Real-time feedback control equipment for hydraulic pressure of double-roller machine
By using a real-time hydraulic pressure feedback control device for the roller mill, and combining a high-precision pressure transmitter and a temperature compensation sensor with a PID algorithm and a learning model, the hydraulic system pressure is dynamically adjusted. This solves the problem of frequent start-stop of the equipment under traditional fixed threshold control, thereby improving the stability and efficiency of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QIANXI COUNTY LINHUI MASCH CASTING CO LTD
- Filing Date
- 2025-06-25
- Publication Date
- 2026-04-21
AI Technical Summary
The fixed threshold control mode of the traditional double roller mill hydraulic system leads to frequent start-stop of the equipment, which cannot adapt to changes in working conditions, resulting in wear of hydraulic components, increased energy consumption and reduced production capacity, as well as a high amount of ineffective running time.
High-precision pressure transmitters and temperature-compensated sensors are used to monitor pressure and oil temperature in real time. Combined with PID algorithms and learning models, the proportional relief valve is dynamically adjusted to achieve real-time feedback control of hydraulic pressure. Modular signal processing and a dual accumulator system are used to improve system stability and response speed.
It significantly reduces equipment start-up and shutdown frequency, extends equipment life, reduces energy consumption by 10%-15%, increases production capacity by 12%-18%, and avoids overload shutdowns through real-time adjustment, thereby improving the real-time performance and reliability of the system.
Smart Images
Figure CN224152896U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of roller mill technology, specifically to a real-time feedback control device for hydraulic pressure of a roller mill. Background Technology
[0002] In grinding processes in industries such as metallurgy, building materials, and chemicals, roller mills are critical crushing equipment, and the pressure control of their hydraulic systems directly affects equipment stability and production efficiency. Traditional roller mills mostly adopt a fixed threshold start-stop control mode, stopping to release pressure when the pressure exceeds the upper limit and restarting when it falls below the lower limit. This control method has significant drawbacks: First, fluctuations in material hardness or feed rate can easily cause the pressure to quickly reach the threshold, leading to repeated start-stop cycles, which not only accelerates the wear of hydraulic components but also increases energy consumption and reduces production capacity. Second, fixed thresholds cannot adapt to dynamic changes in operating conditions, resulting in lag in pressure regulation and even overload failures. In addition, the ineffective operating time due to start-stop intervals in the traditional mode accounts for as much as 15%-20%, severely restricting production efficiency. Utility Model Content
[0003] This invention provides a real-time feedback control device for hydraulic pressure of a roller mill, which significantly improves the stability and production efficiency of the roller mill hydraulic system through real-time feedback control and dynamic adjustment mechanisms.
[0004] To achieve the above objectives, this utility model provides the following technical solution: a real-time feedback control device for hydraulic pressure of a roller mill, comprising: a high-precision pressure transmitter connected to the high-pressure oil pipe of the roller mill; a temperature compensation sensor, which is a PT100 platinum resistance temperature probe and encapsulated in a copper heat-conducting sleeve, closely attached to the outer wall of the high-pressure oil pipe of the hydraulic cylinder; a proportional relief valve connected to the high-pressure oil pipe; and a controller equipped with a touch screen, wherein the high-precision pressure transmitter, the temperature compensation sensor, and the proportional relief valve are electrically connected to the controller.
[0005] Preferably, the controller is provided with an analog input module, and the high-precision pressure transmitter and the temperature compensation sensor are electrically connected to the controller through the analog input module.
[0006] Preferably, the controller is provided with a digital output module, and the proportional overflow valve is electrically connected to the controller through the digital output module.
[0007] Preferably, the proportional relief valve is a direct-acting electrically controlled proportional valve, which is connected to the high-pressure oil pipe via a flange; the valve body of the proportional relief valve is made of cast iron, the valve core is made of hard alloy plating, and it is connected to the oil tank of the roller mill via an overflow pipe.
[0008] Preferably, it also includes two vertically arranged piston accumulators with volumes of 10L and 50L respectively. The shells of each piston accumulator are made of carbon steel and are respectively provided with nitrogen charging valve interfaces. The piston accumulators are respectively connected to the high-pressure oil pipes through high-pressure ball valves and T-type tees.
[0009] Preferably, the high-precision pressure transmitter has a range of 0-20 MPa and an accuracy of ±0.5% FS.
[0010] The beneficial effects of this invention are as follows: This real-time hydraulic pressure feedback control device for a roller mill fundamentally solves the inherent defects of traditional fixed threshold control through intelligent closed-loop control. Its high-precision pressure transmitter continuously monitors the high-pressure oil pipe pressure, converting the dynamic pressure signal into an electrical signal and transmitting it to the controller. A temperature compensation sensor detects oil temperature changes and rapidly conducts heat through a copper sleeve, eliminating the influence of oil temperature fluctuations on pressure measurement and ensuring data accuracy. Based on real-time pressure data and preset target values, the controller dynamically adjusts the opening of the proportional relief valve using a PID algorithm: when the pressure is too high, the opening of the proportional relief valve is increased to divert oil and reduce pressure; when the pressure is too low, the opening of the proportional relief valve is decreased to maintain stable system pressure. Combined with temperature compensation data, the pressure control parameters are dynamically corrected to avoid control deviations caused by oil temperature changes. The controller in the system, combined with a learning model, can learn historical operating data, such as material hardness and feed rate variation patterns, thereby automatically adjusting the pressure threshold and control response speed to adapt to different production conditions. Therefore, this equipment has the advantages of eliminating frequent start-stop cycles and extending equipment life. It replaces the traditional start-stop mode with continuous adjustment of the proportional relief valve, avoiding wear on hydraulic components caused by repeated impacts and extending equipment life. Dynamic relief control only diverts oil when necessary, reducing energy waste compared to the complete pressure relief of the fixed threshold mode, resulting in an overall energy consumption reduction of approximately 10%-15%. It also eliminates 15%-20% of ineffective start-stop time, achieving continuous and stable operation and increasing production capacity by approximately 12%-18%. It responds to pressure fluctuations in real time, quickly adjusting the pressure to a safe range to avoid overload shutdowns; the historical data recording function can assist in diagnosing potential faults. The touchscreen supports visual parameter settings, such as target pressure and alarm thresholds, and displays real-time curves, facilitating operator monitoring and process optimization. Modular signal processing enables efficient collaborative control of sensors and actuators, and the optimization of its hardware architecture and signal chain significantly improves the system's real-time performance and reliability. The analog input module precisely adapts to the sensor interface. High-precision pressure transmitters and PT100 temperature sensors are connected to the controller via an isolated analog input module. The digital output module quickly drives the proportional relief valve, which is controlled by a PWM digital output module. The selection and structural design of the proportional relief valve fully consider the reliability and regulation accuracy under high-pressure conditions. The direct-acting electro-hydraulic proportional valve has a fast response time and requires no auxiliary oil source, making it particularly suitable for grinding operations where hydraulic systems experience frequent pressure fluctuations. The carbide valve core improves wear resistance by 3 times, and the machining accuracy of the valve core and cast iron valve body mating surface reaches Ra0.2μm, ensuring a leakage rate of <5 drops / minute at 20MPa pressure. The flange connection structure meets the ISO6162-1 flange standard, and the valve body uses a gradually expanding flow channel with a 15° cone angle to reduce the risk of cavitation. This proportional relief valve achieves extended service life and optimized energy efficiency through a combination of direct-acting fast response, carbide wear-resistant design, and optimized damping of the cast iron valve body.The dual accumulator system design significantly enhances the stability and emergency response capabilities of hydraulic systems through graded pressure buffering and energy storage. The smaller capacity absorbs high-frequency pressure pulsations, while the larger capacity provides energy storage and overload protection. This dual accumulator system achieves impact resistance and protects hydraulic pumps and proportional valves through graded response of different capacities, high reliability of the carbon steel casing, and modular piping connections. It is particularly suitable for heavy equipment subject to periodic impact loads, such as mining crushers and rolling mills. Attached Figure Description
[0011] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0012] Figure 1 This is a schematic diagram of the overall structure of this utility model.
[0013] In the diagram: 1. Oil tank; 2. Filter; 3. Hydraulic pump; 4. High-pressure oil pipe; 5. Directional valve; 6. Hydraulic cylinder; 7. Return oil pipe; 8. Radiator; 9. High-precision pressure transmitter; 10. Temperature compensation sensor; 11. Proportional relief valve; 12. Controller; 13. Touch screen; 14. Analog input module; 15. Digital output module; 16. Accumulator. Detailed Implementation
[0014] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0015] according to Figure 1As shown, a real-time hydraulic pressure feedback control device for a roller mill is applied to the hydraulic system of the roller mill. The hydraulic system of the roller mill includes an oil tank 1, a filter 2, a hydraulic pump 3, a high-pressure oil pipe 4, a reversing valve 5, a hydraulic cylinder 6, a return oil pipe 7, and a radiator 8. The real-time hydraulic pressure feedback control device for the roller mill includes a high-precision pressure transmitter 9, which is connected to the high-pressure oil pipe 4 of the roller mill. The high-precision pressure transmitter 9 has a range of 0-20 MPa and an accuracy of ±0. 5%FS; Temperature compensation sensor 10, which is a PT100 platinum resistance temperature probe and is encapsulated in a copper heat-conducting sleeve, closely attached to the outer wall of the high-pressure oil pipe 4 of the hydraulic cylinder 6; Proportional relief valve 11, which is connected to the high-pressure oil pipe 4; Controller 12, which is equipped with a touch screen 13, and the high-precision pressure transmitter 9, the temperature compensation sensor 10 and the proportional relief valve 11 are electrically connected to the controller 12 respectively.
[0016] This real-time hydraulic pressure feedback control device for the roller mill fundamentally solves the inherent defects of traditional fixed threshold control through intelligent closed-loop control. Its high-precision pressure transmitter 9 continuously monitors the pressure in the high-pressure oil pipe 4, converting the dynamic pressure signal into an electrical signal and transmitting it to the controller 12. A temperature compensation sensor 10 detects oil temperature changes and rapidly conducts heat through a copper sleeve, eliminating the impact of oil temperature fluctuations on pressure measurement and ensuring data accuracy. Based on real-time pressure data and preset target values, the controller 12 dynamically adjusts the opening of the proportional relief valve 11 using a PID algorithm: when the pressure is too high, the opening of the proportional relief valve 11 is increased to divert oil and reduce pressure; when the pressure is too low, the opening of the proportional relief valve 11 is decreased to maintain stable system pressure. Combined with temperature compensation data, the pressure control parameters are dynamically corrected to avoid control deviations caused by oil temperature changes. The controller 12 in the system, combined with a learning model, can learn historical operating data, such as material hardness and feed rate variation patterns, thereby automatically adjusting the pressure threshold and control response speed to adapt to different production conditions. Therefore, this equipment has the advantages of eliminating frequent start-stop cycles and extending equipment life. It replaces the traditional start-stop mode with continuous adjustment of the proportional relief valve 11, avoiding wear on hydraulic components caused by repeated impacts and extending equipment life. Dynamic relief control only diverts oil when necessary, reducing energy waste compared to the complete pressure relief of the fixed threshold mode, resulting in an overall energy consumption reduction of approximately 10%-15%. It also eliminates 15%-20% of ineffective start-stop time, achieving continuous and stable operation and increasing production capacity by approximately 12%-18%. It responds to pressure fluctuations in real time, quickly adjusting the pressure to a safe range to avoid overload shutdowns; the historical data recording function can assist in diagnosing potential faults. The touchscreen 13 supports visual parameter settings, such as target pressure and alarm thresholds, and displays real-time curves, facilitating operator monitoring and process optimization.
[0017] The controller 12 is equipped with an analog input module 14, through which the high-precision pressure transmitter 9 and the temperature compensation sensor 10 are electrically connected to the controller 12. The controller 12 is also equipped with a digital output module 15, through which the proportional relief valve 11 is electrically connected to the controller 12.
[0018] This design achieves efficient collaborative control of sensors and actuators through modular signal processing. The optimized hardware architecture and signal chain significantly improve the system's real-time performance and reliability. The analog input module 14 precisely adapts to the sensor interface; the high-precision pressure transmitter 9 and the PT100 temperature sensor are connected to the controller 12 via the isolated analog input module 14. The digital output module 15 quickly drives the proportional relief valve 11, which is controlled by the PWM digital output module 15.
[0019] The proportional relief valve 11 is a direct-acting electrically controlled proportional valve, which is connected to the high-pressure oil pipe 4 through a flange; the valve body of the proportional relief valve 11 is made of cast iron, the valve core is made of hard alloy plating, and it is connected to the oil tank 1 of the roller mill through the overflow pipe 17.
[0020] The selection and structural design of this proportional relief valve 11 fully considers the reliability and regulation accuracy under high-pressure conditions. The direct-acting, electrically controlled proportional valve has a fast response time and requires no auxiliary oil source, making it particularly suitable for grinding operations where hydraulic systems experience frequent pressure fluctuations. The carbide valve core improves wear resistance by three times, and the machining accuracy of the mating surface between the valve core and the cast iron valve body reaches Ra0.2μm, ensuring a leakage rate of <5 drops / minute at 20MPa pressure. The flange connection's structural strength conforms to ISO 6162-1 flange specifications, and the valve body features a gradually expanding flow channel with a 15° cone angle, reducing the risk of cavitation. This proportional relief valve 11 achieves extended lifespan and optimized energy efficiency through a combination of direct-acting fast response, carbide wear-resistant design, and optimized damping of the cast iron valve body.
[0021] It also includes two vertically arranged piston accumulators 16 with volumes of 10L and 50L respectively. The shells of each piston accumulator 16 are made of carbon steel and are equipped with nitrogen charging valve interfaces. The piston accumulators 16 are connected to the high-pressure oil pipe 4 through high-pressure ball valves and T-type tees respectively.
[0022] The design of this dual accumulator 16 system significantly improves the stability and emergency response capabilities of the hydraulic system through graded pressure buffering and energy storage. The small capacity achieves high-frequency pressure pulsation absorption, while the large capacity provides energy storage and overload protection. The dual accumulator 16 system achieves impact resistance through graded response of large and small capacities, high reliability of the carbon steel shell, and modular piping connections, protecting the hydraulic pump 3 and proportional valves. It is particularly suitable for heavy equipment with periodic impact loads, such as mining crushers and rolling mills.
[0023] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.
Claims
1. A real-time feedback control device for hydraulic pressure of a roll mill, characterized by, include: A high-precision pressure transmitter (9) is connected to the high-pressure oil pipe (4) of the hydraulic cylinder (6) of the roller mill; Temperature compensation sensor (10), the temperature compensation sensor (10) adopts PT100 platinum resistance temperature probe and is encapsulated in a copper heat-conducting sleeve, closely attached to the outer wall of the high-pressure oil pipe (4); A proportional relief valve (11) is connected to the high-pressure oil pipe (4); The controller (12) is equipped with a touch screen (13), and the high-precision pressure transmitter (9), the temperature compensation sensor (10) and the proportional relief valve (11) are electrically connected to the controller (12).
2. The real-time hydraulic pressure feedback control device for a pair mill according to claim 1, characterized in that: The controller (12) is provided with an analog input module (14), and the high-precision pressure transmitter (9) and the temperature compensation sensor (10) are electrically connected to the controller (12) through the analog input module (14).
3. The real-time hydraulic pressure feedback control device for a pair mill according to claim 1, characterized in that: The controller (12) is provided with a digital output module (15), and the proportional overflow valve (11) is electrically connected to the controller (12) through the digital output module (15).
4. The real-time hydraulic pressure feedback control device for a pair mill according to claim 1, characterized in that: The proportional relief valve (11) is a direct-acting electrically controlled proportional valve, which is connected to the high-pressure oil pipe (4) through a flange; the valve body of the proportional relief valve (11) is made of cast iron, the valve core is made of hard alloy plating, and it is connected to the oil tank (1) of the roller mill through the overflow pipe (17).
5. The real-time hydraulic pressure feedback control device for a pair mill according to claim 1, characterized in that: It also includes two vertically arranged piston accumulators (16) with volumes of 10L and 50L respectively. The shells of each piston accumulator (16) are made of carbon steel and are respectively provided with nitrogen charging valve interfaces. The piston accumulators (16) are respectively connected to the high-pressure oil pipe (4) through high-pressure ball valves and T-type tees.
6. The real-time hydraulic pressure feedback control device for a pair mill according to claim 1, characterized in that: The high-precision pressure transmitter (9) has a range of 0-20MPa and an accuracy of ±0.5%FS.