Sintering process synchronous control method and device based on material layer thickness and air permeability

Abstract

The application discloses a sintering process cooperative control method and device based on material layer thickness and air permeability, which comprises the following steps: S1, data acquisition; S2, data preprocessing; S3, air permeability index calculation; S4, material surface morphology and segregation evaluation; S5, height-air permeability coupling analysis and output. The device comprises a plurality of detection units, a measurement and control cabinet and an upper computer processing system. The application realizes synchronous distributed detection of the material surface height and air permeability of the sintering material layer at multiple points in the horizontal direction, improves the detection precision through multi-factor data correction, establishes a coupling regulation logic of the material surface height and air permeability, effectively improves the horizontal uniformity of the sintering material layer, stabilizes the sintering production process, and improves the finished product quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of material sintering technology, and in particular to a method and apparatus for synchronous control of the sintering process based on the thickness and permeability of the material layer. Background Technology

[0002] Sintering is a core step in the iron and steel metallurgical production process, providing sintered ore as the main raw material for blast furnace smelting. Its production efficiency, finished product quality, and energy consumption directly affect the operational efficiency of the entire iron and steel production line. The permeability of the sintering bed is a key parameter determining the thermal state, uniformity of the sintering endpoint, and yield of the finished product. The bed height (i.e., the bed thickness) is a core factor affecting the permeability distribution and uniformity of material distribution. Therefore, achieving accurate online detection of the sintering bed permeability and bed height, and conducting coordinated control based on the detection results, is an important prerequisite for optimizing sintering process control, improving material distribution uniformity, and reducing energy consumption and return ore rate.

[0003] Currently, the industry primarily uses a main pipe-based testing method to detect the permeability of sintering bed. This method calculates the overall permeability index by measuring the negative pressure and total air volume of the main air box, but it cannot reflect the differences in permeability distribution across different areas of the sintering machine. Some solutions employ single-point static pressure testing devices, but these generally suffer from a limited number of testing points and low spatial resolution, making it difficult to accurately capture lateral permeability segregation in the bed and providing insufficient data support for refined material distribution control. Furthermore, existing permeability calculations mostly use measured static pressure differences directly, failing to fully consider factors such as gas density changes caused by flue gas temperature fluctuations, on-site dust interference, and data jumps caused by timed purging actions. This results in insufficient stability and accuracy of the test data, making it difficult to meet the precision requirements of closed-loop control.

[0004] For detecting the height of the sintering material surface, existing technologies mostly employ laser ranging and radar detection, primarily used to monitor the flatness of the material surface and the overall thickness of the material layer after distribution. However, most of these methods only output height data independently, without spatial correlation and coupling analysis with the permeability detection results at the same location. This makes it impossible to establish a precise correspondence between the material surface height distribution and the permeability distribution, hindering coordinated control based on the coupling logic of the two. Some sintering control systems adjust the material distribution solely based on experience or a single parameter, easily leading to problems such as uniform material surface height but large differences in permeability, or permeability meeting standards but severe material segregation, failing to fundamentally improve the lateral uniformity of the sintering process.

[0005] In summary, existing sintering process detection and control technologies lack a collaborative control scheme that can simultaneously achieve distributed detection of material surface height and permeability and couple the two for analysis. The spatial correspondence of the detection data is poor and the accuracy is insufficient. The control logic is simple and it is difficult to effectively solve the technical problems of lateral segregation of sintering material layer and uneven distribution of sintering endpoint, which restricts the further improvement of sintering production efficiency and finished product quality. Summary of the Invention

[0006] To this end, the present invention provides a method and apparatus for synchronous control of sintering process based on material layer thickness and permeability, which realizes synchronous distributed detection of material surface height and permeability at multiple points in the lateral direction of the sintering material layer, improves detection accuracy through multi-factor data correction, and establishes a coupled control logic for material surface height and permeability, effectively improving the lateral uniformity of the sintering material layer, stabilizing the sintering production process, and improving the quality of finished products and production efficiency.

[0007] To address the aforementioned technical problems, this invention provides a sintering process synergistic control method based on material layer thickness and permeability, comprising the following steps: S1. Data Acquisition: Simultaneously collect data on the sintering material layer height, flue gas static pressure above the sintering material layer, flue gas temperature, and static pressure inside the lower wind box at multiple detection points at different positions in the horizontal direction of the material conveying area between the material feeding station and the ignition station, and upload the data at a fixed sampling frequency. S2. Data preprocessing: Outlier removal and density correction based on flue gas temperature are performed on the raw collected data in sequence to obtain the corrected static pressure difference between the upper and lower layers of the sintering material and the material surface height data. S3. Calculation of air permeability index: Based on the corrected static pressure difference and the sintered material layer thickness converted from the material surface height, combined with the unit area air volume of the corresponding wind box, the air permeability index of the sintered material layer at each detection point is calculated, and the air permeability distribution result of the material conveying area is generated by the interpolation algorithm. S4. Material Surface Morphology and Segregation Assessment: Based on the material surface height data at each detection point, calculate the material surface morphology characteristics and identify material surface defects; S5. Height-permeability coupling analysis and output: Spatially correlate and match the material surface height distribution with the permeability distribution, and output the corresponding fabric control command and air box damper control command for the detection point.

[0008] Furthermore, in step S2, the outlier removal adopts the 3σ criterion, which identifies and replaces the jump data within the continuous sampling window with the moving average of adjacent time points; The density correction based on flue gas temperature is as follows: taking the air density under standard conditions of 20℃ as a benchmark, the static pressure difference is corrected for temperature according to the ideal gas law. The correction formula is: ΔP0=ΔP×(T0 / T), where ΔP0 is the pressure difference after standard temperature correction, ΔP is the measured static pressure difference between the upper and lower parts of the sintering material layer, T0 is the standard thermodynamic temperature of 293.15K, and T is the measured flue gas thermodynamic temperature.

[0009] Further, in step S3, the air permeability index is calculated as follows: K=(Q×h) / ΔP0, where Q is the air volume per unit area of ​​the wind box corresponding to the detection point, h is the thickness of the sintered material layer converted from the material surface height, ΔP0 is the static pressure difference between the upper and lower parts of the sintered material layer after temperature correction, and the larger the K value, the better the air permeability of the sintered material layer. The interpolation algorithm uses cubic spline interpolation, and the generated air permeability distribution results include at least one of the lateral distribution curve and the two-dimensional distribution cloud map.

[0010] Furthermore, in step S4, the material surface morphology features include the lateral height difference of the material surface, the flatness coefficient, and the degree of height segregation, and the material surface defects include local material accumulation and depressions.

[0011] Further, in step S5, the specific logic of the spatial association matching is as follows: when the material surface height of the sintered material layer at the detection point is too high and the air permeability index is too low, a material control command to reduce the material distribution in the area where the corresponding detection point is located is output; when the material surface height of the sintered material layer at the detection point is too low and the air permeability index is too high, a material control command to increase the material distribution in the area where the corresponding detection point is located is output; when the material surface height is uniform but the lateral difference in air permeability exceeds the set threshold, a fine-tuning command for the opening of the corresponding wind box damper is output.

[0012] Furthermore, in step S2, the data preprocessing also includes purging interference compensation, marking the collected data during and after the purging action for a preset duration as invalid, and filling it with steady-state data before purging.

[0013] This invention also provides a sintering process collaborative control device for implementing the aforementioned sintering process collaborative control method, comprising multiple detection units, a measurement and control cabinet, and a host computer processing system; the multiple detection units are located above the material conveying area between the material feeding station and the ignition station of the sintering machine, and each corresponds one-to-one with multiple detection points at different positions in the horizontal direction of the material conveying area, for synchronously collecting data on material surface height, flue gas static pressure, flue gas temperature, and wind box static pressure at each detection point; the measurement and control cabinet is electrically connected to each detection unit, for synchronously collecting detection data at each detection point, and connecting to the unit area airflow signal of the corresponding wind box, and uploading them to the host computer processing system; the host computer processing system has a built-in data preprocessing module, an air permeability distribution calculation module, a material surface morphology analysis module, and a coupling output module, for sequentially executing data correction, air permeability index calculation, material surface morphology evaluation, and coupling control command output.

[0014] Furthermore, the multiple detection units are arranged at equal intervals in the transverse direction along the material conveying area, and each detection unit is located in the same cross-section in the material conveying direction.

[0015] Furthermore, each of the aforementioned detection units includes a laser rangefinder, an upper static pressure tapping tube, a temperature sensor, and a lower static pressure tapping tube. The laser rangefinder is installed inside a water-cooled dustproof sleeve, forming a laser beam path extending downwards in a vertical direction. One end of the upper static pressure tapping tube extends into the water-cooled dustproof sleeve as a first pressure tapping end, with the pressure tapping port horizontally positioned and its center located on the vertical line of the laser beam path. The other end extends out of the water-cooled dustproof sleeve. The temperature sensor is installed outside the water-cooled dustproof sleeve, with its armored probe extending into the upper static pressure tapping tube. The lower static pressure tapping tube extends horizontally into the air box below the corresponding detection point, with the center of its second pressure tapping end aligned with the center of the pressure tapping port of the upper static pressure tapping tube and the laser beam path on the same vertical line. The other end extends out of the air box.

[0016] Furthermore, it also includes a purging unit, comprising a compressed air source, a solenoid valve, a throttling orifice plate, and a purging pipeline; the solenoid valve is signal-connected to the control cabinet and adopts a timed pulse purging mode; the throttling orifice plate is connected in series in the purging pipeline downstream of the solenoid valve to stabilize the purging air flow rate; the purging pipeline is connected to the pressure tapping pipeline of each detection unit for backflushing and clearing blockages.

[0017] The technical solution of the present invention has the following advantages compared with the prior art: (1) By setting multiple detection points in the material conveying area and collecting material surface height, static pressure and temperature data simultaneously, and combining data preprocessing, permeability distributed calculation and material surface morphology evaluation, the final output is a height-permeability coupled control command; multi-parameter distribution information of the sintering material layer in the lateral direction can be obtained, breaking through the limitations of traditional single-point or main pipe detection, establishing the correlation control logic between material layer thickness and permeability, and providing a complete technical path for the refined collaborative control of the sintering process.

[0018] (2) The 3σ criterion is used to remove outliers, which can effectively identify and correct the jump data caused by field interference; combined with the temperature density correction based on the ideal gas state equation, the systematic error of flue gas temperature fluctuation on static pressure detection results can be eliminated, and the accuracy of static pressure difference and subsequent permeability calculation results can be significantly improved.

[0019] (3) By using a clear formula for calculating the permeability index, the permeability performance of the material layer at each test point can be quantitatively characterized; by using a cubic spline interpolation algorithm to generate the lateral distribution results, a continuous permeability distribution curve or cloud map can be obtained based on discrete test points, which can intuitively present the lateral permeability segregation state of the sintered material layer.

[0020] (4) By quantitatively calculating the morphological characteristics such as the lateral height difference and flatness coefficient of the material surface, the uniformity and segregation of the material surface can be accurately assessed, and defects such as local material accumulation and depression can be identified, providing a clear target basis for material adjustment.

[0021] (5) For the three typical working conditions of “high height and low air permeability”, “low height and high air permeability”, and “uniform height but large air permeability difference”, the corresponding material or damper control commands are output respectively, which can realize differentiated precise collaborative control, effectively improve the uniformity of the transverse parameters of the sintering material layer, and stabilize the sintering process state.

[0022] (6) By marking and compensating the data during the purging action period, the data jump and interruption caused by the timed backflushing action can be eliminated, ensuring the continuity and stability of the detection data, and making the method adaptable to the field conditions of purging with pressure tapping pipeline.

[0023] (7) Through the cooperation of the detection components composed of multiple detection units, the measurement and control cabinet and the host computer processing system, the data acquisition, signal aggregation and uploading and data processing and analysis of multiple points can be completed simultaneously, realizing the hardware implementation of the above-mentioned collaborative control method and meeting the operation requirements of online detection and closed-loop control at the sintering site.

[0024] (8) Multiple detection units are arranged at equal intervals along the transverse direction and are located in the same cross section, which can ensure the synchronicity and uniformity of the data of each detection point in spatial position and improve the representativeness and accuracy of the transverse distribution detection results.

[0025] (9) The laser rangefinder is installed in a water-cooled dustproof sleeve, which can be adapted to the harsh working conditions of high temperature and high dust in the sintering site; the upper and lower static pressure tapping tubes adopt a horizontal pressure tapping design, which can avoid the interference of air flow pressure on static pressure detection; the layout of the upper pressure tapping port, the lower pressure tapping end and the laser light path are in the same vertical line, which can ensure the spatial consistency between the material surface height and the upper and lower static pressure detection positions, and improve the correspondence of multi-parameter data and the reliability of detection results.

[0026] (10) The timed pulse purging mode controlled by the solenoid valve can realize automatic backflushing and unblocking of the pressure tapping pipeline; the setting of the throttling orifice plate can stabilize the purging gas flow rate, avoid the interference of purging gas volume fluctuation on the detection data, ensure the long-term stable operation of the device, and reduce the workload of on-site maintenance. Attached Figure Description

[0027] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0028] Figure 1 This is a schematic diagram of the sintering process synchronization control device disclosed in an embodiment of the present invention; Figure 2 This is a schematic diagram of the detection component and purging component disclosed in an embodiment of the present invention; Figure 3 This is a flowchart of the synchronous control method for the sintering process disclosed in an embodiment of the present invention.

[0029] The components include: 1. Trolley; 2. Exhaust box; 3. Sintering material layer; 4. Detection unit; 41. Laser rangefinder; 42. Upper static pressure tapping pipe; 43. Temperature sensor; 44. Lower static pressure tapping pipe; 45. Cooling jacket; 5. Measurement and control cabinet; 6. Upper computer processing system; 7. Purging unit; 71. Compressed air source; 72. Purging pipeline. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0031] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0032] See Figures 1 to 3As shown, this embodiment is applied to a belt sintering production system in the iron and steel metallurgy field. The trolley 2 passes sequentially along the running direction through the material feeding station, the ignition station, and multiple sets of exhaust fans 1. The sintering mixture is laid on the trolley 2 at the material feeding station to form a sintering material layer 3, which is continuously conveyed forward with the trolley 2. The entire invention is set in the material conveying area between the material feeding station and the ignition station, and is used to complete the distributed detection and coordinated control of the initial parameters before the sintering material layer 3 is ignited, thereby improving the lateral uniformity of the material layer from the source.

[0033] Specifically, the material feeding station refers to the station in the sintering production process where sintering mixture is laid onto the trolley 2. It is equipped with equipment such as a material feeding chute and a multi-roller material feeder, which determines the initial material layer thickness and the uniformity of material feeding. It is the core front-end station for controlling the material layer state.

[0034] The ignition station refers to the station where the surface fuel of the sintering layer 3 is ignited by the ignition furnace. It is the starting point of the sintering combustion reaction. After ignition, the material layer undergoes a solid-phase reaction from top to bottom, and the surface morphology and material properties will undergo irreversible changes.

[0035] The material conveying area specifically refers to the trolley conveying section between the outlet of the fabric placement station and the entrance of the ignition station. The sintering material layer 3 in this section is in a static, unburned state with stable parameters and no thermal disturbance, making it the optimal section for initial state testing.

[0036] The sintering process collaborative control device includes multiple detection units 4, a measurement and control cabinet 5, and a host computer processing system 6. The multiple detection units 4 are fixed by mounting brackets and are located above the material conveying area between the material feeding station and the ignition station of the sintering machine, each corresponding one-to-one with multiple detection points at different positions in the horizontal direction of the material conveying area. For sintering machines with an effective width of 3-5m, the number of detection units is 4-6 groups, with a horizontal spacing of 0.8-1.2m and a vertical height of 1.5-2.5m from the material surface, used for synchronously collecting data from each detection point. The system collects data on material surface height, flue gas static pressure, flue gas temperature, and wind box static pressure. The control cabinet 5 is electrically connected to each detection unit and synchronously collects the detection data of each detection point at a fixed sampling frequency of 1Hz. It also receives the unit area airflow signal of the corresponding wind box 1 and uploads it to the host computer processing system 6. The host computer processing system 6 has a built-in data preprocessing module, a permeability distribution calculation module, a material surface morphology analysis module, and a coupling output module, which are used to sequentially perform data correction, permeability index calculation, material surface morphology evaluation, and coupling control command output.

[0037] The sintering process collaborative control method includes the following steps: S1, Data Acquisition: Synchronously acquire the material surface height, flue gas static pressure above the sintering material layer 3, flue gas temperature, and static pressure inside the lower wind box 1 at multiple detection points at different positions in the horizontal direction of the material conveying area between the material feeding station and the ignition station, and upload the data at a fixed sampling frequency; S2, Data Preprocessing: Perform outlier removal, purging interference compensation, and density correction based on flue gas temperature on the original acquired data in sequence to obtain the corrected static pressure difference and material surface height data of the upper and lower sintering material layer 3; S3, Air Permeability Index Calculation: Based on the corrected static pressure difference and the thickness of the sintered material layer 3 calculated from the material surface height, combined with the unit area air volume of the corresponding wind box 1, the air permeability index of the sintered material layer 3 at each detection point is calculated, and the air permeability distribution result of the material conveying area is generated by interpolation algorithm; S4, Material surface morphology and segregation evaluation: Based on the material surface height data of each detection point, the material surface morphology characteristics are calculated and material surface defects are identified; S5, Height-air permeability coupling analysis and output: The material surface height distribution and air permeability distribution are spatially correlated and matched, and the material distribution control command and wind box damper control command of the corresponding detection point are output.

[0038] Specifically, detection unit 4 is an integrated detection device corresponding to a single detection point. Each detection unit 4 can independently complete the synchronous acquisition of multiple parameters at that point. Detection unit 4 is arranged above the material conveying area in the production site, close to the sintered material layer 3 being tested. This shortens the length of the pressure tapping pipeline, reduces signal delay and pipeline resistance loss, and ensures detection accuracy. Multiple detection units correspond one-to-one with detection points, enabling fully lateral distributed synchronous detection. Each detection unit works independently, and a single point failure does not affect the operation of other points, resulting in high system reliability.

[0039] The detection point refers to the parameter collection point marked on the horizontal direction of the trolley 2. Each point corresponds to a set of detection units, which are used to obtain the material layer parameters of that local area and are the basic unit for realizing distributed detection.

[0040] The material surface height refers to the vertical distance between the upper surface of the sintered material layer 3 and the reference surface of the grate bar of the trolley 2. It is obtained by non-contact measurement using a laser rangefinder 41 and is used to calculate the actual material layer thickness.

[0041] The static pressure of flue gas refers to the static pressure of the flue gas above the sintering material layer 3, which is the pressure perpendicular to the airflow direction generated by the thermal motion of gas molecules. It is collected through the upper static pressure tapping pipe 42 and is the core basic parameter reflecting the air permeability resistance of the material layer.

[0042] The static pressure inside the wind box refers to the static pressure of the gas inside the wind box 1 below the trolley 2. It is usually a negative pressure during sintering production. The pressure is collected through the lower static pressure tapping pipe 44. The difference between the static pressure and the static pressure above the material layer is the resistance loss of the gas penetrating the sintering material layer 3.

[0043] The unit area air volume signal refers to the air volume signal from the original air box flow detection system of the sintering plant. It is connected to the measurement and control cabinet 5 through hard wiring or industrial communication to provide air volume parameters for air permeability calculation.

[0044] The fixed sampling frequency refers to the frequency at which the system performs full-point data acquisition once at a fixed time interval. In this embodiment, it is set to 1Hz to balance control real-time performance and data processing load.

[0045] The measurement and control cabinet 5 is an electrical control cabinet located on the production site. It serves as the intermediate hub connecting the front-end detection components and the back-end host computer, responsible for signal acquisition, conversion, and synchronous transmission. Located on a field platform near the detection points, the cabinet provides power to each detection unit and acquires analog or digital signals. It also connects to the existing airflow signal from the existing bellows system 1, enabling synchronous aggregation of multi-source data. The cabinet has a built-in synchronous acquisition module, ensuring that height, static pressure, and temperature data from all detection points are sampled simultaneously, avoiding spatial matching errors caused by time differences and guaranteeing data time synchronization. After preliminary filtering and conversion, the acquired data is uploaded to the host computer processing system 6 in the central control room via industrial Ethernet.

[0046] The host computer processing system 6, located in the central control room, is an industrial computer system and serves as the core of the entire unit's computation and decision-making. It is responsible for data processing, analysis, calculation, and output of control commands. The host computer processing system 6 is functionally divided into four software modules, each corresponding to a step in the control method: the data preprocessing module handles outlier removal, temperature correction, and purging compensation; the permeability distribution calculation module calculates the permeability index and interpolates to generate distribution results; the material surface morphology analysis module calculates material surface characteristics and identifies defects; and the coupling output module handles coupling logic judgment and output of control commands. This modular software architecture is logically clear, facilitating subsequent maintenance and functional expansion. The output control commands can be directly integrated into the existing control system of the sintering plant to achieve closed-loop operation.

[0047] The air permeability index is a standardized index that quantitatively characterizes the air permeability of the sintered material layer 3. It eliminates the interference of air volume and material thickness on pressure difference and can objectively reflect the air permeability performance of the material layer itself.

[0048] Spatial correlation matching refers to aligning the material surface height data and air permeability index data at the same detection point to establish a correspondence between height and air permeability, providing a basis for judgment for coupled control.

[0049] Step S1, selecting the area between the material distribution and ignition as the detection location, has been validated for process compatibility. After the sintering material layer 3 is distributed but before ignition, the particle size distribution, packing density, and surface morphology remain in their initial state after distribution, without changes such as combustion shrinkage or pulverization. At this point, the parameters obtained by the detection component 4 accurately reflect the material distribution quality, and the detection results can be directly fed back to the material distribution control system for real-time correction, resulting in the strongest control timeliness. If the detection location is set after the ignition position, the surface fuel of the material layer has already ignited, the material surface undergoes sintering shrinkage, and the flue gas temperature and composition fluctuate drastically with the combustion process. This not only fails to accurately reflect the initial material distribution state but also leads to severe control lag, making it difficult to fundamentally improve lateral segregation.

[0050] Setting multiple detection points along the transverse direction of the sintering trolley is a key solution to the industry pain point that traditional manifold-type detection cannot reflect transverse differences. The trolley width of a belt sintering machine is typically 3-5 meters. Influenced by factors such as material separation from the feeding chute, natural particle size segregation, and trolley edge effects, significant differences in thickness, particle size, and density are generally observed at different transverse locations in the sintering layer 3. This leads to uneven transverse distribution of air permeability, ultimately causing inconsistencies in the transverse direction of the sintering endpoint and fluctuations in yield. This method, through multi-point transverse distributed data acquisition, can accurately capture parameter differences along the trolley width, providing sufficient data support for refined zone control. A unified timestamp is applied to the collected data to ensure data synchronization across multiple measurement points. Step S2, data preprocessing, is a fundamental step in ensuring data reliability. The sintering environment is complex; electromagnetic interference, dust disturbances, and airflow turbulence can all cause random anomalies in the raw data. Simultaneously, fluctuations in flue gas temperature can cause changes in gas density, leading to systematic deviations in static pressure detection results. Directly using the raw data for calculations would distort the permeability index, resulting in misjudgments in subsequent control logic. By eliminating outliers to remove random interference and by correcting for temperature-related systematic errors through density correction, accurate and stable basic data can be obtained, providing reliable input for subsequent analysis and calculations.

[0051] Step S3, calculating the air permeability index, is the core computational step of this method. A simple static pressure difference cannot objectively reflect the air permeability of the material layer itself—for the same material layer, the pressure difference will be greater with a larger exhaust volume, and the pressure difference will also increase with a thicker material layer. Therefore, it is necessary to combine the air volume per unit area with the material layer thickness to calculate a standardized air permeability index, thus eliminating the influence of operating condition fluctuations and objectively quantifying the air permeability of the material layer itself. Based on this, an interpolation algorithm is used to expand the discrete detection points into a continuous lateral distribution, which can intuitively present the air permeability segregation state across the entire width of the trolley.

[0052] Step S4, the assessment of fabric surface morphology and segregation, is a quantitative evaluation of fabric quality from a geometric perspective. Fabric surface height is the most intuitive indicator of fabric performance. By calculating characteristic parameters such as lateral height difference and flatness, the uniformity of the fabric can be quantitatively assessed, and obvious fabric defects such as localized fabric accumulation and depressions can be identified. This can be used alone to guide fabric adjustments and also provides a geometric basis for subsequent coupled analysis with air permeability parameters.

[0053] The height-permeability coupling analysis and output in step S5 is the core innovation that distinguishes this method from existing technologies. Most existing technologies adjust based solely on height or solely on permeability, easily leading to contradictory problems such as a flat material surface with large permeability differences, or permeability meeting standards but the material layer being too thick / thin. This method spatially correlates the two parameters and outputs differentiated control commands for different combined working conditions, achieving synergistic optimization of thickness and permeability. This fundamentally improves the lateral uniformity of the sintered material layer 3 and stabilizes the thermal state during sintering. ① Edge area material height difference greater than 20mm, permeability greater than 15% → increase edge material distribution ② Middle area material height greater than 10mm, permeability lower than 15% → reduce middle material distribution ③ Material height difference < 15mm but permeability difference > 10% → fine-tune the damper. All control commands are sent to the sintering process control system via OPC communication.

[0054] In this embodiment, the plurality of detection units 4 are arranged at equal intervals in the transverse direction along the material conveying area, and each detection unit 4 is located in the same cross section in the material conveying direction.

[0055] Specifically, equal spacing means that the lateral center distance between two adjacent detection units is equal, which can ensure that the sampling points are evenly distributed in the width direction of the trolley 2 and that there is no biased sampling.

[0056] The same cross section means that all detection units are in the same position in the direction of travel of the trolley 2, that is, they are located in the same vertical plane perpendicular to the direction of travel of the trolley 2, corresponding to the sintered material layer 3 of the same cross section.

[0057] Equal spacing ensures uniformity in lateral sampling, allowing the detection results to reflect the parameter distribution across the entire width of the trolley without bias. Unequal spacing results in higher detection accuracy in denser areas and lower accuracy in sparser areas, leading to deviations in distribution assessment. With equal spacing, interpolation calculations are more uniform in accuracy, segregation identification is more accurate, and it is also easier to correspond one-to-one with the zoned control points of the material distributor, achieving precise matching between detection points and control points.

[0058] All detection units are positioned within the same cross-section to ensure that all detection points correspond to the same sintered material layer 3 on the same cross-section. The trolley 2 moves continuously forward, and material layers at different conveying positions correspond to different material feeding times, resulting in variations in material state. If the detection units are staggered along the conveying direction, they would detect material layers at different times and positions, lacking spatial correspondence and failing to accurately reflect the lateral distribution within the same cross-section. The layout within the same cross-section ensures that all parameters are collected from the same cross-sectional material layer, resulting in strong spatial consistency of data and more accurate results for lateral comparison and coupled analysis.

[0059] In this embodiment, each detection unit includes a laser rangefinder 41, an upper static pressure tapping tube 42, a temperature sensor 43, and a lower static pressure tapping tube 44. The laser rangefinder 41 is installed inside a water-cooled dustproof sleeve 45, forming a laser light path extending downward in a vertical direction. One end of the upper static pressure tapping tube 42 extends into the water-cooled dustproof sleeve 45 as the first pressure tapping end, with the pressure tapping port horizontally positioned 10-20cm above the laser light path, its center located on the vertical line of the laser light path, and the other end extending out of the water-cooled dustproof sleeve 45. The temperature sensor 43 is installed outside the water-cooled dustproof sleeve 45, and its armored probe extends into the upper static pressure tapping tube 42. The lower static pressure tapping tube 44 extends horizontally into the air box 1 below the corresponding detection point, with the center of its second pressure tapping end, the center of the pressure tapping port of the upper static pressure tapping tube 42, and the laser light path located on the same vertical line, and the other end extending out of the air box 1.

[0060] Specifically, the laser rangefinder 41 is a non-contact rangefinder based on the laser time-of-flight principle. It is used to measure the vertical distance to the material surface and calculate the height of the material surface. It has the advantages of high accuracy, fast response, and non-contact operation. The measurement accuracy is ±1mm, and the measuring range is 0.5~5m.

[0061] The water-cooled dustproof sleeve 45 is a protective shell with a water-cooled interlayer and a dustproof viewing window. It is used to protect the internal laser rangefinder 41, isolate it from high temperature and dust at the site, and ensure the long-term stable operation of the instrument.

[0062] The upper static pressure tapping pipe 42 is a pipeline for collecting the static pressure of flue gas above the sintering material layer 3. Its first pressure tapping end is located in the flue gas space above the material surface and is used to obtain the static pressure signal on the upper side of the material layer.

[0063] Temperature sensor 43 is an armored temperature detection element used to detect flue gas temperature and provide temperature parameters for subsequent density correction calculations.

[0064] The lower static pressure tapping pipe 44 is a pipeline for collecting static pressure inside the wind box 1. Its second pressure tapping end is located in the airflow space inside the wind box 1 and is used to obtain the static pressure signal on the lower side of the material layer.

[0065] Horizontal pressure tapping refers to a pressure tapping method in which the end face of the pressure tapping port is arranged vertically and the opening faces horizontally. This avoids the airflow directly impacting the pressure tapping port and eliminates the interference of dynamic pressure on static pressure measurement.

[0066] This detection unit adopts a multi-parameter integrated design, integrating the detection elements of height, upper static pressure, temperature, and lower static pressure at the same detection point, realizing synchronous detection of multiple parameters at a single point.

[0067] The water-cooled dustproof sleeve 45 is a key design feature to adapt to the harsh environment of the sintering site. The sintering site has high temperatures and high dust concentrations; as a precision electronic instrument, the laser rangefinder 41 would age and be damaged rapidly if directly exposed to the environment. The water-cooled dustproof sleeve 45 has circulating cooling water inside, which can remove heat and ensure that the internal instruments are within a suitable operating temperature range. The lower end is equipped with a dustproof optical window, which allows laser light to pass through while blocking dust from entering the sleeve, effectively protecting the laser rangefinder 41.

[0068] Both the upper static pressure tap 42 and the lower static pressure tap 44 adopt a horizontal tapping design, which is a standard requirement for static pressure testing. If the tapping port is directly facing the airflow direction, the dynamic pressure of the airflow will be superimposed on the static pressure, resulting in an overestimation of the measured value. With horizontal tapping, the tapping port is parallel to the airflow direction, only sensing the static pressure of the gas, which can eliminate dynamic pressure interference and ensure the accuracy of static pressure measurement.

[0069] The arrangement of the pressure tapping port of the upper static pressure tapping tube 42, the second pressure tapping end of the lower static pressure tapping tube 44, and the laser optical path along a common vertical line is a core design feature ensuring data spatial consistency. The laser optical path corresponds to the detection position of the material surface height, while the upper and lower pressure tapping ports correspond to the detection position of the pressure difference. The fact that all three are collinear means that the height and pressure difference are detected at the same point on the sintered material layer 3. The calculated permeability index corresponds perfectly spatially to the material surface height at that point, with no positional deviation, resulting in the highest accuracy of the coupled analysis. If the three are misaligned, the height and permeability will correspond to different material layer positions, leading to matching errors in the coupled control logic and affecting control accuracy.

[0070] The probe of the temperature sensor 43 extends into the upper static pressure tapping tube 42, which can directly detect the flue gas temperature in the tapping tube. The detection point is in the same position as the static pressure detection point, and the temperature data has the strongest correspondence with the static pressure data, resulting in the highest accuracy of subsequent density correction.

[0071] In this embodiment, a purging unit 7 is also included. In step S2, the data preprocessing further includes purging interference compensation.

[0072] Specifically, the purging unit 7 is a complete set of devices that provides a stable flow of backflushing air to prevent blockage of the pressure tapping lines and ensure the long-term stable operation of the detection system. The purging action prevents the pressure tapping lines from being blocked by dust. The purging unit 7 periodically introduces compressed air into the pressure tapping lines to perform backflushing and clearing operations, which is a routine maintenance method for the pressure tapping system.

[0073] Purging interference compensation is a necessary optimization measure to adapt to the on-site backflushing conditions. The sintering site has high dust content in the flue gas, and the upper static pressure taps 42 and 44 are prone to dust blockage during long-term operation, thus requiring regular compressed air backflushing. However, during purging, the compressed air alters the pressure field within the taps, causing significant jumps in static pressure detection data, completely deviating from the true value. After purging, the airflow within the pipes needs time to return to a steady state, during which time the data is also unusable. If purging interference is not compensated, the abnormal data during this period will enter the subsequent calculation process, causing false jumps in the permeability index, leading to misjudgments in the control logic and the output of incorrect control commands.

[0074] The purging interference compensation is a software processing mechanism that complements the hardware backflushing action of the purging unit 7. It achieves hardware and software linkage through the timing synchronization signal of the control cabinet 5, completely eliminating the interference of the backflushing action on the detection data and ensuring data continuity and control logic stability.

[0075] In this embodiment, the purging unit 7 includes a compressed air source 71, a solenoid valve 73, a throttling orifice plate 74, and a purging pipeline 72. The solenoid valve 73 is signal-connected to the control cabinet 5 and adopts a timed pulse purging mode with a purging cycle of 5-15 minutes and a single purging duration of 3-10 seconds. The throttling orifice plate 74 is connected in series in the purging pipeline 72 downstream of the solenoid valve 73 to stabilize the purging air flow rate. The purging pipeline 72 is connected to the pressure tapping pipelines of each detection unit for backflushing and clearing blockages. In this embodiment, the typical values ​​are a purging cycle of 10 minutes and a single purging duration of 5 seconds.

[0076] Specifically, the compressed air source 71 provides clean compressed air on-site, which is the power source for backflushing and clearing blockages, and the pressure is usually 0.4~0.6MPa.

[0077] Solenoid valve 73 is an electrically controlled valve used to control the opening and closing of the purging air path and to receive control signals from the control cabinet 5 to achieve automatic opening and closing.

[0078] The orifice plate 74 is a throttling element with a fixed orifice diameter. The orifice plate restricts the airflow through its throttling effect, thereby stabilizing the velocity and pressure of the purging airflow.

[0079] The timed pulse purging mode refers to the working mode in which the solenoid valve 73 is opened for a short period of time according to the set time cycle to perform pulse backflushing, which takes into account both the unblocking effect and the continuity of detection.

[0080] The purging unit 7 is the guarantee for the long-term reliable operation of the pressure tapping system. It enables automatic and stable backflushing to clear blockages in the case of high dust in sintering flue gas.

[0081] Employing a timed pulse purging mode, periodic clearing of blockages can be achieved without affecting normal detection. Each pulse purging cycle is short, with the system in normal detection mode for most of the time, minimizing impact on detection continuity. Timed automatic execution eliminates the need for manual operation, reducing on-site maintenance workload and adapting to unattended operation requirements. In this embodiment, the purging cycle and duration can be flexibly adjusted according to the on-site dust concentration.

[0082] The orifice plate 74 is crucial for achieving constant flow. Without this throttling element, compressed air would directly rush into the pressure tapping tube during purging, resulting in a large airflow and strong pressure surge. This would cause drastic pressure fluctuations within the tapping tube, severely interfering with the detection data. Furthermore, the excessive airflow could damage components such as the temperature sensor 43 within the tapping tube. The orifice plate 74, by limiting the purging flow rate with a fixed orifice diameter, maintains a stable and moderate purging airflow velocity. This effectively removes dust adhering to the tube wall without causing excessive pressure surges, minimizing purging interference with detection and protecting the detection components.

[0083] The purging line 72 is connected to the upper static pressure tapping line 42 and the lower static pressure tapping line 44 of all detection units, which can realize the synchronous backflushing of the two sets of pressure tapping lines. One purging unit 7 can complete the cleaning and maintenance of all pressure tapping lines. The system has a simple structure, low cost and high reliability.

[0084] In this embodiment, in step S2, the outlier removal adopts the 3σ criterion, which identifies and replaces the jump data in the sliding window containing 30 consecutive sampling points with the sliding average value of adjacent time points; the density correction based on flue gas temperature is specifically as follows: taking the air density under the standard state of 20℃ as the benchmark, the static pressure difference is corrected for temperature according to the ideal gas law, and the correction formula is: ΔP0=ΔP×(T0 / T) where ΔP0 is the pressure difference after standard temperature correction, ΔP is the measured static pressure difference between the upper and lower layers of sintering material layer 3, T0 is the standard thermodynamic temperature of 293.15K, and T is the measured flue gas thermodynamic temperature.

[0085] Specifically, the 3σ criterion, also known as the Raida criterion, is an outlier identification method based on the normal distribution. It states that data in a set of measurement data whose deviation from the mean exceeds three times the standard deviation can be identified as outliers. It is the most commonly used outlier identification method in the field of industrial testing.

[0086] The continuous sampling window refers to the length of the continuous data sequence used for outlier detection, which is updated as the sampling process progresses.

[0087] The moving average is a replacement value that uses the arithmetic mean of several normal sampling points before and after an outlier. This ensures the continuity and smoothness of the data sequence and avoids data gaps.

[0088] The ideal gas law is a state equation that describes the relationship between the pressure, volume, and temperature of an ideal gas. In this embodiment, the relationship between pressure and thermodynamic temperature is used to perform density correction and conversion.

[0089] Thermodynamic temperature, also known as Kelvin temperature, is a temperature measurement method with absolute zero as the starting point. The unit is Kelvin (K), and the conversion relationship with Celsius temperature is T(K) = t(°C) + 273.15.

[0090] The 3σ criterion is used for outlier removal, adapting to the interference characteristics of the sintering site. The static pressure and temperature monitoring data at the sintering site generally exhibit steady-state fluctuations, conforming to a normal distribution. The vast majority of data points are concentrated within the range of the mean ± 3 standard deviations; data exceeding this range are primarily caused by transient interference rather than actual changes in the material layer parameters. The 3σ criterion eliminates the need for manually setting thresholds, automatically identifying anomalies based on the data's inherent statistical characteristics. It boasts strong adaptability, a low false positive rate, and is suitable for long-term unattended operation in industrial settings. Using the moving average of adjacent time points for replacement, rather than directly deleting outliers, ensures the temporal continuity of the data sequence, avoiding adverse effects on subsequent interpolation calculations and trend analysis.

[0091] Density correction based on flue gas temperature aims to eliminate the systematic error in static pressure testing caused by temperature fluctuations. Static pressure testing essentially measures the collision pressure of gas molecules. For the same number of molecules, increased temperature leads to increased molecular thermal motion and thus increased static pressure; conversely, decreased temperature leads to decreased static pressure. The flue gas temperature at the sintering site is affected by factors such as ambient temperature, material temperature, and ventilation conditions, and can fluctuate by tens of degrees Celsius. Without temperature correction, material layers with the same permeability will exhibit different static pressure differences at different temperatures, resulting in distorted permeability calculations.

[0092] The physical meaning of this corrected formula is to convert the static pressure difference value under the measured operating temperature into the equivalent pressure difference under the standard condition of 20℃, eliminating the influence of density changes caused by temperature, and making the test results at different temperatures comparable. The corrected pressure difference data can truly reflect the air permeability resistance of the material layer itself, ensuring the accuracy and comparability of the subsequent air permeability index calculation results.

[0093] In this embodiment, in step S3, the air permeability index is calculated using the formula: K = (Q × h) / ΔP0, where Q is the air volume per unit area of ​​the wind box 1 corresponding to the detection point, h is the thickness of the sintered material layer 3 converted from the material surface height, and ΔP0 is the static pressure difference between the upper and lower parts of the sintered material layer 3 after temperature correction. The larger the K value, the better the air permeability of the sintered material layer 3; the unit of K is mm² / (Pa). s), h is in mm, ΔP0 is in Pa, Q is in m³ / (m²) The interpolation algorithm uses cubic spline interpolation, taking each detection point as a reference node, to generate a continuous permeability distribution curve with a resolution of not less than 5 cm along the width direction of the sintering machine; combined with the running speed of the sintering machine, a two-dimensional distribution cloud map along the length direction is further generated.

[0094] Specifically, the air volume per unit area refers to the gas volume flow rate passing through a unit area of ​​sintered material layer 3 per unit time, and the unit is usually m³ / (m²). min) is the core parameter reflecting the intensity of ventilation.

[0095] Cubic spline interpolation is a piecewise interpolation algorithm that constructs a cubic polynomial between every two adjacent discrete points, ensuring that the entire curve is continuous and second-order differentiable. The interpolation results are smooth and highly accurate, making it suitable for continuous processing of industrial parameters.

[0096] The lateral distribution curve is a two-dimensional curve with the lateral position of the trolley as the horizontal axis and the air permeability index as the vertical axis, which intuitively presents the trend of air permeability along the width of the trolley.

[0097] Two-dimensional distribution cloud maps are planar distribution maps that use color depth to represent the degree of air permeability. They can more intuitively present the location and degree of segregation areas, making it easier for on-site operators to quickly identify them.

[0098] The core logic of this permeability index formula is to eliminate the influence of airflow and material thickness, thus obtaining the inherent permeability properties of the material layer itself. According to the basic laws of seepage mechanics, the resistance loss of gas passing through the material layer is directly proportional to the airflow and the material layer thickness, and inversely proportional to the permeability of the material layer. Therefore, the K value obtained by calculating airflow × material thickness / pressure difference is only related to the inherent properties of the material layer itself, such as particle size distribution, packing density, and porosity, and is independent of the exhaust airflow and material layer thickness. It is a standardized permeability performance index.

[0099] The air permeability index calculated using this formula can be directly used for lateral comparisons between different testing points, as well as for historical comparisons under different operating conditions, providing a unified quantitative benchmark for segregation assessment and control decisions. The larger the K value, the smaller the pressure difference under the same air volume and material thickness, the more developed the material layer pores, and the better the air permeability; conversely, it indicates that the material layer is dense and the air permeability resistance is high.

[0100] The use of cubic spline interpolation to generate continuous distribution results addresses the problem of the limited number of discrete detection points, which cannot fully represent the continuous distribution. Due to installation space and cost constraints, the number of lateral detection points is typically 5-10, constituting discrete sampling. Cubic spline interpolation constructs a smooth cubic curve between adjacent detection points, ensuring that the curve passes through all measured points and that the overall curve is smooth and continuous, avoiding the abrupt changes seen in polygonal interpolation. This allows for a more realistic reflection of the continuous trend in air permeability. The generated lateral distribution curve and contour map can be directly displayed on the monitoring interface of the host computer processing system 6, providing operators with an intuitive visual reference.

[0101] In this embodiment, in step S4, the material surface morphology features include the lateral height difference of the material surface, the flatness coefficient and the degree of height segregation, and the material surface defects include local material accumulation and depression.

[0102] Specifically, the lateral height difference of the material surface is the difference between the maximum and minimum heights of the material surface among all detection points, and it is the most intuitive indicator reflecting the overall flatness of the material surface.

[0103] The formula for calculating the flatness coefficient is: C_h = 1 - (Δh_max / h_avg), where Δh_max is the maximum lateral height difference of the material surface, and h_avg is the average height of the material surface at each test point, which is a dimensionless parameter. The closer the ratio is to 1, the flatter the material surface, thus eliminating the influence of the overall material thickness on the flatness evaluation. When Δh_max exceeds 30mm or the flatness coefficient is lower than 0.95, it is judged as excessive segregation of the material surface.

[0104] The degree of height segregation is the average height difference between the edge detection point and the middle detection point, which is used to quantitatively evaluate the difference in material thickness between the edge and the middle of the trolley and reflect the degree of edge effect of the fabric.

[0105] Localized material accumulation is a defect in which the height of a single or several consecutive detection points is significantly higher than the surrounding area. It is usually caused by blockage of the material chute or uneven material distribution.

[0106] Local depressions are defects in which the height of a single or several consecutive detection points is significantly lower than that of the surrounding area. They are usually caused by material segregation or abnormalities in the fabric scraper.

[0107] By calculating the surface morphology characteristics of the material from multiple dimensions, a comprehensive quantitative assessment of the fabric quality can be achieved, rather than a rough judgment based on a single indicator. The lateral height difference is the most basic overall indicator, which can quickly determine the overall undulation of the material surface; the flatness coefficient eliminates the influence of the overall material thickness and can be used for lateral comparison of fabric quality under different production batches and different material thickness settings; the degree of height segregation specifically assesses the edge effect, which is the most common problem in sintered fabrics—materials are prone to rolling off at the edges of the trolley, and are usually thinner and more breathable, with a significant difference from the center, which is an important reason for uneven lateral sintering.

[0108] Identifying localized material build-up and depressions can provide a basis for fault diagnosis and targeted adjustments of the material placing equipment. For example, the continuous occurrence of localized material build-up in fixed locations indicates that there is blockage in the material placing chute or wear on the scraper at the corresponding location; depressions in random locations may be caused by the segregation of large particles in the material. Through defect identification, the control system can not only output material quantity adjustment commands, but also trigger equipment anomaly warnings, assisting on-site operation and maintenance.

[0109] In this embodiment, the specific logic of the spatial association matching in step S5 is as follows: when the material surface height of the sintered material layer 3 at the detection point is too high and the air permeability index is too low, a material control command to reduce the material distribution in the area where the corresponding detection point is located is output; when the material surface height of the sintered material layer 3 at the detection point is too low and the air permeability index is too high, a material control command to increase the material distribution in the area where the corresponding detection point is located is output; when the material surface height is uniform but the lateral difference in air permeability exceeds the set threshold, a fine-tuning command for the opening of the corresponding wind box damper is output.

[0110] Specifically, the fabric control command refers to the control signal sent to the multi-roller fabric distributor or the fabric chute adjustment mechanism to adjust the amount of material falling in the corresponding lateral area and change the local material layer thickness.

[0111] The bellows damper control command refers to the control signal sent to the bellows damper actuator to adjust the damper opening and change the negative pressure and air volume of the corresponding area.

[0112] The threshold settings include a material surface height uniformity judgment threshold and an air permeability difference threshold: the judgment condition for material surface height uniformity is that the maximum lateral height difference is less than 15mm; the allowable value for lateral air permeability difference is expressed as the ratio of the maximum lateral deviation to the average value, which is set to 10% in this embodiment. If this value is exceeded, the damper fine adjustment will be triggered.

[0113] The three types of control logic correspond to three typical fabric-breathability patterns, achieving differentiated and precise coordinated control.

[0114] The first type of working condition, characterized by high height and low breathability, is usually caused by excessive fabric, excessively thick material layers, and fine, dense materials in that area. In this case, simply thinning the material layer can reduce material resistance, improve breathability, and correct material thickness deviations. Therefore, reducing the amount of fabric is the preferred method for control, achieving a dual optimization of thickness and breathability.

[0115] The second type of low-height, high-permeability condition usually occurs when the amount of fabric in the area is insufficient, the material layer is too thin, the material is too coarse, and the porosity is high. In this case, increasing the amount of fabric can not only make up for the thickness of the material layer, but also moderately increase the resistance of the material layer and reduce the difference in permeability with the surrounding area, thus achieving synergistic optimization of the two parameters.

[0116] The third scenario, characterized by highly uniform fabric thickness but significant differences in air permeability, indicates that the fabric thickness itself is not the issue. The air permeability differences are caused by factors beyond thickness, such as material particle size segregation and uneven density. Adjusting the amount of fabric in this case will not solve the problem and may even disrupt the surface smoothness. Therefore, by fine-tuning the opening of the damper corresponding to wind box 1, the local exhaust intensity is moderately altered to compensate for the sintering speed differences caused by the air permeability variations, ensuring a consistent lateral sintering endpoint. This division of labor—adjusting fabric thickness and damper air permeability—achieves uniform air permeability without compromising surface smoothness, resulting in more precise control and fewer side effects.

[0117] In this embodiment, step S2, the purging interference compensation specifically involves marking the collected data during and after the purging action for a preset duration as invalid, and filling it with steady-state data before purging.

[0118] Specifically, the preset duration refers to the delay time required for the data to return to stability after the purging is completed. In this embodiment, it is set to 2 seconds to cover the disturbance period of the residual airflow after purging.

[0119] The steady-state data before purging refers to the average data within the last sampling period before the purging action is triggered, representing the true state of the material layer parameters before purging.

[0120] By marking the data during the purging and recovery periods as invalid and filling them with steady-state data before purging, the interference of purging actions on the detection results can be completely eliminated, ensuring the continuity and stability of the data sequence. This allows the system to meet the maintenance requirements of periodic backflushing and clearing blockages without shutting down or interrupting detection.

[0121] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A sintering process synergistic control method based on material layer thickness and permeability, characterized in that, Includes the following steps: S1. Data Acquisition: Simultaneously collect data on the sintering material layer height, flue gas static pressure above the sintering material layer, flue gas temperature, and static pressure inside the lower wind box at multiple detection points at different positions in the horizontal direction of the material conveying area between the material feeding station and the ignition station, and upload the data at a fixed sampling frequency. S2. Data preprocessing: Outlier removal and density correction based on flue gas temperature are performed on the raw collected data in sequence to obtain the corrected static pressure difference between the upper and lower layers of the sintering material and the material surface height data. S3. Calculation of air permeability index: Based on the corrected static pressure difference and the sintered material layer thickness converted from the material surface height, combined with the unit area air volume of the corresponding wind box, the air permeability index of the sintered material layer at each detection point is calculated, and the air permeability distribution result of the material conveying area is generated by the interpolation algorithm. S4. Material Surface Morphology and Segregation Assessment: Based on the material surface height data at each detection point, calculate the material surface morphology characteristics and identify material surface defects; S5. Height-permeability coupling analysis and output: Spatially correlate and match the material surface height distribution with the permeability distribution, and output the corresponding fabric control command and air box damper control command for the detection point.

2. The sintering process collaborative control method according to claim 1, characterized in that, In step S2, the outlier removal adopts the 3σ criterion, which identifies and replaces the jump data within the continuous sampling window with the moving average of adjacent time points; The density correction based on flue gas temperature is as follows: taking the air density under standard conditions of 20℃ as a benchmark, the static pressure difference is corrected for temperature according to the ideal gas law. The correction formula is: ΔP0=ΔP×(T0 / T), where ΔP0 is the pressure difference after standard temperature correction, ΔP is the measured static pressure difference between the upper and lower parts of the sintering material layer, T0 is the standard thermodynamic temperature of 293.15K, and T is the measured flue gas thermodynamic temperature.

3. The sintering process collaborative control method according to claim 1, characterized in that, In step S3, the air permeability index is calculated using the formula: K=(Q×h) / ΔP0, where Q is the air volume per unit area of ​​the wind box corresponding to the detection point, h is the thickness of the sintered material layer converted from the material surface height, and ΔP0 is the static pressure difference between the upper and lower parts of the sintered material layer after temperature correction. The larger the K value, the better the air permeability of the sintered material layer. The interpolation algorithm uses cubic spline interpolation, and the generated air permeability distribution results include at least one of the lateral distribution curve and the two-dimensional distribution cloud map.

4. The sintering process collaborative control method according to claim 1, characterized in that, In step S4, the material surface morphology features include the lateral height difference of the material surface, the flatness coefficient and the degree of height segregation, and the material surface defects include local material accumulation and depression.

5. The sintering process collaborative control method according to claim 1, characterized in that, In step S5, the specific logic of the spatial association matching is as follows: when the material surface height of the sintered material layer at the detection point is too high and the air permeability index is too low, a material control command to reduce the material distribution in the area where the corresponding detection point is located is output; when the material surface height of the sintered material layer at the detection point is too low and the air permeability index is too high, a material control command to increase the material distribution in the area where the corresponding detection point is located is output; when the material surface height is uniform but the lateral difference in air permeability exceeds the set threshold, a fine-tuning command for the opening of the corresponding wind box damper is output.

6. The sintering process collaborative control method according to claim 1, characterized in that, In step S2, the data preprocessing also includes purging interference compensation, which marks the collected data during and after the purging action for a preset duration as invalid and fills it with steady-state data before purging.

7. A sintering process collaborative control device for implementing the sintering process collaborative control method according to any one of claims 1-6, characterized in that, The system includes multiple detection units, a control cabinet, and a host computer processing system. The multiple detection units are located above the material conveying area between the sintering machine's feeding station and ignition station, and each corresponds to a different detection point in the horizontal direction of the material conveying area. These units are used to simultaneously collect data on the material surface height, flue gas static pressure, flue gas temperature, and wind box static pressure at each detection point. The control cabinet is electrically connected to each detection unit, used to simultaneously collect the detection data from each detection point, and to connect to the corresponding wind box's unit area airflow signal, all of which are then uploaded to the host computer processing system. The host computer processing system includes a built-in data preprocessing module, a permeability distribution calculation module, a material surface morphology analysis module, and a coupling output module, used to sequentially perform data correction, permeability index calculation, material surface morphology evaluation, and coupling control command output.

8. The sintering process collaborative control device according to claim 7, characterized in that, The multiple detection units are arranged at equal intervals in the transverse direction along the material conveying area, and each detection unit is located in the same cross-section in the material conveying direction.

9. The sintering process collaborative control device according to claim 7, characterized in that, Each detection unit includes a laser rangefinder, an upper static pressure tapping tube, a temperature sensor, and a lower static pressure tapping tube. The laser rangefinder is installed inside a water-cooled dustproof sleeve, forming a laser beam path extending downwards in a vertical direction. One end of the upper static pressure tapping tube extends into the water-cooled dustproof sleeve as the first pressure tapping end, with the pressure tapping port horizontally positioned and its center located on the vertical line of the laser beam path. The other end extends out of the water-cooled dustproof sleeve. The temperature sensor is installed outside the water-cooled dustproof sleeve, with its armored probe extending into the upper static pressure tapping tube. The lower static pressure tapping tube extends horizontally into the air box below the corresponding detection point, with the center of its second pressure tapping end aligned with the center of the pressure tapping port of the upper static pressure tapping tube and the laser beam path on the same vertical line. The other end extends out of the air box.

10. The sintering process collaborative control device according to claim 9, characterized in that, It also includes a purging unit, comprising a compressed air source, a solenoid valve, a throttling orifice plate, and a purging pipeline; the solenoid valve is signal-connected to the control cabinet and adopts a timed pulse purging mode; the throttling orifice plate is connected in series in the purging pipeline downstream of the solenoid valve to stabilize the purging air flow; the purging pipeline is connected to the pressure tapping pipeline of each detection unit for backflushing and clearing blockages.

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