CN111025064A - Method and system for realizing detection of working state of ball mill by non-contact speed measurement - Google Patents
Method and system for realizing detection of working state of ball mill by non-contact speed measurement Download PDFInfo
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- G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
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- G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
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Abstract
The invention discloses a method and a system for realizing the detection of the working state of a ball mill by non-contact speed measurement, wherein the method comprises the following steps: the external surface of the ball mill cylinder is provided with a mirror reflection unit, a light source and a photosensitive element which correspond to the motion trail of the reflection unit are arranged outside the ball mill cylinder, and the photosensitive element can receive the light signal of the light source reflected by the reflection unit and is converted into a photosensitive element output voltage through photoelectric conversion; detecting the total number of rising edges of the output voltage of the photosensitive element in unit time, and calculating the rotating speed, the rotating period and the rotating angular speed of the ball mill rotating drum according to the total number of the rising edges; according to the size relation between the actual value and the normal value of any parameter of the rotating speed, the rotating period and the rotating angular speed of the ball mill during working, the current working state of the ball mill is determined, and corresponding processing is carried out when the ball mill is in an abnormal working state. The automatic, real-time and accurate monitoring of the working state of the ball mill can be realized.
Description
Technical Field
The invention relates to the field of detection of the working state of a ball mill, in particular to a method and a system for realizing detection of the working state of the ball mill by using non-contact speed measurement.
Background
In the working environment of the existing ball mill equipment, in order to improve the production efficiency and reduce the cost of replacing the lining plate on the inner wall of the ball mill, the production process needs to be controlled by adjusting the rotating speed of the ball mill according to the working state of the ball mill. The working state of the ball mill can be divided into low rotating speed (angular speed omega < omega)1) State, Normal rotational speed (angular velocity ω)1≤ω≤ω2) State and high rotational speed (angular speed ω > ω2) Status. Fig. 1 to 3 are schematic views of three operating states of the ball mill, including the start and landing points of the grinding media balls (hereinafter referred to as media balls 10) and the material line 30 formed by the sliding material 20. According to physical knowledge, on the premise that the volume of materials in the ball mill is fixed, the positions of the drop point of the medium ball and the material line are both functions of the rotating speed omega of the ball mill. In actual production, enterprises expect that the ball mill is always in a normal rotating speed state, in the normal state, the media ball has a high initial throwing point, the impact is generated below the vicinity of a material line, namely the impact is mainly performed on the material, the kinetic energy is high, and the grinding effect is best. When the ball mill is in a low-rotating-speed state, the impact is generated at a far position below the material line, and at the moment, the media ball is very low in the throwing point or mainly rolls in the material, so that the material cannot be fully ground, and the production efficiency is low. When the ball mill is in a high-rotating-speed state, the media balls are higher in throwing point, and impact occurs above the material line, namely the grinding media balls mainly impact on the lining plate, so that the grinding efficiency is low, and more importantly, the lining plate can be damaged.
At present, the working state of the domestic ball mill is mainly monitored by monitoring by workers, and the working state is distinguished by different sound colors of the medium balls which are impacted under different working states. The method not only consumes manpower, but also can not realize all-weather automatic real-time monitoring.
Disclosure of Invention
Based on the problems existing in the prior art, the invention aims to provide a method and a system for realizing the detection of the working state of a ball mill by using non-contact speed measurement, which can solve the problems that the working state of the ball mill is monitored by workers, the labor is consumed, and the all-weather real-time monitoring cannot be realized.
The purpose of the invention is realized by the following technical scheme:
the embodiment of the invention provides a method for realizing the detection of the working state of a ball mill by using non-contact speed measurement, which comprises the following steps:
the outer surface of a cylinder body of the ball mill is fixedly provided with a mirror reflection unit, and the mirror reflection unit can synchronously move around the axis of the rotary cylinder along with the rotary cylinder; a light source and a photosensitive element corresponding to the motion track of the reflection unit are arranged outside a cylinder of the ball mill, the light emitted by the light source can be reflected to the photosensitive element through a mirror reflection unit on the cylinder, and the photosensitive element can receive the light signal of the light source reflected by the reflection unit and can convert the light signal corresponding to the rotation speed information of the ball mill into a photosensitive element output voltage through photoelectric conversion;
detecting and obtaining the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculating and obtaining the rotating speed, the rotating angular speed and the rotating period of a rotating drum of the ball mill during working according to the total number of the rising edges of the output voltage of the photosensitive element in unit time;
and determining the current working state of the detected ball mill according to the calculated magnitude relation between the actual value and the normal value of any parameter of the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working, and performing corresponding processing when the current working state is an abnormal working state.
The embodiment of the invention also provides a system for realizing the detection of the working state of the ball mill by using non-contact velocity measurement, which is used for realizing the method and comprises the following steps:
the device comprises a mirror reflection unit, a light source, a photosensitive element, a sampling processing device, a detection processing device and an abnormal state processing device; wherein the content of the first and second substances,
the mirror reflection unit is fixedly arranged on the outer surface of the rotary drum of the detected ball mill and can synchronously move around the axis of the rotary drum along with the rotary drum;
the light source and the photosensitive element are respectively arranged at the positions corresponding to the motion tracks of the reflection unit outside the ball mill, the light emitted by the light source can be reflected to the photosensitive element through the mirror reflection unit on the cylinder, and the photosensitive element can receive the light signals of the light source reflected by the mirror reflection unit and can convert the light signals corresponding to the rotation speed information of the ball mill into photosensitive element output voltage through photoelectric conversion;
the sampling processing device is respectively electrically connected with the voltage output end of the photosensitive element and the detection processing device, can sample the output voltage of the photosensitive element, detects the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculates the rotating speed, the rotating angular speed and the rotating period of the rotary drum of the ball mill by using the total number of the rising edges of the output voltage of the photosensitive element;
the detection processing device is electrically connected with the abnormal state processing device and can determine the current working state of the detected ball mill according to the magnitude relation between the actual value and the normal value of any parameter in the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working;
and the abnormal state processing device can perform corresponding processing when the current working state is the abnormal working state according to the current working state of the detected ball mill determined by the detection processing device.
According to the technical scheme provided by the invention, the method and the system for realizing the detection of the working state of the ball mill by using non-contact velocity measurement have the beneficial effects that:
through set up the specular reflection unit on the rotary drum at the ball mill to set up light source and light sensitive element in the rotary drum external position that reflection unit movement track corresponds, realize that non-contact photoelectric conversion tests the speed to the ball mill, through carrying out accurate speed measurement to ball mill actual operating condition under the condition that does not influence production, and then detect out the current operating condition of ball mill, in time handle abnormal operating condition, by manual speed governing if reporting to the police, or automatic speed governing etc.. Compared with the mode of manually monitoring the working state of the ball mill, the automatic detection can be realized, and the real-time and accurate detection can also be realized.
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In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on the drawings without creative efforts.
FIG. 1 is a schematic diagram of a low-speed operation state of a ball mill according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a ball mill operating at a normal rotation speed according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a high-speed operation state of a ball mill according to an embodiment of the present invention;
FIG. 4 is a flowchart of a method for detecting the operating state of a ball mill by non-contact velocity measurement according to an embodiment of the present invention;
fig. 5 is a schematic diagram of a system configuration for implementing the method according to the embodiment of the present invention;
fig. 6 is a schematic diagram of another system configuration for implementing the method according to the embodiment of the present invention;
fig. 7 is a schematic diagram of waveforms of output voltages of the photosensitive elements in a critical operating state of a ball mill at normal rotation speed and low rotation speed according to an embodiment of the present invention;
fig. 8 is a schematic diagram of waveforms of output voltages of the photosensitive elements in a critical operating state of a normal rotation speed and a high rotation speed of the ball mill according to the embodiment of the present invention;
the parts corresponding to each mark in the figure are: 1-a specular reflection unit; 2-a light source; 3-a photosensitive element; 4-a sampling processing device; 5-detecting and processing the device; 6-abnormal state processing means; 7-the outer surface of the bowl of the ball mill; 8-a holder for the light source and the light sensitive element; a-a protective cover for the light source and the light sensitive element; b-optical path.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the specific contents of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention. Details which are not described in detail in the embodiments of the invention belong to the prior art which is known to the person skilled in the art.
As shown in fig. 4, the method for detecting the working state of the ball mill by using non-contact velocity measurement according to the present invention can accurately and rapidly detect the working state of the ball mill by using a non-contact photoelectric velocity measurement method, and further alarm and/or regulate the rotation speed of the ball mill to make the ball mill in a normal rotation speed working state, and comprises:
the outer surface of a cylinder body of the ball mill is fixedly provided with a mirror reflection unit, and the mirror reflection unit can synchronously move around the axis of the rotary cylinder along with the rotary cylinder; a light source and a photosensitive element corresponding to the motion track of the reflection unit are arranged outside a cylinder of the ball mill, the light emitted by the light source can be reflected to the photosensitive element through a mirror reflection unit on the cylinder, and the photosensitive element can receive the light signal of the light source reflected by the reflection unit and can convert the light signal corresponding to the rotation speed information of the ball mill into a photosensitive element output voltage through photoelectric conversion;
detecting and obtaining the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculating and obtaining the rotating speed, the rotating angular speed and the rotating period of a rotating drum of the ball mill during working according to the total number of the rising edges of the output voltage of the photosensitive element in unit time;
and determining the current working state of the detected ball mill according to the calculated magnitude relation between the actual value and the normal value of any parameter of the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working, and performing corresponding processing when the current working state is an abnormal working state.
In the method, a mirror reflection unit is fixedly arranged on the outer surface of a cylinder of the ball mill, and the reflection unit can synchronously move along with the cylinder, and comprises the following steps:
fixedly arranging a mirror reflection unit (see figure 5) at any position of the arc-shaped outer surface of the rotary drum of the ball mill, wherein the mirror reflection unit can synchronously move around the axis of the rotary drum along with the arc-shaped outer surface of the rotary drum;
alternatively, a specular reflection unit (see fig. 6) is fixedly provided at any position of either side surface of the bowl of the ball mill, which is deviated from the axis center, and the magnet is capable of moving synchronously around the axis center of the bowl with the side outer surface of the rotating bowl.
Preferably, both the light source and the photosensitive element can be provided with protective covers, so that the light source can emit light with stronger directivity, and the photosensitive element can better receive the emitted light. Preferably, the light source itself may sample a light source with strong directivity.
In the above method, the step of arranging a light source and a photosensitive element corresponding to the movement locus of the specular reflection unit outside the cylinder of the ball mill, wherein the light emitted by the light source can be reflected to the photosensitive element by the specular reflection unit on the cylinder, and the photosensitive element can receive the optical signal of the light source reflected by the specular reflection unit and convert the optical signal corresponding to the information of the rotation speed of the ball mill into the output voltage of the photosensitive element through photoelectric conversion includes:
the receiving signals of the photosensitive elements are as follows: x (t) s (t- τ) + n (t); wherein x (t) is the received signal of the photosensitive element at time t; tau is the time delay of light in the process of propagation; s (t-tau) is a receiving signal of the photosensitive element when the light source irradiates the mirror reflection unit or the outer surface of the ball mill cylinder to generate reflection; n (t) is noise representing the sum of a signal generated by light source interference in the environment and thermal noise in the circuit; when the light source irradiates the specular reflection unit at the time t, s (t-tau) takes a larger value; when the light source irradiates the ball mill cylinder at the moment t, s (t-tau) takes a small value, and the output voltage of the photosensitive element is a periodic voltage waveform with a rising edge. Thus, the photosensor can output an output voltage waveform having a rising edge periodicity as the bowl of the ball mill rotates.
Since the light source is of higher intensity than the ambient light, the noise is very small and negligible relative to the theoretical output of the photosensor. Meanwhile, when light irradiates on the specular reflection unit, specular reflection and no diffuse reflection are generated, and when light irradiates on the outer surface of the ball mill cylinder, due to the fact that the outer surface of the cylinder is rough, diffuse reflection and no specular reflection are generated. Meanwhile, for the same light source, the intensity of the reflected light of the specular reflection is far greater than that of the reflected light of the diffuse reflection. Therefore, when the light source is irradiated to the reflection unit at time t, s (t- τ) takes a large value; when the light source irradiates the ball mill cylinder at the time t, s (t-tau) is taken to be a smaller value. The waveforms of the output electric pulses of the photosensor are schematically shown in fig. 7 and 8, wherein fig. 7 illustrates the operation states of the bowl of the ball mill at normal and low rotation speeds (n ═ n)1,ω＝ω1,Tω＝T1) The waveform of the output voltage of the photosensitive element in the critical working state of (1); FIG. 8 shows the operation of the bowl of the ball mill at normal and high rotational speeds (n ═ n)2,ω＝ω2,Tω＝T2) The waveform of the output voltage of the light sensitive element in the critical operating state.
In the above method, the total number of rising edges of the output voltage of the photosensor in a unit time is detected as:
at a set sampling period TsSampling the output voltage of the photosensitive element, and recording and obtaining the total number N of rising edges of the output voltage of the photosensitive element in unit time T from a sampling result;
rotational speed of the bowl mill bowl
Wherein T represents a unit time, and N represents a total number of rising edges of the output voltage of the photosensitive element in the unit time;
angular speed of rotation of the bowl mill bowl
Wherein n represents the rotational speed of the drum,t represents a unit time, N represents the total number of rising edges of the output voltage of the photosensitive element in the unit time;
rotation period of the bowl mill bowl
Where N denotes the rotation speed, T denotes the unit time, and N denotes the total number of rising edges of the output voltage of the light sensitive element in the unit time.
In the above method, the rising edge of the output voltage of the light sensitive element is determined by:
if the voltage difference value delta of the electric pulse of the ith sampling point and the last sampling point is calculatediGreater than a predetermined voltage threshold delta0I.e. deltai≥δ0And then confirming that the sampling point is the rising edge of the output voltage of the photosensitive element, and the serial number of the sampling point corresponding to the rising edge of the output voltage of the photosensitive element is i.
In the method, determining the current working state of the detected ball mill according to the calculated magnitude relation between the actual value and the normal value of any parameter of the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working, and performing corresponding processing when the current working state is an abnormal working state comprises the following steps:
(1) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotating speed of the rotating drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
the rotating speed range of the rotary drum in the normal rotating speed working state of the ball mill to be detected is set as n in advance1≤n≤n2Dividing the rotating speed of the revolving drum of the ball mill into three sets according to different working states:
Xhigh speed＝{n|n＞n2}
XIs normal＝{n|n1≤n≤n2}
XLow speed＝{n|n＜n1}；
Calculating said actual measurements during productionThe rotation speed n of the revolving drum of the ball mill is equal to XIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the rotation speed n belongs to XHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the rotation speed n belongs to XLow speedDetermining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed;
(2) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotating angular speed of the revolving drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
the rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected is set to omega in advance1≤ω≤ω2Dividing the rotation angular speed of the revolving drum of the ball mill into three sets according to different working states:
Yhigh speed＝{ω|ω＞ω2}
YIs normal＝{ω|ω1≤ω≤ω2}
YLow speed＝{ω|ω＜ω1}；
Calculating the actually measured rotation angular speed omega of the revolving drum of the ball mill in the production process, and if the rotation angular speed omega belongs to YIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the angular velocity ω ∈ YHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the angular velocity ω ∈ YLow speedDetermining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed;
(3) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotation period of the rotary drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
examined in advanceT within the range of the rotation period of the rotary drum for measuring the normal rotation speed working state of the ball mill1≤Tω≤T2Dividing the rotation period of the revolving drum of the ball mill into three sets according to different working states:
Zhigh speed＝{Tω|Tω＜T1}
ZIs normal＝{Tω|T1≤Tω≤T2}
ZLow speed＝{Tω|Tω＞T2}；
Calculating the rotation period T of the revolving drum of the ball mill actually measured in the production processωIf the period of rotation Tω∈ZIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the period of rotation Tω∈ZHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the period of rotation Tω∈ZLow speedAnd determining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed.
In the method, the rotating speed range of the rotary drum in the detected normal rotating speed working state of the ball mill is set as n in advance1≤n≤n2The rotating speed range of the rotary drum in the normal rotating speed working state of the ball mill to be detected is set as n according to the prior knowledge accumulated in the actual production process1≤n≤n2；
The rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected is set to omega in advance1≤ω≤ω2Setting the rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected as omega according to the prior knowledge accumulated in the actual production process1≤ω≤ω2；
Setting the range of the rotation period of the rotary drum in the normal rotation speed working state of the ball mill to be detected as T in advance1≤Tω≤T2The detection is carried out according to the prior knowledge accumulated in the actual production processThe range of the rotation period of the rotary drum in the normal rotation speed working state of the ball mill is set as T1≤Tω≤T2。
Referring to fig. 5 and 6, an embodiment of the present invention further provides a system for detecting an operating state of a ball mill by using non-contact velocity measurement, so as to implement the method described above, including:
the device comprises a mirror reflection unit, a light source, a photosensitive element, a sampling processing device, a detection processing device and an abnormal state processing device; wherein the content of the first and second substances,
the mirror reflection unit is fixedly arranged on the outer surface of the rotary drum of the detected ball mill and can synchronously move around the axis of the rotary drum along with the rotary drum;
the light source and the photosensitive element are respectively arranged at the positions corresponding to the motion tracks of the reflection unit outside the ball mill, the light emitted by the light source can be reflected to the photosensitive element through the mirror reflection unit on the cylinder, and the photosensitive element can receive the light signals of the light source reflected by the mirror reflection unit and can convert the light signals corresponding to the rotation speed information of the ball mill into photosensitive element output voltage through photoelectric conversion;
the sampling processing device is respectively electrically connected with the voltage output end of the photosensitive element and the detection processing device, can sample the output voltage of the photosensitive element, detects the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculates the rotating speed, the rotating angular speed and the rotating period of the rotary drum of the ball mill by using the total number of the rising edges of the output voltage of the photosensitive element;
the detection processing device is electrically connected with the abnormal state processing device and can determine the current working state of the detected ball mill according to the magnitude relation between the actual value and the normal value of any parameter in the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working;
and the abnormal state processing device can perform corresponding processing when the current working state is the abnormal working state according to the current working state of the detected ball mill determined by the detection processing device.
Preferably, both the light source and the photosensitive element can be provided with protective covers, so that the light source can emit light with stronger directivity, and the photosensitive element can better receive the emitted light. Preferably, the light source itself may sample a light source with strong directivity.
In the above system, the sampling processing device includes: the device comprises a sampling device, a counting device and a signal processing device;
wherein, the sampling device is respectively electrically connected with the counting device and the signal processing device and can perform sampling within a preset sampling period TsSampling the output voltage of the photosensitive element, and outputting the amplitude of the output voltage of the photosensitive element at each sampling point;
the counting device can calculate the total number of the rising edges of the output voltage of the photosensitive element in unit time T according to the amplitude of the output electric pulse of the photosensitive element at each sampling point output by the sampling device after sampling;
the signal processing device can obtain the total number of the rising edges of the output voltage of the photosensitive element in the unit time T through a first formula
Calculating the rotating speed N of the revolving drum of the ball mill, wherein in the first formula, T represents unit time, and N represents the total number of rising edges of the output voltage of the photosensitive element in unit time; by a second formula
Calculating the rotation angular speed omega of the ball mill, wherein in the second formula, N represents the rotation speed of the ball mill revolving drum, T represents unit time, and N represents the total number of rising edges of the output voltage of the photosensitive element in unit time; and by a third formula
Calculating to obtain the rotation period T of the ball millωIn the third formula, N represents the rotation speed of the bowl of the ball mill, T represents a unit of time, and N represents a unitThe total number of rising edges of the photosensor output voltage over time.
In the system, the abnormal state processing device is internally provided with an alarm circuit and/or an automatic control circuit, the component circuit can alarm the abnormal working state, and the automatic control circuit can adjust the rotating speed of the ball mill in the abnormal working state.
The method and the system measure the rotating speed of the ball mill cylinder in a non-contact photoelectric speed measurement mode, further calculate the rotating angular speed and the rotating period of the rotating cylinder, calculate the current working state of the ball mill by utilizing any parameter of the rotating speed, the rotating angular speed and the rotating period, output different signals to the alarm circuit according to the difference of the current working state, control the alarm to give an alarm to workers in the forms of light, sound and the like, remind the workers of changing the working speed of the ball mill, and also regulate the speed of the ball mill by the automatic control circuit so as to restore the ball mill to the normal working state.
The embodiments of the present invention are described in further detail below.
The embodiment of the invention provides a method for realizing the detection of the working state of a ball mill by using non-contact speed measurement, as shown in figure 4, the method mainly comprises the following steps:
step S1: the outer surface of the ball mill cylinder is provided with a mirror reflection unit, a light source with strong directivity and a photosensitive element are arranged at proper positions outside the ball mill, and the rotation speed information of the ball mill is converted into output voltage of the photosensitive element through optical signals by using the photosensitive element.
The step completes the conversion of signal form, converts the optical signal of the rotation speed information of the reaction ball mill into the output voltage of the photosensitive element convenient for processing, and provides convenience for subsequent processing. The method is characterized in that a specular reflection unit is arranged on the outer surface of a ball mill cylinder, a light source with stronger directivity and a photosensitive element are arranged at proper positions outside the ball mill, and alternative schemes include but are not limited to two schemes shown in figures 4 and 5. Let the signal received by the light sensitive element be as follows:
x(t)＝s(t-τ)+n(t)
wherein x (t) is a signal received by the photosensitive element at time t, τ represents the time delay of light in the propagation process, s (t- τ) is a signal received by the photosensitive element when the light source irradiates the specular reflection unit or the outer surface of the ball mill cylinder to generate reflection, and n (t) is the sum of a signal generated by light source interference in the environment and thermal noise in the circuit, which are collectively called noise.
Since the light source is of higher intensity than the ambient light, the noise is very small and negligible relative to the theoretical output of the photosensor. Meanwhile, when light irradiates on the specular reflection unit, specular reflection and no diffuse reflection are generated, and when light irradiates on the outer surface of the ball mill cylinder, due to the fact that the outer surface of the cylinder is rough, diffuse reflection and no specular reflection are generated. Meanwhile, for the same light source, the intensity of the reflected light of the specular reflection is far greater than that of the reflected light of the diffuse reflection. Therefore, when the light source is irradiated to the specular reflection unit at time t, s (t- τ) takes a large value; when the light source irradiates the ball mill cylinder at the time t, s (t-tau) is taken to be a smaller value. The output voltage waveforms of the photosensitive elements are schematically shown in fig. 7 and 8.
Step S2: detecting the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculating the rotating speed, the rotating angular speed and the rotating period of the ball mill rotating drum according to the total number of the rising edges of the output voltage of the photosensitive element in unit time;
with a sampling device, at a sufficiently small sampling period TsThe output current of the photosensitive element is sampled. Setting a voltage threshold δ0The total number of rising edges N of the output voltage of the photosensor in a unit time is calculated. The method for calculating the rising edge of the output voltage of the photosensitive element comprises the following steps: for the ith sampling point, sequentially calculating the voltage difference value delta between the ith sampling point and the last sampling pointiIf deltai≥δ0And then, the point is called as the rising edge of the output voltage of the photosensitive element, the serial number i of the sampling point at the moment is recorded, and the total number N of the rising edges is recorded.
In the unit time T of sampling, the rotating speed of the ball mill is considered to be constant,
the rotation speed of the ball mill drum is:
ball millThe rotating angular speed of the machine drum is as follows:
the rotation period of the ball mill rotary drum is as follows:
step S3: and detecting the working state of the ball mill equipment according to the magnitude relation between the actual value and the normal value of any one parameter of the rotating speed, the rotating angular speed and the rotating period of the rotary drum of the ball mill during working, which is obtained by non-contact measurement and calculation in the step S2, and correspondingly measuring the abnormal working state, such as alarming the abnormal working state and/or automatically regulating the speed of the ball mill.
Fig. 1 to 3 are schematic diagrams of three operating states of the ball mill, which are determined by the relative relationship between the medium ball drop point and the material line. When the medium ball falling point is slightly below the material line, the medium ball falling point is in a normal rotating speed working state; when the medium ball falling point is far below the material line, the medium ball falling point is in a low-rotation-speed working state; when the medium ball falling point is above the material line, the working state is in a high rotating speed working state. According to physical knowledge, the drop point of the medium ball and the position of the material line are functions of the rotating speed of the ball mill cylinder, and under the condition of each rotating speed of the cylinder, a corresponding relation between the drop point of the medium ball and the material line exists.
From the above analysis, three methods are provided for detecting the operating state of the ball mill.
The first method is as follows: according to prior knowledge accumulated in the actual production process, the rotating speed of the rotary drum in the normal rotating speed working state of the ball mill is determined within a certain range, and the rotating speed range of the rotary drum in the normal working state is set as n1≤n≤n2The rotating speeds of the ball mill revolving drum can be divided into three sets according to different working states:
Xhigh speed＝{n|n＞n2}
XIs normal＝{n|n1≤n≤n2}
XLow speed＝{n|n＜n1}
Calculating the rotation speed n of the ball mill revolving drum actually measured by non-contact electromagnetic induction in the production process, and if n belongs to XIs normalThe ball mill is in a normal rotating speed working state, and the current rotating speed is maintained; if n is equal to XHigh speedIf the ball mill is in a high-rotation-speed working state, the rotation speed needs to be reduced; if n is equal to XLow speedIf the ball mill is in a low-rotation-speed working state, the rotation speed needs to be increased.
The second method comprises the following steps: according to prior knowledge accumulated in the actual production process, the rotating angular speed of the rotary drum in the normal rotating speed working state of the ball mill is determined within a certain range, and the rotating angular speed range of the rotary drum in the normal working state is set as omega1≤ω≤ω2Then, the rotation angular speed of the ball mill revolving drum can be divided into three sets according to different working states:
Yhigh speed＝{ω|ω＞ω2}
YIs normal＝{ω|ω1≤ω≤ω2}
YLow speed＝{ω|ω＜ω1}
Calculating the rotation angular speed omega of the ball mill revolving drum actually measured by non-contact electromagnetic induction in the production process, and if omega belongs to YIs normalThe ball mill is in a normal rotating speed working state, and the current rotating speed is maintained; if ω ∈ YHigh speedIf the ball mill is in a high-rotation-speed working state, the rotation speed needs to be reduced; if ω ∈ YLow speedIf the ball mill is in a low-rotation-speed working state, the rotation speed needs to be increased.
The third method comprises the following steps: according to prior knowledge accumulated in the actual production process, the rotation period of the ball mill in the normal rotation speed working state is determined within a certain range, and the rotation period range of the normal work is set as T1≤Tω≤T2Then, the rotation period can be divided into three sets according to different working states:
Zhigh speed＝{Tω|Tω＜T1}
ZIs normal＝{Tω|T1≤Tω≤T2}
ZLow speed＝{Tω|Tω＞T2}
Calculating the rotation period T of the ball mill actually measured by non-contact electromagnetic induction in the production processωIf T isω∈ZIs normalThe ball mill is in a normal rotating speed working state, and the current rotating speed is maintained; if Tω∈ZHigh speedIf the ball mill is in a high-rotation-speed working state, the rotation speed needs to be reduced; if Tω∈ZLow speedIf the ball mill is in a low-rotation-speed working state, the rotation speed needs to be increased.
In summary, the invention obtains the rotating speed, the rotating angular speed and the rotating period of the ball mill cylinder through non-contact photoelectric speed measurement, any one of the parameters can be used for obtaining the current working state of the ball mill, different signals are output to the alarm circuit according to the difference of the current working state, the alarm is controlled to give an alarm to workers in the forms of light, sound and the like, the workers are reminded to change the working speed of the ball mill, and further, the speed of the ball mill can be regulated according to the current working state through the control of the automatic control circuit.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (10)
1. A method for realizing the detection of the working state of a ball mill by using non-contact velocity measurement is characterized by comprising the following steps:
the outer surface of a cylinder body of the ball mill is fixedly provided with a mirror reflection unit, and the mirror reflection unit can synchronously move around the axis of the rotary cylinder along with the rotary cylinder; a light source and a photosensitive element corresponding to the motion track of the reflection unit are arranged outside a cylinder of the ball mill, the light emitted by the light source can be reflected to the photosensitive element through a mirror reflection unit on the cylinder, and the photosensitive element can receive the light signal of the light source reflected by the reflection unit and can convert the light signal corresponding to the rotation speed information of the ball mill into a photosensitive element output voltage through photoelectric conversion;
detecting and obtaining the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculating and obtaining the rotating speed, the rotating angular speed and the rotating period of a rotating drum of the ball mill during working according to the total number of the rising edges of the output voltage of the photosensitive element in unit time;
and determining the current working state of the detected ball mill according to the calculated magnitude relation between the actual value and the normal value of any parameter of the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working, and performing corresponding processing when the current working state is an abnormal working state.
2. The method for detecting the working state of the ball mill by using non-contact velocity measurement according to claim 1, wherein in the method, a mirror reflection unit is fixedly arranged on the outer surface of a cylinder of the ball mill, and the reflection unit can synchronously move along with the cylinder comprises the following steps:
a mirror reflection unit is fixedly arranged at any position of the arc-shaped outer surface of the rotary drum of the ball mill, and can synchronously move around the axis of the rotary drum along with the rotating arc-shaped outer surface of the rotary drum;
or, a mirror reflection unit is fixedly arranged at any position of any side surface of the revolving drum of the ball mill deviating from the axis, and the magnet can synchronously move around the axis of the revolving drum along with the side outer surface of the revolving drum.
3. The method for detecting the operating state of the ball mill by using non-contact velocity measurement according to claim 1 or 2, wherein in the method, a light source and a photosensitive element corresponding to the motion track of the specular reflection unit are arranged outside a cylinder of the ball mill, the light emitted by the light source is reflected to the photosensitive element by the specular reflection unit on the cylinder, and the photosensitive element can receive the light signal of the light source reflected by the specular reflection unit and convert the light signal corresponding to the information of the rotation speed of the ball mill into a photosensitive element output voltage by photoelectric conversion comprises:
the receiving signals of the photosensitive elements are as follows: x (t) s (t- τ) + n (t); wherein x (t) is the received signal of the photosensitive element at time t; tau is the time delay of light in the process of propagation; s (t-tau) is a receiving signal of the photosensitive element when the light source irradiates the mirror reflection unit or the outer surface of the ball mill cylinder to generate reflection; n (t) is noise representing the sum of a signal generated by light source interference in the environment and thermal noise in the circuit; when the light source irradiates the specular reflection unit at the time t, s (t-tau) takes a larger value; when the light source irradiates the ball mill cylinder at the moment t, s (t-tau) takes a small value, and the output voltage of the photosensitive element is a periodic voltage waveform with a rising edge.
4. A method for detecting the operating condition of a ball mill according to claim 1 or 2, wherein the total number of the rising edges of the output voltage of the photosensitive element in a unit time is detected as follows:
at a set sampling period TsSampling the output voltage of the photosensitive element, and recording and obtaining the total number N of rising edges of the output voltage of the photosensitive element in unit time T from a sampling result;
rotational speed of the bowl mill bowl
Wherein T represents a unit time, and N represents a total number of rising edges of the output voltage of the photosensitive element in the unit time;
angular speed of rotation of the bowl mill bowl
Wherein N represents the rotational speed of the drum, T represents a unit time, and N represents the total number of rising edges of the output voltage of the photosensor per unit time;
rotation period of the bowl mill bowl
Where N denotes the rotation speed, T denotes the unit time, and N denotes the total number of rising edges of the output voltage of the light sensitive element in the unit time.
5. The method for detecting the working state of the ball mill by using the non-contact velocity measurement according to claim 4, wherein the rising edge of the output voltage of the photosensitive element is determined by the following method:
if the voltage difference value delta of the electric pulse of the ith sampling point and the last sampling point is calculatediGreater than a predetermined voltage threshold delta0I.e. deltai≥δ0And then confirming that the sampling point is the rising edge of the output voltage of the photosensitive element, and the serial number of the sampling point corresponding to the rising edge of the output voltage of the photosensitive element is i.
6. The method for detecting the working state of the ball mill by using the non-contact velocity measurement according to claim 1 or 2, wherein in the method, determining the current working state of the detected ball mill according to the calculated magnitude relation between the actual value and the normal value of any parameter of the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working, and performing corresponding processing when the current working state is the abnormal working state comprises:
(1) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotating speed of the rotating drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
the rotating speed range of the rotary drum in the normal rotating speed working state of the ball mill to be detected is set as n in advance1≤n≤n2Dividing the rotating speed of the revolving drum of the ball mill into three sets according to different working states:
Xhigh speed＝{n|n＞n2}
XIs normal＝{n|n1≤n≤n2}
XLow speed＝{n|n＜n1}；
Calculating the actually measured rotating speed n of the rotating cylinder of the ball mill in the production process, and if the rotating speed n belongs to XIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the rotation speed n belongs to XHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the rotation speed n belongs to XLow speedDetermining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed;
(2) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotating angular speed of the revolving drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
the rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected is set to omega in advance1≤ω≤ω2Dividing the rotation angular speed of the revolving drum of the ball mill into three sets according to different working states:
Yhigh speed＝{ω|ω＞ω2}
YIs normal＝{ω|ω1≤ω≤ω2}
YLow speed＝{ω|ω＜ω1}；
Calculating the actually measured rotation angular speed omega of the revolving drum of the ball mill in the production process, and if the rotation angular speed omega belongs to YIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the angular velocity ω ∈ YHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the angular velocity ω ∈ YLow speedDetermining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed;
(3) determining the current working state of the detected ball mill according to the size relation between the actual value and the normal value of the rotation period of the rotary drum of the ball mill, and performing corresponding processing when the current working state is an abnormal working state, wherein the method comprises the following steps:
the rotation period of the rotary drum in the normal rotation speed working state of the ball mill to be detected is preset within T1≤Tω≤T2Dividing the rotation period of the revolving drum of the ball mill into three sets according to different working states:
Zhigh speed＝{Tω|Tω＜T1}
ZIs normal＝{Tω|T1≤Tω≤T2}
ZLow speed＝{Tω|Tω＞T2}；
Calculating the rotation period T of the revolving drum of the ball mill actually measured in the production processωIf the period of rotation Tω∈ZIs normalDetermining that the ball mill is in a normal rotating speed working state, and maintaining the current rotating speed; if the period of rotation Tω∈ZHigh speedDetermining that the ball mill is in a high-rotation-speed working state, and performing processing of giving an alarm and/or reducing the rotation speed; if the period of rotation Tω∈ZLow speedAnd determining that the ball mill is in a low-rotation-speed working state, and performing processing of giving an alarm and/or increasing the rotation speed.
7. A method for detecting the operating condition of a ball mill by non-contact velocity measurement according to claim 6, wherein the rotating speed range of the rotating cylinder in the normal rotating speed operating condition of the ball mill to be detected is set to n in advance1≤n≤n2The rotating speed range of the rotary drum in the normal rotating speed working state of the ball mill to be detected is set as n according to the prior knowledge accumulated in the actual production process1≤n≤n2；
The rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected is set to omega in advance1≤ω≤ω2Setting the rotation angular speed range of the rotary drum in the normal rotation speed working state of the ball mill to be detected as omega according to the prior knowledge accumulated in the actual production process1≤ω≤ω2；
In advance, firstlyThe range of the rotation period of the rotary drum of the detected normal rotation speed working state of the ball mill is set as T1≤Tω≤T2Setting the range of the rotation period of the rotary drum in the normal rotation speed working state of the ball mill to be detected as T according to the prior knowledge accumulated in the actual production process1≤Tω≤T2。
8. A system for realizing the detection of the working state of a ball mill by using non-contact velocity measurement, which is characterized in that the system is used for realizing the method of any one of claims 1 to 7 and comprises the following steps:
the device comprises a mirror reflection unit, a light source, a photosensitive element, a sampling processing device, a detection processing device and an abnormal state processing device; wherein the content of the first and second substances,
the mirror reflection unit is fixedly arranged on the outer surface of the rotary drum of the detected ball mill and can synchronously move around the axis of the rotary drum along with the rotary drum;
the light source and the photosensitive element are respectively arranged at the positions corresponding to the motion tracks of the reflection unit outside the ball mill, the light emitted by the light source can be reflected to the photosensitive element through the mirror reflection unit on the cylinder, and the photosensitive element can receive the light signals of the light source reflected by the mirror reflection unit and can convert the light signals corresponding to the rotation speed information of the ball mill into photosensitive element output voltage through photoelectric conversion;
the sampling processing device is respectively electrically connected with the voltage output end of the photosensitive element and the detection processing device, can sample the output voltage of the photosensitive element, detects the total number of the rising edges of the output voltage of the photosensitive element in unit time, and calculates the rotating speed, the rotating angular speed and the rotating period of the rotary drum of the ball mill by using the total number of the rising edges of the output voltage of the photosensitive element;
the detection processing device is electrically connected with the abnormal state processing device and can determine the current working state of the detected ball mill according to the magnitude relation between the actual value and the normal value of any parameter in the rotating speed, the rotating angular speed and the rotating period of the rotating cylinder of the ball mill during working;
and the abnormal state processing device can perform corresponding processing when the current working state is the abnormal working state according to the current working state of the detected ball mill determined by the detection processing device.
9. The system for detecting the working state of the ball mill by using non-contact velocity measurement according to claim 8, wherein the sampling processing device comprises:
the device comprises a sampling device, a counting device and a signal processing device; wherein the content of the first and second substances,
the sampling device is respectively electrically connected with the counting device and the signal processing device and can perform sampling within a preset sampling period TsSampling the output voltage of the photosensitive element, and outputting the amplitude of the output voltage of the photosensitive element at each sampling point;
the counting device can calculate the total number of the rising edges of the output voltage of the photosensitive element in unit time T according to the amplitude of the output electric pulse of the photosensitive element at each sampling point output by the sampling device after sampling;
the signal processing device can obtain the total number of the rising edges of the output voltage of the photosensitive element in the unit time T through a first formula
Calculating the rotating speed N of the revolving drum of the ball mill, wherein in the first formula, T represents unit time, and N represents the total number of rising edges of the output voltage of the photosensitive element in unit time; by a second formula
Calculating the rotation angular speed omega of the ball mill, wherein in the second formula, N represents the rotation speed of the ball mill revolving drum, T represents unit time, and N represents the total number of rising edges of the output voltage of the photosensitive element in unit time; and by a third formula
Calculating to obtain the rotation period T of the ball millωIn the third formula, N represents the rotation speed of the bowl mill revolving drum, T represents unit time, and N represents the total number of rising edges of the output voltage of the photosensitive element in unit time.
10. The system for detecting the working state of the ball mill by using non-contact velocity measurement according to claim 8 or 9, wherein an alarm circuit and/or an automatic control circuit is arranged in the abnormal state processing device, the component circuit can alarm the abnormal working state, and the automatic control circuit can adjust the rotating speed of the ball mill in the abnormal working state.
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