Automatic control method for sintering machine old trolley return on-line unloading

Abstract

The application provides a sintering machine old trolley return online unloading automatic control method, which acquires the return speed, the old trolley absolute position, the preset action time and the completion position in real time, determines the trigger position of the shifting rod and the trigger position of the lifting respectively; when the old trolley absolute position decreases to the trigger position of the shifting rod, the mobile trolley and the return trolley group are controlled to be synchronized and the old trolley to be unloaded and the front and rear adjacent trolleys are shifted apart; after the shifting is completed, the trolley group continues to move, the lifting is started when the old trolley reaches the trigger position of the lifting, the old trolley is lifted to the adsorption position below the electromagnetic suspension device, and then the electromagnetic suspension device adsorbs the old trolley and recycles the lifting device. The application realizes the online unloading of the old trolley under the condition that the sintering machine does not stop and the return trolley group is not disassembled, reduces the stop loss, and improves the automation degree and safety of the unloading operation.

Description

Technical Field

[0001] This invention relates to the field of sintering technology, and in particular to an automatic control method for online unloading of old sintering machine trolleys during return trip. Background Technology

[0002] The sintering machine trolley is the core load-bearing equipment in sintering production. It operates for extended periods in high-temperature, heavy-load, and dusty environments, making its components prone to damage and requiring regular disassembly and replacement. Currently, the industry commonly uses manual labor in conjunction with overhead cranes to unload old trolleys.

[0003] When replacing an old sintering trolley using existing technology, feeding must first be stopped, the faulty trolley moved to a suitable position at the tail of the machine, and then the tail hydraulic device is activated to move the tail moving frame backward, causing the faulty trolley to lose its forward and backward thrust. The entire machine is then stopped, and the old trolley is lifted out manually with the assistance of a crane. This method has the following drawbacks: First, the downtime is relatively long, usually exceeding one hour; second, the downtime causes fluctuations in the sintering production process, reducing the quality of the sintered ore; third, material must be cleared before the lifting equipment is in operation, and the installation of the lifting equipment occupies a significant amount of equipment space, making it difficult to economically retrofit existing sintering machines.

[0004] In addition, manual hoisting and unloading procedures are cumbersome, slow in action, have large alignment deviations, and unstable work rhythm. Long-term high-intensity work can easily lead to personnel fatigue, making it difficult to meet the needs of rapid on-site maintenance and batch replacement of trolleys. Moreover, the entire process relies on manual operation and lacks automated control methods. It is difficult to collect and trace the operation status, equipment condition and fault information in real time, which cannot support intelligent production management.

[0005] Meanwhile, the old trolley moves continuously with the returning trolley group, and the trolleys are subject to pushing constraints due to the tail hammer. If they are lifted or moved directly without stopping the machine, mechanical interference and impact are likely to occur. Existing technology has not yet solved the problem of how to unload the old trolley online without stopping the machine.

[0006] In view of this, it is necessary to propose an automatic control method for online unloading of old sintering machine trolleys during return trip to solve or at least alleviate the above-mentioned defects. Summary of the Invention

[0007] The main objective of this invention is to provide an automatic control method for online unloading of old sintering machine trolleys during return stroke, in order to solve the technical problem of how to reliably unload old trolleys that are in continuous return stroke and subject to pushing constraints without stopping the sintering machine.

[0008] To achieve the above objectives, the present invention provides an automatic control method for online unloading of old sintering machine trolleys during return trips, comprising the following steps: S1, obtain the return speed of the sintering machine trolley, the absolute position of the old trolley, the preset lever action duration, the preset lifting action duration, the preset disengagement completion position, and the preset adsorption completion position; S2, determine the lifting trigger position based on the return speed, the preset lifting action duration and the preset adsorption completion position, so that after the lifting device is started when the absolute position of the old trolley decreases to the lifting trigger position, the absolute position of the old trolley can decrease to the preset adsorption completion position when it is lifted into place. S3. Determine the lever trigger position based on the return speed, preset lever action duration, preset disengagement completion position, and lifting trigger position. This allows the moving trolley to start when the absolute position of the old trolley decreases to the lever trigger position and synchronize with the return trolley group. Furthermore, when the hydraulic lever device is disengaged in the synchronized state, the absolute position of the old trolley is still greater than the lifting trigger position. S4, when the absolute position of the old trolley decreases to the lever trigger position, the moving trolley outputs a lever start command in a synchronized state, causing the hydraulic lever device to push away the old trolley to be unloaded from the trolleys immediately in front and behind; after receiving the push-away signal, when the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output, causing the lifting device to lift the old trolley to be unloaded. S5, upon receiving the lifting-in-place signal, controls the electromagnetic suspension device to adsorb and carry the old trolley to be unloaded; upon receiving the adsorption completion signal, outputs a lifting and recovery command; upon receiving the recovery-in-place signal, outputs a signal indicating that the old trolley has completed its return and online unloading.

[0009] Preferably, step S2 includes the following steps: S21, obtain the preset adsorption completion position; wherein, the preset adsorption completion position is the absolute position of the old trolley when the lifting device is lifted into place and the old trolley to be unloaded is in the adsorption position below the electromagnetic suspension device. S22, based on the real-time acquired return speed and the preset lifting action duration, determine the predicted return displacement of the mobile trolley as it moves with the return trolley group during the lifting device's operation. S23, take the sum of the preset adsorption completion position and the predicted return displacement as the lifting trigger position, so that after the lifting device is activated when the absolute position of the old trolley decreases to the lifting trigger position, it can lift the old trolley into place when the absolute position of the old trolley decreases to the preset adsorption completion position; S24, before outputting the lifting command, update the predicted return displacement and the lifting trigger position according to the real-time acquired return speed, and use the updated lifting trigger position as the comparison benchmark for determining whether to output the lifting command.

[0010] Preferably, step S3 includes the following steps: S31, determine the predicted return displacement of the lever based on the currently acquired return speed and the preset lever action duration; S32, the sum of the preset opening completion position and the predicted return displacement of the lever is taken as the candidate lever trigger position; S33, take the absolute position of the old trolley when the absolute position of the old trolley is reduced to the trigger position of the candidate lever as the starting position; subtract the predicted return displacement of the lever from the starting position as the predicted value of the absolute position of the old trolley when the hydraulic lever device is moved to the position. S34, when the predicted absolute position of the old trolley is greater than or equal to the lifting trigger position, the candidate lever trigger position is taken as the lever trigger position; when the predicted absolute position of the old trolley is less than the lifting trigger position, the lever start command is prohibited from being output, and a signal indicating that the lever and lifting timing do not meet is output. S35, before outputting the lever start command, update the predicted return displacement of the lever, the candidate lever trigger position, the starting position, and the predicted value of the absolute position of the old trolley according to the real-time acquired return speed; when the updated predicted value of the absolute position of the old trolley is greater than or equal to the lifting trigger position, the updated candidate lever trigger position is used as the lever trigger position, and the updated lever trigger position is used as the comparison benchmark for judging whether the absolute position of the old trolley has decreased to the lever trigger position.

[0011] Preferably, step S4 includes the following steps: S41, when the absolute position of the old trolley decreases to the trigger position of the lever, control the moving trolley to accelerate to synchronize with the return trolley group, and output the lever start command when the moving trolley is synchronized with the return trolley group. S42, after outputting the lever start command, obtain the lever displacement and lever holding pressure of the hydraulic lever device; S43, when the displacement of the lever reaches the preset disengagement displacement and the holding pressure of the lever is within the preset holding pressure range, it is determined that the old trolley to be unloaded and the adjacent trolleys in front and behind are disengaged in place, and a disengagement in place signal is output; when the displacement of the lever does not reach the preset disengagement displacement or the holding pressure of the lever is not within the preset holding pressure range, the disengagement in place signal is prohibited from being output. S44, after receiving the signal that the car has been moved into position, the moving trolley continues to move with the group of returning trolleys and continuously acquires the absolute position of the old trolley. When the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output. S45, after outputting the lifting command, obtain the lifting height of the lifting device. When the lifting height reaches the preset lifting height, determine that the old trolley to be unloaded has been lifted to the adsorption position under the electromagnetic suspension device, and output the lifting position signal.

[0012] Preferably, step S5 includes the following steps: S51, after receiving the lifting position signal, outputs an adsorption command to control the electromagnetic suspension device to be energized and adsorb the old trolley to be unloaded. S52, acquire the adsorption current of the electromagnetic suspension device, and when the adsorption current is within the preset adsorption current range, determine that the electromagnetic suspension device has completed adsorption and output an adsorption completion signal. S53, after receiving the adsorption completion signal, outputs a lifting and recovery command to retract the lifting device; S54, determine whether the lifting device and the old trolley to be unloaded have lost contact. When the lifting device and the old trolley to be unloaded have lost contact, it is determined that the lifting device has released the support of the old trolley to be unloaded, and the old trolley to be unloaded is carried by the electromagnetic suspension device. S55: Obtain the lifting and recovery signal. After receiving the recovery signal, output the old trolley return online unloading completion signal.

[0013] Preferably, step S31 includes the following steps: S311, obtain the current return speed, the return speed at the previous acquisition time, and the sampling time interval between two adjacent acquisitions, and calculate the speed change between the current return speed and the return speed at the previous acquisition time; S312, Determine the acceleration of the sintering machine trolley during the operation of the hydraulic lever device based on the speed change and the sampling time interval; S313, Based on the current return speed, the acceleration, and the preset lever action duration, the predicted return displacement of the lever is determined using a uniformly accelerated motion displacement relationship; S314, the predicted return displacement of the lever is output to S32, which is used to sum with the preset disengagement completion position to obtain the candidate lever trigger position.

[0014] Preferably, in step S34, when determining the trigger position of the lever, it is also required that a preset lifting buffer distance be maintained between the predicted absolute position of the old trolley when it is fully disengaged and the lifting trigger position, including the following steps: S341, obtain the preset lifting buffer distance; wherein, the preset lifting buffer distance is the minimum buffer distance reserved between the predicted absolute position of the old trolley and the lifting trigger position when the hydraulic lever device is moved to the position. S342, the sum of the lifting trigger position and the preset lifting buffer distance is determined as the lower limit of the candidate lifting buffer position; S343, when the predicted absolute position of the old trolley when it is pushed into place is greater than or equal to the lower limit of the candidate lift buffer position, the candidate lever trigger position is determined as the lever trigger position. S344, when the predicted absolute position of the old trolley when it is in position is less than the lower limit of the candidate lift buffer position, the output lever start command is prohibited, and the buffer insufficient signal is output.

[0015] Preferably, the step S55 further includes the following steps: S551, after outputting the signal that the old trolley has completed its online unloading return trip, receives the signal that the lever has been reset in place from the lever reset detection switch configured on the hydraulic lever device, and combines it with the received signal that the lifting device has been recovered in place. S552, when the signal indicating that the lever has been reset is received and the signal indicating that the lifting device has been retracted is received, it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset. S553, when it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset, it is determined that the moving trolley can re-enter the standby state for the next unloading operation and outputs a reset completion signal. S554, when the toggle switch reset signal is not received or the lifting device retraction signal is not received, the trolley is kept out of standby mode and a reset error signal is output until the toggle switch reset signal is received and the lifting device retraction signal is received.

[0016] Preferably, the electromagnetic suspension device is positioned above the return path of the sintering machine trolley and is fixedly positioned relative to the return path of the sintering machine trolley.

[0017] Preferably, the mobile trolley accelerates to synchronize with the return trolley group when the absolute position of the old trolley decreases to the trigger position of the lever, and moves synchronously with the return trolley group during the process of the hydraulic lever device moving aside the old trolley to be unloaded and the lifting device lifting the old trolley to be unloaded.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention obtains the return speed, the absolute position of the old trolley, the preset action duration, and the completion position in real time. It then determines the lever trigger position and the lifting trigger position, ensuring that the moving trolley synchronizes with the return trolley group when the absolute position of the old trolley decreases to the lever trigger position. The trolley then separates the old trolley to be unloaded from the adjacent trolleys. After being separated, it continues to move with the trolley group and initiates lifting when the old trolley reaches the lifting trigger position. The old trolley is then lifted to the adsorption position below the electromagnetic suspension device, where it is held and the lifting device is retrieved. This allows for online unloading of the old trolley without stopping the sintering machine or disassembling the return trolley group. This invention uses a closed-loop position trigger and a closed-loop confirmation of completion via a positioning signal. The linkage verification between the lever trigger position and the lifting trigger position avoids mechanical interference, thus overcoming the problems of existing technologies where the old trolley is constrained by the pushing and pulling of the front and rear trolleys, lifting and lever actions are delayed, and the entire machine must be stopped and manual lifting is required. This reduces downtime losses and improves the automation and safety of the unloading operation. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 This is a schematic flowchart of one embodiment of the present invention.

[0021] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0022] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0024] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0025] It is worth noting that this invention applies to an online unloading system for the return trip of an old sintering machine trolley. The system includes a track along the return path of the sintering machine trolley, a movable trolley that can move along the track, a hydraulic lever device and a lifting device mounted on the movable trolley, an electromagnetic suspension device fixed above the return path of the sintering machine trolley, and a position detection device for detecting the positions of the movable trolley and the old trolley to be unloaded. The movable trolley, hydraulic lever device, lifting device, and electromagnetic suspension device can all be implemented using mature mechanisms already existing in the art. For example, the movable trolley can use the trolley-moving mechanism and AGV body disclosed in Chinese Patent CN117760220B, the hydraulic lever device can use a lever mechanism driven by a hydraulic cylinder, the lifting device can use a lifting mechanism driven by a hydraulic cylinder or a folding frame, and the electromagnetic suspension device can use an electromagnet suction cup. The specific structure of the above components is not the improvement point of this invention; the improvement point of this invention lies in the automatic control method for online unloading of the old trolley based on the unloading system.

[0026] The hydraulic lever device position detection switch is used to detect whether the hydraulic lever device is fully engaged, and outputs a position engagement signal to the sintering machine old trolley return online unloading automatic control system when it is fully engaged; the mobile trolley Gray busbar device is used to detect the real-time position of the mobile trolley on the mobile trolley track and feeds back the position of the mobile trolley to the sintering machine old trolley return online unloading automatic control system; the lifting device position detection switch is used to detect whether the lifting device is fully engaged, and outputs a position engagement signal when it is fully engaged; the lifting device retraction position detection switch is used to detect whether the lifting device is fully retracted, and outputs a retraction position signal when it is fully retracted.

[0027] Furthermore, the absolute position of the old trolley can be obtained by the sintering machine trolley return replacement control center based on the old trolley's identification information, return speed, and running displacement, or it can be obtained in conjunction with position detection elements set on the return path; the position of the moving trolley is obtained by the moving trolley's Gray busbar device. Since the electromagnetic suspension device is fixed relative to the sintering machine trolley's return path, the absolute position of the old trolley can be expressed as the distance between the center of the old trolley and the center of the electromagnetic suspension device.

[0028] Please refer to Figure 1 The present invention provides an automatic control method for online unloading of old sintering machine trolleys during return trips, comprising the following steps: S1, acquire the return speed of the sintering machine trolley, the absolute position of the old trolley, the preset lever action duration, the preset lifting action duration, the preset disengagement completion position, and the preset adsorption completion position; the return speed can be acquired by the trolley return replacement control center or position detection device; the preset lever action duration and preset lifting action duration can be the corresponding action times of the hydraulic lever device and the lifting device under no-load conditions, respectively, and are pre-calibrated; the preset disengagement completion position is the absolute position of the old trolley when the hydraulic lever device is disengaged, and the preset adsorption completion position is the absolute position of the old trolley when the lifting device is lifted and the old trolley to be unloaded is in the adsorption position under the electromagnetic suspension device, both of which are pre-calibrated by the equipment installation dimensions and action stroke.

[0029] S2, determine the lifting trigger position based on the return speed, the preset lifting action duration and the preset adsorption completion position, so that after the lifting device is started when the absolute position of the old trolley decreases to the lifting trigger position, the absolute position of the old trolley can decrease to the preset adsorption completion position when it is lifted into place. S3. Determine the lever trigger position based on the return speed, preset lever action duration, preset disengagement completion position, and lifting trigger position. This allows the moving trolley to start when the absolute position of the old trolley decreases to the lever trigger position and synchronize with the return trolley group. Furthermore, when the hydraulic lever device is disengaged in the synchronized state, the absolute position of the old trolley is still greater than the lifting trigger position. S4, when the absolute position of the old trolley decreases to the lever trigger position, the moving trolley outputs a lever start command in a synchronized state, causing the hydraulic lever device to push away the old trolley to be unloaded from the trolleys immediately in front and behind; after receiving the push-away signal, when the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output, causing the lifting device to lift the old trolley to be unloaded. S5, upon receiving the lifting-in-place signal, controls the electromagnetic suspension device to adsorb and carry the old trolley to be unloaded; upon receiving the adsorption completion signal, outputs a lifting and recovery command; upon receiving the recovery-in-place signal, outputs a signal indicating that the old trolley has completed its return and online unloading.

[0030] This invention obtains the return speed, the absolute position of the old trolley, the preset action duration, and the completion position in real time. It then determines the lever trigger position and the lifting trigger position, ensuring that the moving trolley synchronizes with the return trolley group when the absolute position of the old trolley decreases to the lever trigger position. The trolley then separates the old trolley to be unloaded from the adjacent trolleys. After being separated, it continues to move with the trolley group and initiates lifting when the old trolley reaches the lifting trigger position. The old trolley is then lifted to the adsorption position below the electromagnetic suspension device, where it is held and the lifting device is retrieved. This allows for online unloading of the old trolley without stopping the sintering machine or disassembling the return trolley group. This invention uses a closed-loop position trigger and a closed-loop confirmation of completion via a positioning signal. The linkage verification between the lever trigger position and the lifting trigger position avoids mechanical interference, thus overcoming the problems of existing technologies where the old trolley is constrained by the pushing and pulling of the front and rear trolleys, lifting and lever actions are delayed, and the entire machine must be stopped and manual lifting is required. This reduces downtime losses and improves the automation and safety of the unloading operation.

[0031] In a preferred embodiment, S2 includes the following steps: S21, obtain the preset adsorption completion position; wherein, the preset adsorption completion position is the absolute position of the old trolley when the lifting device is lifted into place and the old trolley to be unloaded is in the adsorption position below the electromagnetic suspension device. The electromagnetic suspension device is fixedly positioned above the sintering machine trolley's return path. The absolute position of the old trolley refers to the distance between the center of the old trolley to be unloaded and the center of the electromagnetic suspension device. As the old trolley to be unloaded moves continuously with the return trolley group, its absolute position decreases over time. During actual assembly, the preset adsorption completion position is pre-calibrated based on the installation height of the electromagnetic suspension device, the maximum lifting stroke of the lifting device, and the mating dimensions of the adsorption surface.

[0032] S22, based on the real-time acquired return speed and the preset lifting action duration, determine the predicted return displacement of the mobile trolley as it moves with the return trolley group during the lifting device's operation. The lifting device needs to undergo a certain action process from receiving the lifting command to lifting into position. The time taken for this process is the preset lifting action duration, which can preferably be pre-calibrated through no-load testing. During the preset lifting action duration, the moving trolley does not remain stationary but continues to move forward with the return trolley group at the return speed. Therefore, multiplying the return speed by the preset lifting action duration yields the predicted return displacement of the moving trolley as it moves with the return trolley group during the lifting device's operation.

[0033] S23, take the sum of the preset adsorption completion position and the predicted return displacement as the lifting trigger position, so that after the lifting device is activated when the absolute position of the old trolley decreases to the lifting trigger position, it can lift the old trolley into place when the absolute position of the old trolley decreases to the preset adsorption completion position; During the lifting operation, the old trolley to be unloaded moves forward by the predicted return displacement along with the returning trolley group. If lifting is only initiated when the absolute position of the old trolley reaches the preset adsorption completion position, the old trolley will have already passed the adsorption position by the time the lifting action is completed, and it will not be properly adsorbed by the electromagnetic suspension device. Therefore, lifting is initiated in advance by predicting the return displacement before the absolute position of the old trolley reaches the preset adsorption completion position. In this way, the completion time of the lifting action is matched with the target adsorption position, ensuring that the old trolley to be unloaded is lifted at the correct position during continuous return movement.

[0034] S24, before outputting the lifting command, update the predicted return displacement and the lifting trigger position according to the real-time acquired return speed, and use the updated lifting trigger position as the comparison benchmark for determining whether to output the lifting command.

[0035] During operation, the sintering machine trolley is propelled by the tail counterweight, and its return speed is not absolutely constant but may fluctuate. If the return speed acquired at a certain moment is always used to calculate and predict the return displacement and lifting trigger position, the fixed lifting trigger position will deviate from the actual situation when the speed changes, causing the lifting device to start too early or too late. Therefore, at each judgment moment before outputting the lifting command, the system reacquires the real-time return speed, recalculates the predicted return displacement, updates the lifting trigger position, and compares the updated lifting trigger position with the current absolute position of the old trolley. The lifting command is output when the absolute position of the old trolley decreases to the updated lifting trigger position. The lifting trigger position is dynamically corrected according to the fluctuation of the return speed, ensuring that the actual completion position of the lifting action is close to the preset adsorption completion position, thus improving the lifting accuracy.

[0036] In a preferred embodiment, S3 includes the following steps: S31, determine the predicted return displacement of the lever based on the currently acquired return speed and the preset lever action duration; Further, S31 includes the following steps: S311, obtain the current return speed, the return speed at the previous acquisition time, and the sampling time interval between two adjacent acquisitions, and calculate the speed change between the current return speed and the return speed at the previous acquisition time; It is worth noting that when the speed of the sintering machine trolley fluctuates during its return motion, calculating and predicting the return displacement based on the return speed at a single moment may lead to a mismatch between the trigger position of the lever and the actual speed. This embodiment introduces a uniformly accelerated displacement calculation based on acceleration to more accurately predict the return displacement of the old trolley during the operation of the hydraulic lever device.

[0037] The return speed of the sintering machine trolley can be obtained in real time through the trolley return change control center or position detection device. The time difference between two adjacent return speed acquisitions is recorded as the sampling time interval. Subtracting the return speed at the previous acquisition time from the current return speed yields the speed change, which reflects the trend of return speed change.

[0038] S312, Based on the speed change and the sampling time interval, determine the acceleration of the sintering machine trolley during the operation of the hydraulic lever device; the acceleration is equal to the speed change divided by the sampling time interval, that is, the change in speed per unit time.

[0039] S313, Based on the current return speed, the acceleration, and the preset lever action duration, the predicted return displacement of the lever is determined using a uniformly accelerated motion displacement relationship; The hydraulic lever device requires a preset lever action time from receiving the lever start command to the lever being fully engaged. During this time, the old trolley to be unloaded moves forward with the returning trolley group at a varying return speed. Based on the displacement formula for uniformly accelerated linear motion, incorporating the change in speed over time into displacement prediction is more accurate than simply multiplying the current return speed by the action time.

[0040] S314, the predicted return displacement of the lever is output to S32, which is used to sum with the preset disengagement completion position to obtain the candidate lever trigger position.

[0041] This implementation calculates the acceleration using the velocity change and sampling time interval, then uses the uniform acceleration displacement formula to calculate the predicted return displacement of the lever, and outputs this as a displacement compensation quantity to determine the candidate lever trigger position. In other words, the determination of the lever trigger position takes into account the real-time changes in the sintering machine trolley's return speed, thus ensuring that the hydraulic lever device starts at the correct time even under speed fluctuation conditions, improving the accuracy of the old trolley's disengaging action.

[0042] S32, the sum of the preset opening completion position and the predicted return displacement of the lever is taken as the candidate lever trigger position; S33, the starting position is the absolute position of the old trolley when the absolute position of the old trolley decreases to the trigger position of the candidate lever; the difference between the starting position and the predicted return displacement of the lever is used as the predicted value of the absolute position of the old trolley when the hydraulic lever device is moved to the correct position; the trigger position of the candidate lever is used as the lever starting point, then the absolute position of the old trolley when the lever is started is equal to the trigger position of the candidate lever, i.e., the starting position; after the preset lever action time, the old trolley to be unloaded moves forward by the predicted return displacement of the lever again, so the absolute position of the old trolley when the lever is moved to the correct position should be equal to the starting position minus the predicted return displacement of the lever.

[0043] S34, when the predicted absolute position of the old trolley is greater than or equal to the lifting trigger position, the candidate lever trigger position is taken as the lever trigger position; when the predicted absolute position of the old trolley is less than the lifting trigger position, the lever start command is prohibited from being output, and a signal indicating that the lever and lifting timing do not meet is output. Furthermore, in step S34, when determining the trigger position of the lever, it is also required that a preset lifting buffer distance be maintained between the predicted absolute position of the old trolley when it is fully disengaged and the lifting trigger position, including the following steps: It is worth noting that when determining the activation timing of the hydraulic lever device, in addition to ensuring that it is fully disengaged, sufficient buffer distance is reserved for the subsequent lifting process to prevent the old trolley from having passed the lifting trigger position after the lever is disengaged, thus preventing the lifting device from failing to activate in time. Therefore, this embodiment introduces a preset lifting buffer distance to further limit the conditions for the lever trigger position, as follows: S341, Obtain the preset lifting buffer distance; wherein, the preset lifting buffer distance is the minimum buffer distance reserved between the predicted absolute position of the old trolley and the lifting trigger position when the hydraulic lever device is in place; the preset lifting buffer distance is pre-calibrated based on the time required for the lifting device to start response when the moving trolley moves with the return trolley group and the equipment safety distance, and its function is to reserve the minimum position margin that the old trolley must retain before reaching the lifting trigger position when the lever action is completed.

[0044] S342, the sum of the lifting trigger position and the preset lifting buffer distance is determined as the lower limit of the candidate lifting buffer position; since the absolute position of the old trolley decreases monotonically along the return direction, in order to ensure that the predicted value of the absolute position of the old trolley when it is cleared is at least greater than the preset lifting buffer distance than the lifting trigger position, the lifting trigger position can be superimposed on the preset lifting buffer distance to obtain the lower limit of the candidate lifting buffer position.

[0045] S343, when the predicted absolute position of the old trolley when it is in place is greater than or equal to the lower limit of the candidate lifting buffer position, the candidate lever trigger position is determined as the lever trigger position; at this time, after the lever is moved, the old trolley is still located before the lifting trigger position and there is a margin of not less than the preset lifting buffer distance, which is sufficient to ensure that the lifting device starts in time when the old trolley reaches the lifting trigger position. Therefore, the current candidate lever trigger position is feasible and can be used as the actual lever trigger position.

[0046] S344: When the predicted absolute position of the old trolley when it is fully disengaged is less than the lower limit of the candidate lifting buffer position, the output of the lever start command is prohibited, and a buffer insufficiency signal is output. At this time, after the lever is disengaged, the clearance between the old trolley and the lifting trigger position is less than the preset lifting buffer distance. If the lever is still started at the current candidate lever trigger position, the old trolley may have already passed or gotten too close to the lifting trigger position after the lever is disengaged, causing the lifting device to be unable to start in time and thus failing to complete the unloading. Therefore, the output of the lever start command at the current candidate lever trigger position is prohibited, and a buffer insufficiency signal is output, indicating that the current working condition does not meet the timing requirements of the lever and lifting, and further processing is required. This avoids forcibly disengaging the lever under insufficient buffer conditions, which could lead to lifting failure or mechanical interference.

[0047] S35, before outputting the lever start command, update the predicted return displacement of the lever, the candidate lever trigger position, the starting position, and the predicted value of the absolute position of the old trolley according to the real-time acquired return speed; when the updated predicted value of the absolute position of the old trolley is greater than or equal to the lifting trigger position, the updated candidate lever trigger position is used as the lever trigger position, and the updated lever trigger position is used as the comparison benchmark for judging whether the absolute position of the old trolley has decreased to the lever trigger position.

[0048] In a preferred embodiment, S4 includes the following steps: S41, when the absolute position of the old trolley decreases to the trigger position of the lever, the moving trolley is accelerated to synchronize with the return trolley group, and a lever start command is output when the moving trolley is synchronized with the return trolley group. Since the old trolley moves continuously with the return trolley group, if the lever is extended directly when the moving trolley is not synchronized with the trolley group, the moving old trolley and its adjacent trolleys will move relative to the lever, causing mechanical collision and sliding interference. Therefore, when the absolute position of the old trolley decreases to the trigger position of the lever, the moving trolley is first accelerated to synchronize with the return trolley group, so that the moving trolley and the old trolley to be unloaded are relatively stationary, and then the lever start command is output.

[0049] S42, after outputting the lever start command, the lever displacement and lever holding pressure of the hydraulic lever device are obtained; the lever displacement reflects the actual stroke of the lever extending and pushing the trolley open, and the lever holding pressure reflects the actual force on the lever in the open state. The two can be obtained by the displacement detection element and the pressure detection element, respectively.

[0050] S43, when the displacement of the lever reaches the preset disengagement displacement and the holding pressure of the lever is within the preset holding pressure range, it is determined that the old trolley to be unloaded and the adjacent trolleys in front and behind are disengaged in place, and a disengagement in place signal is output; when the displacement of the lever does not reach the preset disengagement displacement or the holding pressure of the lever is not within the preset holding pressure range, the disengagement in place signal is prohibited from being output. When the lever displacement reaches the preset disengagement distance, it indicates that the lever has extended to the set stroke. When the lever holding pressure is within the preset holding pressure range, it indicates that the lever remains stably held after extending to its full position. Both conditions must be met simultaneously to confirm that the lever has reliably separated the old trolley to be unloaded from the adjacent trolleys. If either condition is not met, it indicates that the lever may not have fully disengaged or not been stably held. In this case, it is forbidden to output a disengagement completion signal to prevent subsequent lifting from proceeding with an insufficiently disengaged lever.

[0051] S44, after receiving the signal indicating that the old trolley has been pushed aside, the moving trolley continues to move with the return trolley group, continuously acquiring the absolute position of the old trolley. When the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output. After being pushed aside, the old trolley to be unloaded has been freed from the pushing constraints of the adjacent trolleys in front and behind, and the moving trolley continues to move forward synchronously with the return trolley group. The system continuously acquires the absolute position of the old trolley, and when it decreases to the lifting trigger position, the predetermined lifting start time is reached, and a lifting command is output. The lifting device is activated when the old trolley reaches the lifting trigger position to ensure that the old trolley reaches the suction position when the lifting action is completed.

[0052] S45, after outputting the lifting command, the lifting height of the lifting device is obtained. When the lifting height reaches the preset lifting height, it is determined that the old trolley to be unloaded has been lifted to the adsorption position below the electromagnetic suspension device, and a lifting completion signal is output. The lifting height reflects the actual height to which the lifting device lifts the old trolley to be unloaded, and is obtained through a height detection element. When the lifting height reaches the preset lifting height, it indicates that the old trolley to be unloaded has been raised to the adsorption position below the electromagnetic suspension device.

[0053] In this implementation, when the old trolley reaches the lever trigger position, the moving trolley is synchronized with the returning trolley group before the lever is activated to avoid relative motion interference. The activation is confirmed to be in place using both lever displacement and lever holding pressure as dual criteria. After activation, the trolley continues to move with the trolley group, and lifting is initiated when the old trolley reaches the lifting trigger position. The lifting height is then used to confirm that the lifting is in place. This implementation correlates the execution of the lever and lifting actions with the actual displacement, pressure, height, and other state parameters of each actuator, ensuring that each action is completed at the correct time and under the correct mechanical condition. This provides sufficient assurance for subsequent electromagnetic suspension adsorption unloading, improving the reliability and safety of online unloading operations.

[0054] In a preferred embodiment, S5 includes the following steps: S51, upon receiving the lifting-in-place signal, outputs a suction command to energize the electromagnetic suspension device and suction the old trolley to be unloaded. The lifting-in-place signal indicates that the old trolley to be unloaded has been raised to the suction position below the electromagnetic suspension device, which is the appropriate time for the electromagnetic suspension device to perform suction. After outputting the suction command, the electromagnetic suspension device is energized, and the electromagnetic chuck generates suction force to hold the old trolley to be unloaded.

[0055] S52, acquire the adsorption current of the electromagnetic suspension device, and when the adsorption current is within the preset adsorption current range, determine that the electromagnetic suspension device has completed adsorption and output an adsorption completion signal. When the electromagnetic suspension device attracts the old trolley, the coil current changes during the attraction process. Once the old trolley is reliably attracted, the attraction current stabilizes within a certain range. By detecting the attraction current and comparing it with a preset attraction current range, it can be determined whether the electromagnetic suspension device has successfully attracted the old trolley. When the attraction current is within the preset attraction current range, attraction is considered complete, and an attraction completion signal is output.

[0056] S53, upon receiving the adsorption completion signal, outputs a lifting and retraction command to retract the lifting device; the adsorption completion signal indicates that the old trolley to be unloaded has been reliably adsorbed by the electromagnetic suspension device, at which point the lifting device can detach from the old trolley and retract it. Outputting a lifting and retraction command controls the lowering and retraction of the lifting device.

[0057] S54: Determine whether the lifting device has disengaged from the old trolley to be unloaded. When the lifting device disengages, it is determined that the lifting device has released its support from the old trolley, and the old trolley is now supported by the electromagnetic suspension device. During the retraction of the lifting device, its top gradually detaches from the bottom surface of the old trolley as it descends. The moment the top of the lifting device disengages from the bottom surface of the old trolley, the lifting device no longer bears the weight of the old trolley, and the entire weight of the old trolley is transferred to the electromagnetic suspension device. By determining whether the two have disengaged, it can be determined whether the support transfer has been completed.

[0058] S55: Obtain the lifting and retraction completion signal. Upon receiving the completion signal, output the old trolley return online unloading completion signal. When the lifting device continues to retract to the set position, the completion detection switch is triggered, and the lifting and retraction completion signal is output. Receiving this signal indicates that the lifting device has been safely retracted to the initial position and will not interfere with subsequent operation. At this time, the entire unloading process is completed, and the system outputs the old trolley return online unloading completion signal.

[0059] In this embodiment, after the trolley is lifted into position, the electromagnetic suspension device is energized to attract the old trolley, and the attraction current is used to confirm the completion of attraction. After attraction is completed, the lifting device is retracted, and the support is confirmed to have been transferred to the electromagnetic suspension device by the lifting device disengaging from the old trolley. After the lifting device is retracted into position, an unloading completion signal is output to ensure that the old trolley is always in a reliable load-bearing state during the unloading process, avoiding interference caused by support gaps and failure of the lifting device to be retracted in time, and realizing the safe and reliable completion of online unloading of the old trolley during the return trip.

[0060] In another preferred embodiment, the step S55 further includes the following steps: S551, after outputting the signal that the old trolley has completed its online unloading return trip, receives the signal that the lever has been reset in place from the lever reset detection switch configured on the hydraulic lever device, and combines it with the received signal that the lifting device has been recovered in place. After unloading, the hydraulic lever device and the lifting device must be retracted to their initial positions. Therefore, a lever reset signal detection switch is installed on the hydraulic lever device to detect whether the lever has been reset and output a lever reset signal. The lifting device's retraction signal is generated by the retraction signal detection switch during the aforementioned lifting and retraction process. It also receives both the lever reset signal and the lifting device retraction signal as the basis for determining whether the two mechanisms have reset.

[0061] S552, when the signal indicating that the lever has been reset is received and the signal indicating that the lifting device has been retracted is received, it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset. The signal indicating that the hydraulic lever has been returned to its initial position is called the "reset to position" signal. The signal indicating that the lifting device has been returned to its initial position is called the "retract to position" signal. If both conditions are met simultaneously, it can be determined that both the hydraulic lever and the lifting device have been reset.

[0062] S553, when it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset, it is determined that the moving trolley can re-enter the standby state for the next unloading operation and outputs a reset completion signal. After the hydraulic lever device and the lifting device have been reset, the mobile trolley can return to standby mode and wait for the next unloading operation.

[0063] S554, when the toggle switch reset signal is not received or the lifting device retraction signal is not received, the trolley is kept out of standby mode and a reset error signal is output until the toggle switch reset signal is received and the lifting device retraction signal is received.

[0064] If either the lever reset signal or the lifting device retracted signal is missing, it indicates that the hydraulic lever device or the lifting device has not yet reset. If the trolley enters standby mode or participates in the next operation at this time, it may interfere with the unretracted mechanism. Therefore, the trolley should not enter standby mode at this time, and a reset error signal should be output to indicate that the reset is not complete, until both signals meet the conditions before the signal is released.

[0065] In this implementation, after unloading is completed, the hydraulic lever device and the lifting device are jointly confirmed to have been reset by the signal indicating that the lever has been reset and the lifting device has been retracted. When the reset is complete, the trolley is released to enter the next standby state and a reset completion signal is output. If the reset is not complete, the trolley is locked in standby mode and a reset error signal is output. This ensures that before the trolley is put back into operation, the hydraulic lever device and the lifting device have been retracted to their initial state, avoiding interference with subsequent equipment due to the mechanism not being reset, and improving the safety and reliability of continuous online unloading operations.

[0066] Preferably, the electromagnetic suspension device is positioned above the return path of the sintering machine trolley and is fixedly positioned relative to the return path of the sintering machine trolley.

[0067] Preferably, the mobile trolley accelerates to synchronize with the return trolley group when the absolute position of the old trolley decreases to the trigger position of the lever, and moves synchronously with the return trolley group during the process of the hydraulic lever device moving aside the old trolley to be unloaded and the lifting device lifting the old trolley to be unloaded.

[0068] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A method for automatic control of online unloading of old sintering machine trolleys during return trip, characterized in that, Includes the following steps: S1, obtain the return speed of the sintering machine trolley, the absolute position of the old trolley, the preset lever action duration, the preset lifting action duration, the preset disengagement completion position, and the preset adsorption completion position; S2, determine the lifting trigger position based on the return speed, the preset lifting action duration and the preset adsorption completion position, so that after the lifting device is started when the absolute position of the old trolley decreases to the lifting trigger position, the absolute position of the old trolley can decrease to the preset adsorption completion position when it is lifted into place. S3. Determine the lever trigger position based on the return speed, preset lever action duration, preset disengagement completion position, and lifting trigger position. This allows the moving trolley to start when the absolute position of the old trolley decreases to the lever trigger position and synchronize with the return trolley group. Furthermore, when the hydraulic lever device is disengaged in the synchronized state, the absolute position of the old trolley is still greater than the lifting trigger position. S4, when the absolute position of the old trolley decreases to the lever trigger position, the moving trolley outputs a lever start command in a synchronized state, causing the hydraulic lever device to push away the old trolley to be unloaded from the trolleys immediately in front and behind; after receiving the push-away signal, when the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output, causing the lifting device to lift the old trolley to be unloaded. S5, upon receiving the lifting-in-place signal, controls the electromagnetic suspension device to adsorb and carry the old trolley to be unloaded; upon receiving the adsorption completion signal, outputs a lifting and recovery command; upon receiving the recovery-in-place signal, outputs a signal indicating that the old trolley has completed its return and online unloading.

2. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 1, characterized in that, S2 includes the following steps: S21, obtain the preset adsorption completion position; wherein, the preset adsorption completion position is the absolute position of the old trolley when the lifting device is lifted into place and the old trolley to be unloaded is in the adsorption position below the electromagnetic suspension device. S22, based on the real-time acquired return speed and the preset lifting action duration, determine the predicted return displacement of the mobile trolley as it moves with the return trolley group during the lifting device's operation. S23, take the sum of the preset adsorption completion position and the predicted return displacement as the lifting trigger position, so that after the lifting device is activated when the absolute position of the old trolley decreases to the lifting trigger position, it can lift the old trolley into place when the absolute position of the old trolley decreases to the preset adsorption completion position; S24, before outputting the lifting command, update the predicted return displacement and the lifting trigger position according to the real-time acquired return speed, and use the updated lifting trigger position as the comparison benchmark for determining whether to output the lifting command.

3. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 2, characterized in that, S3 includes the following steps: S31, determine the predicted return displacement of the lever based on the currently acquired return speed and the preset lever action duration; S32, the sum of the preset opening completion position and the predicted return displacement of the lever is taken as the candidate lever trigger position; S33, take the absolute position of the old trolley when the absolute position of the old trolley is reduced to the trigger position of the candidate lever as the starting position; subtract the predicted return displacement of the lever from the starting position as the predicted value of the absolute position of the old trolley when the hydraulic lever device is moved to the position. S34, when the predicted absolute position of the old trolley is greater than or equal to the lifting trigger position, the candidate lever trigger position is taken as the lever trigger position; when the predicted absolute position of the old trolley is less than the lifting trigger position, the lever start command is prohibited from being output, and a signal indicating that the lever and lifting timing do not meet is output. S35, before outputting the lever start command, update the predicted return displacement of the lever, the candidate lever trigger position, the starting position, and the predicted value of the absolute position of the old trolley according to the real-time acquired return speed; when the updated predicted value of the absolute position of the old trolley is greater than or equal to the lifting trigger position, the updated candidate lever trigger position is used as the lever trigger position, and the updated lever trigger position is used as the comparison benchmark for judging whether the absolute position of the old trolley has decreased to the lever trigger position.

4. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 3, characterized in that, S4 includes the following steps: S41, when the absolute position of the old trolley decreases to the trigger position of the lever, control the moving trolley to accelerate to synchronize with the return trolley group, and output the lever start command when the moving trolley is synchronized with the return trolley group. S42, after outputting the lever start command, obtain the lever displacement and lever holding pressure of the hydraulic lever device; S43, when the displacement of the lever reaches the preset disengagement displacement and the holding pressure of the lever is within the preset holding pressure range, it is determined that the old trolley to be unloaded and the adjacent trolleys in front and behind are disengaged in place, and a disengagement in place signal is output; when the displacement of the lever does not reach the preset disengagement displacement or the holding pressure of the lever is not within the preset holding pressure range, the disengagement in place signal is prohibited from being output. S44, after receiving the signal that the car has been moved into position, the moving trolley continues to move with the group of returning trolleys and continuously acquires the absolute position of the old trolley. When the absolute position of the old trolley decreases to the lifting trigger position, a lifting command is output. S45, after outputting the lifting command, obtain the lifting height of the lifting device. When the lifting height reaches the preset lifting height, determine that the old trolley to be unloaded has been lifted to the adsorption position under the electromagnetic suspension device, and output the lifting position signal.

5. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 4, characterized in that, S5 includes the following steps: S51, after receiving the lifting position signal, outputs an adsorption command to control the electromagnetic suspension device to be energized and adsorb the old trolley to be unloaded. S52, acquire the adsorption current of the electromagnetic suspension device, and when the adsorption current is within the preset adsorption current range, determine that the electromagnetic suspension device has completed adsorption and output an adsorption completion signal. S53, after receiving the adsorption completion signal, outputs a lifting and recovery command to retract the lifting device; S54, determine whether the lifting device and the old trolley to be unloaded have lost contact. When the lifting device and the old trolley to be unloaded have lost contact, it is determined that the lifting device has released the support of the old trolley to be unloaded, and the old trolley to be unloaded is carried by the electromagnetic suspension device. S55, acquire the lifting and recovery signal, and after receiving the recovery signal, output the old trolley return online unloading completion signal.

6. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 3, characterized in that, S31 includes the following steps: S311, obtain the current return speed, the return speed at the previous acquisition time, and the sampling time interval between two adjacent acquisitions, and calculate the speed change between the current return speed and the return speed at the previous acquisition time; S312, Determine the acceleration of the sintering machine trolley during the operation of the hydraulic lever device based on the speed change and the sampling time interval; S313, Based on the current return speed, the acceleration, and the preset lever action duration, the predicted return displacement of the lever is determined using a uniformly accelerated motion displacement relationship; S314, the predicted return displacement of the lever is output to S32, which is used to sum with the preset disengagement completion position to obtain the candidate lever trigger position.

7. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 3, characterized in that, In step S34, when determining the trigger position of the lever, it is also required that a preset lifting buffer distance be maintained between the predicted absolute position of the old trolley when it is fully disengaged and the lifting trigger position, including the following steps: S341, obtain the preset lifting buffer distance; wherein, the preset lifting buffer distance is the minimum buffer distance reserved between the predicted absolute position of the old trolley and the lifting trigger position when the hydraulic lever device is moved to the position. S342, the sum of the lifting trigger position and the preset lifting buffer distance is determined as the lower limit of the candidate lifting buffer position; S343, when the predicted absolute position of the old trolley when it is pushed into place is greater than or equal to the lower limit of the candidate lift buffer position, the candidate lever trigger position is determined as the lever trigger position. S344, when the predicted absolute position of the old trolley when it is in position is less than the lower limit of the candidate lift buffer position, the output lever start command is prohibited, and the buffer insufficient signal is output.

8. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 5, characterized in that, The step following S55 is as follows: S551, after outputting the signal that the old trolley has completed its online unloading return trip, receives the signal that the lever has been reset in place from the lever reset detection switch configured on the hydraulic lever device, and combines it with the received signal that the lifting device has been recovered in place. S552, when the signal indicating that the lever has been reset is received and the signal indicating that the lifting device has been retracted is received, it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset. S553, when it is determined that the hydraulic lever device has been reset and the lifting device has been retracted and reset, it is determined that the moving trolley can re-enter the standby state for the next unloading operation and outputs a reset completion signal. S554, when the toggle switch reset signal is not received or the lifting device retraction signal is not received, the trolley is kept out of standby mode and a reset error signal is output until the toggle switch reset signal is received and the lifting device retraction signal is received.

9. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 1, characterized in that, The electromagnetic suspension device is positioned above the return path of the sintering machine trolley and is fixed relative to the return path of the sintering machine trolley.

10. The automatic control method for online unloading of the old sintering machine trolley during return trip according to claim 1, characterized in that, When the absolute position of the old trolley decreases to the trigger position of the lever, the mobile trolley accelerates to synchronize with the return trolley group, and moves synchronously with the return trolley group during the process of the hydraulic lever device moving aside the old trolley to be unloaded and the lifting device lifting the old trolley to be unloaded.

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