency within a preset historical time window (such as the first 10 minutes), that is, the number of times the valve plate 3 performs opening changes per unit time. Frequent adjustment actions may mean that the valve is at an unstable operating point or the corresponding process parameters fluctuate drastically. From the perspective of equipment protection, it is necessary to avoid further frequent or large-amplitude adjustment commands. Therefore, the adjustment stability coefficient is inversely proportional to the opening adjustment frequency.

[0047] During the correction process, the control module adjusts the original positions of each valve in the first sorting sequence by weighting according to the current adjustment stability coefficient of each valve. Valves with lower adjustment stability coefficients will be moved back in the sorting position, while valves with higher coefficients may remain or move forward slightly. Through this weighted correction, the final allocation sequence is finally generated.

[0048] Specifically, for the second priority rule, the control module sets a sliding time window (e.g., the most recent 60 seconds) in memory and records the number of times the valve executes the opening adjustment command within this window. The adjustment stability coefficient is set to be non-linearly inversely proportional to the cumulative number of times. That is, the more frequently the valve operates recently, the closer its calculated stability coefficient is to zero. The final allocation weight is obtained by multiplying the temperature deviation and the stability coefficient, thereby ensuring that only valves that are urgently needed by the process and have stable operating conditions can obtain high-priority air volume allocation.

[0049] This process ensures that resource allocation decisions not only prioritize responding to the most urgent needs of the process, but also take into account the mechanical reliability of the actuators themselves, avoiding the risk of exacerbating system oscillations due to over-responding to a certain unstable region, thereby achieving intelligent and robust decision-making under constraints.

[0050] Furthermore, in the operating condition management process, the abnormal operating condition mode includes a high-temperature material concentration mode; the identification feature of the high-temperature material concentration mode is that a high-temperature area with a temperature exceeding a preset threshold and an area that continues to expand appears in the clinker temperature distribution; this mode specifically refers to a situation in the clinker layer of the grate where a local area has a temperature significantly higher than the surrounding normal clinker due to abnormal clinker granulation, fluctuations in kiln operating conditions, etc., and the range is spreading, which is often referred to as the "red material" phenomenon in industrial sites.

[0051] The control module identifies the pattern by continuously analyzing the clinker temperature distribution data provided by the infrared thermal imaging device in the sensor group. The identification feature is specified as two quantitative conditions that need to be met simultaneously: First, the temperature condition, that is, there must be a continuous pixel area in the distribution image whose average temperature exceeds a preset threshold (for example, set to 850℃). This threshold is usually set based on the normal cooling temperature of clinker and the upper limit of safe operation. Second, the dynamic trend condition, that is, the area of ​​the high temperature area shows a continuous expansion trend within a continuous monitoring period (for example, 3 to 5 consecutive frames), which indicates that the abnormal high temperature is spreading rather than isolated and static.

[0052] When the analysis algorithm of the control module confirms that the above two conditions are met at the same time, it determines that a high-temperature material concentration mode has occurred and immediately triggers the corresponding multi-valve linkage control strategy. The execution of this strategy includes generating and issuing two logically related and time-synchronized control commands.

[0053] The multi-valve linkage control strategy corresponding to the high-temperature material concentration mode includes: generating a first control command to drive the intelligent flow regulating valve corresponding to the high-temperature area to increase its opening and control its regulating unit 2 to switch to low-damping mode; the command includes two specific actions: first, driving the valve plate 3 to increase its opening to rapidly increase the volumetric flow rate of the cooling air flowing through the valve; second, controlling the regulating unit 2 to switch to low-damping mode. Low-damping mode means that the flow channel inside the regulating unit 2 has the least tortuosity and the lowest flow resistance, thereby further reducing the total pressure loss of the airflow through the valve on the basis of increasing the opening of the valve plate 3, maximizing the flow capacity of the cooling air, so as to achieve enhanced cooling of the high-temperature area.

[0054] Simultaneously, a second control command is generated to drive the intelligent flow regulating valve adjacent to the upstream of the high-temperature area to reduce its opening and control its regulating unit 2 to switch to high-damping mode. This command also includes two coordinated actions: first, driving the valve plate 3 of the upstream valve to reduce its opening to appropriately limit the airflow to the upstream area; second, controlling the regulating unit 2 of the valve to switch to high-damping mode. High-damping mode means significantly increasing the tortuosity of the flow channel, thereby further increasing the local airflow resistance of the valve while reducing the opening.

[0055] The purpose of this combined action is to establish a higher pressure barrier on the upstream side of the high-temperature zone. Its physical effect is to reduce the lateral airflow between the grate chambers through the clinker layer, forcing more cooling airflow to concentrate and penetrate the downstream high-temperature material layer, while also helping to stabilize the overall pressure distribution of the system.

[0056] Through the coordinated execution of the first and second control commands, the control system achieves targeted enhanced cooling of abnormally high-temperature areas and active guidance of airflow paths, thereby quickly suppressing the spread of high-temperature areas and effectively responding to sudden working conditions in production.

[0057] Specifically, as shown in Figure 5, the dynamic response process of the control system in dealing with the local high temperature material concentration mode of the grate bed is illustrated. The horizontal axis of the figure is the system running time (seconds), the left vertical axis is the clinker temperature in the area, and the right vertical axis is the valve opening.

[0058] The test conditions are set as follows: at T=50 seconds, the clinker temperature in the monitoring area suddenly changes and quickly exceeds the preset threshold, triggering the abnormal condition judgment; T=50s~55s (abnormal trigger): the system identifies the trend of high temperature material concentration, at which time the clinker temperature curve (solid line) rises exponentially; T=55s (linkage strategy execution): after calculation, the control module issues two sets of instructions at the same time.

[0059] Command 1: Drive the target area valve (dashed line) to open rapidly and significantly (from 40% to over 85%), and perform powerful cooling in conjunction with the low-damping mode; Command 2: Drive the upstream adjacent valve (dotted line) to close rapidly (from 40% to below 20%), and build a pressure barrier in conjunction with the high-damping mode.

[0060] Under the aforementioned linkage strategy, the clinker temperature curve reaches its peak at around T=60s and then rapidly drops back, eventually converging into the safe temperature range. Therefore, the heat diffusion can be effectively suppressed by using a multi-valve linkage mechanism.

[0061] Furthermore, the control module is also equipped with a thermal protection control strategy. The goal of this strategy is to prevent malfunctions such as thermal expansion deformation, sealing material failure, and jamming of moving parts caused by overheating of the valve body metal through proactive intervention. The triggering and execution of the thermal protection control strategy are independent of the conflict coordination process and the operating mode management process, and have a higher execution priority to ensure the safety of the equipment body. The thermal protection control strategy includes: when the temperature of the valve body detected by the temperature sensor located in a key part of the valve body shell 1 exceeds a preset first safe temperature threshold, which is set according to the allowable operating temperature and safety margin of the valve body material, the control module immediately generates a clear instruction and sends it to the cooling system. The purpose of this instruction is to increase the cooling intensity of the cooling system. The specific execution method can be to increase the flow rate of the cooling medium, increase the speed of the cooling fan, or adjust the temperature of the cooling medium, thereby enhancing the ability to remove heat from the valve body shell 1 and forcing the valve body temperature to drop back to a safe range.

[0062] When the control module calculates, based on real-time monitoring data, that the rate of temperature rise of the valve body exceeds a preset first rate threshold, it indicates that the valve body is undergoing a rapid and potentially uncontrollable heating process. At this time, the control module will perform an operation to increase the control dead zone of the valve plate 3. In the control logic, the control dead zone refers to a preset error band, which is a temporarily relaxed, permissible control deviation range for equipment protection. When the deviation between the actual opening degree of the valve plate 3 and the target opening degree is less than the threshold of this range, the control system will suppress the actuator driving the valve plate 3.

[0063] Increasing the control dead zone of the valve plate 3 means dynamically increasing the value of the threshold when the thermal protection control strategy is triggered. This temporarily relaxes the tracking accuracy requirements of the valve plate 3 opening during the rapid rise of the valve body temperature, avoiding excessive mechanical stress on the drive mechanism due to the difference in thermal expansion deformation between the valve body and the valve stem. This achieves a protective pause, and the original control dead zone setting is restored after the temperature rise rate drops or after a predetermined time.

[0064] Furthermore, the control module also stores a pre-calibrated valve characteristic database, which contains data on the correspondence between valve opening, flow rate, and pressure loss under different damping modes. The valve characteristic database is a set of data that is pre-established and stored inside the control module. The establishment of this database is based on a systematic calibration test of a physical valve prototype on a standard testing device. In the test, under each stable damping mode, a series of data points of the valve plate opening, corresponding output flow rate, and pressure loss before and after the valve are measured and recorded. Through these data, a mathematical model or data lookup table that can reflect the complex correspondence between valve opening, flow rate, and pressure loss under a specific damping mode can be fitted or constructed (or a family of three-dimensional relationship curves between valve opening, flow rate, and pressure loss under different damping modes can be calibrated). The collection of these models or data tables constitutes the valve characteristic database.

[0065] The control module is used to query the valve characteristic database based on the current damping mode when generating the opening command to drive the valve plate 3, and to perform nonlinear compensation on the opening command. In actual operation, when the control module calculates a desired target flow rate according to process requirements, it first needs to generate an initial opening command for the valve plate 3. Before generating the final command, the control module will query the valve characteristic database. The key index for the query is the damping mode of the regulating unit 2. Based on the current damping mode, the control module calls the corresponding data relationship and reverse-calculates the theoretical opening value required by the valve plate 3 to achieve the target flow rate.

[0066] Because the characteristics of the actual valve deviate from the ideal model, and wear or dust accumulation may occur during operation, directly using the theoretical opening degree may not accurately achieve the target flow rate. Therefore, the control module compensates for the initial opening degree command. The compensation is a correction calculation based on database information. This compensation can be an addition or subtraction of an offset from the theoretical opening degree value, or a scaling based on a correction coefficient. The purpose is to ensure that the final issued opening degree command can offset the valve's nonlinearity and individual differences, so that the actual output flow rate after driving the valve to act is as close as possible to the expected target flow rate.

[0067] This mechanism significantly improves the flow control accuracy and consistency of the intelligent flow regulating valve throughout its entire operating range.

[0068] Furthermore, the control module is used to perform system-wide airflow coordination optimization. The necessity of this function lies in the fact that the cooling demand of each area of ​​the grate cooler is dynamically changing, and the damping mode combination adopted by different intelligent flow regulating valves will directly affect the fluid resistance distribution of the entire under-grate air supply network, thereby affecting the total energy consumption of the main fan that works to overcome this resistance. The system-wide airflow coordination optimization has clear optimization objectives and constraints. Its core optimization objective is to reduce the total system energy consumption. In engineering, this total energy consumption is usually positively correlated with the total current or total power of the main motor driving all under-grate fans. Therefore, minimizing the total fan current can be used as a specific, online-monitorable objective function. Its fundamental constraint is that the cooling demand of each grate area must be met. That is, any optimization adjustment cannot be at the expense of sacrificing the clinker cooling effect in key areas. This ensures that the effectiveness of the optimization will not affect the core process.

[0069] The overall system airflow optimization is achieved through iterative calculation. The control module initiates an optimization calculation periodically or when the operating conditions change significantly. In the calculation, while maintaining the current opening of each valve to meet the immediate airflow demand, the damping mode of each intelligent flow regulating valve is used as a freely adjustable decision variable. The control module will construct or call a system resistance model, which can estimate the total resistance characteristics of the entire grate duct system under different valve damping mode combinations.

[0070] Subsequently, the control module performs iterative calculations, which involves systematically or heuristically trying various combinations of damping modes. For each combination, the control module uses the system resistance model and the fan performance curve to calculate the operating point of the fan system when maintaining the required total air volume under that resistance, and calculates the corresponding total current or power value. By comparing the calculation results of different schemes, the control module can select or iteratively approximate a damping mode combination that minimizes the total energy consumption of the system.

[0071] After determining a better combination of damping modes, the control module generates corresponding instructions to coordinately adjust the regulating units 2 of each intelligent flow regulating valve to the new target damping mode.

[0072] This adjustment process is usually carried out smoothly to avoid stressing the system. By continuously or periodically performing this optimization, the control system can actively seek and maintain an operating state with lower system resistance and higher fan efficiency while ensuring the cooling process, thereby achieving significant energy-saving effects.

[0073] Preferably, the system-wide airflow collaborative optimization adopts a step-by-step trial algorithm. When the system is in a steady state, the algorithm is periodically activated to identify the non-critical area valve with the largest current airflow margin as the test node. The algorithm simulates reducing the damping mode of this node by one level (e.g., from high damping mode to medium damping mode) and simultaneously reducing the opening to maintain a constant airflow. Subsequently, the system monitors the feedback of changes in the main pipe pressure. If it is confirmed that the total energy consumption has decreased and there is no temperature abnormality, the state is locked; otherwise, the operation is rolled back and the next node is tried.

[0074] Furthermore, since there is no clinker or only ambient temperature clinker on the grate during cold start-up, the entire system temperature is very low. If conventional control parameters and strategies designed for hot conditions are directly applied, the control behavior may be inappropriate or cause equipment stress. Therefore, the control system also includes an adaptive start-up process. During the cold start-up phase of the system, the first step of the adaptive start-up process executed by the control module is to set all intelligent flow regulating valves to a safe initial state, that is, to control them to be in a fully open state and a low-damping mode. The fully open state means that the valve plate 3 has the largest opening and the airflow channel is the most unobstructed. The low-damping mode means that the regulating unit 2 has the least resistance to the airflow. The purpose of this combination is to allow the maximum amount of ambient temperature air to flow through the grate with minimal resistance in the early stage of start-up, to purge the entire grate cooler system and pipelines, remove any dust that may have accumulated, and to make the equipment temperature rise evenly and slowly, avoiding thermal stress caused by sudden local heating.

[0075] Subsequently, the control module will focus its monitoring on the system exhaust temperature, which typically refers to the gas temperature at the outlet of the grate cooler or the inlet of the waste heat boiler. This is a key parameter reflecting the overall heating status of the system. The control module continuously monitors this temperature signal and analyzes its changing trend, such as calculating the rate of temperature rise per unit time.

[0076] Based on the trend of the exhaust temperature change, the control module begins to dynamically adjust the operating parameters of each intelligent flow regulating valve. When the exhaust temperature is detected to be steadily rising, indicating that hot clinker is starting to enter the grate or the system is starting to be heated, the control module gradually and controllably increases the damping mode level of the regulating unit 2, for example, transitioning from low damping to medium damping, and simultaneously correspondingly reduces the opening of the valve plate 3. This adjustment process is gradual, aiming to gradually tighten the air supply as the system heat load increases, so that the increase in cooling air volume matches the introduction of clinker heat load.

[0077] The adjustment process continues until the exhaust temperature stabilizes within the preset operating range and the temperature change rate drops to a low level.

[0078] At this point, the system is considered to have entered a stable hot-state operation phase from the startup transition period. The control module then exits the adaptive startup process and transfers control of each intelligent flow regulating valve to the conflict coordination process and the operating mode management process, thereby entering steady-state regulation. This process ensures a smooth, safe, and efficient system startup.

[0079] Furthermore, the control module is used to exchange data with the central control system of the cement plant. The primary content of this data exchange is that the control module uploads data to the central control system of the cement plant. The uploaded data mainly includes two categories: the first category is the operating status data of the intelligent flow regulating valve, which is basic information reflecting the physical state of the equipment, such as the real-time opening degree of each valve, the current damping mode of the regulating unit 2, and the valve body temperature directly measured by the sensor; the second category is the execution result data of the collaborative decision-making logic within the control module, which is high-level information reflecting the intelligent decision-making process of the system, such as the final allocation sequence generated in the conflict coordination process, whether abnormal modes are identified and what strategies are triggered in the operating mode management process, and the recommended damping mode combination obtained in the system-wide airflow collaborative optimization.

[0080] Another aspect of the data exchange is that the control module receives data from the central control system of the cement plant. The core data received is the global production target parameters. These parameters represent the macro-operational requirements of the grate cooler and even the entire calcination system at the plant level, such as the set clinker target output, the required secondary air temperature control range, or the maximum allowable system energy consumption index. These production target parameters provide high-level setting basis and optimization direction for various processes within the control module.

[0081] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-stage damping adaptive cooling intelligent flow regulating valve, characterized in that, include: The valve body housing (1), the regulating unit (2), and the valve plate (3) are provided. An airflow channel is formed inside the valve body housing (1), and a cooling channel structure (4) for the flow of cooling medium is provided on the outside of the valve body housing (1). The regulating unit (2) is located upstream of the airflow channel inside the valve body housing (1) and is used to regulate the pressure drop and flow field distribution of the fluid flowing through the airflow channel by changing the tortuous path of the airflow channel. The valve plate (3) is located downstream of the regulating unit (2) and continuously adjusts the cross-sectional area of ​​the airflow channel by changing its rotation angle.

2. A control system for an intelligent flow regulating valve, used in the multi-stage damping adaptive cooling intelligent flow regulating valve as described in claim 1, characterized in that, include: At least one of the intelligent flow regulating valves; a cooling system, fluidly connected to the cooling channel structure (4) of the intelligent flow regulating valve, for cooling the valve body shell (1) of the intelligent flow regulating valve; a sensor group, for acquiring grate pressure, clinker temperature distribution and valve body temperature signals; a control module, communicatively connected to at least one of the intelligent flow regulating valves, the cooling system and the sensor group; the control module is used to execute conflict coordination process and working condition mode management process based on the signals of the sensor group.

3. The control system according to claim 2, characterized in that, The conflict coordination process is used to calculate the allocation weight of each valve based on the first priority rule and the second priority rule when it is determined that multiple intelligent flow control valves simultaneously request an increase in air volume, causing the total air volume demand of the system to exceed the current allocable air volume limit. The operating condition management process is used to identify preset abnormal operating condition modes by analyzing the thermal imaging characteristics of the clinker temperature distribution, and to trigger a multi-valve linkage control strategy corresponding to the abnormal operating condition mode.

4. The control system according to claim 3, characterized in that, The conflict coordination process includes: based on a first priority rule, sorting multiple requests according to the temperature deviation of the area corresponding to each intelligent flow control valve to generate a first sorting sequence, wherein the temperature deviation is proportional to the magnitude of the deviation of the clinker temperature in the current area from the preset cooling curve; based on a second priority rule, weighting and correcting the first sorting sequence according to the adjustment stability coefficient of each intelligent flow control valve to generate a final allocation sequence, wherein the adjustment stability coefficient is inversely proportional to the valve's opening adjustment frequency within a preset historical time window.

5. The control system according to claim 3, characterized in that, In the operating condition management process, the abnormal operating condition mode includes a high-temperature material concentration mode; the identification feature of the high-temperature material concentration mode is that a high-temperature area with a temperature exceeding a preset threshold and an area continuously expanding appears in the clinker temperature distribution; the multi-valve linkage control strategy corresponding to the high-temperature material concentration mode includes: generating a first control command to drive the intelligent flow regulating valve corresponding to the high-temperature area to increase its opening and control its regulating unit (2) to switch to a low-damping mode; at the same time, generating a second control command to drive the intelligent flow regulating valve adjacent to the upstream of the high-temperature area to decrease its opening and control its regulating unit (2) to switch to a high-damping mode.

6. The control system according to claim 2, characterized in that, The control module is also configured with a thermal protection control strategy, which includes: when the valve body temperature is detected to exceed a first safe temperature threshold, generating an instruction to increase the cooling intensity of the cooling system; and when the valve body temperature rise rate is detected to exceed a first rate threshold, increasing the control dead zone of the valve plate (3).

7. The control system according to claim 5, characterized in that, The control module also stores a valve characteristic database, which contains data on the correspondence between valve opening degree, flow rate and pressure loss under different damping modes. The control module is used to query the valve characteristic database based on the current damping mode and compensate the opening command when generating the opening command to drive the valve plate (3).

8. The control system according to claim 6, characterized in that, The control module is used to perform system-wide airflow coordination optimization; the system-wide airflow coordination optimization includes: taking the reduction of total system energy consumption as the optimization goal, and under the premise of meeting the cooling needs of each area, adjusting the damping mode combination of each intelligent flow regulating valve through iterative calculation.

9. The control system according to claim 4, characterized in that, The control system also includes an adaptive startup process; the adaptive startup process includes: during the cold start phase of the system, controlling the intelligent flow regulating valve to be in a fully open state and low damping mode; monitoring the system exhaust temperature, and adjusting the damping mode level and valve plate (3) opening based on the trend of the exhaust temperature change, until entering steady-state regulation.

10. The control system according to claim 2, characterized in that, The control module is used to exchange data with the central control system of the cement plant; the data exchange includes: uploading the operating status data of the intelligent flow regulating valve and the execution result data of the collaborative decision-making logic inside the control module, and receiving production target parameters from the central control system.

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