CN110697439B - Screw type material blanking device controller based on variable speed learning - Google Patents
Screw type material blanking device controller based on variable speed learning Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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- B65G65/00—Loading or unloading
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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Abstract
The invention discloses a variable speed learning-based screw material blanking device controller which comprises an input module, a storage module, an output module and a processing module, wherein the processing module further comprises a prediction module, a weight monitoring module, an error calculation module and a logic control module. Based on the single and accumulated blanking errors, the processing module controls the spiral conveyor through iterative learning, and learning factors of the single and accumulated blanking errors are dynamically adjusted based on the change of the blanking errors in the iterative process. According to the invention, based on the detection of the distance sensor and the weighing module, the material accumulation in the discharging bin is adjusted through the stirrer so as to ensure the stability of the material compactness; compared with the prior art, the invention ensures that the blanking control does not need to repeatedly trial and error parameters, can quickly obtain an iterative formula with better convergence performance, and effectively utilizes the blanking in the iterative learning process.
Description
The application is divisional application with application number 201710905892.3, application date 2017, 09 and 19, and invention title "screw material blanking device based on variable speed learning and controller thereof".
Technical Field
The invention relates to the field of quantitative batching, in particular to a controller of a screw type material blanking device based on variable speed learning.
Background
In industrial and agricultural manufacturing and commodity packaging, a large amount of powder materials, such as polypropylene, polystyrene, polyvinyl chloride, light methyl cellulose, polyacrylonitrile, epoxy resin powder coating and other chemical raw materials, quartz sand, cement and other building raw materials, washing powder and other daily chemical products, millet, soybean and other grain and bean agricultural products, or powder, slag and granular processed food, feed, chemical fertilizer, pesticide and other agricultural production materials, as well as powder and granular health care products, Chinese and Western medicaments, seasonings and the like need to be automatically quantitatively packaged or prepared by batching.
At present, many enterprises in China still adopt manual quantitative batching or packaging, so that on one hand, the labor intensity is high, the speed is low, and the economic benefit is poor; on the other hand, manual quantification of food, medicine and the like often cannot meet the sanitary requirements, toxic and harmful materials are used, and manual quantification is easy to cause harm to human bodies. Therefore, for the manufacturing enterprises, there is an urgent need to provide a multi-component automatic quantitative blanking device or apparatus with lower cost and higher rate and accuracy, which can meet the requirements of quantitative packaging of a large amount of materials or manufacturing of ingredients.
At present, two common methods, namely a positive displacement type and a weighing type, are adopted for automatic quantitative powder material feeding devices at home and abroad. The volumetric quantification is used for metering filling or feeding according to the volume of the material, the quantitative feeding is rapid, but the quality of the quantified material is changed by the change of the density of the material. In order to improve the blanking precision, various adjusting methods are provided, for example, in the chinese patent with application number 201320001933.3, the variable frequency speed regulation is adopted for the screw, the feeding speed is gradually reduced when the target value is approached, and the air drop value is reduced; in the Chinese patent with the application number of 201310234280.8, a large screw and a small screw are adopted in a three-speed variable-frequency feeding process of a soda packing machine for feeding materials in multiple stages; the Chinese patent with the application number of 200920248298.2 reduces the influence of the fall of the feeding by a method of first quick and then slow considering that the quantitative control is difficult to control when the fast feeding is carried out; the final blanking value of the non-weighing schemes can only be close to the expected value, and the accuracy is not high.
The weighing type quantitative feeding method is characterized in that the weighing type quantitative feeding method is used for metering, filling or feeding according to the set once amount of the material, the material needs to be weighed continuously in the feeding process, the feeding amount is controlled in a feedback mode according to the weighing result, and due to the fact that the weighing is greatly influenced by feeding impact and air lag materials, the feeding speed and the feeding precision face a lot of difficulties. In order to compensate the interference of the materials in the air to the metering precision, a technology of closing a valve in advance is adopted in many schemes, for example, a Chinese patent with application number 201410230888.8 divides a material proportioning and weighing process into three stages, and an iterative learning control mode is adopted in the last stage to calculate a closing advance control quantity, but in the scheme, a learning factor of iterative learning needs to be optimized through repeated trial and error and feedback observation, so long-time experiment and debugging are needed, the scheme can only improve the blanking precision after learning is completed, and the accumulated blanking precision in the learning process cannot be guaranteed.
Disclosure of Invention
The simple screw feeder belongs to the volumetric quantitative category, the volumetric quantitative filling measures the quantity of filling materials based on the volume, the structure is simple, the cost is low, but the stability and the precision of the quantitative filling speed depend on the stability of the materials according to the specific gravity, and the influence of physicochemical properties such as the loose degree of the materials, the uniform degree of particles, the hygroscopicity and the like is large.
In principle, volumetric dosing filling can now be divided into two types, controlling the flow rate or time of the filling material and dosing the material with the same dosing container. The former method usually adopts the method of controlling the vibration time of a vibrating feeder or controlling the rotation time of a spiral filling machine to realize quantitative filling; the latter is a quantitative filling machine using a measuring cup, a measuring cylinder or a plunger, etc. Both types have a common problem in that the apparent specific gravity of the material is as stable as possible.
Since the ordinary positive displacement type is conversion type in nature and cannot grasp the exact quality of the blanking like a weighing type, although a scheme combining weighing is provided later, the precision can be ensured only by depending on the extremely low feeding speed at the final stage of the blanking because no empty space amount prediction exists.
In order to predict the air quantity, the time for closing the conveying device in advance is difficult to determine at one time through an off-line experiment because the air blanking quantity in the blanking process is influenced by factors such as the closing speed of the conveying device, the fall between a blanking opening and a scale hopper material surface, the falling form flow rate of the material and the like. In iterative learning control, the learning factor is required to be repeatedly tried out, and the selection of the learning factor is optimized and adjusted by observing error change. Therefore, the conventional iterative learning control requires a long time of repeated experiments to obtain the optimized learning factor, which is not satisfactory for multi-component formulation experiments and rapid manufacturing of multi-component raw materials in the development process.
Therefore, the feeding bin and the measuring hopper of the blanking device are improved, and the air fall and the form change of the material are reduced; detecting the change process of the blanking error in iterative learning in real time and automatically adjusting the value of a learning factor according to the change process; meanwhile, the accumulated error is used as the controlled quantity in the iterative prediction, so that high-precision continuous blanking can be quickly realized, the screw conveyor is operated at a high speed in the control, and the problem that the common screw type blanking device is particularly slow in operation at the final stage is avoided.
The technical scheme of the invention is to provide a screw type material blanking device based on variable speed learning, which has the following structure: the device comprises a frame, a blanking bin, a spiral conveyor, a measuring hopper, a weighing module, a blanking valve, a mixing hopper, a controller, a storage bin and a feeding pump;
the spiral conveyor is positioned below the blanking bin, the blanking bin and the spiral conveyor are 2-6 groups,
the weighing hopper is arranged below the spiral conveyor and is arranged on a weighing module fixed on the frame, and the bottom opening of the weighing hopper is controlled by a blanking valve;
the mixing hopper is positioned below the blanking valve, and the bottom of the mixing hopper is provided with a push plate;
the controller reads the sensing data of the weighing module and performs variable rate-based iterative learning on the empty space amount of each blanking; dynamically adjusting learning factors of single blanking error and accumulated blanking error in iterative learning respectively by comparing the blanking errors of two adjacent times and the variation range of the blanking errors of three continuous times; based on the predicted amount of air, the controller adjusts the closing time and the running speed of the spiral conveyor; the controller controls the screw conveyors to act in sequence, after the formula amount blanking is finished, the blanking valve is opened, then the push plate is opened after the materials in the mixing hopper are detected to be accumulated to a set value, and the uniformly mixed materials are discharged.
Preferably, the feed pump is a screw-type feed pump, the outlet of the feed pipe at the rear end of the feed pump is provided with a spherical cap-shaped material spray head, and round small holes are distributed on the surface of the spherical cap-shaped material spray head; a distributor is arranged at the upper part of the metering hopper; the controller enables the material level of the discharging bin to be within a preset range by controlling the rotating speed of the feeding pump.
Preferably, the rotational speed of the feed pump is controlled according to the following formula:
wherein, V0 feedingA set maximum feeding speed, L is the current material level of the feed bin, LMAnd LmRespectively the preset highest and lowest feeding bin material positions.
Preferably, two distance sensors are installed on the side wall of the lower storage bin, and the two distance sensors respectively indicate a preset material level high point and a preset material level low point in the lower storage bin.
Preferably, the distributor is in a cone structure with a cone-shaped upper part and a flattened lower part, the upper part of the distributor is in an opening shape, and the lower part of the distributor is only provided with slope-shaped nozzles at two ends in the length direction; the measuring hopper is provided with staggered spherical crown-shaped bulges in the direction facing the nozzle.
Preferably, a stirrer is further installed on the side wall of the discharging bin, and the stirrer comprises a base, two support arms, a support arm rotating shaft, a claw rotating shaft and a claw which are connected in sequence.
Preferably, the bottom of the blanking bin is provided with a drawing plate; the screw conveyor comprises a screw box, a conveying screw, a connector and a motor, wherein a motor shell is connected with the screw box through the connector, the conveying screw in the screw box is connected with a motor shaft through a shaft sleeve, a feeding hole is formed in the upper surface of the screw box relative to the opening at the bottom of the discharging bin, and the other end, opposite to the motor, of the screw box is further connected with a vertically-placed discharging pipe.
Preferably, a material level sensor is installed on the side wall of the mixing hopper, a mixer is further arranged in the mixing hopper, the mixer adopts a spiral blade stirrer, and a material conveying pipe is further arranged below the push plate.
Preferably, the controller predicts the blanking air space amount by using the following formula:
Ak＝αk·Ak-1+βk·ek+γ·E，
wherein A isk-1And AkRespectively, two successive predicted values of the amount of air space, ekAnd E is respectively at the k-th timeThe blanking error and the accumulated blanking error, and the learning factors alpha, beta and gamma are dynamically adjusted according to the following modes respectively:
wherein k is greater than or equal to 1, sign () is a sign function, alpha iterates by taking initial values of 1.1 and 0.9 as initial values under the two conditions that the single blanking error e is greater than or equal to zero and less than zero, the initial value of beta is taken as 0.7, gamma is taken as a zero value in the first two times, and the value is taken according to the formula from k being equal to 3.
Preferably, the controller controls the operating speed of the screw conveyor in the following manner:
A. from a stopped state at a rate of mu amaxStarting at acceleration, when the speed reaches lambda.vRKeeping the speed unchanged;
B. when the closing time is up, the value is expressed in mu amaxThe acceleration starts to decelerate until stopping;
wherein, amaxRated maximum acceleration, v, of the screw conveyorRThe maximum speed is mu is an acceleration coefficient between 0.5 and 0.9, and the lambda is a speed coefficient between 0.85 and 1.0;
the closing time means that the current baiting weight read from the weighing module is equal to:
wherein Ws and Wa are respectively the predicted values of the current one-time material discharge amount and the empty space amount, d is the discharge rate of the screw conveyer when the screw rotates at the maximum speed, and t is the discharge rate of the screw conveyer when the screw rotates at the maximum speedsTo reduceFast stop time length: t is ts＝λ·vR/μ·amax。
The invention provides another technical solution, which is to provide a controller of a screw material blanking device based on variable speed learning, comprising an input module, a storage module, an output module and a processing module, wherein the processing module comprises a prediction module, a weight monitoring module, an error calculation module and a logic control module;
the input module receives the touch screen operation instruction and reads the sensing data of the weighing module,
the storage module is used for storing configuration data and processing procedure data,
the weight monitoring module compares the real-time weight value obtained by the input module with the target weight value compensated by the empty space predicted value and closes the screw conveyor at the bottom opening of the lower storage bin through the output module when the two weight values are equal,
the error calculation module calculates and updates the blanking error and the accumulated blanking error,
the prediction module carries out iterative update on the empty quantity predicted value according to the empty quantity predicted value of the last time, the blanking error of the time and the accumulated blanking error, respectively carries out dynamic adjustment on learning factors of single blanking error and accumulated blanking error in iteration by comparing the blanking errors of two adjacent times and the variation range of the blanking errors of three continuous times, and simultaneously respectively adjusts the learning factors of the predicted value of the last time according to the excessive or insufficient blanking,
the logic control module controls the actions of the spiral conveyors, the blanking valve at the bottom of the measuring hopper and the stirrer in the blanking bin in turn, and blanking is carried out according to the formula.
Compared with the prior art, the structure of the invention has the following advantages: according to the invention, the distance sensor and the manipulator-shaped stirrer are respectively adopted to detect and adjust the material accumulation form in the discharging bin, so that the stability of material compactness is ensured; the change of the air fall and the impact quantity of the materials is reduced by arranging the material distributor in the weighing hopper, so that the times required by iterative convergence can be reduced; through the automatic optimization and adjustment of the iterative learning factors, the offline experimental amount can be reduced, and the learning effect that the blanking error is small in overshoot and the adjustment time is short is quickly achieved. Therefore, the device can be applied to small-batch quick batching, and the materials in the iterative prediction process can be effectively utilized by controlling the accumulated error of the blanking, so that the waste of the materials is prevented; meanwhile, the screw rod can keep a high running speed in the blanking process, so that the blanking efficiency is improved.
Drawings
FIG. 1 is a composition structure diagram of a screw material blanking device based on variable speed learning;
FIG. 2 is a structural diagram of the shape of a screw material blanking device based on variable speed learning;
FIG. 3 is a schematic view of a material falling process;
FIG. 4 is a schematic view of a partial structure of a storage silo and a feed silo;
FIG. 5 is a schematic view of the material level in the feed bin;
FIG. 6 is a schematic view of the structure of a stirrer in the blanking bin;
FIG. 7 is a schematic view of the side wall structure of the distributor and the weighing hopper;
FIG. 8 is a schematic view of the layering of a multi-component material in a weighing hopper;
FIG. 9 is a motor speed regulation curve;
FIG. 10 is a graph of variation of single blanking errors of a fixed factor iterative learning material;
FIG. 11 is a schematic view of learning factor zones;
fig. 12 is a composition configuration diagram of a screw material discharge device controller based on speed change learning.
Wherein: 1. the device comprises a discharging bin 2, a screw conveyor 3, a weighing hopper 4, a weighing module 5, a discharging valve 6, a mixing hopper 7, a push plate 8, a conveying pipe 9, a controller 10, a storage bin 11, a feeding pump 12, a stirrer 13, a mixer 14, a material level sensor 15, a feeding pipe 16, a material spray head 17, a small hole 18, a distance sensor 19, a material level surface 20, a distributor 21, a nozzle 22, a protrusion 23 and a discharging pipe
30. Rack
91. Input module 92, processing module 93, storage module 94, output module 95, weight monitoring module 96, logic control module 97, prediction module 98, error calculation module
101. Drawing plate
121. Base 122, support arm 123, support arm rotating shaft 124, claw rotating shaft 125 and claw
201. Screw box 202, conveying screw 203, connector 204 and motor
Detailed Description
Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, but the present invention is not limited to only these embodiments. The invention is intended to cover alternatives, modifications, equivalents and alternatives which may be included within the spirit and scope of the invention.
In the following description of the preferred embodiments of the present invention, specific details are set forth in order to provide a thorough understanding of the present invention, and it will be apparent to those skilled in the art that the present invention may be practiced without these specific details.
The invention is described in more detail in the following paragraphs by way of example with reference to the accompanying drawings. It should be noted that the drawings are in simplified form and are not to precise scale, which is only used for convenience and clarity to assist in describing the embodiments of the present invention.
As shown in fig. 1 and 2, the screw material blanking device based on variable speed learning of the invention comprises a blanking bin 1, a screw conveyor 2, a metering hopper 3, a weighing module 4, a blanking valve 5, a mixing hopper 6 and a controller 9, wherein each group of blanking bin 1 corresponds to the screw conveyor 2, the types of commonly used components are 2-6, and the types of components can be increased according to requirements. Preferably, the lower bin 1 is in a bin-shaped structure consisting of a right trapezoid and a rectangle.
The bottom of the blanking bin 1 is provided with a drawing plate 101, the drawing plate is opened during blanking, and the material flows out from an opening at the bottom of the blanking bin. The screw conveyor 2 comprises a screw box 201, a conveying screw 202, a connector 203 and a motor 204, wherein the shell of the motor 204 is connected with the screw box 201 through the connector 203, and the conveying screw 202 in the screw box 201 is connected with the shaft of the motor 204 through a shaft sleeve; the upper surface of the screw box 201 is provided with a feeding hole corresponding to the opening at the bottom of the discharging bin 1, the other end of the screw box opposite to the motor is connected to a discharging pipe 23, and the discharging pipe 23 is fixed on the frame 30.
Preferably, the inner wall of the blanking pipe 23 can be provided with a spiral groove, and the wall of the spiral groove is discontinuously distributed at the tail section close to the bottom of the blanking pipe.
Preferably, a part consisting of two truncated cones, with opposite vertex and a shower nozzle at the bottom of the lower truncated cone, can be arranged in the blanking pipe 23 to make the material fall down uniformly.
As shown in fig. 1 and 2, during discharging, the controller 9 opens the drawing plate 101, the material falls into the screw box 201 of the screw conveyor 2 from the discharging bin 1, the controller 9 commands the motor 204 to start again, the conveying screw 202 rotates along with the motor, and the material is conveyed to the end discharging pipe 23 and falls into the weighing hopper 3 below from the discharging pipe 23.
The housing 30 serves as a frame of the apparatus for fixing and supporting the other respective components. The weighing module 4 is fixed on the frame 30, the weighing hopper 3 is movably buckled and pressed on the weighing module 4, the bottom of the weighing hopper 3 is provided with an opening, and the opening and the closing of the opening are controlled by the blanking valve 5. The weighing hopper 4 is positioned at the lower part of the blanking pipe 23, and a plurality of screw conveyors 2 are distributed in a radial direction relative to the centers of the blanking pipe 23 and the weighing hopper 4.
As shown in fig. 1 and 12, the controller 9 includes an input module 91, a storage module 93, an output module 94, and a processing module 92, wherein the processing module 92 includes a prediction module 97, a weight monitoring module 95, an error calculation module 98, and a logic control module 96.
The input module 91 receives an operation instruction and reads sensing data of the weighing module, the distance sensor and the like through the touch screen, and the storage module 93 is used for storing configuration data and processing process data. The weight monitoring module 95 compares the real-time weight value obtained by the input module 91 with the target weight value compensated by the empty space predicted value, and closes the screw conveyor 2 at the bottom opening of the blanking bin 1 through the output module 94 when the two weight values are equal, and the error calculation module 98 calculates and updates the blanking error and the accumulated blanking error. The prediction module 97 iteratively updates the empty space prediction value according to the last empty space prediction value, the blanking error and the accumulated blanking error, dynamically adjusts learning factors of the single blanking error and the accumulated blanking error in iteration respectively by comparing the two adjacent blanking errors and the variation range of the three continuous blanking errors, and simultaneously adjusts the learning factors of the last prediction value according to the excessive or insufficient blanking. The logic control module 98 controls the screw conveyors 2, the blanking valve at the bottom of the weighing hopper and other action parts including the action operation of the stirrer in the blanking bin, the push plate in the mixing hopper, the feeding pump and the like in turn, and blanking is carried out according to the formula.
The controller 9 adopts a touch type operation mode, a human-computer interface is arranged on a touch screen of the controller for setting the formula of the multi-component material and other parameters, and the formula comprises the total weight of one-time blanking and the percentage of each component in the weight. The controller 9 dynamically reads the current reading of the weighing module 4, and the blanking according to the formula is realized by controlling each action part.
The mixing hopper 6 is located below the blanking valve 5 and has a push plate 7 at its bottom, below which a feed pipe 8 is connected, which feeds the multicomponent mixture to a packaging bag or a production facility.
Preferably, a level sensor 14 is mounted on the side wall of the mixing hopper 6, and a mixer 15 is arranged inside the level sensor, wherein the mixer 15 is a spiral blade stirrer. The capacity of the mixing hopper 6 is 15 times of that of the weighing hopper 3, after a plurality of one-time baiting is completed, the controller 9 reads the state of the material level sensor 14, if the material level is detected to exceed a set threshold value, the mixer is controlled to rotate and stir, after a plurality of materials are uniformly mixed, under the control of the controller 9, the push plate 7 is opened, and the mixed materials are output from the material conveying pipe 8.
FIG. 3 is a diagram illustrating the change of impact of level drop and falling speed on a weighing hopper during the falling of a material at an initial speed v0Falling from the screw conveyor 2, the distance between the outlet of the screw conveyor 2 and the bottom of the measuring hopper 3 is H, and the distance is along with the material level H in the measuring hopper2Increase of (2), air drop h1It will be smaller.
The mass equivalent change of the material detected by the weighing module can be represented by the following formula:
wherein dm is the blanking mass (g/s) per unit time at the outlet of the screw conveyor 2 at the time t, v0The initial velocity of the material as it falls, the velocity of the material at Δ m as it falls into the weighing hopper, is determined from the velocity v over the time Δ t1Becomes 0.
As can be seen from the formula (1), the air fall h is followed1The impact of the material on the weighing hopper also changes, so that the weight change of the weighing hopper changes with time.
On the other hand, the blanking mass equivalent per unit time in the formula (1) is also influenced by the shape distribution of the materials in the blanking bin 1.
The invention discloses a simple screw type feeder, which belongs to the volumetric quantitative category, and the method adopts dynamic weighing to detect the falling amount of a material and predicts the empty amount of the material through iterative learning. In order to reduce the change of the falling rate of the material during the screw conveying, accelerate the learning convergence rate and inhibit the variable fluctuation range, the invention detects and adjusts the material accumulation form in the blanking bin through the distance sensor and the manipulator-shaped stirrer, so that the dynamic material arch is alternately formed and collapsed above the blanking port, and the material compactness and the stability of the blanking form are ensured.
As shown in FIG. 4, the discharging bin 1 continuously discharges materials, and when the material level in the bin is reduced to a certain value, the materials need to be supplemented. For this purpose, a storage bin 10 is arranged above the lower bin 1, and the material in the storage bin 10 is fed into the lower bin 1 through a feed pump 11 and a feed pipe 15. In order to uniformly feed material particles, a material spray nozzle 16 is arranged at an outlet at the tail end of the feeding pipe 15, the surface of the material spray nozzle 16 is in a spherical shape, round small holes 17 are distributed on the surface of the material spray nozzle, and the aperture of each small hole is optimized according to the granularity of the material. The feed pump 11 is a screw-type feed pump, and its operation is controlled by a controller.
As shown in fig. 5, the feed pump 11 is under the control of the controller,so that the material level of the top surface of the material in the blanking bin is kept at a preset value LTThe rotation speed is controlled by the following formula:
wherein, V0 feedingA set maximum feeding speed, L is the current material level of the feed bin, LMAnd LmAre respectively preset at LTThe highest and lowest levels nearby.
As shown in the combined drawings of FIGS. 4 and 6, the invention ensures the uniform distribution of the materials by the matching of the detection and the action of the distance sensor and the stirrer. As shown in fig. 4, the material level in the lower silo 1 is detected by two small-cone-angle distance sensors 18 installed on the side wall of the lower silo, and since the center D of the material spray head 16 and the feed opening B of the lower silo 1 are not generally on a vertical line, the two distance sensors 18 are arranged eccentrically, and the two high and low distance sensors P, Q are respectively pointed to a material level high point C and a material level low point a preset in the lower silo, wherein C, A and D, B are respectively on the same vertical line. In the blanking process of the blanking bin 1, along with the reduction of the material level 19, when the distance detected by the distance sensor Q is greater than the distance corresponding to QA, the controller commands the feeding pump 11 to act to start feeding to the blanking bin 1; then, the level is raised, and when the distance detected by the distance sensor P is smaller than the distance corresponding to the PC, the controller commands the feed pump 11 to act, and stops feeding to the lower silo 1.
Preferably, bases capable of adjusting the vertical inclination angle can be additionally arranged on the two distance sensors, so that the material layer distribution in the blanking bin can be detected with higher resolution.
Preferably, when two distance sensors are not enough to detect all material hardening due to the difference of the size and the shape of different blanking silos 1, the number of the distance sensors can be increased and the distance sensors can be pointed to different material layer heights.
As shown in fig. 6, the present invention improves the distribution of the materials by installing a stirrer 12 on the sidewall of the lower silo 1. The mixer 12 includes a base 121, two arms 122, an arm rotating shaft 123 connecting the two arms, a claw rotating shaft 124, and a claw 125, which are connected in sequence, wherein the base 121 also includes a rotating shaft.
In the blanking process, the distribution of the materials in the blanking bin is judged by respectively detecting the distance sensor and tracking the blanking rate in unit time, so that the material surface in the blanking bin keeps an approximate parabolic shape. As shown in fig. 4 and 6, the arrangement of the distance sensors is optimized so that when the materials are uniformly distributed, the distances between the materials detected by the distance sensors P and Q are within a certain proportion range. When the materials are locally hardened or stably arched, the reading of the distance sensor exceeds the range, and if the materials are detected in a certain distance, P and Q are not detected, the local abnormity occurs. Meanwhile, the feeding speed of each feeding bin is tracked in real time through the weighing module. When the distance sensor detects the abnormal state or finds that the fluctuation of the blanking amount in unit time exceeds a set threshold value, such as 5 percent, the controller commands the stirrer to act, and the claw of the stirrer turns spirally from the starting point to the low point region of the material level through the high point region of the material level, so that hardening or material arch which is formed occasionally is broken, and the material distribution is recovered to be uniform.
Through dynamic detection and control of material distribution, the materials in the lower hopper are activated, the flow of the materials is improved, and the fluctuation of material compactness is reduced, so that the stability of filling amount in unit time is ensured. And (4) stopping feeding and closing the drawing plate while the stirrer acts.
Referring to FIGS. 3 and 7, it can be seen from the formula (1) that the material falls in the air h1The impact of the material on the weighing hopper is changed, so that the weight increase value of the weighing module in unit time is changed. As shown in FIG. 7, in order to reduce the influence of the change of the air fall, the invention arranges a distributor 20 on the upper part of the weighing hopper 3, and the distributor 20 is an hourglass-shaped distributor with the upper part being a cone and the lower part being a flattened cone structure; wherein the upper part is in an opening shape and receives the materials in the blanking bin; the lower part is symmetrically provided with slope-shaped nozzles 21 only at both ends in the length direction. The measuring hopper 3 faces the nozzle 21, the preferred diameter of the convex part is 0.2-0.6 mm or 2-3 times of the diameter of the fallen materials.
Through the action of the distributor, the falling of the materials is divided into three stages, wherein the first stage is from an opening at the bottom of the blanking bin to the blanking pipe through the screw conveyor, the second stage is from the blanking pipe to the distributor, and the third stage is from the nozzle of the distributor to the material pile in the weighing hopper. In the third stage, due to the action of the staggered and distributed bulges on the distributor and the measuring hopper wall, the speed of the material particles impacting the material surface in the measuring hopper is greatly reduced, and the impact force difference from the distributor nozzle to the material pile surfaces with different heights in the measuring hopper is very small, so that conditions are provided for iterative prediction of the controller.
Fig. 8 shows the distribution of the material in the measuring hopper during the blanking of 4 components.
The traditional iterative learning adopts a fixed learning factor, and does not consider accumulated errors, for example, in the chinese patent with application number 201410230888.8, the iterative formula of the feeder closing lead is:
uk+1＝uk+q·ek。
the empty space amount in the blanking process is predicted by iterative learning of a fixed factor, and fig. 10 illustrates the change of a single blanking error of a material in the iterative process, wherein the abscissa is the blanking frequency and the ordinate is the relative error of each blanking. As can be seen from the figure, the blanking error corresponding to the figure 10a is over-adjusted and the convergence is too slow; the blanking overshoot corresponding to fig. 10b is proper, the convergence trend of the first few times is fast, but the stability of the rear section is slow, and the transition time is too long.
Because the learning factors need to be tried and found in the traditional iterative learning, better parameters can be obtained through repeated experiments and based on operation experience. Therefore, the invention predicts the blanking empty space by observing and analyzing the blanking iterative process and adopting the iterative learning of variable speed, dynamically adjusts the learning factors of the single blanking error and the accumulated blanking error in the iterative learning respectively by comparing the two adjacent blanking errors and the variation range of the three continuous blanking errors, and simultaneously adjusts the learning factors of the previous predicted amount respectively according to the excess or deficiency of the blanking.
Fig. 11 is a schematic view of a partition for adjusting the learning factor of a single blanking error according to the comparison between two adjacent blanking errors. As shown, the horizontal axis is x, and the curves a and d correspond to an envelope curve of x
Curves b and c then correspond to an envelope of lines
In order to ensure that the blanking error is close to zero rapidly and converges as soon as possible, the relative relationship between two adjacent blanking errors is divided into four regions, namely the four regions on the lower side of a curve a, between the curve a and a horizontal axis, between the curve c and the horizontal axis and on the upper side of the curve c.
Based on the variable rate iterative learning, the controller dynamically predicts the empty space amount of the falling of the material, and as shown in the combined graph 9, the controller performs the blanking control by adopting the following steps:
(1) determining the primary blanking amount Ws of each component according to the primary amount and the proportion of each formula, and assigning an initial value 0 to the accumulated blanking error E of each component; setting the current component as a first component;
(2) feeding the current component, reading the sensor value of the weighing module by the controller, recording the initial weight G0 of the weighing hopper, starting the screw conveyer and feeding the weighing hopper with mu amaxAcceleration, when the speed reaches vH＝λ·vRKeeping the speed unchanged;
wherein, amaxRated maximum acceleration, v, of the screw conveyorRThe maximum speed is mu is an acceleration coefficient between 0.5 and 0.9, and the lambda is a speed coefficient between 0.85 and 1.0;
(3) when the weight of the measuring hopper is detected to reach (G0+ Ws-Wa-0.5. lambda. d. t)s) At the beginning, the screw conveyor is closed and the speed is controlled to be mu amaxThe acceleration starts to decelerate until stopping;
wherein d is the discharge of the screw conveyor when the screw is running at maximum speedRate, tsIs from the moment of starting deceleration t2Time t from start to stop3Length of time between: t is ts＝λ·vR/μ·amax；
(4) Waiting for the materials to completely fall to the weighing hopper, reading a sensing value of the weighing module, obtaining the current actual blanking amount Wr, and calculating the blanking error e to be Wr-Ws;
(5) and updating the accumulated blanking error E' ═ E + E, and calculating the predicted value of the air space quantity:
Wa′＝αk·Wa+βk·ek+γ·E，
wherein, the learning factors alpha, beta and gamma are dynamically adjusted according to the following modes respectively:
wherein k is more than or equal to 1, sign () is a sign function, alpha is iterated by taking an initial value of 1.1 and 0.9 as initial values under the two conditions that the single blanking error e is more than or equal to zero and less than zero, the initial value of beta is taken as 0.7, gamma is taken as a zero value in the first two times and is taken as the value from k being equal to 3 according to the formula;
(6) iterating, let E ═ E ', Wa ═ Wa', Ek-2＝ek-1，ek-1＝ekPreparing for next blanking;
(7) replacing the blanking components, if the blanking of all the components is finished, turning to the next step, otherwise, turning to the step 2;
(8) opening a blanking valve to enable the materials with the primary formula amount consisting of the multi-component materials to fall into a mixing hopper, reading the state of a material level sensor, controlling a mixer to rotate and stir if the detected material level exceeds a set threshold value, opening a push plate after uniformly mixing the multi-component materials, and outputting the mixed materials from a material conveying pipe;
(9) if the preset blanking batch is finished, finishing blanking; otherwise, the component is set as the first component, and step 2 is carried out.
During the blanking, the controller also detects the material pile shape in the blanking bin in real time through the calculation and analysis of signals of the distance sensor and the weighing module, and commands the mechanical hand-shaped stirrer to act in time if abnormal blanking is found, so that the integral uniform distribution during the blanking is ensured.
Before continuous blanking, the following operations are carried out:
(i) calibrating the weighing module and the distance sensor through an off-line experiment;
(ii) setting parameters including a time length Tb and the repetition times of calibration of a primary quantity, a formula table, a batch value, a blanking rate and a stable weighing delay Td through a touch screen of a controller;
(iii) carrying out blanking calibration on the components: starting to operate the screw conveyor for a certain time Tb according to or by referring to a speed regulation curve shown in FIG. 9 from the time 0, and respectively reading and recording the weight values Wcb and Wdb of the weighing modules at the time of closing the screw conveyor Tb and the time of Tb + Td after weighing is stable; repeating the steps for several times, calculating the blanking rate d ═ AVG [ Wdb/(Tb-t)s)]And/λ, the initial value Wa of the air volume is AVG (Wdb-Wcb).
The device of the invention is used for blanking, the learning factor is not required to be adjusted by depending on manual experience, and the controller can automatically optimize the blanking error according to the change of the blanking error, so that an iterative formula with better convergence performance can be quickly obtained, and the device is suitable for occasions needing quick adaptation, such as multi-component formula experiments, quick manufacturing of multi-component raw materials and the like in the research and development process. Moreover, compared with other iterative learning, the device does not need to discard materials in the iterative learning process, but can be directly applied to subsequent production, so that the device is also suitable for small-batch quick batching and blanking.
The above-described embodiments do not limit the scope of the present invention. Any modification, equivalent replacement, and improvement made within the spirit and principle of the above-described embodiments should be included in the protection scope of the technical solution.
Claims (6)
1. The screw material blanking device controller based on variable speed learning comprises an input module, a storage module, an output module and a processing module, wherein the processing module comprises a prediction module, a weight monitoring module, an error calculation module and a logic control module;
the input module receives the touch screen operation instruction and reads the sensing data of the weighing module,
the storage module is used for storing configuration data and processing procedure data,
the weight monitoring module compares the real-time weight value obtained by the input module with the target weight value compensated by the empty space predicted value and closes the screw conveyor at the bottom opening of the lower storage bin through the output module when the two weight values are equal,
the error calculation module calculates and updates the blanking error and the accumulated blanking error,
the prediction module carries out iterative updating on the empty volume prediction value according to the last empty volume prediction value, the blanking error and the accumulated blanking error, dynamically adjusts learning factors of a single blanking error and an accumulated blanking error in iteration respectively by comparing two adjacent blanking errors and the variation range of three continuous blanking errors, and simultaneously adjusts the learning factors of the last prediction value respectively according to the excessive or insufficient blanking:
Wa′＝αk·Wa+βk·ek+γ·E，
wherein Wa and Wa' are respectively the predicted values of the air space amount twice continuously, k is subscript, E and E are respectively the blanking error and accumulated blanking error of the time, learning factors alpha, beta and gamma are respectively dynamically adjusted in the following way,
wherein k is more than or equal to 1, sign () is a sign function, alpha is iterated by respectively taking an initial value of 1.1 and an initial value of 0.9 as initial values under the two conditions that the single blanking error e is more than or equal to zero and less than zero, the initial value of beta is taken as 0.7, gamma is taken as a zero value in the first two times and is taken as the value from k to 3 according to the formula,
the logic control module controls the screw conveyors to act in turn.
2. The screw material discharge device controller based on variable rate learning of claim 1 wherein the logic control module controls the discharge valve at the bottom of the weighing hopper to open after completing a batch discharge.
3. The screw material discharge device controller based on variable speed learning of claim 1, wherein after detecting that the material in the mixing hopper is accumulated to a set value, the logic control module controls the push plate to open to discharge the uniformly mixed material.
4. The screw material discharge device controller based on rate of change learning of claim 1 wherein said controller commands a stirrer to operate after a fluctuation of discharge per unit time exceeds a set threshold.
5. The variable rate learning-based screw material discharge device controller of claim 1 wherein the controller commands a stirrer to operate after a distance sensor reading is outside a proportional range.
6. The screw material blanking device controller based on variable speed learning of claim 1, wherein the controller controls the rotational speed of the feed pump to keep the material level in the blanking bin within a preset range;
the rotating speed of the feeding pump is controlled according to the following formula:
wherein, V0 feedingA set maximum feeding speed, L is the current material level of the feed bin, LMAnd LmRespectively the preset highest and lowest feeding bin material positions.
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| CN113666137A (en) * | 2019-09-30 | 2021-11-19 | 北京信谊乾诚科技有限公司 | Conveying device for conveying viscous materials |
| KR20220049407A (en) | 2020-10-14 | 2022-04-21 | 삼성전자주식회사 | Display apparatus and control method thereof |
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| CN114778246B (en) * | 2022-04-19 | 2022-11-01 | 山东金力王实业有限公司 | Kaolin preparation device based on Internet of things and control method |
| CN116991109B (en) * | 2023-09-25 | 2023-12-15 | 江苏博涛智能热工股份有限公司 | Feeding equipment control system based on embedded type |
| CN117485639B (en) * | 2024-01-02 | 2024-04-12 | 河南云瀚实业有限公司 | Intelligent metering and packaging method and device |
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