Automatic raw material batching control system

Abstract

The utility model provides an automatic raw material batching control system, and belongs to the technical field of batching. Comprising a controller, a limestone control unit, a clay control unit, an aeolian sand control unit, an iron ore control unit, a field control unit, an audible and visual alarm, a first sensor module, a second sensor module, a third sensor module, a fourth sensor module, an online element analyzer, a remote controller and an upper computer. The controller is connected with the limestone control unit, the clay control unit, the aeolian sand control unit, the iron ore control unit, the field control unit, the audible and visual alarm, the first sensor module, the second sensor module, the third sensor module, the fourth sensor module, the online element analyzer, the remote controller and the upper computer. The automatic raw material batching control system solves the problems that a traditional raw material batching control system is poor in control precision and not easy to adjust.

Description

Technical Field

[0001] This utility model relates to the field of batching technology, and in particular to an automatic batching control system for raw materials. Background Technology

[0002] In cement production, raw meal batching is a crucial link in production control. The accuracy of raw meal batching has a significant impact on clinker quality and yield. Traditional raw meal batching control systems suffer from poor control accuracy and difficulty in adjustment, which easily leads to uneven batching ratios and makes it difficult to meet the process requirements of large-scale production lines. With the continuous advancement of cement production technology, higher demands are placed on the accuracy and stability of raw meal batching control. Traditional batching systems can no longer meet these requirements; therefore, it is necessary to develop a new, efficient, and automated raw meal batching control system.

[0003] Modern control technologies, such as PID and P-control, as well as the application of high-precision elemental analyzers and sensors, have provided technical support for the development of automated raw material batching control systems. These technologies enable real-time measurement and precise control of the content of various components in raw materials, thereby improving batching accuracy and system stability. Utility Model Content

[0004] The purpose of this invention is to provide an automatic raw material batching control system with good control effect, accurate control of the feeding amount, and to ensure that the components of the raw material reach the optimal ratio.

[0005] To achieve the above objectives, this utility model provides an automatic raw material batching control system, including a controller, a limestone control unit, a clay control unit, an aeolian sand control unit, an iron ore control unit, a field control unit, an audible and visual alarm, a first sensor module, a second sensor module, a third sensor module, a fourth sensor module, an online elemental analyzer, a remote controller, and a host computer. The controller is connected to the limestone control unit, clay control unit, aeolian sand control unit, iron ore control unit, field control unit, audible and visual alarm, first sensor module, second sensor module, third sensor module, fourth sensor module, online elemental analyzer, remote controller, and host computer.

[0006] Preferably, the controller includes a CPU, a digital input module, a pulse input module, an analog input module, a digital output module, a first communication module, a second communication module, a third communication module, a fourth communication module, a fifth communication module, and a sixth communication module. The CPU is connected to the digital input module, the pulse input module, the analog input module, the first communication module, the second communication module, the third communication module, the fourth communication module, the fifth communication module, and the sixth communication module, respectively. The CPU is connected to the audible and visual alarm through the digital output module.

[0007] Preferably, the limestone control unit includes a first frequency converter and a first frequency converter motor, and the controller is connected to the first frequency converter via a first communication module for MPI communication.

[0008] Preferably, the clay control unit includes a second frequency converter and a second frequency converter motor, and the controller is connected to the second frequency converter via a second communication module (MPI communication).

[0009] Preferably, the wind-blown sand control unit includes a third frequency converter and a third frequency converter motor, and the controller is connected to the third frequency converter via a third communication module (MPI communication).

[0010] Preferably, the iron ore control unit includes a fourth frequency converter and a fourth frequency converter motor, and the controller is connected to the fourth frequency converter via a fourth communication module for MPI communication.

[0011] Preferably, the controller communicates with the remote controller via the Profibus-DP protocol, communicates with the host computer via the Modbus TCP / IP protocol, and communicates with the first, second, third, and fourth frequency converters via the MPI protocol.

[0012] Preferably, the field control unit includes a field start / stop button, a field emergency stop button, and a field speed control knob. The field start / stop button and the field emergency stop button are connected to the CPU via a digital input module, and the field speed control knob is connected to the CPU via an analog input module.

[0013] Preferably, the first sensor module includes a first speed sensor and a first load sensor, the second sensor module includes a second speed sensor and a second load sensor, the third sensor module includes a third speed sensor and a third load sensor, and the fourth sensor module includes a fourth speed sensor and a fourth load sensor.

[0014] Therefore, the present invention adopts the above-mentioned automatic raw material batching control system, and the technical effects are as follows:

[0015] 1. High-precision batching control: It adopts closed-loop PID control and P control, combined with a high-precision elemental analyzer and sensors to measure the content of each component of raw material in real time, so as to realize the precise control of the feed amount of each component of raw material and ensure that each component of raw material reaches the optimal ratio.

[0016] 2. High-efficiency operation: Through the close connection between the controller and various control units, sensors, remote controllers, and host computers, real-time data transmission and processing are realized, which improves the system's response speed and operating efficiency, and significantly enhances the working efficiency of the raw material automatic batching control system.

[0017] 3. Stable operation: With the CPU as the control core and combined with various communication modules and input / output modules, the system achieves precise control of each control unit and real-time data processing, ensuring the stable operation of the system. Attached Figure Description

[0018] Figure 1 This is a macroscopic framework diagram of the automatic raw material batching control system of this utility model;

[0019] Figure 2 This is a detailed architecture diagram of the automatic raw material batching control system of this utility model;

[0020] Figure 3 This is the control loop diagram of the automatic raw material batching control system of this utility model. Detailed Implementation

[0021] The technical solution of this utility model will be further described below with reference to the accompanying drawings and embodiments.

[0022] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0023] Example 1

[0024] like Figure 1 As shown, this utility model provides an automatic raw material batching control system, including a controller, a limestone control unit, a clay control unit, an aeolian sand control unit, an iron ore control unit, a field control unit, an audible and visual alarm, a first sensor module, a second sensor module, a third sensor module, a fourth sensor module, an online elemental analyzer, a remote controller, and a host computer. The controller is connected to the limestone control unit, clay control unit, aeolian sand control unit, iron ore control unit, field control unit, audible and visual alarm, first sensor module, second sensor module, third sensor module, fourth sensor module, online elemental analyzer, remote controller, and host computer.

[0025] like Figure 2As shown, the controller is the core component of the system, primarily consisting of a CPU, digital input modules, pulse input modules, analog input modules, digital output modules, a first communication module, a second communication module, a third communication module, a fourth communication module, a fifth communication module, and a sixth communication module. The CPU, as the control core, is responsible for processing all input signals, executing control algorithms, and outputting control commands to complete all automatic raw material batching control functions. The controller communicates with a host computer via the Modbus TCP / IP protocol, transmitting the system's operating status and various sensor signals to the host computer, which displays this information. On-site operators can also perform operations on the host computer. The controller also communicates with a remote controller via the Profibus-DP protocol, transmitting the system's operating status and various sensor signals to the remote controller, which receives, displays, and stores the information in real time.

[0026] like Figure 3 As shown, during remote control, the controller receives the limestone saturation ratio setpoint signal from the remote controller in real time via Profibus-DP communication. The actual limestone saturation ratio value is obtained from the online elemental analyzer and compared with the setpoint. The setpoint frequency value of the first frequency converter is calculated through PID control and transmitted to the first frequency converter via MPI communication to drive the limestone metering feeder. Simultaneously, the material load sensor signal and speed sensor signal of the limestone metering feeder calculate the actual feed rate and transmit the material signal to the controller.

[0027] The controller receives the aluminum ratio setpoint signal from the remote controller in real time via Profibus-DP communication. The actual aluminum ratio value is obtained from the online elemental analyzer and compared with the setpoint. The setpoint frequency of the second frequency converter is calculated using PID control and transmitted via MPI communication to drive the clay feeder. The setpoint frequency of the fourth frequency converter is then calculated using P control and transmitted via MPI communication to drive the iron ore feeder. This allows the iron ore feed rate to be adjusted based on the clay feed rate, achieving the optimal ratio. Simultaneously, the material load sensor and speed sensor signals from both feeders calculate the actual feed rate and transmit the material signals to the controller.

[0028] The controller receives the setpoint signal of the aeolian sand material from the remote controller in real time via Profibus-DP communication. The actual value of the aeolian sand material is obtained from the online elemental analyzer and compared with the setpoint. The setpoint frequency value of the third frequency converter is calculated through PID control and transmitted to the third frequency converter via MPI communication to drive the aeolian sand metering feeder. Simultaneously, the actual feed rate is calculated from the material load sensor and speed sensor signals of the aeolian sand metering feeder and transmitted to the controller.

[0029] The limestone control unit includes a first frequency converter and a first frequency-converter motor. The controller is connected to the first frequency converter via a first communication module using MPI communication, enabling real-time start / stop and frequency control of the first frequency converter, as well as real-time exchange of alarm and fault information. Simultaneously, the remote controller and the host computer can communicate with the first frequency converter via the controller using PROFIBUS-DP and Modbus TCP / IP protocols respectively.

[0030] The clay control unit includes a second frequency converter and a second frequency-converter motor. The controller is connected to the second frequency converter via a second communication module and performs real-time start / stop and frequency control of the second frequency converter, as well as real-time information exchange regarding alarms and faults of the second frequency converter. Simultaneously, the remote controller and the host computer can communicate with the second frequency converter through the controller using the PROFIBUS-DP protocol and the Modbus TCP / IP protocol, respectively.

[0031] The aeolian sand control unit includes a third frequency converter and a third frequency converter motor. The controller is connected to the third frequency converter via a third communication module and performs real-time start / stop and frequency control of the third frequency converter, as well as real-time information exchange on alarms and faults of the third frequency converter. Simultaneously, the remote controller and the host computer can communicate with the third frequency converter via the controller using the PROFIBUS-DP protocol and the Modbus TCP / IP protocol, respectively.

[0032] The iron ore control unit includes a fourth frequency converter and a fourth frequency-controlled motor. The controller is connected to the fourth frequency converter via a fourth communication module (MPI communication) to perform real-time start / stop and frequency control of the fourth frequency converter, and to exchange alarm and fault information in real time. Simultaneously, the remote controller and the host computer can communicate with the fourth frequency converter through the controller using the Profibus-DP protocol and the Modbus TCP / IP protocol, respectively.

[0033] The first sensor module includes a first speed sensor and a first load sensor; the second sensor module includes a second speed sensor and a second load sensor; the third sensor module includes a third speed sensor and a third load sensor; and the fourth sensor module includes a fourth speed sensor and a fourth load sensor. The first, second, third, and fourth load sensors are directly connected to the analog input module, and the first, second, third, and fourth speed sensors are directly connected to the pulse input module. These sensors are used to detect the actual feed rate of each component of the raw material. The controller receives the sensor signals in real time and simultaneously transmits the detected signals to the remote controller and the host computer via the PROFIBUS-DP protocol and the Modbus TCP / IP protocol, respectively.

[0034] The field control unit includes a field start / stop button, a field emergency stop button, and a field speed control knob. The field start / stop button and the field emergency stop button are connected to the CPU via a digital input module, while the field speed control knob is connected to the CPU via an analog input module. During field control, the field start / stop button controls the start and stop of the automatic raw material batching control system, and the field speed control knob adjusts the operating speed of each quantitative feeder, thereby regulating the feed rate of each component of the raw material. In an emergency, the field operator can use the field emergency stop button to achieve an emergency stop.

[0035] The CPU is connected to the audible and visual alarm via a digital output module. When the system experiences an alarm fault such as excessive change in silicon ratio, the audible and visual alarm will flash. When the system experiences a serious fault, the system will automatically shut down, and the audible and visual alarm will remain lit.

[0036] The working process of this utility model's automatic raw material batching control system is as follows:

[0037] The system's automatic operation mode workflow is as follows: The controller receives the limestone saturation ratio setpoint, silicon content setpoint, aluminum content setpoint, and start signal from the remote controller in real time via the Profibus-DP protocol. The controller starts the first, second, and third frequency converters via MPI communication, driving the limestone metering feeder, aeolian sand metering feeder, and clay metering feeder to start operation, respectively. The content of each component (limestone, aeolian sand, and clay) is calculated in real time using an online elemental analyzer and compared with the setpoints. The PID control unit within the controller calculates the operating frequency of each frequency converter in real time based on the deviation between the setpoint and actual values ​​of each component. When the actual values ​​of each component are within the allowable deviation range of the setpoint, the operating frequency of each frequency converter remains stable. Simultaneously, the setpoint frequency value of the fourth frequency converter is calculated via P control and transmitted to the fourth frequency converter via MPI communication, driving the iron ore metering feeder to adjust the iron ore feed rate.

[0038] The system's automatic operation mode alarm handling works as follows: The controller transmits signals such as the actual content of each component and the equipment's operating status to the remote controller and the host computer in real time. If the actual value of a certain component's content suddenly deviates from the set value, the controller issues an alarm signal, triggers an audible and visual alarm, and transmits the alarm signal to the remote controller and the host computer. The PID control unit within the controller adjusts the inverter's frequency in real time based on the deviation between the set value and the actual value of that component's content. The system can automatically reset after the alarm disappears. If the inverter experiences a fault signal, the controller issues a stop signal, triggers a constantly lit audible and visual alarm, and the system cannot automatically reset, requiring manual intervention.

[0039] On-site manual operation mode workflow: The on-site operator presses the on-site start / stop button or operates the system on the host computer to start the system. The controller receives the set value from the on-site speed control knob and transmits the corresponding frequency to each frequency converter via MPI communication, driving the corresponding quantitative feeder to run. The controller calculates the actual content of each component based on the received signal from the online elemental analyzer. The detection signal is transmitted to the remote controller and the host computer via Profibus-DP protocol and Modbus TCP / IP protocol, respectively. When a major system fault occurs, the operator presses the on-site emergency stop button, the audible and visual alarm illuminates continuously, and the system stops running.

[0040] Therefore, this utility model adopts the above-mentioned automatic raw material batching control system, which realizes precise control and efficient operation of raw material batching, and at the same time has fault alarm and automatic shutdown functions, ensuring the safety and reliability of the system.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solution of this utility model, and these modifications or equivalent substitutions cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of this utility model.

Claims

1. An automatic raw material batching control system, characterized in that, It includes a controller, a limestone control unit, a clay control unit, an aeolian sand control unit, an iron ore control unit, a field control unit, an audible and visual alarm, a first sensor module, a second sensor module, a third sensor module, a fourth sensor module, an online elemental analyzer, a remote controller, and a host computer. The controller is connected to the limestone control unit, clay control unit, aeolian sand control unit, iron ore control unit, field control unit, audible and visual alarm, first sensor module, second sensor module, third sensor module, fourth sensor module, online elemental analyzer, remote controller, and host computer, respectively.

2. The automatic raw material batching control system according to claim 1, characterized in that, The controller includes a CPU, a digital input module, a pulse input module, an analog input module, a digital output module, a first communication module, a second communication module, a third communication module, a fourth communication module, a fifth communication module, and a sixth communication module. The CPU is connected to the digital input module, the pulse input module, the analog input module, the first communication module, the second communication module, the third communication module, the fourth communication module, the fifth communication module, and the sixth communication module, respectively. The CPU is connected to the audible and visual alarm through the digital output module.

3. The automatic raw material batching control system according to claim 1, characterized in that, The limestone control unit includes a first frequency converter and a first frequency converter motor. The controller is connected to the first frequency converter via a first communication module and MPI communication.

4. The automatic raw material batching control system according to claim 1, characterized in that, The clay control unit includes a second frequency converter and a second frequency converter motor. The controller is connected to the second frequency converter via a second communication module.

5. The automatic raw material batching control system according to claim 1, characterized in that, The wind-blown sand control unit includes a third frequency converter and a third frequency converter motor. The controller is connected to the third frequency converter via a third communication module and MPI communication.

6. The automatic raw material batching control system according to claim 1, characterized in that, The iron ore control unit includes a fourth frequency converter and a fourth frequency converter motor. The controller is connected to the fourth frequency converter via a fourth communication module and MPI communication.

7. The automatic raw material batching control system according to claim 1, characterized in that, The controller communicates with the remote controller via the Profibus-DP protocol, communicates with the host computer via the Modbus TCP / IP protocol, and communicates with the first, second, third, and fourth frequency converters via the MPI protocol.

8. The automatic raw material batching control system according to claim 1, characterized in that, The field control unit includes a field start / stop button, a field emergency stop button, and a field speed control knob. The field start / stop button and the field emergency stop button are connected to the CPU via a digital input module, and the field speed control knob is connected to the CPU via an analog input module.

9. The automatic raw material batching control system according to claim 1, characterized in that, The first sensor module includes a first speed sensor and a first load sensor, the second sensor module includes a second speed sensor and a second load sensor, the third sensor module includes a third speed sensor and a third load sensor, and the fourth sensor module includes a fourth speed sensor and a fourth load sensor.

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