Method for the abnormal self-diagnosis of a sintering mixer cylinder

Abstract

The present application relates to a kind of sintering mixer cylinder abnormal self-diagnosis method, the method comprises the following steps: S1, a kind of speed measuring device suitable for the working characteristics of cylinder, and can realize anti-slip, anti-weld interference self-resetting, S2, a kind of rotating speed abnormal self-diagnosis device, S3, design a kind of speed measuring device abnormal self-diagnosis method;The technical scheme is ingenious, compact structure, determines using the rotational speed of the on-line continuous measurement cylinder, and using the mode of abnormal self-diagnosis to ensure the reliability of speed measuring device.

Description

Technical Field

[0001] This invention relates to a self-diagnostic method, specifically a self-diagnostic method for abnormalities in a sintering mixer cylinder, belonging to the field of instrumentation and testing technology. Background Technology

[0002] Before blast furnace ironmaking, the sintering process involves mixing various powdered iron-containing raw materials with appropriate amounts of fuel and solvent, along with water. After mixing, granulation, and conveying in a mixer, the materials undergo a series of physicochemical reactions on the sintering equipment, ultimately sintering into blocks. The cylindrical mixer is a key piece of equipment in sintering production. As sintering machines become larger, the volume of the cylindrical mixer also increases, typically reaching four to five meters in diameter and exceeding ten meters in length.

[0003] The cylindrical body is welded together and lined with wear-resistant plates. When the motor in the transmission device rotates, it drives the cylinder to rotate via a spring coupling, reducer, gear coupling, pinion, and large gear ring. Material enters through the cylinder's inlet and moves in the direction of rotation under friction. After multiple lifting and throwing processes, it is discharged from the discharge end onto a conveyor belt. Due to the cylinder's heavy weight and the high technical requirements and difficulty of installation, long-term operation can lead to liner wear and material buildup. This can cause couplings, idler rollers, etc., to break due to vibration and misalignment. At this point, the motor is still running, but the cylinder has stopped rotating. If this is not detected in time, a large amount of material will accumulate inside the cylinder. This not only interrupts sintering production due to the cylinder mixer malfunction, but also requires significant manpower and resources to clean up the accumulated material before production can resume, resulting in longer downtime and economic losses.

[0004] Therefore, it is necessary to manufacture a speed measuring device for the cylinder of a sintering mixer and a method for self-diagnosing device malfunctions to detect the cylinder rotation speed in real time and perform self-diagnosis of malfunctions in the speed measuring device, thereby improving the reliability of the speed measuring device. Summary of the Invention

[0005] This invention addresses the technical problems existing in the prior art by providing a self-diagnostic method for abnormalities in the cylinder of a sintering mixer. This technical solution is ingeniously designed and has a compact structure. It uses online continuous measurement of the cylinder's rotation speed to determine the abnormality and employs a self-diagnostic method to ensure the reliability of the speed measuring device.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows: a method for self-diagnosing abnormalities in a sintering mixer cylinder, the method comprising the following steps:

[0007] S1. To manufacture a speed measuring device suitable for the working characteristics of a cylindrical object, capable of anti-slip, anti-weld interference, and self-resetting.

[0008] S2. Manufacture a device for self-diagnosing abnormal rotation speed.

[0009] S3. Design a method for self-diagnosing abnormal speed measurement device.

[0010] As an improvement of the present invention, the speed measurement device includes a continuous speed measurement device and a device for self-diagnosing abnormal rotation speed. The roller of the continuous speed measurement device is directly below the cylinder. A rubber ring is sleeved outside the roller, and the rubber ring is in direct contact with the surface of the cylinder. A transmission gear is attached to the roller, and the rotation pulse signal of the transmission gear is detected by a gear sensor. The gear sensor is fixed on the support arm. The pulse signal is sent into a speed integrator through a signal cable for calculation and converted into a continuous speed signal. The speed signal is sent into the PLC system. The roller and the transmission gear are installed on a fixed shaft, and the fixed shaft is installed at the front end of the support arm. The support arm is a U-shaped plate. A pin hole is opened behind the fixed shaft of the support arm. There are fixed brackets on both sides of the pin hole. The support arm and the fixed brackets are fixed by a connecting pin. The fixed brackets are welded on a fixed plate, and the fixed plate and the end of the support arm are connected by a telescopic spring.

[0011] The proximity switch of the device for self-diagnosing abnormal rotation speed is installed at one end of the above-mentioned fixed shaft. A paired iron block is welded on the cylinder in the opposite direction of the proximity switch. The signal of the proximity switch is sent into the PLC system through a signal cable. The cylinder speed measurement device and the device for self-diagnosing abnormal rotation speed are installed below the cylinder of the mixer.

[0012] After the manufacture of the cylinder speed measurement device and the device for self-diagnosing abnormal rotation speed is completed, develop a simple and effective method for self-diagnosing abnormal speed measurement device. The logical relationship is as follows: After the cylinder speed signal measured by the speed measurement device is sent into the PLC, set its speed as V1 (unit: mm / s), set the diameter of the cylinder as D (unit: mm), then the circumference of the cylinder is πD (unit: mm), and calculate the time for the cylinder to rotate one circle as T1 = πD / V1 (unit: s). At the same time, for each rotation of the cylinder by the proximity switch of the device for self-diagnosing abnormal rotation speed, it sends a switching quantity signal to the PLC, and calculate the time interval between two switching quantity signals as T2 (unit: s). Then compare the magnitudes of T1 and T2.

[0013] (1) If 0 < T1 - T2 ≤ 2, the speed measurement device is normal.

[0014] (2) If T1 - T2 >, there may be abnormal situations in the speed measurement device such as roller slipping, spring aging, failure, weight dropping, etc.

[0015] (3) If T1 - T2 ≤ 0, it means that the rubber ring outside the roller is severely worn, resulting in a decrease in the diameter of the roller.

[0016] If the above situations (2) and (3) occur, the system will issue an alarm to remind maintenance personnel to conduct timely inspection and maintenance.

[0017] Preferably, the distance from the center of the roller to the bottom of the support arm is greater than the radius of the roller;

[0018] Preferably, the diameter of the transmission gear is smaller than the diameter of the roller, and the transmission gear is selected as a high-precision pulse gear;

[0019] Preferably, the rubber ring has granular stripes to increase friction and prevent the rollers from slipping when the cylinder rotates;

[0020] Preferably, the distance between the fixed bracket and the support arm is less than 2 cm and as small as possible to prevent the support arm from moving significantly left and right on the connecting pin, which would affect the speed measurement accuracy.

[0021] Preferably, the center of the pin hole is on the same horizontal plane as the center of the fixed shaft, and the weight of the rear end of the support arm is slightly greater than the weight of the front end, with the pin hole opening position as the fulcrum.

[0022] Preferably, the length of the telescopic spring is slightly less than the distance from the fixed plate to the bottom of the support arm, and it is slightly stressed in its natural state to ensure that the bottom of the support arm is at an angle of 10-15 degrees to the fixed plate;

[0023] Preferably, a telescopic spring with a suitable telescopic coefficient is selected to ensure that when the weld of the cylinder rotates to the speed measuring roller and causes the support arm to swing downward, the support arm can be pulled back to its original position within 2 seconds to ensure that the roller returns to the contact surface of the cylinder. This ensures continuous real-time measurement of the speed measuring device and prevents excessive wear of the rubber ring due to compression, thus achieving self-resetting against weld interference.

[0024] Preferably, the thickness of the proximity switch pairing iron block welded on the cylinder should be much greater than the thickness of the protruding weld seam on the cylinder, in order to prevent the proximity switch from being affected by the weld seam and causing false signals.

[0025] Preferably, the effective distance between the proximity switch contact and the mating iron block should be less than the radius of the roller.

[0026] Compared with the prior art, the present invention has the following advantages: 1) The overall structure of the technical solution is compact and ingenious. The solution uses online continuous measurement of the rotation speed of the cylinder to determine the speed, and adopts an abnormal self-diagnosis method to ensure the reliability of the speed measuring device; 2) In the solution, the distance from the center of the roller to the bottom of the support arm is greater than the radius of the roller, and the diameter of the transmission gear is smaller than the diameter of the roller. This ensures that the roller and the transmission gear will not hit the bottom of the support arm, and the gap can also effectively prevent dust, debris, etc. from falling in and causing the roller to jam; 3) In the solution, the length of the telescopic spring is slightly less than the distance from the bottom of the support arm to the fixed plate, so that the telescopic spring is slightly stressed in its natural state, and ensures that the bottom of the support arm is at an angle of 10-15 degrees to the fixed plate. This ensures that the rollers on the support arm naturally adhere to the surface of the cylinder due to gravity, fully guaranteeing the friction between the rollers and the cylinder while preventing excessive wear of the rubber ring due to excessive friction, or even causing the rollers to fail to rotate naturally; 4) This solution can ensure continuous real-time measurement of the speed measuring device without causing excessive wear of the rubber ring due to compression, effectively guaranteeing the performance and lifespan of the speed measuring device, and achieving self-resetting against weld interference. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0028] Figure 2 This is a top view schematic diagram of the speed measuring device of the present invention;

[0029] In the diagram: 1. Roller 2. Rubber ring 3. Transmission gear 4. Gear sensor 5. Support arm 6. Fixed shaft 7. Pin hole 8. Fixed bracket 9. Connecting pin 10. Fixed plate 11. Telescopic spring 20. Proximity switch 21. Iron block 22. Cylinder 23. Cylinder weld. Detailed Implementation

[0030] To enhance understanding of the present invention, the embodiments will be described in detail below with reference to the accompanying drawings.

[0031] Example 1: See Figure 1 , Figure 2 This application provides, as follows Figures 1-2 The diagram illustrates an online continuous speed measurement device and a self-diagnostic device for abnormal speed of a sintering mixer cylinder, along with a method for such self-diagnosis. When the sintering machine cylinder experiences liner wear or material buildup, leading to breakage of couplings, idler rollers, etc., due to vibration or misalignment, even though the motor is still running, the device can promptly detect this situation. It immediately triggers an interlock protection system to stop the machine for inspection and repair, effectively preventing the accumulation of large amounts of material inside the cylinder due to delayed detection, thus avoiding escalation of the accident. This provides effective technical support for the stable and smooth operation of the sintering machine. Figure 2 The roller 1 of the speed measuring device is located directly below the cylinder 22. The roller 1 is equipped with a rubber ring 2, which is in direct contact with the surface of the cylinder 22. When the cylinder 22 starts to rotate, it will rotate along with the roller 1 due to friction.

[0032] Specifically, the surface of the rubber ring 2 has granular stripes to increase friction, so as to prevent the roller 1 from slipping when the cylinder 22 rotates.

[0033] Furthermore, the roller 1 is equipped with a transmission gear 3, which drives the transmission gear 3 to rotate simultaneously when the roller 1 starts to rotate.

[0034] Specifically, the transmission gear 3 is designed with 256 high-precision pulse teeth, meaning that every 256 pulse signals received by the proximity sensor 4 represent one rotation of the transmission gear 3. The gear sensor 4 is fixed to the support arm 5. The circumference of the transmission gear 3 is calculated based on its diameter, thus determining the rotational distance represented by each pulse from the gear sensor 4. The speed of the transmission gear 3, i.e., the rotational speed of the cylinder 22, is then calculated based on the number of pulses per unit time. This speed signal is sent to the PLC system for application as the speed of the cylinder 22.

[0035] Furthermore, the roller 1 and the transmission gear 3 are mounted on the fixed shaft 6, which is mounted on the front end of the support arm 5, which is a U-shaped plate.

[0036] Specifically, the distance from the center of the roller 1 to the bottom of the support arm 5 is greater than the radius of the roller 1, and the diameter of the transmission gear 3 is smaller than the diameter of the roller 1. This ensures that the roller 1 and the transmission gear 3 will not touch the bottom of the support arm 5, and the gap can also effectively prevent dust, debris and other objects from falling in and causing the roller 1 to get stuck.

[0037] Furthermore, the support arm 5 has a pin hole 7 behind the fixed shaft 6.

[0038] Specifically, the center of the opening of the pin hole 7 is on the same horizontal plane as the center of the fixed shaft 6, and the weight of the rear end of the support arm 5 is slightly greater than the weight of the front end, with the opening position of the pin hole 7 as the fulcrum.

[0039] Furthermore, there are fixing brackets 8 on both sides of the pin hole 7, and the support arm 5 and the fixing brackets 8 are fixed by connecting pins 9.

[0040] Specifically, the distance between the fixed bracket 8 and the support arm 5 is less than 2 cm and as small as possible to prevent the support arm 5 from moving significantly left and right on the connecting pin 9, which would affect the speed measurement accuracy.

[0041] Furthermore, the fixed bracket 9 is welded to the fixed plate 10, and the fixed plate 10 is connected to the end of the support arm 5 by a telescopic spring 11.

[0042] Specifically, the length of the telescopic spring 11 is slightly less than the distance from the bottom of the support arm 5 to the fixed plate 10, so that the telescopic spring 11 is slightly stressed in its natural state, and ensures that the bottom of the support arm 5 is at an angle of 10-15 degrees to the fixed plate 10. This ensures that the roller 1 on the support arm 5 naturally adheres to the surface of the cylinder 22 due to gravity, fully guaranteeing the friction between the roller 1 and the cylinder 22, while preventing excessive friction from causing excessive wear of the rubber ring 2, or even preventing the roller 2 from rotating naturally.

[0043] To further explain, because the mixer cylinder 22 is welded, the weld seam 23 protrudes from the surface of the cylinder 22. When the weld seam 23 rotates at a certain speed to the roller 1, it causes the entire support arm 5 to swing downwards, causing the roller 1 to detach from the surface of the cylinder 22, making it impossible to measure the speed of the cylinder 22. Therefore, by selecting a telescopic spring 11 with a suitable telescopic coefficient, it can be ensured that after the roller 1 detaches from the surface of the cylinder 22, the difference in weight between the front and rear sections of the support arm 5, as well as the tension of the telescopic spring 11 on the support arm 5, can quickly pull the support arm 5 back to its original position, ensuring that the roller 1 returns to the contact surface of the cylinder 22. The entire detachment process takes no more than 2 seconds. This ensures continuous real-time measurement by the speed measuring device without causing excessive wear on the rubber ring 2 due to compression, effectively guaranteeing the performance and lifespan of the speed measuring device and achieving self-resetting against weld seam interference.

[0044] In addition, since the speed measuring device is designed to reliably detect the rotational speed of the cylinder 22, thereby providing interlock protection for the sintering mixer, it is necessary to ensure the reliability of the speed measuring device, especially to ensure that any abnormalities in the speed measuring device can be detected and dealt with in a timely manner. This technology also designs a self-diagnostic device for abnormal rotational speed, and the specific implementation instructions are as follows.

[0045] like Figure 2 As shown, the proximity switch 20 is installed at one end of the fixed shaft 3. A pair of iron blocks 21 are welded onto the opposite cylinder 22 of the proximity switch 20. The signal of the proximity switch 20 is sent to the PLC system via a signal cable.

[0046] Specifically, the proximity switch 20 is installed on the same fixed axis in a direction parallel to the roller 1, so as to ensure that the time for the iron block 21 in the opposite direction of the proximity switch 20 to rotate one full circle along with the cylinder 22 is exactly the same as the time measured by the speed measuring device for the cylinder 22 to rotate one full circle. Considering that the cylinder weld 23 protrudes from the surface of the cylinder body of the cylinder 22, in order to prevent the proximity switch from being interfered by the weld 23 and generating false signals, the thickness of the paired iron block 21 should be much greater than the thickness of the protrusion of the cylinder weld 23. By adjusting the effective distance between the contact of the proximity switch 20 and the paired iron block 21 in this way, the effective measurement of the pulse signal can be achieved. It should be noted during implementation that this effective distance is less than the radius of the roller 1, otherwise it cannot be installed.

[0047] After the production and installation of the speed measuring device and the abnormal rotation speed self-diagnosis device for the cylinder 22 are completed, the logical relationship of the method for abnormal self-diagnosis of the speed measuring device is very simple and effective: after the speed signal of the cylinder 22 measured by the speed measuring device is sent into the PLC system, set its speed as V1 (unit: mm / s), and set the diameter of the cylinder 22 as D (unit: mm). Then the circumference of the cylinder 22 is πD (unit: mm), and the time for the cylinder 22 to rotate one full circle is calculated as T1 = πD / V1 (unit: s). At the same time, for each full rotation of the cylinder 22, the proximity switch of the abnormal rotation speed self-diagnosis device sends a switching signal to the PLC, and the time interval between two switching signals is T2 (unit: s). The speed V1 of the cylinder 22 measured by the speed measuring device and the pulse signal of the abnormal rotation speed self-diagnosis device are both sent into the PLC system. Just compare the magnitudes of T1 and T2 in the program of the PLC system according to the above method.

[0048] (1) If 0 < T1 - T2 ≤ 2, the speed measuring device is normal;

[0049] (2) If T1 - T2 > 2, there may be abnormal situations in the speed measuring device such as roller slipping, spring aging, failure, weight dropping, etc.;

[0050] (3) If T1 - T2 ≤ 0, it means that the rubber ring outside the roller is severely worn, causing the diameter of the roller to become smaller.

[0051] The "2" in 0 < T1 - T2 ≤ 2 and T1 - T2 > 2 mentioned above represents 2 seconds, which is the time for the speed measuring device to resist weld interference and self-reset. It can be adjusted according to the actual usage situation during specific implementation. Once the above situations (2) and (3) occur, the PLC system will issue an alarm to remind the maintenance personnel to conduct inspections and maintenance in a timely manner on the computer operation screen. It should be noted that the above embodiments are not used to limit the protection scope of the present invention, and equivalent transformations or substitutions made on the basis of the above technical solutions all fall within the protection scope of the claims of the present invention.

Claims

1. A method for self-diagnosing abnormalities in a sintering mixer cylinder, characterized in that, The method includes the following steps: S1. Manufacture a speed measuring device that is suitable for the working characteristics of a cylinder and can achieve anti-slip and self-resetting against weld interference. S2. Manufacture a device for self-diagnosing abnormal rotation speed. S3. Design a method for self-diagnosing abnormal speed measuring device.

2. The self-diagnosis method for abnormalities of the sintering mixer cylinder according to claim 1, characterized in that, The speed measuring device includes a roller, a rubber ring, a transmission gear, a gear sensor, a support arm, a fixed shaft, a pin hole, a fixed bracket, a connecting pin, a fixing plate, and a telescopic spring. The roller of the speed measuring device is directly below the cylinder, and a rubber ring is installed outside the roller, and the rubber ring is in direct contact with the surface of the cylinder. The roller and the transmission gear are installed on the fixed shaft, and the fixed shaft is installed at the front end of the support arm. The support arm is a U-shaped plate. The support arm has a pin hole behind the fixed shaft. There are fixed brackets on both sides of the pin hole, and the support arm and the fixed brackets are fixed by a connecting pin. The fixed brackets are welded to the fixing plate, and the fixing plate and the end of the support arm are connected by a telescopic spring.

3. The self-diagnosis method for abnormalities of the sintering mixer cylinder according to claim 2, characterized in that, The surface of the rubber ring has particle stripes for increasing friction to prevent the roller from slipping when the cylinder rotates.

4. The self-diagnosis method for abnormalities of the sintering mixer cylinder according to claim 2, characterized in that, The distance from the center of the roller to the bottom of the support arm is greater than the radius of the roller, and the diameter of the transmission gear is smaller than the diameter of the roller, ensuring that the roller and the transmission gear will not touch the bottom of the support arm.

5. The self-diagnosis method for abnormalities of the sintering mixer cylinder according to claim 2, characterized in that, The center of the opening of the pin hole and the center of the fixed shaft are on the same horizontal plane, and it is ensured that with the opening position of the pin hole as the fulcrum, the weight of the rear end of the support arm is slightly greater than the weight of the front end.

6. The method for self-diagnosing abnormalities in the sintering mixer cylinder according to claim 2, characterized in that, The distance between the fixed bracket and the support arm is less than 2 cm and as small as possible to prevent the support arm from moving significantly left and right on the connecting pin and affecting the speed measurement accuracy.

7. The method for self-diagnosing abnormalities in the sintering mixer cylinder according to claim 2, characterized in that, When the weld of the cylinder rotates to the speed measuring roller and causes the support arm to swing downward, the telescopic spring can pull the support arm back to its original position within 2 seconds to ensure that the roller returns to the contact surface of the cylinder.

8. The self-diagnosis method for abnormalities of the sintering mixer cylinder according to claim 2, characterized in that, The device for self-diagnosing abnormal rotation speed includes a proximity switch and an iron block. The proximity switch is installed at one end of the above-mentioned fixed shaft, and a paired iron block is welded on the cylinder opposite to the proximity switch. The signal of the proximity switch is sent into the PLC system through a signal cable.

9. The method for self-diagnosing abnormalities in the sintering mixer cylinder according to claim 2, characterized in that, In step S3, after the production and installation of the cylinder speed measuring device and the device for self-diagnosing abnormal rotation speed are completed, when the cylinder speed signal measured by the speed measuring device is sent into the PLC system, its speed is set as V1 (unit: mm / s), and the diameter of the cylinder is set as D (unit: mm). Then the circumference of the cylinder is πD (unit: mm), and the time for the cylinder to rotate one circle is calculated as T1 = πD / V1 (unit: s). At the same time, for each rotation of the cylinder, the proximity switch of the device for self-diagnosing abnormal rotation speed sends a switching quantity signal to the PLC, and the time interval between two switching quantity signals is T2 (unit: s). The cylinder speed V1 measured by the speed measuring device and the pulse signal of the device for self-diagnosing abnormal rotation speed are both sent into the PLC system. In the program of the PLC system, the magnitudes of T1 and T2 can be compared according to the above method. (1) If 0 < T1 - T2 ≤ 2, the speed measuring device is normal. (2) If T1 - T2 > 2, there may be abnormal situations in the speed measuring device such as roller slipping, spring aging, failure, weight dropping, etc. (3) If T1 - T2 ≤ 0, it indicates that the rubber ring outside the roller is severely worn, resulting in a smaller diameter of the roller. The "2" in the above 0 < T1 - T2 ≤ 2 and T1 - T2 > 2 represents 2 seconds, which is the time for the above speed measurement device to resist weld interference and self-reset. Once the above situations (2) and (3) occur, the PLC system will issue an alarm to remind the maintenance personnel to check and maintain in a timely manner on the computer operation screen.

Images