Author: Xiao Zhi Fang Huang beginning Keywords: crushing crushing intelligence agencies: Wuhan University of Technology School of Mechanical and Electrical
Abstract: With the rapid development of science and technology in recent years, a series of advanced industrial countries have emerged state-based monitoring and maintenance systems based on advanced state monitoring instruments and based on the actual operating state of mechanical equipment, and have brought huge Social and economic benefits. If we learn from this idea and develop a monitoring system suitable for the actual building materials industry in China, it will definitely improve the overall technical level of the crushing equipment in China's building materials industry and enhance the comprehensive strength of the industry.
Original: After years of rapid development, China's building materials industry has made certain improvements in the level of science and technology and production modernization, and has made tremendous contributions to China's modernization. However, from the perspective of equipment technology level of the whole industry, it is still at a low level, and there are defects such as outdated technical equipment, high energy consumption, serious pollution, and low production efficiency. Taking pulverizing equipment as an example, except for some imported equipment, most domestically produced equipment lacks the necessary methods and means for energy consumption control and online monitoring of equipment status, which inevitably leads to waste of energy and reduces domestic building materials equipment. Competitiveness in the international market.
In the international arena, with the rapid development of science and technology in recent years, especially the rapid development of signal processing technology and microelectronics technology, in the advanced industrial countries, the state-of-the-art state monitoring instruments have emerged and the mechanical equipment is actually operated. State-based condition monitoring maintenance systems have brought enormous social and economic benefits. If we learn from this idea and develop a monitoring system suitable for the actual building materials industry in China, it will definitely improve the overall technical level of the crushing equipment in China's building materials industry and enhance the comprehensive strength of the industry.
Basic structure of the monitoring system
A complete monitoring system consists of a signal acquisition unit, a signal processing unit and a control unit.
The signal acquisition unit is composed of a sensor and an A/D conversion circuit, which completes state conversion and acquisition of the monitored parameters of the controlled object and transmits the information to the signal processing unit. The signal processing unit is the core of the monitoring system, which completes the transformation, analysis and command of the control mechanism. Since this part can implement some logic operation functions, if you add intelligent control algorithms to this unit, you can implement some simple artificial intelligence. The control unit, as an executing mechanism, receives an instruction issued by the signal processing unit, and further performs a corresponding operation on the controlled object according to the instruction.
Crushing equipment intelligent
The smashing equipment is intelligent in terms of energy conservation and safety. The main idea is to select one or several state parameters as monitoring parameters for different crushing equipments, considering their specific working conditions and structural principles. The analysis of these monitoring parameters determines the operating state of the equipment, and then the control mechanism Implement intelligent control of the equipment to maintain the good working condition of the equipment and timely alarm or stop when the machine fails.
1. Establishment of monitoring plan
For a specific monitoring object, the determination of the monitoring scheme (including the selection of monitoring parameters and the placement of the measuring points) depends on the form and characteristics of the fault, as well as the structure and working conditions.
The first principle of selecting the monitoring parameters is that there is an inherent correspondence between the selected parameters and the operating state of the detected object. That is to say, the change of the operating state of the monitored object will inevitably lead to the corresponding change of the monitoring parameter, so that the actual running state of the machine can be judged by the analysis of the monitoring parameter to achieve the purpose of monitoring.
Another principle for selecting monitoring parameters is that the selected parameters should be as easy to measure as possible, thus making the acquisition of signals less difficult.
At present, the monitoring parameters of the monitoring system applied on the industrial site are generally pressure, temperature, noise, vibration, and the like. For example, most of the ball mills in China's cement plants use acoustic signals to judge the profit and loss of the mill feed. However, using acoustic signals as monitoring parameters has the disadvantages of large interference and easy signal distortion. Therefore, vibration should be used as a monitoring parameter for monitoring the state of such machines. Since such equipment is a fixed device, the vibration signal is used as a monitoring parameter, the interference is small, the signal is stable, and it is also relatively good. For lubrication and hydraulic systems, temperature signals and pressure signals can be used as monitoring parameters, which can reflect the working state of the system more realistically.
2. Determination of control plan
(1) Selection of control parameters. Control parameters refer to the parameters directly involved or adjusted by the actuator or manually. By adjusting them, the operating state of the system under test can be changed accordingly. Therefore, the choice of control parameters is directly related to the control effect. In order to select a suitable control parameter, we should first have a thorough understanding of the structure and working principle of the controlled system. It is known that the adjustment of those parameters can keep the controlled system in a better working state. Considering the current status and principles of most of our crushing equipment, we should consider this issue from the perspective of improving equipment production efficiency and safety. For example, for a ball mill, the feeding amount directly affects the production efficiency of the mill: if the feeding amount is too much, the product quality is not guaranteed, and the grinding efficiency is lowered; if the feeding amount is too small, the grinding wear is aggravated. And increase energy consumption. Therefore, the feed amount should be one of our control parameters. For other equipment, parameters such as speed and pressure are often used as control parameters. (2) Equipment for early warning and emergency handling functions. In order to improve the safety of equipment and avoid economic losses caused by vicious accidents, it is necessary to carry out necessary safety protection functions. Acoustic, optical alarm or emergency stop processing when appropriate. (3) Switch between manual and automatic status. In order to avoid unnecessary losses due to the failure of the automatic device, an automatic/manual switching device should be provided, which can be switched to the manual operation mode if appropriate.
3. Design of signal processing unit
The design of the signal processing unit mainly considers three aspects: (1) reliability. First of all, this design can meet the needs of industrial production. (2) Feasibility. The program is able to stabilize normal long-term work in the harsh environment of industrial sites. (3) Economics. The cost of the program should not be too high and should have a good performance-price ratio.
The design of the solution can start from both software and hardware. On the hardware side, due to the rapid development of computer technology and integrated circuit technology in recent years, the price of computers has been reduced to an acceptable price. Due to the powerful functions of the computer, it is very suitable for signal processing; using computer-rich software functions, software can be used to implement filtering, amplification and other functions, to achieve the corresponding functions without increasing hardware costs; using the high-speed operation characteristics of the computer It can meet the real-time monitoring requirements of the industrial site very well; using the human-machine dialogue function of the computer, it can provide users with a more convenient operation interface.
Here are a few computers for industrial control: (1) a single-chip microcomputer. A single-chip microcomputer is a computer that integrates some external devices and CPUs into one chip. The single chip microcomputer has the advantages of strong anti-interference, high reliability, small size and low price. Suitable for the development of smart meters and small control systems. (2) Industrial PC. Industrial PCs generally use the CPU of a general-purpose microcomputer. In order to meet the needs of the industrial site, a small backplane structure is generally adopted, and corresponding expansions and anti-interference properties are made. It has the advantages of powerful functions and fast speed. It can be programmed in a high-level language, which can shorten the software development cycle and provide a friendly human-machine interface. It has a large advantage in communication and large data storage, but the price is relatively high. Expensive, suitable for more high-end control systems. (3) Digital signal processor. In recent years, it has been widely used in the communication industry. Due to its unique internal structure, such as hardware multipliers and separate data storage and program memory areas, coupled with an instruction system for its hardware development, it enables high-speed processing of digital signals. DSP integration test, reliability, and outstanding performance, its successful application in the field of automatic test equipment can give us a reference.
The selection of the above three computer control systems should be reasonably selected according to the specific conditions of the user. For those simpler applications, it is suitable to use a single-chip microcomputer as a processing unit, which can meet most of the work requirements, and the price is low, which is acceptable to most users. For applications that need to perform a large number of data operations frequently and have high real-time requirements, it is suitable to use DSP as a data processing device because DSP has high computing speed and is especially suitable for FFT and convolution operations, and these are spectrum analysis. An important tool. For those high-end applications, users with higher system requirements and more abundant funds can consider industrial PCs as processing units. For users who need to adopt a distributed control system, a single-chip microcomputer or DSP can be used as the underlying processing unit and an industrial PC can be used as the control computer of the upper layer.
In terms of software, the corresponding signal processing and control algorithms should be selected according to the functions that need to be implemented. Generally, there are relatively mature theoretical guidances such as correlation analysis, waveform analysis and spectrum analysis, and various control algorithms. Designers simply want to translate these theories into languages ​​that computers can recognize.
Abstract: With the rapid development of science and technology in recent years, a series of advanced industrial countries have emerged state-based monitoring and maintenance systems based on advanced state monitoring instruments and based on the actual operating state of mechanical equipment, and have brought huge Social and economic benefits. If we learn from this idea and develop a monitoring system suitable for the actual building materials industry in China, it will definitely improve the overall technical level of the crushing equipment in China's building materials industry and enhance the comprehensive strength of the industry.
Original: After years of rapid development, China's building materials industry has made certain improvements in the level of science and technology and production modernization, and has made tremendous contributions to China's modernization. However, from the perspective of equipment technology level of the whole industry, it is still at a low level, and there are defects such as outdated technical equipment, high energy consumption, serious pollution, and low production efficiency. Taking pulverizing equipment as an example, except for some imported equipment, most domestically produced equipment lacks the necessary methods and means for energy consumption control and online monitoring of equipment status, which inevitably leads to waste of energy and reduces domestic building materials equipment. Competitiveness in the international market.
In the international arena, with the rapid development of science and technology in recent years, especially the rapid development of signal processing technology and microelectronics technology, in the advanced industrial countries, the state-of-the-art state monitoring instruments have emerged and the mechanical equipment is actually operated. State-based condition monitoring maintenance systems have brought enormous social and economic benefits. If we learn from this idea and develop a monitoring system suitable for the actual building materials industry in China, it will definitely improve the overall technical level of the crushing equipment in China's building materials industry and enhance the comprehensive strength of the industry.
Basic structure of the monitoring system
A complete monitoring system consists of a signal acquisition unit, a signal processing unit and a control unit.
The signal acquisition unit is composed of a sensor and an A/D conversion circuit, which completes state conversion and acquisition of the monitored parameters of the controlled object and transmits the information to the signal processing unit. The signal processing unit is the core of the monitoring system, which completes the transformation, analysis and command of the control mechanism. Since this part can implement some logic operation functions, if you add intelligent control algorithms to this unit, you can implement some simple artificial intelligence. The control unit, as an executing mechanism, receives an instruction issued by the signal processing unit, and further performs a corresponding operation on the controlled object according to the instruction.
Crushing equipment intelligent
The smashing equipment is intelligent in terms of energy conservation and safety. The main idea is to select one or several state parameters as monitoring parameters for different crushing equipments, considering their specific working conditions and structural principles. The analysis of these monitoring parameters determines the operating state of the equipment, and then the control mechanism Implement intelligent control of the equipment to maintain the good working condition of the equipment and timely alarm or stop when the machine fails.
1. Establishment of monitoring plan
For a specific monitoring object, the determination of the monitoring scheme (including the selection of monitoring parameters and the placement of the measuring points) depends on the form and characteristics of the fault, as well as the structure and working conditions.
The first principle of selecting the monitoring parameters is that there is an inherent correspondence between the selected parameters and the operating state of the detected object. That is to say, the change of the operating state of the monitored object will inevitably lead to the corresponding change of the monitoring parameter, so that the actual running state of the machine can be judged by the analysis of the monitoring parameter to achieve the purpose of monitoring.
Another principle for selecting monitoring parameters is that the selected parameters should be as easy to measure as possible, thus making the acquisition of signals less difficult.
At present, the monitoring parameters of the monitoring system applied on the industrial site are generally pressure, temperature, noise, vibration, and the like. For example, most of the ball mills in China's cement plants use acoustic signals to judge the profit and loss of the mill feed. However, using acoustic signals as monitoring parameters has the disadvantages of large interference and easy signal distortion. Therefore, vibration should be used as a monitoring parameter for monitoring the state of such machines. Since such equipment is a fixed device, the vibration signal is used as a monitoring parameter, the interference is small, the signal is stable, and it is also relatively good. For lubrication and hydraulic systems, temperature signals and pressure signals can be used as monitoring parameters, which can reflect the working state of the system more realistically.
2. Determination of control plan
(1) Selection of control parameters. Control parameters refer to the parameters directly involved or adjusted by the actuator or manually. By adjusting them, the operating state of the system under test can be changed accordingly. Therefore, the choice of control parameters is directly related to the control effect. In order to select a suitable control parameter, we should first have a thorough understanding of the structure and working principle of the controlled system. It is known that the adjustment of those parameters can keep the controlled system in a better working state. Considering the current status and principles of most of our crushing equipment, we should consider this issue from the perspective of improving equipment production efficiency and safety. For example, for a ball mill, the feeding amount directly affects the production efficiency of the mill: if the feeding amount is too much, the product quality is not guaranteed, and the grinding efficiency is lowered; if the feeding amount is too small, the grinding wear is aggravated. And increase energy consumption. Therefore, the feed amount should be one of our control parameters. For other equipment, parameters such as speed and pressure are often used as control parameters. (2) Equipment for early warning and emergency handling functions. In order to improve the safety of equipment and avoid economic losses caused by vicious accidents, it is necessary to carry out necessary safety protection functions. Acoustic, optical alarm or emergency stop processing when appropriate. (3) Switch between manual and automatic status. In order to avoid unnecessary losses due to the failure of the automatic device, an automatic/manual switching device should be provided, which can be switched to the manual operation mode if appropriate.
3. Design of signal processing unit
The design of the signal processing unit mainly considers three aspects: (1) reliability. First of all, this design can meet the needs of industrial production. (2) Feasibility. The program is able to stabilize normal long-term work in the harsh environment of industrial sites. (3) Economics. The cost of the program should not be too high and should have a good performance-price ratio.
The design of the solution can start from both software and hardware. On the hardware side, due to the rapid development of computer technology and integrated circuit technology in recent years, the price of computers has been reduced to an acceptable price. Due to the powerful functions of the computer, it is very suitable for signal processing; using computer-rich software functions, software can be used to implement filtering, amplification and other functions, to achieve the corresponding functions without increasing hardware costs; using the high-speed operation characteristics of the computer It can meet the real-time monitoring requirements of the industrial site very well; using the human-machine dialogue function of the computer, it can provide users with a more convenient operation interface.
Here are a few computers for industrial control: (1) a single-chip microcomputer. A single-chip microcomputer is a computer that integrates some external devices and CPUs into one chip. The single chip microcomputer has the advantages of strong anti-interference, high reliability, small size and low price. Suitable for the development of smart meters and small control systems. (2) Industrial PC. Industrial PCs generally use the CPU of a general-purpose microcomputer. In order to meet the needs of the industrial site, a small backplane structure is generally adopted, and corresponding expansions and anti-interference properties are made. It has the advantages of powerful functions and fast speed. It can be programmed in a high-level language, which can shorten the software development cycle and provide a friendly human-machine interface. It has a large advantage in communication and large data storage, but the price is relatively high. Expensive, suitable for more high-end control systems. (3) Digital signal processor. In recent years, it has been widely used in the communication industry. Due to its unique internal structure, such as hardware multipliers and separate data storage and program memory areas, coupled with an instruction system for its hardware development, it enables high-speed processing of digital signals. DSP integration test, reliability, and outstanding performance, its successful application in the field of automatic test equipment can give us a reference.
The selection of the above three computer control systems should be reasonably selected according to the specific conditions of the user. For those simpler applications, it is suitable to use a single-chip microcomputer as a processing unit, which can meet most of the work requirements, and the price is low, which is acceptable to most users. For applications that need to perform a large number of data operations frequently and have high real-time requirements, it is suitable to use DSP as a data processing device because DSP has high computing speed and is especially suitable for FFT and convolution operations, and these are spectrum analysis. An important tool. For those high-end applications, users with higher system requirements and more abundant funds can consider industrial PCs as processing units. For users who need to adopt a distributed control system, a single-chip microcomputer or DSP can be used as the underlying processing unit and an industrial PC can be used as the control computer of the upper layer.
In terms of software, the corresponding signal processing and control algorithms should be selected according to the functions that need to be implemented. Generally, there are relatively mature theoretical guidances such as correlation analysis, waveform analysis and spectrum analysis, and various control algorithms. Designers simply want to translate these theories into languages ​​that computers can recognize.
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