Intelligent adjustment granulator

Abstract

The utility model belongs to the granulation field, specifically discloses a kind of intelligent adjustment granulator. Including installation support and the disc granulator installed on it, installation support is equipped with disc inclination angle adjusting shaft, its special feature lies in: the granulator still includes control system, double spray head sprinkling system, laser scattering sensor, first drive motor and second drive motor, the control system includes LabVIEW host computer, PLC controller and the communication connection between both. The utility model realizes particle size real-time monitoring by laser scattering sensor, can give accurate real-time particle condition every time monitoring 1s;Laser scattering sensor realizes real-time data transmission by LabVIEW host computer and PLC, while first drive motor and second drive motor receive data, carry out automatic adjustment, so that both reduce manpower consumption, also realize disc rotational speed inclination angle self-adapting adjustment, optimize granule forming, improve granulating efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of granulation, specifically relating to an intelligent adjustable granulator. Background Technology

[0002] In the field of expanded clay or granular fertilizer, granulation equipment is frequently used, typically a disc granulator. During disc granulation, a binder (such as water mist) and a pore-forming agent are usually sprayed into the disc. However, most current disc granulators control the particle size by manually adjusting the disc's tilt angle and rotation speed, resulting in low granulation efficiency and poor particle uniformity. Furthermore, most rely on manual hand-held spraying or fixed spray devices for applying the binder and pore-forming agent, and these devices are often single-nozzle systems. This makes it difficult to apply the binder and pore-forming agent in precise layers, and liquid residue can easily remain during single-nozzle switching, leading to component contamination.

[0003] Therefore, an intelligent granulation device is needed. Utility Model Content

[0004] In order to solve the problems of low granulation efficiency, poor particle uniformity, inability to accurately apply binders and pore-forming agents in layers, and easy component contamination caused by residual liquid in the existing technology, the purpose of this utility model is to provide an intelligent adjustable granulator.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: An intelligent adjustable granulator includes a mounting bracket and a disc granulator mounted thereon. The mounting bracket is provided with a disc tilt angle adjustment shaft. The granulator is characterized in that it also includes a control system, a dual-nozzle spraying system, a laser scattering sensor, a first drive motor and a second drive motor. The control system includes a LabVIEW host computer and a PLC controller, and the two are communicatively connected. The first drive motor is connected to the drive shaft of the disc granulator, the second drive motor is connected to the disc tilt angle adjustment shaft, the dual-nozzle spraying system is located opposite the disc granulator, and the laser scattering sensor is located diagonally above the material outlet of the disc granulator. The dual-nozzle spray system includes an outer spray housing and an inner spray housing. The outer spray housing is cylindrical and annular. The inner spray housing consists of a first inner spray housing section and two integrally formed inner spray housing sections. Both the first and second inner spray housing sections are cylindrical, with the diameter of the first inner spray housing section being larger than that of the second inner spray housing section. The outer diameter of the first inner spray housing section matches the annular inner diameter of the outer spray housing section. The first inner spray housing section is housed within the annulus of the outer spray housing section, while the second inner spray housing section protrudes from the front end face of the outer spray housing section. The front end face of the outer spray housing section has an external atomizing device on its inner wall and uniformly distributed external nozzles on its outer wall. The front end face of the second inner spray housing section has an internal atomizing device on its inner wall and uniformly distributed internal nozzles on its outer wall. The rear end face of the outer spray housing section is connected to an external spray pipe, and the rear end face of the first inner spray housing section is connected to an internal spray pipe. The external spray pipe and the internal spray pipe are each sequentially equipped with a solenoid valve and an electromagnetic flow meter along the liquid flow direction. The laser scattering sensor is electrically connected to the LabVIEW host computer, and the PLC controller is electrically connected to the first drive motor, the second drive motor, the solenoid valve, and the electromagnetic flow meter.

[0006] Preferably, the granulator also includes a fixing component located opposite the disc granulator; the fixing component includes a base and an inverted U-shaped frame, with one side of the inverted U-shaped frame being longer than the other, and the longer side of the inverted U-shaped frame being vertically fixed to the base; a dual-nozzle spraying system is fixedly installed at the end of the shorter side of the inverted U-shaped frame, and a laser scattering sensor is fixedly installed on the longer side of the inverted U-shaped frame, and the installation positions of the dual-nozzle spraying system and the laser scattering sensor ensure that they do not interfere with each other during operation.

[0007] Preferably, both the first drive motor and the second drive motor are variable frequency motors.

[0008] Preferably, the granulator also includes an alarm located above the control system and electrically connected to the PLC controller.

[0009] Preferably, the alarm is an audible alarm.

[0010] In this invention, both the external atomizing device and the internal atomizing device are atomizing devices known in the art, as long as they can atomize the adhesive or pore-forming agent.

[0011] Beneficial effects: 1. This utility model achieves real-time particle size monitoring through a laser scattering sensor. Each monitoring session lasts 1 second and provides accurate real-time particle status. The laser scattering sensor transmits data in real time through a LabVIEW host computer and a PLC. Simultaneously, the first and second drive motors automatically adjust after receiving the data. This reduces manpower consumption and enables adaptive adjustment of the disc rotation speed and tilt angle, optimizing particle forming and improving granulation efficiency. 2. The dual-nozzle spray system can meet different granulation needs. By adjusting the corresponding solenoid valves, it can spray alternately from the inner and outer nozzles to achieve precise layered addition with spatial isolation, or it can spray from both the inner and outer nozzles simultaneously to achieve mixed addition of two liquids, meeting different pelletizing requirements. The dual-layer nozzles isolate two different substances, reducing the problem of component contamination caused by residual liquid when switching between traditional single nozzles. When the binder and pore-forming agent are sprayed out simultaneously, they can be evenly sprayed onto the material in a certain proportion, avoiding problems with the ratio or uneven distribution of binder and pore-forming agent on the material caused by switching between single nozzles. The electromagnetic flow meter and solenoid valves enable the binder and pore-forming agent to be evenly sprayed onto the material in a specific proportion, thereby achieving controllable and uniform particle porosity and obtaining more products that meet the requirements. 3. The laser scattering sensor is installed above the discharge port and emits a laser beam to the discharged particles. When the laser beam hits the particles, the particles will scatter the laser. By measuring the intensity of the scattered light, the particle size distribution information can be obtained. Attached Figure Description

[0012] Figure 1 : A schematic diagram of the overall structure of this utility model; Figure 2 Schematic diagram of a dual-nozzle spray system; Figure 3 : A partial structural diagram of a dual-nozzle spray system; The attached figures are labeled as follows: 1-mounting bracket; 2-disc granulator; 3-control system; 4-dual-nozzle spraying system; 41-outer spray housing; 42-inner spray housing; 43-outer nozzle; 44-inner nozzle; 45-outer spray pipe; 46-inner spray pipe; 47-solenoid valve; 48-electromagnetic flow meter; 5-laser scattering sensor; 6-alarm; 7-base; 8-inverted U-shaped frame. Detailed Implementation

[0013] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described below with reference to specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the described embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0014] In the following embodiments, the terms "first," "second," etc., are used only for convenience of description and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated.

[0015] Example 1

[0016] like Figures 1-3As shown, an intelligent adjustable granulator includes a mounting bracket 1 and a disc granulator 2 mounted thereon, a control system 3, a dual-nozzle spraying system 4, a laser scattering sensor 5, a first drive motor (not shown), a second drive motor (not shown), a fixing component, and an alarm 6. The control system 3 includes a LabVIEW host computer (not shown) and a PLC controller (not shown) that are communicatively connected. The alarm 6 is located above the control system 3. The mounting bracket 1 is equipped with a disc tilt angle adjustment shaft (not shown). The first drive motor is connected to the drive shaft of the disc granulator 2, and the second drive motor is connected to the disc tilt angle adjustment shaft. All drive motors are variable frequency motors; the dual-nozzle spray system 4 is positioned opposite the disc granulator 2, ensuring it can spray onto the material inside the disc granulator 2; the laser scattering sensor 5 is positioned diagonally above the material outlet of the disc granulator 2; both the dual-nozzle spray system 4 and the laser scattering sensor 5 are fixed by fasteners; the fasteners include a base 7 and an inverted U-shaped frame 8, with one long and one short side frame of the inverted U-shaped frame 8, the longer side frame of the inverted U-shaped frame 8 being vertically fixed to the base 7; the dual-nozzle spray system 4 is fixedly installed at the end of the shorter side frame of the inverted U-shaped frame 8 and faces the material inside the disc granulator 2; the laser scattering sensor 5 is fixedly installed on the longer side frame of the inverted U-shaped frame 8. The installation positions of the system 4 and the laser scattering sensor 5 ensure that they do not interfere with each other during operation. The dual-nozzle spray system 4 includes an outer spray housing 41 and an inner spray housing 42. The outer spray housing 41 is cylindrical and annular. The inner spray housing 42 consists of a first inner spray housing section and two integrally formed inner spray housing sections. Both the first and second inner spray housing sections are cylindrical, and the diameter of the first inner spray housing section is larger than that of the second inner spray housing section. The outer diameter of the first inner spray housing section matches the annular inner diameter of the outer spray housing 41. The first inner spray housing section is built into the annulus of the outer spray housing 41, while the second inner spray housing section protrudes from the front end face of the outer spray housing 41. The front end face of the outer spray housing 41 is provided with a [feature / feature] on the inner wall. The device includes an external atomizing device (not shown) and uniformly distributed external nozzles 43 on the outer wall; the front end face of the two-section internal spray housing is provided with an internal atomizing device (not shown) on the inner wall and uniformly distributed internal nozzles 44 on the outer wall; the rear end face of the external spray housing 41 is connected to an external spray pipe 45, and the rear end face of the one-section internal spray housing is connected to an internal spray pipe 46; the external spray pipe 45 and the internal spray pipe 46 are respectively provided with a solenoid valve 47 and an electromagnetic flow meter 48 along the liquid flow direction; the laser scattering sensor 5 is electrically connected to a LabVIEW host computer, and the PLC controller is electrically connected to the first drive motor, the second drive motor, the solenoid valve 47, the electromagnetic flow meter 48 and the alarm 6 respectively.

[0017] Working process: First, the flow rate setting value is input through the LabVIEW host computer interface. The LabVIEW host computer transmits this flow rate setting value to the PLC controller and stores it in the PLC controller. After power is turned on, when the material is fed into the disc granulator 2, the disc granulator 2 rotates at an initial low speed (5-10 rpm). The material forms a flow layer under gravity. The dual-nozzle spray system 4 sprays binder and pore-forming agent. The laser scattering sensor 5 monitors the particle size in real time. The monitoring data is fed back to the LabVIEW host computer in real time. The LabVIEW host computer sends signals to the PLC controller, which calculates the required disc rotation speed and disc tilt angle through PLC program logic operations. The PLC controller sends signals to the first drive motor, the second drive motor, and solenoid valve 47 to dynamically adjust the disk rotation speed, disk tilt angle, binder flow rate, and pore-forming agent flow rate, respectively. If the monitored particle size is <3mm, the first drive motor is given a high-speed rotation command (15-20rpm) to promote rapid agglomeration of the powder. If the monitored particle size is >8mm, the first drive motor is given a low-speed rotation command (5-8rpm) to finely trim the particles. If the monitored results conflict with the above two situations, the first drive motor is given a linear deceleration command (current actual speed → 8rpm, deceleration rate set to 6-7s) to prevent particle collision and breakage. In the spraying stage of the dual-nozzle spraying system, the inner nozzle 44 sprays an atomized binder (such as silica sol) onto the flowing powder after passing through the inner atomization device. After the powder particles are wetted, they adhere to each other and form micron-sized agglomerates. The outer nozzle 43 then sprays a pore-forming agent (such as 5-20 wt% carbon powder suspension) to form a uniform coating layer on the outside of the bonded powder nuclei. When spraying the binder and the pore-forming agent, the outer spray housing 41 and the inner spray housing 42 are physically isolated, which avoids the uneven composition caused by the premixing of the binder and the pore-forming agent.

[0018] During granulation, if the measured spray volume of the electromagnetic flowmeter 48 is inconsistent with the flow rate setting value stored in the PLC controller (the spray volume is lower or higher than the setting value), the PLC controller controls the corresponding solenoid valve 47 to adjust its opening degree so that the measured spray volume reaches the setting value. The inner nozzle 44 (binder) and the outer nozzle 43 (pore-forming agent) spray alternately with an interval of 0.5s to ensure that the two do not overlap. At the same time, it should be noted that the laser scattering sensor 5 should be used alternately with the dual-nozzle spray system 4: after the nozzle finishes spraying, pause for 1-2 seconds to allow the atomized droplets to settle before turning on the laser scattering sensor 5 for measurement to prevent fogging. The small droplets affect the application of the laser scattering sensor 5. That is, after the inner nozzle 44 sprays, it stops for 0.5s, and the outer nozzle 43 starts spraying. After the outer nozzle 43 sprays, it stops for 1-2s, and the laser scattering sensor 5 starts monitoring. After 1s, the inner nozzle 44 starts spraying again, and so on. If the equipment malfunctions, such as the disc granulator 2 losing control of its speed (speed fluctuation > ±10% of the set value), the PLC controller sends a signal to the first drive motor, solenoid valve 47 and alarm 6. The first drive motor and solenoid valve 47 close, and alarm 6 issues an alarm signal. After the fault is cleared, a new round of granulation work starts.

Claims

1. An intelligent adjustable granulator, comprising a mounting bracket and a disc granulator mounted thereon, wherein the mounting bracket is provided with a disc tilt angle adjustment shaft, characterized in that: The granulator also includes a control system, a dual-nozzle spraying system, a laser scattering sensor, a first drive motor and a second drive motor. The control system includes a LabVIEW host computer and a PLC controller, and the two are connected in communication. The first drive motor is connected to the drive shaft of the disc granulator, the second drive motor is connected to the disc tilt angle adjustment shaft, the dual-nozzle spraying system is located opposite the disc granulator, and the laser scattering sensor is located diagonally above the material outlet of the disc granulator. The dual-nozzle spray system includes an outer spray housing and an inner spray housing. The outer spray housing is cylindrical and annular. The inner spray housing consists of a first inner spray housing section and two integrally formed inner spray housing sections. Both the first and second inner spray housing sections are cylindrical, with the diameter of the first inner spray housing section being larger than that of the second inner spray housing section. The outer diameter of the first inner spray housing section matches the annular inner diameter of the outer spray housing section. The first inner spray housing section is housed within the annulus of the outer spray housing section, while the second inner spray housing section protrudes from the front end face of the outer spray housing section. The front end face of the outer spray housing section has an external atomizing device on its inner wall and uniformly distributed external nozzles on its outer wall. The front end face of the second inner spray housing section has an internal atomizing device on its inner wall and uniformly distributed internal nozzles on its outer wall. The rear end face of the outer spray housing section is connected to an external spray pipe, and the rear end face of the first inner spray housing section is connected to an internal spray pipe. The external spray pipe and the internal spray pipe are each sequentially equipped with a solenoid valve and an electromagnetic flow meter along the liquid flow direction. The laser scattering sensor is electrically connected to the LabVIEW host computer, and the PLC controller is electrically connected to the first drive motor, the second drive motor, the solenoid valve, and the electromagnetic flow meter.

2. The intelligent regulating granulator as described in claim 1, characterized in that: The granulator also includes a fixing component located opposite the disc granulator. The fixing component includes a base and an inverted U-shaped frame. The two side frames of the inverted U-shaped frame are of different lengths, and the longer side frame is vertically fixed to the base. A dual-nozzle spraying system is fixedly installed at the end of the shorter side frame of the inverted U-shaped frame, and a laser scattering sensor is fixedly installed on the longer side frame of the inverted U-shaped frame. The installation positions of the dual-nozzle spraying system and the laser scattering sensor ensure that they do not interfere with each other during operation.

3. The intelligent regulating granulator as described in claim 1, characterized in that: Both the first drive motor and the second drive motor are variable frequency motors.

4. The intelligent regulating granulator as described in claim 1, characterized in that: The granulator also includes an alarm located above the control system and electrically connected to the PLC controller.

5. The intelligent regulating granulator as described in claim 4, characterized in that: The alarm is an audible alarm.

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