Powdering rate estimation method of molding, powdering rate estimation device of molding, and manufacturing method of molding

Abstract

To provide a powdering rate estimation method of a molding, which estimates a powdering rate of a molding when the molding is powdered.SOLUTION: A method estimates a powdering rate of a molding 10 manufactured from a powder body as a raw material. A manufacturing method of the molding 10 includes: a manufacturing step of mixing the powder bodies or the powder bodies and a binder, and kneading and molding them so as to manufacture the molding 10; a classification step of performing classification processing on the molding 10 manufactured in the manufacturing step so as to classify the molding 10 according to whether to have a predetermined particle diameter or more; a molding amount calculation step of calculating molding amount as the amount of the molding 10 classified in the classification step; and a powdering rate estimation step of obtaining the powdering rate from the calculated molding amount.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention is a technique for estimating the powder ratio (dust content) of a molded product produced using powder as a raw material. The powdering rate refers to the proportion of the produced moldings that have been powdered. [Background technology]

[0002] For example, in the iron-making process, the coke charged into a blast furnace is required to have high strength and small particle size variation in order to ensure gas permeability inside the furnace. In order to improve the strength of the coke, it is effective to increase the density of the raw materials charged into the coke oven. As one method for achieving this increase in density, the molded coal charging method, which uses molded coal as the raw material to be charged, is widely used.

[0003] Molded coal is produced by mixing powder made by finely grinding one or more kinds of raw materials such as coal with a binder in a heating range above the melting temperature of the binder, and compressing and molding the mixture using a molding machine. Therefore, molded coal is a molded product with high density. By reducing the distance between the coal particles, it becomes easier for the coal particles to fuse together, which makes it possible to improve the strength of the coke.

[0004] On the other hand, the strength of molded coal after compression changes depending on the particle size, moisture, and supply amount of the main and auxiliary raw materials at the granulation stage, as well as the molding conditions. Therefore, the particle size of the molded coal changes if the molded coal is cracked or chipped. In addition, depending on the state of powdering, it is necessary to change the mixing and molding conditions and operate to reduce powdering of the molded coal.

[0005] Therefore, in the past, a classification device has been installed in the molded coal production line to remove particles below a certain particle size from the molded coal produced, thereby reducing the variation in particle size of the molded coal used (manufactured molded coal) (see Patent Document 1). [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2008-73608 A Summary of the Invention [Problem to be solved by the invention]

[0007] The method described in Patent Document 1 makes it possible to separate the produced molded carbon particles into particles of a predetermined particle size. However, the method described in Patent Document 1 has a problem in that the amount of powder and the amount of molded matter cannot be grasped online.

[0008] The present invention has been made in consideration of the above-mentioned points, and aims to estimate the powdering rate of a molded product. [Means for solving the problem]

[0009] In order to solve the problem, one aspect of the present invention is a method for estimating a powdering rate of a molded product manufactured using a powder as a raw material, the molded product being manufactured by a manufacturing process of mixing the powder or the powder and a binder and molding the mixture to produce a molded product, and a classification process of classifying the molded product manufactured in the manufacturing process to classify molded products having a particle size equal to or larger than a preset particle size, the method also comprising a molded product amount calculation process of calculating a molded product amount, which is the amount of molded products classified in the classification process, and a powdering rate estimation process of determining the powdering rate from the calculated molded product amount. Effect of the Invention

[0010] According to an aspect of the present invention, it is possible to estimate the powdering rate of a molded product. In particular, when information (shape information) specifying the shape of the molded product is obtained from the molded product being classified and transported, it is possible to easily estimate the amount of powdering of the molded product in real time from the obtained information. [Brief description of the drawings]

[0011] [Figure 1]1 is a schematic diagram showing an example of a manufacturing flow of a molded product according to an embodiment of the present invention and an example of the configuration of a powdering rate estimation device. FIG. [Diagram 2] FIG. 13 is a diagram showing an example of a processing configuration for estimating a powdering rate. [Diagram 3] FIG. 13 is a diagram showing an example of a process flow for estimating a powdering rate. [Figure 4] FIG. 11 is a diagram showing an example of a temperature distribution measured using a thermal camera as a management device. [Diagram 5] FIG. 13 is a diagram showing an example of the transition of powdering estimation in an example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Next, an embodiment of the present invention will be described with reference to the drawings. In the following description, molded charcoal is assumed as an example of a molded product. However, the present invention is applicable to any molded product produced by kneading powder and compressing and molding it. Generally, a molded product produced by kneading and compressing and molding has a temperature higher than the ambient temperature.

[0013] (manufacturing equipment) As shown in FIG. 1, the molding production apparatus of this embodiment includes a kneader 4, a molding machine 5, and a classifier. One or more types of raw materials are each finely pulverized, and the powdered raw materials are stored in a hopper 1. Then, each raw material is supplied from the hopper 1 to a kneader 4. The amount of powder supplied to the kneader 4 is measured by a weighing device 2. A binder is also supplied to the kneader 4 from a binder storage unit 3 as appropriate. The binder is not necessarily required.

[0014] The kneader 4 heats and kneads the supplied powder and binder. When a binder is added, the mixture is heated to a temperature equal to or higher than the melting temperature of the binder, and kneading is performed in the heating range. After kneading is completed, the kneader 4 supplies the kneaded mixture to the molding machine 5. The molding machine 5 compresses the kneaded material supplied thereto and molds it into a desired shape to produce a molded product. In this embodiment, the molded product is assumed to have a constant thickness and a flat surface, but is not limited to this shape. The molded product produced by the molding machine 5 is supplied to a classifying device.

[0015] The classifying device performs a classification process of the supplied moldings. In this embodiment, the classification is performed so that moldings larger than a preset particle size remain on the sieve. In other words, the classifying device performs a process of separating the moldings as the finished product from powdered particles / powders generated when the moldings are broken or chipped.

[0016] As shown in FIG. 1, the classification device of this embodiment is composed of a first conveyor device 7 having a sieve function. The first conveyor device 7 has a belt 7A made of a net, punched metal, or the like. Specifically, the belt 7A has a large number of openings at a preset particle size. That is, the belt 7A constitutes a sieve. The molded products placed on the belt 7A are transported by the first conveyor device 7. During the transport, particles / powders 11 that have been pulverized to a particle size of less than a predetermined size due to vibration during transport or the like fall from the belt 7A. The pulverized particles / powders 11 are carried out on a discharge conveyor device 9 arranged below the first conveyor device 7. As a result, only molded products larger than a predetermined particle size remain on the belt 7A that constitutes the sieve as products, and the classification process is performed.

[0017] The molded products transported by the first conveyor device 7 are subjected to the above-mentioned classification treatment while being transported, and are also subjected to heat treatment, processing, etc. (not shown) depending on the application.

[0018] In the above manufacturing flow, after classification, molded products 10 having particle sizes larger than a predetermined particle size remain on the sieve (on the belt 7A) as the product.

[0019] In this embodiment, the molded products 10 classified by the first conveyor device 7 for classification are transferred to the second conveyor device 8 and transported to a destination. The second conveyor device 8 may also be a conveyor device for classification. The first conveyor device 7 and the second conveyor device 8 constitute a transport device for transporting the molded article 10.

[0020] It is also preferable to have a cooling device for cooling the conveyor device constituting the classifier. For example, a cooling device (cooling mechanism) for cooling the belt of the second conveyor device 8 is provided. The cooling device may be configured to spray cold air onto the belt, or may be configured to indirectly cool the belt by cooling the pulley of the conveyor device. However, it is configured so that cold air is not sprayed directly onto the molded products 10 on the belt.

[0021] (Powderization rate estimation device) The powdering rate estimation device performs a process of calculating a molded product amount, which is the amount of molded product classified in a classification process by a classification device, and a process of estimating a powdering rate, which determines the above-mentioned powdering rate from the calculated molded product amount.

[0022] In this embodiment, the classification process (classification step) is performed by the first conveyor device 7, and the molded products 10 remaining on the belt 7A, i.e., on the sieve, are placed on the second conveyor device 8 and continuously transported to the destination. The powdering rate estimation device of this embodiment includes a monitoring device 20 and a calculation device 21, as shown in FIG.

[0023] <Monitoring equipment 20> The monitoring device 20 is a device for non-contact monitoring of the state on the belt 7A of the conveyor device. The monitoring device 20 of this embodiment is composed of a non-contact sensor for acquiring shape information that is information specifying the shape of the molded object 10 that remains on the belt 7A constituting the sieve after the classification process and is transported by the transport device.

[0024] The monitoring device 20 in this embodiment is a thermo camera. The monitoring device 20 captures an image of the molded product 10 being transported from above, such as directly above, and supplies the captured image to the calculation device 21. Imaging by the monitoring device 20 may be performed, for example, when the molding 10 is located below the monitoring device 20 based on the conveying speed of the molding 10 or detection of the molding, or imaging may be performed continuously at a predetermined sampling period.

[0025] <Arithmetic unit 21> As shown in FIG. 2, the calculation device 21 includes a molded product amount calculation unit 21A and a powdering rate estimation unit 21B. [Molding quantity calculation unit 21A] The molding amount calculation unit 21A is a processing unit that performs a molding amount calculation process. The molding amount calculation unit 21A calculates the molding amount, which is the amount of the molding 10 classified by the classifier. In this embodiment, the molding amount is the mass of the produced molding 10.

[0026] In this embodiment, the molding 10 to be imaged is identified from the shape information from the monitoring device 20. As described above, this embodiment is an example of the case where the remaining and transported molded product 10 is photographed by a thermo camera to measure the temperature. The molding quantity calculation unit 21A of this embodiment first inputs a two-dimensional thermal image (captured image) captured by a thermo camera (see step ST1 in FIG. 3). Next, in step ST2, the temperature difference is utilized to perform binarization processing on the input captured image to identify (specify) the conveyed molded product 10. Identification is performed by the binarization processing (ST2).

[0027] Here, the raw material is heated to a predetermined temperature during kneading. Therefore, the produced molded product 10 is at a temperature higher than the surrounding atmospheric temperature. Therefore, a temperature difference occurs between the molded product 10 and a conveying device (e.g., a belt). This temperature difference is utilized to obtain the contour shape of the molded product 10 as viewed from above. At this time, by providing the above-mentioned cooling device, the temperature difference becomes larger, improving the identification accuracy of the molded product 10.

[0028] Here, a distance sensor or a three-dimensional shape sensor may be used as the monitoring device 20 to obtain three-dimensional information of the transported molded product 10 as shape information, thereby obtaining the contour shape of the molded product 10 when viewed from above.

[0029] Next, the area (area when viewed from above) of the identified molding 10 is calculated. In this embodiment, the area within the contour shape obtained above when viewed from above is obtained as the area of ​​the molded product 10. Next, the amount of molding is calculated from the obtained area. In the process of calculating the amount of molded product, a calibration curve for estimating the amount of molded product from the measurement results is created in advance. In other words, the correlation between the area and the amount of molded product is determined in advance. For this purpose, the molded product 10 is transported and imaged in advance. In addition, the transported molded product 10 is sampled to calculate the amount of molded product. The area of ​​the region in the image identified as the molded product 10 is calculated from the imaged result. Then, a calibration curve (correlation information) for estimating the amount of molded product is created from the correlation between the sampling result and the area identified as the molded product 10.

[0030] Then, the molding amount calculation unit 21A refers to the obtained calibration curve (correlation) and estimates the molding amount of the molded product to be conveyed from the result of image processing of the measured captured image (area of ​​the molded product 10). For example, the amount of the molded product is calculated by multiplying the calculated area of ​​the molded product 10 by a conversion coefficient (correlation information) calculated in advance, as shown in the following formula. Molded volume = area x conversion factor The conversion coefficient is, for example, the height of the produced molded product 10 multiplied by the specific gravity.

[0031] In this embodiment, a plurality of data items relating to the area of ​​the identified molded product 10 and the actually measured amount of the molded product are obtained in advance, and a function 30 expressing the correlation between the area and the molded product 10 is calculated from the plurality of data items. The amount of the molded product may be calculated using the following formula with the calculated area as a variable. The correlation function may be calculated using a conventionally known statistical processing method or the like. Molding volume = correlation function (area)

[0032] The following processing may also be performed. A large amount of learning data is obtained, which is composed of images of the molded product 10 captured by the monitoring device 20 and the molded product volume of the molded product 10 at that time. Then, machine learning is performed with the large amount of learning data to obtain a model formula in which the captured images are used as input data and the molded product volume is used as output, and the molded product volume is calculated using the model formula. The captured images used for learning or input may be captured images of the identified molded product.

[0033] [Powdering rate estimation section 21B] The powdering rate estimation unit 21B calculates the powdering rate from the amount of molded product calculated by the molded product amount calculation unit 21A. The powdering rate estimation unit 21B of this embodiment obtains the amount of powdering from the amount of molded product and the total amount of raw materials used to produce the above-mentioned molded product 10 in the production process (total amount of raw materials - amount of molded product) (see step ST5 in Figure 3), and calculates the powdering rate using the following formula.

[0034] Powdering rate (%) = {(total amount of raw materials - amount of molded product) / (total amount of raw materials)} x 100 The total amount of raw materials used to produce the molded product 10 is the sum of the total amount of raw materials and the total amount of binder charged in the kneader 4.

[0035] (Operation etc.) In this embodiment, it is possible to continuously estimate the powdering rate of the molded product 10. In particular, since shape information of the molded product 10 is acquired from the molded product 10 that is classified and transported, it is possible to estimate the amount of powdering of the molded product 10 accurately and in real time (in a short time) from the acquired information.

[0036] That is, in the method of estimating the powdering rate of the molded product 10 of this embodiment, the temperature of the molded product 10 is measured as shape information in a production line for the molded product 10 having a sieving process. As a result, in this embodiment, the amount of the molded product 10 being transported can be estimated, and as a result, the powdering rate can be calculated in real time from the relationship with the total amount of raw materials charged for the molded product 10 being transported.

[0037] FIG. 4 is a diagram showing an example of the temperature distribution results obtained by measuring the molded product 10 and its surroundings using a thermo camera as the monitoring device 20. As shown in FIG. It can be seen from Fig. 4 that the detected temperature has two peaks with the boundary at 40°C. The two peaks indicate the temperature of the equipment and the temperature of the molded product 10 being transported, with the lower peak being the temperature of the equipment and the higher peak being the temperature of the molded product 10. Therefore, it can be seen that the molded product 10 (its outline) can be identified by performing edge processing based on the temperature difference from the image captured by the thermal camera.

[0038] Fig. 5 is a diagram showing the transition of the powder rate continuously obtained in this embodiment. Specifically, Fig. 5 shows the transition of the powder rate (%) obtained by the powder rate estimation device of this embodiment and the transition of the powder rate calculated by sieve analysis. In the sieve analysis, the powder rate was obtained by measuring the powder fraction actually separated by classification processing.

[0039] As can be seen from Fig. 5, it was confirmed that the time when the powdering rate of both samples increased and decreased coincided with each other in the transition of the measured powdering rate. Therefore, it was found that the powdering rate can be easily estimated by measuring the temperature (shape information) of the molded product 10 after classification in a production line for the molded product 10 having a sieve treatment.

[0040] An example of an embodiment to which the present invention is applied has been described above. However, the present invention is not limited by the description and drawings that form a part of the disclosure of the invention according to this embodiment. For example, in the above example, the temperature (shape information) is measured using a thermo camera, but this is not limited to this. For example, the temperature of the molded product 10 being transported is continuously measured by measuring a one-dimensional temperature distribution using a thermocouple or the like. Then, the temperature information may be synthesized and a process may be performed to obtain information equivalent to a thermal image taken by a thermo camera, thereby obtaining the contour of the molded product.

[0041] The monitoring device 20 does not have to capture an image of the molding 10 while the molding 10 is being transported. However, if the image is captured while the molding 10 is being transported, it becomes possible to obtain the powdering rate in real time and earlier. Here, other embodiments, examples, operating techniques, etc. made by the business operators based on this embodiment are all included in the scope of the present invention.

[0042] In addition, by estimating the powdering rate of a molded product manufactured by the powdering rate estimation method of this embodiment, It is possible to judge the quality of the molded product produced, etc. Also, by reviewing part of the molded product manufacturing process based on the estimated powdering rate, it becomes possible to manufacture molded products with improved quality.

[0043] (others) The present disclosure may also have the following configuration. (1) A method for estimating the powdering rate of a molded product produced using a powder as a raw material, comprising the steps of: The manufacturing method of the molded product includes a manufacturing process of kneading a powder or a powder and a binder, and molding the kneaded product to manufacture a molded product, and a classification process of classifying the molded product manufactured in the manufacturing process to classify molded products having a particle size equal to or larger than a preset particle size, A molding amount calculation step of calculating a molding amount, which is the amount of the molding classified in the classification step; A powdering rate estimation step of determining the powdering rate from the calculated amount of molded product; A method for estimating the powdering rate of a molded product comprising the steps of: (2) In the above-mentioned classification step, the molded product placed on the sieve is classified while being transported by a transport device, The molding amount calculation step calculates the amount of the molding based on information from a monitoring device that monitors the moldings remaining on the sieve and being transported by the transport device, The powdering rate estimation step determines the powdering rate from the calculated amount of molded product and the total amount of raw materials used to produce the molded product in the production step. (3) The above-mentioned monitoring equipment is a thermal camera that captures images of the molded product. The molding amount calculation step includes identifying the molding based on the temperature difference with the surroundings of the molding based on information from the monitoring device, determining the area of ​​the identified molding, and calculating the molding amount from the determined area. (4) calculating a correlation between the area of ​​the identified molded object and the amount of the molded object in advance; The molding amount calculation step calculates the molding amount from the area of ​​the identified molding based on the correlation. (5) At least one of the sieve and the conveying device is cooled. (6) A powder fraction estimation device that is provided in a molding production facility that produces moldings having a particle size equal to or larger than a preset particle size by kneading a powder or a powder and a binder, molding the mixture to produce a molding, and classifying the produced moldings with a classifier, and that estimates the powder fraction of the moldings produced, a molding amount calculation unit that calculates a molding amount, which is the amount of moldings classified by the classifier; a powdering rate estimation unit that calculates the powdering rate from the amount of molded product calculated by the molded product amount calculation unit; A powderization rate estimation device comprising: (7) The classifying device is configured to classify the molded product placed on the sieve while conveying it with a conveying device, Further, a monitoring device is provided for monitoring the molded products remaining on the sieve and being transported by the transport device, The molding amount calculation unit calculates the molding amount based on information from the monitoring device, The powdering rate estimation unit calculates the powdering rate from the amount of the molded product and the total amount of raw materials used when producing the molded product. (8) The above monitoring equipment is a thermal camera that captures images of the molded product. The molding amount calculation unit identifies the molding based on the temperature difference with the surroundings of the molding based on information from the monitoring device, calculates the area of ​​the identified molding, and calculates the amount of the molding from the area thus determined. (9) having a correlation between the area of ​​the identified molded product and the amount of the molded product, which has been determined in advance; The molding amount calculation unit calculates the molding amount from the area of ​​the identified molding based on the correlation. (10) A cooling device for cooling the classifying device. (11) A method for manufacturing a molded product, comprising estimating a powdering rate of the molded product using the method for estimating a powdering rate of a molded product disclosed herein. [Explanation of symbols]

[0044] 1 Hopper 2 Measuring instrument 3 Binder storage section 4. Mixing machine 5 Molding machine 7 First conveyor device 7A Belt 8 Second conveyor device 10 Molded object 20 Monitoring equipment 21 Arithmetic unit 21A Molding Quantity Calculation Department 21B Powdering rate estimation section

Claims

1. A method for estimating a powdering rate of a molded product produced using a powder as a raw material, comprising the steps of: The manufacturing method of the molded product includes a manufacturing process of kneading a powder or a powder and a binder, and molding the kneaded product to manufacture a molded product, and a classification process of classifying the molded product manufactured in the manufacturing process to classify molded products having a particle size equal to or larger than a preset particle size, A molding amount calculation step of calculating a molding amount, which is the amount of the molding classified in the classification step; A powdering rate estimation step of determining the powdering rate from the calculated amount of molded product; A method for estimating the powdering rate of a molded product comprising the steps of:

2. In the classification step, the molded product placed on the sieve is classified while being transported by a transport device. The molding amount calculation step calculates the amount of the molding based on information from a monitoring device that monitors the moldings remaining on the sieve and being transported by the transport device, The powdering rate estimation step calculates the powdering rate from the calculated amount of molded product and the total amount of raw materials used to produce the molded product in the production step. A method for estimating a powdering rate of a molded product according to claim 1.

3. The monitoring device is a thermo camera that captures images of the molded product. The molding amount calculation step includes identifying the molding based on the temperature difference with the surroundings of the molding based on the information from the monitoring device, determining the area of ​​the identified molding, and calculating the molding amount from the determined area. A method for estimating a powdering rate of a molded product according to claim 2.

4. A correlation between the area of ​​the identified molded product and the amount of the molded product is obtained in advance, The molding amount calculation step calculates the molding amount from the area of ​​the identified molding based on the correlation. A method for estimating a powdering rate of a molded product according to claim 3.

5. Cooling at least one of the sieve and the conveying device; A method for estimating a powdering rate of a molded product according to claim 3 or 4.

6. A powder fraction estimation device is provided in a molding production facility that produces moldings having a particle size equal to or larger than a preset particle size by kneading a powder or a powder and a binder, molding the mixture to produce a molding, and classifying the produced moldings with a classifier, the powder fraction estimation device estimating the powder fraction of the produced moldings, a molding amount calculation unit that calculates a molding amount, which is the amount of moldings classified by the classifier; a powdering rate estimation unit that calculates the powdering rate from the amount of molded product calculated by the molded product amount calculation unit; A powderization rate estimation device comprising:

7. The classifying device is configured to classify the molded product placed on the sieve while conveying it with a conveying device, Further, a monitoring device is provided for monitoring the molded products remaining on the sieve and being transported by the transport device, The molding amount calculation unit calculates the molding amount based on information from the monitoring device, The powdering rate estimation unit calculates a powdering rate from the amount of the molded product and a total amount of raw materials used to produce the molded product. The dusting rate estimation device according to claim 6.

8. The monitoring device is a thermo camera that captures images of the molded product. The molding amount calculation unit identifies the molding based on a temperature difference with respect to the surroundings of the molding based on information from the monitoring device, calculates an area of ​​the identified molding, and calculates the molding amount from the calculated area. The dusting rate estimation device according to claim 7.

9. A correlation between the area of ​​the identified molded product and the amount of the molded product is obtained in advance, The molding amount calculation unit calculates the molding amount from the area of ​​the identified molding based on the correlation. The dusting rate estimation device according to claim 8.

10. A cooling device for cooling the classification device is provided. The dusting rate estimation device according to claim 8 or 9.

11. A method for manufacturing a molded product, comprising estimating a powdering rate of the molded product by the method for estimating a powdering rate of the molded product according to any one of claims 1 to 4.

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