A fault-tolerant operation device for a pneumatic control system of a hydrocyclone group

Abstract

The application discloses a kind of water power cyclone group pneumatic control system's fault prevention operation device, it is related to mineral classification equipment technical field, including pneumatic control cabinet, cyclone group and pneumatic valve, including pneumatic control cabinet, cyclone group and pneumatic valve, still include gas supply module, self-cleaning module and intelligent control module;Gas supply module is equipped with first gas supply unit, second gas supply unit and switching control unit, and automatically switches to standby gas source when gas supply is abnormal;Self-cleaning module is arranged on the pipeline downstream of each pneumatic valve, including purging unit and control unit, and high-pressure gas is introduced to blow and clean accumulated ore after valve is closed;Intelligent control module includes controller and state detection unit arranged on each valve, and according to preset strategy, valve sequence opening and closing is automatically controlled to realize reverse operation, and gas supply and self-cleaning state are monitored in real time.The application constructs multistage fault protection system from gas source guarantee, valve cleaning, intelligent control three dimensions, guarantees the normal reverse operation of cyclone group, reduces shutdown repair frequency and worker labor intensity.

Description

Technical Field

[0001] This invention relates to the field of mineral grading equipment technology, and more specifically to the field of a fault-prevention operation device for a pneumatic control system of a hydrocyclone assembly. Background Technology

[0002] Hydrocyclones are commonly used equipment for mineral classification and separation based on the principle of centrifugal sedimentation, and are widely used in mining beneficiation, ultrafine enrichment, and other operations. In large hydrocyclone arrays, pneumatic valves are typically used to control the feed flow of each hydrocyclone group, enabling reverse operation and group control. Existing technologies include automated control systems for pneumatic valves in hydrocyclone arrays, such as the technical solution disclosed in Chinese Invention Patent No. CN212107125U, which allows for individual control of valve components on a single hydrocyclone by setting multiple air pipes and multiple individual control switches. Furthermore, Chinese Invention Patent No. CN216459387U also discloses a pneumatic valve control device for the feed pipe of a hydrocyclone, which includes components such as an air compressor and an air storage tank.

[0003] However, in practical production applications, especially in ultrafine enrichment operations, due to the extremely high content and concentration of fine particles in the slurry, hydrocyclone units typically require long-term continuous high-load operation. This leads to frequent malfunctions in the pneumatic control system, severely restricting production efficiency and operational continuity. Existing technologies mainly suffer from the following shortcomings: First, the reliability of the air supply is insufficient. Existing pneumatic control systems for hydrocyclones typically rely on only a single air compressor as the sole air source. This compressor operates continuously under high loads for extended periods, resulting in a high failure rate. If the air compressor fails and shuts down, the air supply to the entire pneumatic control system is interrupted, all pneumatic valves become inoperable, and the reverse rotation of the hydrocyclone assembly is forced to stop. While some existing technologies propose a "one-for-one" backup design, their switching mechanisms are inadequate, lacking automated pressure detection and intelligent switching control, making it difficult to achieve truly uninterrupted air supply.

[0004] Secondly, the problem of ore buildup and jamming in pneumatic valves is prominent. Due to the high content of fine particles in the slurry, ore easily accumulates inside the pneumatic valve and at the valve seat. As the operating time increases, the ore layer gradually thickens, hardens, and forms scale, resulting in insufficient thrust of the pneumatic valve actuator to overcome the resistance of the ore buildup, preventing the valve from opening or closing properly. Especially after the valve is closed, the slurry remaining on the valve sealing surface and in the valve cavity gradually loses water and solidifies under pressure, forming a hard scale layer. When reopening, the actuator must overcome an extremely large opening and closing torque, which can easily cause the valve to jam or damage the actuator.

[0005] Third, there is a lack of systematic intelligent control methods. Existing pneumatic control systems for cyclone separators are mostly decentralized, lacking coordination between valves. Reverse operation relies on manual operation or simple timing control, failing to adapt to actual operating conditions. Furthermore, key operating parameters such as gas source status and valve status lack real-time monitoring and centralized control, making it difficult to detect and handle faults promptly.

[0006] The aforementioned problems have led to frequent shutdowns and maintenance of the hydrocyclone unit, which not only increases the labor intensity of workers but also seriously affects production efficiency and the continuity of ultrafine enrichment operations. Summary of the Invention

[0007] The purpose of this invention is to solve the technical problems in the prior art of air supply interruption due to air compressor failure and inability to reverse normal operation due to ore accumulation in valves, and to provide a fault-prevention operation device for the pneumatic control system of hydrocyclone group.

[0008] To achieve the above objectives, the present invention specifically adopts the following technical solution: This invention provides a fault-prevention operation device for a pneumatic control system of a hydrocyclone group, including a pneumatic control cabinet, several hydrocyclones and pneumatic valves that are correspondingly installed on the feed pipes of each hydrocyclone, and also includes a dual air supply module, a valve anti-jamming self-cleaning module and an intelligent reverse control module. The dual-source air supply module includes a main air compressor, a standby air compressor, a main air tank, a standby air tank, a first switching valve, a second switching valve, and a pressure detection controller. The main air compressor outlet pipe is connected to the main air tank inlet; the standby air compressor outlet pipe is connected to the standby air tank inlet; the main air tank outlet pipe and the standby air tank outlet pipe merge to form an air supply manifold, which is connected to the pneumatic control cabinet inlet; the first switching valve is mounted on the main air tank outlet pipe, and the second switching valve is mounted on the standby air tank outlet pipe; the pressure detection controller collects the internal pressure signals of the main air tank and the standby air tank respectively, and the pressure detection controller outputs control signals that are electrically connected to the first switching valve and the second switching valve respectively. Each valve anti-jamming self-cleaning module is configured in a corresponding manner on the feed pipe between the downstream of each pneumatic valve and the feed inlet of the hydrocyclone. The valve anti-jamming self-cleaning module includes a cleaning gas inlet branch pipe, a cleaning control valve, and a timer controller. One end of the cleaning gas inlet branch pipe draws gas from the main gas supply line inside the pneumatic control cabinet, and the other end is connected to the feed pipe downstream of the pneumatic valve. The cleaning control valve is connected in series on the cleaning gas inlet branch pipe. The timer controller is electrically connected to the cleaning control valve. The timer controller receives the valve closing completion signal and triggers the cleaning control valve to open after a delay after the pneumatic valve completes the closing action, so that high-pressure purging gas is introduced into the feed pipe. The intelligent reverse control module includes a PLC controller and valve position sensors installed on each pneumatic valve. The valve position sensors are used to collect the actual fully open / fully closed valve position status of the pneumatic valves, and the signal output terminal of the valve position sensors is connected to the PLC controller. The PLC controller outputs control signals to connect to the solenoid valves that are matched with each pneumatic valve. The PLC controller establishes signal interaction links with the pressure detection controller and each timer controller.

[0009] In one embodiment, the dual-gas-source supply module is also equipped with an audible and visual alarm, which is electrically connected to the pressure detection controller. When the pressure detection controller detects that the pressure in the gas storage tank is lower than a preset pressure threshold, it drives the audible and visual alarm to output an alarm signal.

[0010] In one embodiment, a one-way valve is connected in series on the clean gas inlet branch pipe. The gas conduction direction of the one-way valve is from the gas supply main pipe to the feed pipe, preventing the slurry from flowing back into the gas supply line.

[0011] In one embodiment, the intelligent reversal control module is equipped with a touch-screen human-machine interface, which is electrically connected to the PLC controller. The touch-screen human-machine interface is used to display the operating status of each unit of the hydrocyclone group, the air source pressure parameters, and to receive process parameters such as reversal sequence, reversal interval, purging delay, and purging duration input by the operator.

[0012] In one embodiment, the pneumatic valve is selected as a wear-resistant knife gate valve or a wear-resistant butterfly valve; the working surface of the pneumatic valve body in contact with the slurry is compositely provided with a wear-resistant ceramic lining.

[0013] In one implementation, the rated discharge pressure of the standby air compressor is consistent with that of the main air compressor, and the discharge capacity of the standby air compressor is set to 30%-50% of that of the main air compressor; the standby air compressor is only used to provide air for the instantaneous opening and closing of pneumatic valves.

[0014] In one embodiment, the valve anti-jamming self-cleaning module further includes a purge nozzle, which is mounted at the inlet of the cleaning gas inlet branch pipe into the feed pipe, and sprays high-pressure gas toward the hydrocyclone inlet.

[0015] In one implementation, the PLC controller is equipped with a fault judgment logic unit. The PLC controller compares the control command output to the pneumatic valve with the actual valve position signal returned by the valve position sensor. When the mismatch between the command and the actual valve position signal continues for more than a set time threshold, the valve is determined to be stuck and a fault alarm signal is output to the touch human-machine interface.

[0016] In one implementation, the pressure detection controller internally sets pressure thresholds, including a primary low-pressure threshold and a backup low-pressure threshold; when the pressure in the main gas storage tank is lower than the primary low-pressure threshold, the gas source switching logic is automatically executed; the switching action to complete the gas supply switching takes less than or equal to 0.5 seconds.

[0017] In one embodiment, the timing controller is configured with a purging delay parameter range of 2-5s and a purging duration parameter range of 3-8s; the purging high-pressure gas pressure is maintained at 0.5-0.7MPa; the cyclone group consists of multiple cyclones connected in parallel, with a total of 43 cyclone groups, and the number of pneumatic valves is matched one-to-one with the number of cyclones.

[0018] The beneficial effects of this invention are as follows: 1. Ensure uninterrupted air supply and continuous system operation. By setting up a dual air supply module, when the main air compressor fails and stops, the pressure detection controller automatically detects the drop in main air supply pressure and immediately controls the first switching valve to close and the second switching valve to open, seamlessly switching to the standby air compressor for air supply. This ensures an uninterrupted air supply to the pneumatic control system and guarantees the normal operation of all pneumatic valves. The standby air compressor can be a small air compressor with lower power, only needing to meet the instantaneous air demand for pneumatic valve operation, resulting in low energy consumption and low investment.

[0019] 2. Effectively prevents valve jamming due to ore buildup, significantly reducing the frequency of manual cleaning. By incorporating a valve anti-jamming self-cleaning module, a timer controller opens the cleaning control valve after a delay each time the pneumatic valve is closed. High-pressure gas is introduced into the downstream pipeline, using its impact force to disperse and remove ore particles accumulated on the valve's sealing surface and within the valve cavity. This design effectively prevents the long-term accumulation of ore at the valve, avoiding the problem of the pneumatic valve becoming unable to move due to excessive ore buildup. This greatly reduces the frequency of manual valve cleaning and extends the valve's service life.

[0020] 3. Achieve integrated intelligent control of the entire system. By setting up an intelligent reverse control module, the PLC controller automatically controls the sequential opening and closing of the pneumatic valves of each hydrocyclone group according to the preset reverse operation strategy and the actual feedback signal from the valve position sensor, realizing the automatic reverse operation of the hydrocyclone group. At the same time, the PLC controller monitors the pressure status of the dual air supply module and the operating status of the valve anti-jamming self-cleaning module in real time, realizing coordinated control and intelligent management of the entire chain of air supply-execution-cleaning.

[0021] 4. Multi-level fault protection significantly improves system reliability. This invention constructs a multi-level fault protection system from three dimensions: air supply guarantee, valve cleaning, and intelligent control. The dual air supply module solves the root cause problem of air supply interruption, the valve anti-jamming and self-cleaning module solves jamming faults at the execution level, and the intelligent reverse control module realizes real-time monitoring of the operating status and abnormal early warning. The three levels of protection cooperate and work together to fundamentally improve the operational reliability of the pneumatic control system.

[0022] 5. Reasonable structure, low modification cost, and wide applicability. This device has a reasonable structure and low modification cost. It can be retrofitted to the existing pneumatic control system of hydrocyclone groups. It is suitable for large-scale mineral processing systems with 43 or more hydrocyclones operating in parallel, and has broad application value. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0025] Figure 2 This is a schematic diagram of the dual-gas-source supply module of the present invention.

[0026] Figure 3 This is a schematic diagram of the installation of the valve anti-jamming self-cleaning module of the present invention.

[0027] Figure 4 This is a control logic block diagram of the intelligent reversal control module of the present invention.

[0028] Figure label: 1. Main air compressor; 2. Backup air compressor; 3. Main gas storage tank; 4. Spare gas storage tank; 5. First switching valve; 6. Second switching valve; 7. Pressure detection controller; 8. Pneumatic control cabinet; 9. Hydrocyclone; 10. Pneumatic valves; 11. Clean gas is introduced into the branch pipe; 12. Cleaning control valve; 13. Timer controller; 14. PLC controller; 15. Valve position sensor; 16. Alarm device; 17. Check valve; 18. Touchscreen human-computer interaction interface. Detailed Implementation

[0029] To make the technical problems, technical solutions, and technical effects of the present invention clearer, 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 some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0030] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0031] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0032] In the description of the embodiments of the present invention, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0033] Example 1 like Figure 1As shown, this embodiment provides a fault-prevention operation device for the pneumatic control system of a hydrocyclone group, including a pneumatic control cabinet 8, 43 hydrocyclones 9, and pneumatic valves 10 correspondingly installed on the feed pipes of each hydrocyclone 9. In this embodiment, the 43 hydrocyclones 9 are arranged in three staggered rows, with approximately 14-15 groups in each row. The feed pipes of each hydrocyclone 9 are led out from the main feed pipe, and each feed pipe is independently equipped with a pneumatic valve 10 to achieve independent control of the feed of each hydrocyclone 9. The pneumatic control cabinet 8 integrates an air source treatment triplet (including a filter, pressure reducing valve, and oil mist lubricator), a solenoid valve group, and a distribution manifold, which are used to purify, regulate, and distribute the input air source, and deliver compressed air to the actuators of each pneumatic valve 10 according to control commands.

[0034] like Figure 1 and combined Figure 2 As shown, the dual-source air supply module includes a main air compressor 1, a standby air compressor 2, a main air storage tank 3, a standby air storage tank 4, a first switching valve 5, a second switching valve 6, and a pressure detection controller 7. The main air compressor 1 is connected to the air inlet of the main air storage tank 3 via a first pipeline, and the standby air compressor 2 is connected to the air inlet of the standby air storage tank 4 via a second pipeline. Both the main air storage tank 3 and the standby air storage tank 4 are pressure vessels, and their volumes are designed according to the air consumption. In this embodiment, the volume of the main air storage tank 3 is 2 m³, and the volume of the standby air storage tank 4 is 1 m³. Drain valves are respectively installed at the bottom of the main air storage tank 3 and the bottom of the standby air storage tank 4 to periodically drain accumulated condensate and oil, ensuring air supply quality. Safety valves are installed on the top of both the main gas storage tank 3 and the standby gas storage tank 4. When the pressure inside the tank exceeds the set safety pressure (e.g., 0.85 MPa), the safety valves automatically open to release pressure, ensuring the safe operation of the gas storage tanks. Pressure gauges are installed on both the main gas storage tank 3 and the standby gas storage tank 4 to display the pressure inside the tank on-site, facilitating intuitive reading by operators during inspections.

[0035] Both the main gas storage tank 3 and the standby gas storage tank 4 are pressure vessels, and their volumes are designed according to the gas consumption. In this embodiment, the main gas storage tank 3 has a volume of 2 m³, and the standby gas storage tank 4 has a volume of 1 m³. Drain valves are installed at the bottom of both the main gas storage tank 3 and the standby gas storage tank 4 to periodically drain accumulated condensate and oil, ensuring gas supply quality. Safety valves are installed at the top of both the main gas storage tank 3 and the standby gas storage tank 4. When the pressure inside the tank exceeds the set safety pressure (e.g., 0.85 MPa), the safety valves automatically open to release pressure, ensuring the safe operation of the gas storage tanks. Pressure gauges are installed on both the main gas storage tank 3 and the standby gas storage tank 4 to display the internal pressure on-site, facilitating intuitive reading by operators during inspections.

[0036] A first switching valve 5 is installed on the outlet pipe of the main gas tank 3, and a second switching valve 6 is installed on the outlet pipe of the backup gas tank 4. After the outlet pipes of the main gas tank 3 and the backup gas tank 4 merge at the junction, they are connected to the air inlet of the pneumatic control cabinet 8 via the main gas supply pipe. In this embodiment, both the first switching valve 5 and the second switching valve 6 are two-position, two-way solenoid valves, which have the advantages of fast response and good sealing performance, and can quickly perform opening or closing actions after receiving an electrical signal. The solenoid coils of the first switching valve 5 and the second switching valve 6 are electrically connected to the pressure detection controller 7, which controls their on / off state according to the detected pressure signal.

[0037] The pressure detection controller 7 is an intelligent controller integrating pressure detection, signal processing, and logic control functions. Specifically, it includes a first pressure sensor, a second pressure sensor, a signal processing circuit, and a microcontroller unit (MCU). The first pressure sensor is installed on the main gas tank 3 or on its outlet pipe, used to detect the gas pressure inside the main gas tank 3 in real time and convert the pressure signal into an electrical signal, which is then transmitted to the MCU. The second pressure sensor is installed on the backup gas tank 4 or on its outlet pipe, used to detect the gas pressure inside the backup gas tank 4 in real time and convert the pressure signal into an electrical signal, which is then transmitted to the MCU. The MCU has a preset pressure threshold program for comparing and judging the received pressure signals, and outputs switching control signals to the first switching valve 5 and the second switching valve 6 based on the judgment result. The MCU can be a PLC module or a microcontroller module; in this embodiment, a Siemens S7-200 series PLC module is preferred due to its high reliability, strong anti-interference capability, and ease of programming. The pressure detection controller 7 is installed inside the pneumatic control cabinet 8 or independently in an explosion-proof control box on site. In this embodiment, it is preferably installed inside the pneumatic control cabinet 8 to reduce external wiring and floor space.

[0038] like Figure 1 and combined Figure 3 As shown, the self-cleaning module has a branch interface on the feed pipe, which is used to connect to the purging unit. The purging unit includes a cleaning gas inlet branch pipe 11, a cleaning control valve 12, and a timer controller 13.

[0039] The clean gas inlet branch pipe 11 is made of pressure-resistant flexible hose or rigid metal pipe. In this embodiment, a steel wire braided rubber hose with an inner diameter of 10mm is preferred, as it has the advantages of high pressure resistance and good flexibility, facilitating on-site pipe laying and installation. One end (inlet end) of the clean gas inlet branch pipe 11 is connected to the main gas supply line of the pneumatic control cabinet 8. Specifically, the inlet end of the clean gas inlet branch pipe 11 is connected to the distribution manifold of the main gas supply line inside the pneumatic control cabinet 8. This distribution manifold is connected to the main gas supply line, and the gas pressure inside it is the same as the pressure of the main gas supply line (approximately 0.5-0.7MPa). The other end (outlet end) of the clean gas inlet branch pipe 11 is connected to the branch interface on the feed pipe downstream of the pneumatic valve 10, thereby connecting the main gas supply line and the feed pipe downstream of the pneumatic valve 10 to form a gas purging channel.

[0040] A cleaning control valve 12 is installed on the cleaning gas inlet branch pipe 11 to control the opening and closing of the cleaning gas inlet branch pipe 11. In this embodiment, the cleaning control valve 12 is a two-position, two-way, direct-acting solenoid valve, which has the advantages of simple structure, rapid response, and reliable sealing, and is suitable for frequent on / off control of pneumatic systems. The solenoid coil of the cleaning control valve 12 is electrically connected to a timer controller 13, which controls its opening and closing. The diameter of the cleaning control valve 12 matches the inner diameter of the cleaning gas inlet branch pipe 11; in this embodiment, a solenoid valve with a diameter of 8mm is selected.

[0041] The timing controller 13 is a dedicated time relay or a controller with integrated timing function, internally equipped with a delay circuit and a timing circuit. The timing controller 13 is signal-connected to the solenoid valve or valve position sensor 15 of the pneumatic valve 10 to obtain the actuation signal of the pneumatic valve 10. Specifically, the input terminal of the timing controller 13 is electrically connected to the control signal terminal of the solenoid valve of the pneumatic valve 10 or the signal output terminal of the valve position sensor 15. When the pneumatic valve 10 performs a closing action (i.e., the solenoid valve receives a closing signal or the valve position sensor 15 detects that the valve is beginning to close), the timing controller 13 is triggered to start timing. The output terminal of the timing controller 13 is electrically connected to the solenoid coil of the cleaning control valve 12, used to output an opening signal to the cleaning control valve 12 after a predetermined delay time, and to output a closing signal to the cleaning control valve 12 after a predetermined purging duration. The timing controller 13 can be a JSZ3 series electronic time relay, whose delay time can be set via a knob or button, offering convenient operation and high accuracy.

[0042] A one-way valve 17 is also installed on the clean gas inlet branch pipe 11. The one-way valve 17 is located downstream of the clean control valve 12 (i.e., near the feed pipe) to prevent slurry in the feed pipe from flowing back into the clean gas inlet branch pipe 11 and the clean control valve 12 during pressure fluctuations. The opening pressure of the one-way valve 17 is 0.02-0.05 MPa. When the gas pressure on the supply side is higher than the gas pressure on the feed pipe side, the one-way valve 17 is open; when the gas pressure on the feed pipe side is higher than the gas pressure on the supply side, the one-way valve 17 is closed, effectively blocking the slurry backflow channel. The one-way valve 17 further improves the operational reliability and safety of the self-cleaning module.

[0043] like Figure 1 and combined Figure 4 As shown, the intelligent reversing control module includes a PLC controller 14 and valve position sensors 15 installed on each pneumatic valve 10. The PLC controller 14 is the core control unit of this device, and it adopts a Siemens S7-1200 series programmable logic controller, which has the advantages of fast operation speed, abundant I / O points, and complete communication interfaces. The I / O ports of the PLC controller 14 are electrically or signal connected to the solenoid valves, pressure detection controllers 7, timing controllers 13, valve position sensors 15, and other components of each pneumatic valve 10.

[0044] Valve position sensors 15 are installed on the actuator or valve body of each pneumatic valve 10 to detect the actual open / closed state of the corresponding pneumatic valve 10. In this embodiment, the valve position sensor 15 is preferably a proximity limit switch, which includes a sensing head fixedly mounted on the valve body and a sensing block mounted on the valve stem or actuator. When the pneumatic valve 10 is in the fully open position, the sensing block approaches the sensing head, and the limit switch outputs an open signal; when the pneumatic valve 10 is in the fully closed position, the sensing block moves away from the sensing head, and the limit switch outputs a closed signal. The valve position sensor 15 can also be a potentiometer-type angular displacement sensor or a magnetic position sensor to provide a continuous change signal in valve opening. In this embodiment, a proximity limit switch with switch output is preferred, as it has a simple structure, low cost, and high reliability. The signal output terminals of each valve position sensor 15 are connected to the corresponding I / O input terminals of the PLC controller 14 via signal cables, feeding back the actual open / closed state of each pneumatic valve 10 to the PLC controller 14 in real time.

[0045] The PLC controller 14 has a pre-set reverse operation control program. This program sets operating parameters such as the reverse sequence, reverse interval, and valve opening holding time for each hydrocyclone 9 according to the reverse process requirements of the hydrocyclone group 9. Based on the preset operating strategy and the actual valve position signals fed back by each valve position sensor 15, the PLC controller 14 outputs open or close control commands to the solenoid valves of each pneumatic valve 10 according to a predetermined timing logic. This drives each pneumatic valve 10 to perform opening and closing actions sequentially, thereby automatically controlling the feeding and stopping of each group of hydrocyclones 9, achieving automatic reverse operation of the hydrocyclone group 9. Specifically, when a group of hydrocyclones 9 needs to be reversed, the PLC controller 14 first sends a closing command to the solenoid valve of the corresponding pneumatic valve 10. The actuator of the pneumatic valve 10 actuates, driving the valve plate to move towards the valve seat until the valve is completely closed. After the valve position sensor 15 detects that the valve is completely closed, it feeds back the closed status signal to the PLC controller 14. After receiving the closure confirmation signal, the PLC controller 14 starts a countdown. Once the set reversal interval is reached, it sends an opening command to the solenoid valve of the corresponding pneumatic valve 10 for that group of hydrocyclones 9. The actuator of the pneumatic valve 10 reverses its movement, driving the valve plate away from the valve seat until the valve is fully open. After the valve position sensor 15 detects that the valve is fully open, it feeds back the opening status signal to the PLC controller 14, completing the reversal operation of one group of hydrocyclones 9. Following this process, the PLC controller 14 sequentially performs reversal operations on each group of hydrocyclones 9, achieving automatic sequential reversal operation of the entire hydrocyclone group 9.

[0046] Meanwhile, the PLC controller 14 is connected to the pressure detection controller 7 and the timer controller 13 respectively, receiving in real time the pressure signals from the main air tank 3 and the backup air tank 4 sent by the pressure detection controller 7, as well as the working status signal of the cleaning control valve 12 sent by the timer controller 13. The PLC controller 14 performs comprehensive monitoring and coordinated control of the operating status of each module based on the received signals. For example, when the PLC controller 14 receives a low pressure signal from the pressure detection controller 7 for the main air tank 3, it can send an alarm display command to the human-machine interface 18 to remind the operator. As another example, when the PLC controller 14 determines that the valve position sensor 15 of a certain group of pneumatic valves 10 has not returned a position signal within a predetermined time, it can determine that the valve may have a jamming fault and send a fault alarm message to the human-machine interface 18. Simultaneously, it can send a forced cleaning command to the timer controller 13 corresponding to the valve, initiating a cleaning and purging program to attempt to remove accumulated ore.

[0047] The working principle and complete workflow of the above device are as follows: The workflow for normal gas supply and automatic gas source switching is as follows: During normal operation, the main air compressor 1 continuously generates compressed air, which enters the main air tank 3 through pipelines for storage and pressure stabilization. The compressed air pressure in the main air tank 3 is typically maintained at 0.6-0.7 MPa. At this time, the pressure detection controller 7 monitors the pressure of the main air tank 3 and the backup air tank 4 in real time and transmits the pressure signal to the PLC controller 14. Under normal circumstances, if the pressure of the main air tank 3 is higher than a set threshold (e.g., 0.5 MPa), the pressure detection controller 7 outputs a control signal to open the first switching valve 5 and close the second switching valve 6. The first switching valve 5 is energized and opens, while the second switching valve 6 is de-energized and closes. The compressed air in the main air tank 3 enters the pneumatic control cabinet 8 through the first switching valve 5 and the main air supply pipeline. After being filtered and pressure regulated by the air source treatment unit, it is distributed to the solenoid valves of each pneumatic valve 10. Under the control of the PLC controller 14, each pneumatic valve 10 operates according to a preset strategy to realize the feeding control and reverse operation of the hydrocyclone 9. The standby air compressor 2 is in a stopped or standby state at this time, and the standby air tank 4 is pre-stored with compressed air at a set pressure as an emergency air source reserve.

[0048] When the main air compressor 1 shuts down due to overload, high temperature, lack of oil, electrical fault, or other reasons, it stops operating, and the main air tank 3 no longer receives new compressed air. As the pneumatic control system continues to use air, the pressure in the main air tank 3 gradually decreases. The first pressure sensor in the pressure detection controller 7 transmits the pressure signal of the main air tank 3 to the microcontroller unit in real time. The microcontroller unit continuously compares the received pressure value with a preset threshold (e.g., 0.4 MPa). When the microcontroller unit determines that the pressure in the main air tank 3 is below 0.4 MPa (i.e., below the set threshold), it confirms that there is an air supply abnormality in the main air supply unit and immediately executes the switching control logic: it outputs a shut-off signal (power off) to the first switching valve 5, which quickly closes, cutting off the air path from the main air tank 3 to the pneumatic control cabinet 8; simultaneously, it outputs an open signal (power on) to the second switching valve 6, which quickly opens, connecting the air path from the backup air tank 4 to the pneumatic control cabinet 8. Compressed air pre-stored in the spare air tank 4 enters the pneumatic control cabinet 8 through the second switching valve 6 and the main air supply line, continuing to provide air power to each pneumatic valve 10. The entire switching process is completed within 0.5 seconds, and the air intake pressure of the pneumatic control cabinet 8 remains basically uninterrupted. Each pneumatic valve 10 can continue to perform its normal operation, and the operation of the cyclone group 9 is unaffected.

[0049] At the same time, the pressure detection controller 7 sends the switching action signal and the low pressure signal of the main air tank 3 to the PLC controller 14. After receiving the signal, the PLC controller 14 records the fault log and sends an alarm display command to the touch human-machine interface 18. The touch human-machine interface 18 displays the prompt message "Main air compressor fault, switched to backup air source" and displays the current air supply status.

[0050] The valve self-cleaning process is as follows: During the normal operation of the pneumatic valve 10, when the PLC controller 14 issues a closing command to the solenoid valve of a certain group of pneumatic valves 10 according to the reverse operation strategy, the actuator of the pneumatic valve 10 drives the valve plate to move towards the valve seat until the valve plate and the valve seat are tightly fitted, and the valve is completely closed. At the moment of valve closing or during the closing process, the timing controller 13 obtains the closing action signal of the pneumatic valve 10 through the signal connection. This signal can be the control signal of the solenoid valve, or it can be the signal from the valve position sensor 15 indicating that the valve has started to close or is fully closed.

[0051] Upon receiving the closing action signal, the timer controller 13 immediately activates its internal delay circuit to begin timing. The delay time is set to 2-5 seconds (adjustable according to actual operating conditions; in this embodiment, it is preferably set to 3 seconds). The purpose of the delay time is to ensure that the pneumatic valve 10 is fully closed, and to wait for the valve actuator to completely stop operating, thus avoiding overlap between the high-pressure gas purging and the valve closing action, which could affect the normal closing and sealing of the valve.

[0052] After a 3-second delay, the output of the timer controller 13 sends an opening signal to the solenoid coil of the cleaning control valve 12. The cleaning control valve 12 is energized and opens, its valve core opens, and the cleaning gas inlet branch pipe 11 changes from a closed state to a conducting state. High-pressure gas (0.5-0.7 MPa) in the main gas supply line of the pneumatic control cabinet 8 passes through the cleaning gas inlet branch pipe 11, the cleaning control valve 12, and the check valve 17, and then enters the feed pipe from the branch interface on the feed pipe downstream of the pneumatic valve 10. After entering the feed pipe, the high-pressure gas creates a strong airflow impact and turbulence effect at the valve outlet. Utilizing the impact force, shear force, and diffusion effect of the high-pressure gas, the slurry particles accumulated on the valve sealing surface, inside the valve cavity, and on the inner wall of the pipe near the valve outlet are blown away, loosened, and carried away, effectively preventing the slurry from remaining, depositing, and hardening into scale at the valve.

[0053] The purging duration is set by the timing circuit inside the timing controller 13, and is set to 3-8 seconds (preferably 5 seconds in this embodiment). After 5 seconds of purging, the output of the timing controller 13 outputs a closing signal to the solenoid coil of the cleaning control valve 12, the cleaning control valve 12 is de-energized and closes, its valve core resets, the cleaning gas inlet branch pipe 11 returns to the shut-off state, and the purging cleaning work is completed. Throughout the purging process, the one-way valve 17 always ensures that gas can only flow from the main gas supply line to the feed pipe, preventing the slurry in the feed pipe from flowing back into the cleaning gas inlet branch pipe 11 due to pressure fluctuations or gravity.

[0054] Each time the pneumatic valve 10 performs a closing action, the above self-cleaning process is automatically executed once, repeating continuously to ensure that the pneumatic valve 10 is cleaned in a timely manner after each closure, effectively preventing the slurry from remaining in the valve cavity for a long time and forming a stubborn deposit of ore.

[0055] The intelligent reverse control workflow is as follows: The reverse operation of the hydrocyclone group 9 refers to the switching process of suspending the feeding of hydrocyclone 9 that has been in operation for a long time and putting hydrocyclone 9 that has been in standby for a long time into operation. Its purpose is to balance the wear of each hydrocyclone group 9, extend the overall service life of the hydrocyclone group 9, and also facilitate the shutdown inspection and maintenance of individual hydrocyclone 9.

[0056] Before starting the reverse operation, the operator sets the reverse operation parameters through the touch-screen human-machine interface 18. The touch-screen human-machine interface 18 is electrically connected to the PLC controller 14. The operator can set the reverse sequence of each group of hydrocyclones (e.g., reverse sequentially in the order of 1→2→3→…→43, or alternately reverse in odd and even groups), the reverse interval time (e.g., 30 seconds, 60 seconds, or 120 seconds between each group of reverse intervals, which can be flexibly set according to process requirements), and the valve action allowance time (e.g., a maximum allowable opening and closing action of 10 seconds). After setting, the operator clicks the "Start Reverse" button, and the PLC controller 14 begins to execute the reverse control program.

[0057] The PLC controller 14 first determines the set of cyclones 9 that need to be reversed according to the preset reversal sequence, and then sends a closing command to the solenoid valve of the pneumatic valve 10 corresponding to that set of cyclones 9. The actuator of the pneumatic valve 10 starts to move, driving the valve plate to move in the closing direction. During the valve operation, the valve position sensor 15 detects the actual position of the valve in real time and continuously feeds back the detection signal to the PLC controller 14. The PLC controller 14 compares the signal fed back by the valve position sensor 15 with the expected state to determine whether the valve has completed the closing action within the allowed time. When the valve position sensor 15 reports that the valve is completely closed, the PLC controller 14 starts timing and records the valve's closing completion time. If the valve position sensor 15 does not report a completely closed signal within the set allowed time, the PLC controller 14 determines that the valve may be jammed, displays the valve's fault alarm information on the touch-screen human-machine interface 18, and pauses the reversal operation, waiting for the operator to handle it.

[0058] After the valve is closed, the PLC controller 14 starts timing the reverse interval. Once the reverse interval is reached, the PLC controller 14 sends an opening command to the solenoid valve of the pneumatic valve 10 corresponding to that group of hydrocyclones 9. The actuator of the pneumatic valve 10 reverses its movement, driving the valve plate to move in the opening direction. The valve position sensor 15 again monitors the actual position of the valve in real time. When the feedback indicates that the valve is fully open, the PLC controller 14 determines that the reverse operation of that group of hydrocyclones 9 is complete. If the valve position sensor 15 indicates that the valve is fully open, the PLC controller 14 automatically switches to the next group of hydrocyclones 9 that need to be reversed, repeating the above process of closing → waiting → opening until all preset hydrocyclone groups 9 that need to be reversed have completed the reverse operation.

[0059] Throughout the reverse operation, the PLC controller 14 also receives pressure signals from the main air tank 3 and the backup air tank 4 from the pressure detection controller 7, as well as the operating status signal of the cleaning control valve 12 from the timer controller 13. When the PLC controller 14 determines that a certain signal is abnormal (such as the pressure of the main air tank 3 dropping below 0.4MPa, or an abnormal cleaning and purging of a certain valve), the PLC controller 14 displays the corresponding status information and alarm prompts on the touch-screen human-machine interface 18, realizing real-time monitoring of the entire system's operating status.

[0060] Through the coordinated operation of the above three modules, this device achieves automated and intelligent control of the entire chain from gas supply and valve operation to valve cleaning, effectively solving the technical problems of gas supply interruption and valve jamming caused by ore accumulation in existing technologies.

[0061] Example 2 like Figure 1 and Figure 2 As shown, the difference between this embodiment and Embodiment 1 is that the dual-source air supply module also includes an alarm 16, which is electrically connected to the pressure detection controller 7. The alarm 16 is an integrated audible and visual alarm, which integrates a buzzer and an LED flashing light. When the pressure detection controller 7 determines that the pressure of the main air tank 3 or the backup air tank 4 is lower than a set threshold, in addition to performing air path switching control, it also outputs an alarm drive signal to the alarm 16. After receiving the drive signal, the alarm 16 emits a rapid "beep beep" alarm sound, and the LED flashing light emits a red flashing light, using both sound and light to alert on-site operators to the abnormal air supply situation, facilitating timely troubleshooting and handling of faults, such as checking the cause of the main air compressor 1's shutdown and arranging maintenance. The alarm 16 is installed on the top of the pneumatic control cabinet 8 or in a prominent location on-site, making it easy for operators to detect the alarm signal from a distance.

[0062] In this embodiment, the intelligent reversing control module also includes a touch-screen human-machine interface 18. The touch-screen human-machine interface 18 is an industrial touchscreen, employing a 7-inch TFT color LCD display with a resolution of 800×480, supporting resistive touch operation. The touch-screen human-machine interface 18 is electrically connected to the PLC controller 14 via an RS485 communication interface or an Ethernet communication interface to achieve bidirectional data transmission. The touch-screen human-machine interface 18 has an embedded configuration software operating environment, which includes multiple visual interfaces such as an equipment operation status monitoring interface, parameter setting interface, fault alarm interface, and operation record interface.

[0063] The equipment operation status monitoring interface graphically displays the real-time operating status of 43 hydrocyclones 9, including the open / closed status of each pneumatic valve 10, the feedback signal status of each valve position sensor 15, the real-time pressure values ​​of the main air tank 3 and the backup air tank 4, and the working status of each cleaning control valve 12. On the parameter setting interface, operators can set operating parameters for each hydrocyclone 9 via touch operation, such as the reverse rotation sequence, reverse rotation interval, valve action allowable time, air supply pressure threshold, cleaning and purging delay time, and cleaning and purging duration. After parameter setting, the parameters are downloaded to the PLC controller 14 and the timer controller 13 via the communication network. The fault alarm interface displays fault records and current alarm information for each module, including detailed information such as fault occurrence time, fault type, and fault location, facilitating quick fault location and handling by operators. The operation record interface records operator login information, parameter modification records, and manual operation records, facilitating equipment management and accident tracing.

[0064] In this embodiment, each pneumatic valve 10 is selected as a wear-resistant knife gate valve, which has the advantages of compact structure, low flow resistance, and reliable sealing. The valve body of the pneumatic valve 10 is made of ductile iron, and the surfaces inside the valve body that come into contact with the slurry (including the inner wall of the valve body flow channel and the valve seat sealing surface) are coated with a wear-resistant ceramic lining with a thickness of 1.5-2.5mm through a thermal spraying process. The wear-resistant ceramic lining is made of alumina or zirconia ceramic material, with a hardness of up to HRA85 or higher, and has good wear resistance and corrosion resistance. It can effectively resist the high-speed scouring and abrasion of solid particles in the slurry, significantly extend the service life of the valve, and reduce the replacement frequency and maintenance cost of the valve.

[0065] Example 3 like Figure 1As shown, the difference between this embodiment and Embodiment 1 is that the rated discharge pressure of the standby air compressor 2 is the same as that of the main air compressor 1 (both are 0.8MPa), but its discharge volume can be 30%-50% of the discharge volume of the main air compressor 1. In this embodiment, the rated discharge volume of the main air compressor 1 is 6.0 m³ / min, and the rated discharge volume of the standby air compressor 2 is selected as 2.5 m³ / min (approximately 42% of the discharge volume of the main air compressor 1). This design is based on the following considerations: when the main air compressor 1 is operating normally, the standby air compressor 2 is only used as an emergency backup air source and does not need to bear the continuous air supply load of the system. When the main air compressor 1 fails and air source switching is required, after switching to the standby air compressor 2 for air supply, its main task is to maintain the instantaneous action requirements of the pneumatic valve 10 (i.e., the short-term large flow of air required for valve opening and closing) within a limited time, and does not need to maintain the full air volume required for the long-term continuous operation of the cyclone separator group 9. Therefore, the discharge capacity of the standby air compressor 2 does not need to be the same as that of the main air compressor 1. It only needs to meet the instantaneous air demand of the pneumatic valves and the basic air replenishment required for system pressure maintenance.

[0066] Using a small-capacity standby air compressor 2 has the following advantages: First, it significantly reduces equipment procurement costs, as the price of a small air compressor is typically one-third to one-half that of a large air compressor; second, it has low energy consumption, as the standby air compressor 2 consumes no electricity in standby mode and only operates briefly after switching, with a power consumption far lower than that of the main air compressor 1; third, it requires less floor space, making it easy to add to existing equipment layouts; and fourth, it is simpler to maintain, with longer maintenance cycles and lower maintenance costs for small air compressors. Through the above design, this embodiment minimizes equipment investment and operation and maintenance costs while ensuring the reliability of emergency air supply, demonstrating good economic efficiency.

[0067] Example 4 like Figure 1 and Figure 4 As shown, the difference between this embodiment and Embodiment 1 is that the PLC controller 14 of the intelligent reversal control module is also connected to a remote communication unit. This remote communication unit communicates with the upper-level monitoring system in the central control room via a wired or wireless network. In this embodiment, the remote communication unit uses an Ethernet communication module, which connects to the industrial Ethernet network of the mining area via shielded twisted-pair cable to exchange data with the upper-level monitoring system in the central control room. Through the remote communication unit, the PLC controller 14 uploads the operating status data of the hydrocyclone group 9, the air supply status data, the valve cleaning status data, and fault alarm information to the upper-level monitoring system in the central control room in real time, achieving remote centralized monitoring. Simultaneously, operators in the central control room can also remotely set reversal operating parameters, manually control the opening and closing of each pneumatic valve 10, and remotely start or stop the self-cleaning program through the upper-level monitoring system, achieving remote operation and control of the field equipment and further improving the automation and informatization level of the ore dressing plant.

[0068] In this embodiment, the microcontroller unit of the pressure detection controller 7 also integrates data storage functionality. It contains an internal non-volatile memory (EEPROM) for recording historical pressure data of the main gas tank 3 and the backup gas tank 4, the number of actuations and actuation time of the switching valve, and log information of pressure anomaly events. The stored historical data can be exported to external devices via a communication interface for equipment operation status analysis and fault diagnosis, facilitating predictive maintenance.

[0069] Example 5 like Figure 3 As shown, the difference between this embodiment and Embodiment 1 is that, in addition to the cleaning control valve 12 and the one-way valve 17, the cleaning gas inlet branch pipe 11 of the valve anti-jamming self-cleaning module also includes a flow regulating valve and a filter. The flow regulating valve is located upstream of the cleaning control valve 12 (i.e., on the side closer to the main gas supply line) and is used to regulate the flow rate of the high-pressure gas entering the cleaning gas inlet branch pipe 11, thereby controlling the impact force of the purging gas. Operators can adjust the opening of the flow valve according to the actual working conditions such as the viscosity, concentration, and particle size of the slurry to obtain the best purging effect, avoiding excessive purging force that could damage the valve sealing surface or insufficient purging force that would fail to effectively remove accumulated ore.

[0070] The filter is located upstream of the flow regulating valve (i.e., on the side closest to the main gas supply line) to filter the high-pressure gas entering the clean gas inlet branch pipe 11. It removes any moisture, oil, and solid particulate impurities that may be present in the gas, ensuring the cleanliness of the purging gas and preventing impurities from entering the valve sealing surface and causing secondary contamination or accelerated wear. In this embodiment, a pneumatic filter with a 5μm precision is selected. Its filter cup is made of transparent material, facilitating observation of the internal filter element's contamination level. The filter element is replaceable, making maintenance convenient.

[0071] Furthermore, in this embodiment, each pneumatic valve 10 is equipped with a manual operating device for its drive actuator. The manual operating device is a handwheel or handle located on the actuator of the pneumatic valve 10. When the pneumatic control system fails to automatically drive the valve due to extreme malfunctions (such as failure of both air sources or complete power failure of the electrical control system), the operator can manually operate the manual operating device on-site to manually drive the valve stem to rotate or move, thereby manually opening or closing the pneumatic valve 10. This ensures that the feeding of the hydrocyclone group 9 can still be manually controlled even in extreme situations, further improving the system's emergency response capability and safety in extreme malfunction situations.

[0072] Example 6 The difference between this embodiment and Embodiment 1 is that the number of hydrocyclone groups 9 is not limited to 43 groups, but can be set to 16, 24, 32, 48 groups, or any other arbitrary number, depending on the actual mineral processing requirements. The arrangement of each hydrocyclone 9 is not limited to a three-row staggered arrangement; it can also adopt a single-row arrangement, a double-row face-to-face arrangement, a ring arrangement, and other various layout forms. The number of pneumatic valves 10 corresponds one-to-one with the number of hydrocyclones 9, and each hydrocyclone 9 has an independently installed pneumatic valve 10 on its feed pipe. In this embodiment, each pneumatic valve 10 can also be a wear-resistant butterfly valve instead of a wear-resistant gate valve. Wear-resistant butterfly valves have the characteristics of simple structure, small size, light weight, and rapid opening and closing, and are also suitable for on / off control of slurry pipeline systems. The surface of the wear-resistant butterfly valve body that contacts the slurry is also provided with a wear-resistant ceramic lining or a wear-resistant rubber lining to ensure the service life of the valve.

[0073] Example 7 The difference between this embodiment and Embodiment 1 is that when the pressure detection controller 7 detects that the pressure in the main air tank 3 is lower than a set threshold (e.g., 0.4 MPa) and executes air source switching control, the pressure detection controller 7 also simultaneously sends a shutdown signal to the inverter or starter of the main air compressor 1 to control the main air compressor 1 to stop running, preventing the main air compressor 1 from continuing to run idle or under load in a faulty state, thus preventing further damage to the equipment. At the same time, the pressure detection controller 7 also sends a start signal to the inverter or starter of the standby air compressor 2 to control the standby air compressor 2 to start running from standby mode and begin continuously replenishing air to the standby air tank 4, maintaining the pressure in the standby air tank 4 within the normal operating pressure range of 0.6-0.7 MPa, thereby extending the continuous air supply time of the standby air source.

[0074] In this embodiment, a check valve is also installed on the pipeline between the standby air compressor 2 and the standby air tank 4. When the standby air compressor 2 is not started or is in a stopped state, the check valve can prevent the compressed air in the standby air tank 4 from flowing back to the standby air compressor 2, ensuring that the standby air tank 4 is always pressurized and can provide emergency air supply at any time.

[0075] In this embodiment, the working power supply of the cleaning control valve 12 and the timer controller 13 adopts a dual-power supply design, that is, it is connected to the main power supply and the backup power supply (such as UPS uninterruptible power supply) respectively. When the main power supply fails and power is interrupted, it automatically switches to the backup power supply to ensure that the valve anti-jamming self-cleaning module can still work normally in the event of a power outage, which further improves the power supply reliability and overall operation stability of the device.

[0076] Example 8 like Figure 4As shown, the difference between this embodiment and Embodiment 1 is that the PLC controller 14 also integrates a self-learning optimization control algorithm. This algorithm gradually optimizes the reversal control strategy of each group of hydrocyclones 9 by recording and analyzing operational data such as the actual action time, success rate, feedback delay time of the valve position sensor 15, and cleaning / purging effect of each pneumatic valve 10 during each reversal operation. Specifically, for valves with longer action times (possibly those with severe ore accumulation or significant actuator wear), the PLC controller 14 can automatically extend their reversal interval or add a pre-cleaning purge before reversal to remove ore accumulation at the valve in advance, ensuring smooth valve operation. For valves with shorter and more stable action times, the PLC controller 14 can appropriately shorten their reversal interval to improve reversal efficiency. Through the above self-learning optimization, the intelligent reversal control module of this embodiment can continuously adapt to changes in on-site conditions during long-term operation, automatically adjust control parameters, and achieve optimal control of the reversal operation of the hydrocyclone group 9, further reducing the workload of manual intervention and parameter adjustment.

[0077] Example 9 The difference between this embodiment and Embodiment 2 is that the touch-screen human-machine interface 18 also integrates a voice broadcast function, and it is equipped with a voice synthesis module and a speaker. When the equipment malfunctions and alarms (such as main air compressor 1 malfunction, low air supply pressure, valve action timeout, etc.), the voice synthesis module synthesizes corresponding voice prompt information (such as "Please note that the main air compressor has malfunctioned and has been switched to the backup air source", "Please note that valve number 8 has timed out, please check") based on the alarm type code sent by the PLC controller 14, and broadcasts it through the speaker. The voice broadcast function complements the audible and visual alarm function of the audible and visual alarm 16, which can effectively prevent operators from ignoring alarm information due to visual fatigue or obstructed vision, and further improve the timeliness and effectiveness of the alarm.

[0078] Example 10 The difference between this embodiment and Embodiment 1 is that a main pressure gauge and a main pressure switch are also installed on the main air supply line of the pneumatic control cabinet 8. The main pressure gauge is a mechanical pointer type with a range of 0-1.0 MPa and an accuracy of 1.6 class. It is used to visually display the real-time pressure value of the main air supply line on-site, facilitating quick reading by operators during inspections. The main pressure switch is an adjustable pressure switch, and its pressure setpoint can be adjusted according to process requirements (set to 0.45 MPa in this embodiment). When the pressure of the main air supply line is lower than the set value, the main pressure switch outputs a switching signal to the PLC controller 14 as a second detection signal for the air supply pressure. This signal and the pressure signal from the pressure detection controller 7 are mutually redundant and verified. When the two pressure signals are inconsistent, the PLC controller 14 can issue a "pressure detection abnormality" prompt message on the touch-screen human-machine interface 18, reminding the operator to check whether the pressure detection element is faulty, thereby further improving the reliability of pressure detection and the safety of the system.

[0079] Example 11 The difference between this embodiment and Embodiment 1 is that the actuator of each pneumatic valve 10 is a double-acting cylinder actuator, which includes a cylinder body, piston, piston rod, and return spring. The double-acting cylinder actuator drives the piston to reciprocate by controlling the direction of compressed air in and out on both sides of the piston, which in turn drives the valve plate or valve core to open and close the valve via the piston rod. Double-acting cylinders have the advantages of large output thrust, smooth operation, and fast response, making them particularly suitable for large-diameter valves and high pressure differential conditions. The solenoid valve of each pneumatic valve 10 is a two-position five-way solenoid valve, which has five ports and two working positions. The direction of compressed air flow is controlled by the on / off state of the solenoid coil, achieving the reversing control of the double-acting cylinder. The air inlet of the two-position five-way solenoid valve is connected to the main air supply line of the pneumatic control cabinet 8, the two working ports are connected to the two air ports of the double-acting cylinder, and the two exhaust ports are used to discharge the compressed air from the cylinder. When the solenoid valve is energized, compressed air enters one chamber of the cylinder, pushing the piston in one direction (e.g., opening the valve), while air in the other chamber is discharged through the exhaust port. When the solenoid valve is de-energized, compressed air enters the other chamber of the cylinder, pushing the piston in the opposite direction (e.g., closing the valve). By controlling the on / off time and sequence of the solenoid valve, the opening and closing actions of the pneumatic valve 10 can be precisely controlled.

[0080] Example 12 The difference between this embodiment and Embodiment 1 is that the cleaning gas inlet branch pipe 11 of the valve anti-jamming self-cleaning module is equipped with a Venturi tube or ejector structure at the branch interface on the feed pipe. The Venturi tube or ejector utilizes high-pressure gas to accelerate through a converging section, forming a low-pressure zone at the throat. This effectively carries residual slurry and sediment in the feed pipe towards the hydrocyclone 9, enhancing the purging and cleaning effect. Specifically, the Venturi tube is located on the feed pipe, downstream of the branch interface (i.e., near the feed inlet of the hydrocyclone 9). Its inlet end is connected to the feed pipe, and its outlet end is connected to the feed inlet of the hydrocyclone 9. High-pressure gas enters the throat of the Venturi tube from the branch interface, forming a high-speed airflow and a negative pressure zone at the throat. This suction effect on the slurry at the inlet end of the Venturi tube rapidly draws the slurry accumulated near the valve outlet and transports it into the hydrocyclone 9. This effectively avoids the problem of the slurry churning back and forth in the pipe during purging without being effectively removed, making it particularly suitable for high-concentration slurry conditions.

Claims

1. A fault-prevention operating device for a pneumatic control system of a hydrocyclone assembly, comprising a pneumatic control cabinet, several hydrocyclones, and pneumatic valves correspondingly installed on the feed pipes of each hydrocyclone, characterized in that, It also includes a dual-gas-source supply module, a valve anti-jamming self-cleaning module, and an intelligent reverse control module; The dual-source air supply module includes a main air compressor, a standby air compressor, a main air tank, a standby air tank, a first switching valve, a second switching valve, and a pressure detection controller. The main air compressor outlet pipe is connected to the main air tank inlet; the standby air compressor outlet pipe is connected to the standby air tank inlet; the main air tank outlet pipe and the standby air tank outlet pipe merge to form an air supply manifold, which is connected to the pneumatic control cabinet inlet; the first switching valve is mounted on the main air tank outlet pipe, and the second switching valve is mounted on the standby air tank outlet pipe; the pressure detection controller collects the internal pressure signals of the main air tank and the standby air tank respectively, and outputs control signals that are electrically connected to the first switching valve and the second switching valve respectively. The valve anti-jamming self-cleaning module is configured one-to-one with the feed pipe position between the downstream of each pneumatic valve and the feed port of the cyclone separator; the valve anti-jamming self-cleaning module includes a cleaning gas inlet branch pipe, a cleaning control valve, and a timer controller; one end of the cleaning gas inlet branch pipe draws gas from the main gas supply line inside the pneumatic control cabinet, and the other end is connected to the feed pipe downstream of the pneumatic valve; the cleaning control valve is assembled in series on the cleaning gas inlet branch pipe; the timer controller is electrically connected to the cleaning control valve, and the timer controller receives the valve closing completion signal, and after the pneumatic valve completes the closing action, it triggers the cleaning control valve to open after a delay, and introduces high-pressure purging gas into the feed pipe; The intelligent reverse control module includes a PLC controller and valve position sensors installed on each pneumatic valve. The valve position sensors are used to collect the actual fully open / fully closed valve position status of the pneumatic valves, and the signal output terminal of the valve position sensors is connected to the PLC controller. The PLC controller outputs control signals to connect to the solenoid valves that are matched with each pneumatic valve. The PLC controller establishes signal interaction links with the pressure detection controller and each timing controller.

2. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The dual-gas-source supply module is also equipped with an audible and visual alarm, which is electrically connected to the pressure detection controller. When the pressure detection controller detects that the pressure in the gas storage tank is lower than the preset pressure threshold, it drives the audible and visual alarm to output an alarm signal.

3. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, A one-way valve is connected in series on the clean gas inlet branch pipe. The gas conduction direction of the one-way valve is from the gas supply main pipeline to the feed pipeline, preventing the slurry from flowing back into the gas supply pipeline.

4. The fault-prevention operation device of the pneumatic control system for a hydrocyclone assembly according to claim 1, characterized in that, The intelligent reversal control module is equipped with a touch-screen human-machine interface, which is electrically connected to the PLC controller. The touch-screen human-machine interface is used to display the operating status of each unit of the hydrocyclone group, the air source pressure parameters, and to receive process parameters such as reversal sequence, reversal interval, purging delay, and purging duration input by the operator.

5. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The pneumatic valve is selected from wear-resistant knife gate valves or wear-resistant butterfly valves; the working surface of the pneumatic valve body in contact with the slurry is compositely equipped with a wear-resistant ceramic lining.

6. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The rated exhaust pressure of the standby air compressor is consistent with that of the main air compressor, and the exhaust volume of the standby air compressor is set to 30%-50% of the exhaust volume of the main air compressor; the standby air compressor is only used to provide air for the instantaneous opening and closing of pneumatic valves.

7. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The valve anti-jamming self-cleaning module also includes a purge nozzle, which is installed at the inlet of the cleaning gas inlet branch pipe into the feed pipe. The purge nozzle sprays high-pressure gas toward the hydrocyclone inlet.

8. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The PLC controller is equipped with a fault judgment logic unit. The PLC controller compares the control command output to the pneumatic valve with the actual valve position signal returned by the valve position sensor. When the command and the actual valve position signal do not match for a continuous period of time exceeding the set threshold, the valve is judged to be stuck and a fault alarm signal is output to the touch human-machine interface.

9. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The pressure detection controller is internally set with pressure thresholds, including a primary low-pressure threshold and a backup low-pressure threshold. When the pressure in the main gas tank is lower than the primary low-pressure threshold, the gas source switching logic is automatically executed. The switching action to complete the gas supply switching takes less than or equal to 0.5 seconds.

10. The fault-prevention operation device for the pneumatic control system of a hydrocyclone assembly according to claim 1, characterized in that, The timing controller is configured with a purging delay parameter range of 2-5s and a purging duration parameter range of 3-8s; the purging high-pressure gas pressure is maintained at 0.5-0.7MPa; the cyclone group consists of multiple cyclones connected in parallel, with a total of 43 cyclones, and the number of pneumatic valves is matched one-to-one with the number of cyclones.

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