A self-adaptive circulation control method and system for an ash discharge valve of a sintering machine large flue bulk material system

Abstract

This invention discloses an adaptive cyclic control method for ash discharge valves in a sintering machine's main flue gas duct bulk material handling system, relating to the technical field of ash discharge valve control methods. The method includes the following steps: identifying ash discharge valves in the system that frequently experience material blockage and marking them as easily blocked ash discharge valves; establishing independent control logic, creating an independent control logic module for the marked easily blocked ash discharge valves in the central control unit of the bulk material handling system; setting a dedicated cycle T1 shorter than the system's main cycle time for the independent control logic module; independent parallel control operation, with the main control program continuing to control ash discharge valves other than the easily blocked ash discharge valves according to the system's main cycle time; simultaneously, the independent control logic module runs in parallel, driving the easily blocked ash discharge valves to start and stop cyclically according to the dedicated cycle T1. This overcomes the shortcomings of existing systems that easily lead to local valve blockage and high equipment wear, achieving independent and precise control of easily blocked ash discharge valves.

Description

Technical Field

[0001] This invention relates to the technical field of ash discharge valve control methods, and in particular to an adaptive cyclic control method and system for ash discharge valves in a sintering machine flue bulk material system. Background Technology

[0002] In sintering production, the main flue gas system is responsible for collecting and transporting the dust generated during the sintering process. Currently, this system generally adopts a centralized and unified time-sequence control mode, that is, all ash discharge valves in the system start and stop synchronously according to a preset, fixed cycle time (e.g., 150 minutes).

[0003] This "one-size-fits-all" control method has significant drawbacks: due to differences in material characteristics, bulk density, humidity and flowability at the locations of various ash discharge valves in the system, some "easy-to-clog ash discharge valves" are prone to material accumulation and caking inside the valve under a uniform long circulation time, leading to severe blockage. Each blockage not only requires a significant investment of manpower for time-consuming manual unblocking, severely impacting production continuity and efficiency; but also, frequent blockages and forced unblocking operations cause severe mechanical wear on easily clogged ash discharge valves and related equipment, leading to accelerated equipment wear, increased maintenance costs and replacement frequency, posing a significant challenge to stable production operation. Therefore, existing technologies cannot achieve a balance between equipment protection and operational economy while ensuring system smoothness. Summary of the Invention

[0004] The purpose of this invention is to provide an adaptive cyclic control method for the ash discharge valve of the bulk material system in the large flue of a sintering machine. This method overcomes the shortcomings of existing bulk material systems that use uniform cycle time control, which can easily lead to local valve blockage and high equipment wear. It enables independent and precise control of the easily blocked ash discharge valve.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: An adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the main flue of a sintering machine includes the following steps. Step S10: Identify the ash discharge valves in the system that frequently experience material blockage and mark them as ash discharge valves prone to blockage; Step S20: Establish independent control logic. In the central control unit of the bulk material system, create an independent control logic module for the marked easily clogged ash discharge valve. Step S30: Set a dedicated loop period T1 for the independent control logic module that is shorter than the system main loop time; Step S40: Independent parallel control operation, the main control program continues to control the ash discharge valves other than the easily clogged ash discharge valve according to the system main cycle time; at the same time, the independent control logic module runs in parallel, driving the easily clogged ash discharge valve to start and stop in a cycle according to the dedicated cycle T1.

[0006] Furthermore, in step S10, easily clogged ash discharge valves are identified based on historical operating data and maintenance records.

[0007] Furthermore, the independent control logic module in step S20 decouples itself from the main timing program of the control system at the program level to independently control the target's easily clogged ash discharge valve.

[0008] Furthermore, the dedicated loop period T1 in step S30 is one-third to two-thirds of the system's main loop time.

[0009] Furthermore, it also includes step S50: performing status monitoring and making adaptive adjustments based on the monitoring results.

[0010] Furthermore, the status monitoring in step S50 includes adding a material level or pressure sensor at the easily clogged ash discharge valve.

[0011] Furthermore, the adaptive adjustment in step S50 includes the independent control logic module receiving sensor signals, immediately triggering ash discharge when the material level reaches a high threshold, and extending the cycle interval when the material level remains low (within a continuously set time).

[0012] The present invention also discloses a system that adopts the above-mentioned adaptive cyclic control method for the ash discharge valve of the sintering machine flue bulk material system, including a central control unit, an independent control logic module configured for the easily clogged ash discharge valve, and an actuator that drives the ash discharge valve. The independent control logic module is programmed to execute an independent cyclic logic that is different from the timing of the central control unit.

[0013] In summary, the present invention has the following beneficial effects: 1. Eliminate blockages and ensure continuous and stable production: By implementing independent short-cycle cyclic control on blockage-prone points, the caking and blockage of materials in the valves are prevented from the source, completely avoiding unplanned downtime and large-scale manual unblocking operations caused by blockages, and ensuring the continuous and stable operation of the sintering main line. 2. Significantly reduce equipment wear and maintenance costs: It avoids pressure buildup and overload operation caused by material blockage, as well as mechanical damage caused by rough manual unblocking. This significantly reduces the wear of the ash discharge valve and its actuator, effectively extending the overall service life of the equipment and reducing spare parts consumption and maintenance costs. 3. Achieve refined energy saving and consumption reduction: Independent control ensures that the easily clogged valve operates only at an optimized frequency when necessary, avoiding the energy consumption of idling that may be caused by all valves running at the same time for a long time. At the same time, it reduces the abnormal energy consumption of the system caused by blockage handling, thus achieving a reduction in the overall energy consumption of the system. 4. Improved operational safety and automation: The system transforms manual, experience-based maintenance of clogged points into program-controlled, preventative automated operation, significantly reducing the number of times operators need to access the site to handle clogs, thus lowering labor intensity and safety risks. The control interface provides intuitive monitoring of the status of easily clogged valves, enhancing the convenience and reliability of system operation. Attached Figure Description

[0014] Figure 1 This is a control interface diagram of an adaptive cyclic control method for the ash discharge valve of a sintering machine flue material distribution system according to the present invention. Detailed Implementation

[0015] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. These embodiments do not constitute a limitation of the present invention. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this application.

[0016] An adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the large flue of a sintering machine, such as... Figure 1 As shown, it includes the following steps: Step S10: Based on historical operating data and maintenance records, identify the ash discharge valves in the system that frequently experience material blockage and mark them as "clogging-prone ash discharge valves"; Step S20: Establish independent control logic. In the central control unit (such as PLC or DCS) of the bulk material system, create an independent control logic module for the marked "easy-to-clog ash discharge valve". The independent control logic module independently controls the target easy-to-clog ash discharge valve by decoupling it from the main timing program of the control system at the program level.

[0017] Step S30: Set a dedicated cycle T1 for the independent control logic module that is shorter than the system main cycle time T0; in some embodiments, the dedicated cycle T1 is limited to one-third to two-thirds of the system main cycle time T0, and an independent discharge time is also set for more accurate discharge control. For example, when the main cycle time T0 of the system is 150 minutes, through simulation experiments and on-site debugging, T1 is set to 80 minutes for the easily clogged ash discharge valve. This optimized cycle aims to start unloading before the material forms a stubborn blockage, so as to achieve preventive unblocking.

[0018] Step S40: Independent parallel control operation, the main control program continues to control the ash discharge valves other than the easy-to-clog ash discharge valve according to the system main cycle time T0 (i.e. the original timing); at the same time, the independent control logic module set up for the "easy-to-clog ash discharge valve" runs in parallel, driving the easy-to-clog ash discharge valve to start and stop in a cycle according to the exclusive cycle period T1 (i.e. the optimized short cycle).

[0019] Step S50: To further improve the level of intelligence, status monitoring can be performed, and adaptive adjustments can be made based on the monitoring results; Status monitoring includes adding material level or pressure sensors at easily clogged ash discharge valves; The adaptive adjustment includes an independent control logic module that receives sensor signals to achieve adaptive control based on the actual material accumulation state: when the material level reaches a high threshold, ash unloading is triggered immediately; when the material level remains low, the cycle interval is extended according to the preset step size parameter, thereby further optimizing the equipment operation frequency and system energy consumption while ensuring no blockage.

[0020] This embodiment also discloses a system that adopts the above-mentioned adaptive cyclic control method for the ash discharge valve of the sintering machine large flue bulk material system. The system includes a central control unit, an independent control logic module configured for the easily clogged ash discharge valve, and an actuator that drives the ash discharge valve. The independent control logic module is programmed to execute an independent cyclic logic that is different from the timing of the central control unit (i.e., the original timing).

[0021] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within the scope of its essence and protection. Such modifications or equivalent substitutions should also be considered to fall within the protection scope of the present invention.

Claims

1. An adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the main flue of a sintering machine, characterized in that: Includes the following steps, Step S10: Identify the ash discharge valves in the system that frequently experience material blockage and mark them as ash discharge valves prone to blockage; Step S20: Establish independent control logic. In the central control unit of the bulk material system, create an independent control logic module for the marked easily clogged ash discharge valve. Step S30: Set a dedicated loop period T1 for the independent control logic module that is shorter than the system main loop time; Step S40: Independent parallel control operation, the main control program continues to control the ash discharge valves other than the easily clogged ash discharge valve according to the system main cycle time; at the same time, the independent control logic module runs in parallel, driving the easily clogged ash discharge valve to start and stop in a cycle according to the dedicated cycle T1.

2. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the sintering machine's main flue as described in claim 1, characterized in that: In step S10, the ash discharge valve that is prone to clogging is identified based on historical operating data and maintenance records.

3. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the large flue of a sintering machine according to claim 1 or 2, characterized in that: The independent control logic module in step S20 decouples itself from the main timing program of the control system at the program level to independently control the target's easily clogged ash discharge valve.

4. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the sintering machine's main flue as described in claim 1, characterized in that: The dedicated loop period T1 in step S30 is one-third to two-thirds of the system's main loop time.

5. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the sintering machine's main flue as described in claim 1, characterized in that: It also includes step S50: performing status monitoring and making adaptive adjustments based on the monitoring results.

6. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the sintering machine's main flue as described in claim 5, characterized in that: The status monitoring in step S50 includes adding a material level or pressure sensor at the easily clogged ash discharge valve.

7. The adaptive cyclic control method for the ash discharge valve of the bulk material distribution system in the sintering machine's main flue as described in claim 6, characterized in that: The adaptive adjustment in step S50 includes the independent control logic module receiving sensor signals, immediately triggering ash discharge when the material level reaches a high threshold, and extending the cycle interval when the material level remains low.

8. A system employing the adaptive cyclic control method for the ash discharge valve of a sintering machine flue gas duct bulk material distribution system as described in claim 1, characterized in that: It includes a central control unit, an independent control logic module configured for the easily clogged ash discharge valve, and an actuator that drives the ash discharge valve. The independent control logic module is programmed to execute independent loop logic that is different from the timing of the central control unit.

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