An automatic screening and detection system for medium crushing

Abstract

This invention relates to the field of testing technology for carbon anode production in aluminum, and discloses an automatic screening and testing system for medium crushing, including sampling, screening and testing, and control modules. The sampling and screening and testing modules are connected through sampling pipelines, and the control module is electrically connected and manages the entire process. The sampling module includes a pneumatic telescopic automatic sampling device corresponding to each particle size outlet, and two sets of sampling pipelines are equipped with three-way valves to achieve conveying switching. The screening and testing module consists of two parallel testing units consisting of screening calibration, weighing, and automatic waste disposal devices, which serve as backups for each other. After testing, the samples are returned to the production process through the waste disposal pipeline. The control module includes a PLC controller and a touch screen, with control modules for each testing unit, and adopts a three-level network architecture. The central control room workstation enables remote monitoring. This system has an adjustable sampling cycle and can perform multiple samplings to obtain an average sample, improving sample representativeness and testing accuracy, and realizing full automation of the screening and testing process.

Description

Technical Field

[0001] The present invention relates to the technical field of production detection of carbon anodes for aluminum, and particularly relates to an automatic medium crushing and screening detection system. Background Art

[0002] With the promotion of the industrial intelligent transformation, intelligent manufacturing has become the core direction of the high-quality development of the manufacturing industry. Realizing the informatization control of all production elements and processes and the intelligent upgrade of equipment is the key path to improving the quality and production efficiency of industrial manufacturing. As an important supporting link in non-ferrous metal smelting, the product quality of carbon anodes for aluminum directly affects the production efficiency and energy consumption level of electrolytic aluminum. The control of the screening purity of calcined coke and residual anodes is a key control factor in the production process of carbon anodes. The particle size accuracy of aggregate screening directly determines the rationality of downstream batching, and thus affects the final quality of formed carbon blocks.

[0003] In the aggregate screening link of traditional carbon anode production for aluminum, problems such as breakage and blockage are likely to occur in the screens for screening calcined petroleum coke and residual anodes. If not discovered and processed in time, it will directly reduce the screening efficiency and damage the accuracy of the batching ratio. However, currently, the industry generally adopts the method of manual sampling and detection to carry out screening quality control. Only 1-2 samplings are completed per shift. The samples need to be sent to the laboratory for manual screening measurement and purity calculation, and then the operation status of the screen is inferred through the calculation results. This mode has significant detection lag. Once the screen anomaly is detected, it takes several hours to feedback to the production workshop and complete the processing. During this period, a large number of unqualified aggregates enter the downstream process, which is extremely likely to cause batch product quality problems.

[0004] At the same time, affected by factors such as manual operation and environmental interference, problems such as insufficient sampling representativeness and large screening measurement errors are prominent in the manual detection mode, and it is difficult to accurately reflect the real state of aggregate screening. The high degree of participation in the whole process of manual sampling and detection not only greatly increases the labor intensity of workers, but also has safety and environmental protection hazards such as high-altitude operation and material dust, which does not meet the safety and environmental protection requirements of modern production. In addition, traditional detection has no real-time data recording and traceability ability, and the production quality control lacks data support. Moreover, the equipment is single, and any detection link failure will cause the entire control process to stagnate, making it difficult to meet the requirements of continuous production.

[0005] Under this industry background, aiming at the pain points of aggregate screening detection in carbon anode production for aluminum, developing a set of automatic medium crushing and screening detection system for forming, which can break through the bottleneck of industry quality control and promote the intelligent upgrade of carbon anode production for aluminum, has become an urgent problem to be solved. It can not only solve the problems of lag and low accuracy of the traditional detection mode, but also further improve the safety and environmental protection level of the production process, and provide technical support for the enterprise to achieve quality traceability and efficient management. Summary of the Invention

[0006] The present invention aims to provide an automatic screening and detection system for medium crushing to solve the problems of high manual involvement, delayed result feedback, and low accuracy in aggregate screening and detection during the production of carbon anodes for aluminum.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: An automatic screening and testing system for medium crushing includes: a sampling module, a screening and testing module, and a control module. The sampling module and the screening and testing module are connected through a sampling pipeline. The control module is electrically connected to both the sampling module and the screening and testing module to control the entire sampling and testing process. The sampling module includes an automatic sampling device and sampling pipelines. The automatic sampling device is adapted for sampling of calcined coke and residual anode. The number of automatic sampling devices is determined based on the particle size classification of the calcined coke and residual anode materials. Each automatic sampling device corresponds one-to-one with the discharge port of the screening machine for each particle size classification of calcined coke and residual anode. The automatic sampling device is a pneumatic telescopic head type sampler. The sampling pipelines are provided in two sets, which are respectively connected to the automatic sampling device for calcined coke and the calcined coke screening and detection unit, and the automatic sampling device for residual anode and the residual anode screening and detection unit. A three-way valve is provided in the sampling pipelines to allow the sample transport to be switched between the two sets of sampling pipelines. The screening and testing module includes a screening calibration device, a weighing device, an automatic waste disposal device, and a waste disposal pipeline. The screening calibration device, the weighing device, and the automatic waste disposal device are connected in sequence to form two sets of testing units. The two sets of testing units are respectively connected to two sets of sampling pipelines. The two sets of testing units are arranged in parallel and serve as backups for each other. The tested samples are returned to the production process pipeline through the automatic waste disposal device and the waste disposal pipeline. The control module includes a PLC controller and a touch screen. The screening and detection modules for calcined coke and residual anode are equipped with corresponding control modules. The control modules are integrated into the main equipment, and a workstation is deployed in the central control room to realize remote monitoring and control. The control module adopts a three-level network architecture of management layer, control layer and equipment layer.

[0008] The principle and advantages of this solution are as follows: In practical application, the control module, in conjunction with the sampling module, accurately extracts material from the discharge ports of each particle size of the screening machine. The material is then transported to the parallel screening and testing module via a switchable sampling pipeline. Particle size detection is completed through screening verification and precise weighing. After testing, the sample is returned to the production process via a sealed waste material system. The two sets of testing units serve as backups for each other. This solution achieves full automation of the aggregate screening and testing process, solving the problems of high lag in manual sampling and testing, low detection accuracy due to interference from human and environmental factors, system downtime and low testing efficiency caused by the failure of a single testing device, poor sample representativeness, and errors in material weighing due to center of gravity shift. Furthermore, it solves the problems of dust and material leakage during the testing process, poor environmental performance, and lack of real-time data traceability for production quality.

[0009] Preferably, as an improvement, the particle size classification of calcined coke sampling and residual anode sampling includes coarse calcined coke, medium calcined coke, fine calcined coke, coarse residual anode, and fine residual anode.

[0010] Technical effects: The particle size classification standards for three grades of calcined coke and two grades of residual anode were clarified, which enabled the configuration of the automatic sampling device to match the particle size of the actual material in production, and achieved accurate and independent sampling of materials of each particle size.

[0011] Preferably, as an improvement, the pneumatic telescopic head sampler includes a cylinder, a sampling head, a scraper, and a sampling cup. In the non-sampling state, the sampling port is closed. When sampling, the cylinder drives the sampling head to extend out of the sampling port to collect the material. After receiving the material, it retracts, and the scraper scrapes the material in the sampling head into the sampling cup.

[0012] Technical benefits: Facilitates fully enclosed sampling throughout the entire process, eliminating dust and material leakage, meeting environmental protection requirements, while reducing equipment failure rate and improving sampling efficiency.

[0013] Preferably, as an improvement, the screening and calibration device has a modular structure, including three screening units with screens of different particle sizes. The screening units are connected by quick clamps, and the screens adopt a quick-release structure with pins for fixing. The screening and calibration device is mounted on a shock-absorbing spring, and a vibration motor is provided on one side of the bottom screening unit. When testing the calcined coke, all three screen units work. When testing the residual anode, the middle screen unit stops working, while the other two screen units work normally.

[0014] Technical benefits: The modular and quick-release structural design facilitates screen replacement and equipment maintenance, adapting to the particle size detection requirements of different production processes; shock-absorbing springs isolate vibration, preventing vibration from affecting subsequent weighing accuracy; automatic switching of screening logic according to material type enables one device to be compatible with the detection of calcined coke and residual anode, improving equipment versatility; two sets of devices are connected in parallel as backups for each other, ensuring continuous operation of the detection system and reducing the risk of downtime.

[0015] Preferably, as an improvement, the weighing device includes a vertically arranged connecting hose, a weighing hopper, a valve, and a vibration motor. The weighing sensors are arranged in a three-point configuration on the lower outer side of the weighing hopper. Before weighing, the valve is closed, the weight of the empty hopper is weighed and recorded, and the material enters the weighing hopper through the connecting hose. The weighing sensors collect the total weight of the hopper and the material, and the weight of the empty hopper is subtracted to obtain the net weight of the material. After weighing, the control module commands the valve to open and simultaneously starts the vibration motor, allowing the material to be quickly discharged under the combined action of gravity and vibration.

[0016] Technical benefits: The weighing sensors, arranged symmetrically in a three-point equilateral triangle, completely elevate the hopper, eliminating interference from other supports and avoiding center of gravity shift errors caused by uneven material accumulation. Combined with zeroing the hopper when empty, this improves weighing accuracy. The vertical, tiered arrangement adapts to the logic of material gravity descent, and the vibration motor, in conjunction with the valve, enables rapid and residue-free material discharge. The connecting hose isolates upstream vibration, further ensuring the accuracy of weighing data and achieving precise measurement of material particle size.

[0017] Preferably, as an improvement, the automatic waste disposal device includes a flexible connection, an on / off valve, two vibrating motors, and pipeline accessories. One end of the flexible connection is sealed to the discharge end of the upstream metering and weighing device, and the other end is connected to the top inlet of the on / off valve. The two vibrating motors are installed on both sides of the on / off valve, and the sample is discharged under its own weight and the vibration of the vibrating motors. One end of the pipeline accessories is sealed to the bottom outlet of the on / off valve, and the other end is sealed to the production process pipeline.

[0018] Technical effect: The sample is returned to the production process pipeline through an automatic waste disposal device, realizing material recycling and avoiding waste.

[0019] Preferably, as an improvement, the PLC controller is a Rockwell CompactLogix series, and the touch screen is a Panelview 800 series. The PLC controller has two EtherNet / IP communication ports and one USB communication port, including 16 sink / pull-out type 24V DC digital input points and 16 pull-out type 24V DC digital output points, supporting 256 EtherNet / IP connections and 120 TCP connections. The touch screen is compatible with EtherNet / IP, DF1 and DH-485 and Modbus series communication protocols.

[0020] Technical benefits: The combination of Rockwell CompactLogix series PLC and Panelview 800 series touch screen features multiple communication ports and abundant I / O points, supports multi-protocol communication, and enables accurate acquisition of equipment-level signals and reliable control of actions; it facilitates the stability, scalability, and compatibility of the control system, and adapts to the complex environment of industrial production.

[0021] Preferably, as an improvement, the control module can automatically identify the types of calcined coke and residual anode samples and switch the corresponding detection parameters; the control module has data processing and storage, abnormal alarm, and operation permission protection functions, calculates the proportion of particle size materials in real time, generates production reports, alarms in real time for unqualified particle size results and equipment failure status, and sets multi-level operator operation permissions.

[0022] Technical benefits: It facilitates reduced manual intervention, improves testing efficiency, enables timely handling of production issues, and ensures the safety and reliability of system operation.

[0023] Preferably, as an improvement, the sampling period for a single particle size material in the sampling module is adjustable, and multiple samplings can be set within the sampling period. After the average sample is obtained, it is sent to the screening and detection module.

[0024] Technical benefits: It facilitates the effective improvement of sample representativeness, avoids detection errors caused by the randomness of single instantaneous sampling, and makes the test results more realistically reflect the actual screening state of aggregates at the production end, further improving the accuracy and reliability of screening detection. Attached Figure Description

[0025] Figure 1 This is a flowchart of an automatic screening and detection system for medium-sized crushing. Figure 2 This is a flowchart illustrating the screening and detection module according to an embodiment of the present invention. Detailed Implementation

[0026] The following detailed description illustrates the specific implementation methods: The basic implementation examples are as follows: Figure 1 As shown: An automatic screening and testing system for medium crushing includes a sampling module, a screening and testing module, and a control module. The sampling module and the screening and testing module are connected through a sampling pipeline. The control module is electrically connected to both the sampling module and the screening and testing module to control the entire sampling and testing process.

[0027] The sampling module includes an automatic sampling device and a sampling pipeline. The automatic sampling device is adapted for sampling calcined coke and residual anode. The number of automatic sampling devices is determined based on the particle size classification of the calcined coke and residual anode materials. In this embodiment, the particle size classification of the calcined coke and residual anode materials includes coarse calcined coke, medium calcined coke, fine calcined coke, coarse residual anode, and fine residual anode. Therefore, 5 sets of automatic sampling devices are set up. The 5 sets of automatic sampling devices correspond one-to-one with the discharge ports of the screening machines for coarse calcined coke, medium calcined coke, fine calcined coke, coarse residual anode, and fine residual anode.

[0028] The sampling module automatically samples the material on-site using an automatic sampling device. The sample is then transported to the screening and testing module via sampling pipelines. In this embodiment, the automatic sampling device is a pneumatic telescopic head sampler. Two sets of sampling pipelines are provided, connecting the automatic sampling device for calcined coke to the calcined coke screening and testing unit, and the automatic sampling device for residual anodes to the residual anode screening and testing unit, respectively. A three-way valve is installed in the sampling pipelines, allowing the sample transport to switch between the two sets of sampling pipelines. By switching the discharge pipeline, the transmission path is changed, ensuring the sample falls into either the calcined coke screening and testing module or the residual anode screening and testing module. When a screening and testing module needs calibration or is shut down for maintenance, the sample to be tested is transported to the other screening and testing module for screening and testing by switching the sampling pipeline via the three-way valve, ensuring the normal operation of the system.

[0029] The pneumatic telescopic head sampler includes a cylinder, a sampling head, a scraper, and a sampling measuring cup. The cylinder provides power, the sampling head performs the sampling action, the scraper scrapes and discharges the material, and the sampling measuring cup receives and stores the material. The technical parameters of the pneumatic telescopic head sampler are shown in Table 1. Table 1

[0030] The cylinder is fixed to the rear end of the housing of the pneumatic telescopic head sampler. The sampling head is connected to the cylinder's telescopic rod and is located in the middle of the housing. The cylinder is a double-acting pneumatic cylinder. The front end of its telescopic rod is rigidly connected to the center of the tail of the sampling head via a flange or thread. The tail of the cylinder body is fixed to the inner wall of the rear end of the sampler housing via a bracket. The cylinder's telescopic rod moves in a reciprocating linear motion in the horizontal direction, directly driving the sampling head to extend / retract synchronously. The two are fully linked, with consistent movement trajectories and speeds. The scraper is sleeved on the outside of the sampling head and fixed inside the housing. The scraper is an annular plate with an inner ring diameter that matches the outer wall of the sampling head. The scraper is installed directly opposite the inner side of the sampling port of the housing, which is the necessary passage for the sampling head to retract into the housing. The scraper as a whole does not move. The sampling cup is located directly below the sampling head and fixed to the bottom of the housing. The sampling cup has a funnel-shaped structure with an open top. The open area completely covers the material feeding range after the sampling head retracts, ensuring that no scraped material enters the cup. The bottom of the cup is connected to the sampling pipeline, and the material enters the subsequent conveying process by gravity.

[0031] The sampling machine housing has a sampling port on the side facing the chute. The sampling port is equipped with an automatic sealing door. When not sampling, the cylinder extension rod is fully retracted, the entire sampling head is located inside the housing, the sampling port sealing door is closed, the scraper is in contact with the outer wall of the sampling head, and the sampling measuring cup is in an empty standby state. When the control module issues a sampling command, the sampling port sealing door opens simultaneously. The cylinder vents and drives the telescopic rod to extend horizontally forward, causing the sampling head to pass through the inner ring of the scraper and extend from the sampling port into the material flow in the chute. The material naturally enters the storage chamber of the sampling head. After the sampling head receives material for a preset time (e.g., 5 seconds), the control module issues a retraction command, and the cylinder telescopic rod retracts horizontally backward, causing the sampling head to retract from the chute and move along the inner ring of the scraper into the housing. During the retraction process, the outer wall of the sampling head precisely fits against the inner ring of the scraper, and the scraper scrapes off all the material in the storage chamber of the sampling head, preventing the material from adhering to the sampling head. The scraped material falls vertically under gravity and enters the sampling measuring cup directly below, completing a single sampling. Subsequently, the material in the measuring cup enters the sampling pipeline through the bottom outlet and is transported to the screening and detection module. The sampling port sealing door closes, and the equipment returns to standby mode.

[0032] The automatic sampling device can collect representative samples at regular intervals and in specific quantities. In this embodiment, the automatic sampling device takes approximately 100g of samples per cycle, and the sampling cycle for a single particle size material is preset to 10 minutes. This cycle parameter can be adjusted through a human-machine interface. Within the sampling cycle, the number of samplings by the sampling device can be set to obtain instantaneous samples at different time points. These samples are then aggregated to obtain an average sample, making the samples more representative and the test results more accurate. If the sampling cycle for a single particle size material is set to one sampling, an instantaneous sample is obtained and tested.

[0033] like Figure 2 As shown, the screening and testing module includes a screening calibration device, a weighing device, an automatic waste disposal device, and a waste disposal pipeline. These devices are sequentially connected to form two sets of testing units. Each set of testing units is connected to one of two sampling pipelines. The two sets of testing units are arranged in parallel and serve as backups for each other. The testing units are controlled automatically by a PLC throughout the process, accurately measuring the samples and eliminating errors from manual testing. The screening and testing module internally stores two sets of screening and testing programs for self-calibration. It also automatically or manually switches between programs in case of a failure or maintenance of one testing unit to ensure normal operation. The samples entering the screening and testing module are average samples within the sampling period, reflecting the true state of the material flow and eliminating the influence of unrepresentative samples on the test results, making the test results more accurate and representative.

[0034] The screening and calibration device has a modular structure, comprising three screening units equipped with screens of different particle sizes. In this embodiment, according to the material testing requirements for calcined coke and residual anodes, the three screening units are as follows: the upper screening unit is equipped with a screen corresponding to the coarse coke aperture, used for screening and storing coarse coke samples; the middle screening unit is equipped with a screen corresponding to the medium coke aperture, used for screening and storing medium coke samples; and the bottom screening unit is equipped with a screen corresponding to the fine coke aperture, used for screening and storing fine coke samples. The screening units operate in different states when testing different materials. When testing calcined coke, all three screening units with different particle sizes work together. When testing residual anodes, the middle screen is not working and is in a vertical position, while the other two screens are working.

[0035] The screens of the screening unit are mounted on an internal rotating mechanism, allowing for independent control of screen rotation and integrating screening and discharging functions. Screening units are connected by quick-release clamps, and the screens utilize a pin-fixed quick-release structure for easy equipment maintenance and parts replacement. The screening calibration device is mounted on shock-absorbing springs, with a vibration motor on one side of the bottom screening unit, keeping the screening device in a floating state. Vibrations generated during operation are absorbed by the springs, reducing the impact on equipment components and ensuring the safety and reliability of the entire screening process. The technical parameters of the screening calibration device are shown in Table 2. Table 2

[0036] The weighing device features automatic weighing, calculation, and cleaning functions. It includes a vertically arranged, tiered connecting hose, weighing hopper, valve, and vibrating motor. The upper end of the connecting hose is sealed to the outlet of the upstream screening and calibration device, while the lower end is sealed to the top inlet of the weighing hopper via a clamp. This flexible connection ensures no material spillage into the hopper and isolates the vibration from the upstream screening device, preventing vibration from affecting the accuracy of the weighing sensor. The valve is an open-close discharge valve, directly installed at the bottom outlet of the weighing hopper and sealed with the hopper via a flange, serving as the sole discharge channel for the hopper's materials. The valve's opening and closing are controlled by a control module. During static weighing, the valve is completely closed to ensure a sealed hopper and prevent material leakage. After weighing, the valve opens, cooperating with the vibrating motor to achieve rapid material discharge. Two vibratory motors are symmetrically installed on both sides of the outer wall of the valve or directly installed in the discharge section below the weighing hopper, and are rigidly connected to the valve / hopper with bolts. The vibratory motors provide auxiliary vibration force for discharge and work in conjunction with the valve to prevent material from accumulating or jamming at the bottom of the hopper or inside the valve. Three load cells are symmetrically distributed in an equilateral triangle on the lower part of the outer wall of the weighing hopper. The upper ends of the load cells are fixed to the outer wall of the hopper with bolts, and the lower ends are fixed to the fixed frame of the device. The hopper is completely suspended by the three load cells without any other contact support. The entire weight of the material after it enters is accurately collected by the load cells, achieving three-point weighing calibration and avoiding center of gravity offset errors. The technical parameters of the weighing device are shown in Table 3. Table 3

[0037] Before weighing, the valve is closed. The weight of the empty hopper is first weighed and recorded. The material enters the weighing hopper through the connecting hose. The weighing sensor collects the total weight of the hopper and the material. The weight of the empty hopper is deducted to obtain the net weight of the material. After weighing, the control module commands the valve to open and the vibration motor to start. The material is quickly discharged under the combined action of gravity and vibration.

[0038] The sample obtained by the sampling module falls into the sieving and verification module. The vibration motor is powered on and starts to sieve the sample into different particle sizes. The sieved samples are stored on the corresponding particle size screens for testing. The weighing device weighs the mass of each sample in sequence according to the program settings and records the data. After the weighing and recording are completed, the data is fed back to the control module, which issues a discard command. The discard device discharges the sample back to the production process pipeline and empties the hopper for the next test.

[0039] The weighing process for calcined coke material samples includes: 1. The calcined coke sampling device performs cyclic sampling and sieving of coarse, medium and fine coke, weighing them one by one; 2. The control system calculates the weighing data of each particle size material, calculates the particle size distribution of each particle size material, records the relevant data, issues early warnings for abnormal data, and generates reports from the detection data.

[0040] The weighing process for residual anode material samples includes: 1. The residual anode sampling device performs cyclic sampling and sieving for coarse and fine residual anodes, weighing them one by one; 2. The control module calculates the weighing data of materials of each particle size, calculates the particle size distribution of materials of each particle size, records the relevant data, issues early warnings for abnormal data, and generates reports from the detection data.

[0041] The automatic waste disposal device includes a flexible connector, an on / off valve, two vibrating motors, and pipeline accessories. One end of the flexible connector is sealed to the discharge end of the upstream weighing device, and the other end is connected to the top inlet of the on / off valve. The two vibrating motors are installed on both sides of the on / off valve. When a sample completes sieving, the control module issues a waste disposal command, opening the valve at the discharge port of the automatic waste disposal device and simultaneously activating the vibrating motors. The sample is discharged under its own weight and the vibration of the motors. One end of the pipeline accessories is sealed to the bottom discharge port of the on / off valve, and the other end is sealed to the production process pipeline. The entire waste disposal process is completed within a closed pipeline and container, avoiding dust and ash leakage during the process. The parameter configuration of the automatic waste disposal device is shown in Table 4. Table 4

[0042] The control module includes a PLC controller and a touch screen. The PLC controller is a Rockwell CompactLogix series, and the touch screen is a Panelview 800 series. The PLC controller has two EtherNet / IP communication ports and one USB communication port, including 16 sink / pull-out type 24V DC digital input points and 16 pull-out type 24V DC digital output points, supporting 256 EtherNet / IP connections and 120 TCP connections. The PLC controller parameters are shown in Table 5. Table 5

[0043] The touchscreen is compatible with EtherNet / IP, DF1, DH-485, and Modbus communication protocols. The touchscreen parameters are shown in Table 6. Table 6

[0044] The screening and detection modules for calcined coke and residual anode are each equipped with a corresponding control module. The control module is integrated into the main equipment, and a workstation is deployed in the central control room to realize remote monitoring and control. The control module adopts a three-level network architecture of management layer, control layer and equipment layer.

[0045] The control module is used to acquire and control all equipment signals and actions at the equipment level, and to perform automatic data calculation, storage, and push functions; it also enables the automatic sampling, screening, verification, and discarding of materials in the forming and crushing automatic screening and testing system. Specifically, it includes: 1. The testing equipment has a built-in material formula, enabling the screening and testing of different types of samples on the same equipment. When changing the test sample, it automatically identifies the sample type, switches and applies the corresponding sample formula, and automatically matches relevant testing parameters. 2. It enables the timely and quantitative acquisition of representative samples of calcined coke and residual anodes, and through the control of various equipment, it achieves system monitoring functions, automatically processes the data, and derives judgment results. Once a material has completed screening and testing, it automatically discards the material. 3. The control layer PLC processes the screening process data in real time, calculates the proportion of various particle sizes, and generates a conclusion on whether the material is qualified or not based on the calculation results; it generates various production reports, historical data records, trend curve records, etc., based on the collected real-time data; and it allows querying of stored equipment data by time, time period, equipment, alarm, and other methods. 4. After calculating the proportion of various particle size materials, the control layer PLC displays alarm information in real time for non-conforming results; it also displays the fault status of all equipment in the system's equipment layer in real time. The system can query alarms by time, order, equipment name, accident, and fault. 5. The system has multiple safety devices, operator access control settings, operation command confirmation, operation password confirmation, and equipment interlocking functions, ensuring safe, reliable, and normal operation. The system has operator access control level settings, allowing for login operations with appropriate permissions based on operational requirements.

[0046] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. An automatic screening and detection system for medium crushing, characterized in that: include: The system includes a sampling module, a sieving and testing module, and a control module. The sampling module and the sieving and testing module are connected through a sampling pipeline. The control module is electrically connected to both the sampling module and the sieving and testing module to control the entire sampling and testing process. The sampling module includes an automatic sampling device and sampling pipelines. The automatic sampling device is adapted for sampling of calcined coke and residual anode. The number of automatic sampling devices is determined based on the particle size classification of the calcined coke and residual anode materials. Each automatic sampling device corresponds one-to-one with the discharge port of the screening machine for each particle size classification of calcined coke and residual anode. The automatic sampling device is a pneumatic telescopic head type sampler. The sampling pipelines are provided in two sets, which are respectively connected to the automatic sampling device for calcined coke and the calcined coke screening and detection unit, and the automatic sampling device for residual anode and the residual anode screening and detection unit. A three-way valve is provided in the sampling pipelines to allow the sample transport to be switched between the two sets of sampling pipelines. The screening and testing module includes a screening calibration device, a weighing device, an automatic waste disposal device, and a waste disposal pipeline. The screening calibration device, the weighing device, and the automatic waste disposal device are connected in sequence to form two sets of testing units. The two sets of testing units are respectively connected to two sets of sampling pipelines. The two sets of testing units are arranged in parallel and serve as backups for each other. The tested samples are returned to the production process pipeline through the automatic waste disposal device and the waste disposal pipeline. The control module includes a PLC controller and a touch screen. The screening and detection modules for calcined coke and residual anode are equipped with corresponding control modules. The control modules are integrated into the main equipment, and a workstation is deployed in the central control room to realize remote monitoring and control. The control module adopts a three-level network architecture of management layer, control layer and equipment layer.

2. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The particle size classification of calcined coke and residual anode samples includes coarse calcined coke, medium calcined coke, fine calcined coke, coarse residual anode, and fine residual anode.

3. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The pneumatic telescopic head sampler includes a cylinder, a sampling head, a scraper, and a sampling cup. The sampling port is closed when not sampling. When sampling, the cylinder drives the sampling head to extend out of the sampling port to collect the material. After receiving the material, the head retracts, and the scraper scrapes the material in the sampling head into the sampling cup.

4. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The screening and calibration device has a modular structure, including three screening units with screens of different particle sizes. The screening units are connected by quick clamps, and the screens are fixed by pins for quick release. The screening and calibration device is mounted on a shock-absorbing spring, and a vibration motor is installed on one side of the bottom screening unit. When testing the calcined coke, all three screen units work. When testing the residual anode, the middle screen unit stops working, while the other two screen units work normally.

5. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The weighing device includes a vertically arranged connecting hose, a weighing hopper, a valve, and a vibration motor. The weighing sensors are arranged in a three-point configuration on the lower outer side of the weighing hopper. Before weighing, the valve is closed, and the weight of the empty hopper is first weighed and recorded. The material enters the weighing hopper through the connecting hose, and the weighing sensors collect the total weight of the hopper and the material. The weight of the empty hopper is then subtracted to obtain the net weight of the material. After weighing, the control module commands the valve to open and simultaneously starts the vibration motor, allowing the material to be quickly discharged under the combined action of gravity and vibration.

6. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The automatic waste disposal device includes a flexible connector, an on / off valve, two vibrating motors, and pipeline accessories. One end of the flexible connector is sealed to the discharge end of the upstream metering and weighing device, and the other end is connected to the top inlet of the on / off valve. The two vibrating motors are installed on both sides of the on / off valve. The sample is discharged under its own weight and the vibration of the vibrating motors. One end of the pipeline accessories is sealed to the bottom outlet of the on / off valve, and the other end is sealed to the production process pipeline.

7. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The PLC controller is a Rockwell CompactLogix series, and the touch screen is a Panelview 800 series. The PLC controller has two EtherNet / IP communication ports and one USB communication port, including 16 sink / pull-out type 24V DC digital input points and 16 pull-out type 24V DC digital output points, supporting 256 EtherNet / IP connections and 120 TCP connections. The touch screen is compatible with EtherNet / IP, DF1 and DH-485 and Modbus series communication protocols.

8. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The control module can automatically identify the types of calcined coke and residual anode samples and switch the corresponding detection parameters. The control module has data processing and storage, abnormal alarm, and operation permission protection functions. It can calculate the proportion of particle size materials in real time, generate production reports, and provide real-time alarms for unqualified particle size results and equipment failure status. At the same time, it can set multi-level operator operation permissions.

9. The automatic screening and detection system for medium crushing according to claim 1, characterized in that: The sampling module has an adjustable sampling cycle for materials of a single particle size. Multiple samplings can be set within the sampling cycle, and the average sample obtained is then sent to the screening and detection module.

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