An intelligent operation and maintenance method and device for an adaptive suction system

Abstract

This invention relates to an intelligent operation and maintenance method and device for an adaptive material suction system, comprising: Step 1, configuring the hardware of the material suction system; Step 2, adaptive material suction time parameters; Step 3, adaptive material cleaning time parameters; Step 4, self-diagnosis of material suction pump failure, pressure sensor failure, and pipe breakage in the front pipeline; Step 5, self-maintenance of material jamming on the material suction sealing plate, and self-diagnosis of material shortage and pipe breakage in the rear pipeline; Step 6, self-maintenance of filter element clogging by spray cleaning, and self-diagnosis of cleaning the filter barrel and replacing the filter element. This invention solves the high-frequency industry problem of "material suction failure" by adapting key parameters of the material suction and cleaning system, intelligent operation and maintenance of cleaning the material suction sealing plate and filter element clogging, and self-diagnosis of multiple faults such as the material suction pump, pressure sensor, and pipe breakage. It achieves zero user experience and zero operational requirements, extends the service life of core components such as the material suction pump, pipelines, and filter elements, reduces operating costs, and increases material suction capacity.

Description

Technical Field

[0001] This invention relates to the field of intelligent operation and maintenance technology for material suction systems, and in particular to an adaptive intelligent operation and maintenance method and apparatus for material suction systems. Background Technology

[0002] Material feeding systems are core feeding equipment in industries such as injection molding, plastic processing, and chemical powder conveying, primarily used for the automated conveying of granular and irregularly shaped raw materials. Feeding parameters (including feeding time and cleaning time) are key parameters determining the pressure conditions during system operation, the quality of raw materials conveyed by the feeder, the conveying capacity per unit time, the amount of raw material remaining in the feeding pipe, and the lifespan of system accessories (including wear parts such as feed pipes, filter elements, and filter screens). Currently, traditional material feeding systems face numerous unresolved technical challenges in industrial applications, severely restricting production efficiency and equipment reliability. 1. The most frequent fault in the application of traditional material feeders is material suction failure. The main causes of this failure are: poor closure due to material jamming at the feeder sealing plate or insufficient negative pressure established in the feeder and suction pipeline due to filter blockage. This negative pressure hinders the smooth flow of raw materials, leading to material suction failure. This is especially true when conveying materials prone to static adhesion or irregular shapes, which are more likely to get stuck or stick to the feeder sealing plate. After a material suction failure, manual shutdown for cleaning is required, directly causing material shortages and shutdowns in the injection molding production line, poor raw material drying, increased product defect rates, and significantly increased labor and maintenance costs.

[0003] 2. The suction parameters of traditional suction machines in the industry are all set manually based on experience. When the volume of the suction machine, the suction height and horizontal distance, and the type or shape of the raw material are different, the manual experience parameters often cannot make the system fully efficient. In fact, the set parameters may not be suitable for the current working conditions, which will cause the suction system to frequently experience abnormalities such as excessive suction and poor cleaning, insufficient suction and insufficient capacity, and suction failure. Moreover, it requires a high level of professional experience from the operators, and inexperienced operators cannot quickly adapt to the equipment working conditions.

[0004] 3. Faults cannot be automatically diagnosed and located: Problems such as suction pump failure, pressure sensor failure, and pipeline damage require manual inspection one by one, resulting in low maintenance efficiency, long downtime, and serious impact on continuous production.

[0005] 4. Significantly shortened lifespan of equipment components: The system operates under extreme pressure for extended periods, resulting in severe wear and tear on core components and vulnerable parts such as the suction pump, feed pipe, filter element, and filter screen. This leads to a short overall lifespan for the equipment and high maintenance costs.

[0006] 5. Delayed filter maintenance leads to a chain of failures: The filter element of the feeder is not a consumable item that can be ignored. It is a key barrier to protect the suction pump and ensure the stable and efficient operation of the system. Filter failure will lead to a decline in system performance, increased energy consumption, damage to the air pump, and motor burnout, resulting in production pollution and safety risks. Traditional methods rely on manual periodic inspection and replacement, which cannot automatically identify the state of dirt and blockage.

[0007] To address the aforementioned common industry problems, this invention proposes an intelligent operation and maintenance method and device for an adaptive material suction system, which achieves parameter self-adaptation, component self-maintenance, and fault self-diagnosis, filling the technological gap in intelligent operation and maintenance of traditional material suction systems. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide an intelligent operation and maintenance method and device for an adaptive material suction system, which realizes automatic adaptation of material suction parameters, intelligent self-cleaning of sealing plates and filter elements, automatic fault identification and location, reduces system failure rate, increases conveying capacity, extends equipment service life, and reduces manual operation and maintenance costs.

[0009] The technical solution adopted by this invention to solve its technical problem is: to provide an intelligent operation and maintenance method for an adaptive material suction system, the method comprising the following steps: Step 1: Configure the hardware of the material suction system: Build the main structure of the material suction system, which consists of a material suction pump, control device, filter device, collection box, cleaning suction box, and suction device. Install pressure sensor, filter element spraying device, suction device sealing plate spraying device and material level switch on the material suction system, and collect pressure signal and material level signal through data acquisition module. Step 2, Adaptive suction time parameters: Preset negative pressure establishment time and suction timeout time, collect dynamic changes in pipeline pressure in real time during the suction cycle, identify and determine the time and steady-state pressure value corresponding to the single pressure steady-state inflection point and the secondary pressure steady-state inflection point, determine the full material state of the suction device based on the occurrence conditions of the secondary pressure inflection point, and adaptively calculate and generate matching suction time parameters. If no effective full material pressure feature is identified after the timeout, the suction is determined to be a failure and the pressure parameters are reset. Step 3, Adaptive Cleaning Time Parameters: The cleaning time ratio coefficient is preset, and the temporary cleaning time is calculated based on the adaptively obtained suction time parameters. The temporary cleaning time is adaptively increased or decreased according to the number of times the pressure inflection point occurs within a single suction cycle, and adaptive cleaning time parameters are generated. Step 4: Self-diagnosis of suction pump failure, pressure sensor failure, and front pipeline rupture; Step 5: Self-maintenance of material suction and sealing plate cleaning, self-diagnosis of raw material shortage and pipe breakage in the rear pipeline; Step Six: Self-maintenance of filter element cleaning and self-diagnosis for cleaning filter cartridges and replacing filter elements.

[0010] As a supplement to the technical solution described in this invention, the configuration of the material suction system hardware specifically includes: The material suction system includes a material suction pump, a control device, a filter device, a collection box, a cleaning material suction box, and a material suction device. The material suction pump is connected to the filter device through a front-end air suction pipe, and the filter device is connected to the material suction device through a rear-end air suction pipe. A cleaning material suction box is installed at the bottom outlet of the collection box, and the cleaning material suction box is connected to the material suction device through a material pipe. The control device is used to control the material suction pump, the filter device, the cleaning material suction box, and the material suction device. Install high-precision pressure sensors at key locations in the material suction system. The number of pressure sensors should be at least one. Key locations include: the front suction pipe, the rear suction pipe, and the material pipe. A filter element cleaning device is installed at the filter unit. The filter element cleaning device controls the pulse solenoid valve to use compressed air to clean the dust or impurities remaining on the filter element after use, effectively restoring the filter element's filtration capacity. A suction plate cleaning device and a material level switch are installed at the suction plate. The suction plate cleaning device controls the solenoid valve to use compressed air to clean the residual plastic particles or irregular crushed plastic particles on the suction plate, ensuring that there is no material jamming on the suction plate. The material level switch at the suction plate detects whether the current system material level is full or low. The data acquisition module is used to acquire signals from the pressure sensor and the level switch at a preset acquisition frequency. The material suction system delivers raw materials according to the material level. When the material level switch detects a material shortage, the suction pump starts, and the pipeline gradually forms a negative pressure. The raw materials are drawn from the collection box to the suction device due to the negative pressure. After the raw materials are sufficient, the material cleaning suction box cuts off the raw materials, so that the raw materials in the collection box are no longer delivered. At the same time, the remaining raw materials in the pipeline continue to be delivered and gradually emptied. After the emptying is completed, the suction pump stops. The process from the start of the suction pump to the stop of the suction pump is defined as one suction cycle.

[0011] As a supplement to the technical solution described in this invention, the adaptive feeding time parameter specifically includes: Set the negative pressure establishment time Ta and the material suction timeout time Tb, the material suction time parameter Sx, the first pressure decrease time Sa, the second pressure decrease time Sb, the material suction pressure parameter Pf1, and the full suction pressure parameter Pf2; in: The duration is 5 to 15 seconds, with a default preset of 10 seconds; Tb is 15 seconds to 120 seconds, with the default preset being 100 seconds; The feed time parameter Sx defaults to 0 seconds; The secondary pressure reduction time parameter Sb is set to 0 seconds by default. The material suction pressure parameter Pf1 is defaulted to 0 kPa; The full suction pressure parameter Pf2 is defaulted to 0 kPa; Use the data acquisition module to collect the signals of the pressure sensor and the level switch at a preset acquisition frequency; Detect the lack of material level and the material suction time parameter Sx = 0, the material suction pressure parameter Pf1 = 0 and the full suction pressure parameter Pf2 = 0; The material suction pump starts, and a negative pressure is gradually formed in the pipeline. The raw materials are sucked from the aggregate box to the material suction device due to the traction of the negative pressure; Within the negative pressure establishment time Ta, if the pressure value decreases and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the pressure decrease time Sa once, and calculate and record the average value Pf1 of the current stable pressure value; Within the material suction overtime time Tb, if the pressure value decreases again and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the secondary pressure decrease time Sb, and at the same time calculate and record the average value Pf2 of the current stable pressure value; When Pf2 < 0 and Sb < Tb, it is determined that the material suction device is full. Pf2 is the pressure value when full, Sb is the time required to be full, Pf1 is the pressure value during the negative pressure flow of the raw materials, and calculate the material suction time parameter Sx using the first calculation formula; The first calculation formula is: Sx = INT(Sb); Where, Sx is the material suction time parameter, Sb is the secondary pressure decrease time parameter, and INT is to take an integer; When the total running time exceeds Tb and Pf2 = 0, it is determined that the material suction fails this time, and then set Pf1 = 0.

[0012] As a supplement to the technical solution described in the present invention, the cleaning time parameter is adaptive, specifically including: Set the cleaning time ratio coefficient K, the temporary cleaning time Sk, the cleaning time parameter Sq and the full hopper flag F; Where: K is 0.1 - 0.5, and the default preset is 0.5; Calculate the temporary cleaning time Sk using the second calculation formula; The second calculation formula is: Sk = Sx * K; Where, Sx is the material suction time parameter and K is the cleaning time ratio coefficient; The cleaning time parameter Sq is defaulted to 0 seconds; The full hopper flag F is defaulted to 0; Use the data acquisition module to collect the signals of the pressure sensor and the level switch at a preset acquisition frequency; If a material shortage is detected and the material suction time parameter Sx > 0, the material clearing time Sq = 0. When analyzing the pressure changes over a feeding cycle, the following scenarios can be considered: The first scenario: If the pressure value decreases twice within a feeding cycle, it is determined that the feeder is full and the feeding amount needs to be reduced. In this case, the cleaning time ratio coefficient K is increased by 0.1, and the maximum value of K is 0.5, which means that the temporary cleaning time is increased. At the same time, F is set to 1. The second method is: if the pressure value decreases only once within a feeding cycle, it is determined that the feeder is not fully fed and the feeding volume can be increased. In this case, the cleaning time ratio coefficient K is set to 0.1, and the minimum value of K is 0.1, which means reducing the temporary cleaning time. The third scenario: If the pressure value does not decrease once within a feeding cycle, proceed to step four. When K=0.1 or F=1, the cleaning time Sq is calculated using the third calculation formula; The third calculation formula is: Sq = Sx * K; Where Sx is the material feeding time parameter, and K is the material cleaning time ratio coefficient.

[0013] As a supplement to the technical solution described in this invention, the self-diagnosis of suction pump failure, pressure sensor failure, and front pipeline rupture specifically includes: The pressure value did not decrease even once within a feeding cycle or feeding timeout Tb; The following methods can be used to accurately diagnose fault types, including suction pump failure, pressure sensor failure, and front pipeline rupture. First, determine whether the suction pump is faulty by combining the detection of the thermal protection components of the suction pump motor and the current transformer or transmitter. Second, the changes in the pressure sensor readings between the previous feeding cycle and the current feeding process are used to determine whether the pressure sensor is faulty. Third, if the above two faults are ruled out, it can be determined that the front pipeline between the front end of the pressure sensor and the suction pump is broken.

[0014] As a supplement to the technical solution described in this invention, the self-maintenance of the material suction sealing plate for cleaning up stuck materials, and the self-diagnosis of material shortage and pipe breakage in the rear pipeline specifically include: Set the preset value of sealing plate clamping pressure Pm, and count the number of times the negative pressure is insufficient (Ca). When the suction pressure parameter Pf1 < 0, the preset value of the sealing plate clamping pressure Pm is calculated using the fourth calculation formula; The fourth calculation formula is: Pm = Pf1 * 0.85; Wherein, Pf1 is the suction pressure parameter; The default value for counting insufficient negative pressure is 0. During a material suction cycle, if the pressure value decreases only once and the pressure value > Pm, the negative pressure deficiency count Ca increases by one; Start the self-maintenance cleaning of the sealing plate of the material suction device to clean the material jamming on the sealing plate; Continue the material suction and execute according to the following two situations: During a material suction cycle, if the pressure value decreases and the pressure value <= Pm, then Ca = 0, and the self-maintenance of cleaning the material jamming on the suction sealing plate is carried out to avoid the problem of material suction failure caused by material jamming on the sealing plate; During a material suction cycle, if the pressure value decreases only once and the pressure value > Pm, then repeat the previous two steps. When Ca > 3, the self-diagnosis determines that the failure is due to lack of raw materials or a broken pipe in the rear pipeline.

[0015] As a supplement to the technical solution described in the present invention, the self-maintenance of cleaning the dirty and blocked filter element by spraying, the self-diagnosis of cleaning the filter barrel and replacing the filter element specifically include: Set the preset value Pn of the filter element dirty and blocked pressure and the count Cb of the filter element dirty and blocked; When the full suction pressure parameter Pf2 < 0, calculate the preset value Pn of the filter element dirty and blocked pressure by using the fifth calculation formula; The fifth calculation formula is: Pn = Pf2 * 0.8; Where Pf2 is the full suction pressure parameter; The count Cb of the filter element dirty and blocked is defaulted to 0; S1. During a material suction cycle, if the pressure value decreases once and the pressure value < Pn, then the count Cb of the filter element dirty and blocked increases by one; S2. Start the self-maintenance of cleaning the dirty and blocked filter element by spraying to clean the residual dust or impurities on the filter element; Continue the material suction and execute according to the following two situations: During a material suction cycle, if the pressure value decreases once and the pressure value > Pn, then Cb = 0, and the self-maintenance of cleaning the dirty and blocked filter element by spraying is carried out to avoid the problem of material suction failure caused by the dirty and blocked filter element; During a material suction cycle, if the pressure value decreases once and the pressure value < Pn, then repeat the previous two steps of S1 and S2. When Cb > 3, the self-diagnosis determines that the filter barrel needs to be cleaned or the filter element needs to be replaced.

[0016] An intelligent operation and maintenance device for an adaptive material suction system is disclosed. This device implements the aforementioned intelligent operation and maintenance method for the adaptive material suction system. The device includes: a structure setting module for setting up the material suction system and correspondingly installing a pressure sensor, a filter element cleaning device, a material suction plate cleaning device, and a material level switch; a parameter adaptation module for adaptively setting material suction time parameters and material cleaning time parameters; a front pipeline self-diagnosis module for self-diagnosis of material suction pump failure, pressure sensor failure, and front pipeline rupture; a rear pipeline maintenance and self-diagnosis module for self-maintenance of material suction plate jamming and cleaning, material shortage, and rear pipeline rupture; and a filter element clogging self-maintenance and self-diagnosis module for self-maintenance of filter element clogging by spray cleaning, and self-diagnosis of filter barrel cleaning and filter element replacement.

[0017] A computer-readable storage medium storing computer program instructions thereon, which, when executed by a processor, implement the intelligent operation and maintenance method for the adaptive material feeding system.

[0018] An electronic device includes a memory and a processor, the memory being used to store one or more computer program instructions, wherein the one or more computer program instructions are executed by the processor to implement the intelligent operation and maintenance method of the adaptive material feeding system.

[0019] Beneficial effects: This invention relates to an intelligent operation and maintenance method and device for an adaptive material suction system, which has the following advantages: 1. Intelligent maintenance and cleaning of feeder sealing plate solves the high-frequency problem of "feeding failure" in the industry: The intelligent self-cleaning maintenance method of feeder sealing plate can realize self-identification, self-cleaning and self-circulation of material jamming on the sealing plate. It solves the high-frequency failure of traditional feeder sealing plate, which causes frequent material jamming and feeding failure, requiring manual troubleshooting and cleaning. It effectively reduces the failure rate of the feeding system, reduces manual intervention, avoids the shutdown of injection molding production line due to material shortage, and avoids the increase in product defect rate caused by poor raw material drying. 2. Key parameters are self-adaptive, requiring zero user experience and zero operational requirements: The material suction and cleaning parameters are automatically and adaptively adjusted, requiring no manual experience to set, and adapting to all working conditions and material types; 3. The key parameter adaptive feeding system operates more stably and has a more efficient feeding capacity: By controlling the feeding time to control the feeding amount to 85%~95% of the current feeder volume, the amount of raw material conveyed each time is close to the feeder's optimal capacity. The system pressure operates below the pressure value that ensures smooth flow of raw materials, resulting in the optimal feeding amount and the shortest feeding time, thereby achieving the highest feeding capacity. 4. Adaptive key parameters extend the service life of the core component, the suction pump, and other major wear parts: By automatically setting the suction time, the suction volume is controlled to be 85%~90% of the current suction device volume. This avoids the system operating under extreme working pressure, effectively reducing the operating load of the suction pump and reducing the wear of wear parts such as material pipes, filter elements, and filter screens under greater pressure differentials. Overall, this extends the service life of the suction pump, pipelines, filter elements, and other wear parts. 5. Intelligent operation and maintenance of filter element cleaning ensures stable and efficient operation of the suction pump and system: By analyzing the pressure value changes of the pressure sensor online, the filter element is automatically identified as clogged, and the filter element pulse spray cleaning device is activated in time to clean the filter element, ensuring efficient filtration of the filter element, and thus ensuring that the suction system operates more reliably and effectively under stable and efficient working conditions. Attached Figure Description

[0020] Figure 1 This is a flowchart of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention.

[0021] Diagram: 1. Suction pump, 2. Control device, 3. Front suction pipe, 4. Filter device, 5. Collection box, 6. Cleaning suction box, 7. Rear suction pipe, 8. Suction device, 9. Material pipe, 101. Filter element spraying device, 102. Pressure sensor, 103. Suction device sealing plate spraying device, 104. Material level switch. Detailed Implementation

[0022] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0023] The first embodiment of the present invention relates to an intelligent operation and maintenance method for an adaptive material suction system, such as... Figure 1-2 As shown, the method includes the following steps: Step 1: Configure the hardware of the material suction system: Build the main structure of the material suction system, which consists of a material suction pump, control device, filter device, collection box, cleaning suction box, and material suction device. Install pressure sensor 102, filter element spraying device 101, material suction device sealing plate spraying device 103 and material level switch 104 on the material suction system, and collect pressure signal and material level signal through data acquisition module. Specifically, the hardware configuration for the material suction system includes: The material suction system includes a material suction pump 1, a control device 2, a filter device 4, a collection box 5, a cleaning material suction box 6, and a material suction device 8. The material suction pump 1 and the filter device 4 are connected through a front-end air suction pipe 3, and the filter device 4 and the material suction device 8 are connected through a rear-end air suction pipe 7. A cleaning material suction box 6 is installed at the bottom outlet of the collection box 5, and the cleaning material suction box 6 is connected to the material suction device 8 through a material pipe 9. The control device 2 is used to control the material suction pump 1, the filter device 4, the cleaning material suction box 6, and the material suction device 8. High-precision pressure sensors 102 are installed at key locations in the material suction system. At least one pressure sensor 102 is set. Key locations include: the front suction pipe 3, the rear suction pipe 7, and the material pipe 9. A filter element cleaning device 101 is installed at the filter device 4. The filter element cleaning device 101 controls the pulse solenoid valve to use compressed air to clean the dust or impurities remaining after the filter element is used, effectively restoring the filter element's filtration capacity. A suction plate cleaning device 103 and a material level switch 104 are installed at the suction plate 8. The suction plate cleaning device 103 controls the solenoid valve to use compressed air to clean the residual plastic particles or irregular crushed plastic particles on the suction plate, ensuring that there is no material jamming on the suction plate. The material level switch 104 at the suction plate 8 detects whether the current system material level is full or low. The data acquisition module acquires signals from pressure sensor 102 and level switch 104 at a preset acquisition frequency. The material suction system transports raw materials according to the material level. When the material level switch 104 detects a material shortage, the suction pump 1 starts, and the pipeline gradually forms a negative pressure. Due to the negative pressure, the raw material is transported from the collection box 5 to the suction device 8. After the raw material is sufficient, the cleaning suction box 6 cuts off the raw material, so that the raw material inside the collection box 5 is no longer transported. At the same time, the remaining raw material in the pipeline continues to be transported and gradually emptied. After the emptying is completed, the suction pump 1 stops. The process from the start of the suction pump 1 to the stop of the suction pump 1 is defined as one suction cycle.

[0024] Step 2: Adaptive feeding time parameters, specifically including: Set the negative pressure establishment time Ta and the material suction timeout time Tb, the material suction time parameter Sx, the first pressure decrease time Sa, the second pressure decrease time Sb, the material suction pressure parameter Pf1, and the full suction pressure parameter Pf2; in: The duration is 5 to 15 seconds, with a default preset of 10 seconds; Tb is 15 seconds to 120 seconds, with the default preset being 100 seconds; The feed time parameter Sx defaults to 0 seconds; The secondary pressure reduction time parameter Sb is set to 0 seconds by default. The material suction pressure parameter Pf1 is defaulted to 0 kPa; The full suction pressure parameter Pf2 is defaulted to 0 kPa; Use the data acquisition module to collect the signals of the pressure sensor 102 and the level switch 104 at a preset acquisition frequency; Detect the lack of material level and the material suction time parameter Sx = 0, the material suction pressure parameter Pf1 = 0 and the full suction pressure parameter Pf2 = 0; The material suction pump 1 starts, and a negative pressure is gradually formed in the pipeline. The raw material is sucked from the aggregate box 5 to the material suction device 8 due to the negative pressure traction; Within the negative pressure establishment time Ta, if the pressure value becomes smaller and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the pressure reduction time Sa once, and calculate and record the average value Pf1 of the current stable pressure value; Within the material suction timeout time Tb, if the pressure value becomes smaller again and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the secondary pressure reduction time Sb, and at the same time calculate and record the average value Pf2 of the current stable pressure value; When Pf2 < 0 and Sb < Tb, it is determined that the material suction device 8 is full. Pf2 is the pressure value when full, Sb is the time required to be full, Pf1 is the pressure value during the negative pressure flow of the raw material, and calculate the material suction time parameter Sx using the first calculation formula; The first calculation formula is: Sx = INT(Sb); Where, Sx is the material suction time parameter, Sb is the secondary pressure reduction time parameter, and INT is to take the integer; When the total running time exceeds Tb and Pf2 = 0, it is determined that the material suction fails this time, and then set Pf1 = 0.

[0025] Step 3: The cleaning time parameter is adaptive, specifically including: Set the cleaning time proportion coefficient K, the temporary cleaning time Sk, the cleaning time parameter Sq and the full hopper flag F; Where: K is 0.1 - 0.5, and the default preset is 0.5; Calculate the temporary cleaning time Sk using the second calculation formula; The second calculation formula is: Sk = Sx * K; Where, Sx is the material suction time parameter and K is the cleaning time proportion coefficient; The cleaning time parameter Sq is defaulted to 0 seconds; The full hopper flag F is defaulted to 0; Use the data acquisition module to collect the signals of the pressure sensor 102 and the level switch 104 at a preset acquisition frequency; If a material shortage is detected and the material suction time parameter Sx > 0, the material clearing time Sq = 0. When analyzing the pressure changes over a feeding cycle, the following scenarios can be considered: The first scenario: If the pressure value decreases twice within a feeding cycle, it is determined that the feeder 8 is full and the feeding amount needs to be reduced. In this case, the cleaning time ratio coefficient K is increased by 0.1, and the maximum value of K is 0.5, which means that the temporary cleaning time is increased. At the same time, F is set to 1. The second method: If the pressure value decreases only once within a feeding cycle, it is determined that the feeder 8 is not fully fed and the feeding amount can be increased. In this case, the cleaning time ratio coefficient K is set to 0.1, and the minimum value of K is 0.1, which means reducing the temporary cleaning time. The third scenario: If the pressure value does not decrease once within a feeding cycle, proceed to step four. When K=0.1 or F=1, the cleaning time Sq is calculated using the third calculation formula; The third calculation formula is: Sq = Sx * K; Where Sx is the material feeding time parameter, and K is the material cleaning time ratio coefficient.

[0026] The automatic adaptive adjustment of suction and cleaning parameters eliminates the need for manual setting and adapts to all working conditions and raw material types. The self-setting suction time controls the suction volume to 85%~95% of the current feeder volume, ensuring that the amount of raw material delivered each time is close to the feeder's optimal capacity. The system pressure operates below the pressure value that ensures smooth material flow, resulting in optimal suction volume and shortest suction time, thus maximizing suction capacity. Adaptive key parameters extend the service life of the core component, the suction pump, and other major wear parts: The self-setting suction time controls the suction volume to 85%~90% of the current feeder volume, preventing the system from operating at extreme pressures. This effectively reduces the operating load on the suction pump and minimizes wear on wear parts such as pipes, filter elements, and filter screens under greater pressure differentials, thus extending the overall service life of the suction pump, pipes, and filter elements.

[0027] Step 4: Self-diagnosis of suction pump 1 malfunction, pressure sensor 102 malfunction, and upstream pipeline rupture, specifically including: The pressure value did not decrease even once within a feeding cycle or feeding timeout Tb; The following methods can be used to accurately diagnose fault types, including faults in suction pump 1, pressure sensor 102, and front pipeline rupture. First, determine whether the suction pump 1 is faulty by combining the detection of the thermal protection components of the suction pump motor and the current transformer or transmitter; Second, based on the changes in the detection values of the pressure sensor during the previous material suction cycle and the current material suction process, determine whether the pressure sensor 102 is faulty; Third, if the above two types of faults are excluded, it can be determined that there is a pipe break in the front pipeline between the front end of the pressure sensor and the material suction pump.

[0028] Step Five: Self-maintenance for cleaning the material suction sealing plate jamming, self-diagnosis for raw material shortage and pipe break in the rear pipeline, specifically including: Set the preset value Pm of the sealing plate jamming pressure and the counting Ca of insufficient negative pressure; When the material suction pressure parameter Pf1 < 0, calculate the preset value Pm of the sealing plate jamming pressure using the fourth calculation formula; The fourth calculation formula is: Pm = Pf1 * 0.85; where Pf1 is the material suction pressure parameter; The counting Ca of insufficient negative pressure is defaulted to 0; During one material suction cycle, if the pressure value decreases only once and the pressure value > Pm, then increment the counting Ca of insufficient negative pressure by one; Start the self-maintenance of the material suction device sealing plate spray cleaning to clean the sealing plate jamming; Continue the material suction and execute according to the following two situations: During one material suction cycle, if the pressure value decreases and the pressure value <= Pm, then Ca = 0. Through the self-maintenance of cleaning the material suction sealing plate jamming, it is used to avoid the problem of material suction failure caused by the sealing plate jamming; During one material suction cycle, if the pressure value decreases only once and the pressure value > Pm, then repeat the previous two steps. When Ca > 3, the self-diagnosis determines that the fault is raw material shortage or pipe break in the rear pipeline.

[0029] Step Six: Self-maintenance for spray cleaning of the filter element dirt blockage, self-diagnosis for cleaning the filter barrel and replacing the filter element, specifically including: Set the preset value Pn of the filter element dirt blockage pressure and the counting Cb of the filter element dirt blockage; [[ID=CO2]]When the full suction pressure parameter Pf2 < 0, calculate the preset value Pn of the filter element dirt blockage pressure using the fifth calculation formula; The fifth calculation formula is: Pn = Pf2 * 0.8; where Pf2 is the full suction pressure parameter; The counting Cb of the filter element dirt blockage is defaulted to 0; S1. During one material suction cycle, if the pressure value decreases once and the pressure value < Pn, then increment the counting Cb of the filter element dirt blockage by one; S2. Start the self-maintenance of spray cleaning the filter element dirt blockage to clean the residual dust or impurities on the filter element; Continue the material suction and execute according to the following two situations: During a material suction cycle, if the pressure value decreases once and the pressure value > Pn, then Cb = 0, and self-maintenance is performed through filter element clogging spray cleaning to avoid material suction failure problems caused by filter element clogging; During a material suction cycle, if the pressure value decreases once and the pressure value < Pn, then the previous two steps S1 and S2 are repeated. When Cb > 3, self-diagnosis determines that the filter barrel needs to be cleaned or the filter element needs to be replaced.

[0030] The intelligent operation and maintenance of the filter element ensures the stable and efficient operation of the material suction pump and the system. By online analyzing the change of the pressure value of the pressure sensor, it automatically identifies the clogging condition of the filter element and timely drives the filter element pulse spray cleaning device to clean the filter element, ensuring the high-efficiency filtration of the filter element, and further ensuring that the material suction system operates more reliably and effectively under stable and efficient working conditions.

[0031] The second embodiment of the present invention relates to an intelligent operation and maintenance device for an adaptive material suction system. The device includes: A structure setting module for setting the material suction system and correspondingly installing a pressure sensor, a filter element spray cleaning device, a material suction device sealing plate spray cleaning device, and a material level switch; A parameter adaptive module for adaptively setting the material suction time parameter and the material cleaning time parameter; A front pipeline self-diagnosis module for self-diagnosis of material suction pump failure, pressure sensor failure, and front pipeline rupture; A rear pipeline maintenance and self-diagnosis module for self-maintenance of material suction sealing plate clogging cleaning, self-diagnosis of raw material shortage, and rear pipeline rupture; A filter element clogging self-maintenance and self-diagnosis module for self-maintenance of filter element clogging spray cleaning, self-diagnosis of filter barrel cleaning, and filter element replacement.

[0032] The third embodiment of the present invention relates to a computer-readable storage medium, on which computer program instructions are stored. When the computer program instructions are executed by a processor, an intelligent operation and maintenance method for an adaptive material suction system is implemented.

[0033] The fourth embodiment of the present invention relates to an electronic device, including a memory and a processor. The memory is used to store one or more computer program instructions. Among them, the one or more computer program instructions are executed by the processor to implement an intelligent operation and maintenance method for an adaptive material suction system.

[0034] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0035] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0036] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0037] The above provides a detailed description of the intelligent operation and maintenance method and device for an adaptive material feeding system provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. An intelligent operation and maintenance method of an adaptive suction system, characterized in that: The method includes the following steps: Step 1: Configure the hardware of the material suction system: Build the main structure of the material suction system, which consists of a material suction pump, control device, filter device, collection box, cleaning suction box, and suction device. Install pressure sensor, filter element spraying device, suction device sealing plate spraying device and material level switch on the material suction system, and collect pressure signal and material level signal through data acquisition module. Step 2: Adaptive Feeding Time Parameters: Preset negative pressure establishment time and feeding timeout time. Real-time acquisition of pipeline pressure dynamics within the feeding cycle. Identify and determine the time and steady-state pressure value corresponding to the primary and secondary pressure steady-state inflection points. The primary pressure steady-state inflection point occurs within the negative pressure establishment time; if the pressure value decreases and the fluctuation is no greater than 0.5 kPa for at least 2 consecutive seconds, record the primary pressure decrease time and calculate and record the average value of the current stable pressure. The secondary pressure steady-state inflection point occurs within the feeding timeout time; if the pressure value decreases a second time and the fluctuation is no greater than 0.5 kPa for at least 2 consecutive seconds, record the secondary pressure decrease time and calculate and record the average value of the current stable pressure. Based on the occurrence conditions of the above secondary pressure steady-state inflection points, determine the feeder's full-load status and adaptively generate matching feeding time parameters. If no valid full-load pressure characteristic is identified within the timeout period, the feeding is considered a failure and the pressure parameters are reset. Step 3, Adaptive Cleaning Time Parameters: Preset the cleaning time ratio coefficient, calculate the temporary cleaning time based on the adaptively obtained suction time parameters, and adaptively increase or decrease the temporary cleaning time according to the number of times the pressure steady-state inflection point occurs within a single suction cycle, thereby generating adaptive cleaning time parameters. Step 4: Self-diagnosis of suction pump failure, pressure sensor failure, and front pipeline rupture; Step 5: Self-maintenance of material suction and sealing plate cleaning, self-diagnosis of raw material shortage and pipe breakage in the rear pipeline; Step Six: Self-maintenance of filter element cleaning and self-diagnosis for cleaning filter cartridges and replacing filter elements. 2.The intelligent operation and maintenance method of the self-adaptive suction system according to claim 1, characterized in that: The configured material suction system hardware specifically includes: The material suction system includes a material suction pump, a control device, a filter device, a collection box, a cleaning material suction box, and a material suction device. The material suction pump is connected to the filter device through a front-end air suction pipe, and the filter device is connected to the material suction device through a rear-end air suction pipe. A cleaning material suction box is installed at the bottom outlet of the collection box, and the cleaning material suction box is connected to the material suction device through a material pipe. The control device is used to control the material suction pump, the filter device, the cleaning material suction box, and the material suction device. Install pressure sensors at key locations in the material suction system. The number of pressure sensors should be at least one. Key locations include: the front suction pipe, the rear suction pipe, and the material pipe. A filter element spray washing device is installed at the filter unit, and a feeder sealing plate spray washing device and a material level switch are installed at the feeder; the material level switch at the feeder is used to detect whether the current system material level is full or low. The data acquisition module is used to acquire signals from the pressure sensor and the level switch at a preset acquisition frequency. The material suction system conveys raw materials according to the material level. When the material level switch detects a lack of material level, the suction pump starts, and a negative pressure gradually forms in the pipeline. The raw materials are conveyed from the aggregate bin to the suction device due to the traction of the negative pressure. After there is enough raw material, the cleaning and suction box operates to cut off the raw materials, so that the raw materials inside the aggregate bin are no longer conveyed. At the same time, the remaining raw materials in the pipeline continue to be conveyed and gradually emptied. After the emptying is completed, the suction pump stops. Defining the process from the start of the suction pump to the stop of the suction pump as a suction cycle. 3.The intelligent operation and maintenance method of the adaptive suction system according to claim 2, characterized in that: The suction time parameter is adaptive, specifically including: Set the negative pressure establishment time Ta, the suction timeout time Tb, the suction time parameter Sx, the primary pressure reduction time Sa, the secondary pressure reduction time Sb, the suction pressure parameter Pf1, and the full suction pressure parameter Pf2; Among them: Ta is 5 seconds to 15 seconds, and the default preset is 10 seconds; Tb is 15 seconds to 120 seconds, and the default preset is 100 seconds; The suction time parameter Sx is default preset to 0 seconds; The secondary pressure reduction time parameter Sb is default preset to 0 seconds; The suction pressure parameter Pf1 is default preset to 0 kPa; The full suction pressure parameter Pf2 is default preset to 0 kPa; Use the data acquisition module to collect the signals of the pressure sensor and the material level switch at a preset acquisition frequency; Detect a lack of material level and the suction time parameter Sx = 0, the suction pressure parameter Pf1 = 0, and the full suction pressure parameter Pf2 = 0; The suction pump starts, and a negative pressure gradually forms in the pipeline. The raw materials are sucked from the aggregate bin to the suction device due to the traction of the negative pressure; Within the negative pressure establishment time Ta, if the pressure value decreases and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the primary pressure reduction time Sa, and calculate and record the average value Pf1 of the current stable pressure value; Within the suction timeout time Tb, if the pressure value decreases a second time and the fluctuation is not greater than 0.5 kPa for at least 2 consecutive seconds, record the secondary pressure reduction time Sb, and at the same time calculate and record the average value Pf2 of the current stable pressure value; When Pf2 < 0 and Sb < Tb, it is determined that the suction device is full. Pf2 is the pressure value when full, Sb is the time required to be full, Pf1 is the pressure value during the negative pressure flow of the raw materials, and use the first calculation formula to calculate the suction time parameter Sx; The first calculation formula is: Sx = INT(Sb); Among them, Sx is the suction time parameter, Sb is the secondary pressure reduction time parameter, and INT is to take an integer; When the total running time exceeds Tb and Pf2 = 0, it is determined that this suction fails, and then set Pf1 = 0. 4.The intelligent operation and maintenance method of the self-adaptive suction system according to claim 2, characterized in that: The cleaning time parameter is adaptive, specifically including: Set the cleaning time proportion coefficient K, the temporary cleaning time Sk, the cleaning time parameter Sq, and the full hopper flag F; Among them: K is 0.1 to 0.5, and the default preset is 0.5; Use the second calculation formula to calculate the temporary cleaning time Sk; The second calculation formula is: Sk = Sx * K; Among them, Sx is the suction time parameter, and K is the cleaning time proportion coefficient; The cleaning time parameter Sq is default preset to 0 seconds; The full hopper flag F is default preset to 0; The data acquisition module is used to acquire signals from the pressure sensor and the level switch at a preset acquisition frequency. If a material shortage is detected and the material suction time parameter Sx > 0, the material clearing time Sq = 0. When analyzing the pressure changes over a feeding cycle, the following scenarios can be considered: The first scenario: If the pressure value decreases twice within a feeding cycle, it is determined that the feeder is full and the feeding amount needs to be reduced. In this case, the cleaning time ratio coefficient K is increased by 0.1, and the maximum value of K is 0.5, which means that the temporary cleaning time is increased. At the same time, F is set to 1. The second method: If the pressure value decreases only once within a feeding cycle, it is determined that the feeder is not fully fed and the feeding amount can be increased. In this case, the cleaning time ratio coefficient K is set to 0.1, and the minimum value of K is 0.1, which means reducing the temporary cleaning time. The third scenario: If the pressure value does not decrease once within a feeding cycle, proceed to step four. When K=0.1 or F=1, the cleaning time Sq is calculated using the third calculation formula; The third calculation formula is: Sq = Sx * K; Where Sx is the material feeding time parameter, and K is the material cleaning time ratio coefficient. 5.The intelligent operation and maintenance method of the adaptive suction system according to claim 4, characterized in that: The self-diagnosis of the suction pump failure, pressure sensor failure, and upstream pipeline rupture specifically includes: The pressure value did not decrease even once within a feeding cycle or feeding timeout Tb; The following methods can be used to accurately diagnose fault types, including suction pump failure, pressure sensor failure, and front pipeline rupture. First, determine whether the suction pump is faulty by combining the detection of the thermal protection components of the suction pump motor and the current transformer or transmitter. Second, the changes in the pressure sensor readings between the previous feeding cycle and the current feeding process are used to determine whether the pressure sensor is faulty. Third, if the above two faults are ruled out, it can be determined that the front pipeline between the front end of the pressure sensor and the suction pump is broken. 6.The intelligent operation and maintenance method of the adaptive suction system according to claim 2, characterized in that: The self-maintenance system for cleaning and clearing jammed material from the suction sealing plate, as well as the self-diagnosis system for material shortages and pipe breaks in the rear pipeline, specifically includes: Set the preset pressure value Pm for sealing plate clamping material, and count the number of times the negative pressure is insufficient (Ca). When the suction pressure parameter Pf1 < 0, the preset value of the sealing plate clamping pressure Pm is calculated using the fourth calculation formula; The fourth calculation formula is: Pm = Pf1 * 0.85; Wherein, Pf1 is the suction pressure parameter; The default value for counting insufficient negative pressure is 0. If the pressure value decreases only once within a feeding cycle, and the pressure value is greater than Pm, then the count of Ca is increased by one if the negative pressure is insufficient. Start the feeder sealing plate spray cleaning device to clean the sealing plate of jammed material; Continue feeding material, and proceed according to the following two scenarios: A1. If the pressure value decreases within a feeding cycle and the pressure value is <= Pm, then Ca=0. Self-maintenance is achieved by cleaning up the material stuck in the feeding plate to avoid feeding failure caused by the material stuck in the plate. A2. If the pressure value decreases only once within a feeding cycle and the pressure value is greater than Pm, repeat steps A1 and A2. When Ca > 3, the self-diagnosis determines the fault as insufficient raw material or a broken pipe in the downstream pipeline. 7.The intelligent operation and maintenance method of the adaptive suction system according to claim 2, characterized in that: The self-maintenance system for cleaning and purging filter elements, as well as the self-diagnosis system for cleaning the filter cartridge and replacing filter elements, specifically includes: Set the preset value of the filter element clogging pressure Pn and the filter element clogging count Cb; When the full suction pressure parameter Pf2 < 0, calculate the preset value of the filter element clogging pressure Pn using the fifth calculation formula; The fifth calculation formula is: Pn = Pf2 * 0.8; Where Pf2 is the full suction pressure parameter; The filter element clogging count Cb is defaulted to 0; S1. In one material suction cycle, if the pressure value decreases once and the pressure value < Pn, then increment the filter element clogging count Cb by one; S2. Start the self-maintenance of the filter element clogging spray cleaning to clean the residual dust or impurities on the filter element; Continue to suck materials and execute according to the following two situations: In one material suction cycle, if the pressure value decreases once and the pressure value > Pn, then Cb = 0, and perform self-maintenance through the filter element clogging spray cleaning to avoid the problem of material suction failure caused by filter element clogging; In one material suction cycle, if the pressure value decreases once and the pressure value < Pn, then repeat the above two steps of S1 and S2. When Cb > 3, self-diagnosis determines that the filter barrel needs to be cleaned or the filter element needs to be replaced.

8. An intelligent operation and maintenance device of an adaptive suction system, characterized in that: The device is used to implement the method described in any one of claims 1-7. The device includes: a structure setting module for setting the material suction system and correspondingly installing a pressure sensor, a filter element spray cleaning device, a suction feeder seal plate spray cleaning device, and a material level switch; a parameter adaptive module for adaptively setting the material suction time parameter and the material cleaning time parameter; a front pipeline self-diagnosis module for self-diagnosis of the suction pump failure, the pressure sensor failure, and the front pipeline pipe breakage; a rear pipeline maintenance and self-diagnosis module for self-maintenance of the suction feeder seal plate material jamming cleaning, self-diagnosis of the raw material shortage, and the rear pipeline pipe breakage; a filter element clogging self-maintenance and self-diagnosis module for self-maintenance of the filter element clogging spray cleaning, self-diagnosis of the filter barrel cleaning, and the filter element replacement.

9. A computer readable storage medium having stored thereon computer program instructions, characterized in that: When the computer program instructions are executed by the processor, the adaptive material suction system intelligent operation and maintenance method described in any one of claims 1-7 is implemented. 10.An electronic device comprising a memory and a processor, the electronic device characterized by: The memory is used to store one or more computer program instructions, where the one or more computer program instructions are executed by the processor to implement the adaptive material suction system intelligent operation and maintenance method described in any one of claims 1-7.

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