CN106123792A - A kind of drying grate material layer thickness imaging system and method - Google Patents

Abstract

The present invention proposes a kind of drying grate material layer thickness imaging system and method, belong to pelletizing cloth technical field of imaging, this system includes The Cloud Terrace, laser material position meter, motor encoder, data processing module and image-forming module, this system can realize drying grate whole strip situation, operator are allowed to observe drying grate monolith layer state intuitively, pelletizing system, drying grate feeding system and heat balance system are given the strong foundation of correct adjustment, make drying grate production capacity maximize, promote integrated artistic production procedure optimization；Improve productivity ratio and qualification rate, effectively reduce and fried ball and the phenomenon of blastomere occur, reach the purpose of energy-saving and emission-reduction；This system has wide market prospect, can bring direct economic benefit and indirectly social benefit to enterprise.

Description

A kind of drying grate material layer thickness imaging system and method

Technical field

The invention belongs to pelletizing cloth technical field of imaging, be specifically related to a kind of drying grate material layer thickness imaging system and side Method.

Background technology

During pelletizing production, drying grate cloth it is critical that a link, drying grate material layer thickness and all Evenness is always the speed that the change remote-effects grate of the parameter of a most important thing, thickness of feed layer and the uniformity thereof is run Degree, hot-air system etc., and directly affect quality and the yield of finished ball.Engineering was in accordance with drying grate chassis width and set in the past Several fixed type radar level-sensing devices, also can only detect some thickness of feed layer, need to compare by PLC system, substantially obtain the bed of material Whether there is deviation, can not accurately detect at all the average thickness of the current bed of material and deviation flex point where, have how many Individual flex point and the instantaneous upper doses of drying grate；Problems above always affects in the major issue of pelletizing actual production Point；

Based on pelletizing plant, production capacity and automatization level requirement are improved constantly and reach the purpose of energy-saving and emission-reduction, need The efficiency of production to be improved, and drying grate material layer thickness and green-ball amount directly affect quality and the yield of finished ball；Therefore chain is combed Machine thickness of feed layer and the detection of green-ball amount and imaging are all very important for pelletizing production operates.

Summary of the invention

For the deficiencies in the prior art, the present invention proposes a kind of drying grate material layer thickness imaging system and method, to reach Improve production capacity, automatization level, the efficiency of production, the quality of finished ball and the purpose of yield.

A kind of drying grate material layer thickness imaging system, including: The Cloud Terrace, laser material position meter, motor encoder, data process mould Block and image-forming module, wherein,

The Cloud Terrace: for fixing and rotary laser level-sensing device, when being sampled by each sampled point, laser material position meter is combed with chain simultaneously Machine trolley vertical line angulation is to data processing module；

Laser material position meter: the thickness of the pellet bed of material on on-line measurement drying grate chassis, and send to data process In module；

Motor encoder: for the rotating speed of on-line measurement drying grate main driving motor, the speed of drying grate is carried out online Detection, and send to data processing module；

Data processing module: for according to one-tenth-value thickness 1/10, velocity amplitude and the angle value gathered, it is thus achieved that and show drying grate chassis Upper any sampled point material is thick, the sampling period averagely expects averagely to expect cycle instantaneous doses thick, each, each on thickness, integral trolley Current total stuff amount and the speed of service on cycle accumulation doses, chassis；

Image-forming module: for pellet thickness of feed layer on drying grate chassis being formed 3 D stereo Dynamic Graph by 3D software Picture.

Described laser material position meter, is positioned at directly over drying grate chassis plate upper surface width midpoint.

The formation method using drying grate material layer thickness imaging system to carry out, comprises the following steps:

Step 1, the number of sampled point in sampling period and each cycle is set, with drying grate chassis plate upper surface width Midpoint be initial point build rectangular coordinate system；

Step 2, by 0 ° rotary head, drive laser material position meter rotate arrive first test point measure drying grate chassis Upper pellet one-tenth-value thickness 1/10, and send the coordinate obtaining this test point to data processing module；

Step 3, The Cloud Terrace are rotated further to next test point, use laser material position measurement to measure this dot thickness value, and send extremely Data processing module obtains the coordinate of this test point；

Step 4, repeatedly execution step 3, until The Cloud Terrace completes the rotation of 360 °, all test points in i.e. completing this cycle Measure, test point coordinate curve in all effective ranges is connected, it is thus achieved that pellet on drying grate chassis in this cycle Thickness curve；

Step 5, the rotating speed of employing motor encoder on-line measurement drying grate main driving motor, and send to data process mould In block；

Step 6, according to the one-tenth-value thickness 1/10 of test point in all effective ranges in the cycle, it is thus achieved that in this cycle chain comb The average thickness of feed layer of machine, further according to the meansigma methods of stream speed actual measurement in this cycle, it is thus achieved that the current material thick detection cycle is instantaneous Doses；

Step 7, obtain according to the average thickness of feed layer of each cycle drying grate and averagely expect thickness on integral trolley；

Step 8, according to averagely expecting pellet on thickness, drying grate chassis effective material containing length, chassis on integral trolley Bulk density and drying grate chassis width, it is thus achieved that current total stuff amount on chassis；Or obtain chassis according to each cycle doses cumulant Upper current total stuff amount；

Pellet thickness of feed layer on drying grate chassis is formed three-dimensional dynamic image by step 9, employing 3D software.

The invention have the advantages that

The present invention proposes a kind of drying grate material layer thickness imaging system and method, and this system can realize the whole band of drying grate Material situation, allows operator observe drying grate monolith layer state intuitively, flat to pelletizing system, drying grate feeding system and heat Balance system provides the strong foundation of correct adjustment, makes drying grate production capacity maximize, and promotes integrated artistic production procedure optimization； Productivity ratio and qualification rate can be improved, effectively reduce and fried ball and the phenomenon of blastomere occur, reach the purpose of energy-saving and emission-reduction；State at present Drying grate strip state all cannot be accomplished the doses etc. in Central Control Room 3D imaging with drying grate by inside and outside pelletizing plant, because chain is combed Machine has upper cover, and operator to scene also cannot observe on a large scale, and this cover system can solve these problems, so having wide Wealthy market prospect, can bring direct economic benefit and indirectly social benefit to enterprise.

Accompanying drawing explanation

Fig. 1 is the drying grate material layer thickness imaging system structural representation of one embodiment of the present invention, and wherein, 1 represents Laser material position meter, 2 represent The Cloud Terrace, and 3 represent pellet bed of material lower surface, and 4 represent drying grate chassis, and 5 represent drying grate transmission electricity Machine encoder, 6 represent drying grate material layer thickness curve；

Fig. 2 is the drying grate material layer thickness formation method flow chart of one embodiment of the present invention；

Fig. 3 is the drying grate chassis material thickness Cleaning Principle schematic diagram of one embodiment of the present invention；

Fig. 4 is that the laser material position meter of one embodiment of the present invention sets up rectangular coordinate system signal with The Cloud Terrace rotation combination Figure；

Fig. 5 is the rectangular coordinate system in space signal of the drying grate material layer thickness imaging system of one embodiment of the present invention Figure；

Fig. 6 be one embodiment of the present invention after x cycle detection, drying grate chassis be covered with material space right-angle sit Mark system schematic diagram；

Fig. 7 be one embodiment of the present invention after x+1 cycle detection, drying grate chassis is covered with the space right-angle of material Coordinate system schematic diagram；

Fig. 8 is the drying grate chassis cloth material 3D imaging schematic diagram of one embodiment of the present invention.

Detailed description of the invention

Below in conjunction with the accompanying drawings an embodiment of the present invention is described further.

In the embodiment of the present invention, as it is shown in figure 1, drying grate material layer thickness imaging system includes: The Cloud Terrace, laser material position meter (Ou Pu Tyke SSR-CP), motor encoder (ZKT-D100H45-51.2B-8-30E), data processing module and image-forming module (3D laser material level gauge imaging software, Siemens S7-300 and Siemens Win-CC), wherein, The Cloud Terrace is for fixing and rotary laser Level-sensing device, when being sampled by each sampled point, laser material position meter and drying grate chassis vertical line angulation are to data processing module；Swash Light level-sensing device is positioned at directly over drying grate chassis plate upper surface width midpoint；Laser material position meter is used for on-line measurement drying grate platform The thickness of each sampled point of pellet on car, and send to data processing module；Motor encoder is combed for on-line measurement chain The rotating speed of owner's driving motor, carries out on-line checking to the speed of drying grate, and sends to data processing module；Data process Module is for according to one-tenth-value thickness 1/10, velocity amplitude and the angle value gathered, it is thus achieved that and show on drying grate chassis any test point material thickness, Sampling period averagely expects averagely to expect cycle instantaneous doses thick, each, each cycle accumulation doses, chassis on thickness, integral trolley Upper current total stuff amount and the speed of service；Image-forming module is for being formed pellet thickness of feed layer on drying grate chassis by 3D software Three-dimensional dynamic image.

In the embodiment of the present invention, as in figure 2 it is shown, drying grate material layer thickness is by laser material level meter and 360 ° of rotary heads Coordinate setting composition；The built-in visible laser of laser material level meter aims at measured medium, built-in high-accuracy high-resolution time set Measure iraser two-way time between launch point and measured medium, if the spacing of launch point and measured medium is L, then Have:

$L=\frac{t*c}{2}---\left(1\right)$

Wherein, t represents two-way time between launch point and measured medium, and c represents the light velocity；

In the embodiment of the present invention, as in figure 2 it is shown, at an angle between laser material level meter and horizontal line time, corresponding drying grate chassis phase The material answering pellet at coordinate is thick, and formula is as follows:

H=h-(L+l) * sin α (2)

Wherein, α represents the angle between laser material level meter and horizontal line；L represents laser material level meter launch point and The Cloud Terrace rotating shaft The distance of centreline space, lectotype selection is constant after determining；H represents on cradle head device shaft centerline and drying grate chassis base plate Distance between surface, equipment is constant (5.5m) after installing；When H represents at an angle between laser material level meter and horizontal line, corresponding chain is combed At machine trolley corresponding coordinate, the material of pellet is thick；

In the embodiment of the present invention, using the formation method that drying grate material layer thickness imaging system is carried out, method flow diagram is such as Shown in Fig. 3, comprise the following steps:

Step 1, the number of sampled point in sampling period and each cycle is set, with drying grate chassis plate upper surface width Midpoint be initial point build rectangular coordinate system；

In the embodiment of the present invention, for realizing describing the material thickness of drying grate chassis material thickness detection particular location, this is logical 360 ° of rotary heads realize, and the rotation of The Cloud Terrace can represent (α is shown in Fig. 2) with α, rotate clouds when α is increased to 360 ° by 0 ° Platform completes the measurement in a cycle, and then α is again by 0 °, enters the next measurement cycle, and each is effective at one N test point (as shown in Figure 4) got by measurement cycle inner laser level-sensing device；In Fig. 4, N₁......N_nRepresent that The Cloud Terrace drives laser Level-sensing device proceed to effectively to measure first is to the n-th test point, and oral thermometer shows with in drying grate chassis plate upper surface width Point is the initial point of rectangular coordinate system, and β represents that The Cloud Terrace drives laser material level meter to proceed to the minimum critical angle effectively measured；

Step 2, by 0 ° rotary head, drive laser material position meter rotate arrive first test point measure drying grate chassis Upper pellet one-tenth-value thickness 1/10, and send the coordinate obtaining this test point to data processing module；

In the embodiment of the present invention, n test point correspondence provides concrete coordinate in rectangular coordinate system, such as N₅Represent The Cloud Terrace band The coordinate that dynamic laser material level meter proceeds to effectively measure in (that is: α >=β) corresponding rectangular coordinate system of the 5th detection afterwards is (H₅,-W₅)；

Because The Cloud Terrace is constant speed driven gas heat pump, and detect at effective range (β≤α≤β+γ) laser material level meter every time Interval time is the same, and namely The Cloud Terrace corner between adjacent two measuring points is the same, now sets The Cloud Terrace at adjacent two Corner between measuring point is δ, then have:

$\mathrm{\δ}=\frac{\mathrm{\γ}}{n-1}---\left(3\right)$

Wherein, γ represents within a cycle, and The Cloud Terrace drives laser material level meter to realize effectively detecting the angle turned over；

N can be obtained by formula (3)₅α be:

$\mathrm{\α}=4*\mathrm{\δ}=\frac{4*\mathrm{\γ}}{n-1}---\left(4\right)$

Can be obtained by Fig. 4:

$W_5=(L+l)*cos\mathrm{\α}=(L+l)*cos\frac{4*\mathrm{\γ}}{n-1}---\left(5\right)$

So N₅Coordinate (H₅,-W₅) it is:

$(h-(L+l)*sin\frac{4*\mathrm{\γ}}{n-1},-(L+l)*cos\frac{4*\mathrm{\γ}}{n-1})---\left(6\right)$

The above is as a example by the 5th test point, and that the most just seeks the seat of i-th (1 >=i >=n, i are natural number) individual test point Mark, i.e. puts N_iCoordinate (H_i,-W_i) it is:

$(h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1},-(L+l)*cos\frac{(i-1)*\mathrm{\γ}}{n-1})---\left(7\right)$

Step 3, The Cloud Terrace are rotated further to next test point, use laser material position measurement to measure this dot thickness value, and send extremely Data processing module obtains the coordinate of this test point；

Step 4, repeatedly execution step 3, until The Cloud Terrace completes the rotation of 360 °, all test points in i.e. completing this cycle Measure, all test point coordinate curves are connected, it is thus achieved that pellet thickness curve on drying grate chassis in this cycle；

In the embodiment of the present invention, combined with rotary head by laser material level meter, complete within a cycle drying grate N the detection that chassis material is thick, the most also provides concrete coordinate in rectangular coordinate system by the result that n time is detected, and is detected Result couple together with smoothed curve in the range of effective, thus can draw the thickness of feed layer of this cycle any point；

Step 5, the rotating speed of employing motor encoder on-line measurement drying grate main driving motor, and send to data process mould In block；

In the embodiment of the present invention, drying grate machine speed is by the rotary encoder on drying grate driving motor main shaft, Realize the detection to main driving motor actual revolution, then by gear ratio mechanically and the drive diameter driving drying grate, can To be the detection realizing true speed of service v of drying grate；

Step 6, according to the one-tenth-value thickness 1/10 of each test point in the cycle, it is thus achieved that in this cycle, the average bed of material of drying grate is thick Degree, further according to the meansigma methods of stream speed actual measurement in this cycle, it is thus achieved that the thick detection cycle instantaneous doses of current material；

In the embodiment of the present invention, release average thickness of feed layer H at a detection cycle drying grate according to formula (7)_PFor:

$H_P=\frac{H_1+H_2+---+H_n}{n}=\frac{1}{n}*\underset{i=1}{\overset{n}{\Σ}}h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1}---\left(8\right)$

Due to known chain comb machine trolley width W, it is possible to obtain the bed of material cross-sectional area S of current period:

S=H_P*W (9)

Bring formula (8) into formula (9), can obtain:

$S=W*\frac{1}{n}*\underset{i=1}{\overset{n}{\Σ}}h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1}---\left(10\right)$

Because the meansigma methods of stream speed actual measurement is v within the cycle of t_t, so in current material thick wink in detection cycle Time doses W_tFor:

$W_t=\mathrm{\ρ}*v_t*S=\mathrm{\ρ}*v_t*W*\frac{1}{n}*\underset{i=1}{\overset{n}{\Σ}}h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1}---\left(11\right)$

Wherein, ρ represents the bulk density (1.9t/m of pellet on chassis³), it is noted that at debugging stage suggestion experiment method Give experimental test data；

Step 7, obtain according to the average thickness of feed layer of each cycle drying grate and averagely expect thickness on integral trolley；

Current drying grate chassis material thickness overall average H can be calculated by formula (8)_PZFor:

$H_{Pz}=\frac{1}{x}\underset{j=1}{\overset{x}{\Σ}}{H}_{Pj}---\left(12\right)$

Wherein, x represents total number of cycles；

Step 8, according to averagely expecting pellet on thickness, drying grate chassis effective material containing length, chassis on integral trolley Bulk density and drying grate chassis width, it is thus achieved that current total stuff amount on chassis；Or obtain chassis according to each cycle doses cumulant Upper current total stuff amount；

In the embodiment of the present invention, the rectangular coordinate system data set up with rotary head according to laser material level meter, adding cochain Comb machine trolley material containing runs, and can set up rectangular coordinate system in space as it is shown in figure 5, wherein, L_jqPoint is that laser material level meter is vertical Lower section and the intersection point of drying grate chassis plate upper surface, be constant (1.5m)；L_jzPoint is that z axis leaves at the bottom of drying grate chassis with material The intersection point of the end line of plate, is constant (60m), the i.e. length of drying grate；t₁Curve is to have in first detection cycle of this system Effect is measured n point and is expected that position, in rectangular coordinate system in space, connects with smoothed curve and forms；X-axis: material on drying grate chassis Width, Y-axis: the thickness direction of material on drying grate chassis, Z axis: the length direction of material on drying grate chassis；

It is engraved in during due to drying grate chassis material containing and runs along Z axis, the speed v that actual measurement drying grate runs, if the inspection of this system The survey cycle is Δ t, can have accumulation doses W first detection cycle according to formula (11)_L1For:

$W_{L1}=\mathrm{\ρ}*v_{t1}*\mathrm{\Δ}t*S=\mathrm{\ρ}*v_{t1}*\mathrm{\Δ}t*W*\frac{1}{n}*\underset{i=1}{\overset{n}{\Σ}}h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1}---\left(13\right)$

Wherein, v_t1Represent the speed v surveying drying grate operation meansigma methods within the Δ t time；

In the embodiment of the present invention, because the drying grate speed of service is scalable, so speed v is likely in real-time change, for Raising certainty of measurement, line assumes speed v sampling 100 times within first detection period Δ t time that actual measurement drying grate runs, then Have:

$v_{t1}=\frac{1}{100}*\underset{j=1}{\overset{100}{\Σ}}{v}_j---\left(14\right)$

Formula (14) is substituted in formula (13), can have:

$W_{L1}=\frac{1}{100*n}*\mathrm{\ρ}*\underset{j=1}{\overset{100}{\Σ}}{v}_j*\mathrm{\Δ}t*W*\underset{i=1}{\overset{n}{\Σ}}h-(L+l)*sin\frac{(i-1)*\mathrm{\γ}}{n-1}---\left(15\right)$

This system is from first detection cycle, and have passed through the Δ t time is put into second detection cycle, at second The detection cycle similarly generates a t₂Curve and W_L2, t simultaneously₁Curve also along Z axis forward with actual measurement drying grate speed of service v Speed moves forward distance for L_Z1:

L_Z1=Δ t*v_t1 (16)

By that analogy, when through x all after date, t₁Curve movement has arrived the end (as shown in Figure 6) of drying grate chassis, That is:

$\underset{xi=1}{\overset{x}{\Σ}}{L}_{Zi}\≤L_{jz}-L_{jq}\≤\frac{x+1}{x}\underset{xi=1}{\overset{x}{\Σ}}{L}_{Zi}$

Because length L of the effective material containing of drying grate chassis_jz-L_jqIt is known constant (4.5m) with width W, so by formula (12) total stuff amount W on current drying grate chassis can be calculated_LZFor:

$W_{LZ}=\mathrm{\ρ}*(L_{jz}-L_{jq})*W*H_{Pz}=\mathrm{\ρ}*(L_{jz}-L_{jq})*W*\frac{1}{x}\underset{j=1}{\overset{x}{\Σ}}{H}_{Pj}---\left(17\right)$

In the embodiment of the present invention, it is also possible to calculated by each cycle doses cumulant formula (15):

$W_{LZ}=\underset{j=1}{\overset{x}{\Σ}}{W}_{Lj}---\left(18\right)$

It is put into (x+1)th the detection cycle through a Δ t time, similarly generates one in (x+1)th the detection cycle t_x+1Curve and W_Lx+1, t simultaneously₁Curve is by t₂Curve extrusion drying grate chassis effective material containing scope, will not in space coordinates Show again, and t₂Curved path walking is to the end of drying grate chassis, and in corresponding calculating, the parameter in first cycle is all by (x+1)th The relevant parameter in individual detection cycle substitutes, and drying grate ceaselessly runs, and parameter is also with replacement, as shown in Figure 7.

Because have been built up rectangular coordinate system in space in the range of the effective material containing of drying grate chassis, so to any point Material position can show.

Pellet thickness of feed layer on drying grate chassis is formed three-dimensional dynamic image by step 9, employing 3D software.

In the embodiment of the present invention, based on 3D laser material level gauge imaging software, by institute in the range of effective for drying grate chassis material containing There is a measuring point space coordinates, form the graphics on a material surface, at the graphics that drying grate is formed without material as drying grate The profile of chassis, thus forms the 3D rendering of material on drying grate chassis, and the speed that drying grate is run acts on each On measuring point coordinate, the 3D rendering thus forming a Real-time and Dynamic shows as shown in Figure 8 on screen.

In the embodiment of the present invention, screen can show simultaneously: current detection bed of material average thickness, click on screen Arbitrfary point can show that this some material is thick, show and averagely expect the highest position thick with minimum material of thickness, display, display on whole chassis Chassis currently goes up doses, the doses shown on whole chassis, accumulation doses and the operation time parameters of each operation section of drying grate Deng.

Claims (3)

1. a drying grate material layer thickness imaging system, it is characterised in that including: The Cloud Terrace, laser material position meter, motor encoder, Data processing module and image-forming module, wherein,

The Cloud Terrace: for fixing and rotary laser level-sensing device, laser material position meter and drying grate platform when each sampled point being sampled simultaneously Car vertical line angulation is to data processing module；

Laser material position meter: the thickness of the pellet bed of material on on-line measurement drying grate chassis, and send to data processing module In；

Motor encoder: for the rotating speed of on-line measurement drying grate main driving motor, the speed of drying grate is carried out on-line checking, And send to data processing module；

Data processing module: for according to one-tenth-value thickness 1/10, velocity amplitude and the angle value gathered, it is thus achieved that and show that drying grate chassis is taken up an official post Meaning sampled point material is thick, the sampling period averagely expects averagely to expect cycle instantaneous doses thick, each, each cycle on thickness, integral trolley Current total stuff amount and the speed of service on accumulation doses, chassis；

Image-forming module: for pellet thickness of feed layer on drying grate chassis being formed three-dimensional dynamic image by 3D software.

Drying grate material layer thickness imaging system the most according to claim 1, it is characterised in that described laser material position meter, It is positioned at directly over drying grate chassis plate upper surface width midpoint.

3. use the formation method that the drying grate material layer thickness imaging system described in claim 1 is carried out, it is characterised in that include Following steps:

Step 1, the number of sampled point in sampling period and each cycle is set, with in drying grate chassis plate upper surface width Point builds rectangular coordinate system for initial point；

Step 2, by 0 ° rotary head, drive laser material position meter to rotate and arrive the first test point and measure ball on drying grate chassis Nodulizing one-tenth-value thickness 1/10, and send the coordinate obtaining this test point to data processing module；

Step 3, The Cloud Terrace are rotated further to next test point, use laser material position measurement to measure this dot thickness value, and send to data Processing module obtains the coordinate of this test point；

Step 4, repeatedly execution step 3, until The Cloud Terrace completes the rotation of 360 °, the survey of all test points in i.e. completing this cycle Amount, connects test point coordinate curve in all effective ranges, it is thus achieved that in this cycle, on drying grate chassis, pellet is thick Write music line；

Step 5, the rotating speed of employing motor encoder on-line measurement drying grate main driving motor, and send to data processing module In；

Step 6, according to the one-tenth-value thickness 1/10 of test point in all effective ranges in the cycle, it is thus achieved that drying grate in this cycle Average thickness of feed layer, further according to the meansigma methods of stream speed actual measurement in this cycle, it is thus achieved that current detection cycle instantaneous doses；

Step 7, obtain according to the average thickness of feed layer of each cycle drying grate and averagely expect thickness on integral trolley；

Step 8, according to averagely expecting thickness, drying grate chassis effective material containing length, drying grate chassis width and platform on integral trolley The bulk density of pellet on car, it is thus achieved that current total stuff amount on chassis；Or it is fooled to obtain chassis according to each cycle doses cumulant Front total stuff amount；

Pellet thickness of feed layer on drying grate chassis is formed three-dimensional dynamic image by step 9, employing 3D software.