Multi-section columnar moving mechanical reciprocating grate with steps

Abstract

The application discloses a multi-section column moving mechanical reciprocating grate with steps, which comprises a grate body and a grate control system. Each grate section comprises a grate frame, a driving mechanism, a movable frame, a grate beam assembly and a grate gap adjusting device. The grate beam assembly comprises multiple dynamic beams and multiple static beams, and the dynamic beams and the static beams are alternately arranged along the width direction of the grate. The dynamic beams are installed on the movable frame, and the static beams are installed on the grate frame. The grate gap adjusting device is installed on the side plate of the grate frame. The grate control system is electrically connected with the driving mechanism. The grate control system is configured to collect real-time operation parameters representing incineration conditions, process the real-time operation parameters based on a preset control algorithm, generate speed control instructions corresponding to each grate section, and send the speed control instructions to the driving mechanism. The application realizes comprehensive improvement of the operation reliability of the incinerator, the combustion efficiency and the environmental protection index.

Description

Technical Field

[0001] This invention relates to the field of waste incineration equipment technology, specifically a multi-stage reciprocating mechanical grate with steps. Background Technology

[0002] The waste incineration industry primarily uses mechanical reciprocating grate furnaces. As a core component of the incinerator, the mechanical reciprocating grate performs crucial functions such as waste conveying, agitation, mixing, and combustion air distribution. Currently, a commonly used type of reciprocating mechanical grate in the industry employs a front-end drive layout. Its drive linkage passes through the front plate of the grate frame and connects to an external power source. The moving beams and stationary beams of the grate are arranged at intervals along the width direction, and the gap between the moving and stationary beams is fixed during cold installation and cannot be dynamically adjusted during operation.

[0003] The existing grate structure described above has revealed numerous problems during long-term operation: First, because the gap between the grate beams is not adjustable, as the incinerator operates for longer periods, the surface thickness of the grate beams decreases due to wear from waste, causing the gap between the moving and stationary beams to gradually widen. This not only results in a persistently high ash leakage rate but also makes it easy for hard foreign objects to become embedded in the gaps, leading to grate jamming or even forced shutdown. Second, to allow for thermal expansion, the gap often needs to be manually enlarged during cold installation, which further exacerbates the air leakage problem in the early stages of operation, leading to a decrease in the thermal efficiency of the incinerator. In addition, the structure of the drive connecting rod penetrating the front plate has inherent sealing defects, making it easy for high-temperature corrosive flue gas to leak out, which not only pollutes the environment but also increases the workload and maintenance frequency of on-site operation and maintenance personnel.

[0004] To address the shortcomings of the aforementioned structure, the industry has developed another improved type of reciprocating mechanical grate. This improved grate moves the drive mechanism to the side of the grate, and the rear end of the moving beam is supported by rollers, attempting to absorb thermal expansion and wear by allowing slight displacement of the grate beam in the width direction. However, this improved structure still faces challenges in practical applications: on the one hand, limited by the structural dimensions of the support points, the lateral movement of the grate beam is extremely limited, usually failing to cover the maximum wear of the grate blocks throughout their entire lifespan, resulting in a significant reduction in the actual service life of the grate beam; on the other hand, during long-term operation, uneven wear at the contact point between the rear end of the moving beam and the rollers can create step-like defects, which severely hinder the lateral sliding of the grate beam, rendering the theoretically feasible gap adjustment function ineffective in actual operation. Simultaneously, existing grate systems generally lack intelligent closed-loop control strategies, with grate operating speed largely relying on manual experience settings, unable to adaptively adjust in real time according to fluctuations in waste composition, changes in bed thickness, and furnace combustion conditions, leading to incomplete combustion, large fluctuations in pollutant emissions, and poor operational stability.

[0005] In summary, existing reciprocating grates generally suffer from problems such as failure of the gap adjustment mechanism, limited thermal expansion compensation capacity, rapid wear of key moving parts, and lagging automation control, which seriously restrict the long-term stable operation and economy of incinerators. Summary of the Invention

[0006] The purpose of this application is to provide a multi-segment reciprocating mechanical grate with steps, so as to at least partially solve the problems existing in the prior art. This purpose is achieved through the following technical solution:

[0007] This application proposes a multi-segment reciprocating mechanical grate with steps, including a grate body and a grate control system; wherein:

[0008] The grate body includes multiple grate sections arranged sequentially along the material conveying direction. At least some adjacent grate sections are provided with steps. Each grate section includes a grate frame, a drive mechanism, a movable frame, a grate beam assembly, and a grate gap adjustment device.

[0009] The grate beam assembly includes multiple moving beams and multiple stationary beams, with the moving beams and stationary beams arranged alternately along the width of the grate; the moving beams are installed on the movable frame, and the stationary beams are installed on the grate frame;

[0010] The grate gap adjustment device is installed on the side plate of the grate frame and is used to push the grate beam assembly to move along the width direction of the grate to adjust the gap between the moving beam and the stationary beam.

[0011] The grate control system is electrically connected to the drive mechanism. The grate control system is configured to: collect real-time operating parameters characterizing the incineration conditions, process the real-time operating parameters based on a preset control algorithm, generate speed control commands corresponding to each grate section, and send the speed control commands to the drive mechanism to adjust the operating speed of each grate section, thereby achieving adaptive matching of the waste drying, combustion, and burnout processes.

[0012] In some embodiments, the grate frame includes a front plate assembly, a rear plate assembly, and two side plates, the side plates being arranged at an angle to form a grate tilt angle;

[0013] The drive mechanism includes a hydraulic cylinder, a drive shaft, an inner swing arm, and a tie rod; the hydraulic cylinder is arranged on the outside of the grate frame and is connected to the inner swing arm through the drive shaft passing through the side plate; one end of the tie rod is connected to the inner swing arm, and the other end is connected to the movable frame;

[0014] The grate inclination angle is 10° or 15°, and the angle between the inclination angle of the movable frame base plate and the grate inclination angle is 30°, so that the movable frame has an upward component velocity when pushing materials.

[0015] In some embodiments, in the grate beam assembly, the front end of the moving beam is engaged with the supporting round steel at the front end of the movable frame, and the rear end of the moving beam rests on the supporting profile steel at the rear end of the movable frame via angle steel; the front end of the stationary beam is engaged with the supporting round steel of the front plate assembly of the grate frame, and the rear end of the stationary beam rests on the supporting profile steel of the rear plate assembly of the grate frame via angle steel.

[0016] Both the supporting round steel and the supporting profile steel are continuous structures, which allows the moving beam and the stationary beam to move freely along the width direction of the grate when heated and expanded.

[0017] In some embodiments, the grate gap adjusting device includes a mounting base, a first sliding assembly, a disc spring assembly, a second sliding assembly, a clamping flange, and adjusting bolts;

[0018] The mounting base is fixed to the side plate facade of the grate frame. The first sliding component is arranged closer to the inside of the furnace, and the second sliding component is arranged closer to the outside of the furnace. The disc spring assembly is disposed between the first sliding component and the second sliding component.

[0019] The adjusting bolt passes through the clamping flange and abuts against the second sliding assembly;

[0020] During cold adjustment, turning the adjusting bolt compresses the disc spring assembly through the second sliding component, thereby pushing the first sliding component to press against the grate beam assembly; during hot operation, the thermal expansion force of the grate beam compresses the disc spring assembly through the first sliding component, and the elastic deformation of the disc spring assembly absorbs the expansion and maintains a constant pressing force.

[0021] In some embodiments, the upper surface of the base plate of the movable frame completely covers the pin of the idler roller supporting the movable frame within the stroke range to prevent slag from leaking into the pin and bearing parts.

[0022] The movable frame is equipped with guide devices on both sides along the width direction of the grate to limit the displacement of the movable frame in the width direction and ensure the straightness of the movement trajectory.

[0023] In some embodiments, the grate control system includes an air volume and oxygen volume control module, which is configured to perform the following operations:

[0024] The boiler evaporation rate is set and measured. The deviation between the measured and set values ​​is calculated. The evaporation rate deviation is used as input to output the adjustment amount of the combustion air volume through PID calculation.

[0025] Obtain the set value and measured value of oxygen content in flue gas at boiler outlet, calculate the deviation of flue gas oxygen content between the measured value and the set value, and use the flue gas oxygen content deviation as input to output the speed reference value of the pusher and grate through PID calculation.

[0026] The adjustment amount of the combustion air volume is used as a feedforward signal in the calculation of the speed reference value to compensate for the lag in the measurement of the oxygen content in the flue gas, ensuring that the combustion air volume is automatically increased when the boiler evaporation rate is lower than the set value, and the operating speed of the pusher and each grate section is increased synchronously when the oxygen content in the flue gas increases accordingly.

[0027] In some embodiments, the grate control system further includes a bed thickness control module, which is configured to perform the following operations:

[0028] Pressure measuring points are installed in the primary air chamber of each grate section, and flue gas pressure measuring points are installed in the furnace to collect the pressure of the air chambers in each grate section in real time. With furnace pressure Calculate the differential pressure between zones = - ;

[0029] Based on the partition differential pressure Zoned grate area The air volume measured by the anemometer and the actual air temperature measured by thermocouples The real-time material layer thickness is obtained by substituting the preset dimensionless material layer thickness formula. :

[0030]

[0031] Select the thickness of the material layer in the second grate As the master control object, its calculated value is compared with the set value using a PID controller, and the grate speed factor is output. The grate speed factor is defined as the first grate speed. With the second grate speed ratio / ;

[0032] The speed of the first grate and the pusher is adjusted according to the grate speed factor coupling: when the calculated value of the second section material layer thickness is greater than the set value, the ratio is reduced to slow down the speed of the first grate and the pusher, and prolong the residence time of the waste in the drying section; when the calculated value of the second section material layer thickness is less than the set value, the ratio is increased to increase the speed of the first grate and the pusher.

[0033] In some embodiments, the grate control system further includes a hydraulic actuation control module configured to perform the following operations:

[0034] Displacement sensors are installed on the drive hydraulic cylinders of each grate section to collect displacement signals of the hydraulic cylinder piston rods in real time, and the actual movement speed of each hydraulic cylinder is calculated based on the displacement change per unit time.

[0035] The speed setpoint of each grate section is compared with the actual speed by PID control, and the proportional valve opening control signal is output.

[0036] Based on the preset mapping relationship between the proportional valve opening and the flow rate, the opening of the proportional valve on the oil pipeline of each hydraulic cylinder is adjusted to change the flow rate and direction of the hydraulic oil, thereby precisely controlling the extension and retraction speed of each hydraulic cylinder.

[0037] In the PID comparison process, dead zone compensation logic is introduced. When the deviation between the actual movement speed and the set value is less than the preset dead zone threshold, the opening of the proportional valve is locked to avoid hydraulic oscillation caused by frequent operation of the proportional valve within a small deviation range.

[0038] In some embodiments, the multi-section grate section includes a drying section, a combustion section, and a burnout section;

[0039] The grate inclination angle of the drying section is greater than that of the grate inclination angle of the subsequent combustion section and burnout section; the height of the step is set to 0.8 meters to 1.2 meters; the length of each grate section is 1.8 meters to 3.5 meters;

[0040] The grate body is arranged in either a single row or a double row depending on its width: when the grate width is less than 6.5 meters, a single row arrangement is adopted, and the drive mechanism is only set on one side of the grate frame; when the grate width is greater than or equal to 6.5 meters, a double row arrangement is adopted, and the drive mechanism is set on both sides of the grate frame.

[0041] In some embodiments, the grate gap adjustment device is configured to provide a grate beam lateral movement stroke of not less than 250 mm to absorb the thermal expansion of the grate blocks and compensate for the wear caused by long-term operation.

[0042] For a double-row grate arrangement, the static beams on the left and right sides are fixed independently in the width direction, allowing for independent adjustment of the grate gap between the left and right rows.

[0043] In one or more of the above specific embodiments, the multi-segment reciprocating mechanical grate with steps provided by the present invention has the following technical effects:

[0044] This invention overcomes the bottleneck of limited lateral movement of traditional grates by using a continuous arrangement of supporting round steel and shaped steel, combined with a gap adjustment device with disc springs. It not only provides an adjustment margin of no less than 250mm to fully absorb the thermal expansion of the grate blocks and compensate for long-term wear, but also utilizes the elastic deformation characteristics of disc springs to create a flexible buffer between cold pre-tightening and hot expansion. This solves the problem of jamming or excessive loosening that is easily caused by rigid top-tightening structures, keeps the gap between the dynamic and static beams stable throughout the entire life cycle, and significantly reduces the slag leakage rate.

[0045] Meanwhile, the movable frame base plate fully covers the idler roller pins, effectively preventing high-temperature slag from intruding into the moving parts, avoiding lateral displacement failure caused by wear forming steps at the rear end of the moving beam, and improving the service life of key components.

[0046] In terms of control strategy, the three-level closed-loop control system of air volume and oxygen content, material layer thickness, and hydraulic execution constructed in this invention realizes refined intelligent control of the incineration process; at the macro level, the feedforward of the evaporation signal compensates for the lag in the measurement of oxygen content in the flue gas, ensuring the boiler load response speed and combustion stability; at the core control level, a dimensionless material layer thickness calculation model based on the differential pressure method is used to accurately sense the material layer status in the combustion section, and intelligently match the residence time of waste in the drying section by dynamically adjusting the speed factors of the first and second grate sections to prevent incomplete combustion; at the execution level, hydraulic servo control with dead zone compensation logic is introduced to eliminate hydraulic oscillations caused by frequent operation of the proportional valve, ensuring the smooth operation of the grate.

[0047] In addition, the multi-stage stepped layout, combined with the differentiated tilt angle design of 15° for the drying section and 10° for the other sections, optimizes the waste falling and tumbling path, enhances the drying and mixing effect, and the flexible switching between single-row and double-row drive modes improves engineering adaptability, can meet the needs of incineration lines of different widths, and ultimately achieves a comprehensive improvement in the reliability of incinerator operation, combustion efficiency and environmental protection indicators.

[0048] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0049] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0050] Figure 1This is a schematic diagram of the multi-segment reciprocating mechanical grate provided by the present invention.

[0051] Figures 2-3 This is a schematic diagram of the drive mechanism provided by the present invention;

[0052] Figures 4-6 This is a schematic diagram of the structure of the grate beam assembly provided by the present invention;

[0053] Figures 7-9 This is a schematic diagram of the grate gap adjustment device provided by the present invention;

[0054] Figures 10-13 This is a schematic diagram of the structure of the active frame provided by the present invention. Detailed Implementation

[0055] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0056] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0057] Although terms such as first, second, third, etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or segment discussed below may be referred to as the second element, component, region, layer, or segment without departing from the teachings of the exemplary embodiments.

[0058] For ease of description, spatial relative terms may be used in the text to describe the relationship of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "inside," "outside," "middle," "outer," "below," "below," "above," "over," etc. Such spatial relative terms are intended to include different orientations of the device in use or operation, other than those depicted in the figure. For example, if the device in the figure is flipped, an element described as "below other elements or features" or "below other elements or features" would subsequently be oriented as "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0059] In one specific implementation, such as Figure 1 As shown, this invention proposes a multi-segment reciprocating mechanical grate with steps, including a grate body and a grate control system; wherein: the grate body includes multiple grate segments arranged sequentially along the material conveying direction, such as... Figure 1 The first grate 101, second grate 102, third grate 103, and fourth grate 104 described herein; obviously, it is not limited to four grate sections, and more sections can be provided. A step 105 is provided between some adjacent grate sections. For example, in this embodiment, a step is provided between the first grate section and the second grate section, but no step is provided between the second grate section and the third grate section. Figures 2-7 As shown, each grate section includes a grate frame 1, a drive mechanism 2, a movable frame 3, a grate beam assembly 4, and a grate gap adjustment device 5. The grate beam assembly includes multiple moving beams 11 and multiple stationary beams, with the moving beams and stationary beams arranged alternately along the width of the grate. The moving beams are fixedly connected to the movable frame, and the stationary beams are fixedly connected to the grate frame. The grate gap adjustment device is installed on the side plate of the grate frame and is used to push the grate beam assembly to move along the width of the grate to adjust the gap between the moving beams and the stationary beams. The grate control system is electrically connected to the drive mechanism. The grate control system is configured to: collect real-time operating parameters characterizing the incineration conditions, process the real-time operating parameters based on a preset control algorithm, generate speed control commands corresponding to each grate section, and send the speed control commands to the drive mechanism to adjust the operating speed of each grate section, thereby achieving adaptive matching of the waste drying, combustion, and burnout processes.

[0060] During operation, the waste is first pushed to the drying section grate by the feeder, and then moves downstream along a multi-segmented, stepped path under the influence of gravity and grate thrust. During this process, the grate control system acts as the central nervous system, collecting real-time operating parameters such as evaporation rate, oxygen content, air pressure, and air temperature through a sensor array distributed throughout the furnace and air chambers. The built-in control algorithm of the grate control system processes this massive amount of data, identifying the current degree of dryness, combustion status, and burnout of the waste, and then generates differentiated speed control commands. These commands are sent to the corresponding drive mechanisms of each grate segment, driving the material to move at different speeds: appropriately slowing down in the drying section to ensure sufficient dehydration, matching the optimal air velocity and speed in the combustion section to achieve vigorous combustion, and controlling the speed in the burnout section to ensure that the residual heat loss on ignition meets the standard. This automatic matching of waste characteristics and process requirements requires no manual intervention.

[0061] This solution breaks through the limitations of traditional grate mechanization and human experience-based control. Through an integrated grate unit and intelligent control system, it achieves multi-dimensional adaptive matching throughout the incineration process. This not only significantly improves the uniformity and thoroughness of waste combustion and effectively reduces flue gas pollutants and slag loss on ignition, but also greatly enhances the incinerator's adaptability to drastic fluctuations in waste composition through precise process control. This ensures the stability of boiler output and compliance with environmental emission standards, truly realizing intelligent operation of the incinerator.

[0062] The following is combined Figure 2 , Figure 3 and Figure 5 The driving mechanism 2 provided by the present invention is described in detail. In some embodiments, the grate frame 1 includes a front plate assembly, a rear plate assembly, and two side plates, the side plates being arranged at an inclination to form a grate tilt angle; the driving mechanism 2 includes a hydraulic cylinder 21, a drive shaft 23, an inner swing arm 24, and a tie rod 25; the hydraulic cylinder 21 is arranged on the outside of the grate frame 1 and is connected to the inner swing arm 24 through the drive shaft passing through the side plate; one end of the tie rod 25 is connected to the inner swing arm 24, and the other end is connected to the movable frame; the grate tilt angle is 10° or 15°, and the angle between the tilt angle of the bottom plate of the movable frame and the grate tilt angle is 30°, so that the movable frame has an upward component velocity when pushing materials.

[0063] When the hydraulic cylinder of drive mechanism 2 is activated, the linear thrust it generates is converted into rotational torque through the drive shaft, which drives the inner swing arm to swing in a fan shape. The inner swing arm transmits the rotational motion to the movable frame through the tie rod. Because the inclination angle of the bottom plate of the movable frame is specifically designed to differ from the grate inclination angle by 30°, the movable frame, when pushing materials, not only has a component velocity downstream (discharge end) along the grate, but also a significant vertical upward component velocity. This composite motion trajectory allows the moving beam to slightly lift the waste while pushing it downstream, effectively overcoming the downward resistance caused by the weight of the waste and the grate inclination angle. This ensures stable and reliable upward or horizontal conveying of waste on a 15° or 10° inclined surface, preventing slippage or stagnation due to insufficient friction.

[0064] like Figure 2 , Figure 3 and Figure 5 As shown, the drive mechanism 2 includes a hydraulic cylinder 21, an outer swing arm 22, a drive shaft 23, an inner swing arm 24, a tie rod 25, and a bearing assembly. The hydraulic cylinder 21 is located on the outer side of the grate frame 1 of the incinerator grate. The piston rod of the hydraulic cylinder is hinged to one end of the outer swing arm 22, and the other end of the outer swing arm 22 is fixedly sleeved on the end of the drive shaft 23, used to drive the drive shaft 23 to perform reciprocating rotational motion. The drive shaft 23 passes horizontally through the side plate of the grate frame 1. The portion of the drive shaft 23 located inside the frame is fixedly equipped with the inner swing arm 24. The inner swing arm 24 is connected to the movable frame 3 of the grate via the tie rod 25, used to convert rotational motion into linear motion to drive the movable frame 3 to reciprocate. The bearing assembly includes a rolling bearing 26 located on the outer side of the grate frame 1 and a sliding bearing 27 located on the inner side of the grate frame 1. The drive shaft 23 is mounted on the grate frame 1 via the rolling bearing 26 and the sliding bearing 27.

[0065] Thus, the drive mechanism provided by the present invention uses a hydraulic cylinder, an outer swing arm, a drive shaft, an inner swing arm, and a tie rod to form a transmission route. During operation, the hydraulic cylinder pushes the outer swing arm, which drives the drive shaft to rotate back and forth. The inner swing arm then converts the rotation into the linear motion of the tie rod, which ultimately drives the movable grate to move back and forth. This reduces the intermediate transmission structure, makes the power transmission more direct, the operation more stable, and the failure rate lower.

[0066] A sealing structure is provided at the position where the drive shaft 23 passes through the side plate of the grate frame 1. The drive shaft 23 passes through the side plate of the grate frame 1 without interfering with the front plate of the grate frame 1. In this way, the drive shaft passes through the grate side plate instead of extending into the furnace through the front plate. Since the drive shaft only performs rotational motion and not extension or retraction motion, the sealing structure is simple and reliable, and it is not easy to leak air or ash. In addition, the side plate is far away from the high-temperature zone, the working environment of the seal is better, and the service life is significantly extended.

[0067] The following is combined with Figures 4-6 The structure of the grate beam assembly 4 is described in detail below. In the grate beam assembly 4, the front end of the moving beam is engaged with the supporting round steel at the front end of the movable frame, and the rear end of the moving beam rests on the supporting profile steel at the rear end of the movable frame via angle steel; the front end of the stationary beam is engaged with the supporting round steel of the front plate assembly of the grate frame, and the rear end of the stationary beam rests on the supporting profile steel of the rear plate assembly of the grate frame via angle steel; both the supporting round steel and the supporting profile steel are continuous structures, allowing the moving beam and the stationary beam to move freely along the width direction of the grate when heated and expanded.

[0068] During the start-up, shutdown, or variable load operation of the incinerator, the grate beam assembly undergoes significant thermal expansion and contraction due to temperature changes. Because the front end of the moving beam is secured to the round steel of the movable frame, and the rear end rests on the angle steel, while the front end of the stationary beam is secured to the round steel of the grate frame, and the rear end rests on the rear plate steel, this "front-end securing, rear-end supporting" structural design ensures the grate beam is firmly locked longitudinally, preventing axial movement. Simultaneously, since both the supporting round steel and the steel profiles are designed as continuous lengths, eliminating intermediate support obstacles, when the grate beam widens due to thermal expansion or narrows due to wear, the beam can slide freely and unobstructed laterally along the width direction of the grate on the support surface of the rear angle steel, automatically absorbing the expansion or compensating for wear gaps, thus maintaining a balanced stress state at all times.

[0069] In this way, the structure meets the dual requirements of longitudinal positioning and lateral free expansion. The front-end locking mechanism prevents longitudinal displacement of the grate beam during reciprocating motion, ensuring the accuracy of movement; the rear-end sliding mechanism releases thermal stress, preventing the grate beam from arching, twisting, or breaking due to unreleased thermal expansion. The full-length support structure provides an infinitely long track for this free displacement, solving the problem of lateral movement constraints on the grate beam caused by traditional segmented support structures, and improving the high-temperature operation safety and structural stability of the grate.

[0070] like Figures 4-6 As shown, the grate beam assembly 4 provided by this invention includes a stationary beam 43, a moving beam 46, round steel, and angle steel. Both the moving beam 46 and the stationary beam 43 are composed of welded steel beams and multiple grate blocks 41 arranged longitudinally along the steel beams. The grate blocks 41 are fastened to the steel beams with bolts, facilitating the replacement of the grate blocks. Moving beams and stationary beams are arranged at intervals along the width of each grate section, following the pattern: outermost stationary beam - moving beam - stationary beam - multiple moving beams, stationary beam - moving beam - outermost stationary beam. That is, each moving beam is adjacent to two stationary beams, and all stationary beams except the outermost stationary beam are adjacent to two moving beams.

[0071] The front end of the grate moving beam is secured to the round steel at the front end of the movable frame, while its rear end rests on the rear section steel of the movable frame via angle steel. This structure ensures that the reciprocating motion of the movable frame 3 causes the upper moving beam to reciprocate as well. The front end of the grate stationary beam is secured to the round steel of the front plate assembly of the grate frame 1, while its rear end rests on the section steel of the rear plate assembly of the grate frame 1 via angle steel. The design of the grate moving and stationary beams, with their front ends secured to round steel and their rear ends resting on section steel, allows for longitudinal positioning of the moving and stationary beams relative to the movable frame 3 and grate frame 1 at the front end, preventing longitudinal displacement during grate operation. The rear end resting on section steel via angle steel allows the grate beams to move freely during longitudinal expansion without being subjected to excessive constraint forces that could cause damage. This structure also allows the grate beams to move along the width of the grate. When the grate beam widens due to thermal expansion or when the side of the grate beam narrows due to wear during operation, the grate beam can be moved along the width of the incinerator to control the gap between the grate blocks on the grate beam within a reasonable range.

[0072] For double-row grates, the stationary beam (i.e., the middle stationary beam) between the moving beams on the left and right sides is fixed in the transverse direction (i.e., the width direction) of the grate, facilitating the adjustment of the grate gap on the left and right sides respectively. For single-row grates, the outermost stationary beam on one side is fixed in the width direction.

[0073] The lateral expansion of each grate beam is approximately 2mm, which is automatically adjusted by the gap adjustment device during operation. The maximum wear of each beam is 10mm. Thus, the difference between the reserved expansion space and the wear compensation space for each beam is 12mm. For a grate with a width of 20 beams on one side, the required lateral displacement is 240mm.

[0074] During operation, the moving beam reciprocates with the movable frame 3, creating relative displacement with the fixed static beam to propel, mix, and loosen the material. During operation, the moving and static beams move freely due to thermal expansion via the rear angle steel structure, and can also move along the width direction under the action of the grate gap adjustment device, compensating for grate block wear and thermal expansion. This intermittent arrangement of the grate beam components ensures uniform waste distribution, and the relative movement of the moving and static beams improves waste combustion efficiency. Longitudinal positioning is stable and allows for free thermal expansion, preventing deformation or breakage due to thermal stress at high temperatures. The adjustment stroke of ≥250mm in the width direction effectively maintains a reasonable gap between grate blocks, reducing slag and air leakage. The differentiated fixing design for double and single rows facilitates gap adjustment and maintenance.

[0075] The following is combined with Figures 7-9The grate gap adjustment device is described in detail below. In some embodiments, the grate gap adjustment device 5 includes a mounting base 51, a first sliding assembly 52, a disc spring assembly 53, a second sliding assembly 54, a clamping flange 55, and an adjusting bolt 56. The mounting base 51 is fixed to the side panel of the grate frame 1. The first sliding assembly 52 is arranged closer to the inside of the furnace, and the second sliding assembly 54 is arranged closer to the outside of the furnace. The disc spring assembly 53 is disposed between the first sliding assembly 52 and the second sliding assembly 54. The adjusting bolt 56 passes through the clamping flange 55 and abuts against the second sliding assembly 54. During cold adjustment, turning the adjusting bolt 56 compresses the disc spring assembly 53 through the second sliding assembly 54, thereby pushing the first sliding assembly 52 to press against the grate beam assembly 4. During hot operation, the thermal expansion force of the grate beam compresses the disc spring assembly 53 through the first sliding assembly 52, and the elastic deformation of the disc spring assembly 53 absorbs the expansion and maintains a constant clamping force.

[0076] During gap adjustment, the operator tightens the adjusting bolt, pushing the second sliding assembly inwards into the furnace, compressing the middle disc spring assembly. The reaction force of the disc spring assembly is transmitted to the side of the grate beam through the first sliding assembly, pressing the grate beam to the appropriate position. At this time, the disc spring assembly stores a certain amount of elastic potential energy. During hot operation, as the grate temperature rises, the grate beam thermally expands and exerts an outward thrust on the first sliding assembly. At this time, the disc spring assembly is further compressed, absorbing the expansion displacement of the grate beam through its own elastic deformation, maintaining a constant pressing force on the grate beam. Conversely, when the grate cools and contracts, the disc spring assembly rebounds, maintaining contact and preventing gap impact. This flexible force transmission mechanism allows the grate beam to maintain a suitable pressing state at different temperatures.

[0077] In this way, the disc spring assembly overcomes the drawbacks of traditional rigid tightening devices, which are prone to both loosening and jamming. The disc spring assembly acts as a mechanical spring damper, automatically compensating for dimensional fluctuations caused by temperature changes and wear, maintaining a constant preload across the entire temperature range. This not only effectively prevents deformation or damage to the grate beam due to thermal expansion, but also avoids localized stress concentration caused by excessive rigidity, significantly extending the service life of the grate beam and the adjustment device itself, and ensuring the long-term stability of the grate gap under frequent start-stop and variable load conditions.

[0078] Specifically, the gap adjusting device is a spring-type furnace-side clamping device for adjusting the gap of a moving grate. In one embodiment, the gap adjusting device 5 includes a mounting base 51, a first sliding assembly 52, a disc spring assembly 53, a second sliding assembly 54, a clamping flange 55, adjusting bolts 56, welding nuts 57, and locking nuts 58. The mounting base is connected to the vertical surface of the side plate of the grate frame via a flange. A first slider guide plate is installed inside the mounting base near the furnace interior. A flange is installed at one end of the mounting base outside the furnace and is bolted to the clamping flange. The first sliding assembly is welded from round steel and a circular steel plate. The round steel passes through the first slider guide plate, and the circular steel plate is placed vertically within the mounting base, allowing the first sliding assembly to slide within the mounting base. The disc spring assembly consists of multiple disc springs, vertically arranged within the mounting base and located between the first and second sliding assemblies. The second sliding assembly is welded from round steel and a circular steel plate. The round steel passes through the inner hole of the disc spring assembly, and the circular steel plate is placed vertically within the mounting base, allowing the second sliding assembly to also slide within the mounting base. The outer side of the clamping flange is connected to the mounting base by fasteners, with a welded nut at its center. The nut is connected to the bolt, and a locking nut is provided outside the welded nut. This structure allows the bolt to move laterally by rotation and can be locked after adjustment.

[0079] During cold adjustment, loosening the locking nut and tightening the bolts allows the second sliding assembly, disc spring assembly, and first sliding assembly to move sequentially into the furnace. During this process, the disc spring assembly is compressed, allowing the second sliding assembly to directly push the first sliding assembly, which in turn pushes the grate beam inward along the width of the incinerator until it reaches a compressed state. Then, loosen the bolts and tighten the locking nut according to the set amount. At this time, under the action of the disc spring assembly, the second sliding assembly does not directly contact the first sliding assembly. During hot expansion of the grate beam, the outer stationary beam moves outward, sequentially pushing the first sliding assembly, disc spring assembly, and second sliding assembly outward until the second sliding assembly is limited by the bolts. At this time, the disc spring assembly has a certain amount of compression, and the first sliding block does not directly contact the second sliding assembly. The change in grate expansion is absorbed by the compression of the disc spring assembly, ensuring a constant tightening force. The round steel and shaped steel supporting the static beams of each column of the grate are continuous structures, and the round steel and shaped steel supporting the moving beams on each movable frame are also continuous structures. This continuous structure cooperates with the gap adjustment device and grate beam provided by this invention, ensuring the lateral movement space to guarantee the degree of freedom of thermal expansion without affecting the longitudinal positioning of the grate beam, and together realizes the gap adjustment function. The effective length of the bolt is about 300mm. Combined with the compression of the disc spring assembly, the adjustment range of the adjustment device reaches more than 250mm, ensuring the adjustment stroke in the width direction of the grate beam.

[0080] The following is combined Figures 10-13The movable frame provided by this invention is described in detail. In some embodiments, the bottom plate of the movable frame 3 completely covers the pins of the rollers supporting the movable frame within its stroke range to prevent slag from leaking into the pins and bearings. Guide devices are provided on both sides of the movable frame 3 along the width direction of the grate to limit the displacement of the movable frame in the width direction and ensure the straightness of the movement trajectory. During a complete stroke of the grate's reciprocating motion, the bottom plate of the movable frame moves back and forth along with the movable frame. Because the size design of the bottom plate covers the area where the roller pins are located, regardless of whether the movable frame is at its forward or backward limit position, the roller pins and bearings are always enclosed below the bottom plate, physically isolated from the slag leaking down from above. Simultaneously, the guide devices (such as guide wheels or sliders) installed on both sides of the movable frame are always in close contact with the inner wall of the side plate of the grate frame, limiting the swaying of the movable frame in the width direction. This dual protection mechanism ensures that the movable frame can still slide smoothly along a preset straight trajectory without deviation or torsion under heavy load and high temperature conditions.

[0081] In this way, the bottom plate effectively prevents sharp, high-temperature, and corrosive slag particles from entering the roller bearing area, solving problems such as bearing jamming and rapid pin wear caused by foreign objects, and reducing the equipment failure rate. Combined with a high-precision guiding device, it ensures the linearity and stability of the moving frame movement, reduces movement impact and noise, improves the mechanical life and operational reliability of the entire grate transmission system, and reduces the frequency of downtime for maintenance.

[0082] Furthermore, the movable frame 3 is arranged within the grate frame 1 to support the grate moving beams 11. Similar to existing technologies, grate blocks 41 are installed on the grate moving beams 11. The movable frame 3 is configured to support 3, 4, or 5 grate moving beams 11, depending on the grate width. Each drive shaft is configured to drive one or two of the movable frames to move synchronously. Depending on the grate width, the movable frame is designed to support 3, 4, or 5 grate moving beams 11; each drive shaft can drive one or two movable frames to move synchronously, adapting to the needs of incinerators of different sizes. This achieves modular and universal design of the movable frame, reducing customized development workload, lowering design and manufacturing costs, and improving adaptability to different furnace types.

[0083] The movable frame is configured to adapt to grates with different inclination angles; specifically, when adapting to a 15° inclination grate, the movable frame advances upward at a 15° angle; when adapting to a 10° inclination grate, the movable frame advances upward at a 20° angle, in order to match the overall inclination angle of the grate and the waste conveying requirements, so that the same movable frame structure can adapt to multiple inclination grates, ensuring waste conveying efficiency and combustion effect, and improving product versatility and engineering applicability.

[0084] In a specific application scenario, the movable frame is arranged inside the grate frame, supporting the grate moving beams 11. The lower front and rear ends of the movable frame 3 are supported by rollers (2-3 per end). The rollers are fixed to the front plate assembly and the rear plate assembly of the grate frame, respectively. Specifically, there are at least two front rollers, which are located on the lower part of the front plate assembly of the movable frame and fixed to the support beam of the grate frame to support the movable frame at the front end; there are at least two rear rollers, which are located on the lower part of the rear plate assembly of the movable frame and fixed to the support beam of the grate frame to support the movable frame at the rear end. The specifications of the movable frame vary depending on the width of the grate. Each movable frame can support 3 / 4 / 5 moving beams. Each drive shaft drives 1-2 movable frames. Guide devices are provided at the front and rear ends to limit displacement in the width direction. In terms of the movement trajectory, the angle between the sliding plate of the movable frame and the grate is 30°. That is, a 15° grate corresponds to the movable frame moving upward by 15°, and a 10° grate corresponds to the movable frame moving upward by 20°. The whole structure moves back and forth along the direction of the sliding plate's inclination.

[0085] The movable frame 3 includes front rollers 31, rear rollers 32, a front plate assembly, a rear plate assembly, and a longitudinal beam assembly 33. At least two front rollers 31 are provided and located at the lower front end of the movable frame. The front rollers 31 are fixed to the support beams of the grate frame to support the movable frame at the front end. Specifically, the rollers are bolted to the beams of the grate frame via supports. The movable frame reciprocates under the traction and push of the pull rods, causing the sliding plate to move and the rollers to rotate. At least two rear rollers 32 are provided. Each of the following is provided: a rear support roller 32 is fixed to the rear plate assembly to support the movable frame at the rear end; the front end of the grate moving beam 11 is installed on the front plate assembly to achieve longitudinal positioning of the grate moving beam 11 at the front end; the rear end of the grate moving beam 11 overlaps the rear plate assembly to allow the grate moving beam 11 to move freely under longitudinal thermal expansion; the front end of the longitudinal beam assembly 33 is installed on the front plate assembly, and its rear end is installed on the rear plate assembly.

[0086] During grate operation, the movable frame rests entirely on the front support rollers 31 and the rear support rollers 32. The front support rollers 31 are fixed to the front plate assembly, and the rear support rollers 32 are fixed to the rear plate assembly, jointly supporting the weight of the movable frame. The drive mechanism drives the movable frame to reciprocate along the tilt angle of the grate movable frame slide plate via a tie rod. The front end of the grate moving beam 11 is mounted on the front plate assembly for longitudinal positioning; the rear end overlaps the rear plate assembly. When the grate expands due to heat, the rear end of the moving beam can slide freely along the rear plate assembly, thereby releasing thermal stress. The longitudinal beam assembly 33 connects the front plate assembly and the rear plate assembly, forming an integral load-bearing skeleton. In this way, the beam support method of front-end positioning and rear-end overlapping and sliding ensures the longitudinal position stability of the grate moving beam 11 while allowing its longitudinal thermal expansion to be released freely, avoiding deformation or breakage caused by thermal stress. The front and rear support rollers separate the movable frame from the grate frame, allowing the drive components to avoid high-temperature and high-dust areas, significantly reducing wear rate and improving operational reliability.

[0087] The aforementioned front plate assembly includes a round steel bar 34, a front crossbeam 35, a column 36, and a front sliding plate 37. The round steel bar 34 is a continuous round steel bar extending along the width direction of the grate, and the front end of the grate moving beam 11 is engaged with the round steel bar 34. The round steel bar 34 is fixed to the front crossbeam 35 via a round steel support plate 38, and the front crossbeam 35 is connected to the front sliding plate 37 via the column 36. A wear-resistant plate 39 is detachably mounted on the front sliding plate 37. Thus, the front end of the grate moving beam 11 is engaged with the round steel bar 34, which extends continuously along the width direction of the grate. The round steel bar 34 is fixed to the front crossbeam 35 via the round steel support plate 38, and the front crossbeam 35 is connected to the front sliding plate 37 via the column 36. The wear-resistant plate 39 is detachably mounted on the front sliding plate 37, allowing relative sliding with the contact surface during the reciprocating motion of the movable frame. The continuous round steel 34 ensures that the front ends of multiple moving beams are on the same straight line, improving installation accuracy; the wear-resistant plate 9 has a detachable design, so that only the wear-resistant plate 39 needs to be replaced after wear, without replacing the entire front plate assembly, which greatly reduces maintenance costs.

[0088] Furthermore, the front plate assembly also includes an ear plate 310, which is connected to the drive rod of the moving grate and fixedly connected to the column 36. The ear plate 310 is fixed to the column 36, and the drive rod is hinged to the ear plate 310. When the drive mechanism operates, the tension is transmitted through the ear plate 310, column 36, and front crossbeam 35 to the entire movable frame, driving the movable frame to reciprocate. In this way, the driving load is evenly transmitted to the front plate assembly through the ear plate 310, avoiding localized stress concentration and improving structural fatigue life. Simultaneously, the detachable or welded connection between the ear plate 310 and the column 36 facilitates assembly and maintenance.

[0089] In a specific application scenario, the front assembly includes round steel 34, round steel support plate 38, front crossbeam 35, column 36, front sliding plate 37, and wear-resistant plate 39. The grate moving beam 11 is clamped on the round steel 34 of the front assembly. The round steel 34 is supported by the round steel support plate 38 welded to the front crossbeam 35. The round steel 34 and the round steel support plate 38 are connected by welding. The front crossbeam 35 is connected to the front sliding plate 37 and wear-resistant plate 39 through the column 36. The sliding plate and wear-resistant plate 39 are connected by countersunk screws to facilitate the replacement of wear-resistant plate 39. The column 36 is connected to the ear plate 310 for connecting the tie rod. The ear plate 310 and the column 36 are connected by welding or bolting.

[0090] The aforementioned rear plate assembly includes a supporting steel section 311, a rear crossbeam 312, and a rear sliding plate 313. The supporting steel section 311 is a non-continuous structure, corresponding one-to-one with the grate moving beam 11. One end of the supporting steel section 311 is welded to the grate moving beam 11, and the other end overlaps the rear crossbeam 312. A wear-resistant plate 39 is detachably mounted on the rear sliding plate 313. The rear end of the grate moving beam 11 overlaps the supporting steel section 311 fixed to the rear crossbeam 312. The rear sliding plate 313 engages with the contact surface via the detachable wear-resistant plate 39, bearing the pressure and friction at the rear end of the moving beam during the reciprocating motion of the movable frame. Thus, the supporting steel section 311 provides a continuous support surface for the rear end of the moving beam, allowing it to slide freely during thermal expansion. The detachable wear-resistant plate 39 design reduces subsequent maintenance costs and ensures the flatness of the rear support surface. In other words, the rear assembly includes a rear crossbeam 312, a rear sliding plate 313, and a wear-resistant plate 39. The wear-resistant plate 39 is mounted on the rear crossbeam 312, and the wear-resistant plate 39 and the crossbeam are connected by bolts, which facilitates the replacement of the wear-resistant plate 39. The rear sliding plate 313 is welded to the crossbeam, and the sliding plate and the wear-resistant sliding plate are also connected by countersunk bolts, which also facilitates the replacement of the wear-resistant plate 39.

[0091] In some embodiments, the grate control system includes an air volume and oxygen volume control module, which is configured to perform the following operations:

[0092] The boiler evaporation rate is set and measured. The deviation between the measured and set values ​​is calculated. The evaporation rate deviation is used as input to output the adjustment amount of the combustion air volume through PID calculation.

[0093] Obtain the set value and measured value of oxygen content in flue gas at boiler outlet, calculate the deviation of flue gas oxygen content between the measured value and the set value, and use the flue gas oxygen content deviation as input to output the speed reference value of the pusher and grate through PID calculation.

[0094] The adjustment amount of the combustion air volume is used as a feedforward signal in the calculation of the speed reference value to compensate for the lag in the measurement of the oxygen content in the flue gas, ensuring that the combustion air volume is automatically increased when the boiler evaporation rate is lower than the set value, and the operating speed of the pusher and each grate section is increased synchronously when the oxygen content in the flue gas increases accordingly.

[0095] During system operation, the system first monitors the actual and set values ​​of boiler evaporation in real time. After calculating the deviation, it quickly outputs the adjustment amount of combustion air volume through a PID controller. Subsequently, the system monitors the actual and set values ​​of flue gas oxygen content and calculates the oxygen deviation. Based on traditional oxygen cascade control, this system innovatively introduces the combustion air volume adjustment amount as a feedforward signal, which participates in the output calculation of the oxygen control loop. When the evaporation suddenly drops and air needs to be added, the feedforward signal acts on the grate speed control in advance, anticipating and compensating for the large lag characteristic of oxygen measurement. This allows the oxygen control loop to respond more quickly to load changes, adjust the pusher and grate speeds in a timely manner, and maintain the optimal ratio of combustion air to fuel.

[0096] This control strategy effectively solves the combustion instability problems caused by large fluctuations in calorific value and lag in oxygen measurement during waste incineration. Through airflow feedforward compensation, the system possesses advanced adjustment capabilities, significantly shortening the adjustment time under load disturbances and reducing the fluctuation range of flue gas oxygen content. This not only ensures the stability and economy of boiler combustion, avoiding the generation of large amounts of CO due to oxygen-deficient combustion or the reduction in thermal efficiency due to excessive oxygen combustion, but also reduces the workload of operators, achieving stable and efficient operation of the incineration process.

[0097] Furthermore, the grate control system also includes a material bed thickness control module, which is configured to perform the following operations:

[0098] Pressure measuring points are installed in the primary air chamber of each grate section, and flue gas pressure measuring points are installed in the furnace to collect the pressure of the air chambers in each grate section in real time. With furnace pressure Calculate the differential pressure between zones = - ;

[0099] Based on the partition differential pressure Zoned grate area The air volume measured by the anemometer and the actual air temperature measured by thermocouples The real-time material layer thickness is obtained by substituting the preset dimensionless material layer thickness formula. :

[0100]

[0101] Select the thickness of the material layer in the second grate As the master control object, its calculated value is compared with the set value using a PID controller, and the grate speed factor is output. The grate speed factor is defined as the first grate speed. With the second grate speed ratio / ;

[0102] The speed of the first grate and the pusher is adjusted according to the grate speed factor coupling: when the calculated value of the second section material layer thickness is greater than the set value, the ratio is reduced to slow down the speed of the first grate and the pusher, and prolong the residence time of the waste in the drying section; when the calculated value of the second section material layer thickness is less than the set value, the ratio is increased to increase the speed of the first grate and the pusher.

[0103] The system uses differential pressure sensors installed in the air chamber and furnace to calculate the ventilation resistance of each zone in real time. This resistance is then used to input a dimensionless formula for material layer thickness, which includes airflow, air temperature, and area, to calculate the actual thickness of the waste layer on the second grate. This calculated thickness is compared with a set value using a PID controller to obtain the grate speed factor (v1 / v2). If the calculated thickness is greater than the set value, it indicates excessive waste in the combustion zone, and the system automatically reduces the speed factor, slowing down the first grate speed and reducing the feed rate, allowing the waste to remain in the drying zone for a longer period. Conversely, if the calculated thickness is less than the set value, the system increases the speed factor to accelerate the feed. This mathematical model-based calculation control achieves precise quantitative management of the material layer thickness.

[0104] The pressure differential method-based soft measurement technology for bed thickness solves the problem of directly measuring the bed level in the high-temperature, high-dust environment inside the incinerator. By establishing a precise mathematical model, the system can accurately monitor the combustion status inside the furnace in real time, and dynamically control the waste drying time by adjusting the speed ratio of the first and second grate sections. This effectively prevents flameout or incomplete combustion caused by insufficiently dried waste entering the combustion section, as well as excessive air supply resistance due to an excessively thick bed, significantly improving combustion efficiency and automation control level.

[0105] In some embodiments, the grate control system further includes a hydraulic actuation control module configured to perform the following operations:

[0106] Displacement sensors are installed on the drive hydraulic cylinders of each grate section to collect displacement signals of the hydraulic cylinder piston rods in real time, and the actual movement speed of each hydraulic cylinder is calculated based on the displacement change per unit time.

[0107] The speed setpoint of each grate section is compared with the actual speed by PID control, and the proportional valve opening control signal is output.

[0108] Based on the preset mapping relationship between the proportional valve opening and the flow rate, the opening of the proportional valve on the oil pipeline of each hydraulic cylinder is adjusted to change the flow rate and direction of the hydraulic oil, thereby precisely controlling the extension and retraction speed of each hydraulic cylinder.

[0109] In the PID comparison process, dead zone compensation logic is introduced. When the deviation between the actual movement speed and the set value is less than the preset dead zone threshold, the opening of the proportional valve is locked to avoid hydraulic oscillation caused by frequent operation of the proportional valve within a small deviation range.

[0110] The system receives the speed setpoint from the upper-level control loop (such as material layer thickness control) and simultaneously calculates the actual speed by providing real-time feedback on the actual position of the piston rod through the displacement sensor on the hydraulic cylinder. The setpoint and actual speeds are then compared using a PID controller to output the proportional valve opening command. Specifically, a dead-zone compensation logic is introduced into the PID algorithm: when the deviation between the actual speed and the setpoint is within a very small preset range (dead zone), the system is considered to be in a steady state, and the proportional valve opening is locked without adjustment; only when the deviation exceeds the dead zone is PID regulation initiated. This mechanism effectively filters out sensor noise and minor disturbances, avoiding frequent, minute movements of the proportional valve near the target value.

[0111] In this way, the introduction of dead-zone compensation logic completely solves the "creeping" phenomenon and high-frequency oscillation problems that are easily caused by hydraulic systems when performing minor error corrections. It ensures smooth and stable operation of the hydraulic actuators, reduces hydraulic shock and energy consumption, and extends the service life of proportional valves, hydraulic cylinders, and hydraulic oil. At the same time, precise speed control makes the start-up, shutdown, and speed adjustment of the grate more gentle, reduces the impact on mechanical transmission components, and improves the mechanical life and control accuracy of the entire grate system.

[0112] In some embodiments, the multi-section grate section includes a drying section, a combustion section, and a burnout section;

[0113] The grate inclination angle of the drying section is greater than that of the grate inclination angle of the subsequent combustion section and burnout section; the height of the step is set to 0.8 meters to 1.2 meters; the length of each grate section is 1.8 meters to 3.5 meters;

[0114] The grate body is arranged in either a single row or a double row depending on its width: when the grate width is less than 6.5 meters, a single row arrangement is adopted, and the drive mechanism is only set on one side of the grate frame; when the grate width is greater than or equal to 6.5 meters, a double row arrangement is adopted, and the drive mechanism is set on both sides of the grate frame.

[0115] The waste undergoes three stages on the grate: drying, combustion, and burnout. In the drying section, a steeper incline (15°) facilitates the rapid descent of the waste and its absorption of radiant heat. As the waste tumbles over the first step and falls into the combustion section, it undergoes violent tumbling and loosening, increasing its contact area with air. The combustion and burnout sections employ a smaller incline (10°) to reduce the waste's descent speed and prolong combustion and burnout time. Depending on the grate width, the system automatically matches single-row or double-row drive modes: narrow grates use single-side drive for simplified structure; wide grates use double-side drive to ensure balanced driving torque. The length of each grate section can be flexibly configured within the range of 1.8 meters to 3.5 meters to adapt to different process requirements.

[0116] The multi-segment design, combined with differentiated tilt angles, perfectly matches the process curves of waste drying, combustion, and burnout, optimizing the residence time and trajectory of waste within the furnace. The stepped design, with its cascading and loosening effect, significantly enhances the combustion kinetics of the waste. The ability to freely switch between single-row and double-row drive gives the grate exceptional engineering adaptability, meeting the compact needs of small and medium-sized incinerators while also accommodating the high-load requirements of large incinerators, demonstrating remarkable engineering design flexibility and economy.

[0117] In some embodiments, the grate gap adjustment device is configured to provide a grate beam lateral movement stroke of not less than 250 mm to absorb the thermal expansion of the grate blocks and compensate for the wear caused by long-term operation.

[0118] For a double-row grate arrangement, the middle static beam is fixed in the width direction, allowing the grate gap between the left and right rows to be adjusted independently.

[0119] Thanks to the long supporting round steel and shaped steel sections, as well as the optimized slider structure, the grate gap adjustment device can provide an effective lateral travel of no less than 250mm. This large adjustment margin is sufficient to cover the thermal expansion and wear of the grate blocks throughout their entire life cycle from installation to scrapping. For double-row grates, since the middle static beam is fixed in the width direction, operators can operate the gap adjustment devices on the left and right sides separately to independently adjust the gap between the left and right grates. This independence allows for precise compensation even when one side of the grate wears faster or has different expansion rates, without the need for overall adjustment.

[0120] The extra-large adjustment stroke of over 250mm fundamentally solves the problem of short lifespan caused by insufficient adjustment range in traditional grates, significantly extending the service life of the grate. The dual-row independent adjustment function further enhances the convenience and precision of maintenance, allowing for personalized repairs based on the wear condition of different rows, avoiding the side effects of a "one-size-fits-all" adjustment. This not only reduces the consumption of spare parts but also ensures that the grate maintains excellent sealing and ventilation control performance even after long-term operation, guaranteeing long-term stability of combustion efficiency.

[0121] In one or more of the above specific embodiments, the multi-segment reciprocating mechanical grate with steps provided by the present invention has the following technical effects:

[0122] This invention overcomes the bottleneck of limited lateral movement of traditional grates by using a continuous arrangement of supporting round steel and shaped steel, combined with a gap adjustment device with disc springs. It not only provides an adjustment margin of no less than 250mm to fully absorb the thermal expansion of the grate blocks and compensate for long-term wear, but also utilizes the elastic deformation characteristics of disc springs to create a flexible buffer between cold pre-tightening and hot expansion. This solves the problem of jamming or excessive loosening that is easily caused by rigid top-tightening structures, keeps the gap between the dynamic and static beams stable throughout the entire life cycle, and significantly reduces the slag leakage rate.

[0123] Meanwhile, the movable frame base plate fully covers the idler roller pins, effectively preventing high-temperature slag from intruding into the moving parts, avoiding lateral displacement failure caused by wear forming steps at the rear end of the moving beam, and improving the service life of key components.

[0124] In terms of control strategy, the three-level closed-loop control system of air volume and oxygen content, material layer thickness, and hydraulic execution constructed in this invention realizes refined intelligent control of the incineration process; at the macro level, the feedforward of the evaporation signal compensates for the lag in the measurement of oxygen content in the flue gas, ensuring the boiler load response speed and combustion stability; at the core control level, a dimensionless material layer thickness calculation model based on the differential pressure method is used to accurately sense the material layer status in the combustion section, and intelligently match the residence time of waste in the drying section by dynamically adjusting the speed factors of the first and second grate sections to prevent incomplete combustion; at the execution level, hydraulic servo control with dead zone compensation logic is introduced to eliminate hydraulic oscillations caused by frequent operation of the proportional valve, ensuring the smooth operation of the grate.

[0125] In addition, the multi-stage stepped layout, combined with the differentiated tilt angle design of 15° for the drying section and 10° for the other sections, optimizes the waste falling and tumbling path, enhances the drying and mixing effect, and the flexible switching between single-row and double-row drive modes improves engineering adaptability, can meet the needs of incineration lines of different widths, and ultimately achieves a comprehensive improvement in the reliability of incinerator operation, combustion efficiency and environmental protection indicators.

[0126] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application.

[0127] The above description is merely a preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A multi-segment reciprocating mechanical grate with steps, characterized in that, Includes the grate body and grate control system; wherein: The grate body includes multiple grate sections arranged sequentially along the material conveying direction. At least some adjacent grate sections are provided with steps. Each grate section includes a grate frame, a drive mechanism, a movable frame, a grate beam assembly, and a grate gap adjustment device. The grate beam assembly includes multiple moving beams and multiple stationary beams, with the moving beams and stationary beams arranged alternately along the width of the grate; the moving beams are installed on the movable frame, and the stationary beams are installed on the grate frame; The grate gap adjustment device is installed on the side plate of the grate frame and is used to push the grate beam assembly to move along the width direction of the grate to adjust the gap between the moving beam and the stationary beam. The grate control system is electrically connected to the drive mechanism. The grate control system is configured to: collect real-time operating parameters characterizing the incineration conditions, process the real-time operating parameters based on a preset control algorithm, generate speed control commands corresponding to each grate section, and send the speed control commands to the drive mechanism to adjust the operating speed of each grate section, thereby achieving adaptive matching of the waste drying, combustion, and burnout processes.

2. The multi-segment reciprocating grate with steps as described in claim 1, characterized in that, The grate frame includes a front plate assembly, a rear plate assembly, and two side plates, with the upper surface of the side plates arranged at an angle to form a grate tilt angle. The drive mechanism includes a hydraulic cylinder, a drive shaft, an inner swing arm, and a tie rod; the hydraulic cylinder is arranged on the outside of the grate frame and is connected to the inner swing arm through the drive shaft passing through the side plate; one end of the tie rod is connected to the inner swing arm, and the other end is connected to the movable frame; The grate inclination angle is 10° or 15°, and the angle between the inclination angle of the movable frame base plate and the grate inclination angle is 30°, so that the movable frame has an upward component velocity when pushing materials.

3. The multi-segment reciprocating grate with steps as described in claim 2, characterized in that, In the grate beam assembly, the front end of the moving beam is engaged with the supporting round steel at the front end of the movable frame, and the rear end of the moving beam rests on the supporting profile steel at the rear end of the movable frame via angle steel; the front end of the stationary beam is engaged with the supporting round steel of the front plate assembly of the grate frame, and the rear end of the stationary beam rests on the supporting profile steel of the rear plate assembly of the grate frame via angle steel. Both the supporting round steel and the supporting profile steel are continuous structures, which allows the moving beam and the stationary beam to move freely along the width direction of the grate when heated and expanded.

4. The multi-segment reciprocating grate with steps according to claim 3, characterized in that, The grate gap adjustment device includes a mounting base, a first sliding assembly, a disc spring assembly, a second sliding assembly, a clamping flange, and adjusting bolts; The mounting base is fixed to the side plate facade of the grate frame. The first sliding component is arranged closer to the inside of the furnace, and the second sliding component is arranged closer to the outside of the furnace. The disc spring assembly is disposed between the first sliding component and the second sliding component. The adjusting bolt passes through the clamping flange and abuts against the second sliding assembly; During cold adjustment, turning the adjusting bolt compresses the disc spring assembly through the second sliding component, thereby pushing the first sliding component to press against the grate beam assembly; during hot operation, the thermal expansion force of the grate beam compresses the disc spring assembly through the first sliding component, and the elastic deformation of the disc spring assembly absorbs the expansion and maintains a constant pressing force.

5. The multi-segment reciprocating grate with steps according to claim 1, characterized in that, The upper surface of the base plate of the movable frame completely covers the pin of the roller supporting the movable frame within the stroke range to prevent slag from leaking into the pin and bearing parts. The movable frame is equipped with guide devices on both sides along the width direction of the grate to limit the displacement of the movable frame in the width direction and ensure the straightness of the movement trajectory.

6. The multi-segment reciprocating grate with steps according to claim 1, characterized in that, The grate control system includes an air volume and oxygen volume control module, which is configured to perform the following operations: The boiler evaporation rate is set and measured. The deviation between the measured and set values ​​is calculated. The evaporation rate deviation is used as input to output the adjustment amount of the combustion air volume through PID calculation. Obtain the set value and measured value of oxygen content in flue gas at boiler outlet, calculate the deviation of flue gas oxygen content between the measured value and the set value, and use the flue gas oxygen content deviation as input to output the speed reference value of the pusher and grate through PID calculation. The adjustment amount of the combustion air volume is used as a feedforward signal in the calculation of the speed reference value to compensate for the lag in the measurement of the oxygen content in the flue gas, ensuring that the combustion air volume is automatically increased when the boiler evaporation rate is lower than the set value, and the operating speed of the pusher and each grate section is increased synchronously when the oxygen content in the flue gas increases accordingly.

7. The multi-segment reciprocating grate with steps according to claim 6, characterized in that, The grate control system also includes a material bed thickness control module, which is configured to perform the following operations: Pressure measuring points are installed in the primary air chamber of each grate section, and flue gas pressure measuring points are installed in the furnace to collect the pressure of the air chambers in each grate section in real time. With furnace pressure Calculate the differential pressure between zones = - ; Based on the partition differential pressure Zoned grate area The air volume measured by the anemometer and the actual air temperature measured by thermocouples The real-time material layer thickness is obtained by substituting the preset dimensionless material layer thickness formula. : Select the thickness of the material layer in the second grate As the master control object, its calculated value is compared with the set value using a PID controller, and the grate speed factor is output. The grate speed factor is defined as the first grate speed. With the second grate speed ratio / ; The speed of the first grate and the pusher is adjusted according to the grate speed factor coupling: when the calculated value of the material layer thickness of the second section is greater than the set value, the ratio is reduced to slow down the speed of the first grate and the pusher, and prolong the residence time of the waste in the drying section. When the calculated thickness of the second material layer is less than the set value, the ratio is increased to improve the speed of the first grate and pusher.

8. The multi-segment reciprocating grate with steps according to claim 7, characterized in that, The grate control system also includes a hydraulic actuation control module, which is configured to perform the following operations: Displacement sensors are installed on the drive hydraulic cylinders of each grate section to collect displacement signals of the hydraulic cylinder piston rods in real time, and the actual movement speed of each hydraulic cylinder is calculated based on the displacement change per unit time. The speed setpoint of each grate section is compared with the actual speed by PID control, and the proportional valve opening control signal is output. Based on the preset mapping relationship between the proportional valve opening and the flow rate, the opening of the proportional valve on the oil pipeline of each hydraulic cylinder is adjusted to change the flow rate and direction of the hydraulic oil, thereby precisely controlling the extension and retraction speed of each hydraulic cylinder. In the PID comparison process, dead zone compensation logic is introduced. When the deviation between the actual movement speed and the set value is less than the preset dead zone threshold, the opening of the proportional valve is locked to avoid hydraulic oscillation caused by frequent operation of the proportional valve within a small deviation range.

9. The multi-segment reciprocating grate with steps according to claim 1, characterized in that, The multi-section grate section includes a drying section, a combustion section, and a burnout section; The grate inclination angle of the drying section is greater than that of the grate inclination angle of the subsequent combustion section and burnout section; the height of the step is set to 0.8 meters to 1.2 meters; the length of each grate section is 1.8 meters to 3.5 meters; The grate body is arranged in either a single row or a double row depending on its width: when the grate width is less than 6.5 meters, a single row arrangement is adopted, and the drive mechanism is only set on one side of the grate frame; when the grate width is greater than or equal to 6.5 meters, a double row arrangement is adopted, and the drive mechanism is set on both sides of the grate frame.

10. The multi-segment reciprocating grate with steps according to claim 4, characterized in that, The grate gap adjustment device is configured to provide a lateral movement stroke of not less than 250 mm for the grate beam, so as to absorb the thermal expansion of the grate blocks and compensate for the wear caused by long-term operation. For a double-row grate arrangement, the static beams on the left and right sides are fixed independently in the width direction, allowing for independent adjustment of the grate gap between the left and right rows.

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