Sintering flue dust valve control system and method thereof

Abstract

This invention discloses a control system and method for ash discharge valves in sintering flues, belonging to the field of sintering production technology. The invention includes a left flue and a right flue, with multiple sets of ash discharge valves evenly distributed on both flues. The ash discharge valves in the left flue are interlocked with the conveyor belt of the left bulk material system; the ash discharge valves in the right flue are interlocked with the conveyor belt of the right bulk material system. This invention, through grouped and rotating ash discharge, avoids problems such as belt overload, blockage, and spillage caused by concentrated ash discharge, ensuring thorough ash discharge from the ash hopper. The interlocking of the ash discharge valves with the belt is stable and reliable and supports single-action debugging, effectively improving system operational safety and debugging flexibility. Simultaneously, it incorporates a three-step stepped parameter optimization scheme, which is tailored to on-site conditions, convenient to debug, and highly adaptable to various operating conditions, significantly reducing the blockage of ash discharge valves at the head and tail of the large flue. The entire scheme achieves fully automatic closed-loop control, comprehensively improving the operational stability and overall efficiency of the bulk material conveying system.

Description

Technical Field

[0001] This invention relates to the field of sintering production technology, and more specifically, to a control system and method for a sintering flue ash discharge valve. Background Technology

[0002] During the sintering machine production process, the sintering flue is equipped with numerous double-layer ash discharge valves via dual dust collection pipes to periodically discharge deposited materials into the bulk material conveyor system. Traditional ash discharge control methods often employ simple timed control, which has the following problems:

[0003] (1) The ash discharge valves do not have a reasonable grouping and rotation logic, which can easily lead to belt overload, material spillage and blockage due to concentrated ash discharge;

[0004] (2) The ash discharge valve and the bulk material conveyor belt have a simple interlock relationship, and the start and stop are not synchronized, which can easily cause ash accumulation, air leakage or equipment idling and waste energy;

[0005] (3) The operating parameters were not set according to the different characteristics of ash accumulation and blockage in the ash hopper at different locations of the main flue, which caused the ash discharge valve to be easily blocked;

[0006] (4) There is a lack of step-by-step production practice optimization methods. On-site debugging relies on experience, resulting in low automation and poor operational stability.

[0007] The invention patent publication number is CN219141520U, entitled "Rapid Ash Discharge and Dust Evacuation Device for Ash Hopper in Sintering Machine Large Flue". It utilizes the suction force of the main exhaust fan to draw air into the ash hopper through the pipe, quickly disrupting the equilibrium state of the dust particles suspended in the upper part of the ash hopper and accelerating the dust particles to fall into the ash discharge valve, thus enabling smooth ash discharge. The ash discharge logic, such as the time interval and duration of ash discharge for each ash hopper, is written in the control unit 13 of this patent, which uses the grouped and segmented control logic of the ash discharge valves of each ash hopper. Furthermore, the focus of this patent is to achieve smooth ash discharge from the large flue ash hopper, which is different from this patent.

[0008] Patent CN219572705U describes an intelligent ash discharge system for sintering flue ash hoppers. While this patent uses level gauges to control the ash discharge valves, level gauges installed inside the sintering flue under high temperature and pressure conditions are prone to damage and unsuitable for long-term use. This patent employs a complete method of "group rotation timing calculation and differentiated intervals based on blockage characteristics" to effectively vent the ash discharge valve group; the solution is simple and practical.

[0009] Therefore, there is an urgent need for a bulk material unloading control method that can be grouped and rotated, has precise timing, reliable interlocking, and can adaptively adjust according to the blockage situation. Summary of the Invention

[0010] 1. The technical problem that the invention aims to solve

[0011] To address the problems of uneven ash discharge, easy blockage, uncoordinated interlocking, and low automation level in existing sintering machine bulk material unloading systems, this invention provides a sintering flue ash discharge valve control system and method. Through group rotation, timing calculation, step-by-step parameter optimization, and belt delay interlocking, the ash discharge system achieves stable, efficient, and fully automatic operation.

[0012] 2. Technical Solution

[0013] To achieve the above objectives, the technical solution provided by this invention is as follows:

[0014] The present invention discloses a sintering flue ash discharge valve control system, comprising a left flue and a right flue respectively arranged on both sides along the sintering direction, wherein multiple sets of ash discharge valves are evenly distributed on the left and right flues, and are divided into left flue ash discharge valves and right flue ash discharge valves according to their location; the left flue ash discharge valve is interlocked with the left bulk material system conveyor belt; the right flue ash discharge valve is interlocked with the right bulk material system conveyor belt; the left bulk material system conveyor belt and the right bulk material system conveyor belt are jointly arranged on the displacement path of the main belt of the bulk material system.

[0015] Furthermore, the left flue ash discharge valve includes left odd-numbered group A ash discharge valve, left odd-numbered group B ash discharge valve, left odd-numbered group C ash discharge valve and left odd-numbered group D ash discharge valve; the right flue ash discharge valve includes right even-numbered group A ash discharge valve, right even-numbered group B ash discharge valve, right even-numbered group C ash discharge valve and right even-numbered group D ash discharge valve.

[0016] The odd-numbered A-group ash discharge valves on the left and the even-numbered A-group ash discharge valves on the right are respectively installed in the material feeding and ignition sections of the sintering flue.

[0017] The odd-numbered Group B ash discharge valves on the left and the even-numbered Group B ash discharge valves on the right are respectively installed in the low-temperature section of the sintering flue.

[0018] The odd-numbered C-group ash discharge valves on the left and the even-numbered C-group ash discharge valves on the right are respectively installed in the medium-temperature section of the sintering flue.

[0019] The odd-numbered group D ash discharge valve on the left and the even-numbered group D ash discharge valve on the right are respectively installed in the high-temperature section of the sintering flue.

[0020] The ash discharge valves in the corresponding groups on the left and right sides operate synchronously.

[0021] A method for controlling the ash discharge valve in a sintering flue, comprising the following steps:

[0022] Step 1: System Interlocking and Grouping Settings

[0023] The sintering flue is divided into a left flue and a right flue arranged side by side. Multiple sets of ash discharge valves are evenly distributed on the left and right flues. The ash discharge valves are grouped according to their location in the flue. The ash discharge valves in the corresponding groups on the left and right sides operate synchronously, and each valve group is interlocked with the conveyor belt of the bulk material system in the corresponding area.

[0024] Step 2: Construct a time-series calculation model for the ash unloading cycle

[0025] The rotation time and interval of each set of ash discharge valves can be set on the computer control screen. A calculation model is established based on the total ash discharge time, number of actions, single action time, number of valve groups, and interval time.

[0026]

[0027] In the formula:

[0028] T 总 Total ash unloading time for each group;

[0029] n: Number of times the ash discharge valve is activated in each group;

[0030] T 固定 : Single action time of the ash discharge valve;

[0031] N: Number of ash discharge valves in each group;

[0032] T 间隔 Valve operation interval time;

[0033] Step 3: Three-step production practice parameter optimization

[0034] The ash unloading cycle operating parameters were gradually optimized in three stages: the first stage adopted a 30-minute cycle and a total ash unloading time of 6 minutes per group for trial operation; the second stage extended the cycle to 60 minutes and the total ash unloading time of 12 minutes per group; the third stage, based on the operating characteristic that the ash unloading valves at the head and tail of the main flue are more likely to be blocked than those in the middle, the action interval time was set differently for valve groups at different positions.

[0035] Step 4: Belt Delay Interlock Control for Bulk Material Handling System

[0036] Full-process interlocking closed-loop control: Following the control principle of "starting the belt first, then opening the ash discharge valve, closing the ash discharge valve first, and then stopping the belt", the control process of sequentially starting the bulk material belt, rotating the ash discharge valve in groups, delaying the valve closure after ash discharge, and sequentially stopping the bulk material belt is executed in sequence. The ash discharge cycle is automatically executed in a cycle according to the set standby time, and an abnormal working condition interlocking protection mechanism is configured.

[0037] Step 5: Fully Automatic Closed-Loop Control

[0038] In step three, after the second-stage parameter optimization is completed, the program automatically controls the ash discharge valve to stop and the bulk material conveyor belt to stop sequentially; the automatic start of the conveyor belt and the waiting timer after ash discharge are established to achieve automatic control of the entire ash discharge-ash conveying process.

[0039] Furthermore, in step two, T固定 The time for one operation of the upper and lower valves of the sintering double-layer ash discharge valve is set to 8 seconds; T 间隔 Set to 10 seconds.

[0040] Furthermore, step three specifically includes:

[0041] 3-1: The first step of production practice adopts a 30-minute cycle.

[0042] The total ash unloading time for each group should be controlled within 6 minutes.

[0043] Group A performed the movement 3 times, T 间隔 =10s, T 轮动 =33s;

[0044] Group D exercises 2 times, T 间隔 =10s, T 轮动 =118s;

[0045] Groups B and C each perform one action, T 间隔 =10s, T 轮动 The values ​​are 298s and 280s respectively.

[0046] After 6 minutes of ash discharge, delay for 1.5 minutes to stop the ash discharge valve and sequentially stop the bulk material conveyor belt; after 30 minutes of standby, restart the system and observe the ash discharge situation for 6-8 minutes. Adjust the number of actions and time parameters according to the degree of ash hopper discharge.

[0047] 3-2: The second step of production practice adopts a 60-minute cycle.

[0048] Based on the success of the first step, the total ash unloading time for each group is extended to 12 minutes:

[0049] Group A, 6 repetitions, T 间隔 =10s, T 轮动 =76s;

[0050] Group D exercises 4 times, T 间隔 =10s, T 轮动 =187s;

[0051] Groups B and C each performed the movement 3 times, T 间隔 =10s, T 轮动 The times are 297s and 280s, respectively.

[0052] After 12 minutes of ash unloading, delay for 1.5 minutes to stop the ash unloading valve and the bulk material conveyor belt; after 60 minutes of standby, restart and observe the ash unloading effect for 12-15 minutes, and optimize and adjust the parameters.

[0053] 3-3 Third step of production practice: settings differentiated according to the degree of blockage.

[0054] Based on the fact that the probability of clogging of the ash discharge valves at the head and tail of the main flue is higher than that in the middle section, the single valve operating time and interval time are set for the ash discharge valves respectively:

[0055] The single-run time of all ash discharge valves is uniformly set to 18 seconds.

[0056] The interval between ash discharge valves in the middle of the main flue is shortened, while the interval between ash discharge valves at the head and tail ends is correspondingly extended.

[0057] Different interval times are set for the left and right ash discharge valves to reduce the occurrence of blockages.

[0058] Furthermore, step four is described in detail below:

[0059] 4-1: Interlocking Mode Selection and Initial Condition Determination

[0060] The system is set to two working modes: interlocking automatic mode and screen-based single-action mode.

[0061] In interlocked automatic mode, the ash discharge valve can only be started if the corresponding bulk material conveyor belt is running; if the belt fails, stops, or is not started, the corresponding ash discharge valve must not be opened.

[0062] In single-action mode, the interlock between the ash discharge valve and the belt can be released, allowing the ash discharge valve or belt to be operated independently on the control screen for maintenance, debugging, and single-point testing.

[0063] Initial condition determination: The automatic ash unloading program can only be entered when the system is powered on, there is no emergency stop, no fault, and the interlock is effectively engaged.

[0064] 4-2: Sequential Start-up Control of Bulk Conveyor Belts

[0065] After receiving the ash discharge start command, the system does not open the ash discharge valve directly, but first starts each bulk material conveyor belt according to the preset delay.

[0066] The belt start delay is set as follows:

[0067] The left-side bulk material conveyor belt has a delay of 83 seconds;

[0068] The conveyor belt of the bulk material handling system on the right side has a delay of 83 seconds;

[0069] The main belt of the bulk material handling system is delayed by 90 seconds.

[0070] The control system starts the belts sequentially according to the delay time, ensuring that the upstream belt starts first and the downstream belt starts later, forming a continuous and stable ash conveying channel; the corresponding area ash discharge valve can only be put into operation after each belt has started in place and fed back the operation signal.

[0071] 4-3: Group rotation and interlocking action of ash discharge valves

[0072] After all the belts have started and are running stably, the system starts the ash discharge valve rotation program in the order of groups A, B, C, and D.

[0073] The ash discharge valve in the left flue only operates when the conveyor belt of the left bulk material system is running; the ash discharge valve in the right flue only operates when the conveyor belt of the right bulk material system is running.

[0074] The left and right ash discharge valves in each group operate synchronously, with the valves operating sequentially at a set interval of 10 seconds to avoid excessive ash discharge caused by simultaneous ash discharge.

[0075] Each group operates in a cyclical manner according to the calculated rotation time, completing the set number of ash unloading cycles within the total ash unloading cycle;

[0076] During the ash unloading process, if the corresponding belt suddenly stops, the system will immediately interlock and close all ash unloading valves on that side to prevent ash accumulation, blockage, and spillage.

[0077] 4-4: Delayed valve stop control after ash unloading is completed

[0078] When the set total ash unloading time is over, the system does not stop the belt immediately, but continues to run the belt and closes all ash unloading valves after a delay of 1.5 minutes;

[0079] During the delay period, the belt continues to run, conveying away the accumulated dust remaining in the chute and on the belt, thus avoiding downtime while carrying material.

[0080] After the delay period, all ash discharge valves are closed and a signal indicating that they are fully closed is received.

[0081] 4-5: Sequential Stop Control of Bulk Conveyor Belts

[0082] 4-6: Cyclic Loop and Automatic Restart Control

[0083] 4-7: Interlocking protection for abnormal operating conditions.

[0084] Furthermore, 4-5 specifically refers to:

[0085] After all the ash discharge valves are closed, the system stops the bulk conveyor belt in the reverse order of startup.

[0086] The stopping process still follows its respective delay parameters to ensure that the belt stops under no-load conditions segment by segment, without dust accumulation or material pressure.

[0087] After all the conveyor belts have stopped, the ash unloading cycle ends and the system enters standby mode.

[0088] Furthermore, the aforementioned 4-6 specifically refers to

[0089] In the first step of the experiment, after 30 minutes of standby, the system automatically restarts the conveyor belt and the ash discharge valve, and enters the next ash discharge cycle;

[0090] In the second step of the practice, the system automatically restarts after 60 minutes of standby, achieving a longer period of stable ash removal;

[0091] After each restart, the system automatically checks the belt status, interlocking conditions, and gray position status. If the conditions are met, it continues to run automatically; otherwise, it remains in standby mode and triggers an alarm.

[0092] Furthermore, 4-7 specifically refers to:

[0093] If the belt is overloaded, runs off-track, or tears, immediately interlock and close the corresponding ash discharge valve;

[0094] When the ash discharge valve is subjected to excessive torque or fails to switch properly, it will automatically skip the valve and trigger an alarm, without affecting the operation of other valves and belts in the same group.

[0095] When the ash hopper is at a high level, the system will automatically increase the number of ash discharges or shorten the interval to prevent ash blockage.

[0096] 3. Beneficial effects

[0097] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0098] This invention avoids belt overload, material blockage, and spillage caused by centralized ash discharge through grouped, rotating ash discharge, ensuring thorough ash discharge from the ash hopper. The ash discharge valve and belt interlock are stable and reliable, and support single-action debugging, effectively improving system operation safety and debugging flexibility. It also features a three-step stepped parameter optimization scheme that fits the on-site working conditions, is easy to debug, and has strong adaptability. By differentiating the ash discharge interval based on blockage characteristics, it significantly reduces blockage of the ash discharge valves at the head and tail of the main flue. The entire solution achieves fully automatic closed-loop control, reducing manual intervention and comprehensively improving the operational stability and overall efficiency of the bulk material conveying system. Attached Figure Description

[0099] Figure 1 This is a system structure diagram of the present invention.

[0100] In the diagram: 1. Left flue; 2. Right flue; 3. Left flue ash discharge valve; 31. Left odd-numbered A group ash discharge valve; 32. Left odd-numbered B group ash discharge valve; 33. Left odd-numbered C group ash discharge valve; 34. Left odd-numbered D group ash discharge valve; 4. Right flue ash discharge valve; 41. Right even-numbered A group ash discharge valve; 42. Right even-numbered B group ash discharge valve; 43. Right even-numbered C group ash discharge valve; 44. Right even-numbered D group ash discharge valve; 5. Left bulk material system conveyor belt; 6. Right bulk material system conveyor belt; 7. Bulk material system main belt. Detailed Implementation

[0101] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0102] Example 1

[0103] from Figure 1 As can be seen, the sintering flue ash discharge valve control system of this embodiment includes a left flue 1 and a right flue 2 respectively arranged on both sides along the sintering direction. Multiple sets of ash discharge valves are evenly distributed on the left flue 1 and the right flue 2, and are divided into left flue ash discharge valve 3 and right flue ash discharge valve 4 according to their location. The left flue ash discharge valve 3 is interlocked with the left bulk material system conveyor belt 5; the right flue ash discharge valve 4 is interlocked with the right bulk material system conveyor belt 6; the left bulk material system conveyor belt 5 and the right bulk material system conveyor belt 6 are jointly arranged on the displacement path of the main belt 7 of the bulk material system.

[0104] The left flue ash discharge valve 3 includes left odd-numbered group A ash discharge valve 31, left odd-numbered group B ash discharge valve 32, left odd-numbered group C ash discharge valve 33, and left odd-numbered group D ash discharge valve 34; the right flue ash discharge valve 4 includes right even-numbered group A ash discharge valve 41, right even-numbered group B ash discharge valve 42, right even-numbered group C ash discharge valve 43, and right even-numbered group D ash discharge valve 44.

[0105] The odd-numbered A-group ash discharge valve 31 on the left and the even-numbered A-group ash discharge valve 41 on the right are respectively installed in the material distribution and ignition sections of the sintering flue.

[0106] The odd-numbered B-group ash discharge valve 32 on the left and the even-numbered B-group ash discharge valve 42 on the right are respectively installed in the low-temperature section of the sintering flue.

[0107] The odd-numbered C-group ash discharge valve 33 on the left and the even-numbered C-group ash discharge valve 43 on the right are respectively installed in the medium-temperature section of the sintering flue.

[0108] The odd-numbered group D ash discharge valve 34 on the left and the even-numbered group D ash discharge valve 44 on the right are respectively installed in the high-temperature section of the sintering flue.

[0109] The ash discharge valves in the corresponding groups on the left and right sides operate synchronously.

[0110] Example 2

[0111] from Figure 1 As can be seen, the steps of the sintering flue ash discharge valve control method in this embodiment are as follows:

[0112] Step 1: System Interlocking and Grouping Settings

[0113] The sintering flue is divided into a left flue 1 and a right flue 2 arranged side by side. Multiple sets of ash discharge valves are evenly distributed on the left flue 1 and the right flue 2. The ash discharge valves are grouped according to the location of the flue. The ash discharge valves in the corresponding groups on the left and right sides operate synchronously, and each valve group establishes an interlock control relationship with the bulk material system belt in the corresponding area.

[0114] It also supports disengaging the interlock on the control screen, enabling the belt to be operated manually on its own.

[0115] This embodiment takes a 360㎡ sintering machine as an example. The sintering machine has a double dust collection pipe, i.e., flue structure. It is equipped with 36 sintering ash discharge valves, which are evenly distributed in the two flues. All of them adopt a periodic timed automatic ash discharge mode. The sintering ash discharge valves in the two flues are divided into four groups: A, B, C, and D. They are divided into left and right sides, with the left side numbered with odd numbers and the right side numbered with even numbers. The corresponding groups on the left and right sides operate synchronously and run synchronously with the conveyor belt of the bulk material system. The specific layout structure is the same as in Embodiment 1.

[0116] Based on the characteristics of sintering production, the sintering flue section corresponding to Group A ash discharge valve and Group D ash discharge valve has more scattered material, while the sintering flue section corresponding to Group B ash discharge valve and Group C ash discharge valve has less scattered material but more water vapor.

[0117] Step 2: Construct a time-series calculation model for the ash unloading cycle

[0118] The rotation time and interval of each set of ash discharge valves can be set on the computer control screen. A calculation model is established based on the total ash discharge time, number of actions, single action time, number of valve groups, and interval time.

[0119]

[0120] In the formula:

[0121] T 总 Total ash unloading time for each group;

[0122] n: Number of times the ash discharge valve is activated in each group;

[0123] T 固定 : Single action time of the ash discharge valve; T 固定 The time for the upper and lower valves of the sintering double-layer ash discharge valve to operate once is set to 8 seconds.

[0124] N: Number of ash discharge valves in each group;

[0125] T 间隔 : Valve operation interval time; T 间隔 Set to 10 seconds;

[0126] Step 3: Three-step production practice parameter optimization

[0127] The ash unloading cycle operating parameters were gradually optimized in three stages: the first stage adopted a 30-minute cycle and a total ash unloading time of 6 minutes per group for trial operation; the second stage extended the cycle to 60 minutes and the total ash unloading time of 12 minutes per group; the third stage, based on the operating characteristic that the ash unloading valves at the head and tail of the main flue are more likely to be blocked than those in the middle, the action interval time was set differently for valve groups at different positions.

[0128] Step three specifically involves:

[0129] 3-1: The first step of production practice adopts a 30-minute cycle.

[0130] The total ash unloading time for each group should be controlled within 6 minutes.

[0131] Group A performed the movement 3 times, T 间隔 =10s, T 轮动 =33s;

[0132] Group D exercises 2 times, T 间隔 =10s, T 轮动 =118s;

[0133] Groups B and C each perform one action, T 间隔 =10s, T 轮动 The values ​​are 298s and 280s respectively.

[0134] After 6 minutes of ash discharge, delay for 1.5 minutes to stop the ash discharge valve and sequentially stop the bulk material conveyor belt; after 30 minutes of standby, restart the system and observe the ash discharge situation for 6-8 minutes. Adjust the number of actions and time parameters according to the degree of ash hopper discharge.

[0135] 3-2: The second step of production practice adopts a 60-minute cycle.

[0136] Based on the success of the first step, the total ash unloading time for each group is extended to 12 minutes:

[0137] Group A, 6 repetitions, T 间隔 =10s, T 轮动 =76s;

[0138] Group D exercises 4 times, T 间隔 =10s, T 轮动 =187s;

[0139] Groups B and C each performed the movement 3 times, T 间隔 =10s, T 轮动 The times are 297s and 280s, respectively.

[0140] After 12 minutes of ash unloading, delay for 1.5 minutes to stop the ash unloading valve and the bulk material conveyor belt; after 60 minutes of standby, restart and observe the ash unloading effect for 12-15 minutes, and optimize and adjust the parameters.

[0141] 3-3 Third step of production practice: settings differentiated according to the degree of blockage.

[0142] Based on the fact that the probability of clogging of the ash discharge valves at the head and tail of the main flue is higher than that in the middle section, the single valve operating time and interval time are set for the ash discharge valves respectively:

[0143] The single-run time of all ash discharge valves is uniformly set to 18 seconds.

[0144] The interval between ash discharge valves in the middle of the main flue is shortened, while the interval between ash discharge valves at the head and tail ends is correspondingly extended.

[0145] Different interval times are set for the left and right ash discharge valves to reduce the occurrence of blockages.

[0146]

[0147] The principle for setting this time is that the blockage of the ash discharge valves at the head and tail of the main flue is greater than that of the ash discharge valves in the middle, so the operating interval of the ash discharge valves in the middle of the main flue is shorter.

[0148] Step 4: Belt Delay Interlock Control for Bulk Material Handling System

[0149] Full-process interlocking closed-loop control: Following the control principle of "starting the belt first, then opening the ash discharge valve, closing the ash discharge valve first, and then stopping the belt", the control process of sequentially starting the bulk material belt, rotating the ash discharge valve in groups, delaying the valve closure after ash discharge, and sequentially stopping the bulk material belt is executed in sequence. The ash discharge cycle is automatically executed in a cycle according to the set standby time, and an abnormal working condition interlocking protection mechanism is configured.

[0150] Step four, the specific steps are as follows:

[0151] 4-1: Interlocking Mode Selection and Initial Condition Determination

[0152] The system is set to two working modes: interlocking automatic mode and screen-based single-action mode.

[0153] In interlocked automatic mode, the ash discharge valve can only be started if the corresponding bulk material conveyor belt is running; if the belt fails, stops, or is not started, the corresponding ash discharge valve must not be opened.

[0154] In single-action mode, the interlock between the ash discharge valve and the belt can be released, allowing the ash discharge valve or belt to be operated independently on the control screen for maintenance, debugging, and single-point testing.

[0155] Initial condition determination: The automatic ash unloading program can only be entered when the system is powered on, there is no emergency stop, no fault, and the interlock is effectively engaged.

[0156] 4-2: Sequential Start-up Control of Bulk Conveyor Belts

[0157] After receiving the ash discharge start command, the system does not open the ash discharge valve directly, but first starts each bulk material conveyor belt according to the preset delay.

[0158] The belt start delay is set as follows:

[0159] Left bulk material handling system conveyor belt 5 delay 83 seconds;

[0160] The delay time for conveyor belt 6 of the bulk material handling system on the right is 83 seconds.

[0161] The delay time for the main belt 7 of the bulk material handling system is set together for 90 seconds.

[0162] The control system starts the belts sequentially according to the delay time, ensuring that the upstream belt starts first and the downstream belt starts later, forming a continuous and stable ash conveying channel; the corresponding area ash discharge valve can only be put into operation after each belt has started in place and fed back the operation signal.

[0163] 4-3: Group rotation and interlocking action of ash discharge valves

[0164] After all the belts have started and are running stably, the system starts the ash discharge valve rotation program in the order of groups A, B, C, and D.

[0165] The left flue ash discharge valve 3 only operates when the left bulk material system conveyor belt 5 is running; the right flue ash discharge valve 4 only operates when the right bulk material system conveyor belt 6 is running.

[0166] The left and right ash discharge valves in each group operate synchronously, with the valves operating sequentially at a set interval of 10 seconds to avoid excessive ash discharge caused by simultaneous ash discharge.

[0167] Each group operates in a cyclical manner according to the calculated rotation time, completing the set number of ash unloading cycles within the total ash unloading cycle;

[0168] During the ash unloading process, if the corresponding belt suddenly stops, the system will immediately interlock and close all ash unloading valves on that side to prevent ash accumulation, blockage, and spillage.

[0169] 4-4: Delayed valve stop control after ash unloading is completed

[0170] When the set total ash unloading time is over, the system does not stop the belt immediately, but continues to run the belt and closes all ash unloading valves after a 1.5-minute delay;

[0171] During the delay period, the belt continues to run, conveying away the accumulated dust remaining in the chute and on the belt, thus avoiding downtime while carrying material.

[0172] After the delay period, all ash discharge valves are closed and a signal indicating that they are fully closed is received.

[0173] 4-5: Sequential stop control of bulk material conveyor belts;

[0174] Specifically:

[0175] After all the ash discharge valves are closed, the system stops the bulk conveyor belt in the reverse order of startup.

[0176] The stopping process still follows its respective delay parameters to ensure that the belt stops under no-load conditions segment by segment, without dust accumulation or material pressure.

[0177] After all the conveyor belts have stopped, the current ash unloading cycle ends, and the system enters standby mode.

[0178] 4-6: Cyclic Loop and Automatic Restart Control;

[0179] Specifically:

[0180] In the first step of the experiment, after 30 minutes of standby, the system automatically restarts the conveyor belt and the ash discharge valve, and enters the next ash discharge cycle;

[0181] In the second step of the practice, the system automatically restarts after 60 minutes of standby, achieving a longer period of stable ash removal;

[0182] After each restart, the system automatically checks the belt status, interlocking conditions, and gray position status. If the conditions are met, it continues to run automatically; otherwise, it remains in standby mode and triggers an alarm.

[0183] 4-7: Interlocking protection for abnormal operating conditions.

[0184] Specifically:

[0185] If the belt is overloaded, runs off-track, or tears, immediately interlock and close the corresponding ash discharge valve;

[0186] When the ash discharge valve is subjected to excessive torque or fails to switch properly, it will automatically skip the valve and trigger an alarm, without affecting the operation of other valves and belts in the same group.

[0187] When the ash hopper is at a high level, the system will automatically increase the number of ash discharges or shorten the interval to prevent ash blockage.

[0188] Step 5: Fully automatic closed-loop control;

[0189] In step three, after the second-stage parameter optimization is completed, the program automatically controls the ash discharge valve to stop and the bulk material conveyor belt to stop sequentially; the automatic start of the conveyor belt and the waiting timer after ash discharge are established to achieve automatic control of the entire ash discharge-ash conveying process.

[0190] This embodiment uses 36 sintering ash discharge valves evenly distributed on a 360m² sintering machine. Four groups (A, B, C, and D) are used for synchronous left-right rotation control. A timing calculation model is established, and the ash discharge cycle parameters are gradually optimized through three production practice steps: Step 1: 30-minute cycle, 6-minute ash discharge; Step 2: 60-minute cycle, 12-minute ash discharge; Step 3: Differentiated interval time settings based on the tendency of the large flue to clog at the beginning and end. Simultaneously, a fixed delay is set for the bulk material conveyor belt, achieving interlocking between the ash discharge valves and the belt, and fully automatic closed-loop operation. This invention effectively avoids material blockage, spillage, and ash discharge valve clogging, improving the system's automation level and operational stability. It is suitable for controlling bulk material dust removal and ash discharge systems in sintering machines.

[0191] This invention proposes a complete control method that calculates the timing of group rotations and differentiates intervals based on blockage characteristics. Compared with existing technical solutions that are limited to partial improvements such as hardware interlocking, single valve timing, and material level control, this invention constructs a complete overall control process and supporting parameter system. Moreover, this method is closely aligned with the actual working conditions of the sintering machine, and the parameters are clear and can be directly implemented, thus meeting the requirements for patent applicability.

[0192] This invention avoids belt overload, material blockage, and spillage caused by centralized ash discharge through grouped, rotating ash discharge, ensuring thorough ash discharge from the ash hopper. The ash discharge valve and belt interlock are stable and reliable, and support single-action debugging, effectively improving system operation safety and debugging flexibility. It also features a three-step stepped parameter optimization scheme that fits the on-site working conditions, is easy to debug, and has strong adaptability. By differentiating the ash discharge interval based on blockage characteristics, it significantly reduces blockage of the ash discharge valves at the head and tail of the main flue. The entire solution achieves fully automatic closed-loop control, reducing manual intervention and comprehensively improving the operational stability and overall efficiency of the bulk material conveying system.

[0193] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A sintering flue ash discharge valve control system, comprising a left flue (1) and a right flue (2) respectively arranged on both sides along the sintering direction, characterized in that: Multiple sets of ash discharge valves are evenly distributed on the left flue (1) and right flue (2), and are divided into left flue ash discharge valve (3) and right flue ash discharge valve (4) according to their location; the left flue ash discharge valve (3) is interlocked with the left bulk material system conveyor belt (5); the right flue ash discharge valve (4) is interlocked with the right bulk material system conveyor belt (6); the left bulk material system conveyor belt (5) and the right bulk material system conveyor belt (6) are set together on the displacement path of the main belt (7) of the bulk material system.

2. The sintering flue ash discharge valve control system according to claim 1, characterized in that: The left flue ash discharge valve (3) includes left odd-numbered A group ash discharge valve (31), left odd-numbered B group ash discharge valve (32), left odd-numbered C group ash discharge valve (33), and left odd-numbered D group ash discharge valve (34); the right flue ash discharge valve (4) includes right even-numbered A group ash discharge valve (41), right even-numbered B group ash discharge valve (42), right even-numbered C group ash discharge valve (43), and right even-numbered D group ash discharge valve (44). The odd-numbered A-group ash discharge valve (31) on the left and the even-numbered A-group ash discharge valve (41) on the right are respectively installed in the material feeding and ignition sections of the sintering flue; The odd-numbered B-group ash discharge valve (32) on the left and the even-numbered B-group ash discharge valve (42) on the right are respectively installed in the low-temperature section of the sintering flue; The odd-numbered C-group ash discharge valve (33) on the left and the even-numbered C-group ash discharge valve (43) on the right are respectively set in the medium temperature section of the sintering flue; The left-side odd-numbered group D ash discharge valve (34) and the right-side even-numbered group D ash discharge valve (44) are respectively set in the high-temperature section of the sintering flue; The ash discharge valves in the corresponding groups on the left and right sides operate synchronously.

3. The method for controlling the ash discharge valve in a sintering flue according to claim 1, characterized in that: The steps are as follows: Step 1: System Interlocking and Grouping Settings The sintering flue is divided into a left flue (1) and a right flue (2) arranged side by side. Multiple sets of ash discharge valves are evenly distributed on the left flue (1) and the right flue (2). The ash discharge valves are grouped according to the location of the flue. The ash discharge valves in the corresponding groups on the left and right sides operate synchronously, and each valve group establishes an interlock control relationship with the conveyor belt of the bulk material system in the corresponding area. Step 2: Construct a time-series calculation model for the ash unloading cycle The rotation time and interval of each set of ash discharge valves can be set on the computer control screen. A calculation model is established based on the total ash discharge time, number of actions, single action time, number of valve groups, and interval time. In the formula: T 总 Total ash unloading time for each group; n: Number of times the ash discharge valve is activated in each group; T 固定 : Single action time of the ash discharge valve; N: Number of ash discharge valves in each group; T 间隔 Valve operation interval time; Step 3: Three-step production practice parameter optimization The ash unloading cycle operating parameters were gradually optimized in three stages: the first stage adopted a 30-minute cycle and a total ash unloading time of 6 minutes per group for trial operation; the second stage extended the cycle to 60 minutes and the total ash unloading time of 12 minutes per group; the third stage, based on the operating characteristic that the ash unloading valves at the head and tail of the main flue are more likely to be blocked than those in the middle, the action interval time was set differently for valve groups at different positions. Step 4: Belt Delay Interlock Control for Bulk Material Handling System Full-process interlocking closed-loop control: Following the control principle of "starting the belt first, then opening the ash discharge valve, closing the ash discharge valve first, and then stopping the belt", the control process of sequentially starting the bulk material belt, rotating the ash discharge valve in groups, delaying the valve closure after ash discharge, and sequentially stopping the bulk material belt is executed in sequence. The ash discharge cycle is automatically executed in a cycle according to the set standby time, and an abnormal working condition interlocking protection mechanism is configured. Step 5: Fully Automatic Closed-Loop Control In step three, after the second-stage parameter optimization is completed, the program automatically controls the ash discharge valve to stop and the bulk material conveyor belt to stop sequentially; the automatic start of the conveyor belt and the waiting timer after ash discharge are established to achieve automatic control of the entire ash discharge-ash conveying process.

4. The method for controlling the ash discharge valve in a sintering flue according to claim 1, characterized in that: In step two, T 固定 The time for one operation of the upper and lower valves of the sintering double-layer ash discharge valve is set to 8 seconds; T 间隔 Set to 10 seconds.

5. The method for controlling the ash discharge valve in a sintering flue according to claim 1, characterized in that: Step three specifically includes: 3-1: The first step of production practice adopts a 30-minute cycle. The total ash unloading time for each group should be controlled within 6 minutes. Group A performed the movement 3 times, T 间隔 =10s, T 轮动 =33s; Group D exercises 2 times, T 间隔 =10s, T 轮动 =118s; Groups B and C each perform one action, T 间隔 =10s, T 轮动 The values ​​are 298s and 280s respectively. After 6 minutes of ash discharge, delay for 1.5 minutes to stop the ash discharge valve and sequentially stop the bulk material conveyor belt; after 30 minutes of standby, restart the system and observe the ash discharge situation for 6-8 minutes, adjusting the number of actions and time parameters according to the degree of ash hopper emptying. 3-2: The second step of production practice adopts a 60-minute cycle. Based on the success of the first step, the total ash unloading time for each group is extended to 12 minutes: Group A, 6 repetitions, T 间隔 =10s, T 轮动 =76s; Group D exercises 4 times, T 间隔 =10s, T 轮动 =187s; Groups B and C each performed the movement 3 times, T 间隔 =10s, T 轮动 The times are 297s and 280s, respectively. After 12 minutes of ash unloading, delay for 1.5 minutes to stop the ash unloading valve and the bulk material conveyor belt; after 60 minutes of standby, restart and observe the ash unloading effect for 12-15 minutes, and optimize and adjust the parameters. 3-3 Third step of production practice: settings differentiated according to the degree of blockage. Based on the fact that the probability of clogging of the ash discharge valves at the head and tail of the main flue is higher than that in the middle section, the single valve operating time and interval time are set for the ash discharge valves respectively: The single-run time of all ash discharge valves is uniformly set to 18 seconds. The interval between ash discharge valves in the middle of the main flue is shortened, while the interval between ash discharge valves at the head and tail ends is correspondingly extended. Different interval times are set for the left and right ash discharge valves to reduce the occurrence of blockages.

6. The method for controlling the ash discharge valve in a sintering flue according to claim 1, characterized in that: Step four, as described above, consists of the following steps: 4-1: Interlocking Mode Selection and Initial Condition Determination The system is set to two working modes: interlocking automatic mode and screen-based single-action mode. In interlocked automatic mode, the ash discharge valve can only be started if the corresponding bulk material conveyor belt is running; if the belt fails, stops, or is not started, the corresponding ash discharge valve must not be opened. In single-action mode, the interlock between the ash discharge valve and the belt can be released, allowing the ash discharge valve or belt to be operated independently on the control screen for maintenance, debugging, and single-point testing. Initial condition determination: The automatic ash unloading program can only be entered when the system is powered on, there is no emergency stop, no fault, and the interlock is effectively engaged. 4-2: Sequential Start-up Control of Bulk Conveyor Belts After receiving the ash discharge start command, the system does not open the ash discharge valve directly, but first starts each bulk material conveyor belt according to the preset delay. The belt start delay is set as follows: The left-side bulk material system conveyor belt (5) has a delay of 83 seconds; The right-side bulk material system conveyor belt (6) has a delay of 83 seconds; The main belt (7) of the bulk material system is set to delay for 90 seconds; The control system starts the belts sequentially according to the delay time, ensuring that the upstream belt starts first and the downstream belt starts later, forming a continuous and stable ash conveying channel; the corresponding area ash discharge valve can only be put into operation after each belt has started in place and fed back the operation signal. 4-3: Group rotation and interlocking action of ash discharge valves After all the belts have started and are running stably, the system starts the ash discharge valve rotation program in the order of groups A, B, C, and D. The left flue ash discharge valve (3) operates only when the left bulk material system conveyor belt (5) is running; the right flue ash discharge valve (4) operates only when the right bulk material system conveyor belt (6) is running. The left and right ash discharge valves in each group operate synchronously, with the valves operating sequentially at a set interval of 10 seconds to avoid excessive ash discharge caused by simultaneous ash discharge. Each group operates in a cyclical manner according to the calculated rotation time, completing the set number of ash unloading cycles within the total ash unloading cycle; During the ash unloading process, if the corresponding belt suddenly stops, the system will immediately interlock and close all ash unloading valves on that side to prevent ash accumulation, blockage, and spillage. 4-4: Delayed valve stop control after ash unloading is completed When the set total ash unloading time is over, the system does not stop the belt immediately, but continues to run the belt and closes all ash unloading valves after a 1.5-minute delay; During the delay period, the belt continues to run, conveying away the accumulated dust remaining in the chute and on the belt, thus avoiding downtime while carrying material. After the delay period, all ash discharge valves are closed and a signal indicating that they are fully closed is received. 4-5: Sequential Stop Control of Bulk Conveyor Belts 4-6: Cyclic Loop and Automatic Restart Control 4-7: Interlocking protection for abnormal operating conditions.

7. The method for controlling the ash discharge valve in a sintering flue according to claim 6, characterized in that: Specifically, 4-5 refers to: After all the ash discharge valves are closed, the system stops the bulk conveyor belt in the reverse order of startup. The stopping process still follows its respective delay parameters to ensure that the belt stops under no-load conditions segment by segment, without dust accumulation or material pressure. After all the conveyor belts have stopped, the current ash unloading cycle ends, and the system enters standby mode.

8. The method for controlling the ash discharge valve in a sintering flue according to claim 6, characterized in that: The 4-6 mentioned above are specifically... In the first step of the experiment, after 30 minutes of standby, the system automatically restarts the conveyor belt and the ash discharge valve, and enters the next ash discharge cycle; In the second step of the practice, the system automatically restarts after 60 minutes of standby, achieving a longer period of stable ash removal; After each restart, the system automatically checks the belt status, interlocking conditions, and gray position status. If the conditions are met, it continues to run automatically; otherwise, it remains in standby mode and triggers an alarm.

9. The method for controlling the ash discharge valve in a sintering flue according to claim 6, characterized in that: Specifically, 4-7 refers to: If the belt is overloaded, runs off-track, or tears, immediately interlock and close the corresponding ash discharge valve; When the ash discharge valve is subjected to excessive torque or fails to switch properly, it will automatically skip the valve and trigger an alarm, without affecting the operation of other valves and belts in the same group. When the ash hopper is at a high level, the system will automatically increase the number of ash discharges or shorten the interval to prevent ash blockage.

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