A Real-time Feedback System for Activated Feeders

Abstract

This utility model relates to a real-time feedback system for an activated feeder, comprising a primary spacing detector, a secondary spacing detector, an amplitude detector, a control system, and a vibration force adjustment system. The primary spacing detector is arranged between the equipment body and the support frame to detect the spacing between the bottom surface of the equipment body and the upper surface of the support frame. The secondary spacing detector is arranged above the equipment body to detect the spacing between the upper surface of the equipment body and the bottom surface of the upper hopper. The amplitude detector is arranged on the equipment body to detect the amplitude of the equipment body's vibration. The primary spacing detector, secondary spacing detector, amplitude detector, and vibration force adjustment system are all electrically connected to the control system via signal cables. This utility model can decompose and detect the vibration state of the activated feeder, and monitor and adjust the real-time vibration state.

Description

Technical Field

[0001] This utility model belongs to the field of power system information and automation technology, and particularly relates to a real-time feedback system for an activated feeder. Background Technology

[0002] As a vibrating feeder, the feeding capacity of the activated feeder is affected by the incoming material conditions. Activated feeders can be used under tippers, truck unloading pits, silos, and circular stockyards. Factors affecting the feeding rate include: 1. Impact from above-feeding materials due to tipping over of vehicles or material scattering within the silo can affect feeding stability; 2. Changes in the material properties can lead to variations in flowability; 3. Insufficiently timely overall plant scheduling can cause the equipment to operate in a no-load vibrating state.

[0003] The influencing factors of the incoming material to the activation feeder are numerous and difficult to control. Therefore, generally only the output of the equipment is constrained. That is, the feed rate of the belt conveyor at the bottom is measured using existing belt scales. Based on the output rate feedback from the belt scale, the vibration system of the activation feeder is remotely adjusted to correct the vibration state of the equipment.

[0004] In practical applications, the location of the belt scale is often far from the activation feeder due to the influence of the on-site equipment layout. In addition, the belt scale needs a sufficiently long belt section to measure accurately. All of these factors combined result in a large delay between the measured feed value and the vibration state of the activation feeder. The measured feed amount of the belt scale cannot be used to adjust the vibration state of the activation feeder in time, which may also lead to more unstable operation of the equipment. Summary of the Invention

[0005] In order to overcome the shortcomings of the existing technology, the vibration state of the activated feeder is decomposed and detected, and the real-time vibration state is monitored and adjusted.

[0006] This invention provides a real-time feedback system for an activation feeder, which effectively solves the problem that existing technologies cannot adjust the activation feeder in real time.

[0007] This utility model adopts the following technical solution: a real-time feedback system for an activated feeder, wherein the activated feeder includes a device body with a vibration motor, a support bracket for supporting the device body, and a hopper disposed on the top of the device body. The support bracket and the device body are elastically connected by vibration isolation springs. The real-time feedback system for the activated feeder includes a primary spacing detector, a secondary spacing detector, an amplitude detector, a control system, and a vibration force adjustment system. The primary spacing detector is arranged between the device body and the support bracket to detect the spacing between the bottom surface of the device body and the upper surface of the support bracket. The secondary spacing detector is arranged above the device body to detect the spacing between the upper surface of the device body and the bottom surface of the upper hopper. The amplitude detector is arranged on the device body to detect the amplitude of the device body. The primary spacing detector, the secondary spacing detector, the amplitude detector, and the vibration force adjustment system are all electrically connected to the control system via signal cables.

[0008] The control system is a PLC controller.

[0009] The excitation force adjustment system includes an air source device, a pressurized air system, and an actuator cylinder. The vibrating motor has an eccentric block, and the actuator cylinder is mounted on the eccentric block of the vibrating motor. The air source device is connected to the actuator cylinder through the pressurized air system. The high-pressure air generated by the air source device is delivered to the actuator cylinder through the pressurized air system. By adjusting the pressure delivered to the actuator cylinder, the rotational center of mass of the eccentric block can be changed, thereby adjusting the excitation force of the vibrating motor and thus controlling the feeding capacity of the activated feeder in real time.

[0010] In the above technical solution, the compressed air system includes a refrigerated dryer, a filter, a proportional valve, and a pressure regulating valve connected in sequence. Both the proportional valve and the pressure regulating valve are equipped with signal receiving terminals connected to the output of the PLC controller. The primary spacing detector, the secondary spacing detector, and the amplitude detector are all electrically connected to the signal acquisition terminals of the PLC controller via communication cables. Based on the feedback signals from the signal acquisition terminals, the PLC controller outputs execution signals to the pneumatic control valve assembly (proportional valve and pressure regulating valve) according to a preset logic method. The pneumatic control valve assembly then changes the air pressure delivered to the actuator cylinder.

[0011] In the above technical solution, the first-level spacing detector sends a confirmation signal when it detects that the spacing has reached the required value, and there is no signal feedback if the spacing is not within this range. This detection value can be adjusted between 20-30mm by adjusting the knob. The second-level spacing detector sends a confirmation signal when it detects that the spacing has reached the required value, and there is no signal feedback if the spacing is not within this range. This detection value can be adjusted between 60-90mm by adjusting the handle. The specific detection values ​​mentioned above can be set according to the actual situation of the project site.

[0012] In the above technical solution, the compressed air system is also electrically connected to a fault alarm device. When a fault alarm signal is output in a preset logic mode, the fault alarm device will sound an alarm and automatically power off the equipment after a preset time has elapsed.

[0013] In the above technical solution, the preset time can be any time not exceeding 5 minutes.

[0014] Before the activated feeder is officially put into operation, on-site commissioning is conducted to obtain the feeding capacity required by the user. The final air pressure parameters and amplitude that have passed the commissioning are set as the base air pressure and base amplitude (generally between 2-10mm, usually around 4mm). Based on this, the real-time feedback system of the activated feeder is implemented, and its working mode and feedback logic are as follows:

[0015] After the activation feeder is turned on, the working air pressure is set to the base air pressure. After 1-3 minutes of stable operation, the activation feeder's real-time feedback system will be activated manually or automatically. All detectors will begin measuring signals. If the primary and secondary spacing detectors show no signal, and the amplitude collected by the control system from the amplitude detector remains between 2-10mm for 10 seconds, the control system will adjust the air pressure to 50% of the current air pressure. If the amplitude collected by the control system from the amplitude detector remains greater than 10mm for 10 seconds, regardless of other signal feedback, the control system will send an execution signal to the fault alarm device and the vibration motor, and automatically stop the machine after a preset time. If both the primary and secondary spacing detectors show a continuous signal, the system will continue to monitor the signal. If a definite signal is transmitted for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains less than 2 mm for 10 seconds, the control system will adjust the air pressure to 120% of the current air pressure. If the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains at the baseline amplitude for 10 seconds, the control system will adjust the air pressure to 105% of the current air pressure. If the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains higher than the baseline amplitude for 10 seconds, the control system will adjust the air pressure to 95% of the current air pressure. If the signal does not meet the above requirements, the current air volume will remain unchanged.

[0016] This invention can monitor and adjust the real-time vibration status, effectively solving the problem that the existing technology cannot adjust the activation feeder in real time. Attached Figure Description

[0017] Figure 1 This is a layout diagram of the present invention.

[0018] Figure 2 for Figure 1 The left view.

[0019] Figure 3 This is a diagram showing the electrical signal connection method of this utility model. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0021] Generally, the only output data of an activation feeder is the discharge rate, which needs to be measured by a belt scale. Belt scales are typically located at the end of the entire conveyor belt and cannot provide real-time feedback. The time error in correcting the feeding status based on the final discharge rate is very large, making the correction effect unsatisfactory in practical applications. To achieve real-time feedback to the activation feeder, values ​​must be obtained from the equipment's own vibration parameters, thereby reducing the feedback cycle.

[0022] The vibration parameters of the activated feeder itself contain complex characteristics. Theoretically, the feed rate should remain constant during normal, stable operation. Fluctuations in feed rate are caused by three factors: first, the collapse-like descent of material at the inlet; second, changes in the material's properties, such as moisture content, particle size, and bulk density; and third, changes in the feed rate due to operational issues within the conveyor system. Regardless of the cause, these changes are influenced by the characteristics of the incoming material. As a transfer device, it is neither possible nor suitable to constrain the upstream material. Therefore, at this stage, the effective components of the equipment's vibration parameters should be monitored and adjusted to compensate for and correspond with changes in the upstream material.

[0023] When the activated feeder undergoes simple harmonic motion, the forward sliding exponent of the material is:

[0024]

[0025] In the formula: A is the amplitude, ω is the angular frequency, g is the gravitational constant, μ0 is the static friction angle of the conveyed material, δ is the angle between the vibration direction and the equipment trough surface, and α is the angle between the equipment trough surface and the horizontal.

[0026] Since the shape and angle of the trough are fixed, the material sliding feed speed and amplitude are directly related. When the amplitude changes, the material sliding feed speed will inevitably change. Therefore, the amplitude of the activated feeder should be monitored.

[0027] Meanwhile, the compression distance of the vibration isolation springs also reflects the operating status of the equipment. A compression distance below the rated range indicates that material is not entering the feeder body and the equipment is in an unloaded state; excessive air vibration should be avoided to prevent damage. A compression distance exceeding the rated range indicates excessive pressure in the hopper; in this case, the vibration isolation springs will be over-compressed, leading to increased lateral stiffness, requiring increased excitation force to maintain stable amplitude. Fluctuations in the compression distance reflect the impact of material collapse or impact during feeding. Significant, stable changes in the compression distance indicate a change in the quality of the conveyed material. These changes in incoming material conditions are addressed by automatically adjusting the excitation force of the feeder using the PLC, thus reducing the impact of incoming material on the equipment and improving the feeding status. The adjustment logic is as follows:

[0028] After the activation feeder is turned on, the working air pressure will reach the preset base air pressure value. After 1-3 minutes of stable operation, the activation feeder's real-time feedback system will be activated manually or automatically. All detectors will begin measuring signals. If the primary and secondary spacing detectors have no signal, and the control system collects the amplitude from the amplitude detector, which remains between 2-10mm for 10 seconds, the control system will adjust the air pressure to 50% of the current air pressure value. If the amplitude from the amplitude detector remains greater than 10mm for 10 seconds, regardless of the signal feedback from other detectors, the control system will send a signal to the fault alarm device and the vibration motor, and automatically stop the machine after a preset time. (The last sentence appears to be incomplete and possibly refers to a different scenario.) If all detectors continuously transmit a definite signal for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains less than 2 mm, the control system will adjust the air pressure to 120% of the current air pressure. If the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains at the baseline amplitude for 10 seconds, the control system will adjust the air pressure to 105% of the current air pressure. If the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude of the amplitude detector collected by the control system remains higher than the baseline amplitude for 10 seconds, the control system will adjust the air pressure to 95% of the current air pressure. If the signal does not meet the above requirements, the current air volume will remain unchanged.

[0029] Once the device is powered on, the detection and judgment logic is always enabled and continuously loops, unless manually shut down or until the device is stopped.

[0030] The electrical / pneumatic signal connection relationship of this utility model is as follows:

[0031] The amplitude detector, primary spacing detector, and secondary spacing detector on the equipment body collect 4-20mA analog signals and transmit them to the signal acquisition terminal of the control system via electrical connections. The control system processes the signals according to the aforementioned logic and then sends execution signals to the compressed air system. The pressure regulation system adjusts the compressed air input from the air source device and outputs it to the actuator cylinder. The control system also sends 4-20mA analog signals to the fault alarm device and the vibration motor power switch according to the aforementioned logic. The aforementioned pressure regulation system is generally a proportional valve and a pressure regulating valve, but it can also be other solenoid valve groups with the ability to regulate air pressure. The aforementioned air source device is generally an air compressor, but it can also be other devices that can provide 6-12 bar compressed air.

[0032] Based on the above logic and electrical communication relationships, this utility model adopts the following technical solution: a real-time feedback system for an activated feeder, comprising a device body with a vibrating motor and a support bracket for supporting the device body, and further comprising a primary spacing detector, a secondary spacing detector, an amplitude detector, a control system, and a pressurized air system; the pressurized air system includes an air source device, a pressure regulating system, and an actuator cylinder; the primary spacing detector is arranged between the device body and the support bracket; the secondary spacing detector is arranged above the device body; the amplitude detectors are all arranged on the device body; the vibrating motor is mounted on the device body to drive the device body to vibrate together, and the actuator cylinder is mounted on the eccentric block of the vibrating motor. High-pressure air generated by the air source device is delivered to the actuator cylinder through the pressurized air system. By adjusting the pressure delivered to the actuator cylinder, the rotational center of mass of the eccentric block can be changed, thereby adjusting the excitation force of the vibrating motor, thereby controlling the feeding capacity of the activated feeder in real time.

[0033] In the above technical solution, the control system is a PLC controller, wherein the aforementioned primary spacing detector, secondary spacing detector and amplitude detector are all electrically connected to the signal acquisition terminal of the control system through communication cables. The control system outputs an execution signal to the pressure regulation system according to the feedback signal from the signal acquisition terminal through a preset logic method. The pressure regulation system changes the air pressure delivered to the execution cylinder.

[0034] In the above technical solution, the first-level spacing detector sends a confirmation signal when it detects that the spacing has reached the required value, and there is no signal feedback if the spacing is not within this range. This detection value can be adjusted between 20-30mm by adjusting the knob. The second-level spacing detector sends a confirmation signal when it detects that the spacing has reached the required value, and there is no signal feedback if the spacing is not within this range. This detection value can be adjusted between 60-90mm by adjusting the handle. The specific detection values ​​mentioned above can be set according to the actual situation of the project site.

[0035] The advantage of adopting the above features is that appropriate detection values ​​can be selected according to different working environments and material conditions on site, so as to provide the equipment with adaptability to working conditions and environment.

[0036] In the above technical solution, the compressed air system is also electrically connected to a fault alarm device. When a fault alarm signal is output in a preset logic mode, the fault alarm device will sound an alarm and automatically power off the equipment after a preset time has elapsed.

[0037] In the above technical solution, the preset time can be any time not exceeding 5 minutes.

[0038] The advantage of adopting the above features is that it can flexibly realize on-site observation shutdown, remote operation shutdown or automatic shutdown according to different situations of operators, and can also automatically avoid risks while receiving control from operators.

[0039] This equipment starts after the activated feeder is running and automatically performs the following functions: 1. When the equipment is unloaded and there is no material inside, it locks low-amplitude vibration to avoid damage caused by excessive vibration; 2. It monitors the operating status at any time and automatically or manually stops the machine quickly if an abnormal condition occurs; 3. When the material flow properties decrease, causing it to accumulate inside the equipment and resulting in excessive spring compression due to excessive load, the feedback system automatically increases the excitation force to expel the material inside the machine as quickly as possible to restore normal operation; 4. When the equipment amplitude deviates from the baseline value, it automatically adjusts the excitation force and locks the working intensity of the equipment.

[0040] Example: Figures 1 to 3As shown, the activation feeder includes a device body 5, a hopper 7, and a support 1. A vibration motor 4 (such as the motor described in CN206313599U or a commercially available three-phase asynchronous vibration motor) is connected to the device body 5. The support 1 and the device body 5 are elastically supported by two rows of parallel vibration-damping spring groups 10. The hopper 7 is located on top of the device body 5, inserted into the device body 5 but not in contact with it. A first-level spacing detector 3 (a commercially available inductive proximity switch element SN04 series) is arranged between the device body 5 and the support 1 (for detecting the distance between the bottom surface of the device body and the upper surface of the support). A second-level spacing detector 6 (a commercially available inductive proximity switch element SN04 series) is arranged above the device body 5 (for detecting the distance between the upper surface of the device body 5 and the bottom surface of the upper hopper 7). An amplitude detector 8 (a commercially available amplitude detector) is also present. The AS63 series vibration detectors (purchased as finished products) are all arranged on the equipment body 5 (for detecting the amplitude of the equipment body); the vibration motor 4 is installed on the equipment body 5 to drive the equipment body 5 to vibrate together; the actuator cylinder 9 is installed on the eccentric block of the vibration motor 4; high-pressure air is delivered from the air source device 12 to the actuator cylinder 9 through the pressure regulating system 11, changing the rotation center of the eccentric block of the vibration motor 4, thereby adjusting the excitation amplitude of the activated feeder; all the aforementioned detectors are electrically connected to the control system 2 and the pressure regulating system 11 (a system composed of a refrigerated dryer, filter, proportional valve, pressure regulating valve and control cabinet) through signal cables; the PLC controller of the control system 2 processes the received analog signals and adjusts the pressure of the actuator cylinder 9 according to the preset logic principle, thereby adjusting the excitation force of the vibration motor 4.

[0041] This invention monitors the amplitude and spacing of key points on the activated feeder equipment, combining this with the working principle of the activated feeder to determine its real-time working status, thereby enabling rapid and timely adjustments. This technology is completely different from traditional conveyor lines that control the feeding equipment based on the conveying volume of the belt scale at the end of the conveyor. On conveyor lines of at least 50 meters, the feedback cycle of this technology can be reduced by more than 80% compared to the old technology. It can also automatically achieve the following effects: 1. Locking low-amplitude vibration when the equipment is unloaded and there is no material inside, avoiding damage caused by excessive vibration; 2. Monitoring the operating status at any time, automatically or manually stopping the machine quickly when abnormal conditions occur; 3. When the material flow properties decrease, causing accumulation inside the equipment and excessive spring compression due to excessive load, the feedback system automatically increases the excitation force to quickly discharge the material inside the equipment to restore normal operation; 4. Automatically adjusting the excitation force and locking the working intensity of the equipment when the equipment amplitude deviates from the basic value.

[0042] The working method of this utility model is as follows: First, start the activation feeder equipment. After the equipment has been running stably and normally for 1-3 minutes, start the real-time feedback system of the activation feeder. After starting, the first-level spacing detector, the second-level spacing detector and the amplitude detector begin to receive and feed back signals to the signal acquisition terminal of the control system. The PLC controller of the control system outputs an execution signal to the pressure regulation system according to the received signal and through a preset logic judgment method.

[0043] When this equipment encounters working condition one: poor material feeding at the upper part of the equipment, or no material coming from the upper belt conveyor causing the equipment to run unloaded, the equipment will vibrate significantly due to the lack of material passing through it. Prolonged large-amplitude unloaded vibration will affect the equipment's lifespan. After the activated feeder's real-time feedback system is started, because there is no material inside the machine, the primary and secondary spacing detectors will not return any data within their detection range. Simultaneously, the equipment amplitude will normally remain within the rated operating range of 2-10mm. This achieves the situation where the primary and secondary spacing detectors have no signal and the equipment amplitude remains between 2-10mm for 10 seconds. The system logic... The PLC automatically reduces the working pressure of the actuator cylinder to 50% of its current value, significantly reducing the vibration amplitude of the equipment to adapt to the no-load condition. Subsequently, the real-time feedback system of the activated feeder will make another judgment. If the amplitude of the equipment still exceeds the set amplitude, the working pressure of the actuator cylinder will be reduced again. Because the equipment is no-load, the primary spacing detector will not detect any signal. When the pressure of the actuator cylinder is low enough that the amplitude detector cannot detect an amplitude of more than 2mm for 10 seconds, the vibration amplitude of the equipment is already very low and will not affect the life of the equipment. The equipment continues to vibrate and can return to normal working condition at any time after the material from the upper part resumes.

[0044] When this equipment encounters working state two: the equipment malfunctions, such as spring breakage or structural damage, and the vibration state is unstable, the amplitude will exceed the standard limit. When the amplitude signal continues to exceed 10mm for 10 seconds, it can be inferred that the operating state of the equipment is extremely unstable. At this time, the system logic PLC will send the execution signal to the fault alarm device and the vibration motor, and automatically stop the machine after a preset time, realizing remote and local fault shutdown warning notification, activating the self-locking function of the feeder itself to support the need for fault shutdown.

[0045] When this equipment encounters operating state three: uneven material feeding or material layer collapse causing a large amount of material to be fed rapidly in a short period, or a sudden decrease in material flowability, the material accumulates rapidly inside, leading to excessive compression of the equipment body and increased stiffness of the vibration isolation springs, thus affecting the equipment's vibration feeding capacity. At this time, both the primary and secondary spacing detectors of the equipment body can detect signals. Simultaneously, the increased stiffness causes the equipment amplitude to be too low. When the amplitude signal remains below 2mm for more than 10 seconds, it can be inferred that the equipment's excitation force is insufficient to meet the current requirements. At this point, the system logic PLC transmits the execution signal to the execution cylinder and adjusts the working pressure to 120% of the current value. By increasing the excitation force amplitude to achieve a strong vibration mode, the short-term accumulated material is conveyed to the lower equipment to alleviate the overpressure situation.

[0046] When this equipment encounters working state four: due to other reasons, the excitation feeding capacity of the equipment exceeds the basic value, the material inside the equipment moves as soon as it arrives, and the height of the equipment body will return to normal. At this time, if the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude collected by the control system from the amplitude detector is higher than the basic amplitude for 10 seconds, it can be determined that the feeding capacity is slightly higher than the standard requirement. At this time, the control system will adjust the air pressure value to 95% of the current air pressure value; by slightly reducing the excitation amplitude, the equipment will avoid being in this excessive vibration state.

[0047] When this equipment encounters working state five: due to other reasons, the excitation feeding capacity of the equipment is lower than the basic value. At this time, the material flow is slow but will not cause the vibration isolation springs to collapse. In this case, the primary spacing detector has a signal but the secondary spacing detector has no signal for 10 seconds, and the amplitude collected by the control system from the amplitude detector is lower than the basic amplitude for 10 seconds. It can be determined that the excitation force is slightly lower than the standard requirement. Therefore, the control system adjusts the air pressure value to 105% of the current air pressure value, and increases the excitation force amplitude slightly to avoid the equipment being in a slow material flow state.

[0048] When the equipment encounters other working states: the upper part of the equipment is feeding normally and stably. At this time, the material inside the equipment is transferred normally and does not accumulate. The equipment is in a normal and stable working state. The system logic PLC will keep the working pressure value of the cylinder unchanged.

Claims

1. A real-time feedback system for an activation feeder, the activation feeder comprising a device body with a vibration motor, a support bracket for supporting the device body, and a hopper disposed on top of the device body, wherein the support bracket and the device body are elastically connected by vibration-damping springs, characterized in that: It includes a primary spacing detector, a secondary spacing detector, an amplitude detector, a control system, and an excitation force adjustment system; The first-level spacing detector is arranged between the device body and the support, and is used to detect the spacing between the bottom surface of the device body and the top surface of the support. The secondary spacing detector is arranged above the equipment body and is used to detect the spacing between the upper plane of the equipment body and the lower bottom surface of the upper hopper; the amplitude detector is arranged on the equipment body and is used to detect the amplitude of the equipment body. The primary spacing detector, secondary spacing detector, amplitude detector, and excitation force adjustment system are all electrically connected to the control system via signal cables.

2. The real-time feedback system for the activation feeder according to claim 1, characterized in that: The control system is a PLC controller.

3. The real-time feedback system for the activation feeder according to claim 1 or 2, characterized in that: The excitation force adjustment system includes an air source device, a compressed air system, and an actuator cylinder; the vibrating motor has an eccentric block, the actuator cylinder is mounted on the eccentric block of the vibrating motor, and the air source device is connected to the actuator cylinder through the compressed air system.

4. The real-time feedback system for the activation feeder according to claim 3, characterized in that: The compressed air system includes a refrigerated dryer, a filter, a proportional valve, and a pressure regulating valve connected in sequence. Both the proportional valve and the pressure regulating valve are equipped with signal receiving terminals that are connected to the output of the PLC controller.

5. The real-time feedback system for the activation feeder according to claim 1 or 2, characterized in that: The effective detection spacing of the first-level spacing detector is 20-30mm, and the effective detection spacing of the second-level spacing detector is 60-90mm.

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