Grease post-spraying adding equipment

Abstract

The invention discloses grease post-spraying adding equipment which comprises a first vertical rack, two particle containing hoppers, a material spraying barrel and a mixing feeding groove are sequentially installed on the inner side of the first vertical rack from top to bottom, and the upper ends of the two particle containing hoppers are jointly and fixedly connected with a three-way feeding pipe. The device has the advantages that through the symmetrical layout design of the double granular material containing hoppers and the double grease metering barrels, the multiple weighing meters on the outer sides of the granular material containing hoppers are matched, feed granules can be accurately weighed in real time, the weighing meters are arranged on the outer sides of the granular material containing hoppers, and the weighing meters are arranged on the outer sides of the granular material containing hoppers. Meanwhile, the grease metering barrels can synchronously achieve quantitative storage and heating pretreatment of grease, during working, the double-particle containing hopper and the double grease metering barrels all adopt an alternate working mode, and continuous supply of feed particles and grease can be achieved through orderly regulation and control of the pneumatic discharging valves, the oil inlet control valves and the oil outlet control valves.

Description

Technical Field

[0001] This invention relates to the field of feed production equipment technology, specifically to a post-oil spraying and adding equipment. Background Technology

[0002] In feed production, adding animal or vegetable oils to feed can increase its energy content, promote the absorption of fat-soluble vitamins and pigments, accelerate animal growth, and reduce animal diseases. Oil addition is generally done after the feed pelleting process. Using a post-oil spraying device, the oil is evenly sprayed onto the surface of the feed pellets. This increases the feed's energy and palatability, improves pellet quality, and reduces dust generation during subsequent production and handling.

[0003] In existing oil and grease post-coating and adding equipment used in feed production plants, most of them use single-weighing to measure oil and feed, which makes it impossible to guarantee the accuracy and continuity of oil addition to feed, and the spraying efficiency is not high enough. Moreover, the multiple nozzles of the existing oil and grease post-coating and adding equipment operate synchronously and cannot be independently controlled or freely switched. Therefore, it is not possible to adjust the nozzle outlet pressure by automatically controlling the number of nozzles opening according to production needs through the control system. The uniformity of oil spraying cannot be guaranteed, and the nozzles cannot be replaced independently. When a nozzle is damaged and needs to be repaired or replaced, the entire equipment needs to be shut down, which affects production efficiency. To address these issues, we propose an oil and grease post-coating and adding equipment. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0005] The present invention solves the above-mentioned technical problems by adopting the following technical solutions: This invention provides a post-coating grease application device, comprising a first vertical frame. Two granular material hoppers, a material spraying barrel, and a mixing feed trough are sequentially installed from top to bottom on the inner side of the first vertical frame. A three-way feed pipe is fixedly connected to the upper ends of the two granular material hoppers. Multiple weighing devices are fixedly installed on the outer sides of each of the two granular material hoppers, and all the weighing devices are fixedly mounted on the first vertical frame. A control assembly is provided between the granular material hoppers and the material spraying barrel. An oil spraying unit is provided on the material spraying barrel. The inner cavity of the mixing feed trough is configured with... The system includes a mixing and conveying assembly. A second vertical frame is located on one side of the first vertical frame. Two grease metering tanks are installed inside the second vertical frame. Heaters are installed inside the cavities of the two grease metering tanks. Oil inlet pipes are connected to the upper ends of the two grease metering tanks. An oil injection pump is mounted on the inner side of the second vertical frame below the two grease metering tanks. Oil outlet pipes are fixedly connected to the lower ends of the two grease metering tanks. The other ends of the two oil outlet pipes are fixedly connected to the oil inlet of the oil injection pump, and the oil outlet of the oil injection pump is connected to the oil injection unit.

[0006] Preferably, the control component includes two pneumatic discharge valves, each of which is located at the lower end of a corresponding granular material container. The lower ends of the two pneumatic discharge valves are fixedly connected to a three-way conveying component, which is fixedly connected to the upper end of the material spraying bucket.

[0007] Preferably, the spraying unit includes two sets of spraying components installed on the outside of the material spraying barrel. Each set of spraying components includes at least two nozzles installed on the outside of the material spraying barrel. The ends of the nozzles away from the material spraying barrel are fixedly connected to connecting pipes. The other ends of the connecting pipes are fixedly connected to an oil supply branch. One end of the oil supply branch is fixedly connected to the oil outlet of the spraying pump.

[0008] Preferably, the mixing conveying assembly includes a drive motor fixedly installed on one side of the mixing feeding trough. The output end of the drive motor is fixedly connected to a rotating rod that is rotatably connected to the mixing feeding trough. An auger conveying blade is fixedly connected to the outer side of the rotating rod. A filter screen is sleeved on the outer side of the end of the auger conveying blade away from the drive motor. A discharge port opened on the mixing feeding trough is provided below the filter screen. An inspection door is installed on the outer side of the mixing feeding trough. At least two first fastening bolts are provided on the inspection door. The threaded ends of the plurality of first fastening bolts are threadedly connected to the mixing feeding trough. A first handle is fixedly connected to the outer side of the inspection door.

[0009] Preferably, an observation window is provided on the outside of the material spraying bucket, and at least two second fastening bolts are provided on the observation window. The threaded end of the second fastening bolt is threadedly connected to the material spraying bucket, and a second handle is fixedly connected to the outside of the observation window.

[0010] Preferably, an oil inlet control valve is installed on the outside of the oil inlet pipe, and an oil outlet control valve is installed on the outside of the oil outlet pipe.

[0011] The present invention also provides a method for adding grease after spraying, comprising: Real-time monitoring of the conveying rate of the mixing feeder; Based on the conveying rate, a target particle mass flow rate setpoint and a target oil mass flow rate setpoint are generated; Real-time acquisition of the actual mass flow rate of the current granular material and the actual mass flow rate of the current oil; A compensation control signal is generated based on the first deviation between the target particle mass flow rate setpoint and the actual mass flow rate of the particle material, and the second deviation between the target oil mass flow rate setpoint and the actual mass flow rate of the oil. Based on the target particle mass flow rate setpoint, the target oil mass flow rate setpoint, and the compensation control signal, a final control signal is generated to adjust the supply of the particle material and the oil, respectively.

[0012] Preferably, generating the target particle mass flow rate setpoint and the target oil mass flow rate setpoint based on the conveying rate includes: Based on the conveying rate and the preset linear density of the granules, the target granule mass flow rate setting value is generated; The target oil mass flow rate setting value is generated based on the target particle mass flow rate setting value and the preset target oil ratio.

[0013] Preferably, generating the final control signal based on the target particle mass flow rate setpoint, the target oil mass flow rate setpoint, and the compensation control signal includes: Based on the target particle mass flow rate setpoint, a first basic control signal is obtained from the first actuator characteristic mapping table; The first basic control signal and the first compensation control signal are combined to generate a first final control signal to regulate the supply of the granular material. Based on the target oil mass flow rate setpoint, the second basic control signal is obtained from the second actuator characteristic mapping table; The second basic control signal is combined with the second compensation control signal to generate a second final control signal to regulate the supply of the grease.

[0014] Preferably, the method further includes: For the first actuator used to supply the granular material, under a series of different control inputs, its corresponding stable mass flow rate is measured and recorded to construct a characteristic mapping table of the first actuator; For the second actuator used to supply the grease, under a series of different control inputs, its corresponding stable mass flow rate is measured and recorded to construct a characteristic mapping table for the second actuator.

[0015] Preferably, the method further includes: The remaining weight of the pellet material container during monitoring operations; When the remaining weight is lower than the first preset switching threshold, the supply of the granular material is smoothly switched to the standby granular material container. The remaining weight of the grease measuring container during monitoring operations; When the remaining weight is lower than the second preset switching threshold, the supply of grease is smoothly switched to the standby grease metering tank.

[0016] Compared with the prior art, the present invention provides a post-coating grease application device, which has the following beneficial effects: 1. This invention features a symmetrical layout design of two pellet feed hoppers and two oil metering tanks. With the addition of multiple weighing devices on the outside of the pellet feed hoppers, the feed pellets can be weighed accurately in real time. At the same time, the oil metering tanks can simultaneously achieve quantitative storage and heating pretreatment of oil. During operation, both the two pellet feed hoppers and the two oil metering tanks operate in an alternating mode. Through the orderly regulation of the pneumatic unloading valve, oil inlet control valve, and oil outlet control valve, the uninterrupted supply of feed pellets and oil can be achieved, avoiding downtime during single-tank metering and feeding, and improving the overall spraying efficiency.

[0017] 2. The oil spraying unit of this invention adopts a two-set oil spraying component design, with each set containing multiple independent nozzles. Each nozzle is connected to the corresponding oil supply branch through a connecting pipe. In conjunction with the control system, the number of nozzles opened and the outlet pressure can be automatically adjusted according to production needs. Combined with the material distribution guide structure inside the material spraying tank, the feed particles fall in a curtain shape, ensuring that the oil can evenly cover each feed particle, improving the spraying quality. At the same time, each nozzle can be independently controlled to turn on and off. When a single nozzle malfunctions, the faulty nozzle can be turned off and a backup nozzle can be switched. Repair and replacement can be completed without stopping the machine, effectively avoiding the impact of equipment downtime on production continuity, thereby ensuring production efficiency.

[0018] 3. This invention, by setting auger conveyor blades in the mixing and feeding trough, can fully stir and mix the sprayed feed particles, avoiding localized oil accumulation. At the same time, in conjunction with the filter screen, it can filter and separate lumpy materials, preventing lumpy materials from entering the next process and causing equipment blockage, thus improving the product qualification rate. In addition, the mixing and feeding trough is equipped with a detachable maintenance door, which can facilitate operators to quickly clean the filter screen and maintain internal components. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a partial structural diagram of the present invention. Figure 1 ; Figure 3 This is a partial structural diagram of the present invention. Figure 2 ; Figure 4 This is a schematic diagram of the mixing feed trough structure of the present invention; Figure 5 This is a schematic diagram of the material spraying bucket structure of the present invention; Figure 6 This is a partial structural cross-sectional view of the present invention; Figure 7 This is a cross-sectional view of the mixing feed trough structure of the present invention; Figure 8 This is a flowchart of the post-coating grease application method of the present invention; Figure 9 The graph shows the response comparison under different conditions.

[0020] In the diagram: 1. First vertical frame; 2. Granular material holding hopper; 3. Material spraying bucket; 4. Mixing and feeding trough; 5. Three-way feed pipe; 6. Weighing device; 7. Pneumatic discharge valve; 8. Three-way conveyor; 9. Drive motor; 11. Rotating rod; 12. Screw conveyor blades; 13. Filter screen; 14. Bearing; 15. Discharge port; 16. Inspection door; 17. First fastening bolt; 18. First handle; 19. Second vertical frame; 20. Oil inlet control valve; 21. Oil inlet pipe; 22. Grease metering bucket; 23. Oil outlet control valve; 24. Oil injection pump; 25. Oil outlet pipe; 26. Oil supply branch; 27. Connecting pipe; 28. Nozzle; 29. ​​Observation window; 30. Second fastening bolt; 31. Second handle; 32. Heater. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1-7 A post-coating grease application device includes a first vertical frame 1. Two granular material hoppers 2, a material spraying tank 3, and a mixing feed trough 4 are sequentially installed from top to bottom on the inner side of the first vertical frame 1. A three-way feed pipe 5 is fixedly connected to the upper ends of the two granular material hoppers 2. Multiple weighing devices 6 are fixedly installed on the outer sides of each of the two granular material hoppers 2. The multiple weighing devices 6 are all fixedly installed on the first vertical frame 1. A control assembly is provided between the granular material hoppers 2 and the material spraying tank 3. An oil spraying unit is provided on the material spraying tank 3. A mixing conveying assembly is provided inside the mixing feed trough 4. A second vertical frame 19 is provided on one side of the first vertical frame 1. Two grease metering tanks 22 are installed inside the second vertical frame 19. Heaters 32 are installed in the inner cavity of the two grease metering tanks 22 respectively. Oil inlet pipes 21 are connected to the upper ends of the two grease metering tanks 22 respectively. A fuel injection pump 24 is installed and hung inside the second vertical frame 19 below the two grease metering tanks 22. Oil outlet pipes 25 are fixedly connected to the lower ends of the two grease metering tanks 22 respectively. The other ends of the two oil outlet pipes 25 are fixedly connected to the oil inlet end of the fuel injection pump 24, and the oil outlet end of the fuel injection pump 24 is connected to the fuel injection unit.

[0023] In this embodiment, the control component includes two pneumatic unloading valves 7. The two pneumatic unloading valves 7 are respectively set at the lower end of the corresponding granular material holding hopper 2. The lower ends of the two pneumatic unloading valves 7 are fixedly connected to a three-way conveying component 8, which is fixedly connected to the upper end of the material spraying bucket 3.

[0024] Specifically, feed pellets are first added to the two pellet holding hoppers 2 through the three-way feed pipe 5. At this time, multiple weighing and measuring devices 6 installed on the outside of the pellet holding hoppers 2 and fixed on the first vertical frame 1 can accurately weigh the pellet holding hoppers 2. When the feed pellets are sprayed, the weighed feed pellets can be sent into the material spraying bucket 3 through the three-way conveyor 8 by controlling the pneumatic discharge valve 7 in the control and regulating component. At this time, the two pellet holding hoppers 2 adopt an alternating working mode, and with the orderly control of the pneumatic discharge valve 7, the feed pellets can be continuously supplied to the spraying device.

[0025] In this embodiment, the oil spraying unit includes two sets of oil spraying components installed on the outside of the material spraying tank 3. Each set of oil spraying components includes at least two nozzles 28 installed on the outside of the material spraying tank 3. The ends of the multiple nozzles 28 away from the material spraying tank 3 are all fixedly connected to a connecting pipe 27. The other ends of the multiple connecting pipes 27 are all fixedly connected to an oil supply branch 26. One end of the oil supply branch 26 is fixedly connected to the oil outlet end of the oil spraying pump 24.

[0026] Specifically, the oil raw material is fed into two oil metering tanks 22 inside the second vertical frame 19 via the oil inlet pipe 21. The heater 32 inside the oil metering tank 22 heats the oil to the appropriate temperature required for this spraying process. After heating, the oil is supplied to the spray pump 24 via the oil outlet pipe 25. The two oil metering tanks 22 also operate in rotation to ensure a continuous supply of oil to the spray pump 24. After the spray pump 24 starts, it pressurizes and pumps the oil to the oil supply branch 26, and then delivers it via the connecting pipe 27 to the nozzle 28 outside the material spraying tank 3, uniformly spraying the feed particles through the spraying device with oil. Inside the material spraying tank 3, feed pellets are discharged from the corresponding collection structure and then form a curtain shape through the appropriate bulk material guide structure, falling in a uniform and stable state. The nozzles 28 on both sides of the material spraying tank 3 spray oil onto the feed pellets flowing out of the curtain shape. At this time, the control system can automatically control the number of nozzles 28 that are opened according to the actual production needs, and automatically adjust the outlet pressure of the nozzles 28 to ensure the uniformity of oil spraying. When a nozzle 28 is not working properly, it can be closed and another spare nozzle 28 can be opened. Thus, the faulty nozzle 28 can be repaired or replaced without stopping the equipment, thereby ensuring the continuity of production.

[0027] In this embodiment, the mixing conveying assembly includes a drive motor 9 fixedly installed on one side of the mixing feed trough 4. The output end of the drive motor 9 is fixedly connected to a rotating rod 11 that is rotatably connected to the mixing feed trough 4. An auger conveying blade 12 is fixedly connected to the outside of the rotating rod 11. A filter screen 13 is sleeved on the outside of the end of the auger conveying blade 12 away from the drive motor 9. A discharge port 15 is provided below the filter screen 13 and is opened on the mixing feed trough 4. An inspection door 16 is provided on the outside of the filter screen 13 and is installed on the outside of the mixing feed trough 4. At least two first fastening bolts 17 are provided on the inspection door 16. The threaded ends of the multiple first fastening bolts 17 are all threadedly connected to the mixing feed trough 4. A first handle 18 is fixedly connected to the outside of the inspection door 16.

[0028] Specifically, after the feed pellets have been coated with grease, they will fall from the material spraying tank 3 into the mixing and feeding trough 4. At this time, the drive motor 9 is started to drive the rotating rod 11 and the auger conveying blades 12 to fully stir and mix them and convey them to the other end of the mixing and feeding trough 4. A bearing 14 is set at the end of the mixing and feeding trough 4 away from the drive motor 9. The design of the bearing 14 can further improve the stability of the rotating rod 11 and the auger conveying blades 12 when rotating. At this time, the feed pellets are filtered and separated by the filter screen 13, which can effectively prevent the feed pellets from sticking and clumping. Finally, the qualified material is smoothly conveyed to the next process through the discharge port 15, thereby realizing the post-coating treatment of grease.

[0029] More specifically, the design of the inspection door 16 facilitates the inspection and maintenance of the filter screen 13 in case of blockage. The inspection door 16 adopts a detachable fastening structure and is fixed by at least two first fastening bolts 17. After the threaded end of the bolt passes through the preset through hole of the inspection door 16, it precisely engages with the threaded hole on the outer wall of the mixing feed trough 4. This not only ensures the firmness of the connection between the inspection door 16 and the trough, but also improves the sealing of the connection and prevents material leakage or dust escape during feeding.

[0030] In this embodiment, an observation window 29 is provided on the outside of the material spraying bucket 3. At least two second fastening bolts 30 are provided on the observation window 29. The threaded end of the second fastening bolt 30 is threadedly connected to the material spraying bucket 3, and a second handle 31 is fixedly connected to the outside of the observation window 29.

[0031] Specifically, the visual observation design of the observation window 29 allows operators to monitor the remaining amount of material, mixing uniformity, and material status in the barrel in real time without opening the barrel. This effectively avoids material contamination, volatilization, or leakage caused by frequent opening of the lid. Furthermore, the observation window 29 is fastened to the outer wall of the material spraying barrel 3 by at least two second fastening bolts 30, ensuring the sealing and structural stability of the connection between the observation window 29 and the barrel, and adapting to the pressure environment during spraying operations. The second handle 31 on its outer side facilitates quick disassembly, cleaning, or replacement of the observation window 29 by operators, further improving the ease of equipment maintenance.

[0032] In this embodiment, an oil inlet control valve 20 is installed on the outside of the oil inlet pipe 21, and an oil outlet control valve 23 is installed on the outside of the oil outlet pipe 25.

[0033] Specifically, by setting up a matching structure of an oil inlet control valve 20 and an oil inlet pipe 21 at the oil inlet end, the operator can precisely adjust the oil inlet flow rate according to the actual oil supply needs of the equipment, thereby achieving flexible control of the oil supply rate. At the same time, an oil outlet control valve 23 is installed on the outside of the oil outlet pipe 25 at the oil outlet end, which can monitor the on / off state and flow parameters of the output oil in real time, effectively avoiding problems such as backflow, leakage or unstable flow during oil transportation. By using the two together, bidirectional control of the entire oil transportation process can be formed, ensuring the stability and accuracy of the equipment's oil supply system operation.

[0034] During operation, feed pellets are first added to two pellet holding hoppers 2 through the three-way feed pipe 5. Multiple weighing devices 6, installed on the outside of the pellet holding hoppers 2 and fixed to the first vertical frame 1, accurately weigh the pellet holding hoppers 2. When spraying the feed pellets, the weighed feed pellets are fed into the material spraying tank 3 via the three-way conveyor 8 through the pneumatic discharge valve 7 in the control and regulation component. The two pellet holding hoppers 2 operate alternately, and with the orderly control of the pneumatic discharge valve 7, a continuous supply of feed pellets to the spraying device can be achieved. Simultaneously, oil raw materials are fed into two oil metering tanks 22 inside the second vertical frame 19 through the oil inlet pipe 21 and oil inlet control valve 20. The heater 32 inside the oil metering tank 22 heats the oil to the appropriate temperature required for this spraying process. After heating, the oil is supplied to the oil spraying pump 24 through the oil outlet pipe 25 and oil outlet control valve 23. The two oil metering tanks 22 also operate alternately. The system ensures a continuous supply of grease to the oil injection pump 24. After the oil injection pump 24 starts, it pressurizes and pumps the grease to the oil supply branch 26, and then through the connecting pipe 27 to the nozzles 28 on the outside of the material spraying tank 3. The feed particles passing through the spraying device are uniformly sprayed with grease. Inside the material spraying tank 3, the feed particles are discharged from the corresponding collection structure and form a curtain shape through the appropriate material guide structure, falling in a uniform and stable state. The nozzles 28 on both sides of the material spraying tank 3 spray grease onto the feed particles flowing out of the curtain shape. At this time, the control system can automatically control the number of nozzles 28 opened according to the actual production needs, and automatically adjust the outlet pressure of the nozzles 28 to ensure the uniformity of grease spraying. When a nozzle 28 is not working properly, it can be closed and another spare nozzle 28 can be opened. Then, without stopping the equipment, the faulty nozzle 28 can be repaired or replaced by visual observation through the observation window 29 on the outside of the material spraying tank 3, ensuring production continuity.

[0035] After the feed pellets have been coated with grease, they will fall from the material spraying tank 3 into the mixing and feeding tank 4. At this time, the drive motor 9 is started to drive the rotating rod 11 and the auger conveying blades 12 to fully stir and mix them and transport them to the other end of the mixing and feeding tank 4. Then, they are filtered and separated by the filter screen 13, which can effectively prevent the feed pellets from sticking and clumping. Finally, the qualified material is smoothly transported to the next process through the discharge port 15, thereby realizing the post-coating treatment of grease.

[0036] This invention also provides a method for post-coating grease application, which is performed by the aforementioned equipment, such as... Figure 8 As shown, the process includes the following steps: S100: System initialization and calibration.

[0037] In one embodiment, this step is performed before the start of a new production task or after a change of material type, and specifically includes the following sub-steps: S110, Set basic parameters. In this sub-step, the operator inputs basic process parameters related to the current production task through the human-machine interface (HMI). These parameters are stored in the non-volatile storage area of ​​the central control unit M100 as the basis for subsequent calculations. These parameters mainly include two core values: the target oil ratio. and the average linear density of granules Target oil ratio It is the percentage of the total mass (mass of pellets + mass of oil) in the final product, and this parameter is determined by the specific feed formulation process.

[0038] For example, if a feed formula requires the addition of 5% oil, the operator will enter the value 5.0, which will be stored internally by the system as 0.05.

[0039] Average linear density of granules The unit is kilograms per meter (kg / m), and its physical meaning is the mass of pellets carried per unit length of conveyor belt when the pellets are conveyed in a normal stacked state on the conveyor belt of the mixing feed trough 4. Since different types of feed have different pellet sizes, shapes, and bulk densities, this parameter needs to be calibrated when using different materials. Preferably, the calibration method can be: at a constant conveying speed... (Unit: m / s) The equipment is designed to transport only granular material and run for a precise period of time. (Unit: seconds), while simultaneously using a high-precision container and scale to collect and weigh the total mass of the granular material conveyed during this time at the outlet. (Unit: kg). Therefore, the average linear density of the granular material... .

[0040] For example, assume that the conveying speed is set during calibration. The speed is 1.0 m / s, and the running time is... The run lasted 60 seconds; after the run, the total mass of the collected pellets was measured. If the weight is 150.0 kg, then the average linear density of this batch of pellets is... .

[0041] S120, perform sensor zero-point calibration.

[0042] In this sub-step, it is ensured that both the pellet hopper 2 and the grease metering tank 22 are in an unloaded state. Subsequently, the central control unit M100 instructs the sensor data acquisition module M500 to read the initial readings of all weighing meters 6 and flow meters. These readings may not be completely zero due to sensor drift or environmental influences. The system stores these initial readings as their respective zero-point offset values. In subsequent normal operation, all real-time values ​​read from the sensors will be subtracted from their corresponding zero-point offset values ​​to obtain more accurate measurement results.

[0043] For example, in an unloaded state, the weighing scale reading of hopper A is 0.15 kg, and the weighing scale reading of hopper B is -0.08 kg. The system will record these two values ​​as their respective zero-point offsets. When hopper A is subsequently filled and the reading is 200.15 kg, the system calculates the net weight as 200.15 - 0.15 = 200.00 kg, and so on.

[0044] S130, Generate actuator characteristic calibration and mapping table.

[0045] First, the first actuator used to supply granular material is calibrated; this first actuator can be a pneumatic discharge valve 7. The central control unit M100 sequentially instructs the valve to perform multiple different control inputs in an open-loop manner. Since the valve is controlled by a PWM signal, its control input is the PWM duty cycle.

[0046] For example, the central control unit M100 will sequentially set the PWM duty cycle to 20%, 30%, 40%, 50%, 60%, 70%, 80%, and 90%; under each duty cycle setting, the system will maintain this state for a period of time (e.g., 30 seconds) until the actual mass flow rate of the pellet material is measured. Once a stable value is reached, the system records the current [PWM duty cycle, stable flow rate] as a data pair. For example, if the stable flow rate is measured to be 2.45 kg / s when the PWM duty cycle is 50%, the data pair (50.0, 2.45) is recorded, and so on.

[0047] After completing tests for all preset duty cycles, the system obtained a series of such data pairs. These data pairs together constitute the first actuator characteristic mapping table.

[0048] Then, the system performs a similar calibration process on the second actuator used to supply grease, which is the inverter-controlled fuel injection pump 24, whose control input is the inverter's output frequency.

[0049] For example, the central control unit M100 sequentially sets the pump's operating frequency to 15.0 Hz, 20.0 Hz, 25.0 Hz, ..., 45.0 Hz. At each frequency setting, the system waits for the grease flow meter reading to stabilize and records the data pair (pump frequency, stable flow rate). For example, when the frequency is 30.0 Hz and the measured stable flow rate is 0.128 kg / s, the data pair (30.0, 0.128) is recorded, and so on. After completing all tests, the system obtains a series of data pairs describing the characteristics of the grease pump, which constitute the second actuator characteristic mapping table.

[0050] These two mapping tables are stored in the memory of the central control unit M100. In subsequent steps, when it is necessary to determine the actuator's control input based on the target flow rate, the system will look up the corresponding mapping table. If the target flow rate falls exactly between two calibrated data points, the system will use linear interpolation to calculate the precise control input value.

[0051] S200: Real-time monitoring of the conveying rate of the mixing feeder.

[0052] In this embodiment, the following sub-steps are specifically included: S210, in this step, as the drive motor 9 of the hybrid conveying subsystem M400 rotates, a rotary encoder mounted on its shaft generates continuous electrical pulse signals proportional to the rotational speed. A high-speed counter module inside the sensor data acquisition module M500 counts these pulses at a fixed high-frequency sampling period (e.g., 100 milliseconds). Subsequently, the processor within the module converts the pulse count value per unit time into the current linear velocity of the hybrid feed trough 4 based on the known encoder resolution and the known mechanical transmission ratio of the device. The encoder has a resolution of 2048 pulses per revolution, and the mechanical transmission ratio is the distance the conveyor belt travels per revolution of the motor. This data is packaged into sensor data frames and periodically sent to the central control unit M100.

[0053] For example, assuming the encoder resolution is 2048 pulses / revolution and the mechanical transmission ratio is 0.2 meters of conveyor belt advance per motor revolution; within a 100-millisecond sampling period, the high-speed counter module counts 4096 pulses; then the number of motor revolutions within that period is... Turn; the corresponding conveyor belt advance distance is Meters. Therefore, the current delivery rate Calculated as And so on.

[0054] S300: Generates mixed control commands.

[0055] This step is executed cyclically by the central control unit M100 within a fixed 100-millisecond control cycle, and it includes three sub-steps: feedforward calculation, feedback deviation calculation, and PID compensation calculation. S310 performs feedforward calculations.

[0056] In this sub-step, the central control unit M100 performs calculations of the feedforward prediction model to predict in advance the basic material flow required to maintain the target ratio based on the current production rate.

[0057] Specifically, the central control unit M100 receives the real-time transmission rate. And read the set parameters from memory. and Then, perform the following calculations: First, generate the target particle mass flow rate setpoint: This means that if the mass of particles per unit length of conveyor belt is So, to keep up with the speed is The mass of granular material that needs to be supplied per second by the conveyor belt is the product of the two.

[0058] Secondly, generate the target oil mass flow rate setpoint: It is important to note that when the oil ratio When the value is small, approximate formulas are usually used to simplify calculations. , here It can be less than 10%; under strict process requirements, because This indicates the proportion of fat to total mass, so the former should be used.

[0059] These two calculated and These are dynamically changing setpoints, which constitute the objectives of the control system.

[0060] For example, at a certain moment , measured The parameters that have been set are: and (i.e., 0.05). Therefore: Target particle mass flow rate setpoint .

[0061] Target oil mass flow rate setpoint If an approximate formula is used, then it is... .

[0062] S320 performs feedback deviation calculation.

[0063] In this sub-step, the central control unit M100 compares the target given by the feedforward model with the actual results measured by the sensors to calculate the current control deviation.

[0064] Specifically, the central control unit M100 obtains the real-time weight of the current working hopper from the sensor data frame. Real-time readings of grease flow meter This value represents the actual mass flow rate of the oil. To obtain the actual mass flow rate of the pelleted material... The system needs to process the weight data. The data is processed. Directly subtracting the weights of two adjacent sampling points and then dividing by the time interval (i.e., numerical differentiation) is severely interfered with by sensor noise. Therefore, this embodiment performs least-squares linear fitting on a series of real-time weight data within a preset, fixed-length sliding time window.

[0065] For example, assuming a control period of 100 milliseconds, the length of the sliding time window is set to 10 sampling points, or 1 second. At time... The system memory stores data from Instant arrival 10 weight data points per second The system performs linear regression analysis on these 10 data points to find a best-fit line. This makes the sum of squared residuals Minimum. According to the principle of least squares, the slope The calculation formula is ,in Its slope This represents the average rate of change in weight within that time window. Since the material is flowing out, the weight decreases, therefore the slope... It should be a negative value. Therefore, the actual mass flow rate of the pellets is determined to be... .

[0066] Assume at time... The slope of the fitted straight line obtained by calculating the 10 weight data points within the sliding window. The value is -9.95 kg / s. The system then determines the actual mass flow rate of the current pellets. At the same time, the actual flow rate of the oil is read from the flow meter. .

[0067] Subsequently, the central control unit M100 calculates the flow deviation: First deviation (particle flow rate deviation): .

[0068] Second deviation (oil flow deviation): .

[0069] Based on the example data, ; These two deviation signals will serve as inputs to the PID controller.

[0070] S330 performs PID compensation calculations.

[0071] In this sub-step, two parallel PID controllers inside the central control unit M100 process the deviation signal calculated by S320 to generate control quantities for compensation.

[0072] A standard PID control algorithm consists of three parts: proportional (P), integral (I), and derivative (D). Its output... It is the sum of three: in, These are the three gain parameters of the PID controller, which need to be tuned according to the dynamic response characteristics of the system; among them, the proportional term... Provides immediate control action proportional to the current deviation; integral term Used to eliminate steady-state errors in the system, the integral term will continue to accumulate as long as the deviation is not zero, thereby driving changes in the control output until the deviation is eliminated; the derivative term... It provides predictive control based on the rate of change of the deviation, thereby suppressing overshoot and accelerating system response.

[0073] For example, such as Figure 9 As shown, the integral gain can be adjusted first. and differential gain Set it to 0, then gradually increase the proportional gain from small to large. Simultaneously, a small step disturbance is applied to the system's setpoint to observe its response; for example, the target flow setpoint is suddenly increased by 10%. When the system produces a constant-amplitude oscillation in response to this step disturbance, the gain at this point is recorded as the critical gain. and the oscillation period as the critical period Then, the PID parameters were set to... , , .

[0074] In this embodiment, the central control unit M100 performs the following calculations: First compensation control signal (granular material): Second compensation control signal (grease): For example, suppose the parameters of the pellet PID controller are tuned using the method described above. , , At that moment ,deviation And assuming the current value of the integral accumulator term is -0.2, and the rate of change of the deviation is 0.1, then the compensation output at this moment is... The unit of this compensation signal is the same as that of the control signal, and it will be used to correct the base control signal.

[0075] S400: Supply particles.

[0076] In this embodiment, the following sub-steps are specifically included: S410, in this step, the central control unit M100 combines the results of the feedforward calculation with the results of the feedback compensation to generate the final physical control signal, which is then executed by the particle supply subsystem M200.

[0077] Specifically, the central control unit M100 first sets the target particle mass flow rate based on the calculated value. The lookup is performed in the generated particle actuator characteristic mapping table.

[0078] For example, suppose Consulting the mapping table revealed that a flow rate of 9.8 kg / s corresponds to a PWM duty cycle of 70%, and a flow rate of 10.2 kg / s corresponds to a PWM duty cycle of 72%. Therefore, using linear interpolation, the base PWM duty cycle for 10.0 kg / s was calculated. .

[0079] Then, the first compensation control signal, after being converted by an appropriate scaling factor, This is superimposed on this base value; assuming the compensation signal of -0.044, after scaling, corresponds to a duty cycle adjustment of -0.5%, then the final PWM duty cycle... .

[0080] After receiving the 70.5% duty cycle command, the particle supply subsystem M200 will generate a periodic fixed square wave signal with a high level time accounting for 70.5% of the total cycle. This square wave signal is used to control the solenoid valve of the pneumatic unloading valve 7 at high frequency, thereby achieving precise regulation of the particle flow rate.

[0081] S500: Supply grease.

[0082] This step is executed in parallel with S400 and specifically includes two aspects: flow control and temperature control. S510 performs flow control.

[0083] The central control unit M100 sets the target oil mass flow rate. Find the basic pump frequency in the grease pump characteristic mapping table. Then, the scaled second compensation control signal Superimpose the values ​​to obtain the final frequency setpoint. .

[0084] For example, if table lookup and interpolation If the adjustment amount corresponding to the compensation signal is -0.2 Hz, then the final frequency... .

[0085] After receiving the frequency command, the grease supply subsystem M300 generates a corresponding analog signal (e.g., a 7.06mA signal corresponding to 35.3 Hz) at its pump drive interface and sends this analog signal to the inverter of the fuel injection pump 24, thereby adjusting the pump speed in real time and precisely controlling the injected grease flow rate. S520 performs temperature control.

[0086] The PID controller inside the grease supply subsystem M300 (or the central control unit M100) continuously receives real-time temperature data from the temperature sensor inside the grease metering tank 22. and the target temperature set by the user (e.g., 80°C) is compared to calculate the temperature deviation. Based on this deviation, the PID controller outputs a PWM signal or a switching signal to control the power or on / off state of the heater 32, thereby precisely stabilizing the grease temperature near the target value (e.g., 80±1°C) to ensure that the grease has a suitable viscosity for easy spraying.

[0087] S600: Container shift change.

[0088] In this embodiment, the following sub-steps are specifically included: S610, the system continuously monitors the remaining weight of the currently operating pellet hopper A. Meanwhile, a first preset switching threshold is stored in the system memory. The threshold setting needs to provide sufficient safety buffer. Its minimum value should not be less than the amount of material consumed at the maximum production rate in the first time period. The first time period can be a complete control response cycle plus the actuator switching time. Here, the first time period can be set to 5 seconds.

[0089] For example, if the maximum pellet flow rate is 12 kg / s, then 60 kg will be consumed within 5 seconds. To allow for a margin, [the following can be added]: Set to 100 kg. Alternatively, it can be set to a fixed percentage of the hopper's full load weight, such as 10%. When the central control unit M100 detects... Once it is confirmed that the spare B-type pellet hopper is fully loaded and ready, the switching procedure is triggered, whereby the switching procedure can be a smooth transfer of control signals.

[0090] Preferably, smooth switching can be achieved using a linear ramp function with a switching time set to 1 second. That is, within 1 second, the control signal driving valve A decreases linearly from its current value to 0, while the control signal driving valve B increases linearly from 0 to the target value. This ensures that the total material flow remains stable during the switching process, avoiding production interruptions or quality fluctuations.

[0091] After the switch is completed, the system completely closes the valve of bucket A and sends a command to the upstream feeding system to feed bucket A.

[0092] It should be noted that the switching logic for the dual oil metering tanks is exactly the same as that for the pellet material container, except that it monitors the weight of the oil and compares it with a second preset switching threshold. This will not be elaborated upon here.

[0093] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0094] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A post-coating grease application device, comprising a first vertical frame (1), characterized in that: Two granular material holding hoppers (2), a material spraying barrel (3), and a mixing feed trough (4) are installed sequentially from top to bottom on the inner side of the first vertical frame (1). The upper ends of the two granular material holding hoppers (2) are fixedly connected to a three-way feed pipe (5). Multiple weighing meters (6) are fixedly installed on the outer sides of the two granular material holding hoppers (2). The multiple weighing meters (6) are fixedly installed on the first vertical frame (1). An adjustment component is provided between the granular material holding hoppers (2) and the material spraying barrel (3). An oil spraying unit is provided on the material spraying barrel (3). A mixing conveying component is provided in the inner cavity of the mixing feed trough (4). A mixing conveying component is provided on one side of the first vertical frame (1). There is a second vertical frame (19), and two grease metering tanks (22) are installed on the inner side of the second vertical frame (19). Heaters (32) are installed in the inner cavity of the two grease metering tanks (22). The upper ends of the two grease metering tanks (22) are respectively connected to oil inlet pipes (21). A fuel injection pump (24) is installed on the inner side of the second vertical frame (19) below the two grease metering tanks (22). The lower ends of the two grease metering tanks (22) are respectively fixedly connected to oil outlet pipes (25). The other ends of the two oil outlet pipes (25) are fixedly connected to the oil inlet end of the fuel injection pump (24), and the oil outlet end of the fuel injection pump (24) is connected to the fuel injection unit.

2. The grease post-coating addition device according to claim 1, characterized in that: The control component includes two pneumatic discharge valves (7), each of which is located at the lower end of the corresponding granular material holding hopper (2). The lower ends of the two pneumatic discharge valves (7) are fixedly connected to a three-way conveying component (8), which is fixedly connected to the upper end of the material spraying bucket (3).

3. The grease post-coating addition device according to claim 1, characterized in that: The spraying unit includes two sets of spraying components installed on the outside of the material spraying tank (3). Each set of spraying components includes at least two nozzles (28) installed on the outside of the material spraying tank (3). One end of each nozzle (28) away from the material spraying tank (3) is fixedly connected to a connecting pipe (27). The other end of each connecting pipe (27) is fixedly connected to an oil supply branch (26). One end of the oil supply branch (26) is fixedly connected to the oil outlet of the spraying pump (24).

4. The grease post-coating addition device according to claim 1, characterized in that: The mixing conveying assembly includes a drive motor (9) fixedly installed on one side of the mixing feed trough (4). The output end of the drive motor (9) is fixedly connected to a rotating rod (11) rotatably connected to the mixing feed trough (4). An auger conveying blade (12) is fixedly connected to the outside of the rotating rod (11). A filter screen (13) is sleeved on the outside of the end of the auger conveying blade (12) away from the drive motor (9). A discharge port (15) is provided below the filter screen (13) on the mixing feed trough (4). An inspection door (16) is installed on the outside of the filter screen (13) and installed on the outside of the mixing feed trough (4). At least two first fastening bolts (17) are provided on the inspection door (16). The threaded ends of the plurality of first fastening bolts (17) are threadedly connected to the mixing feed trough (4). A first handle (18) is fixedly connected to the outside of the inspection door (16).

5. The grease post-coating addition device according to claim 1, characterized in that: An observation window (29) is provided on the outside of the material spraying bucket (3). At least two second fastening bolts (30) are provided on the observation window (29). The threaded end of the second fastening bolt (30) is threadedly connected to the material spraying bucket (3), and a second handle (31) is fixedly connected to the outside of the observation window (29).

6. A method for adding grease after spraying, characterized in that, include: Real-time monitoring of the conveying rate of the mixing feeder; Based on the conveying rate, a target particle mass flow rate setpoint and a target oil mass flow rate setpoint are generated; Real-time acquisition of the actual mass flow rate of the current granular material and the actual mass flow rate of the current oil; A compensation control signal is generated based on the first deviation between the target particle mass flow rate setpoint and the actual mass flow rate of the particle material, and the second deviation between the target oil mass flow rate setpoint and the actual mass flow rate of the oil. Based on the target particle mass flow rate setpoint, the target oil mass flow rate setpoint, and the compensation control signal, a final control signal is generated to adjust the supply of the particle material and the oil, respectively.

7. The method according to claim 6, characterized in that, The process of generating the target particle mass flow rate setpoint and the target oil mass flow rate setpoint based on the conveying rate includes: Based on the conveying rate and the preset linear density of the granules, the target granule mass flow rate setting value is generated; The target oil mass flow rate setting value is generated based on the target particle mass flow rate setting value and the preset target oil ratio.

8. The method according to claim 6, characterized in that, The step of generating the final control signal based on the target particle mass flow rate setpoint, the target oil mass flow rate setpoint, and the compensation control signal includes: Based on the target particle mass flow rate setpoint, a first basic control signal is obtained from the first actuator characteristic mapping table; The first basic control signal and the first compensation control signal are combined to generate a first final control signal to regulate the supply of the granular material. Based on the target oil mass flow rate setpoint, the second basic control signal is obtained from the second actuator characteristic mapping table; The second basic control signal is combined with the second compensation control signal to generate a second final control signal to regulate the supply of the grease.

9. The method according to claim 8, characterized in that, The method further includes: For the first actuator used to supply the granular material, under a series of different control inputs, its corresponding stable mass flow rate is measured and recorded to construct a characteristic mapping table of the first actuator; For the second actuator used to supply the grease, under a series of different control inputs, its corresponding stable mass flow rate is measured and recorded to construct a characteristic mapping table for the second actuator.

10. The method according to claim 7, characterized in that, The method further includes: The remaining weight of the pellet material container during monitoring operations; When the remaining weight is lower than the first preset switching threshold, the supply of the granular material is smoothly switched to the standby granular material container. The remaining weight of the grease measuring container during monitoring operations; When the remaining weight is lower than the second preset switching threshold, the supply of grease is smoothly switched to the standby grease metering tank.

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