A control system for material level and material thickness in a sintering machine's small ore bin

Abstract

This application discloses a control system for the material level and material thickness in a small sintering trough of a sintering machine, including a controller. The controller is configured to: input sintering process parameters into a small trough material level model; determine whether the weight of the mixture is within a first weight range; if not, adjust the first process parameters to make the weight of the mixture in the small trough within the first weight range; calculate a first average absolute percentage error; if the first average absolute percentage error meets a preset accuracy requirement, input the sintering process parameters into a material layer thickness model and determine a second process parameter; calculate a second average absolute percentage error; if the second average absolute percentage error does not meet the preset accuracy requirement, readjust the first process parameters until both the first and second average absolute percentage errors meet the preset accuracy requirement; thereby achieving automated and precise coordinated control of the material level and material thickness in the small trough, and improving the stability and controllability of the sintering process.

Description

Technical Field

[0001] This application relates to the field of metallurgical sintering production technology, and in particular to a control system for the material level and material thickness in the small ore bin of a sintering machine. Background Technology

[0002] In the steel production process, the sintering process is a crucial step. Its core function is to precisely proportion, mix, and granulate iron-containing raw materials, fuels, and fluxes, and then sinter them at high temperatures to form porous, blocky sintered ore with a certain strength, providing the main raw material for subsequent blast furnace ironmaking. In the material distribution stage of the sintering machine, the mixture is conveyed to a small ore bin for temporary storage via the feeding system, and then discharged through a gate and roller feeder below the small ore bin. Finally, it is evenly spread onto the continuously running sintering trolley by a multi-roller distribution device.

[0003] To achieve precise control of the sintering machine's feeding process, current methods primarily rely on manual adjustments based on operator experience. By adjusting parameters such as gate opening, roller feeder speed, multi-roller distributor speed, and sintering trolley speed, a dynamic balance is maintained between the feed and discharge rates in the small ore bins, thereby controlling the material layer thickness within a reasonable range. Ideally, this dynamic balance should keep the material weight in the small ore bins stable within a suitable range of 60% to 80% to support the continuous and stable operation of the sintering machine.

[0004] However, when production rhythms change, such as requiring increased or decreased output, manual adjustments relying on operator experience often result in a delayed response, making it difficult to quickly adapt to new production demands and easily disrupting the dynamic equilibrium of the small ore bins. When the material level in the small ore bins is too low, the sintering machine will stop waiting for material; when the material level in the small ore bins is too high, it will damage the spherical structure of the mixture, forcing the batching system to stop feeding. Both of these extreme situations severely impact the safe operation of the sintering equipment and the quality of the sintered ore. Furthermore, operators need to undergo repeated and lengthy trial-and-error adjustments to restore the material layer thickness to stability, and the continuous fluctuations in the material layer thickness during this process further exacerbate the fluctuations in the quality of the sintered ore. Summary of the Invention

[0005] This application provides a control system for the material level and material thickness in the small ore bin of a sintering machine, in order to solve the technical problem that in the current sintering machine material feeding process, the material level and material thickness in the small ore bin are difficult to control stably due to the reliance on manual adjustment by the operator's experience, which in turn affects the sintering production quality and efficiency.

[0006] This application provides a control system for the material level and material distribution thickness in the small ore bin of a sintering machine, including: A data acquisition module, connected to the sintering process apparatus, is configured to: Obtain sintering process parameters; the sintering process parameters include: weight of the mixture on the feeding belt, feeding belt speed, small ore bin weighing sensor data, gate opening, rotary feeder speed, multi-roller distributor speed, mixture density, and the thickness of the mixture layer corresponding to each gate. A controller, connected to the data acquisition module, is configured to: Based on the data from the weighing sensor in the small ore bin, the weight of the mixture in the small ore bin is determined; The sintering process parameters are input into the small ore bin level model to determine whether the weight of the mixture in the small ore bin is within the first weight range. If not, the first process parameter of the sintering process device is adjusted so that the weight of the mixture in the small ore bin is within the first weight range. The small ore bin level model is generated by training with historical data of sintering process parameters. The small ore bin level model is configured to determine the target first process parameter range when the weight of the mixture in the small ore bin is within the first weight range. Calculate the first mean absolute percentage error of the small ore bin level model; If the first average absolute percentage error is less than 10%, the sintering process parameters are input into the material layer thickness model, and the second process parameters are determined when the mixed material layer thickness corresponding to each gate and the average mixed material layer thickness are within the first preset thickness target range and the second preset thickness target range; the material layer thickness model is generated by training with historical data of sintering process parameters; Calculate the second mean absolute percentage error of the material layer thickness model; If the second average absolute percentage error is greater than or equal to 10%, then the first process parameters of the small ore bin level model are modified again until the small ore bin level model and the material layer thickness model simultaneously satisfy the first average absolute percentage error and the second average absolute percentage error being less than 10%, and the first process parameters and the second process parameters are output. The sintering process device is driven to operate with the first process parameters and the second process parameters, so that the weight of the mixture in the small ore bin is within the first weight range, and the thickness of the mixture layer corresponding to each gate is within the first preset thickness standard range and the average thickness of the mixture layer is within the second preset thickness standard range.

[0007] In some embodiments, the sintering process apparatus includes: A feeding belt, which is used to transport the mixture to a small ore bin; A belt scale is attached to the feeding belt and is used to obtain the weight of the mixture on the feeding belt. The small ore trough is connected to a four-corner weighing device, which is used to acquire the weighing sensor data of the small ore trough. A gate is provided at the discharge port of the small ore bin. The gate is connected to a discharge gate controller, which is used to open or close the gate and adjust the gate opening. A circular roller feeder, located below the gate, is used to convey the mixed material discharged from the small ore trough to the multi-roller distributor; The multi-roller feeder is located below the circular roller feeder. The mixture is transferred to the multi-roller feeder after passing through the gate and the circular roller feeder. The multi-roller feeder is used to distribute the mixture onto the sintering trolley.

[0008] In some embodiments, the controller is further configured to: Obtain historical data of sintering process parameters; The historical data of the sintering process parameters are preprocessed; the preprocessing includes: outlier removal and normalization. The historical data of the sintering process parameters are classified according to the first weight range, the second weight range, the third weight range and the process flow to obtain training data; The training data is divided into a training set and a validation set, with 70% and 30% respectively. Using the training set and the validation set, a model is constructed and trained to obtain a small ore bin material level model and a material layer thickness model.

[0009] In some embodiments, after the step of determining whether the weight of the mixture in the small ore bin is within a first weight range, the method includes: If so, adjust the gate opening and the rotation speed of the roller feeder to the target first process parameter range so that the weight of the mixture in the small ore bin is maintained within the first weight range.

[0010] In some embodiments, the controller is further configured to: If the weight of the mixture in the small ore bin is within the second weight range, then the feed rate and the actual discharge rate of the small ore bin per unit time are determined based on the sintering process parameters. The material quantity deviation is determined based on the feed rate and the actual discharge rate from the small ore bin; Based on the material quantity deviation, the gate opening is increased and the rotation speed of the roller feeder is increased so that the weight of the mixture in the small ore bin is within the first weight range.

[0011] In some embodiments, the controller is further configured to: If the weight of the mixture in the small ore bin is within the third weight range, then the feed rate and the actual discharge rate of the small ore bin per unit time are determined based on the sintering process parameters. The material quantity deviation is determined based on the feed rate and the actual discharge rate from the small ore bin; Based on the material quantity deviation, the gate opening is reduced and the rotation speed of the roller feeder is decreased so that the weight of the mixture in the small ore bin is within the first weight range.

[0012] In some embodiments, the controller is further configured to: The feed rate of the small ore bin per unit time is determined based on the weight of the mixture on the feeding belt and the pulling speed of the feeding belt. Based on the feed rate and the data from the weighing sensor of the small ore trough, the actual discharge amount of the small ore trough per unit time is determined.

[0013] In some embodiments, the controller is further configured to: The average thickness of the mixture layer is determined based on the thickness of the mixture layer on the sintering trolley corresponding to each gate. The material layer thickness model is configured as follows: The sintering locomotive speed is determined based on the actual discharge volume of the small ore bin, the average thickness of the mixed material layer, and the density of the mixed material. Based on the trolley speed, the rotation speed of the multi-roller feeder and the thickness of the mixed material layer on the sintering trolley corresponding to each gate are determined. The controller is further configured to: Using the material layer thickness model, the predicted values ​​of the multi-roller feeder speed and the sintering trolley speed are determined when the thickness of the mixed material layer on the sintering trolley corresponding to each gate and the average thickness of the mixed material layer are within the first preset thickness standard range and the second preset thickness standard range. The multi-roller feeder and the sintering trolley are driven to operate at the predicted speed values ​​of the multi-roller feeder and the sintering trolley, so that the thickness of the mixed material layer on the sintering trolley corresponding to each gate and the average thickness of the mixed material layer are within the first preset thickness standard range and the second preset thickness standard range.

[0014] This application provides a control system for the material level and material distribution thickness in a sintering machine's small trough, comprising: a data acquisition module connected to the sintering process device, configured to acquire sintering process parameters; the sintering process parameters including: the weight of the mixture on the feeding belt, the feeding belt speed, data from the small trough weighing sensor, the gate opening, the rotation speed of the roller feeder, the rotation speed of the multi-roller distributor, the density of the mixture, and the thickness of the mixture layer corresponding to each gate; and a controller connected to the data acquisition module, configured to: based on the data from the small trough weighing sensor... The weight of the mixture in the small ore bin is determined; the sintering process parameters are input into the small ore bin level model to determine whether the weight of the mixture in the small ore bin is within a first weight range. If not, the first process parameter of the sintering process device is adjusted so that the weight of the mixture in the small ore bin is within the first weight range. The small ore bin level model is generated by training with historical data of sintering process parameters. The small ore bin level model is configured to determine the target first process parameter range when the weight of the mixture in the small ore bin is within the first weight range. The first average absolute value of the small ore bin level model is calculated. Percentage error; if the first average absolute percentage error is less than 10%, the sintering process parameters are input into the material layer thickness model, and the second process parameters are determined when the thickness of the mixed material layer corresponding to each gate and the average thickness of the mixed material layer are within the first preset thickness target range and the second preset thickness target range; the material layer thickness model is generated by training with historical data of sintering process parameters; the second average absolute percentage error of the material layer thickness model is calculated; if the second average absolute percentage error is greater than or equal to 10%, the first process parameters of the small ore bin level model are modified again, until... When the material level model of the small ore trough and the material layer thickness model simultaneously satisfy the first average absolute percentage error and the second average absolute percentage error being less than 10%, the first process parameters and the second process parameters are output; the weight of the mixture in the small ore trough is driven to be within the first weight range, and the thickness of the mixture layer corresponding to each gate is within the first preset thickness standard range and the average thickness of the mixture layer is within the second preset thickness standard range, so as to realize the automated and precise collaborative control of the material level and material layer thickness in the small ore trough, thereby improving the stability and controllability of the sintering process. Attached Figure Description

[0015] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1This is a schematic diagram of the control system for the material level and material distribution thickness in the sintering machine's small ore bin in this application; Figure 2 This is a flowchart of the method for controlling the material level and material thickness in the small ore bin of the sintering machine in this application.

[0017] Explanation of reference numerals in the attached figures: 1-Data acquisition module; 2-Sintering process device; 21-Feeding belt; 22-Small ore bin; 221-Gate; 222-Discharge gate controller; 23-Belt scale; 24-Multi-roller distributor; 25-Round roller feeder; 26-Sintering trolley; 3-Controller. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this application.

[0019] For example, existing fabric systems lack sufficient intelligence, rely excessively on manual experience for adjustments, and struggle to respond quickly to changes in production conditions. At the same time, the collected operational data is not thoroughly analyzed and utilized, failing to form a closed-loop optimization control, which restricts the improvement of process accuracy and efficiency.

[0020] While maintaining a stable material level in the small ore bin, the system lacks the real-time autonomous control capability to dynamically balance the feed and discharge rates. Insufficient coordinated control among multiple parameters such as conveyor belt weighing, gate opening, and roller speed can easily lead to material level fluctuations, affecting the uniformity and stability of material distribution.

[0021] Regarding multi-stage coordination, it is currently difficult to achieve real-time dynamic matching between the discharge rate of the small ore bin 22 and the speeds of the multi-roller distributor 24 and the sintering trolley 26. This causes the thickness of the material layer on the sintering trolley 26 to fluctuate easily and cannot be kept stable, thus restricting the optimization of the overall process effect of sintering.

[0022] To address the technical problem that the sintering machine's material feeding process relies heavily on manual adjustments based on operator experience, leading to difficulties in stably controlling the material level and feeding thickness in the small ore bin, this application provides a control system for the material level and feeding thickness in the small ore bin of a sintering machine. The control system for the material level and feeding thickness in the small ore bin of a sintering machine is described below: like Figure 1 The diagram shown is a structural schematic of the control system for the material level and material thickness in the small ore bin of the sintering machine in this application.

[0023] This application provides a control system for the material level and material distribution thickness in a small sintering machine trough, characterized in that it includes: Data acquisition module 1 is connected to sintering process device 2.

[0024] Specifically, the sintering process apparatus 2 includes: Feeding belt 21, the feeding belt 21 is used to transport the mixture to the small ore bin 22; A belt scale 23 is attached to the feeding belt 21 and is used to obtain the weight of the mixture on the feeding belt. The small ore trough 22 is connected to a four-corner weighing device, which is used to acquire the weighing sensor data of the small ore trough. A gate 221 is provided at the discharge port of the small ore trough 22. The gate 221 is connected to the discharge gate controller 222. The discharge gate controller 222 is used to open or close the gate 221 and adjust the opening degree of the gate 221. A circular roller feeder 25 is located below the gate 221 and is used to transport the mixed material discharged from the small ore trough 22 to the multi-roller distributor 24. The multi-roller distributor 24 is located below the circular roller feeder 25. The mixture is transferred to the multi-roller distributor 24 after passing through the gate 221 and the circular roller feeder 25. The multi-roller distributor 24 is used to distribute the mixture to the sintering trolley 26.

[0025] like Figure 2 The diagram shown is a flowchart of the method for controlling the material level and material thickness in the small ore bin of the sintering machine in this application.

[0026] The data acquisition module 1 is configured as follows: Obtain sintering process parameters; these parameters include: the weight of the mixture on the feeding belt, the feeding belt speed, the data from the small ore bin weighing sensor, the gate opening, the rotation speed of the roller feeder, the rotation speed of the multi-roller distributor, the density of the mixture, and the thickness of the mixture layer corresponding to each gate 221. In this embodiment, eight gates 221 are used as an example.

[0027] Controller 3, connected to the data acquisition module 1, is configured to: Based on the data from the weighing sensor in the small ore trough, the weight of the mixture in the small ore trough 22 is determined; the weighing sensor installed in the small ore trough 22 can collect the weight of the mixture in the small ore trough 22.

[0028] The sintering process parameters are input into the small ore bin level model to determine whether the weight of the mixture in the small ore bin 22 is within the first weight range. If not, the first process parameter of the sintering process device 2 is adjusted so that the weight of the mixture in the small ore bin 22 is within the first weight range. The small ore bin level model is generated by training with historical data of sintering process parameters. The small ore bin level model is configured to determine the target first process parameter range when the weight of the mixture in the small ore bin 22 is within the first weight range.

[0029] After determining whether the weight of the mixture in the small ore bin 22 is within the first weight range, the following steps are included: If so, adjust the opening of the gate 221 and the rotation speed of the roller feeder 25 to maintain the weight of the mixture in the small ore trough 22 within the first weight range.

[0030] The controller 3 is further configured as follows: If the weight of the mixture in the small ore bin 22 is within the third weight range, then the feed rate and actual discharge rate of the small ore bin 22 per unit time are determined based on the sintering process parameters.

[0031] Specifically, the controller 3 is further configured as follows: Based on the weight of the mixture on the feeding belt and the feeding belt speed, the feed rate of the small ore bin 22 per unit time is determined; the feed rate is set by the production rhythm or batching room, and the feed weight per unit time can be calculated by the belt scale 23.

[0032] Based on the feed rate and the data from the weighing sensor of the small ore trough, the actual discharge amount of the small ore trough 22 per unit time is determined.

[0033] The material quantity deviation is determined based on the feed rate and the actual discharge rate.

[0034] Based on the material quantity deviation, the opening of the gate 221 is reduced and the rotation speed of the roller feeder 25 is decreased, so that the weight of the mixture in the small ore trough 22 is within the first weight range.

[0035] In this embodiment, the controller 3 is further configured as follows: If the weight of the mixture in the small ore bin 22 is within the second weight range, then the feed rate and actual discharge rate of the small ore bin 22 per unit time are determined based on the sintering process parameters.

[0036] Specifically, the feed rate is set by the production rhythm or the batching room, and the feed weight per unit time can be calculated using a belt scale; the feed rate is: ; In the formula, Characterized as The cumulative amount of material transported within the time interval; The time taken for the mixture to pass through the feed conveyor belt is represented by hours (h). It is represented as the weight of material per unit length of the feeding conveyor belt, with the unit being t / m; It is characterized by the speed of the material running on the feeding belt, and the unit is m / h.

[0037] The discharge capacity of the small ore bin is determined by the opening degree of the eight gates and the rotation speed of the roller feeder. The discharge weight per unit time can be calculated using the small ore bin weighing sensor. The actual discharge volume is: ; In the formula, Characterized as The amount of material discharged from the small ore bin within the time interval; Characterized as At any given moment, the weight of the mixture in the small ore bin. Dynamic balance control of the weight in the small ore bin refers to maintaining a dynamic consistency between the feed rate and the discharge rate, i.e., requiring... , In particular, by adjusting the rotation speed of the multi-roller feeder 24 and the speed of the sintering trolley 26, it can handle the amount of mixed material required to maintain the dynamic balance of the material weight in the small ore bin 22.

[0038] Furthermore, by adjusting the rotation speed of the multi-roller distributor 24, the mixture from the round roller feeder 25 is reasonably spread onto the sintering trolley 26.

[0039] Furthermore, by using multiple material layer thickness detection devices installed on the sintering trolley 26, the material layer thickness is ensured to be stable within the ideal material layer thickness range, and the micro-U-shaped material distribution effect is monitored after material distribution, so as to avoid material accumulation, empty material or groove phenomenon in front of the multi-roller distributor 24.

[0040] The material quantity deviation is determined based on the feed rate and the actual discharge rate.

[0041] Based on the material quantity deviation, the opening of the gate 221 is increased and the rotation speed of the roller feeder 25 is increased so that the weight of the mixture in the small ore trough 22 is within the first weight range.

[0042] Specifically, when the feed rate is greater than the discharge rate, the weight of the material in the small ore bin 22 will increase to more than 75%. At this time, it is necessary to recalculate and determine the corresponding combination of control parameters based on the increase in the feed rate, which is defined as the second range. Similarly, when the feed rate is less than the discharge rate, the weight of the material in the small ore bin 22 will decrease to less than 65%. At this time, it is necessary to recalculate and determine the corresponding combination of control parameters based on the decrease in the feed rate, which is defined as the third range.

[0043] Specifically, when increasing production: feed rate Greater than the amount of material to be fed ,Right now: ; In the formula, The deviation between the feed rate and the discharge rate after sintering production increase.

[0044] As the feed rate of the small feed trough 22 increases, the material level gradually rises and enters the second zone.

[0045] When the weight of the material in the small ore bin 22 begins to increase, the feed rate becomes: .

[0046] At this point, the feed rate should be increased to allow the weight of material in the small ore bin 22 to first decrease to the ideal range. Therefore, the initial calculation should be: discharge rate = feed rate + cumulative deviation. The adjustment strategy is as follows: .

[0047] When the material weight in the small ore bin 22 returns to approximately 70% of its original weight, switch to the second control setting to restore the balance between feed and discharge. This allows the material level in the small ore bin 22 to stabilize again.

[0048] During production reduction: feed rate Less than the amount of material to be fed ,Right now: .

[0049] When the feed rate of the small ore bin 22 decreases, the material level gradually drops and enters the third zone.

[0050] When the weight of the material in small ore bin 22 begins to decrease, the feed rate becomes: .

[0051] At this point, the feed rate should be reduced to allow the weight of material in the small ore bin 22 to rise to the ideal range first. Therefore, the formula "Discharge rate = Feed rate - Cumulative deviation" should be executed first. The regulatory strategy is as follows: .

[0052] When the material weight in the small ore bin 22 returns to approximately 70% of its original weight, switch to the third gear control to restore the balance between feed and discharge. This allows the material level in the small ore bin 22 to stabilize again.

[0053] After the material weight in the small ore bin 22 stabilizes, the first average absolute percentage error of the material level model in the small ore bin is calculated, and it is verified whether the first average absolute percentage error is less than 10%. If it does not meet the requirement, the first process parameters are readjusted until the first average absolute percentage error is less than 10%, thereby determining the gate opening and the rotation speed of the roller feeder.

[0054] If the first average absolute percentage error is less than 10%, the sintering process parameters are input into the material layer thickness model, and the second process parameters are determined when the thickness of the mixed material layer and the average thickness of the mixed material layer under each gate 221 are within the first preset thickness standard range and the second preset thickness standard range; the material layer thickness model is generated by training with historical data of sintering process parameters.

[0055] Specifically, the controller 3 is further configured as follows: Obtain historical data of sintering process parameters.

[0056] The historical data of the sintering process parameters are preprocessed; the preprocessing includes: removing outliers and normalization.

[0057] The historical data of the sintering process parameters are classified according to the first weight range, the second weight range, the third weight range, and the process flow to obtain training data.

[0058] The training data is divided into a training set and a validation set, with 70% and 30% of the data allocated to each set.

[0059] Using the training set and the validation set, a model is constructed and trained to obtain a small ore bin material level model and a material layer thickness model.

[0060] The historical data of sintering process parameters are classified according to the first weight range, the second weight range, the third weight range, and the process flow to obtain training data. Taking 70% of the maximum material weight as the ideal material level, the material weight range of [65%, 75%] is set as the first range (ideal material level). When the feed rate is greater than the discharge rate, resulting in a material weight range of [75%, 85%] in the small ore bin, it is the second range (overweight). When the feed rate is less than the discharge rate, resulting in a material weight range of [65%, 75%] in the small ore bin, it is the third range (underweight). Based on these ranges, the historical data of sintering process parameters in the database are classified. Each category of historical data contains a complete sequence of process parameters, aligned by time series, to obtain training data.

[0061] The training data is divided into a training set and a validation set according to a first ratio and a second ratio. Using machine learning methods, each type of data is divided into a training set and a validation set at a ratio of 70% and 30% respectively, for model training, validation and optimization.

[0062] Using the training set and the validation set, a model is constructed and trained to obtain a small ore bin material level model and a material layer thickness model.

[0063] The expression for the small ore bin level model is: ; In the formula, The predicted material feed rate should be close to the actual material feed rate. Characterized by the intercept; , The coefficients of the independent variables are used to represent the variables. The larger the coefficient, the more significant the influence of the independent variable, and the more likely it is to be adjusted. Characterized by 8 gate opening degrees; Characterized by the rotational speed of the roller feeder; It is represented as an error term.

[0064] The loss function of the small ore bin level model is minimized using the least squares method, i.e.: ; In the formula: It is the sample size; This is the actual amount of material fed; It is the model's predicted material feed rate.

[0065] The first mean absolute percentage error (MAPE1) is used as the evaluation index, namely: ; when When the level is less than 10%, the small ore bin level model is considered to have high prediction accuracy and can be used for actual control.

[0066] Specifically, the controller 3 is further configured as follows: Based on the thickness of the mixture layer on the sintering trolley 26 corresponding to each gate 221, the average thickness of the mixture layer is determined; the average thickness of the mixture layer is: .

[0067] The material layer thickness model is configured as follows: Based on the actual discharge volume of the small ore bin, the average thickness of the mixed material layer, and the density of the mixed material, the sintering locomotive speed is determined; the sintering locomotive speed is: .

[0068] Based on the speed of the trolley machine, the rotation speed of the multi-roller feeder and the thickness of the mixed material layer on the corresponding sintering trolley 26 under each of the gates 221 are determined.

[0069] The controller 3 is further configured as follows: Using the material layer thickness model, the predicted values ​​of the mixed material layer thickness on the sintering trolley 26 corresponding to each gate 221 and the predicted values ​​of the multi-roller feeder 24 speed and sintering trolley 26 speed are determined when the average thickness of the mixed material layer is within the first preset thickness standard range and the second preset thickness standard range.

[0070] Specifically, the material layer thickness model is used to verify whether the thickness of the eight material layers corresponding to the eight gate openings meets the standard, and to determine whether a micro-U-shaped material surface is formed. The expression of the material layer thickness model is as follows: ; In the formula, This represents the thickness of the material surface corresponding to each gate, in mm; The speed of the multi-roller feeder is used as the characterization factor; the speed of the sintering trolley is the independent variable.

[0071] After the first average absolute percentage error is less than 10% and the weight of the mixture in the small ore bin 22 is determined to be within the first weight range, the second average absolute percentage error of the material layer thickness model is calculated; the second average absolute percentage error is: .

[0072] If the second average absolute percentage error is greater than or equal to 10%, then the first process parameters of the small ore trough level model are modified again until the small ore trough level model and the material layer thickness model simultaneously satisfy the first average absolute percentage error and the second average absolute percentage error being less than 10%, and the first process parameters and the second process parameters are output.

[0073] The sintering process device 2 is driven to operate with the first process parameters and the second process parameters, so that the weight of the mixture in the small ore bin 22 is within the first weight range, and the thickness of the mixture layer corresponding to each gate 221 is within the first preset thickness standard range and the average thickness of the mixture layer is within the second preset thickness standard range.

[0074] Specifically, the multi-roller feeder 24 and the sintering trolley 26 are driven to operate at the predicted rotational speed of the multi-roller feeder 24 and the predicted machine speed of the sintering trolley 26, so that the thickness of the mixed material layer on the sintering trolley 26 corresponding to each gate 221 and the average thickness of the mixed material layer are within the first preset thickness standard range and the second preset thickness standard range.

[0075] This application provides a control system for the material level and material thickness in the small ore bin of a sintering machine. Through real-time data acquisition, multi-zone modeling, and dynamic compensation control, the system achieves coordinated intelligent control of the material level and material thickness in the small ore bin, significantly improving the stability and uniformity of the sintering material feeding process and providing a reliable guarantee for the consistency of sintered ore quality.

[0076] This application provides a control system for the material level and material distribution thickness in the small ore bin of a sintering machine, the specific implementation of which is as follows: Specific Implementation Example 1: Steady-State Intelligent Control under Normal Production Conditions Background and Objective: The sintering machine is planned to produce 6,000 tons of sinter per day. The total capacity of the small ore bin 22 is 36 tons, and the ideal material level is set at 70% of the maximum capacity, approximately 25.2 tons. This embodiment demonstrates how the control system optimizes and maintains stable material level and uniform material distribution thickness in the small ore bin under the planned output through the following steps.

[0077] 1. Data Acquisition and Preprocessing: The system collects data in real time: the instantaneous flow rate of belt scale 23 is 250t / h (corresponding to a daily output of 6000t), and the belt speed is constant; the weighing sensor in the small ore bin shows that the material weight is 24.8 tons (within the ideal material level range of [65%, 75%]); the opening of the 8 gates 221 is between 45% and 50%; the rotation speed of the roller feeder 25 is 6.0 rpm; the speed of the sintering trolley 26 is 1.6 m / min; and the thickness detection devices show that the material layer thickness fluctuates between 880-920 mm.

[0078] 2. Steady-state model matching and control: Controller 3 identifies that the current material weight (24.8t, accounting for 69%) in the small ore bin 22 belongs to the first interval (ideal material level) and automatically calls the pre-trained first interval control model.

[0079] Dynamic balance control of material level: Based on the feed rate of 250t / h, the material level model of the small ore bin automatically fine-tunes the opening of 8 gates (such as adjusting gate 221 of No. 3 from 48% to 47.5%) and the rotation speed of the roller feeder 25 (fine-tuned to 6.1rpm), so that the feed rate M(t) predicted by the material level model of the small ore bin is infinitely close to the feed rate W(t), realizing a dynamic balance of |W(t)-M(t)|≈0, and stabilizing the material level at around 25.2 tons.

[0080] Fabric thickness uniformity control: Simultaneously, the material layer thickness model is used for reverse verification to ensure uniform material layer thickness. The system reads 8 thickness detection values ​​and calculates an average thickness of 900mm. The material layer thickness model ensures that, at the current gate 221 opening and roller feeder 25 speed, the sintering trolley 26 can precisely receive the balanced feed amount and stabilize the 8-point thickness within the ideal range of [850, 950mm], while forming an ideal "micro-U-shaped" material surface.

[0081] In this embodiment, the system operates fully automatically without manual intervention. The material level fluctuation range of the small ore bin 22 is controlled within ±0.5 tons; the thickness difference at the 8 points is less than 40 mm, and the average thickness is stable at 900 ± 10 mm, providing a solid foundation for the stability and efficiency of the sintering process.

[0082] Specific Implementation Example 2: Dynamic Intelligent Adjustment During Production Rhythm Changes (Production Increase) Background and Objective: Due to adjustments in the production plan, the output needs to be increased from 6000 tons / day (250 t / h) to 6600 tons / day (275 t / h). This example demonstrates how the control system responds to a sudden increase in feed, dynamically adjusts, and quickly establishes a new equilibrium.

[0083] 1. Disturbance generation and detection: The feed conveyor belt 21 is set to increase its flow rate to 275 t / h, resulting in an increase in W(t). In the initial stage, the discharge rate M(t) is still output according to the original parameters, which causes the feed rate to be greater than the discharge rate, resulting in a positive cumulative deviation ξ>0.

[0084] The weighing sensor data in the small ore bin showed that the material level continued to rise, reaching 28.5 tons (79.2% of the capacity) after 15 minutes, entering the second range (overweight).

[0085] 2. Dynamic compensation and adjustment strategy activated: Controller 3 detects that the material level has entered the second zone and immediately triggers the "production increase dynamic adjustment strategy".

[0086] Step 1: Rapidly consume accumulated surplus material. The system executes the strategy of "discharge amount = new feed amount + accumulated deviation ξ". That is, within a short period of time, the controller 3 instructs the synchronous increase of the opening of the 8 gates 221 (e.g., a uniform increase of 8%) and the increase of the rotation speed of the roller feeder 25 (e.g., to 7.0 rpm), so that the instantaneous discharge amount M(t) is greater than the current feed amount W(t), in order to quickly consume the surplus material accumulated in the small ore bin.

[0087] Step 2: Material level return and gear switching. When the material level drops back to the ideal range (approximately 25.2 tons), the system immediately exits the compensation mode.

[0088] 3. The establishment of a new steady state: The system switches to the "second gear range" (which corresponds to the optimized parameter set for higher material flow and output) for control.

[0089] Based on the new gear ratio's multiple regression model, controller 3 automatically optimizes a new set of balance parameters: the gate 221 opening is increased to the 50%-55% range, the roller feeder 25 speed is stabilized at 6.8 rpm, the sintering trolley 26 speed is increased to 1.76 m / min, and the multi-roller distributor 24 speed is adjusted accordingly. Under these parameters, the feed rate 275 t / h and the discharge rate reach a dynamic balance again, W(t) = M(t).

[0090] The system confirmed through thickness detection that the fabric thickness remained stable within the target range of approximately 900mm under the new parameters.

[0091] Faced with a 10% production disruption, the control system automatically and smoothly transitions the entire material distribution system from its original equilibrium state to a new equilibrium state within approximately 20-30 minutes using a two-step strategy of "rapid compensation and smooth transition." This process avoids potential problems such as overflow and material compression caused by excessively high material levels in the small ore bin (22), and also ensures stable material distribution thickness, significantly outperforming control methods that rely on repeated trial and error based on manual experience.

[0092] The above detailed embodiments further illustrate the purpose, technical solution, and beneficial effects of the embodiments of this application. It should be understood that the above are merely specific embodiments of the embodiments of this application and are not intended to limit the protection scope of the embodiments of this application. Any modifications, equivalent substitutions, improvements, etc., made on the basis of the technical solutions of the embodiments of this application should be included within the protection scope of the embodiments of this application.

Claims

1. A control system for the material level and material distribution thickness in a small ore bin of a sintering machine, characterized in that, include: Data acquisition module (1), the data acquisition module (1) is connected to the sintering process device (2), and the data acquisition module (1) is configured as follows: Obtain sintering process parameters; The sintering process parameters include: the weight of the mixture on the feeding belt, the feeding belt speed, the data of the small ore bin weighing sensor, the gate opening, the rotation speed of the round roller feeder, the rotation speed of the multi-roller distributor, the density of the mixture, and the thickness of the mixture layer corresponding to each gate (221). Controller (3), the controller (3) is connected to the data acquisition module (1), and the controller (3) is configured to: Based on the data from the weighing sensor in the small ore bin, the weight of the mixture in the small ore bin (22) is determined; The sintering process parameters are input into the small ore bin level model to determine whether the weight of the mixture in the small ore bin (22) is within the first weight range. If not, the first process parameter of the sintering process device (2) is adjusted so that the weight of the mixture in the small ore bin (22) is within the first weight range. The small ore bin level model is generated by training with historical data of sintering process parameters. The small ore bin level model is configured to determine the target first process parameter range when the weight of the mixture in the small ore bin (22) is within the first weight range. Calculate the first mean absolute percentage error of the small ore bin level model; If the first average absolute percentage error is less than 10%, the sintering process parameters are input into the material layer thickness model, and the second process parameters are determined when the thickness of the mixed material layer and the average thickness of the mixed material layer under each gate (221) are within the first preset thickness standard range and the second preset thickness standard range; the material layer thickness model is generated by training with historical data of sintering process parameters; Calculate the second mean absolute percentage error of the material layer thickness model; If the second average absolute percentage error is greater than or equal to 10%, then the first process parameters of the small ore bin level model are modified again until the small ore bin level model and the material layer thickness model simultaneously satisfy the first average absolute percentage error and the second average absolute percentage error being less than 10%, and the first process parameters and the second process parameters are output. The sintering process device (2) is driven to operate with the first process parameters and the second process parameters, so that the weight of the mixture in the small ore bin (22) is within the first weight range, and the thickness of the mixture layer corresponding to each gate (221) is within the first preset thickness standard range and the average thickness of the mixture layer is within the second preset thickness standard range.

2. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 1, characterized in that, The sintering process apparatus (2) includes: Feeding belt (21), the feeding belt (21) is used to transport the mixture to the small ore bin (22); A belt scale (23) is attached to the feeding belt (21) and is used to obtain the weight of the mixture on the feeding belt; The small ore trough (22) is connected to a four-corner weighing device, which is used to acquire the weighing sensor data of the small ore trough. The small ore bin (22) is provided with a gate (221) at the discharge port. The gate (221) is connected to the discharge gate controller (222). The discharge gate controller (222) is used to open or close the gate (221) and adjust the opening degree of the gate (221). A circular roller feeder (25) is located below the gate (221) and is used to convey the mixture discharged from the small ore bin (22) to the multi-roller distributor (24). The multi-roller feeder (24) is located below the circular roller feeder (25). The mixture is transferred to the multi-roller feeder (24) after passing through the gate (221) and the circular roller feeder (25). The multi-roller feeder (24) is used to feed the mixture to the sintering trolley (26).

3. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 2, characterized in that, The controller (3) is also configured to: Obtain historical data of sintering process parameters; The historical data of the sintering process parameters are preprocessed; the preprocessing includes: outlier removal and normalization. The historical data of the sintering process parameters are classified according to the first weight range, the second weight range, the third weight range and the process flow to obtain training data; The training data is divided into a training set and a validation set, with 70% and 30% respectively. Using the training set and the validation set, a model is constructed and trained to obtain a small ore bin material level model and a material layer thickness model.

4. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 3, characterized in that, After the step of determining whether the weight of the mixture in the small ore bin (22) is within the first weight range, the following steps are included: If so, adjust the opening of the gate (221) and the rotation speed of the roller feeder (25) to the target first process parameter range so that the weight of the mixture in the small ore bin (22) is maintained within the first weight range.

5. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 3, characterized in that, The controller (3) is further configured as follows: If the weight of the mixture in the small ore bin (22) is within the second weight range, then the feed rate and the actual discharge rate of the small ore bin (22) per unit time are determined based on the sintering process parameters. The material quantity deviation is determined based on the feed rate and the actual discharge rate from the small ore bin; Based on the material quantity deviation, the opening of the gate (221) is increased and the rotation speed of the roller feeder (25) is increased so that the weight of the mixture in the small ore bin (22) is within the first weight range.

6. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 3, characterized in that, The controller (3) is further configured as follows: If the weight of the mixture in the small ore bin (22) is within the third weight range, then the feed rate and the actual discharge rate of the small ore bin (22) per unit time are determined based on the sintering process parameters. The material quantity deviation is determined based on the feed rate and the actual discharge rate from the small ore bin; Based on the material quantity deviation, the opening of the gate (221) is reduced and the rotation speed of the roller feeder (25) is reduced so that the weight of the mixture in the small ore trough (22) is within the first weight range.

7. A control system for the material level and material distribution thickness in a sintering machine's small ore bin according to claim 5 or 6, characterized in that, The controller (3) is further configured as follows: Based on the weight of the mixture on the feeding belt and the feeding speed of the feeding belt, the feed rate of the small ore bin (22) per unit time is determined; Based on the feed rate and the data from the weighing sensor of the small ore trough, the actual amount of material discharged from the small ore trough (22) per unit time is determined.

8. The control system for the material level and material distribution thickness in the small ore bin of a sintering machine according to claim 7, characterized in that, The controller (3) is also configured to: The average thickness of the mixture layer is determined based on the thickness of the mixture layer on the sintering trolley (26) corresponding to each gate (221); The material layer thickness model is configured as follows: The sintering locomotive speed is determined based on the actual discharge volume of the small ore bin, the average thickness of the mixed material layer, and the density of the mixed material. Based on the speed of the trolley machine, the rotation speed of the multi-roller feeder and the thickness of the mixed material layer on the sintering trolley (26) corresponding to each gate (221) are determined; The controller (3) is further configured as follows: Using the material layer thickness model, the predicted values ​​of the mixed material layer thickness on the sintering trolley (26) corresponding to each gate (221) and the predicted values ​​of the multi-roller feeder (24) speed and sintering trolley (26) speed when the average thickness of the mixed material layer is within the first preset thickness standard range and the second preset thickness standard range are determined; The multi-roller feeder (24) and the sintering trolley (26) are driven to run at the predicted speed of the multi-roller feeder (24) and the predicted speed of the sintering trolley (26), so that the thickness of the mixed material layer on the sintering trolley (26) corresponding to each gate (221) and the average thickness of the mixed material layer are within the first preset thickness standard range and the second preset thickness standard range.

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