A method for adjusting the steel ball gradation

Abstract

This invention relates to the field of inspection and control technology, and discloses an inspection and control method for adjusting the gradation of steel balls. The method includes: obtaining a set of target gradation ratios for grinding media; obtaining target bulk density and porosity characterization values; determining the initial gradation ratio; conducting multi-time-dimensional grinding tests on the initial gradation ratio using a proportionally scaled-down mixture under experimental-grade negative pressure conditions in an experimental-grade grinding equipment, obtaining a multi-stage sieve residue data sequence; extracting industrial-grade negative pressure parameters of the industrial-grade grinding equipment during actual operation, and calculating a dynamic grinding compensation factor; performing nonlinear correction on the multi-stage sieve residue data sequence based on the dynamic grinding compensation factor, and determining the optimal grinding media gradation strategy based on the corrected grinding efficiency evaluation index. This invention improves the accuracy of steel ball gradation inspection and the stability of grinding efficiency and product quality.

Description

Technical Field

[0001] This invention relates to the field of inspection and control technology, and in particular to an inspection and control method for adjusting the gradation of steel balls. Background Technology

[0002] In modern cement industry production environments, material grinding is the most energy-intensive process with the most profound impact on finished product quality. The rationality of the grinding media gradation directly determines the energy transfer efficiency of the grinding equipment. In practical applications, key quality indicators such as cement fineness and specific surface area often fluctuate drastically due to improper grinding media configuration. This not only disrupts the continuity and stability of the production process but also severely interferes with the precision control of subsequent material proportioning, thus causing irreversible negative impacts on the overall cement product output and grade quality. When addressing the problem of grinding media gradation optimization, correlation technology typically relies on two independent and isolated execution logics. The first logic involves trial-and-error adjustments on large industrial grinding equipment, using data statistics from the production line over several weeks to infer the quality of the gradation. The second logic relies solely on microscale grinding tests using a standard laboratory mill, recording the percentage of residue on the sieve at different grinding times. After obtaining a seemingly ideal set of residue data, this data is directly scaled up and applied to large-scale grinding equipment.

[0003] However, the above-mentioned solutions have revealed hidden and fatal technical obstacles in long-term engineering practice. Due to the nonlinear difference between the static characteristics of steel ball accumulation and the dynamic trajectory of the group motion, relying solely on small-scale grinding experiments completely isolates the unique aerodynamic flow field environment of industrial-grade equipment. Experimental equipment usually only maintains a very weak micro-negative pressure operating state, while industrial-grade mills are filled with strong high-frequency negative pressure ventilation for material suspension and coarse-fine classification. This severe disconnect between static miniaturization and dynamic ventilation parameters leads to serious distortion of grinding efficiency when the optimal gradation obtained in the laboratory is applied to industrial equipment. Not only can it not accurately reflect the actual ball carrying and crushing capacity of large mills, but it also causes over-crushing or frequent slag discharge, resulting in high downtime verification costs and a huge waste of electricity. Summary of the Invention

[0004] This invention provides an inspection and control method for adjusting the gradation of steel balls to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides an inspection and control method for adjusting the gradation of steel balls, comprising: A method for inspection and control of adjusting steel ball gradation, the method comprising: S1. Obtain the target gradation ratio set of grinding media, wherein the target gradation ratio set includes the initial mass ratio of grinding media with various diameters; S2. Based on the volume calibration component and calibration fluid, perform static physical feature extraction on the grinding media sample configured according to the target gradation ratio set to obtain the target bulk density and porosity characterization values. S3. Input the target bulk density and the porosity characterization value into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio; S4. Under the negative pressure conditions of the experimental flow field in the experimental grinding equipment, the initial sieve gradation ratio is subjected to multi-time dimension grinding tests using a mixture that is scaled down proportionally, and a multi-stage sieve residue data sequence is obtained. S5. Extract the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation, and calculate the dynamic grinding compensation factor based on the comparison between the experimental flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters. S6. Based on the dynamic grinding compensation factor, the multi-stage sieve residue data sequence is nonlinearly corrected, and the optimal grinding media gradation strategy is determined according to the corrected grinding efficiency evaluation index.

[0006] In a preferred embodiment, static physical feature extraction is performed on the grinding media samples configured according to the target gradation ratio set based on the volume calibration component and calibration fluid to obtain target bulk density and porosity characterization values, including: Obtain the internal cavity volume and empty mass of the volume calibration component; The grinding media sample is filled to the flush height position of the volume calibration component, and the total filling mass is obtained; Inject the calibration fluid into the volume calibration assembly until the liquid level is flush with the cross-section of the uppermost grinding body, and obtain the mass of the injected fluid. The target packing density is calculated based on the difference between the total packed mass and the empty mass, combined with the internal cavity volume. The porosity characterization value is calculated based on the injected fluid mass, fluid density parameter, and internal cavity volume.

[0007] In a preferred embodiment, the target bulk density and the porosity characterization value are input into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio, including: Obtain the pre-set lower limit of bulk density and the tolerance range of porosity; Determine whether the target packing density is greater than or equal to the lower limit of the packing density reference; Under the condition that the target packing density is greater than or equal to the lower limit of the packing density reference, the porosity characterization value is extracted; Verify whether the porosity characterization value falls within the porosity tolerance range; When the dual verification conditions are met, the corresponding target gradation ratio set is marked as the initial screening gradation ratio.

[0008] In a preferred embodiment, under the experimental-grade negative pressure conditions of an experimental-grade grinding equipment, the initial sieve gradation ratio is subjected to multi-time-dimensional grinding tests using a proportionally scaled-down mixture to obtain a multi-stage sieve residue data sequence, including: Obtain a raw material ratio list for an industrial environment, the raw material ratio list including the mass percentage of clinker, gypsum, slag, coarse fly ash and limestone; Primary crushing and size screening are performed on each component in the original material ratio list to obtain standard material to be ground that meets the preset particle size threshold. According to the preset mass scaling factor, the standard materials to be ground are weighed according to the mass ratio of the original material proportion list to construct the mixture. According to the preset mass scaling factor, the experimental grade grinding media group with reduced total mass is configured according to the initial screening gradation ratio; The experimental-grade grinding media and the mixture are added to the experimental-grade grinding equipment.

[0009] In a preferred embodiment, under the experimental-grade negative pressure conditions of an experimental-grade grinding equipment, the initial sieve gradation ratio is subjected to multi-time-dimensional grinding tests using a proportionally scaled-down mixture to obtain a multi-stage sieve residue data sequence, further comprising: The experimental-grade grinding equipment is controlled to start operation under the set negative pressure conditions of the experimental-grade flow field; When the first preset runtime, the second preset runtime, and the third preset runtime are reached, respectively, a shutdown sampling action is performed; A negative pressure sieve with a specific aperture is used to perform micron-level sieving on each sampled material to obtain the corresponding first-stage sieve residue value, second-stage sieve residue value and third-stage sieve residue value. The first stage screening value, the second stage screening value, and the third stage screening value are spliced ​​together along the time axis to construct the multi-stage screening data sequence.

[0010] In a preferred embodiment, the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation are extracted, and based on the comparison between the experimental-grade flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters, a dynamic grinding compensation factor is calculated, including: Analysis of the static operating pressure difference range corresponding to the negative pressure condition of the experimental flow field; Obtain the dynamic ventilation pressure differential range of the industrial-grade grinding equipment when it is running at full load; The median reference value of the static operating pressure differential range is extracted as the first dynamic reference, and the median fluctuation value of the dynamic ventilation pressure differential range is extracted as the second dynamic reference. Calculate the absolute ratio of the second power reference to the first power reference; The absolute ratio is substituted into a preset aerodynamic scaling compensation model, and spatial geometric coefficients are introduced for exponential cascade operation to output the dynamic grinding compensation factor.

[0011] In a preferred embodiment, before inputting the target bulk density and the porosity characterization value into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio, the method further includes: Establish a spatial interaction matrix between porosity and density; Extract the first derivative feature of the target packing density and extract the micro-volume variation rate of the porosity characterization value; The first derivative feature is multiplied by the micro volume change rate to construct the density physical crash barrier value. Abnormal sample data where the density physical barrier value exceeds the set physical safety range are filtered out to prevent the grinding body group from mechanically locking up inside the cylinder.

[0012] In a preferred embodiment, nonlinear correction is performed on the multi-stage sieve residue data sequence based on the dynamic grinding compensation factor, including: The initial crushing rate is calculated using the first-stage sieve residue value and the second-stage sieve residue value in the multi-stage sieve residue data sequence. The final grinding rate is calculated using the sieve residue values ​​from the second and third stages. The dynamic grinding compensation factor is used as a weighting multiplier to compensate for the initial crushing rate and the final grinding rate, respectively, to obtain the corrected initial rate and the corrected final rate.

[0013] In a preferred embodiment, determining the optimal grinding media gradation strategy based on the modified grinding efficiency evaluation index includes: Calculate the gradient descent difference between the corrected initial rate and the corrected final rate; Determine whether the gradient descent deviation value is within the preset anti-over-shattering stable range; If so, the initial gradation ratio corresponding to the third-stage sieve residue value is extracted as the optimal grinding media gradation strategy. If not, a negative feedback adjustment mechanism is triggered to extract the grinding media corresponding to the abnormal particle size range that caused the gradient descent deviation value to exceed the limit. The proportion of grinding media of that particle size is reduced according to the reverse adjustment step size, and the static physical feature extraction action is returned to be executed again.

[0014] In a preferred embodiment, after determining the optimal grinding media gradation strategy, the method further includes: The optimal grinding media gradation strategy is converted into an instruction array for the device control layer; The instruction array is analyzed to extract the target grinding media replenishment mass and feeding timing parameters corresponding to each compartment; Based on the feeding timing parameters, the electrically controlled valve of the automated ball-adding device is triggered to introduce grinding media of the same mass as the target grinding media into the designated grinding chamber of the industrial-grade grinding equipment.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention solves the technical pain point of poor adaptability between experimental and industrial scenarios in traditional steel ball gradation testing. By constructing a dynamic grinding compensation factor and combining the negative pressure parameters of the flow field and the difference in equipment cavity volume between experimental and industrial levels, it achieves accurate mapping of experimental data to actual industrial scenarios, significantly improves the accuracy of gradation testing, avoids gradation adaptation distortion caused by scenario differences, and effectively reduces grinding energy consumption and equipment wear in industrial production.

[0016] 2. This invention constructs a full-process inspection and control system encompassing static feature extraction, initial screening optimization, dynamic testing, data correction, and negative feedback adjustment. It avoids the risk of mechanical locking of grinding media by using joint screening of porosity and density, and filtering abnormal samples through a physical anti-collision wall based on density. Combined with multi-time-dimensional grinding testing and nonlinear correction, it accurately matches the performance requirements of all stages of grinding, while simultaneously achieving automated delivery and dynamic tracking optimization of the optimal gradation. This system balances grinding efficiency, product quality stability, and production automation levels, adapting to the actual needs of various grinding production scenarios. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating an inspection and control method for adjusting the gradation of steel balls according to an embodiment of the present invention. The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0018] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0019] This application provides an inspection and control method for adjusting steel ball gradation. The executing entity of this inspection and control method for adjusting steel ball gradation includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the inspection and control method for adjusting steel ball gradation can be executed by software or hardware installed on a terminal device or a server device. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster. The server can be an independent server or a cloud server that provides basic cloud computing services such as cloud services, cloud databases, cloud computing, cloud functions, cloud storage, network services, cloud communication, middleware services, domain name services, security services, content delivery networks (CDNs), and big data and artificial intelligence platforms.

[0020] Reference Figure 1 The diagram shown is a flowchart illustrating an inspection and control method for adjusting steel ball gradation according to an embodiment of the present invention. In this embodiment, the inspection and control method for adjusting steel ball gradation includes: Step 1: Obtain the target gradation ratio set of grinding media, which includes the initial mass ratio of grinding media with different diameters; Step 2: Based on the volume calibration component and calibration fluid, perform static physical feature extraction on the grinding media sample configured according to the target gradation ratio set to obtain the target bulk density and porosity characterization values; Step 3: Input the target bulk density and the porosity characterization value into the preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio; Step 4: Under the experimental flow field negative pressure conditions of the experimental grinding equipment, the initial sieve gradation ratio is subjected to multi-time dimension grinding tests using a mixture of materials that are scaled down proportionally, and a multi-stage sieve residue data sequence is obtained. Step 5: Extract the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation, and calculate the dynamic grinding compensation factor based on the comparison between the experimental flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters. Step 6: Based on the dynamic grinding compensation factor, perform nonlinear correction on the multi-stage sieve residue data sequence, and determine the optimal grinding media gradation strategy according to the corrected grinding efficiency evaluation index.

[0021] The above approach first constructs a target gradation set with multiple specifications and ratios, extracts the static physical characteristics of the grinding media, and performs preliminary screening to obtain a reasonable gradation. Through multi-time-dimensional grinding tests, sieve residue data is obtained, and a compensation factor is calculated based on the difference in negative pressure between industrial and experimental flow fields to perform nonlinear correction on the data. Finally, through gradient analysis and negative feedback adjustment, the optimal gradation suitable for industrial scenarios is determined, solving the problem of mismatch in traditional gradation testing. This approach balances grinding efficiency, product quality, and energy consumption control, achieving accurate testing and automated implementation of steel ball gradation, and adapting to the actual needs of various grinding production scenarios.

[0022] In some embodiments, a target gradation ratio set for grinding media is obtained, the target gradation ratio set including the initial mass ratios of grinding media with various diameters, including: Various steel balls of different diameters are extracted as grinding media, including large-diameter grinding media for coarse crushing and small-diameter grinding media for fine grinding, to construct an initial formulation matrix; the mass distribution weight of each diameter grinding media in the total load is set to form a target gradation ratio set containing multiple ratio combinations; according to the characteristics of the material to be ground, the weight range of each specification of grinding media is dynamically adjusted to eliminate extreme ratio combinations and ensure that the ratio set is suitable for different grinding needs.

[0023] Specifically, the grinding media diameters cover a variety of specifications, meeting the dual needs of impact crushing and surface fine grinding, and are suitable for materials with different hardness and initial particle size. The initial formulation matrix stores the theoretical loading mass of each specification of grinding media under different weights, facilitating subsequent retrieval, adjustment, and verification comparison. The weight range can be dynamically adjusted according to the material hardness and initial particle size. Hard materials can have their weight increased by increasing the weight of large-diameter grinding media to enhance impact crushing capability, while easily grindable materials can have their weight increased by increasing the weight of small-diameter grinding media to improve fine grinding effect. This avoids the limitations of fixed ratios and provides a reasonable and comprehensive sample basis for subsequent testing, ensuring the universality and reliability of subsequent test results.

[0024] In some embodiments, based on a volume calibration component and a calibration fluid, static physical feature extraction is performed on the grinding media samples configured according to the target gradation ratio set to obtain target bulk density and porosity characterization values, and the static physical features of the grinding media samples are extracted, including: Static testing was conducted on a grinding media sample configured according to the target gradation ratio using a volume calibration component and calibration fluid. The cavity volume and empty mass of the calibration component were obtained. The grinding media sample was uniformly filled into the calibration component, and the total filling mass was obtained. Calibration fluid was injected into the component until it was flush with the upper surface of the grinding media, and the mass of the injected fluid was obtained. Based on the above data, the target bulk density and porosity characterization values ​​of the grinding media sample were calculated as static physical characteristic parameters.

[0025] Specifically, the volume calibration component uses a regular container to ensure accurate and traceable cavity volume, reducing volume measurement errors; the grinding media adopts a layered vibration filling method to avoid density measurement deviations caused by uneven stacking, ensuring that the sample filling state conforms to actual industrial loading scenarios; the calibration fluid is selected as a liquid with stable density, non-volatile properties, and no reaction with the grinding media, ensuring the accuracy of porosity calculation; the target bulk density reflects the compactness of the grinding media, directly affecting the impact and grinding efficiency during the grinding process; the porosity characterization value reflects the proportion of voids between the grinding media, affecting the flow of materials between the grinding media and the uniformity of grinding. Both serve as the core judgment basis for subsequent gradation screening, avoiding screening deviations caused by single parameter judgments and improving the rationality of the initial screening.

[0026] In some embodiments, the target bulk density and the porosity characterization value are input into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio, including: First, abnormal sample data is filtered out. By constructing the interaction relationship between porosity and density, samples with reasonable packing state and no risk of mechanical locking are selected. The lower limit of packing density and the tolerance range of porosity are preset. The calculated target packing density and porosity characterization values ​​are substituted into the screening logic. The ratio that meets the packing density standard and the porosity is within the tolerance range is marked as the initial screening gradation ratio, which narrows the search range of subsequent tests and reduces the workload of invalid tests.

[0027] Specifically, abnormal sample filtering can effectively eliminate mixtures that are too loosely or too densely packed. Loose packing leads to insufficient grinding impact and low grinding efficiency, while dense packing can easily cause problems such as mechanical locking of grinding media and accelerated equipment wear. This prevents such abnormal mixtures from entering the subsequent testing stage, saving inspection time and costs. The bulk density benchmark and porosity tolerance range are preset according to the grinding scenario, equipment model, and material characteristics. The dual-condition joint screening can ensure that the initial screening gradation can meet the impact crushing requirements and ensure smooth material flow, taking into account both impact crushing and fine grinding effects. This provides a high-quality sample basis for subsequent grinding tests, improving inspection efficiency and accuracy.

[0028] In some embodiments, the total amount of mixed materials and grinding media is reduced proportionally to the industrial scenario, and an experimental-grade mixed material and grinding media group is configured and added to an experimental-grade grinding equipment. The equipment is controlled to operate under a preset static micro-negative pressure condition, and the machine is stopped and samples are taken when the preset time periods of the initial, middle and late grinding are reached. The sampled materials are sieved using a standard negative pressure sieve, and the sieve residue values ​​at each stage are calculated. The data are spliced ​​in chronological order to form a multi-stage sieve residue data sequence, which comprehensively reflects the degree of material refinement at different grinding times and provides data support for subsequent performance evaluation.

[0029] Specifically, proportionally scaling the total amount of mixed materials and grinding media ensures maximum consistency between the experimental and industrial scenarios, avoiding deviations in grinding effects caused by differences in material and grinding media quantities, and ensuring that experimental data effectively reflects actual industrial conditions. Pre-setting static micro-negative pressure conditions, equipment speed, and other parameters simulates the actual operating state of industrial grinding equipment, reducing environmental differences between experimental and industrial scenarios. Three preset durations correspond to the initial grinding stage (coarse crushing), middle grinding stage (fine grinding), and later grinding stage (refined grinding), comprehensively capturing efficiency changes at different grinding stages and avoiding information loss due to sampling at a single time point. Standard negative pressure sieving can quickly and accurately separate powders of different particle sizes, calculate the sieve residue values ​​at each stage, and the resulting sieve residue data sequence clearly reflects the impact of grinding media gradation on grinding effects, providing reliable experimental data for subsequent data correction and efficiency evaluation.

[0030] In some embodiments, the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation are extracted, and the dynamic grinding compensation factor is calculated based on the comparison between the experimental-grade flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters, including: The static operating pressure difference range of the experimental-grade grinding equipment and the dynamic ventilation pressure difference range of the industrial-grade equipment are extracted, and the median value of the two ranges is taken as the dynamic reference. The absolute ratio of the industrial-grade and experimental-grade dynamic references is calculated, and combined with the equipment cavity volume ratio as the spatial geometric coefficient, it is substituted into the preset aerodynamic scaling compensation model. Through exponential cascade operation, the dynamic grinding compensation factor is output to correct the grinding effect deviation between experimental and industrial scenarios, ensuring that the experimental data can accurately reflect the actual industrial grinding efficiency.

[0031] Specifically, the dynamic baseline reflects the actual state of negative pressure inside the equipment and is a key factor affecting powder separation rate and grinding efficiency during the grinding process. Differences in negative pressure between experimental and industrial equipment can lead to deviations in grinding performance, requiring correction through comparison with the dynamic baseline. The absolute ratio reflects the degree of negative pressure difference between industrial and experimental scenarios, while the spatial geometric coefficient compensates for differences in grinding environment caused by variations in cavity volume between experimental and industrial equipment. The compensation factor is not a simple constant scaling but a scientific compensation based on aerodynamics, effectively bridging the differences in powder separation rate caused by different wind speed gradients in experimental and industrial scenarios. This ensures that the corrected experimental data accurately reflects grinding efficiency in industrial scenarios, solving the core problem of poor adaptability between experimental and industrial scenarios in traditional testing. The specific calculation formula for the dynamic grinding compensation factor is as follows: ; In the formula, This is a dynamic grinding compensation factor used to correct the deviation between experimental and industrial grinding data. It has no unit and its value ranges from 0.8 to 1.2. The closer it is to 1, the better the adaptability between experimental and industrial scenarios. This is the flow field correction coefficient, determined by experimental calibration. The value is taken according to the type of grinding equipment, and the range is 0.95~1.05. It is used to compensate for the error caused by the difference in the degree of turbulence in the flow field. The reference value for dynamic ventilation differential pressure of industrial-grade grinding equipment is the median value of the dynamic ventilation differential pressure range during actual operation of industrial-grade equipment. The static operating differential pressure reference value is the experimental-grade grinding equipment, and the median value of the static operating differential pressure range during the operation of the experimental-grade equipment. This refers to the volume of the grinding chamber in industrial-grade grinding equipment, i.e., the effective volume of the grinding chamber in industrial equipment. This refers to the cavity volume of the experimental-grade grinding equipment, i.e., the effective volume of the grinding chamber of the experimental equipment. The spatial scaling index, determined by aerodynamic characteristics, ranges from 0.3 to 0.5 and is used to correct for the influence of equipment volume differences on the grinding flow field.

[0032] In some embodiments, the multi-stage sieve residue data sequence is nonlinearly corrected based on the dynamic grinding compensation factor, and the optimal grinding media gradation strategy is determined according to the corrected grinding efficiency evaluation index, including: Based on the multi-stage sieve residue data sequence, the grinding rates in the initial and later stages are calculated, and the rates are nonlinearly corrected by combining the dynamic grinding compensation factor. The gradient descent deviation of the corrected initial and later rates is calculated to determine whether it is within the preset anti-over-grinding stable range. If it is within the range, the corresponding initial sieve gradation is the optimal gradation. If it is not within the range, negative feedback adjustment is triggered, the grinding media ratio is adjusted, and the test is repeated until it meets the requirements. Finally, the optimal gradation is converted into equipment control commands to achieve automated dispensing and ensure accurate implementation of the optimal gradation.

[0033] Specifically, the initial grinding rate mainly reflects the impact crushing ability of the grinding media, while the later grinding rate mainly reflects the fine grinding ability. The difference in the gradient descent between the two reflects the rationality of the gradation. If the gradient descent is too fast, it indicates insufficient fine grinding ability; if the gradient descent is too slow, it easily leads to over-grinding of materials, increasing energy consumption. By using a dynamic grinding compensation factor to nonlinearly correct the rate, the experimental grinding rate can be converted into the actual industrial rate, ensuring that the evaluation results fit the industrial scenario. The preset anti-over-grinding stable range can effectively avoid the problems of over-grinding or insufficient grinding, balancing grinding efficiency and product quality. Negative feedback adjustment can specifically solve the problem of proportion imbalance. Through cyclical testing and adjustment, it is ensured that the finally determined optimal gradation can accurately match the actual operating requirements of industrial grinding equipment. Automated dispensing commands can achieve accurate dispensing of the optimal gradation, reduce human operation errors, and improve production efficiency and gradation application effects.

[0034] In some embodiments, the reasons for the gradient descent deviation value exceeding the limit are analyzed, and the grinding media particle size range that causes the abnormal rate is extracted; according to the preset reverse adjustment step size, the proportion of grinding media in this particle size range is adjusted, the proportion of abnormal particle size grinding media is reduced, and grinding media with suitable particle size are added; after the adjustment is completed, the process of static physical feature extraction, initial screening, grinding test and other processes are repeated until the gradient descent deviation value falls into the stable range, ensuring that the finally determined gradation can meet the industrial grinding requirements. Specifically, the core reason for the gradient descent deviation exceeding the limit is the imbalance of grinding media gradation, such as an excessively low initial rate or an excessively rapid rate decline in the later stage. This may be due to an insufficient proportion of large-diameter grinding media and an excessively high proportion of small-diameter grinding media, or vice versa. By accurately locating the particle size range that causes the abnormal rate, the proportion can be adjusted accordingly to quickly optimize the gradation performance. For example, if the rate decline is too rapid, the proportion of small-diameter grinding media can be increased and the proportion of large-diameter grinding media can be reduced to optimize the fineness effect in the later stage of grinding. If the initial rate is too low, the proportion of large-diameter grinding media can be increased to enhance the impact crushing ability. Through cyclical testing and adjustment, the optimal proportion can be gradually converged to ensure that the final gradation can take into account both impact crushing and fine grinding effects, and adapt to the needs of the entire industrial grinding process.

[0035] In some embodiments, the optimal gradation strategy is converted into an instruction array of the equipment control layer, and the replenishment mass and feeding sequence of the grinding media corresponding to each grinding chamber are parsed out. Based on the feeding sequence, the controller triggers the electronically controlled valve of the automated ball-adding device to accurately introduce the grinding media of each specification into the designated chamber according to the target mass, so as to avoid uneven accumulation caused by mixing grinding media of different specifications, ensure the actual application effect of the optimal gradation, and achieve seamless connection between gradation inspection and production application.

[0036] Specifically, the instruction array contains key information such as grinding media quality, feeding chamber, feeding sequence, and feeding interval. The feeding sequence is set according to the function of each chamber. The coarse grinding chamber prioritizes feeding large-diameter grinding media, focusing on impact crushing; the fine grinding chamber feeds small-diameter grinding media, focusing on fine grinding. The feeding interval effectively avoids uneven accumulation caused by mixing grinding media of different specifications, ensuring that the grinding media are evenly distributed in the chamber and fully maximizing grinding efficiency. The electrically controlled valves respond quickly and control precisely, strictly dispensing grinding media according to the target quality and timing in the instruction array, reducing errors caused by manual operation, achieving automated and precise dispensing of optimal gradation, and rapidly translating inspection results into production efficiency, improving production efficiency and product quality stability.

[0037] In some embodiments, the method further includes a follow-up optimization step after gradation testing: After the optimal gradation is applied, the operating parameters and product quality data of the industrial grinding equipment are continuously collected, including grinding current, energy consumption, and product particle size distribution. The collected data is compared with the corrected data in the inspection stage to analyze the deviation between the actual application effect and the inspection results. If the deviation exceeds the preset allowable range, the calculation parameters of the dynamic grinding compensation factor are adjusted based on the cause of the deviation, and the gradation strategy is re-optimized to achieve dynamic tracking and continuous optimization of the gradation, thereby further improving grinding efficiency and product quality stability.

[0038] Specifically, in industrial production processes, material properties and equipment operating conditions may fluctuate, leading to deviations in the application effect of optimal gradation. By continuously tracking equipment operating parameters and product quality data, deviations can be identified and their causes analyzed in a timely manner, such as changes in material hardness or decreased grinding efficiency due to equipment wear. By adjusting the calculation parameters of the dynamic grinding compensation factor and re-optimizing the gradation strategy, the gradation can always adapt to changes in the production scenario, avoiding a decrease in grinding efficiency due to external factors. This achieves full life-cycle optimization of steel ball gradation, further reducing energy consumption and improving product quality consistency.

[0039] In the several embodiments provided by this invention, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the system embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and other division methods may be used in actual implementation.

[0040] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0041] Furthermore, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or in the form of hardware plus software functional modules.

[0042] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for inspecting and controlling the gradation of steel balls, characterized in that, The method includes: S1. Obtain the target gradation ratio set of grinding media, wherein the target gradation ratio set includes the initial mass ratio of grinding media with various diameters; S2. Based on the volume calibration component and calibration fluid, perform static physical feature extraction on the grinding media sample configured according to the target gradation ratio set to obtain the target bulk density and porosity characterization values. S3. Input the target bulk density and the porosity characterization value into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio; S4. Under the negative pressure conditions of the experimental flow field in the experimental grinding equipment, the initial sieve gradation ratio is subjected to multi-time dimension grinding tests using a mixture that is scaled down proportionally, and a multi-stage sieve residue data sequence is obtained. S5. Extract the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation, and calculate the dynamic grinding compensation factor based on the comparison between the experimental flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters. S6. Based on the dynamic grinding compensation factor, the multi-stage sieve residue data sequence is nonlinearly corrected, and the optimal grinding media gradation strategy is determined according to the corrected grinding efficiency evaluation index.

2. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, Based on the volume calibration component and calibration fluid, static physical feature extraction is performed on the grinding media samples configured according to the target gradation ratio set to obtain target bulk density and porosity characterization values, including: Obtain the internal cavity volume and empty mass of the volume calibration component; The grinding media sample is filled to the flush height position of the volume calibration component, and the total filling mass is obtained; Inject the calibration fluid into the volume calibration assembly until the liquid level is flush with the cross-section of the uppermost grinding body, and obtain the mass of the injected fluid. The target packing density is calculated based on the difference between the total packed mass and the empty mass, combined with the internal cavity volume. The porosity characterization value is calculated based on the injected fluid mass, fluid density parameter, and internal cavity volume.

3. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, The target bulk density and the porosity characterization value are input into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio, including: Obtain the pre-set lower limit of bulk density and the tolerance range of porosity; Determine whether the target packing density is greater than or equal to the lower limit of the packing density reference; Under the condition that the target packing density is greater than or equal to the lower limit of the packing density reference, the porosity characterization value is extracted; Verify whether the porosity characterization value falls within the porosity tolerance range; When the dual verification conditions are met, the corresponding target gradation ratio set is marked as the initial screening gradation ratio.

4. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, Under experimental-grade negative pressure conditions in an experimental-grade grinding equipment, a multi-time-dimensional grinding test was conducted on the initial sieve gradation ratio using a proportionally scaled-down mixture, yielding a multi-stage sieve residue data sequence, including: Obtain a raw material ratio list for an industrial environment, the raw material ratio list including the mass percentage of clinker, gypsum, slag, coarse fly ash and limestone; Primary crushing and size screening are performed on each component in the original material ratio list to obtain standard material to be ground that meets the preset particle size threshold. According to the preset mass scaling factor, the standard materials to be ground are weighed according to the mass ratio of the original material proportion list to construct the mixture. According to the preset mass scaling factor, the experimental grade grinding media group with reduced total mass is configured according to the initial screening gradation ratio; The experimental-grade grinding media and the mixture are added to the experimental-grade grinding equipment.

5. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, Under experimental-grade negative pressure conditions in an experimental-grade grinding equipment, a multi-time-dimensional grinding test was conducted on the initial sieve gradation ratio using a proportionally scaled-down mixture to obtain a multi-stage sieve residue data sequence, which also includes: The experimental-grade grinding equipment is controlled to start operation under the set negative pressure conditions of the experimental-grade flow field; When the first preset runtime, the second preset runtime, and the third preset runtime are reached, respectively, a shutdown sampling action is performed; A negative pressure sieve with a specific aperture is used to perform micron-level sieving on each sampled material to obtain the corresponding first-stage sieve residue value, second-stage sieve residue value and third-stage sieve residue value. The first stage screening value, the second stage screening value, and the third stage screening value are spliced ​​together along the time axis to construct the multi-stage screening data sequence.

6. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, Extract the industrial-grade flow field negative pressure parameters of the industrial-grade grinding equipment during actual operation, and calculate the dynamic grinding compensation factor based on the comparison between the experimental-grade flow field negative pressure conditions and the industrial-grade flow field negative pressure parameters, including: Analysis of the static operating pressure difference range corresponding to the negative pressure condition of the experimental flow field; Obtain the dynamic ventilation pressure differential range of the industrial-grade grinding equipment when it is running at full load; The median reference value of the static operating pressure differential range is extracted as the first dynamic reference, and the median fluctuation value of the dynamic ventilation pressure differential range is extracted as the second dynamic reference. Calculate the absolute ratio of the second power reference to the first power reference; The absolute ratio is substituted into a preset aerodynamic scaling compensation model, and spatial geometric coefficients are introduced for exponential cascade operation to output the dynamic grinding compensation factor.

7. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, Before inputting the target bulk density and the porosity characterization value into a preset initial screening logic tree for joint comparison to determine the initial screening gradation ratio, the method further includes: Establish a spatial interaction matrix between porosity and density; Extract the first derivative feature of the target packing density and extract the micro-volume variation rate of the porosity characterization value; The first derivative feature is multiplied by the micro volume change rate to construct the density physical crash barrier value. Abnormal sample data where the density physical barrier value exceeds the set physical safety range are filtered out to prevent the grinding body group from mechanically locking up inside the cylinder.

8. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, The multi-stage sieve residue data sequence is nonlinearly corrected based on the dynamic grinding compensation factor, including: The initial crushing rate is calculated using the first-stage sieve residue value and the second-stage sieve residue value in the multi-stage sieve residue data sequence. The final grinding rate is calculated using the sieve residue values ​​from the second and third stages. The dynamic grinding compensation factor is used as a weighting multiplier to compensate for the initial crushing rate and the final grinding rate, respectively, to obtain the corrected initial rate and the corrected final rate.

9. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, The optimal grinding media gradation strategy was determined based on the revised grinding efficiency evaluation index, including: Calculate the gradient descent difference between the corrected initial rate and the corrected final rate; Determine whether the gradient descent deviation value is within the preset anti-over-shattering stable range; If so, the initial gradation ratio corresponding to the third-stage sieve residue value is extracted as the optimal grinding media gradation strategy. If not, a negative feedback adjustment mechanism is triggered to extract the grinding media corresponding to the abnormal particle size range that caused the gradient descent deviation value to exceed the limit. The proportion of the grinding media of that particle size is reduced according to the reverse adjustment step size, and the static physical feature extraction action is returned to be executed again.

10. The inspection and control method for adjusting steel ball gradation as described in claim 1, characterized in that, After determining the optimal grinding media gradation strategy, the following steps are also included: The optimal grinding media gradation strategy is converted into an instruction array for the device control layer; The instruction array is analyzed to extract the target grinding media replenishment mass and feeding timing parameters corresponding to each compartment; Based on the feeding timing parameters, the electrically controlled valve of the automated ball-adding device is triggered to introduce grinding media of the same mass as the target grinding media into the designated grinding chamber of the industrial-grade grinding equipment.

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