A ceramic sand cooling device

Abstract

The application belongs to the technical field of ceramic sand preparation, and specifically discloses a ceramic sand stepwise cooling device, which comprises a rotary cooling kiln, a water cooling adjusting assembly, a temperature monitoring assembly and a control system; the rotary cooling kiln is sequentially divided into a first cooling zone, a second cooling zone and a third cooling zone along an axial direction; and a spray pipe that is independently controllable is arranged above each zone; the water cooling adjusting assembly realizes accurate adjustment of the spray flow of each zone through a partitioned water supply pipeline, an electric regulating valve and a flowmeter; the control system dynamically calculates a cooling rate deviation through a material temperature prediction model and a cooling strategy model based on a preset material forming quality and cooling rate relationship curve, in combination with real-time temperature and flow data, and intelligently adjusts the spray flow of each partition, so that the actual cooling rate is stably set in a set range. The application realizes stepwise and intelligent control of the ceramic sand cooling process, effectively improves product quality consistency, reduces cooling water consumption, and prolongs the service life of the equipment.

Description

Technical Field

[0001] This invention belongs to the field of ceramsite sand preparation technology, and specifically relates to a stepped cooling device for ceramsite sand. Background Technology

[0002] The rotary kiln is a key piece of equipment in the production of ceramsite sand, serving as the device for transforming ceramsite sand from a semi-finished product to a finished product. The semi-finished product enters the rotary kiln through the kiln tail, while natural gas, providing the heat source, enters the kiln through the kiln head burner. As the kiln rotates, the semi-finished product undergoes radial and axial displacement within the kiln, gradually absorbing heat and being calcined into the finished product. The calcined ceramsite sand then enters the cooling rotary kiln through a chute. The cooling process in the cooling rotary kiln is divided into internal cooling and external cooling. Internal cooling primarily occurs through contact between the ceramsite sand and flowing air, while external cooling mainly involves spraying natural water onto the kiln body, achieving an indirect cooling effect.

[0003] However, existing external kiln cooling methods typically employ uniform overflow without staged control based on the cooling characteristics of ceramsite sand at different temperature stages. Specifically, the lack of staged control over the cooling rate means that constant overflow not only wastes a large amount of cooling water resources and increases operating costs, but also leads to uneven heating of the kiln body due to localized overcooling or undercooling. Over long-term operation, this can easily cause kiln deformation or refractory material spalling, shortening the equipment's service life. Summary of the Invention

[0004] The purpose of this invention is to overcome the defects in the prior art and provide a stepped cooling device for ceramsite sand.

[0005] This invention provides a stepped cooling device for ceramsite sand, comprising: A cooling rotary kiln has a water collection tank at its bottom for collecting cooling water; a support block is installed inside the water collection tank, a drive bracket is installed on the support block, and at least two drive components are installed on the drive bracket to drive the cooling rotary kiln to rotate; an overflow box is installed at the top of the cooling rotary kiln, and several spray pipes are installed on both sides of the overflow box. The water-cooled regulating component includes several zoned water supply pipelines, electric regulating valves installed on each zoned water supply pipeline, and flow meters; the zoned water supply pipelines distribute cooling water in the overflow tank to each spray pipe; the electric regulating valves adjust the opening of their respective pipelines based on control commands to control the flow rate of cooling water to the corresponding spray pipes; the flow meters monitor the spray flow rate of their respective pipelines in real time. A temperature monitoring component is used to monitor the surface temperature and discharge temperature at a preset location of the cooling rotary kiln. The control system acquires control signals based on the discharge temperature requirements and cooling rate of the rotary kiln, acquires control commands based on the control signals, and sends control commands to drive the water-cooled regulating components to control the spray flow rate of each spray pipe, so as to adjust the cooling rate and the discharge temperature of the rotary kiln.

[0006] A further solution is to divide the rotary kiln into a primary cooling zone, a secondary cooling zone, and a tertiary cooling zone along its axis, with three separate water supply pipelines corresponding to the primary, secondary, and tertiary cooling zones respectively. The preset location of the cooling rotary kiln includes at least the boundary between the primary cooling zone and the secondary cooling zone, as well as the boundary between the secondary cooling zone and the tertiary cooling zone.

[0007] A further embodiment is that the control system includes a parameter setting module, a data acquisition module, a calculation and analysis module, and an optimization output module; The parameter setting module is used to set the target temperature of the final discharge of the ceramsite sand, and based on the preset material forming quality and cooling rate relationship curve, to set the corresponding benchmark cooling rates for the first-level cooling zone, the second-level cooling zone and the third-level cooling zone respectively. The data acquisition module is used to collect the water supply parameters of the water-cooled regulating component and the temperature parameters of the temperature monitoring component in real time. Based on the real-time collected parameter information, the calculation and analysis module dynamically calculates the real-time cooling rate of each cooling zone, and compares the real-time cooling rate with the corresponding benchmark cooling rate to obtain the cooling rate difference. ; The optimized output module is based on the cooling rate difference. Adjust the spray flow rate of the spray pipes in the water supply pipelines of each zone to achieve the difference in cooling rate. The flow rate approaches 0, and the spray flow rate of the spray pipe is converted into an opening control command corresponding to the electric regulating valve and sent to the electric regulating valve.

[0008] A further embodiment is that the data acquisition module includes: The temperature acquisition unit is used to acquire the temperature at the junction of the primary cooling zone and the secondary cooling zone, the temperature at the junction of the secondary cooling zone and the tertiary cooling zone, and the discharge temperature; Water acquisition unit, used to acquire the spray flow rate of each pipeline; The temperature difference calculation unit is used to calculate the real-time effective temperature difference of the first-level cooling zone, the second-level cooling zone, and the third-level cooling zone based on the real-time average temperature of the material in each cooling zone and the inlet temperature of the cooling water output by the material temperature prediction model. The dwell time acquisition unit calculates and acquires the theoretical dwell time of the ceramsite sand in the primary cooling zone, secondary cooling zone and tertiary cooling zone according to the rotation speed and tilt angle of the cooling rotary kiln. The initial temperature transfer unit is used to take the material entry temperature of the first-level cooling zone as a constant input, and to transfer the estimated material temperature at the end of the previous cooling zone as the initial temperature of the next cooling zone.

[0009] A further approach is that the construction process of the material temperature prediction model is as follows: The model inputs are the kiln wall surface temperature, cooling water flow rate into the cooling zone, cooling water inlet temperature, and real-time rotation speed of the rotary kiln corresponding to several cooling zones. The model outputs the real-time temperature of the material in the cooling zone. The neural network model is iteratively trained to obtain a material temperature prediction model that estimates the real-time average temperature of the material based on the kiln wall surface temperature, cooling water flow rate into the cooling zone, cooling water inlet temperature, and real-time rotation speed of the rotary kiln in the future.

[0010] A further solution is that the optimized output module has a pre-trained cooling strategy model built in. The cooling strategy model includes a labeling unit, a synchronization unit, and a matching unit. The labeling unit is used to label the cooling rate difference. After the annotation is completed, the synchronization unit will be used to make it possible The optimal spray flow rate adjustment for each spray pipe, approaching zero, is synchronized to the spray flow rate adjustment library; the marked cooling rate difference... It utilizes human experts in a large number of... Greater than the first threshold Less than the second threshold For positive and Negative cooling rate difference The spray flow rate adjustment is marked in the figure; the spray flow rate adjustment library is set up with three, which are used to store the optimal spray flow rate adjustment corresponding to the primary cooling zone, the secondary cooling zone and the tertiary cooling zone respectively; The matching unit is used to obtain the difference between the optimal spray flow rate adjustment and the cooling rate. The mapping relationship is established, and the real-time optimal spray flow adjustment amount for the corresponding cooling zone is selected from the spray flow adjustment library based on the mapping relationship.

[0011] A further solution is that the preset material forming quality and cooling rate relationship curve in the parameter setting module is obtained through training with historical process data, and is used to define the optimal cooling rate range corresponding to obtaining the best internal structural stability of the material and the minimum thermal stress crack defects at different cooling stages. The set value of the reference cooling rate is within the range of the optimal cooling rate for the corresponding stage.

[0012] A further embodiment is that the spray pipe has an arc-shaped structure, and several spray heads are arranged along the spray pipe.

[0013] A further embodiment is that the temperature monitoring component includes: At least two thermocouples are located at the junction of the primary cooling zone and the secondary cooling zone, as well as at the junction of the secondary cooling zone and the tertiary cooling zone; the thermocouples are embedded in the outer wall of the cooling rotary kiln, and a baffle plate is provided above each thermocouple mounting point to prevent overflow water from directly scouring the kiln. An infrared thermometer is installed at the discharge port of the cooling rotary kiln to measure the surface temperature of the final discharged ceramsite sand.

[0014] A further embodiment is that a temperature sensor is installed inside the overflow tank, and a coolant filling device is connected to the water supply pipe of the overflow tank. The optimized output module is connected to the temperature sensor signal to monitor the temperature of the cooling water in the overflow tank in real time. The optimized output module also has a preset cooling water temperature threshold. When the temperature value monitored by the temperature sensor exceeds the cooling water temperature threshold, the optimized output module sends a filling command to the filling device to inject a certain amount of coolant into the water supply pipe of the overflow tank to adjust the cooling water temperature in the overflow tank.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The control system of this invention acquires adjustment signals based on the discharge temperature requirements and cooling rate of the cooling rotary kiln, and then acquires control commands based on these signals to control the spray flow rate of each spray pipe, thereby adjusting the cooling rate and the discharge temperature of the cooling rotary kiln. This effectively suppresses defects such as thermal stress cracks caused by improper cooling. By dividing the cooling rotary kiln into primary, secondary, and tertiary cooling zones along its axial direction, and setting a benchmark cooling rate for each zone that conforms to the material cooling law, the cooling intensity at each stage is ensured to be constrained within the optimal range. Combined with real-time feedback from the temperature monitoring components and dynamic adjustments from the control system, the actual cooling rate can accurately follow the preset optimal process path, thus ensuring the integrity of the product's internal structure and the stability of its performance.

[0016] This invention establishes independent zoned water supply pipelines, each equipped with an electric regulating valve and flow meter. The control system dynamically adjusts the opening of the corresponding water supply pipelines based on the cooling rate requirements of each cooling zone, achieving on-demand distribution of cooling water. Furthermore, it dynamically optimizes based on real-time calculated cooling rate deviations, continuously seeking the minimum necessary water consumption to meet current cooling process requirements, and automatically corrects flow redundancy caused by changes in feed or environment, thereby achieving efficient utilization of water resources at its source.

[0017] Because of temperature differences at different locations within the kiln body, traditional uniform cooling methods easily lead to uneven axial heating of the kiln body. This invention's zoned control strategy achieves proactive and balanced temperature regulation of the kiln's outer wall. By monitoring the kiln wall temperature at key interface points and intelligently adjusting the spray intensity in corresponding areas, the system can achieve a more uniform distribution of heat load on the kiln surface, mitigating alternating thermal stress caused by localized overheating or undercooling. Furthermore, this invention addresses the issue of potentially reduced cooling capacity due to increased circulating cooling water temperature by incorporating an automatic coolant replenishment device, avoiding the negative impact of forcibly increasing the overall spray flow rate to compensate for the increased water temperature.

[0018] This invention introduces a data-driven material temperature prediction model. This model takes real-time collected data such as kiln wall temperature, cooling water parameters, and kiln rotation speed as input, and uses a pre-trained neural network to calculate the average temperature of the material in each cooling zone online. This solves the problem of directly and continuously measuring the material temperature inside the kiln, providing crucial state awareness for control decisions. Based on this, the system's built-in cooling strategy model further provides intelligent cooling decision-making. This model can quickly match real-time operating conditions with a knowledge base, simulating expert experience to generate precise spray flow adjustment commands. Operators only need to set the final target temperature and the baseline cooling rate for each cooling zone, and the system can automatically complete closed-loop control without manual intervention. Attached Figure Description

[0019] The following figures are for illustrative purposes only and are not intended to limit the scope of the invention, wherein: Figure 1 : Schematic diagram of the assembly structure of the present invention; Figure 2 Schematic diagram of rotary cooling zone kiln zoning; Figure 3 : Block diagram of the control system principle of this invention; Figure 4 : Schematic diagram of coolant filling; In the diagram: 1. Cooling rotary kiln; 2. Support block; 3. Drive bracket; 4. Drive component; 5. Support frame; 6. Overflow box; 7. Spray pipe; 8. Water collection tank; 9. Overflow hole; 10. Primary cooling zone; 11. Secondary cooling zone; 12. Tertiary cooling zone; 13. Zoned water supply pipeline; 14. Electric regulating valve; 15. Flow meter; 16. Control system; 17. Parameter setting module; 18. Data acquisition module; 19. Calculation and analysis module; 20. Optimization output module; 21. Temperature acquisition unit; 22. Water acquisition unit; 23. Temperature difference calculation unit; 24. Stagnation time acquisition unit; 25. Initial temperature transfer unit; 26. Material temperature prediction model; 27. Cooling strategy model; 28. Labeling unit; 29. ​​Synchronization unit; 30. Matching unit; 31. Thermocouple; 32. Coolant charging device; 33. Temperature sensor. Detailed Implementation

[0020] To make the objectives, technical solutions, design methods, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention.

[0021] like Figure 1 As shown, this embodiment provides a stepped cooling device for ceramsite sand, including a cooling rotary kiln 1. A water collection tank 8 is provided below the cooling rotary kiln 1 to collect cooling water. A support block 2 is provided inside the water collection tank 8, and a drive bracket 3 is provided on the support block 2. At least two drive components 4 are provided on the drive bracket 3 to drive the cooling rotary kiln 1 to rotate. An overflow box 6 is provided on the top of the cooling rotary kiln 1. The overflow box 6 is fixed to the top of the cooling rotary kiln 1 by a support frame 5. Several overflow holes 9 are provided on the top of the overflow box 6, and several spray pipes 7 are provided on both sides of the overflow box 6. The spray pipes 7 have an arc-shaped structure, and several nozzles are provided along the spray pipes 7. Figure 2As shown, the rotary kiln 1 is divided into three cooling zones along its axis, sequentially from the material inlet direction: primary cooling zone 10, secondary cooling zone 11, and tertiary cooling zone 12. A water-cooling regulating assembly is also installed inside the overflow tank 6, including three zone water supply pipelines 13 corresponding to the three cooling zones, electric regulating valves 14 installed on each zone water supply pipeline 13, and flow meters 15. The zone water supply pipelines 13 distribute the cooling water in the overflow tank 6 to each spray pipe 7. The electric regulating valves 14 adjust the opening of their respective pipelines based on control commands to control the flow rate of cooling water to the corresponding spray pipe 7. The flow meters 15 monitor the spray flow rate of their respective pipelines in real time. A temperature monitoring assembly is also included to monitor the preset position of the rotary kiln. The surface temperature and discharge temperature are measured. In this embodiment, the preset location of the cooling rotary kiln is the junction of the primary cooling zone 10 and the secondary cooling zone 11, and the junction of the secondary cooling zone 11 and the tertiary cooling zone 12. The temperature monitoring components specifically consist of two thermocouples 31 and an infrared thermometer. The two thermocouples 31 are located at the junction of the primary cooling zone 10 and the secondary cooling zone 11, and the junction of the secondary cooling zone 11 and the tertiary cooling zone 12. The thermocouples 31 are embedded in the outer wall of the cooling rotary kiln 1, and a baffle plate is provided above each thermocouple 31 installation point to prevent overflow water from directly scouring the surface. The infrared thermometer is located at the discharge port of the cooling rotary kiln to measure the surface temperature of the final discharged ceramsite sand. Figure 2 As shown, this embodiment also includes a control system 16 composed of a parameter setting module 17, a data acquisition module 18, a calculation and analysis module 19, and an optimization output module 20. The control system 16 acquires control signals based on the discharge temperature requirements and cooling rate of the rotary kiln 1, and acquires control commands based on these signals. The control system 16 then sends control commands to drive the water-cooling adjustment component to control the spray flow rate of each spray pipe 7, thereby adjusting the cooling rate and the discharge temperature of the rotary kiln 1. Specifically, the parameter setting module 17 is used to set the target temperature for the final discharge of the ceramsite sand, and based on a preset curve showing the relationship between material forming quality and cooling rate, sets corresponding benchmark cooling rates for the primary cooling zone 10, the secondary cooling zone 11, and the tertiary cooling zone 12. The data acquisition module 18 is used to collect the water supply parameters of the water-cooling adjustment component and the temperature parameters of the temperature monitoring component in real time. The calculation and analysis module 19 dynamically calculates the real-time cooling rate of each cooling zone based on the real-time collected parameter information, and compares the real-time cooling rate with the corresponding benchmark cooling rate to obtain the cooling rate difference. The optimized output module 20 is based on the cooling rate difference. Adjust the spray flow rate of the spray pipes 7 in each zone's water supply pipeline 13 to achieve the difference in cooling rate. The spray flow rate approaches 0, and the spray flow rate of the spray pipe 7 is converted into an opening control command corresponding to the electric regulating valve 14 and sent to the electric regulating valve 14.

[0022] In this embodiment, the cooling rate is affected by four factors: the duration of material residence in the cooling zone, the cooling water volume (determined by the spray flow rate), the initial temperature of the material, and the temperature difference between the material and the cooling water. In actual control, the duration of material residence in the cooling zone is determined by the rotational speed and inclination angle of the cooling rotary kiln 1, which is usually fixed in production. The initial temperature of the material is determined by the previous cooling zone and is a state variable that cannot be directly adjusted. The temperature difference between the material and the cooling water depends on the material temperature and the inlet temperature of the cooling water. The inlet temperature of the cooling water may be affected by the environment or reuse and is not always adjustable. Therefore, the main variable that can be actively adjusted is the spray flow rate. Thus, by adjusting the spray flow rate, the cooling intensity can be changed, thereby affecting the cooling rate. Approaching 0. Based on this, in the above:

[0023]

[0024] In the formula, For the first Cooling rate of each cooling zone For integers between 1 and 3, when When it is 1, it represents the cooling rate of the first-stage cooling zone 10. When it is 2, it represents the cooling rate of the secondary cooling zone 11. A value of 3 represents the cooling rate of the third-stage cooling zone 12. The reference cooling rate for each cooling zone is set by the parameter setting module 17. For the first Cooling water flow rate of each cooling zone The overall heat transfer coefficient is obtained through experimental or historical data fitting. For materials to enter the first The initial temperature of each cooling zone is set, wherein the initial temperature of the first-stage cooling zone 10 is set to the temperature at the end of the calcination process. For materials to leave the first The temperature of each cooling zone, wherein the temperature at which the material leaves the third-stage cooling zone is the discharge temperature. The dwell time of the material in each cooling zone is set to be the same in this embodiment.

[0025] In the above, the preset material forming quality and cooling rate relationship curve in the parameter setting module 17 is obtained through training with historical process data and is used to define the optimal cooling rate range corresponding to obtaining the best internal structural stability of the material and the minimum thermal stress crack defects at different cooling stages; the set value of the reference cooling rate is within the optimal cooling rate range of the corresponding stage.

[0026] Similarly, since the factors affecting the cooling rate are the material's dwell time in the cooling zone, the cooling water volume (determined by the spray flow rate), the initial temperature of the material, and the temperature difference between the material and the cooling water, the data acquisition module 18 includes a temperature acquisition unit 21, a water volume acquisition unit 22, a temperature difference calculation unit 23, and a dwell time acquisition unit 24. In this embodiment, the material flows continuously within the cooling rotary kiln 1 and sequentially passes through three cooling zones. The material temperature leaving the primary cooling zone is the same as the material temperature entering the secondary cooling zone; the temperature leaving the secondary cooling zone is the same as the temperature entering the tertiary cooling zone. To connect the three independent cooling zones into an organic whole in terms of control logic, the data acquisition module 18 also includes an initial temperature transmission unit 25, which uses the material temperature at the end of the previous zone calculated by the calculation and analysis module 19 as a key initial condition and transmits it in real time to the control logic of the next zone for calculation. Specifically, the temperature acquisition unit 21 is used to acquire the temperature at the junction of the primary cooling zone 10 and the secondary cooling zone 11, the temperature at the junction of the secondary cooling zone 11 and the tertiary cooling zone 12, and the discharge temperature; the water volume acquisition unit 22 is used to acquire the spray flow rate of each pipeline; the temperature difference calculation unit 23 is used to calculate the real-time effective temperature difference of the primary cooling zone 10, the secondary cooling zone 11, and the tertiary cooling zone 12 based on the real-time average temperature of the material in each cooling zone and the inlet temperature of the cooling water output by the material temperature prediction model 26; the dwell time acquisition unit 24 calculates and acquires the theoretical dwell time of the ceramsite sand in the primary cooling zone 10, the secondary cooling zone 11, and the tertiary cooling zone 12 based on the rotation speed and tilt angle of the cooling rotary kiln 1; and the initial temperature transmission unit 25 is used to take the material entry temperature of the primary cooling zone 10 as a constant input and transmit the estimated material temperature at the end of the previous cooling zone as the initial temperature of the next cooling zone.

[0027] In this embodiment, the material temperature prediction model 26 aims to establish a mapping relationship between key operating parameters of the cooling process and the real-time temperature of the material through a data-driven approach, thereby achieving indirect, continuous, and high-precision prediction of the material temperature inside the kiln and providing core temperature feedback for the control system.

[0028] The material temperature prediction model 26 calculates the average temperature of the ceramsite sand material in each cooling zone in real time based on the kiln wall surface temperature, cooling water parameters, and rotational speed. The cooling process of the material in the rotary kiln is a complex heat exchange process, mainly affected by factors such as kiln wall heat transfer, spray water cooling, and material residence time. By collecting a large amount of historical or experimental data covering different operating conditions, and utilizing the nonlinear fitting capability of neural networks, the intrinsic physical relationship between these input parameters and material temperature is learned, thereby constructing a black-box prediction model.

[0029] Data collection was conducted in the following ways: Kiln wall surface temperature: collected in real time in each cooling zone by thermocouples 31 embedded and protected by baffles.

[0030] Cooling water flow rate and inlet water temperature: These are collected in real time by flow meters 15 on each zone's water supply pipeline 13 and temperature sensors 33 installed in the main water supply pipe or overflow box 6.

[0031] Real-time rotational speed of the rotary kiln: obtained from the frequency converter or encoder signal of drive component 4.

[0032] Real-time material temperature: The real-time temperature of the material in different cooling zones is measured by an infrared thermometer. Specifically, an observation window is opened on the kiln wall. The observation window is made of high-purity quartz glass with low bubble content. The infrared thermometer is fixed outside the kiln and aimed at the material flow in the window. Multiple windows can be arranged to simultaneously collect the temperature of the material in different cooling zones as training parameters for the model.

[0033] Simultaneously, the input parameters (kiln wall temperature, water flow rate, water temperature, rotation speed) at a certain moment and the material surface temperature measured by the infrared thermometer at the corresponding moment are recorded. After calibration and averaging, this temperature can approximately represent the real-time average temperature of the material in the cooling zone. By changing the operating conditions such as spray flow rate and rotation speed, a large amount of sample data covering different working conditions is collected to form a training dataset.

[0034] A feedforward neural network is used as the basic architecture. Iterative training is performed using kiln wall temperature, cooling water flow rate, cooling water inlet temperature, and rotational speed as input layer features, and real-time material temperature as the output layer target. Finally, an independent test set is used to evaluate the model's prediction accuracy, ensuring it can make reliable predictions on unseen new data. The trained material temperature prediction model 26 is integrated into the calculation and analysis module 19 of the control system 16. During actual operation, the system acquires the current input parameters in real time, inputs them into the model, and then outputs an estimate of the average material temperature in each cooling zone in real time.

[0035] In the above, the optimized output module 20 has a pre-trained cooling strategy model 27 built in; the cooling strategy model 27 is a decision-making model driven by expert experience and historical data, based on the real-time calculated cooling rate deviation. It can quickly find and output the optimal spray flow rate adjustment to achieve precise and stable control of the cooling process.

[0036] The cooling strategy model 27 includes a labeling unit 28, a synchronization unit 29, and a matching unit 30. The labeling unit 28 is used to label the cooling rate difference. After the annotation is completed, the synchronization unit 29 will be used to make it possible The optimal spray flow rate adjustment for each spray pipe 7, approaching 0, is synchronized to the spray flow rate adjustment library; the marked cooling rate difference... It utilizes human experts in a large number of... Greater than the first threshold Less than the second threshold For positive and Negative cooling rate difference The spray flow rate adjustment is marked in the code; the spray flow rate adjustment library has three parts, which are used to store the optimal spray flow rate adjustment for the primary cooling zone 10, the secondary cooling zone 11, and the tertiary cooling zone 12, respectively; specifically, during the system debugging phase, a large amount of operating condition data is collected, including the cooling rate difference at a certain moment. And the results given by human experts after observation and judgment, which enable... The optimal spray flow rate adjustment effectively approaches zero. Human experts analyzed various typical... The situations are marked. Among them, typical ones are... include: Typical Size and typical The positive and negative signs, for example, Operating conditions greater than 30°C / min and Operating conditions less than 30°C / min. (The marked text appears to be incomplete and requires further context.) The correspondence between the optimal adjustment amounts is stored in three spray flow adjustment databases, corresponding to the primary cooling zone 10, the secondary cooling zone 11, and the tertiary cooling zone 12, respectively. Each adjustment database can be a multidimensional lookup table or a set of organized rules.

[0037] The matching unit 30 is used to obtain the difference between the optimal spray flow rate adjustment and the cooling rate. The matching unit 30 establishes a mapping relationship and selects the optimal real-time spray flow adjustment for the corresponding cooling zone from the spray flow adjustment library based on this mapping relationship. In actual operation, the matching unit 30 continuously receives real-time cooling rate differences from the calculation and analysis module 19. Matching unit 30 will currently The value is matched against the labeled states stored in the spray flow adjustment library. If a perfectly matching state is found, the corresponding optimal adjustment amount is directly output. If no perfectly matching state is found, a nearest neighbor search or multidimensional interpolation algorithm is used to calculate a reasonable adjustment amount from the adjacent labeled states. The calculated optimal spray flow adjustment amount is converted into the corresponding opening change command of the electric regulating valve 14 and sent to the actuator through the optimization output module 20, thereby completing one control closed loop.

[0038] In this embodiment, since the overflow tank 6 is located at the top of the cooling rotary kiln 1, the water temperature inside the overflow tank 6 will rise as cooling proceeds. To achieve automatic adjustment of the water temperature inside the overflow tank 6, such as... Figure 4 As shown, a temperature sensor 33 is installed inside the overflow tank 6, and a coolant filling device 32 is connected to the water supply pipe of the overflow tank 6. The optimization output module 20 is signal-connected to the temperature sensor 33 and is used to monitor the temperature of the cooling water in the overflow tank 6 in real time. The optimization output module 20 is also preset with a cooling water temperature threshold. When the temperature value monitored by the temperature sensor 33 exceeds the cooling water temperature threshold, the optimization output module 20 sends a filling command to the filling device to inject a certain amount of coolant into the water supply pipe of the overflow tank 6 to adjust the cooling water temperature in the overflow tank 6.

[0039] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or technical improvements to the embodiments in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A stepped cooling device for ceramsite sand, characterized in that, include: A cooling rotary kiln (1) is provided with a water collection tank (8) below it for receiving cooling water; a support block (2) is provided inside the water collection tank (8), a drive bracket (3) is provided on the support block (2), and at least two drive components (4) are provided on the drive bracket (3) to drive the cooling rotary kiln (1) to rotate; an overflow box (6) is provided on the top of the cooling rotary kiln (1), and several spray pipes (7) are provided on both sides of the overflow box (6); The water-cooled regulating component includes several zone water supply pipelines (13), an electric regulating valve (14) installed on each zone water supply pipeline (13), and a flow meter (15); the zone water supply pipelines (13) distribute the cooling water in the overflow tank (6) to each spray pipe (7); the electric regulating valve (14) adjusts the opening of its pipeline based on control commands to control the flow rate of cooling water to the corresponding spray pipe (7); the flow meter (15) monitors the spray flow rate of its pipeline in real time; Temperature monitoring component, used to monitor the surface temperature and discharge temperature at a preset position of the cooling rotary kiln (1); The control system (16) obtains a control signal based on the discharge temperature requirement and cooling rate of the rotary kiln (1), obtains a control command based on the control signal, and sends a control command to drive the water-cooled adjustment component to control the spray flow of each spray pipe (7) in order to adjust the cooling rate and the discharge temperature of the rotary kiln (1).

2. The stepped cooling device for ceramsite sand according to claim 1, characterized in that, The rotary kiln (1) is divided into a primary cooling zone (10), a secondary cooling zone (11) and a tertiary cooling zone (12) along its axial direction. The partition water supply pipeline (13) is provided with three lines, which correspond to the primary cooling zone (10), the secondary cooling zone (11) and the tertiary cooling zone (12) respectively. The preset location of the cooling rotary kiln (1) includes at least the junction of the primary cooling zone (10) and the secondary cooling zone (11) as well as the junction of the secondary cooling zone (11) and the tertiary cooling zone (12).

3. The stepped cooling device for ceramsite sand according to claim 2, characterized in that, The control system (16) includes a parameter setting module (17), a data acquisition module (18), a calculation and analysis module (19), and an optimization output module (20). The parameter setting module (17) is used to set the target temperature of the final discharge of the ceramsite sand, and based on the preset material forming quality and cooling rate relationship curve, to set the corresponding reference cooling rates for the first-level cooling zone (10), the second-level cooling zone (11) and the third-level cooling zone (12). The data acquisition module (18) is used to collect the water supply parameters of the water-cooled regulating component and the temperature parameters of the temperature monitoring component in real time. The calculation and analysis module (19) dynamically calculates the real-time cooling rate of each cooling zone based on the real-time collected parameter information, and compares the real-time cooling rate with the corresponding reference cooling rate to obtain the cooling rate difference. ; The optimized output module (20) is based on the cooling rate difference. Adjust the spray flow rate of the spray pipes (7) in each zone's water supply pipeline (13) to achieve the difference in cooling rate. The flow rate approaches 0, and the spray flow rate of the spray pipe (7) is converted into the opening control command of the electric regulating valve (14) and sent to the electric regulating valve (14).

4. The stepped cooling device for ceramsite sand according to claim 3, characterized in that, The data acquisition module (18) includes: Temperature acquisition unit (21) is used to acquire the temperature at the junction of the primary cooling zone (10) and the secondary cooling zone (11), the temperature at the junction of the secondary cooling zone (11) and the tertiary cooling zone (12), and the discharge temperature; Water acquisition unit (22) is used to acquire the spray flow rate of each pipeline; The temperature difference calculation unit (23) is used to calculate the real-time effective temperature difference of the first-level cooling zone (10), the second-level cooling zone (11) and the third-level cooling zone (12) respectively based on the real-time average temperature of the material in each cooling zone and the inlet temperature of the cooling water output by the material temperature prediction model (26). The dwell time acquisition unit (24) calculates and acquires the theoretical dwell time of the ceramsite sand in the first-level cooling zone (10), the second-level cooling zone (11) and the third-level cooling zone (12) according to the rotation speed and tilt angle of the cooling rotary kiln (1); The initial temperature transfer unit (25) is used to take the material entry temperature of the first-level cooling zone (10) as a constant input and to transfer the estimated material temperature at the end of the previous cooling zone as the initial temperature of the next cooling zone.

5. The stepped cooling device for ceramsite sand according to claim 4, characterized in that, The construction process of the material temperature prediction model (26) is as follows: The kiln wall surface temperature, cooling water flow rate into the cooling zone, cooling water inlet temperature, and real-time rotation speed of the cooling rotary kiln (1) corresponding to several cooling zones are used as model inputs. The real-time temperature of the material in the cooling zone is used as the model output for iterative training of the neural network model to obtain a material temperature prediction model (26) for predicting the real-time average temperature of the material output based on the kiln wall surface temperature, cooling water flow rate into the cooling zone, cooling water inlet temperature, and real-time rotation speed of the cooling rotary kiln (1) in the future.

6. The stepped cooling device for ceramsite sand according to claim 5, characterized in that, The optimized output module (20) has a pre-trained cooling strategy model (27) built in. The cooling strategy model (27) is equipped with a labeling unit (28), a synchronization unit (29), and a matching unit (30). The labeling unit (28) is used to label the cooling rate difference. After the annotation is completed, the synchronization unit (29) will be used to make it possible The optimal spray flow rate adjustment for each spray pipe (7) approaching 0 is synchronized to the spray flow rate adjustment library; the marked cooling rate difference It utilizes human experts in a large number of... Greater than the first threshold Less than the second threshold For positive and Negative cooling rate difference The spray flow rate adjustment amount is marked in the middle; the spray flow rate adjustment library is set up with three, which are used to store the optimal spray flow rate adjustment amount corresponding to the first-level cooling zone (10), the second-level cooling zone (11) and the third-level cooling zone (12) respectively; The matching unit (30) is used to obtain the difference between the optimal spray flow rate adjustment and the cooling rate. The mapping relationship is established, and the real-time optimal spray flow adjustment amount for the corresponding cooling zone is selected from the spray flow adjustment library based on the mapping relationship.

7. The stepped cooling device for ceramsite sand according to claim 6, characterized in that, The preset material forming quality and cooling rate relationship curve in the parameter setting module (17) is obtained by training with historical process data and is used to define the optimal cooling rate range corresponding to obtaining the best internal structural stability of the material and the minimum thermal stress crack defects at different cooling stages. The set value of the reference cooling rate is within the range of the optimal cooling rate for the corresponding stage.

8. The stepped cooling device for ceramsite sand according to claim 7, characterized in that, The spray pipe (7) has an arc-shaped structure, and several nozzles are arranged along the spray pipe (7).

9. The stepped cooling device for ceramsite sand according to claim 8, characterized in that, The temperature monitoring component includes: At least two thermocouples (31) are located at the junction of the primary cooling zone (10) and the secondary cooling zone (11) and at the junction of the secondary cooling zone (11) and the tertiary cooling zone (12); the thermocouples (31) are embedded in the outer wall of the cooling rotary kiln (1), and a baffle plate is provided above the mounting point of each thermocouple (31) to prevent overflow water from directly scouring the surface; An infrared thermometer is installed at the discharge port of the cooling rotary kiln (1) to measure the surface temperature of the final discharged ceramsite sand.

10. A stepped cooling device for ceramsite sand according to claim 9, characterized in that, A temperature sensor (33) is installed inside the overflow tank (6), and a coolant filling device (32) is also connected to the water supply pipe of the overflow tank (6). The optimized output module (20) is connected to the temperature sensor (33) for real-time monitoring of the temperature of the cooling water in the overflow tank (6). The optimized output module (20) also has a preset cooling water temperature threshold. When the temperature value monitored by the temperature sensor (33) exceeds the cooling water temperature threshold, the optimized output module (20) sends a filling command to the filling device to inject a certain amount of coolant into the water supply pipe of the overflow tank (6) to adjust the cooling water temperature in the overflow tank (6).

Images