Self-adaptive control system of soil granulator based on humidity feedback

Abstract

This invention discloses an adaptive control system for a soil granulator based on humidity feedback, relating to the field of intelligent control technology for soil granulation equipment. The system includes a temperature acquisition module, a central control module, an execution adjustment module, and a data storage and calibration module. The humidity acquisition module collects humidity data in real time throughout the entire soil granulation process, including soil humidity at the granulation chamber inlet, humidity of the mixture in the middle section of the granulation chamber, and humidity of the finished particles at the granulation chamber outlet. This humidity data is transmitted to the central control module. The central control module incorporates an adaptive control algorithm and a multi-type soil humidity threshold library. It receives the real-time data transmitted from the humidity acquisition module, compares and analyzes it with preset thresholds, and calculates the humidity deviation value. This adaptive control system for a soil granulator based on humidity feedback addresses the technical problems of existing technologies, such as lag in humidity control, low accuracy, poor adaptability, high reliance on manual intervention, and unstable granulation quality.

Description

Technical Field

[0001] This invention relates to the field of intelligent control technology for soil granulation equipment, and in particular to an adaptive control system for a soil granulator based on humidity feedback. Background Technology

[0002] Soil granulation is a crucial step in soil improvement, organic fertilizer processing, and the utilization of mineral powder resources. Soil moisture during granulation is a core factor affecting pellet formation, granulation rate, and pellet strength. Excessive moisture easily leads to material sticking to the walls, machine blockage, and pellet agglomeration; insufficient moisture makes it difficult to form qualified pellets, resulting in a high pulverization rate in the finished product, while also increasing equipment wear and energy consumption. Current soil granulators rely heavily on manual operation for moisture control. Operators judge soil moisture based on experience and manually adjust parameters such as water spray volume, feed rate, and granulation speed, which has many shortcomings.

[0003] On the one hand, manual adjustment is inherently lagging and cannot respond in real time to dynamic changes in soil moisture. This is especially true in scenarios involving multiple raw material mixing, soil type switching, or large-scale continuous production, where moisture fluctuations are frequent. Manual adjustments struggle to achieve precise matching, resulting in unstable particle quality, low granulation rates (typically below 80%), and significant material waste. On the other hand, the optimal granulation moisture varies considerably among different soil types. Manual adjustments cannot accurately adapt to the needs of various soil types, requiring multiple machines or repeated shutdowns for adjustments. This increases equipment and labor costs, and the adjustments disrupt continuous production, leading to low efficiency.

[0004] Some existing granulation equipment attempts to incorporate humidity detection, but most rely on single-sensor, single-point data collection. This results in significantly reduced accuracy due to soil salinity and material adhesion, and a lack of closed-loop control logic. They can only monitor humidity and cannot automatically adapt parameters. A few intelligent granulation devices employ simple control algorithms, using fixed thresholds for triggering adjustments. These algorithms fail to consider soil type differences and humidity fluctuations, leading to over- or under-adjustment of parameters and hindering adaptability to different production scenarios. Furthermore, existing systems lack regular calibration mechanisms, causing sensor accuracy to degrade over time, resulting in diminished control effectiveness and high equipment maintenance costs. Summary of the Invention

[0005] The purpose of this invention is to provide an adaptive control system for a soil granulator based on humidity feedback, so as to solve the technical problems of lag in humidity control, low precision, poor adaptability, strong reliance on manual labor, and unstable granulation quality in the prior art.

[0006] This invention provides an adaptive control system for a soil granulator based on humidity feedback, comprising a temperature acquisition module, a central control module, an execution adjustment module, and a data storage and calibration module. The humidity acquisition module collects humidity data in real time throughout the entire soil granulation process, including soil humidity at the granulation chamber inlet, humidity of the mixture in the middle section of the granulation chamber, and humidity of the finished particles at the granulation chamber outlet. This humidity data is transmitted to the central control module. The central control module incorporates an adaptive control algorithm and a multi-type soil humidity threshold library. It receives the real-time data from the humidity acquisition module, compares and analyzes it with preset thresholds, calculates the humidity deviation, and generates corresponding adaptive control commands. The execution adjustment module responds to the control commands from the central control module, dynamically adjusting the granulator's water spray volume, granulation speed, disc tilt angle, and feed rate to achieve precise matching between humidity and granulation parameters. The data storage and calibration module stores humidity data, control parameters, and finished particle quality data during the granulation process, periodically calibrates the humidity acquisition module, and optimizes the adaptive control algorithm parameters based on historical data.

[0007] Preferably, the humidity acquisition module uses a capacitive soil moisture sensor. The probe of the capacitive soil moisture sensor is made of corrosion-resistant stainless steel and is installed in close contact with the soil material. At least one sensor is installed at the inlet, middle section and outlet of the granulation chamber. The sensor at the inlet of the granulation chamber is used to predict the humidity of the raw material.

[0008] Preferably, the central control module has a multi-type soil moisture threshold library that presets the optimal moisture range for granulation of sandy soil, clay soil, loam soil, and mixed improved soil. It also supports users to add threshold parameters for specific soil types. The optimal moisture range is preset according to soil viscosity, granulation requirements, and subsequent drying processes, and can be dynamically updated through historical operating data.

[0009] Preferably, the adaptive control algorithm includes a data preprocessing unit, a deviation analysis unit, and a parameter matching unit; the data preprocessing unit filters and reduces noise in the collected humidity data and removes abnormal data; the deviation analysis unit calculates the deviation value between the real-time humidity and the corresponding optimal humidity range of the soil and determines the deviation level; the parameter matching unit matches the corresponding control parameter adjustment range according to the deviation level and soil type.

[0010] Preferably, the adjustment module includes a water spray adjustment unit, a speed adjustment unit, an inclination angle adjustment unit, and a feed adjustment unit. The water spray adjustment unit uses a variable frequency water pump to precisely adjust the water spray volume and speed according to the control command, adapting to fluctuations in raw material humidity. The speed adjustment unit adjusts the main shaft speed of the granulator; when the humidity is high, the speed is increased to enhance the material tumbling intensity, and when the humidity is low, the speed is decreased to extend the material residence time. The inclination angle adjustment unit uses a hydraulic adjustment structure; when the humidity is high, the inclination angle is increased to shorten the material residence time, and when the humidity is low, the inclination angle is decreased to improve the pellet forming effect. The feed adjustment unit adjusts the speed of the screw propeller.

[0011] Preferably, the data storage and calibration module includes a data storage unit and an automatic calibration unit; the data storage unit uses a non-volatile memory chip and supports data export for process optimization; the automatic calibration unit periodically triggers the calibration process, uses standard humidity soil samples to calibrate the sensor, and simultaneously corrects the threshold parameters and algorithm adjustment range of the central control module based on the outlet humidity data and finished particle quality data.

[0012] Preferably, it also includes an alarm module, which is electrically connected to the central control module. When the humidity acquisition module malfunctions, the real-time humidity deviation exceeds the severe deviation range and continues for a preset time, or the control module fails to respond to the control command, the alarm module issues an audible and visual alarm and transmits the alarm information to the central control module, triggering a shutdown protection or backup control scheme.

[0013] Preferably, the central control module supports remote communication and can realize real-time data monitoring, parameter setting and control command issuance through the Internet of Things platform, adapting to the management and control needs of large-scale cluster production; at the same time, it has a fault prediction function, which can predict potential problems such as sensor aging and actuator failure based on historical operating data modeling.

[0014] Preferably, the adaptive control algorithm supports multi-parameter linkage control. When humidity deviation is accompanied by uneven particle size, the rotation speed, tilt angle and water spray volume are adjusted simultaneously to construct a linkage control model of humidity-rotation speed-tilt angle to ensure that the particle quality meets the standards. At the same time, it has a formula switching adaptation function. When the soil raw material formula changes, the corresponding humidity threshold and control parameters are automatically matched.

[0015] Preferably, it also includes a temperature auxiliary acquisition unit, which is electrically connected to the central control module to collect temperature data inside the granulation chamber in real time; the central control module combines temperature data and humidity data for coordinated regulation to avoid soil moisture detection deviation caused by temperature changes, while optimizing water spray volume and rotation speed adjustment parameters to balance granulation and energy consumption control.

[0016] Therefore, the present invention adopts the above-mentioned adaptive control system for soil granulators based on humidity feedback to solve the technical problems of lag in humidity control, low precision, poor adaptability, strong reliance on manual labor, and unstable granulation quality in the prior art.

[0017] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the module connection of an adaptive control system for a soil granulator based on humidity feedback according to the present invention. Figure 2 This is a schematic diagram of the working process of an adaptive control system for a soil granulator based on humidity feedback according to the present invention. Figure 3 This is a schematic diagram of the adaptive control algorithm of an adaptive control system for a soil granulator based on humidity feedback according to the present invention. Detailed Implementation

[0019] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0020] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0021] The terms "first," "second," and similar words used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0022] Example 1 like Figures 1-3 As shown, the present invention discloses an adaptive control system for a soil granulator based on humidity feedback, which is applied to the granulation of organic fertilizer in clay soil. The granulator is a disc granulator and includes a temperature acquisition module, a central control module, an execution adjustment module, and a data storage and calibration module. The modules are electrically connected by wires to form a closed-loop control architecture.

[0023] The humidity acquisition module collects humidity data in real time throughout the entire soil granulation process. The humidity data includes the soil humidity at the granulation chamber inlet, the humidity of the mixed materials in the middle section of the granulation chamber, and the humidity of the finished particles at the granulation chamber outlet, and transmits it to the central control module.

[0024] The humidity acquisition module employs a capacitive soil moisture sensor. The sensor probe is made of corrosion-resistant stainless steel and is installed in close contact with the soil material, with an insertion depth of 5cm to ensure tight contact. The acquisition frequency is 1 time / second, with an accuracy of ±1%. The optimal humidity range for clay soil is preset to 28%-35%. Data is transmitted to the central control module to prevent material adhesion and probe corrosion. At least one sensor is installed at the granulation chamber inlet, middle section, and outlet. The sensor at the granulation chamber inlet is used to predict raw material humidity, the sensor in the middle section is used to dynamically monitor humidity during the granulation process, and the sensor at the granulation chamber outlet is used to verify the control effect. Multi-point data collaboration improves acquisition accuracy.

[0025] The central control module uses a PLC controller. The central control module has a built-in adaptive control algorithm and a multi-type soil moisture threshold library. It receives real-time data transmitted by the humidity acquisition module, compares and analyzes it with the preset threshold, calculates the humidity deviation value, and generates corresponding adaptive control instructions.

[0026] The central control module has a multi-type soil moisture threshold library that presets the optimal moisture range for granulation of sandy soil, clay soil, loam soil, and mixed improved soil. It also supports users to add threshold parameters for specific soil types. The optimal moisture range is preset according to soil viscosity, granulation requirements, and subsequent drying processes, and can be dynamically updated through historical operating data.

[0027] The central control module supports remote communication and can realize real-time data monitoring, parameter setting and control command issuance through the Internet of Things platform, adapting to the management and control needs of large-scale cluster production; it also has a fault prediction function, which can predict potential problems such as sensor aging and actuator failure based on historical operating data modeling.

[0028] The adaptive control algorithm includes a data preprocessing unit, a deviation analysis unit, and a parameter matching unit. The data preprocessing unit filters and reduces noise in the collected humidity data to remove abnormal data. The deviation analysis unit calculates the deviation between the real-time humidity and the corresponding optimal humidity range for the soil and determines the deviation level (slight deviation, moderate deviation, severe deviation). The parameter matching unit matches the adjustment range of the corresponding control parameters according to the deviation level and soil type to avoid fluctuations in granulation quality caused by sudden parameter changes.

[0029] The adaptive control algorithm supports multi-parameter linkage control. When humidity deviation is accompanied by uneven particle size, it synchronously adjusts the rotation speed, tilt angle, and water spray volume to construct a linkage control model of humidity-rotation speed-tilt angle, ensuring that particle quality meets standards. It also has a formula switching adaptation function. When the soil raw material formula changes, it automatically matches the corresponding humidity threshold and control parameters, shortening the switching time to within 5 minutes.

[0030] The execution adjustment module responds to the control commands of the central control module, dynamically adjusting the water spray volume, granulation speed, disc tilt angle and feeding rate of the granulator to achieve precise matching between humidity and granulation parameters.

[0031] The control module includes a water spray control unit, a speed control unit, an inclination angle control unit, and a feed control unit. The water spray control unit uses a variable frequency water pump to precisely adjust the water spray volume and speed according to control commands, adapting to fluctuations in raw material humidity. The speed control unit adjusts the spindle speed of the granulator; when humidity is high, the speed is increased to enhance material tumbling intensity, and when humidity is low, the speed is decreased to extend material residence time. The inclination angle control unit uses a hydraulic adjustment structure with an adjustment range of 30°-50° and an accuracy of ±1°; when humidity is high, the inclination angle is increased to shorten material residence time, and when humidity is low, the inclination angle is decreased to improve pellet forming effect. The feed control unit adjusts the speed of the screw propeller to achieve stable control of the feed rate, coordinating with the humidity control.

[0032] The data storage and calibration module is used to store humidity data, control parameters, and finished particle quality data during the granulation process. It periodically calibrates the accuracy of the humidity acquisition module and optimizes the adaptive control algorithm parameters based on historical data.

[0033] The data storage and calibration module includes a data storage unit and an automatic calibration unit. The data storage unit uses a non-volatile memory chip with a storage period of no less than one year and supports data export for process optimization. The automatic calibration unit periodically triggers the calibration process, uses standard humidity soil samples to calibrate the sensors, and, based on the outlet humidity data and finished particle quality data, reversely corrects the threshold parameters and algorithm adjustment range of the central control module to improve the long-term operational stability of the system.

[0034] It also includes an alarm module, which is electrically connected to the central control module. When the humidity acquisition module malfunctions, the real-time humidity deviation exceeds the severe deviation range and continues for a preset time, or the control module fails to respond to the control command, the alarm module will issue an audible and visual alarm and transmit the alarm information to the central control module to trigger a shutdown protection or backup control scheme.

[0035] It also includes a temperature auxiliary acquisition unit, which is electrically connected to the central control module to collect temperature data inside the granulation chamber in real time. The central control module combines temperature data and humidity data for coordinated regulation to avoid soil moisture detection deviation caused by temperature changes. At the same time, it optimizes the water spray volume and speed adjustment parameters, taking into account both granulation and energy consumption control, and reducing the energy consumption per ton of granulation.

[0036] The system initializes and starts. Operators select the clay soil type via the central control module, and the system calls the optimal humidity range (28%-35%) to complete initialization. Raw material humidity prediction and pre-adjustment: Clay soil raw material enters the granulation chamber. The inlet sensor collects raw material humidity data (assumed to be 22%, indicating a significant deviation) and transmits it to the central control module. Dynamic control during granulation: After processing by an adaptive control algorithm, if a significant deviation (deviation value 8%) is identified, control commands are generated: the water spray unit increases the water spray volume by 25%, the feed unit decreases the feed rate by 20%, the speed unit reduces the speed to 80 r / min, and the tilt unit adjusts the tilt angle to 32°. Finished product humidity verification and parameter correction: During granulation, the intermediate sensor collects real-time humidity data of the mixed materials (assumed to rise to 30% after adjustment, within the optimal range). The temperature sensor collects the temperature of the granulation chamber (assumed to be 32℃), and the central control module fine-tunes the water spray volume (increasing it by 5%) to maintain stable humidity. For data storage and closed-loop optimization, the outlet sensor collects the humidity data of the finished granules (31%), which meets the optimal range requirements. The data storage and calibration module stores the data from this operation. After 15 days of operation, the automatic calibration unit triggers the calibration process, using standard humidity soil samples to calibrate the three sensors to ensure the accuracy of data collection. For fault warning and remote control, if a mid-section sensor malfunctions during operation, the alarm module issues an audible and visual alarm, the central control module switches to the inlet and outlet sensor data for temporary adjustment, and simultaneously reminds the operator to perform maintenance.

[0037] Example 2 This granulator, applied to sandy soil and straw mixing granulation scenarios, is a dual-membrane granulator, essentially the same as in Example 1, with the following differences: the humidity acquisition module is equipped with four capacitive sensors—one at the granulation chamber inlet, one in the middle of the granulation chamber, and one at the granulation chamber outlet—improving the accuracy of raw material humidity monitoring. In a multi-type soil humidity threshold library, the optimal humidity range for a 7:3 mixture of sandy soil and straw is preset to 20%-26%, supporting user-defined ratios and threshold settings. The adaptive control algorithm features a new formula switching function, quickly adapting to the granulation needs of mixing sandy soil with different proportions of straw. The water spraying unit of the execution control module uses a dual-channel variable frequency water pump, adapting to high-capacity water spraying requirements, with a water volume adjustment range of 0-100L / min; a rotation speed adjustment range of 60-220r / min; and a tilt angle adjustment range of 30°-48°.

[0038] Therefore, the present invention adopts the above-mentioned adaptive control system for soil granulators based on humidity feedback to solve the technical problems of lag in humidity control, low precision, poor adaptability, strong reliance on manual labor, and unstable granulation quality in the prior art.

[0039] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. An adaptive control system for a soil granulator based on humidity feedback, characterized in that, The system includes a temperature acquisition module, a central control module, an execution adjustment module, and a data storage and calibration module. The humidity acquisition module collects humidity data in real time throughout the entire soil granulation process, including soil humidity at the granulation chamber inlet, humidity of the mixed materials in the middle of the granulation chamber, and humidity of the finished particles at the granulation chamber outlet. The humidity data is transmitted to the central control module. The central control module has a built-in adaptive control algorithm and a multi-type soil humidity threshold library. It receives the real-time data transmitted by the humidity acquisition module, compares and analyzes it with preset thresholds, calculates the humidity deviation value, and generates corresponding adaptive control commands. The execution adjustment module responds to the control commands of the central control module and dynamically adjusts the water spray volume, granulation speed, disc tilt angle, and feed rate of the granulator. The data storage and calibration module stores humidity data, control parameters, and finished particle quality data during the granulation process, periodically calibrates the accuracy of the humidity acquisition module, and optimizes the adaptive control algorithm parameters based on historical data.

2. The adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The humidity acquisition module uses a capacitive soil moisture sensor. The probe of the capacitive soil moisture sensor is made of corrosion-resistant stainless steel and is installed in close contact with the soil material. At least one sensor is installed at the inlet, middle section and outlet of the granulation chamber. The sensor at the inlet of the granulation chamber is used to predict the humidity of the raw material.

3. The adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The central control module has a multi-type soil moisture threshold library that presets the optimal moisture range for granulation of sandy soil, clay soil, loam soil, and mixed improved soil. It also supports users to add threshold parameters for specific soil types. The optimal moisture range is preset according to soil viscosity, granulation requirements, and subsequent drying processes, and can be dynamically updated through historical operating data.

4. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The adaptive control algorithm includes a data preprocessing unit, a deviation analysis unit, and a parameter matching unit. The data preprocessing unit filters and reduces noise in the collected humidity data and removes abnormal data. The deviation analysis unit calculates the deviation between the real-time humidity and the corresponding optimal humidity range for the soil and determines the deviation level. The parameter matching unit matches the corresponding control parameter adjustment range according to the deviation level and soil type.

5. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The control module includes a water spray control unit, a speed control unit, an inclination angle control unit, and a feed control unit. The water spray control unit uses a variable frequency water pump to precisely adjust the water spray volume and speed according to control commands, adapting to fluctuations in raw material humidity. The speed control unit adjusts the spindle speed of the granulator; when humidity is high, the speed is increased to enhance material tumbling intensity, and when humidity is low, the speed is decreased to extend material residence time. The inclination angle control unit uses a hydraulic adjustment structure; when humidity is high, the inclination angle is increased to shorten material residence time, and when humidity is low, the inclination angle is decreased to improve pellet forming effect. The feed control unit adjusts the speed of the screw propeller.

6. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The data storage and calibration module includes a data storage unit and an automatic calibration unit. The data storage unit uses a non-volatile memory chip and supports data export for process optimization. The automatic calibration unit periodically triggers the calibration process, uses standard humidity soil samples to calibrate the sensors, and simultaneously corrects the threshold parameters and algorithm adjustment range of the central control module based on the outlet humidity data and finished particle quality data.

7. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, It also includes an alarm module, which is electrically connected to the central control module. When the humidity acquisition module malfunctions, the real-time humidity deviation exceeds the severe deviation range and continues for a preset time, or the control module fails to respond to the control command, the alarm module will issue an audible and visual alarm and transmit the alarm information to the central control module to trigger a shutdown protection or backup control scheme.

8. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The central control module supports remote communication and can realize real-time data monitoring, parameter setting and control command issuance through the Internet of Things platform, adapting to the management and control needs of large-scale cluster production; it also has a fault prediction function, which can predict potential problems such as sensor aging and actuator failure based on historical operating data modeling.

9. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, The adaptive control algorithm supports multi-parameter linkage control. When humidity deviation is accompanied by uneven particle size, the rotation speed, tilt angle and water spray volume are adjusted simultaneously to build a linkage control model of humidity-rotation speed-tilt angle to ensure that the particle quality meets the standards. It also has a formula switching adaptation function. When the soil raw material formula changes, it automatically matches the corresponding humidity threshold and control parameters.

10. An adaptive control system for a soil granulator based on humidity feedback according to claim 1, characterized in that, It also includes a temperature auxiliary acquisition unit, which is electrically connected to the central control module to collect temperature data inside the granulation chamber in real time. The central control module combines temperature data and humidity data for coordinated regulation to avoid soil moisture detection deviation caused by temperature changes, while optimizing water spray volume and rotation speed adjustment parameters to balance granulation and energy consumption control.

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