A new pallet of sintering machine return journey on-line installation automatic control method

Abstract

The application provides a kind of sintering machine new trolley return online installation automatic control method, by receiving old trolley unloading completion signal, determine the front adjacent trolley and the rear adjacent trolley defined installation space, and keep mobile trolley with return trolley group synchronous movement;According to the position of front adjacent trolley and rear adjacent trolley, determine the center of space, calculate the position difference between lifting device center and space center as follow-up deviation, and determine the suspension reference according to the suspension positioning data, whether follow-up deviation and reference deviation is in calibration range as lifting receiving condition;Only when the receiving state data meets the calibration receiving condition, output the power-off demagnetization instruction, so that the new trolley is transferred from electromagnetic suspension device to lifting device;Output lifting recovery instruction to make new trolley drop into installation space, and output release limit instruction after landing, so that mobile trolley is separated.The application can complete automatic alignment, controlled release and accurate landing of new trolley without stopping sintering machine.

Description

Technical Field

[0001] This invention relates to the field of sintering technology, and in particular to an automatic control method for online installation of a new sintering machine trolley during return. Background Technology

[0002] Currently, the installation of new trolleys on sintering production lines in steel enterprises typically employs a manual, offline hoisting method. Relying on simple tools such as overhead cranes, lifting equipment, and crowbars, workers manually complete processes including trolley transfer, alignment, docking, clamping, and fastening. This process relies entirely on visual judgment and multi-person coordination. This method requires the sintering machine to be shut down and the trolley group to cease operation, making it difficult to complete under conditions of continuous operation of the sintering machine, uninterrupted material supply, and continuous operation of the return trolley group. This method suffers from drawbacks such as long downtime, significant capacity loss, difficulty in guaranteeing installation accuracy, uncontrollable operation process, and lack of data traceability, failing to meet the needs of continuous operation and intelligent management of sintering production lines.

[0003] In view of this, it is necessary to propose an automatic control method for the online installation of the new sintering machine trolley during return trip, so as to solve or at least alleviate the above-mentioned defects. Summary of the Invention

[0004] The main objective of this invention is to provide an automatic control method for the online installation of new sintering machine trolleys during the return trip, in order to solve the technical problem that it is difficult to complete the online installation of new trolleys during the continuous operation of the return trip trolley group under the conditions that the sintering machine does not need to be stopped and manual hoisting and alignment is reduced or replaced.

[0005] To achieve the above objectives, the present invention provides an automatic control method for online installation of a new sintering machine trolley during return trip, comprising the following steps: S1, acquire the signal indicating that the old trolley has been unloaded, the position of the trolley immediately preceding the empty space to be installed, the position of the trolley immediately following the rear of the empty space, and the position of the center of the lifting device; wherein, the empty space to be installed is the space defined by the trolley immediately preceding the old trolley and the trolley immediately following the rear of the empty space after the old trolley has been unloaded. S2, determine the center of the empty space to be installed based on the position of the front adjacent trolley and the position of the rear adjacent trolley, and calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; when the follow-up deviation is within the calibrated follow-up range, maintain the limit engagement state between the mobile trolley equipped with the lifting device and the front adjacent trolley and the rear adjacent trolley. S3, acquire the suspension positioning data after the electromagnetic suspension device adsorbs the new trolley, and determine the suspension reference of the new trolley based on the suspension positioning data; S4, obtain the position of the center of the lifting device and the position of the suspension reference, calculate the reference deviation based on the position of the center of the lifting device and the position of the suspension reference; when the reference deviation is within the calibration transfer range, output a lifting command to raise the lifting device to the receiving position of the new trolley. S5, acquire the receiving status data of the lifting device, the receiving status data including the lifting position signal; when the receiving status data meets the calibrated receiving conditions, output a power-off and demagnetization command to transfer the new trolley from the electromagnetic suspension device to the lifting device. S6 outputs a lifting and retraction command, causing the lifting device to lower the new trolley into the installation space; after the new trolley enters the installation space, it outputs a release limit command, causing the mobile trolley to detach from the front and rear adjacent trolleys.

[0006] Preferably, step S2 includes the following steps: S21, obtain the positions of the front and rear adjacent trolleys of the empty space to be installed, and determine the center of the empty space to be installed based on the positions of the front and rear adjacent trolleys. S22, calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; S23, compare the following deviation with the calibrated following range. When the following deviation is within the calibrated following range, determine that the moving trolley maintains a limit engagement state with the front adjacent trolley and the rear adjacent trolley, and allow the output of the lifting command. S24, when the follow-up deviation exceeds the calibrated follow-up range, the lifting command is prohibited from being output, the electromagnetic suspension device is kept in the state of adsorbing the new trolley, and a follow-up abnormal signal is output.

[0007] Preferably, the direction of return travel is defined as the first direction, and the direction perpendicular to the return travel direction is defined as the second direction; the suspension positioning data includes: multiple vertical distance values ​​obtained by multiple laser rangefinders arranged in an array along the first and second directions after the electromagnetic suspension device adsorbs the new trolley, a horizontal distance value obtained by a laser rangefinder measuring the side of the new trolley, and the position of the center of the electromagnetic suspension device. S3 includes the following steps: S31, determine the first attitude offset of the new trolley around the first direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the second direction, determine the second attitude offset of the new trolley around the second direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the first direction, and determine the position offset of the new trolley along the second direction based on the horizontal distance measurement value. S32, when the first attitude offset is within the calibrated attitude range, the second attitude offset is within the calibrated attitude range, and the position offset is within the calibrated position range, the suspension state of the new trolley is determined to be qualified. S33, determine the suspension reference of the new trolley based on the position of the center of the electromagnetic suspension device, the first attitude offset, the second attitude offset, and the position offset.

[0008] Preferably, step S4 includes the following steps: S41, obtain the position of the center of the lifting device and the position of the suspension reference, and calculate the position difference between the center of the lifting device and the suspension reference along the return travel direction based on the position of the center of the lifting device and the position of the suspension reference, as the reference deviation; S42, obtain the operating speed of the return trolley group and the calibrated lifting time required for the lifting device to rise from the current position to the new trolley receiving position; S43, calculate the lifting start distance based on the running speed and the calibrated lifting time; obtain the real-time center distance between the center of the moving trolley output by the Gray busbar device and the center of the electromagnetic suspension device; when the real-time center distance reaches the lifting start distance, estimate that when the lifting device rises to the new trolley receiving position, the center of the lifting device and the suspension reference will be aligned along the return running direction. S44, when the real-time center distance reaches the lifting start distance and the reference deviation is within the calibration transfer range, a lifting command is output to raise the lifting device to the receiving position of the new trolley.

[0009] Preferably, after determining in step S43 that the center of the lifting device is aligned with the suspension reference along the return travel direction after the calibrated lifting time, the step further includes the following step: S431 continuously acquires the real-time running speed of the return trolley group, the real-time center distance output by the Gray busbar device, the real-time lifting height data of the lifting device, and the actual duration after the lifting command is output after outputting the lifting command. S432, determine the actual lifting progress based on the real-time lifting height data and the calibrated total lifting height, wherein the actual lifting progress is equal to the ratio of the real-time lifting height to the calibrated total lifting height; determine the theoretical lifting progress based on the actual duration and the calibrated lifting duration, wherein the theoretical lifting progress is the ratio of the actual duration to the calibrated lifting duration; and use the difference between the actual lifting progress and the theoretical lifting progress as the lifting progress deviation. S433, based on the real-time center distance, the real-time running speed and the actual lifting progress, predict the predicted alignment deviation between the center of the lifting device and the suspension reference along the return running direction when the lifting device rises to the new trolley receiving position; S434, when the lifting progress deviation is within the calibrated progress range and the predicted alignment deviation is within the calibrated alignment range, the lifting operation continues; S435, when the lifting progress deviation exceeds the calibrated progress range, or the predicted alignment deviation exceeds the calibrated alignment range, first adjust the lifting speed of the lifting device. If the speed does not return to the calibrated progress range and the calibrated alignment range after adjustment, then suspend lifting until the lifting progress deviation returns to the calibrated progress range and the predicted alignment deviation returns to the calibrated alignment range.

[0010] Preferably, step S5 includes the following steps: S51, acquire the lifting position signal, the position difference of the new trolley relative to the installation space along the return travel direction and the position difference along the direction perpendicular to the return travel direction; S52, when the lifting position signal is valid, the position difference along the return travel direction is within the calibrated return travel direction range, and the position difference along the perpendicular to the return travel direction is within the calibrated vertical direction range, a release permission signal is generated; S53, according to the release permission signal, outputs a power-off and demagnetization command, causing the new trolley to transfer from the electromagnetic suspension device to the lifting device.

[0011] Preferably, step S6 includes the following steps: S61, after outputting the lifting and retraction command, receives the lifting and retraction in place signal to confirm that the lifting device has been retracted in place; S62, after confirming that the lifting device has been retracted into place, obtain the first closed gap between the new trolley and the front adjacent trolley, and the second closed gap between the new trolley and the rear adjacent trolley; S63, when both the first closing gap and the second closing gap are within the calibrated closing range, it is determined that the new trolley has been correctly placed in the empty space to be installed; S64, after determining that the new trolley has been correctly positioned, outputs a release limit command to control the hydraulic lever device on the mobile trolley to retract, so that the mobile trolley is separated from the front adjacent trolley and the rear adjacent trolley. S65, after receiving the signal that the hydraulic lever device has been retracted into position, outputs a signal that the online installation of the new trolley is complete.

[0012] Preferably, the step S6 is followed by the following step: After the mobile trolley detaches from the immediate front trolley and the immediate rear trolley, the current position of the mobile trolley is obtained, and a reset command is output to make the mobile trolley return to the initial position.

[0013] Preferably, the electromagnetic suspension device releases the adsorption of the new trolley by de-energizing. The de-energizing is carried out by gradually reducing the excitation current, so that the new trolley can smoothly detach from the electromagnetic suspension device.

[0014] Preferably, the center of the empty space to be installed is determined based on the midpoint between the rear end position of the immediately preceding trolley and the front end position of the immediately following trolley.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention receives the unloading completion signal of the old trolley, determines the installation space defined by the immediately preceding and following trolleys, and maintains the limiting engagement state of the moving trolley with the immediately preceding and following trolleys, so that the moving trolley moves synchronously with the returning trolley group. Therefore, the installation of the new trolley can be completed without stopping the sintering machine, reducing downtime. At the same time, this invention determines the center of the empty space based on the positions of the immediately preceding and following trolleys, calculates the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation, and determines the suspension reference of the new trolley based on the suspension positioning data. Whether the follow-up deviation and the reference deviation are within the calibration range is used as the condition for lifting and receiving, realizing the automatic alignment of the new trolley with the empty space to be installed, and improving the installation accuracy. Furthermore, this invention only outputs a power-off and demagnetization command when the acceptance status data meets the calibrated acceptance conditions, allowing the new trolley to transfer from the electromagnetic suspension device to the lifting device. This enables controlled release of the new trolley, preventing premature detachment or uneven loading and improving installation reliability. By outputting a lifting and retraction command, the lifting device lowers the new trolley into the installation space. After the new trolley enters the installation space, a release limit command is output, causing the mobile trolley to detach from the adjacent front and rear trolleys. This ensures accurate placement of the new trolley and automatic detachment of the mobile trolley, making the installation process controllable. The position and status data acquired at each step form an automatic control closed loop, making the installation process collectable and traceable. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a schematic flowchart of one embodiment of the present invention.

[0018] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0019] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0021] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0022] It should be noted that the system used in the method of the present invention includes an electromagnetic suspension device, a lifting device, a hydraulic lever device, a moving trolley, a moving trolley track, and a position detection element. The lifting device and the hydraulic lever device are both mounted on the moving trolley, which can run along the moving trolley track to carry the lifting device and the hydraulic lever device and move synchronously with the return trolley group.

[0023] The electromagnetic suspension device is used to attract new trolleys and can be demagnetized by power-off to release the attraction; the lifting device is used to raise and support new trolleys and to retract and lower new trolleys into the installation space; the hydraulic lever device is used to form a limiting engagement with the adjacent trolleys in front and behind the installation space, and can be retracted to release the limiting engagement.

[0024] The position detection components include a hydraulic lever device position detection switch, a mobile trolley Gray busbar device 8, a lifting device position detection switch, a lifting device retraction position detection switch, and a detection device for detecting the trolley position and measuring distance. Specifically, the hydraulic lever device position detection switch detects whether the hydraulic lever device is retracted or extended; the mobile trolley Gray busbar device outputs the real-time center distance between the center of the mobile trolley and the center of the electromagnetic suspension device; the lifting device position detection switch outputs a lifting position signal; and the lifting device retraction position detection switch outputs a lifting retraction position signal.

[0025] It should be noted that the aforementioned lifting device can employ a hydraulic cylinder-driven lifting mechanism, the electromagnetic suspension device can employ an electromagnetic chuck, the hydraulic lever device can employ a hydraulic cylinder-driven lever mechanism, and the moving trolley can employ a known traveling trolley in the art; the position detection switch, Gray busbar device, laser rangefinder, etc., are all conventional position detection elements in the art. This invention does not impose specific limitations on these components, and those skilled in the art can select known mature structures to implement the device based on site conditions.

[0026] Please refer to Figure 1The present invention provides an automatic control method for online installation of a new sintering machine trolley during return trip, comprising the following steps: S1, acquire the signal indicating that the old trolley has been unloaded, the position of the trolley immediately preceding the empty space to be installed, the position of the trolley immediately following the rear of the empty space, and the position of the center of the lifting device; wherein, the empty space to be installed is the space defined by the trolley immediately preceding the old trolley and the trolley immediately following the rear of the empty space after the old trolley has been unloaded. S2, determine the center of the empty space to be installed based on the position of the front adjacent trolley and the position of the rear adjacent trolley, and calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; when the follow-up deviation is within the calibrated follow-up range, maintain the limit engagement state between the mobile trolley equipped with the lifting device and the front adjacent trolley and the rear adjacent trolley. S3, acquire the suspension positioning data after the electromagnetic suspension device adsorbs the new trolley, and determine the suspension reference of the new trolley based on the suspension positioning data; S4, obtain the position of the center of the lifting device and the position of the suspension reference, calculate the reference deviation based on the position of the center of the lifting device and the position of the suspension reference; when the reference deviation is within the calibration transfer range, output a lifting command to raise the lifting device to the receiving position of the new trolley. S5, acquire the receiving status data of the lifting device, the receiving status data including the lifting position signal; when the receiving status data meets the calibrated receiving conditions, output a power-off and demagnetization command to transfer the new trolley from the electromagnetic suspension device to the lifting device. S6 outputs a lifting and retraction command, causing the lifting device to lower the new trolley into the installation space; after the new trolley enters the installation space, it outputs a release limit command, causing the mobile trolley to detach from the front and rear adjacent trolleys.

[0027] This invention receives the unloading completion signal of the old trolley, determines the installation space defined by the immediately preceding and following trolleys, and maintains the limiting engagement state of the moving trolley with the immediately preceding and following trolleys, so that the moving trolley moves synchronously with the returning trolley group. Therefore, the installation of the new trolley can be completed without stopping the sintering machine, reducing downtime. At the same time, this invention determines the center of the empty space based on the positions of the immediately preceding and following trolleys, calculates the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation, and determines the suspension reference of the new trolley based on the suspension positioning data. Whether the follow-up deviation and the reference deviation are within the calibration range is used as the condition for lifting and receiving, realizing the automatic alignment of the new trolley with the empty space to be installed, and improving the installation accuracy. Furthermore, this invention only outputs a power-off and demagnetization command when the acceptance status data meets the calibrated acceptance conditions, allowing the new trolley to transfer from the electromagnetic suspension device to the lifting device. This enables controlled release of the new trolley, preventing premature detachment or uneven loading and improving installation reliability. By outputting a lifting and retraction command, the lifting device lowers the new trolley into the installation space. After the new trolley enters the installation space, a release limit command is output, causing the mobile trolley to detach from the adjacent front and rear trolleys. This ensures accurate placement of the new trolley and automatic detachment of the mobile trolley, making the installation process controllable. The position and status data acquired at each step form an automatic control closed loop, making the installation process collectable and traceable.

[0028] In a preferred embodiment, S2 includes the following steps: S21, obtain the positions of the front and rear adjacent trolleys of the empty space to be installed, and determine the center of the empty space to be installed based on the positions of the front and rear adjacent trolleys. After the old trolley is removed from the return trolley group, the adjacent trolleys located in front of and behind the old trolley along the return travel direction form a vacant position, which is the installation space. Specifically, the front adjacent trolley is the trolley located in front of the installation space along the return travel direction, and the rear adjacent trolley is the trolley located behind the installation space along the return travel direction. The positions of the front and rear adjacent trolleys can be obtained using a trolley position detection device installed in the sintering machine's return zone, such as a Gray busbar device or position sensors detecting the real-time coordinates of each trolley on the return track. The center of the vacant space can be taken as the midpoint between the end face positions of the front and rear adjacent trolleys facing the installation space.

[0029] S22, calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; the lifting device is mounted on the moving trolley, and the position of the center of the lifting device can be obtained by detecting the position of the moving trolley and combining it with the fixed offset of the center of the lifting device relative to the positioning reference point of the moving trolley. The follow-up deviation can be obtained by subtracting the position of the empty space center from the position of the center of the lifting device.

[0030] S23, compare the following deviation with the calibrated following range. When the following deviation is within the calibrated following range, determine that the moving trolley maintains a limit engagement state with the front adjacent trolley and the rear adjacent trolley, and allow the output of the lifting command. The calibrated follow-up range is a pre-defined allowable deviation interval based on the sintering machine trolley dimensions and permissible installation tolerances. When the positional difference between the center of the lifting device and the center of the empty space is within the calibrated follow-up range, it indicates that the lifting device has been aligned with the empty space to be installed, and the limiting engagement between the moving trolley and the immediately preceding and following trolleys is effective. At this time, it is determined that the moving trolley is in the correct follow-up state, and subsequent lifting commands are allowed to be output, thereby ensuring that the lifting and receiving action is performed on the premise that the lifting device and the empty space to be installed are aligned, avoiding misalignment during subsequent lifting due to positional deviations.

[0031] S24, when the follow-up deviation exceeds the calibrated follow-up range, the lifting command is prohibited from being output, the electromagnetic suspension device is kept in the state of adsorbing the new trolley, and a follow-up abnormal signal is output.

[0032] If the follow-up deviation exceeds the calibrated follow-up range, it indicates an abnormal follow-up relationship between the moving trolley and the empty space to be installed. At this time, lifting commands should be prohibited, and the electromagnetic suspension device should maintain its attachment to the new trolley to prevent it from being picked up or released if the lifting device is not aligned with the empty space to be installed. Simultaneously, a follow-up abnormality signal should be output, prompting the user to check the position detection data of the hydraulic lever device, the immediately preceding and following trolleys, and the follow-up status of the moving trolley.

[0033] As a preferred embodiment, the direction along the return travel direction is defined as the first direction, and the direction perpendicular to the return travel direction is defined as the second direction; the suspension positioning data includes: multiple vertical distance values ​​obtained by multiple laser rangefinders arranged in an array along the first and second directions after the electromagnetic suspension device adsorbs the new trolley, a horizontal distance value obtained by a laser rangefinder measuring the side of the new trolley, and the position of the center of the electromagnetic suspension device. Multiple laser rangefinders are arranged in an array along a first and a second direction, forming multiple ranging points covering the back of the new trolley in two directions in the horizontal plane, used to obtain vertical ranging values ​​at different locations. Since each laser rangefinder measures vertically downwards, the ranging value reflects the vertical distance from the laser rangefinder to the back of the new trolley. The horizontal ranging value is obtained by a laser rangefinder illuminating the side of the new trolley along the second direction, reflecting the horizontal distance from the side of the new trolley to that laser rangefinder along the second direction. The position of the center of the electromagnetic suspension device is obtained through a position detection device.

[0034] S3 includes the following steps: S31, determine the first attitude offset of the new trolley around the first direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the second direction, determine the second attitude offset of the new trolley around the second direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the first direction, and determine the position offset of the new trolley along the second direction based on the horizontal distance measurement value. Specifically, the difference between multiple vertical ranging values ​​spaced apart along the second direction reflects the tilt of the new trolley around the first direction: when the new trolley is in a horizontal state, the ranging values ​​along the second direction are basically equal; when the new trolley tilts around the first direction, the distance from the laser rangefinder located at different positions in the second direction to the back of the new trolley will be different. Therefore, the first attitude offset of the new trolley around the first direction can be determined based on the difference between multiple vertical ranging values ​​spaced apart along the second direction.

[0035] Similarly, the difference between multiple vertical ranging values ​​arranged at intervals along the first direction reflects the tilt of the new trolley around the second direction: when the new trolley tilts around the second direction, the distance from the laser rangefinder at different positions in the first direction to the back of the new trolley will be different. Therefore, the second attitude offset of the new trolley around the second direction can be determined based on the difference between multiple vertical ranging values ​​arranged at intervals along the first direction.

[0036] The horizontal distance measurement value reflects the horizontal distance from the side of the new trolley to the laser rangefinder along the second direction. The difference between this horizontal distance and the ideal horizontal distance from the side of the new trolley to the laser rangefinder, as pre-calibrated, is the position offset of the new trolley along the second direction.

[0037] The positional offset of the new trolley along the first direction is determined by the real-time center distance between the center of the moving trolley and the center of the electromagnetic suspension device, output by the Gray busbar device. Since the new trolley is attracted by and moves with the electromagnetic suspension device, the positional change of the center of the electromagnetic suspension device along the first direction directly reflects the positional change of the new trolley along the first direction. Therefore, by detecting the distance between the center of the moving trolley and the center of the electromagnetic suspension device through the Gray busbar device, the positional offset of the new trolley along the first direction can be determined.

[0038] S32, when the first attitude offset is within the calibrated attitude range, the second attitude offset is within the calibrated attitude range, and the position offset is within the calibrated position range, the suspension state of the new trolley is determined to be qualified. The calibration attitude range and calibration position range are preset based on the allowable tilt limits and position deviation limits of the new trolley, respectively. When both the first and second attitude offsets are within the calibration attitude range, it indicates that the tilt of the new trolley around the first and second directions is within the allowable range; when the position offset is within the calibration position range, it indicates that the translational offset of the new trolley along the first and second directions is within the allowable range. At this point, the control system determines that the new trolley is in a qualified suspension state, that is, the new trolley has been correctly attracted, and its attitude and position meet the subsequent receiving requirements.

[0039] S33. Determine the suspension reference of the new trolley based on the position of the center of the electromagnetic suspension device, the first attitude offset, the second attitude offset, and the position offset. The actual center position of the new trolley, which is the suspension reference, can be calculated based on the position of the center of the electromagnetic suspension device, combined with the first attitude offset, the second attitude offset, and the position offset along the first and second directions.

[0040] In a preferred embodiment, S4 includes the following steps: S41, obtain the position of the center of the lifting device and the position of the suspension reference, and calculate the position difference between the center of the lifting device and the suspension reference along the return travel direction based on the position of the center of the lifting device and the position of the suspension reference, as the reference deviation; The lifting device is mounted on a moving trolley. The position of the lifting device's center can be calculated by detecting the position of the moving trolley and combining this with a fixed offset of the lifting device's center relative to the trolley's positioning reference point. The difference between the position of the lifting device's center and the position of the suspension reference point along the return travel direction is the reference deviation. The reference deviation reflects the magnitude and direction of the lifting device's deviation relative to the suspended new trolley along the return travel direction.

[0041] S42, obtain the operating speed of the return trolley group and the calibrated lifting time required for the lifting device to rise from the current position to the new trolley receiving position; The operating speed of the return trolley group is the same as that of the sintering machine's return trolley group. It can be obtained through a trolley operating speed detection device or calculated based on the displacement and time of the return trolley group. The calibrated lifting time refers to the time required for the lifting device to rise from its current standby position to the new trolley receiving position. This time can be pre-calibrated based on the hydraulic system response characteristics and lifting stroke of the lifting device.

[0042] S43, calculate the lifting start distance based on the running speed and the calibrated lifting time; obtain the real-time center distance between the center of the moving trolley output by the Gray busbar device and the center of the electromagnetic suspension device; when the real-time center distance reaches the lifting start distance, estimate that when the lifting device rises to the new trolley receiving position, the center of the lifting device and the suspension reference will be aligned along the return running direction. Within the calibrated lifting time required for the lifting device to rise from its current standby position to the new trolley receiving position, the return trolley group will continue to move a certain distance at its operating speed. Optionally, if the sintering machine's operating speed under stable production conditions is considered to be uniform, this distance is equal to the product of the operating speed and the calibrated lifting time, which is the lifting start distance. When the real-time center distance between the center of the moving trolley and the center of the electromagnetic suspension device shrinks to this lifting start distance, the lifting action is initiated. Then, at the instant the lifting device reaches the new trolley receiving position, the center of the lifting device can theoretically be aligned with the suspension reference along the return travel direction.

[0043] The Gray busbar device is located between the moving trolley and the electromagnetic suspension device. It is used to output the real-time center distance between the center of the moving trolley and the center of the electromagnetic suspension device. When the real-time center distance reaches the lifting start distance, it is estimated that when the lifting device rises to the new trolley receiving position, it can be aligned with the suspension reference along the return travel direction.

[0044] S44, when the real-time center distance reaches the lifting start distance and the reference deviation is within the calibration transfer range, a lifting command is output to raise the lifting device to the receiving position of the new trolley.

[0045] The calibration transfer range is a pre-set allowable range of reference deviations based on permissible installation tolerances. When the real-time center distance reaches the lifting start distance, it indicates that the lifting start time has arrived. When the reference deviation is within the calibration transfer range, it indicates that the positional difference between the center of the lifting device and the suspension reference along the return travel direction is within the allowable range. At this time, starting the lifting will not produce unacceptable misalignment. When both conditions are met simultaneously, the control system outputs a lifting command, driving the lifting device to rise to the receiving position of the new trolley, ensuring that the lifting and receiving action is performed at the correct time and in the correct position.

[0046] As another preferred embodiment, after determining in step S43 that the center of the lifting device is aligned with the suspension reference along the return travel direction after the calibrated lifting time, the step further includes the following step: S431 continuously acquires the real-time running speed of the return trolley group, the real-time center distance output by the Gray busbar device, the real-time lifting height data of the lifting device, and the actual duration after the lifting command is output after outputting the lifting command. Specifically, after the lifting command is output, the lifting device begins to rise, while the return trolley group continues to operate continuously. To ensure that the lifting device and the moving new trolley remain aligned throughout the lifting process, dynamic parameters related to alignment need to be continuously monitored. The real-time operating speed of the return trolley group is obtained through a trolley operating speed detection device, reflecting the current speed of the return trolley group; the real-time center distance is output by the Gray busbar device, reflecting the change in distance between the center of the moving trolley and the center of the electromagnetic suspension device over time; the real-time lifting height data is obtained by a height detection device installed on the lifting device, reflecting the current position of the lifting device; and the actual duration is recorded by the control system as the time elapsed since the lifting command was output.

[0047] S432, determine the actual lifting progress based on the real-time lifting height data and the calibrated total lifting height, wherein the actual lifting progress is equal to the ratio of the real-time lifting height to the calibrated total lifting height; determine the theoretical lifting progress based on the actual duration and the calibrated lifting duration, wherein the theoretical lifting progress is the ratio of the actual duration to the calibrated lifting duration; and use the difference between the actual lifting progress and the theoretical lifting progress as the lifting progress deviation. The calibrated total lifting height is the calibrated total stroke from the standby position to the new trolley receiving position. Actual lifting progress is equal to the ratio of real-time lifting height to the calibrated total lifting height, reflecting the degree of completion achieved by the lifting device based on the actual lifting height. Theoretical lifting progress is equal to the ratio of actual lifting time to the calibrated lifting time, reflecting the degree of completion the lifting device should achieve within the calibrated lifting time by advancing linearly at equal times. If the lifting device lifts normally at the predetermined speed, the actual lifting progress should be basically consistent with the theoretical lifting progress; however, due to hydraulic response lag, load changes, or speed fluctuations, the actual lifting progress will differ from the theoretical lifting progress. Subtracting the theoretical lifting progress from the actual lifting progress yields the lifting progress deviation, which can be used to determine whether the lifting device is ahead of or behind the theoretical progress.

[0048] S433, based on the real-time center distance, the real-time running speed and the actual lifting progress, predict the predicted alignment deviation between the center of the lifting device and the suspension reference along the return running direction when the lifting device rises to the new trolley receiving position; The lifting device needs to travel a remaining lifting distance from its current height to the receiving position of the new trolley. The remaining lifting time corresponding to this remaining lifting distance can be estimated from the difference between the calibrated lifting time and the actual lifting progress. During the remaining lifting time, the return trolley group continues to move at the real-time operating speed, causing the new trolley to change position relative to the lifting device along the return operating direction. Based on the real-time center distance, real-time operating speed, and actual lifting progress, the distance between the center of the lifting device and the suspension reference along the return operating direction when the lifting device finally rises to the receiving position of the new trolley can be predicted. This predicted alignment deviation can be used to determine whether alignment can still be achieved at the moment of lifting into position if the lifting continues at the current speed and progress.

[0049] S434, when the lifting progress deviation is within the calibrated progress range and the predicted alignment deviation is within the calibrated alignment range, the lifting operation continues; The calibration progress range and calibration alignment range are preset based on the allowable progress deviation limits and alignment deviation limits, respectively. When the lifting progress deviation is within the calibration progress range, it indicates that the actual lifting progress of the lifting device is basically consistent with the theoretical progress, without significant ahead or behind. When the predicted alignment deviation is within the calibration alignment range, it indicates that if the lifting continues under the current conditions, alignment can still be achieved when the device is lifted to the correct position. When both conditions are met simultaneously, the lifting process is deemed normal, and the control system continues to execute the lifting, maintaining the current lifting speed to reach the new trolley receiving position.

[0050] S435, when the lifting progress deviation exceeds the calibrated progress range, or the predicted alignment deviation exceeds the calibrated alignment range, first adjust the lifting speed of the lifting device. If the speed does not return to the calibrated progress range and the calibrated alignment range after adjustment, then suspend lifting until the lifting progress deviation returns to the calibrated progress range and the predicted alignment deviation returns to the calibrated alignment range.

[0051] If the lifting progress deviation exceeds the calibrated progress range, or the predicted alignment deviation exceeds the calibrated alignment range, it indicates that continuing to lift at the current speed will not achieve alignment upon reaching the desired position, requiring intervention and adjustment. The control system first adjusts the lifting speed of the lifting device, for example, by adjusting the flow rate of the hydraulic system to change the lifting speed, in order to correct the deviation between the lifting progress and the theoretical progress. If, after adjusting the lifting speed, the lifting progress deviation and the predicted alignment deviation still fail to return to the corresponding calibrated range, lifting is paused, and the operation status of the return trolley group and the position relationship of the new trolley are restored to an aligned state before lifting continues. In this way, by adjusting the lifting speed and pausing when necessary, a closed-loop correction of the lifting process is achieved, ensuring that the center of the lifting device and the suspension reference are aligned along the return travel direction upon reaching the desired position, avoiding misalignment caused by speed fluctuations or load changes.

[0052] In a preferred embodiment, S5 includes the following steps: S51, acquire the lifting position signal, the position difference of the new trolley relative to the installation space along the return travel direction and the position difference along the direction perpendicular to the return travel direction; After the lifting device rises to the receiving position of the new trolley, the lifting position detection switch outputs a lifting position signal, indicating that the lifting device has reached the height capable of receiving the new trolley. Simultaneously, it is necessary to confirm the alignment of the new trolley with the corresponding installation space in the horizontal plane. The positional difference between the new trolley and the corresponding installation space along the return travel direction reflects whether the new trolley is forward or backward relative to the installation space along the return travel direction; the positional difference between the new trolley and the corresponding installation space perpendicular to the return travel direction reflects whether the new trolley is left or right relative to the installation space along the perpendicular travel direction.

[0053] S52, when the lifting position signal is valid, the position difference along the return travel direction is within the calibrated return travel direction range, and the position difference along the perpendicular to the return travel direction is within the calibrated vertical direction range, a release permission signal is generated; The calibration ranges for the return direction and vertical direction are preset based on the allowable alignment deviation limits along the return direction and perpendicular to the return direction, respectively. A valid lifting-in-place signal indicates that the lifting device has reached the correct position and is ready to receive the new trolley. If the position difference along the return direction is within the calibration range for the return direction, it indicates that the new trolley is aligned with the installation space along the return direction; if the position difference perpendicular to the return direction is within the calibration range for the vertical direction, it indicates that the new trolley is aligned with the installation space along the vertical direction. When all three conditions are met simultaneously, it indicates that the new trolley meets the receiving conditions in both the height and horizontal directions, and the control system generates a release permission signal accordingly.

[0054] S53, according to the release permission signal, outputs a power-off and demagnetization command, causing the new trolley to transfer from the electromagnetic suspension device to the lifting device.

[0055] After generating the release permission signal, the control system outputs a power-off and demagnetization command. This command reduces or disconnects the excitation current of the electromagnetic suspension device, decreasing or eliminating its attraction to the new trolley. Since the lifting device has already risen to the receiving position, and the new trolley is aligned in both the return direction and the vertical return direction, the new trolley can smoothly transfer from the electromagnetic suspension device to the lifting device after losing electromagnetic attraction, without lateral misalignment, uneven loading, or detachment.

[0056] In a preferred embodiment, step S6 includes the following steps: S61, after outputting the lift and retraction command, receives a lift and retraction completion signal to confirm that the lifting device has been retracted into place. After the lifting device has descended into place, the lift and retraction completion detection switch outputs a lift and retraction completion signal. The control system receives this signal to confirm that the lifting device has been retracted to a position that allows the new trolley to be placed in the empty space to be installed. By receiving the lift and retraction completion signal, it ensures that subsequent judgments are only made after the lifting device's retraction action is completed, avoiding misjudging the placement status of the new trolley before the lifting device has been retracted into place.

[0057] S62, after confirming that the lifting device has been retracted into place, the first closed gap between the new trolley and the immediately preceding trolley, and the second closed gap between the new trolley and the immediately following trolley are obtained; after the new trolley descends into the installation space, its two ends along the return travel direction face the immediately preceding trolley and the immediately following trolley, respectively. The first closed gap is the gap between one end of the new trolley along the return travel direction and the immediately preceding trolley, and the second closed gap is the gap between the other end of the new trolley along the return travel direction and the immediately following trolley. The closed gaps can be calculated by the position detection device after obtaining the positions of the immediately preceding trolley, the immediately following trolley, and the new trolley.

[0058] S63, when both the first closing gap and the second closing gap are within the calibrated closing range, it is determined that the new trolley has been correctly placed in the empty space to be installed; The calibration closure range is a range preset based on the allowable normal contact gap between the sintering machine trolleys. When both the first and second closure gaps are within the calibration closure range, it indicates that the new trolley has formed a normal contact gap with the adjacent trolley in front and the adjacent trolley behind at both ends along the return travel direction, meaning that the new trolley has correctly fallen into the installation position.

[0059] S64, after determining that the new trolley has been correctly positioned, outputs a release limit command to retract the hydraulic lever device on the moving trolley, causing the moving trolley to detach from the preceding and following adjacent trolleys. After confirming that the new trolley has been correctly positioned, the control system outputs a release limit command to drive the hydraulic lever device on the moving trolley to retract. After the hydraulic lever device is retracted, the contact relationship between it and the preceding and following adjacent trolleys is released, and the moving trolley detaches from them, no longer being held and followed by the returning trolley group. By releasing the limit only after confirming that the new trolley has been correctly positioned, premature detachment of the moving trolley is avoided, preventing the new trolley from being unstable in its positioning or colliding with the preceding and following trolleys.

[0060] S65, after receiving the signal indicating that the hydraulic lever device has been retracted to its position, outputs a signal indicating that the online installation of the new trolley is complete. After the hydraulic lever device retracts to its initial position, the hydraulic lever retraction detection switch outputs a signal indicating that the hydraulic lever device has been retracted to its position. The control system receives this signal, confirming that the hydraulic lever device has been retracted, the moving trolley has disengaged from the adjacent front and rear trolleys, and the online installation of the new trolley is complete. Based on this, it outputs a signal indicating that the online installation of the new trolley is complete.

[0061] Furthermore, the step S6 is followed by the following steps: After the mobile trolley detaches from the immediately preceding and following adjacent trolleys, it acquires its current position and outputs a reset command to return it to its initial position. This initial position is the standby position for the mobile trolley before the next online installation operation begins. By acquiring the current position and outputting the reset command, the mobile trolley automatically returns to its initial standby position after completing one installation, preparing for the next installation operation. This achieves automatic reset of the installation process and reduces manual intervention.

[0062] Furthermore, the electromagnetic suspension device releases the adsorption of the new trolley by de-energizing. The de-energizing is achieved by gradually reducing the excitation current, allowing the new trolley to smoothly detach from the electromagnetic suspension device.

[0063] When demagnetization is required, cutting off the excitation current all at once would cause the adsorption force to disappear instantly, potentially causing the new trolley to fall suddenly with significant acceleration, resulting in an impact and affecting positioning accuracy. To avoid this impact, demagnetization employs a method of gradually reducing the excitation current, i.e., decreasing the excitation current in preset steps or continuous ramps, thus gradually reducing the adsorption force of the electromagnetic suspension device. When the adsorption force gradually decreases to an insufficient level to support the new trolley, the trolley, already supported by the lifting device, smoothly detaches from the electromagnetic suspension device and transfers to the lifting device. By gradually reducing the excitation current, the new trolley can smoothly detach from the electromagnetic suspension device, avoiding the impact, uneven loading, or detachment caused by sudden release.

[0064] Furthermore, the center of the empty space to be installed is determined based on the midpoint between the rear end position of the immediately preceding trolley and the front end position of the immediately following trolley. Preferably, the center of the empty space is taken as the midpoint between the rear end position of the immediately preceding trolley and the front end position of the immediately following trolley.

[0065] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A method for automatic control of online installation of a new sintering machine trolley during return trip, characterized in that, Includes the following steps: S1, acquire the signal indicating that the old trolley has been unloaded, the position of the trolley immediately preceding the empty space to be installed, the position of the trolley immediately following the rear of the empty space, and the position of the center of the lifting device; wherein, the empty space to be installed is the space defined by the trolley immediately preceding the old trolley and the trolley immediately following the rear of the empty space after the old trolley has been unloaded. S2, determine the center of the empty space to be installed based on the position of the front adjacent trolley and the position of the rear adjacent trolley, and calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; when the follow-up deviation is within the calibrated follow-up range, maintain the limit engagement state between the mobile trolley equipped with the lifting device and the front adjacent trolley and the rear adjacent trolley. S3, acquire the suspension positioning data after the electromagnetic suspension device adsorbs the new trolley, and determine the suspension reference of the new trolley based on the suspension positioning data; S4, obtain the position of the center of the lifting device and the position of the suspension reference, calculate the reference deviation based on the position of the center of the lifting device and the position of the suspension reference; when the reference deviation is within the calibration transfer range, output a lifting command to raise the lifting device to the receiving position of the new trolley. S5, acquire the receiving status data of the lifting device, the receiving status data including the lifting position signal; when the receiving status data meets the calibrated receiving conditions, output a power-off and demagnetization command to transfer the new trolley from the electromagnetic suspension device to the lifting device. S6 outputs a lifting and retraction command, causing the lifting device to lower the new trolley into the installation space; after the new trolley enters the installation space, it outputs a release limit command, causing the mobile trolley to detach from the front and rear adjacent trolleys.

2. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 1, characterized in that, S2 includes the following steps: S21, obtain the positions of the front and rear adjacent trolleys of the empty space to be installed, and determine the center of the empty space to be installed based on the positions of the front and rear adjacent trolleys. S22, calculate the position difference between the center of the lifting device and the center of the empty space as the follow-up deviation; S23, compare the following deviation with the calibrated following range. When the following deviation is within the calibrated following range, determine that the moving trolley maintains a limit engagement state with the front adjacent trolley and the rear adjacent trolley, and allow the output of the lifting command. S24, when the follow-up deviation exceeds the calibrated follow-up range, the lifting command is prohibited from being output, the electromagnetic suspension device is kept in the state of adsorbing the new trolley, and a follow-up abnormal signal is output.

3. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 1 or 2, characterized in that, The direction of return travel is defined as the first direction, and the direction perpendicular to the return travel direction is defined as the second direction. The suspension positioning data includes: multiple vertical distance values ​​obtained by multiple laser rangefinders arranged in an array along the first and second directions after the electromagnetic suspension device adsorbs the new trolley; a horizontal distance value obtained by a laser rangefinder measuring the side of the new trolley; and the position of the center of the electromagnetic suspension device. S3 includes the following steps: S31, determine the first attitude offset of the new trolley around the first direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the second direction, determine the second attitude offset of the new trolley around the second direction based on the difference between multiple vertical distance measurement values ​​arranged at intervals along the first direction, and determine the position offset of the new trolley along the second direction based on the horizontal distance measurement value. S32, when the first attitude offset is within the calibrated attitude range, the second attitude offset is within the calibrated attitude range, and the position offset is within the calibrated position range, the suspension state of the new trolley is determined to be qualified. S33, determine the suspension reference of the new trolley based on the position of the center of the electromagnetic suspension device, the first attitude offset, the second attitude offset, and the position offset.

4. The automatic control method for online installation of the new sintering machine trolley during return trip according to claim 3, characterized in that, S4 includes the following steps: S41, obtain the position of the center of the lifting device and the position of the suspension reference, and calculate the position difference between the center of the lifting device and the suspension reference along the return travel direction based on the position of the center of the lifting device and the position of the suspension reference, as the reference deviation; S42, obtain the operating speed of the return trolley group and the calibrated lifting time required for the lifting device to rise from the current position to the new trolley receiving position; S43, calculate the lifting start distance based on the running speed and the calibrated lifting time; obtain the real-time center distance between the center of the moving trolley output by the Gray busbar device and the center of the electromagnetic suspension device; when the real-time center distance reaches the lifting start distance, estimate that when the lifting device rises to the new trolley receiving position, the center of the lifting device and the suspension reference will be aligned along the return running direction. S44, when the real-time center distance reaches the lifting start distance and the reference deviation is within the calibration transfer range, a lifting command is output to raise the lifting device to the receiving position of the new trolley.

5. The automatic control method for online installation of the new sintering machine trolley during return trip according to claim 4, characterized in that, After determining in step S43 that the center of the lifting device is aligned with the suspension reference along the return travel direction after the calibrated lifting time, the step further includes the following steps: S431 continuously acquires the real-time running speed of the return trolley group, the real-time center distance output by the Gray busbar device, the real-time lifting height data of the lifting device, and the actual duration after the lifting command is output after outputting the lifting command. S432, determine the actual lifting progress based on the real-time lifting height data and the calibrated total lifting height, wherein the actual lifting progress is equal to the ratio of the real-time lifting height to the calibrated total lifting height; determine the theoretical lifting progress based on the actual duration and the calibrated lifting duration, wherein the theoretical lifting progress is the ratio of the actual duration to the calibrated lifting duration; and use the difference between the actual lifting progress and the theoretical lifting progress as the lifting progress deviation. S433, based on the real-time center distance, the real-time running speed and the actual lifting progress, predict the predicted alignment deviation between the center of the lifting device and the suspension reference along the return running direction when the lifting device rises to the new trolley receiving position; S434, when the lifting progress deviation is within the calibrated progress range and the predicted alignment deviation is within the calibrated alignment range, the lifting operation continues; S435, when the lifting progress deviation exceeds the calibrated progress range, or the predicted alignment deviation exceeds the calibrated alignment range, first adjust the lifting speed of the lifting device. If the speed does not return to the calibrated progress range and the calibrated alignment range after adjustment, then suspend lifting until the lifting progress deviation returns to the calibrated progress range and the predicted alignment deviation returns to the calibrated alignment range.

6. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 4, characterized in that, S5 includes the following steps: S51, acquire the lifting position signal, the position difference of the new trolley relative to the installation space along the return travel direction and the position difference along the direction perpendicular to the return travel direction; S52, when the lifting position signal is valid, the position difference along the return travel direction is within the calibrated return travel direction range, and the position difference along the perpendicular to the return travel direction is within the calibrated vertical direction range, a release permission signal is generated; S53, according to the release permission signal, outputs a power-off and demagnetization command, causing the new trolley to transfer from the electromagnetic suspension device to the lifting device.

7. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 6, characterized in that, S6 includes the following steps: S61, after outputting the lifting and retraction command, receives the lifting and retraction in place signal to confirm that the lifting device has been retracted in place; S62, after confirming that the lifting device has been retracted into place, obtain the first closed gap between the new trolley and the front adjacent trolley, and the second closed gap between the new trolley and the rear adjacent trolley; S63, when both the first closing gap and the second closing gap are within the calibrated closing range, it is determined that the new trolley has been correctly placed in the empty space to be installed; S64, after determining that the new trolley has been correctly positioned, outputs a release limit command to control the hydraulic lever device on the mobile trolley to retract, so that the mobile trolley is separated from the front adjacent trolley and the rear adjacent trolley. S65, after receiving the signal that the hydraulic lever device has been retracted into position, outputs a signal that the online installation of the new trolley is complete.

8. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 1, characterized in that, Following step S6, the following steps are also included: After the mobile trolley detaches from the immediate front trolley and the immediate rear trolley, the current position of the mobile trolley is obtained, and a reset command is output to make the mobile trolley return to the initial position.

9. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 1, characterized in that, The electromagnetic suspension device releases its attraction to the new trolley by de-energizing. The de-energizing is achieved by gradually reducing the excitation current, allowing the new trolley to smoothly detach from the electromagnetic suspension device.

10. The automatic control method for online installation of a new sintering machine trolley during return trip according to claim 1, characterized in that, The center of the empty space to be installed is determined by the midpoint between the rear end position of the immediately preceding trolley and the front end position of the immediately following trolley.

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