Anti-blocking method and device for grain dryer, electronic equipment and storage medium

Abstract

The application discloses a method and device for preventing blockage of a grain dryer, electronic equipment and a storage medium. The method comprises the following steps: acquiring the rotating speed of a lifting motor in real time, taking the deviation of the rotating speed of the lifting motor relative to the rated rotating speed as a feedback signal, and automatically adjusting the operating speed of a grain discharging motor. A closed-loop coordinated control mechanism is constructed between the lifting motor and the grain discharging motor, so that the grain discharging speed can be dynamically adjusted adaptively according to the actual grain flow condition in the lifting pipeline. Therefore, the technical problems that the lifting pipeline is blocked due to the mismatch between the rotating speeds of the grain discharging motor and the lifting motor and the low operation efficiency caused by the heavy dependence on the operation experience of the user can be solved. The technical effects of reducing manual intervention, reducing the dependence on the experience level of the operator, preventing the blockage of the lifting pipeline, improving the grain drying operation efficiency and the equipment operation reliability are achieved.

Description

Technical Field

[0001] This disclosure relates to the field of data processing technology, and in particular to a method, apparatus, electronic device, and storage medium for preventing clogging in a grain dryer. Background Technology

[0002] Grain dryers are important pieces of equipment in the field of agricultural machinery and are widely used in grain drying operations. In related technologies, a grain dryer control system is constructed through the coordinated operation of the grain discharge motor, the lifting motor, and the frequency converter.

[0003] The existing control methods for grain dryers rely on manual control, which leads to reduced operational efficiency due to insufficient user experience. Summary of the Invention

[0004] This disclosure provides a method, apparatus, electronic device, and storage medium for preventing clogging in a grain dryer.

[0005] According to a first aspect of this disclosure, a method for preventing clogging in a grain dryer is provided, comprising: Obtain the actual speed of the booster motor; The load state of the lifting motor is determined based on the deviation of the actual speed from the rated speed. Based on the load status, a speed adjustment command for the grain discharge motor is generated; The speed of the grain discharge motor is adjusted according to the speed adjustment command to coordinate the operating states of the lifting motor and the grain discharge motor.

[0006] Optionally, the step of obtaining the actual speed of the hoisting motor includes: The pulse signal corresponding to the speed of the hoisting motor is collected by a speed detection component installed on the drive shaft of the hoist; The actual speed of the booster motor is calculated based on the pulse signal.

[0007] Optionally, the speed detection component includes a speed measuring bracket fixed to the hoist drive shaft and a sensor for detecting the rotation of the speed measuring bracket; the step of calculating the actual speed of the hoist motor based on the pulse signal includes: The actual speed of the lifting motor is calculated based on the ratio between the number of pulse signals collected by the sensor within the preset sampling time and the number of blades on the speed measuring bracket.

[0008] Optionally, determining the load state of the hoisting motor based on the deviation of the actual rotational speed from the rated rotational speed includes: Calculate the percentage decrease in the actual speed of the booster motor relative to its rated speed, and; The lifting motor is judged to be overloaded or close to overloaded based on the descent ratio.

[0009] Optionally, generating a speed adjustment command for the grain discharge motor based on the load state includes: Calculate the target output frequency of the grain discharge motor inverter based on the load condition; The target output frequency is compared with a preset frequency range. If the target output frequency is between the preset minimum frequency and the initial frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the target output frequency. If the target output frequency is less than the preset minimum frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency.

[0010] Optionally, the method further includes: Record and store the speed measurement values ​​of the lifting motor and the historical frequency setting values ​​of the grain discharge motor inverter in the most recent few times; Based on the changing trends of the measured rotational speed and the historical frequency setting, it is determined whether the current rotational speed of the grain discharge motor matches the rotational speed of the lifting motor, and the operating frequency of the grain discharge motor inverter is adaptively fine-tuned.

[0011] Optionally, the method further includes: Based on the preset control parameters of the human-machine interface, the control parameters include the rated speed of the boost motor, the initial frequency of the grain discharge motor inverter, and the upper and lower limits of the frequency of the grain discharge motor inverter; wherein, the initial frequency is less than the upper limit and greater than or equal to the lower limit.

[0012] According to a second aspect of this disclosure, an anti-clogging device for a grain dryer is provided, comprising: The acquisition unit is used to acquire the actual speed of the lifting motor; The determination unit is used to determine the load state of the hoisting motor based on the deviation of the actual rotational speed from the rated rotational speed. The generation unit is used to generate a speed adjustment command for the grain discharge motor based on the load state. The adjustment unit is used to adjust the speed of the grain discharge motor according to the speed adjustment command, so that the operating states of the lifting motor and the grain discharge motor are coordinated.

[0013] Optionally, the acquisition unit is further configured to: The pulse signal corresponding to the speed of the hoist motor is collected by a speed detection component installed on the drive shaft of the hoist. The actual speed of the booster motor is calculated based on the pulse signal.

[0014] Optionally, the acquisition unit is further configured to: The rotational speed detection assembly includes a speed measuring bracket fixed on the drive shaft of the hoist and a sensor for detecting the rotation of the speed measuring bracket; The actual speed of the lifting motor is calculated based on the ratio between the number of pulse signals collected by the sensor within the preset sampling time and the number of blades on the speed measuring bracket.

[0015] Optionally, the determination unit is further configured to: Calculate the percentage decrease in the actual speed of the boost motor relative to its rated speed; The lifting motor is judged to be overloaded or close to overloaded based on the descent ratio.

[0016] Optionally, the generation unit is further configured to: Calculate the target output frequency of the grain discharge motor inverter based on the load condition; The target output frequency is compared with a preset frequency range. If the target output frequency is between the preset minimum frequency and the initial frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the target output frequency. If the target output frequency is less than the preset minimum frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency.

[0017] Optional, also includes: The recording unit is used to record and store the speed measurement values ​​of the lifting motor and the historical frequency setting values ​​of the grain discharge motor inverter in the most recent few times. The fine-tuning unit is used to determine whether the current speed of the grain discharge motor matches the speed of the hoisting motor based on the changing trend of the measured speed value and the changing trend of the historical frequency setting value, and to adaptively fine-tune the operating frequency of the grain discharge motor inverter.

[0018] Optional, also includes: The parameter preset unit is used to preset control parameters based on the human-machine interface. The control parameters include the rated speed of the boost motor, the initial frequency of the grain discharge motor inverter, and the upper and lower limits of the frequency of the grain discharge motor inverter; wherein the initial frequency is less than the upper limit and greater than or equal to the lower limit.

[0019] According to a third aspect of this disclosure, an electronic device is provided, comprising: At least one processor; and A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor to enable the at least one processor to perform the method described in the first aspect above.

[0020] According to a fourth aspect of this disclosure, a non-transitory computer-readable storage medium is provided storing computer instructions, wherein the computer instructions are configured to cause the computer to perform the method described in the first aspect above.

[0021] According to a fifth aspect of this disclosure, a computer program product is provided, comprising a computer program that, when executed by a processor, implements the method described in the first aspect above.

[0022] The anti-clogging method, device, electronic equipment, and storage medium for the grain dryer disclosed herein employ real-time acquisition of the lifting motor speed and using its deviation from the rated speed as a feedback signal to automatically adjust the operating speed of the discharge motor. This establishes a closed-loop coordinated control mechanism between the lifting motor and the discharge motor, enabling the discharge rate to be dynamically adjusted adaptively according to the actual grain flow conditions within the lifting pipe. Therefore, it can solve the technical problems of existing grain dryers that lead to grain blockage in the lifting pipe due to reliance on manual control and mismatch between the speeds of the discharge motor and the lifting motor, as well as the low operating efficiency caused by heavy reliance on user experience. This achieves the technical effects of reducing manual intervention, lowering reliance on the operator's experience level, preventing grain blockage in the lifting pipe, and improving the efficiency of grain drying operations and the reliability of equipment operation.

[0023] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent from the following description. Attached Figure Description

[0024] The accompanying drawings are provided to better understand this solution and do not constitute a limitation of this disclosure. Wherein: Figure 1 This is a schematic flowchart illustrating an anti-clogging method for a grain dryer provided in an embodiment of this disclosure. Figure 2 This is a simplified installation diagram of a detection system provided in an embodiment of this application; Figure 3 This is a simplified installation diagram of another detection system provided in an embodiment of this application; Figure 4 This is a schematic diagram of the structure of an anti-clogging device for a grain dryer provided in an embodiment of the present disclosure; Figure 5 This is a schematic diagram of the structure of an anti-clogging device for a grain dryer provided in an embodiment of the present disclosure; Figure 6 A schematic block diagram of an example electronic device provided for embodiments of this disclosure. Detailed Implementation

[0025] The exemplary embodiments of this disclosure are described below with reference to the accompanying drawings, including various details of the embodiments to aid understanding, and should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of this disclosure. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0026] The following description, with reference to the accompanying drawings, describes an anti-clogging method, apparatus, electronic device, and storage medium for a grain dryer according to embodiments of the present disclosure.

[0027] Figure 1 This is a schematic flowchart illustrating an anti-clogging method for a grain dryer provided in an embodiment of this disclosure.

[0028] like Figure 1 As shown, the method includes the following steps: Step 101: Obtain the actual speed of the booster motor; The speed acquisition device can employ any non-contact or contact measurement method suitable for industrial environments. Its core function is to convert the rotational motion of the lifting motor into an electrical signal or data stream that can be processed by the controller.

[0029] In a specific application scenario, the device may include a speed-measuring element, such as a speed-measuring bracket, fixed to the shaft of the hoisting motor, and a sensor (such as a proximity switch sensor) that works in conjunction with it to sense the periodic passage of the speed-measuring element. The sensor generates corresponding pulse signals based on the rotation cycle of the speed-measuring element. The controller then collects the number of these pulse signals per unit time and, combined with the characteristic parameters of the speed-measuring element (such as the number of blades), uses a preset calculation model to calculate the actual rotational speed of the hoisting motor. This acquired actual rotational speed will serve as the basis for subsequent judgment of the motor load status and adaptive coordinated control.

[0030] Step 102: Determine the load state of the lifting motor based on the deviation of the actual rotational speed from the rated rotational speed; This step compares the actual rotational speed with the preset rated speed of the hoisting motor, calculates the deviation between the two, and determines the current load state of the hoisting motor based on the degree of speed change reflected by this deviation. Specifically, when the grain flows smoothly in the hoisting pipe and the motor is in normal operation, the actual rotational speed is close to the rated speed, and the deviation is small or zero; however, when the grain gradually accumulates in the pipe and the motor load increases, the actual rotational speed will decrease relative to the rated speed, and the deviation will increase accordingly.

[0031] The controller classifies the load state of the lifting motor by comparing the deviation with a preset judgment threshold, such as classifying it as a normal load state, a warning state, or an abnormal load state indicating impending blockage. The deviation can be calculated in various forms, such as absolute difference or relative ratio. For example, in a specific application scenario, the percentage decrease in actual speed relative to rated speed can be calculated. This involves dividing the difference between the actual and rated speed by the rated speed and multiplying by a percentage factor to obtain a dimensionless deviation index, facilitating unified processing and comparison in subsequent control logic. Through this deviation analysis process, the system can identify the abnormal increase in motor load before the pipeline becomes completely blocked, providing a basis for subsequent adaptive adjustment decisions.

[0032] Step 103: Based on the load status, generate a speed adjustment command for the grain discharge motor; The basic control principle is that the actual speed change of the hoisting motor directly reflects the flow of grain in the hoisting pipe. When the load indicates that the grain accumulation in the pipe is becoming serious, the system generates an adjustment command to reduce the speed of the discharge motor to reduce the rate at which grain enters the hoisting pipe, thereby alleviating the congestion trend in the pipe. Conversely, when the load indicates that the flow in the pipe has returned to normal, the system generates an adjustment command to gradually increase the speed of the discharge motor, so that the discharge rate returns to the initial set value to restore normal operating efficiency.

[0033] The generation of adjustment commands follows the basic logic of closed-loop feedback control, that is, dynamically determining the adjustment direction and adjustment magnitude based on the difference between the current load state and the desired normal state, so that the speed of the grain discharge motor can be coordinated and matched with the actual load capacity of the motor. For example, in a specific application scenario, the controller can calculate the target frequency value to which the grain discharge motor inverter needs to be adjusted according to a preset algorithm model based on the speed deviation ratio calculated in the aforementioned steps, and use this target frequency value as the adjustment command, which is sent to the grain discharge motor inverter for execution through the communication interface. The system can also perform comprehensive analysis on load status data collected multiple times and historical adjustment records to judge the adjustment effect and avoid frequent or inappropriate adjustment actions caused by instantaneous fluctuations at a single sampling point, thereby achieving more stable and accurate adaptive coordinated control.

[0034] Step 104: Adjust the speed of the grain discharge motor according to the speed adjustment command to coordinate the operating states of the lifting motor and the grain discharge motor.

[0035] The adjustment command is transmitted to the drive actuator of the grain discharge motor through a preset control communication path. The drive actuator adjusts the actual speed of the grain discharge motor according to the command, so that the speed of the grain discharge motor approaches the target value indicated by the adjustment command, and finally realizes the dynamic coordination and matching between the operating state of the lifting motor and the operating state of the grain discharge motor.

[0036] The execution of the adjustment command brings the output speed of the grain discharge motor to a level adapted to the current load state of the hoisting motor, maintaining a dynamic balance between the grain inflow rate and the hoisting capacity in the hoisting pipe, thereby eliminating the risk of pipe congestion caused by the mismatch between the two rates. The drive actuator can be a frequency converter, servo driver, or other power electronic control device capable of continuously adjusting the motor speed, which achieves continuous speed adjustment by changing the power supply parameters applied to the grain discharge motor.

[0037] In a specific application scenario, the controller sends the calculated target frequency value of the frequency converter to the grain discharge motor frequency converter via a serial communication protocol. After receiving the instruction, the frequency converter adjusts its output frequency, thereby changing the power supply frequency of the grain discharge motor, so that the actual speed of the grain discharge motor changes accordingly, until it is coordinated with the current load capacity of the motor.

[0038] After the adjustment command is executed, the system continues to collect the actual speed of the boost motor in a loop and re-evaluate the load status and adjustment effect. If it is detected that the coordination status has not been fully restored, a new adjustment command is generated based on the current data and the adjustment continues to be executed, forming a continuous closed-loop control process.

[0039] When the system collects data multiple times and it shows that the actual speed of the hoisting motor has stabilized and recovered to near the rated speed, and the speed of the grain discharge motor has also stabilized, it can be determined that the operating states of the hoisting motor and the grain discharge motor have reached a coordinated match. The system will continue to operate with the current working parameters until the next load state change triggers a new adjustment cycle.

[0040] In some embodiments, the step of obtaining the actual speed of the lifting motor includes: The pulse signal corresponding to the speed of the hoisting motor is collected by a speed detection component installed on the drive shaft of the hoist; The actual speed of the booster motor is calculated based on the pulse signal.

[0041] The speed measuring bracket is a rotating component with a preset number of blades, rigidly connected to the bottom drive shaft of the hoist by mechanical fixing, and rotates synchronously with the drive shaft driven by the hoisting motor. The proximity switch sensor is installed on the hoist frame near the periphery of the speed measuring bracket, with its sensing surface facing the blades of the speed measuring bracket. This ensures that each time the speed measuring bracket rotates once, and each blade sequentially passes through the sensing area of ​​the proximity switch sensor, the proximity switch sensor generates a corresponding electrical pulse signal upon sensing the passage of the blade.

[0042] When the lifting motor drives the drive shaft to rotate, the speed measuring bracket rotates synchronously with the shaft. The number of pulse signals collected by the proximity switch sensor per unit time is directly related to the rotational speed of the lifting motor and the number of blades on the speed measuring bracket. The pulse signals are transmitted to the PLC controller of the grain dryer via signal cables. The PLC controller counts the received pulse signals within a preset sampling period and, combined with the known number of blades on the speed measuring bracket, calculates the actual rotational speed of the lifting motor according to a preset conversion formula.

[0043] The PLC controller counts the total number of pulses output by the proximity switch sensor within a 3-second sampling window. This total number of pulses is divided by the number of blades on the speed measuring bracket, and then multiplied by a time conversion factor of 20 (i.e., 60 seconds divided by a 3-second sampling period) to obtain the actual speed of the lifting motor in revolutions per minute. This speed value serves as the basic input data for subsequent load status determination.

[0044] In some embodiments, the speed detection assembly includes a speed measuring bracket fixed to the drive shaft of the hoist and a sensor for detecting the rotation of the speed measuring bracket; the step of calculating the actual speed of the hoisting motor based on the pulse signal includes: The actual speed of the lifting motor is calculated based on the ratio between the number of pulse signals collected by the sensor within the preset sampling time and the number of blades on the speed measuring bracket.

[0045] The speed measuring bracket is a disc-shaped or spoke-shaped rotating component with multiple blades evenly distributed circumferentially. This bracket is fixedly installed on the bottom drive shaft of the hoist via key connections, set screws, or clamps, and rotates synchronously with the drive shaft driven by the hoist motor. The sensor is a proximity switch sensor, employing inductive or capacitive detection principles. It is fixedly installed on the hoist frame at an appropriate position near the periphery of the speed measuring bracket. Its sensing end face remains within the effective sensing distance of the path of each blade on the speed measuring bracket. Each time a blade passes through the sensor's sensing area, the sensor outputs a standard electrical pulse signal.

[0046] Within a preset sampling time, there is a definite proportional relationship between the total number of pulse signals collected by the sensor and the number of blades on the speed measuring bracket: for each rotation of the speed measuring bracket, the number of pulses output by the sensor is exactly equal to the number of blades on the speed measuring bracket. Therefore, the total number of pulses within the sampling time divided by the number of blades gives the number of rotations of the hoisting motor drive shaft within that sampling period. After obtaining this total number of pulse signals, the PLC controller divides it by the known number of blades on the speed measuring bracket to obtain the number of rotations within the sampling period. Then, combined with the preset sampling time, it converts this into the number of rotations per unit time, thus obtaining the actual speed of the hoisting motor in revolutions per minute (RPM).

[0047] When the speed measuring bracket has N3 blades and the preset sampling time is 3 seconds, if the sensor collects N2 pulse signals within this sampling period, the actual speed N4 of the lifting motor is calculated as follows: N4 equals N2 divided by N3 multiplied by 20, where the coefficient 20 is a time conversion factor, obtained by dividing 60 seconds by the 3-second sampling time. This proportional calculation eliminates the influence of the number of blades on the speed calculation, making this method applicable to speed measuring brackets with different blade configurations and exhibiting good versatility.

[0048] In some embodiments, determining the load state of the hoisting motor based on the deviation of the actual rotational speed from the rated rotational speed includes: Calculate the percentage decrease in the actual speed of the booster motor relative to its rated speed, and; The lifting motor is judged to be overloaded or close to overloaded based on the descent ratio.

[0049] The rated speed is the standard operating speed of the hoisting motor under normal load conditions, which is input by the user through the human-machine interface during system initialization and stored in the PLC controller. After each speed sampling calculation to obtain the actual speed of the hoisting motor, the PLC controller compares the actual speed with the rated speed and calculates the decrease ratio of the actual speed relative to the rated speed according to a preset calculation formula. Specifically, the formula for calculating the decrease ratio R1 is: R1 equals the difference between the rated speed N0 and the actual speed N4, divided by the rated speed N0, and then multiplied by 100, expressed as a percentage.

[0050] The descent ratio R1 directly reflects the degree to which the actual speed of the hoisting motor deviates from its rated speed, that is, the magnitude of the load increase on the hoist's drive shaft caused by the accumulation of grain in the pipe. When the grain flows smoothly in the pipe and the motor is under normal load, the actual speed is close to the rated speed, and the descent ratio R1 approaches zero or is at an extremely low level. As the grain gradually accumulates in the pipe, the load on the hoisting motor increases, the drive shaft speed decreases accordingly, the difference between the actual speed and the rated speed increases, and the descent ratio R1 increases accordingly.

[0051] The PLC controller compares the calculated descent ratio R1 with a preset load judgment threshold: when the descent ratio R1 is lower than the set warning threshold, the hoisting motor is determined to be under normal load; when the descent ratio R1 reaches or exceeds the warning threshold but does not reach the overload threshold, the hoisting motor is determined to be approaching overload; when the descent ratio R1 reaches or exceeds the overload threshold, the hoisting motor is determined to be overloaded. Through the above quantitative judgment process based on the descent ratio, the system can promptly identify the trend of abnormally increasing load before the hoisting motor completely stalls due to excessive load or the pipeline becomes completely blocked, providing a clear judgment basis for the subsequent adaptive adjustment of the grain discharge motor speed.

[0052] In some embodiments, generating a speed adjustment command for the grain discharge motor based on the load state includes: Calculate the target output frequency of the grain discharge motor inverter based on the load condition; The target output frequency is compared with a preset frequency range. If the target output frequency is between the preset minimum frequency and the initial frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the target output frequency. If the target output frequency is less than the preset minimum frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency.

[0053] Based on the calculated reduction ratio R1 of the actual speed of the lifting motor relative to the rated speed, the target output frequency of the grain discharge motor inverter is calculated using a preset frequency calculation model. The calculation formula of the frequency calculation model is: P1 equals the initial frequency P0 of the grain discharge motor inverter minus P0 multiplied by 2, then multiplied by the reduction ratio R1, and divided by 100, with the result rounded down. The initial frequency P0 is the preset operating frequency of the grain discharge motor inverter input by the user through the human-machine interface during the system initialization phase. This value must meet the constraint that it is greater than the preset minimum frequency PMIN and less than the preset maximum frequency PMAX.

[0054] The physical meaning of this formula is as follows: the larger the descent ratio R1 is, the heavier the load on the lifting motor and the more serious the grain accumulation in the pipe. At this time, the target output frequency P1 will decrease by a larger margin, and the speed of the grain discharge motor will decrease by a larger margin to slow down the rate at which the grain enters the lifting pipe. Conversely, when the descent ratio R1 is small or zero, the target output frequency P1 is close to the initial frequency P0, and the grain discharge motor maintains a grain discharge rate close to normal levels. After calculating the target output frequency P1, the PLC controller compares the target output frequency P1 with the preset frequency range boundary value and generates corresponding adjustment instructions based on the comparison result: When the target output frequency P1 meets the condition of being greater than the preset minimum frequency PMIN and less than the initial frequency P0, that is, P1 is within the effective adjustment range between the preset minimum frequency and the initial frequency, the PLC controller generates an instruction to adjust the operating frequency of the grain discharge motor inverter to the target output frequency P1, and sends the frequency value P1 to the grain discharge motor inverter through the serial communication protocol. The inverter adjusts the output frequency to P1 accordingly, so that the speed of the grain discharge motor decreases accordingly; When the target output frequency P1 is less than or equal to the preset minimum frequency PMIN, it indicates that the load on the lifting motor has reached a serious level. At this time, the PLC controller generates an instruction to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency PMIN, that is, sends the PMIN value to the inverter, ensuring that the grain discharge motor runs at the lowest speed allowed by the system, which not only slows down the rate at which grain enters the lifting pipe to alleviate the grain blockage trend, but also avoids the grain discharge motor from stopping or stalling due to excessively low frequency.

[0055] In some embodiments, the method further includes: Record and store the speed measurement values ​​of the lifting motor and the historical frequency setting values ​​of the grain discharge motor inverter in the most recent few times; Based on the changing trends of the measured rotational speed and the historical frequency setting, it is determined whether the current rotational speed of the grain discharge motor matches the rotational speed of the lifting motor, and the operating frequency of the grain discharge motor inverter is adaptively fine-tuned.

[0056] The PLC controller cyclically collects the actual speed of the hoisting motor at a preset sampling period, and stores the collected speed measurement values ​​in chronological order into its internal data buffer, always saving the three most recent speed measurement values ​​n0, n1, and n2, where n0 is the most recent measurement, n1 is the previous measurement, and n2 is the two measurements before that. Simultaneously, the PLC controller also records the frequency setting values ​​sent to the grain discharge motor inverter each time, always saving the four most recent frequency setting values ​​m0, m1, m2, and m3, where m0 is the most recent setting and m3 is the earliest setting. Based on the changing trends of the above historical data, the PLC controller comprehensively judges whether the current operating frequency of the grain discharge motor is coordinated and matched with the speed of the hoisting motor, and performs corresponding adaptive fine-tuning. When at least one of the three most recent speed measurement values ​​is not equal to the rated speed (i.e., n0 is not equal to N0, or n1 is not equal to N0, or n2 is not equal to N0), it indicates that the hoisting motor is still under abnormal load. The PLC controller then calculates the target frequency according to the aforementioned steps and performs corresponding adjustments.

[0057] When the three most recent speed measurements are all equal to the rated speed, i.e., n0 equals N0, n1 equals N0, and n2 equals N0, and the two most recent frequency settings show a downward trend, i.e., m0 is greater than m1, the PLC controller determines that the grain blockage fault has been eliminated. At this time, the inverter's operating frequency is increased by 1 Hz based on the current value, i.e., P equals P plus 1, and the frequency is continuously used for observation for 3 minutes to gradually increase the grain discharge rate.

[0058] When the three most recent speed measurements are equal to the rated speed, and the four most recent frequency settings are equal (m0 = m1 = m2 = m3), and the current frequency P is still less than the initial frequency P0, the PLC controller determines that the discharge motor speed is still too low and the discharge rate needs to be further increased. The inverter operating frequency is also increased by 1 Hz (P = P + 1), and observation continues for 3 minutes. When the two most recent speed measurements are equal to the rated speed, but the third is not (n0 = n1 = N0 > n2), and the three most recent frequency settings are equal, but the fourth setting is larger (m0 = m1 = m2 < m3), and the current frequency P is still less than the initial frequency P0, the PLC controller determines that the discharge motor speed is too high. The inverter operating frequency is reduced by 2 Hz from the current value (P = P - 2) to prevent the excessively fast discharge rate from causing abnormal load on the lifting pipeline again. Through this adaptive fine-tuning mechanism based on historical data trend analysis, the system can gradually and precisely converge the operating frequency of the discharge motor inverter to a level that best matches the current speed of the lifting motor.

[0059] In some embodiments, the method further includes: Based on the preset control parameters of the human-machine interface, the control parameters include the rated speed of the boost motor, the initial frequency of the grain discharge motor inverter, and the upper and lower limits of the frequency of the grain discharge motor inverter; wherein, the initial frequency is less than the upper limit and greater than or equal to the lower limit.

[0060] The human-machine interface is located on the control cabinet panel of the grain dryer. It provides a parameter input interface for users to input the following four control parameters sequentially: the rated speed of the lifting motor, the initial frequency of the discharge motor inverter, the upper limit of the discharge motor inverter frequency, and the lower limit of the discharge motor inverter frequency. The rated speed of the lifting motor is the standard speed value corresponding to the lifting motor under normal load conditions. This value is determined by the user based on the calibration parameters on the lifting motor nameplate or actual operating conditions, and serves as the benchmark reference value for subsequent calculations of speed deviation and descent ratio. The initial frequency of the discharge motor inverter is the starting operating frequency of the discharge motor inverter after the system starts automatic control, representing the inverter output frequency corresponding to the user's desired normal discharge rate.

[0061] The upper limit of the frequency of the grain discharge motor inverter is the highest frequency that the system allows the inverter to output, and the lower limit of the frequency of the grain discharge motor inverter is the lowest frequency that the system allows the inverter to output. Together, they define the adjustable range of the grain discharge motor inverter's operating frequency. The initial frequency setting must meet the constraint that it is less than the upper limit and greater than or equal to the lower limit. That is, the upper limit is greater than the initial frequency, and the initial frequency is greater than or equal to the lower limit. This constraint condition is verified by the PLC controller after the user completes the parameter input. If it is not met, the user is prompted to re-enter the value through the human-machine interface to ensure that the set initial frequency is within the effective adjustable range.

[0062] After the user completes the setting of all four control parameters, the parameter values ​​are written into the non-volatile memory of the PLC controller and saved, serving as reference parameters for calculation and judgment during subsequent automatic control processes. In addition, the human-machine interface also displays real-time operating information such as the actual operating frequency of the grain discharge motor inverter, hot air temperature, operating status, and fault alarms, allowing the user to monitor the operation process.

[0063] The following example illustrates a method for preventing clogging in a grain dryer provided in this application.

[0064] Please see Figure 2 and Figure 3 , Figure 2 This is a simplified installation diagram of a detection system provided in an embodiment of this application. Figure 3 This is a simplified installation diagram of another detection system provided in an embodiment of this application, as shown below. Figure 2 and Figure 3As shown, the equipment includes a hoist motor, a discharge motor, a discharge motor frequency converter, a speed measuring bracket 10, a proximity switch sensor 11, a control cabinet 12, and a PLC controller mounted on the control cabinet 12. The speed measuring bracket 10 is fixed to the bottom shaft of the hoist. The proximity switch sensor 11 detects the speed signal of the hoist motor and transmits the speed signal to the PLC controller 13. The PLC controller 13 calculates the current speed value of the hoist motor based on the received speed signal, communicates with the discharge motor frequency converter via a serial communication protocol, and generates corresponding control commands. The actuator adjusts the speed of the discharge motor according to the control commands to achieve automated control during the grain drying process.

[0065] The human-machine interface (HMI) in the aforementioned system is used by the user to input necessary parameters for automatic control, including the rated speed N0 of the hoisting motor, the rated speed N1 of the grain discharge motor, the initial frequency P0 of the grain discharge motor's inverter, and the maximum and minimum frequency values ​​PMAX and PMIN of the grain discharge motor's inverter. The initial frequency setting of the inverter must satisfy the following condition: maximum frequency of the grain discharge motor inverter > initial frequency of the grain discharge motor inverter > minimum frequency of the grain discharge motor inverter. After the above five parameter settings are input, if the user clicks the automatic control button, the system enters the automatic control state. In this state, the PLC controls the speed of the grain discharge motor based on the speed of the hoisting motor. If the user does not click the automatic control button, the system enters the manual control state, and the speed of the grain discharge motor is set by the user, but it is not allowed to be lower than the minimum value or higher than the maximum value. In addition, the HMI also displays information such as the actual operating frequency of the grain discharge motor inverter, hot air temperature, operating status, and fault alarms.

[0066] The system is equipped with a proximity switch sensor to collect the pulse signal when the speed measuring bracket rotates and send the pulse signal to the grain dryer PLC controller.

[0067] The grain dryer's PLC controller calculates the hoisting motor's speed N4 (revolutions per minute) based on the pulse signal N2 from the proximity switch sensor and the number of blades N3 on the speed measuring bracket over a 3-second period. The PLC controller calculates the hoisting motor's speed using the following formula. N4 = (N2 / N3) * 20; The grain dryer PLC controller calculates the descent rate of the lifting motor according to the following formula. R1 = (N0 - N4) / N0 * 100; The grain dryer PLC controller calculates the frequency of the grain discharge motor and performs a rounding operation based on the following formula: P1 = P0 - (P0*2*R1) / 100; During the operation of the grain dryer, the PLC controller will save the latest three measured rotational speed values n0, n1, n2, and the latest four calculated frequency values m0, m1, m2, m3 Precondition: n0≠N0 or n1≠N0 or n2≠N0 If PMIN<P1<P0, then the PLC controller of the grain dryer sends the P1 value to the grain discharging motor frequency converter according to the serial port communication protocol, and sets the operating frequency of the frequency converter to P = P1; If P1<PMIN, then the PLC controller of the grain dryer sends the PMIN value to the grain discharging motor frequency converter according to the serial port communication protocol, and sets the operating frequency of the frequency converter to P = PMIN.

[0068] Precondition: n0=N0&n1=N0&n2=N0&m0>m1 At this point, it can be determined that the grain blockage fault has been resolved. Then the PLC controller of the grain dryer sends a value to the grain discharging motor frequency converter according to the serial port communication protocol, sets the operating frequency of the frequency converter to P = P + 1, and the controller continues to observe for 3 minutes; If n0=N0&n1=N0&n2=N0&m0 = m1 = m2 = m3 and P<P0, at this time the PLC controller considers that the rotational speed of the grain discharging motor is still low, then the PLC controller of the grain dryer sends a value to the grain discharging motor frequency converter according to the serial port communication protocol, sets the operating frequency of the frequency converter to P = P + 1, and the controller continues to observe for 3 minutes; If n0=n1=N0>n2, m0 = m1 = m2<m3 and P<P0, at this time the PLC controller considers that the rotational speed of the grain discharging motor is on the high side, then the PLC controller of the grain dryer sends a value to the grain discharging motor frequency converter according to the serial port communication protocol, sets the operating frequency of the frequency converter to P = P - 2, and the frequency converter operates at this set frequency, so that the rotational speed of the lifting motor and the grain discharging motor can be coordinated and matched with each other.

[0069] Corresponding to the above anti-blocking method for the grain dryer, the present invention further proposes an anti-blocking device for the grain dryer. Since the device embodiment of the present invention corresponds to the above method embodiment, for details not disclosed in the device embodiment, reference may be made to the above method embodiment, and repeated description will not be elaborated in the present invention.

[0070] Figure 4 is a schematic structural diagram of an anti-blocking device for a grain dryer provided by an embodiment of the present disclosure, as shown in Figure 4 the figure, includes: An acquisition unit 21, configured to acquire the actual rotational speed of the lifting motor; The determination unit 22 is used to determine the load state of the lifting motor based on the deviation of the actual speed from the rated speed; The generation unit 23 is used to generate a speed adjustment command for the grain discharge motor based on the load state. The adjustment unit 24 is used to adjust the speed of the grain discharge motor according to the speed adjustment command, so that the operating states of the lifting motor and the grain discharge motor are coordinated.

[0071] Furthermore, in one possible implementation of this disclosure, the acquisition unit 21 is further configured to: The pulse signal corresponding to the speed of the hoist motor is collected by a speed detection component installed on the drive shaft of the hoist. The actual speed of the booster motor is calculated based on the pulse signal.

[0072] Furthermore, in one possible implementation of this disclosure, the acquisition unit 21 is further configured to: The rotational speed detection assembly includes a speed measuring bracket fixed on the drive shaft of the hoist and a sensor for detecting the rotation of the speed measuring bracket; The actual speed of the lifting motor is calculated based on the ratio between the number of pulse signals collected by the sensor within the preset sampling time and the number of blades on the speed measuring bracket.

[0073] Furthermore, in one possible implementation of this disclosure embodiment, the determination unit 22 is further configured to: Calculate the percentage decrease in the actual speed of the boost motor relative to its rated speed; The lifting motor is judged to be overloaded or close to overloaded based on the descent ratio.

[0074] Furthermore, in one possible implementation of this disclosure embodiment, the generation unit 23 is further configured to: Calculate the target output frequency of the grain discharge motor inverter based on the load condition; The target output frequency is compared with a preset frequency range. If the target output frequency is between the preset minimum frequency and the initial frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the target output frequency. If the target output frequency is less than the preset minimum frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency.

[0075] Furthermore, in one possible implementation of the embodiments of this disclosure, such as Figure 5 As shown, it also includes: Recording unit 25 is used to record and store the speed measurement values ​​of the lifting motor and the historical frequency setting values ​​of the grain discharge motor inverter in the most recent few times; The fine-tuning unit 26 is used to determine whether the current speed of the grain discharge motor matches the speed of the lifting motor based on the changing trend of the measured speed value and the changing trend of the historical frequency setting value, and to adaptively fine-tune the operating frequency of the grain discharge motor inverter.

[0076] Furthermore, in one possible implementation of the embodiments of this disclosure, such as Figure 5 As shown, it also includes: The parameter preset unit 27 is used to preset control parameters based on the human-machine interface. The control parameters include the rated speed of the boost motor, the initial frequency of the grain discharge motor inverter, and the upper and lower limits of the frequency of the grain discharge motor inverter. The initial frequency is less than the upper limit and greater than or equal to the lower limit.

[0077] It should be noted that the foregoing explanation of the method embodiments also applies to the apparatus of the embodiments of this disclosure, and the principle is the same. Therefore, the embodiments of this disclosure are not limited thereto.

[0078] According to embodiments of this disclosure, this disclosure also provides an electronic device, a readable storage medium, and a computer program product.

[0079] Figure 6 A schematic block diagram of an example electronic device 400 that can be used to implement embodiments of the present disclosure is shown. The electronic device is intended to represent various forms of digital computers, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. The electronic device may also represent various forms of mobile devices, such as personal digital assistants, cellular phones, smartphones, wearable devices, and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the present disclosure described and / or claimed herein.

[0080] like Figure 6 As shown, the electronic device 400 includes a computing unit 401, which can perform various appropriate actions and processes based on a computer program stored in ROM (Read-Only Memory) 402 or a computer program loaded from storage unit 408 into RAM (Random Access Memory) 403. The RAM 403 may also store various programs and data required for the operation of the electronic device 400. The computing unit 401, ROM 402, and RAM 403 are interconnected via a bus 404. An I / O (Input / Output) interface 405 is also connected to the bus 404.

[0081] Multiple components in electronic device 400 are connected to I / O interface 405, including: input unit 406, such as keyboard, mouse, etc.; output unit 407, such as various types of displays, speakers, etc.; storage unit 408, such as disk, optical disk, etc.; and communication unit 409, such as network card, modem, wireless transceiver, etc. Communication unit 409 allows electronic device 400 to exchange information / data with other devices through computer networks such as the Internet and / or various telecommunications networks.

[0082] The computing unit 401 can be a variety of general-purpose and / or special-purpose processing components with processing and computing capabilities. Some examples of the computing unit 401 include, but are not limited to, CPUs (Central Processing Units), GPUs (Graphics Processing Units), various special-purpose AI (Artificial Intelligence) computing chips, various computing units running machine learning model algorithms, DSPs (Digital Signal Processors), and any suitable processor, controller, microcontroller, etc. The computing unit 401 performs the various methods and processes described above, such as the anti-clogging method for a grain dryer. For example, in some embodiments, the anti-clogging method for a grain dryer may be implemented as a computer software program tangibly contained in a machine-readable medium, such as storage unit 408. In some embodiments, part or all of the computer program may be loaded and / or installed on the electronic device 400 via ROM 402 and / or communication unit 409. When the computer program is loaded into RAM 403 and executed by the computing unit 401, one or more steps of the methods described above may be performed. Alternatively, in other embodiments, the computing unit 401 may be configured to perform the aforementioned anti-clogging method for the grain dryer by any other suitable means (e.g., by means of firmware).

[0083] Various implementations of the systems and techniques described above herein can be implemented in digital electronic circuit systems, integrated circuit systems, FPGAs (Field Programmable Gate Arrays), ASICs (Application-Specific Integrated Circuits), ASSPs (Application-Specific Standard Products), SOCs (System-on-Chips), CPLDs (Complex Programmable Logic Devices), computer hardware, firmware, software, and / or combinations thereof. These various implementations may include implementations in one or more computer programs that can be executed and / or interpreted on a programmable system including at least one programmable processor, which may be a dedicated or general-purpose programmable processor, capable of receiving data and instructions from a storage system, at least one input device, and at least one output device, and transmitting data and instructions to the storage system, the at least one input device, and the at least one output device.

[0084] The program code used to implement the methods of this disclosure may be written in any combination of one or more programming languages. This program code may be provided to a processor or controller of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus, such that when executed by the processor or controller, the program code causes the functions / operations specified in the flowcharts and / or block diagrams to be implemented. The program code may be executed entirely on a machine, partially on a machine, as a standalone software package partially on a machine and partially on a remote machine, or entirely on a remote machine or server.

[0085] In the context of this disclosure, a machine-readable medium can be a tangible medium that may contain or store a program for use by or in conjunction with an instruction execution system, apparatus, or device. A machine-readable medium can be a machine-readable signal medium or a machine-readable storage medium. A machine-readable medium can be, but is not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatus, or devices, or any suitable combination of the foregoing. More specific examples of machine-readable storage media include electrical connections based on one or more wires, portable computer disks, hard disks, RAM, ROM, EPROM (Electrically Programmable Read-Only Memory) or flash memory, optical fiber, CD-ROM (Compact Disc Read-Only Memory), optical storage devices, magnetic storage devices, or any suitable combination of the foregoing.

[0086] To provide interaction with a user, the systems and techniques described herein can be implemented on a computer having: a display device for displaying information to the user (e.g., a CRT (Cathode-Ray Tube) or LCD (Liquid Crystal Display) monitor); and a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the computer. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form (including sound input, voice input, or tactile input).

[0087] The systems and technologies described herein can be implemented in computing systems that include backend components (e.g., as data servers), or computing systems that include middleware components (e.g., application servers), or computing systems that include frontend components (e.g., user computers with graphical user interfaces or web browsers through which users can interact with implementations of the systems and technologies described herein), or any combination of such backend, middleware, or frontend components. The components of the system can be interconnected via digital data communication of any form or medium (e.g., communication networks). Examples of communication networks include LANs (Local Area Networks), WANs (Wide Area Networks), the Internet, and blockchain networks.

[0088] Computer systems can include clients and servers. Clients and servers are generally geographically separated and typically interact via communication networks. The client-server relationship is created by computer programs running on the respective computers and having a client-server relationship with each other. A server can be a cloud server, also known as a cloud computing server or cloud host, a hosting product within the cloud computing service system that addresses the shortcomings of traditional physical hosts and VPS (Virtual Private Server) services, such as high management difficulty and weak business scalability. Servers can also be servers for distributed systems or servers incorporating blockchain technology.

[0089] It's important to note that artificial intelligence (AI) is the study of enabling computers to simulate certain human thought processes and intelligent behaviors (such as learning, reasoning, thinking, and planning). It encompasses both hardware and software technologies. AI hardware technologies generally include sensors, dedicated AI chips, cloud computing, distributed storage, and big data processing. AI software technologies primarily include computer vision, speech recognition, natural language processing, machine learning / deep learning, big data processing, and knowledge graph technologies.

[0090] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this disclosure can be achieved, and this is not limited herein.

[0091] The specific embodiments described above do not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A method for preventing clogging in a grain dryer, characterized in that, include: Obtain the actual speed of the booster motor; The load state of the lifting motor is determined based on the deviation of the actual speed from the rated speed. Based on the load state, a speed adjustment command for the grain discharge motor is generated. The target output frequency of the grain discharge motor inverter is calculated by a preset frequency calculation model based on the decrease ratio R1 of the actual speed relative to the rated speed. The calculation formula of the frequency calculation model is: P1 is equal to the initial frequency P0 of the grain discharge motor inverter minus P0 multiplied by 2 multiplied by the decrease ratio R1 and then divided by 100. The speed of the grain discharge motor is adjusted according to the speed adjustment command to coordinate the operating states of the lifting motor and the grain discharge motor.

2. The method according to claim 1, characterized in that, The process of obtaining the actual speed of the lifting motor includes: The pulse signal corresponding to the speed of the hoist motor is collected by a speed detection component installed on the drive shaft of the hoist. The actual speed of the booster motor is calculated based on the pulse signal.

3. The method according to claim 2, characterized in that, The speed detection component includes a speed measuring bracket fixed to the drive shaft of the hoist and a sensor for detecting the rotation of the speed measuring bracket; the calculation of the actual speed of the hoisting motor based on the pulse signal includes: The actual speed of the lifting motor is calculated based on the ratio between the number of pulse signals collected by the sensor within the preset sampling time and the number of blades on the speed measuring bracket.

4. The method according to claim 1, characterized in that, Determining the load state of the hoisting motor based on the deviation of the actual rotational speed from the rated rotational speed includes: Calculate the percentage decrease in the actual speed of the boost motor relative to its rated speed; The lifting motor is judged to be overloaded or close to overloaded based on the descent ratio.

5. The method according to claim 1, characterized in that, The step of generating a speed adjustment command for the grain discharge motor based on the load state includes: Calculate the target output frequency of the grain discharge motor inverter based on the load condition; The target output frequency is compared with a preset frequency range. If the target output frequency is between the preset minimum frequency and the initial frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the target output frequency. If the target output frequency is less than the preset minimum frequency, an instruction is generated to adjust the operating frequency of the grain discharge motor inverter to the preset minimum frequency.

6. The method according to claim 1, characterized in that, The method further includes: Record and store the speed measurement values ​​of the lifting motor and the historical frequency setting values ​​of the grain discharge motor inverter in the most recent few times; Based on the changing trends of the measured rotational speed and the historical frequency setting, it is determined whether the current rotational speed of the grain discharge motor matches the rotational speed of the lifting motor, and the operating frequency of the grain discharge motor inverter is adaptively fine-tuned.

7. The method according to claim 1, characterized in that, The method further includes: Based on the preset control parameters of the human-machine interface, the control parameters include the rated speed of the boost motor, the initial frequency of the grain discharge motor inverter, and the upper and lower limits of the frequency of the grain discharge motor inverter; wherein, the initial frequency is less than the upper limit and greater than or equal to the lower limit.

8. An anti-clogging device for a grain dryer, characterized in that, include: The acquisition unit is used to acquire the actual speed of the lifting motor; The determination unit is used to determine the load state of the hoisting motor based on the deviation of the actual rotational speed from the rated rotational speed. The generation unit is used to generate a speed adjustment command for the grain discharge motor based on the load state. The target output frequency of the grain discharge motor inverter is calculated by a preset frequency calculation model based on the decrease ratio R1 of the actual speed relative to the rated speed. The calculation formula of the frequency calculation model is: P1 is equal to the initial frequency P0 of the grain discharge motor inverter minus P0 multiplied by 2 multiplied by the decrease ratio R1 and then divided by 100. The adjustment unit is used to adjust the speed of the grain discharge motor according to the speed adjustment command, so that the operating states of the lifting motor and the grain discharge motor are coordinated.

9. An electronic device, characterized in that, include: At least one processor; as well as A memory communicatively connected to the at least one processor; wherein, The memory stores instructions that can be executed by the at least one processor to enable the at least one processor to perform the method of any one of claims 1-7.

10. A non-transitory computer-readable storage medium storing computer instructions, characterized in that, The computer instructions are used to cause the computer to perform the method according to any one of claims 1-7.

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