CN113967529B - Intelligent optimization energy-saving system based on rolling energy efficiency analysis module - Google Patents
Intelligent optimization energy-saving system based on rolling energy efficiency analysis module Download PDFInfo
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- CN113967529B CN113967529B CN202111229134.7A CN202111229134A CN113967529B CN 113967529 B CN113967529 B CN 113967529B CN 202111229134 A CN202111229134 A CN 202111229134A CN 113967529 B CN113967529 B CN 113967529B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C25/00—Control arrangements specially adapted for crushing or disintegrating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C4/00—Crushing or disintegrating by roller mills
- B02C4/02—Crushing or disintegrating by roller mills with two or more rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C4/00—Crushing or disintegrating by roller mills
- B02C4/28—Details
Abstract
The invention discloses an intelligent optimization energy-saving system based on a rolling energy efficiency analysis module, which comprises a user interaction terminal, a rolling machine operation monitoring unit and an energy efficiency analysis system, wherein the user interaction terminal is connected with the rolling machine operation monitoring unit; the energy efficiency analysis system comprises a micro-processing module, a roll gap detection module, a pressure detection module, a feeding granularity detection module, a feeding amount detection module, a powder return amount detection module, a finished product yield metering module and an electric quantity calculation module. The intelligent optimization energy-saving system can be converted into the optimal unit consumption under the production state, the unit consumption is used as a management index, and the optimal roll gap difference, the optimal given pressure and the optimal powder return curve parameters under the lowest electricity consumption can be predicted according to the corresponding logical quantity relation by properly selecting the roll gap distance, the given pressure, the feeding quantity and the powder return data index of the roll press, so that the idle work consumption of the roll press is reduced under the condition of ensuring the product quality, the yield and the equipment safety, and the aim of saving energy is fulfilled.
Description
Technical Field
The invention relates to the technical field of energy conservation of roller presses, in particular to an intelligent optimization energy-saving system based on a roller press energy analysis module.
Background
The main factors influencing the running efficiency of the roller press are cake thickness, cake throughput, hydraulic system pressure, roller gap size and the like, and the unit consumption of the roller press is different under different technological parameters. The thickness of the material cake is too thin, so that the roller press is easy to vibrate, the supporting bolt is damaged, the thickness of the material cake is increased, a buffer layer between two rollers can be thickened, the impact load of a roller press transmission system is reduced, the roller press is relatively stable to operate, the throughput stability of the roller press is ensured, and the feeding performance is ensured. The control of the throughput of the material cake can be realized by adjusting the inclined spile, the roller press has small roller gap and low current, the throughput of the roller press can be improved by lifting the inclined spile upwards, the roller press has large roller gap and high current, and the throughput can be reduced by moving the inclined spile downwards.
Under the condition that the current of the main motor is unchanged, the pressure of the hydraulic system is inversely proportional to the thickness of the cake, the extrusion effect needs to be improved, the hydraulic pressure needs to be increased, the thickness of the cake needs to be reduced, and when the throughput needs to be increased, the thickness of the large cake needs to be increased, the operation pressure of the hydraulic system needs to be reduced. Under normal conditions, the higher the pressure is, the better the extrusion effect is, but after the pressure is increased to a certain value, the extrusion effect is not obviously improved along with the increase of the pressure, and the service life of a roller press system is greatly influenced by the high pressure.
At present, the operation of the roller press is operated by a shift operator according to post operation specifications, along with the operation proficiency, the operator can operate according to own experience, only the product quality is met, the change relation of unit consumption under different process parameters is not considered completely in normal production of the operator, the condition of high-energy-consumption production exists, and the roller press belongs to obvious energy waste.
Disclosure of Invention
The invention aims to provide an intelligent optimization energy-saving system based on a rolling energy efficiency analysis module, which is used for at least solving one of the problems in the prior art.
In view of this, the scheme of the invention is as follows:
an intelligent optimization energy-saving system based on a rolling energy analysis module comprises a user interaction terminal, a rolling machine equipment unit and a rolling machine analysis system, wherein the user interaction terminal, the rolling machine equipment unit and the rolling machine analysis system are in bidirectional electrical connection; the roll squeezer analysis system comprises a data acquisition module and a micro-processing module, wherein the data acquisition module acquires energy parameters of roll squeezer equipment units and transmits the energy parameters to the micro-processing module, the micro-processing module calculates current energy consumption and compares historical energy consumption, the energy parameters under the current and the lowest historical energy consumption are respectively output and are sent to a user interaction terminal for display, and the user interaction terminal sends an instruction generated manually to the roll squeezer equipment units to adjust the current energy parameters.
In the energy-saving system, the data acquisition module comprises a roll gap detection module, a pressure detection module, a feeding amount detection module, a feeding granularity detection module, a powder return amount detection module and a finished product yield metering module which are respectively and electrically connected with the micro-processing module (31) in a bidirectional mannerAnd an electric quantity calculation module; the roll gap detection module, the pressure detection module, the feeding amount detection module, the feeding granularity detection module and the powder return amount detection module respectively collect roll gaps S and pressure P of a roll squeezer equipment unit m Feeding amount W Feeding device The feeding density rho and the powder return quantity W Returning to The method comprises the steps of carrying out a first treatment on the surface of the The finished product yield metering module is used for calculating the finished product yield Z, and the electric quantity calculating module is used for collecting and calculating the electric quantity P used in unit time sum 。
Preferably, the electricity quantity calculation module collects data every 5 seconds, counts the electricity quantity every 15 minutes, and sums the electricity quantity every hour.
Preferably, the micro-processing module is used for controlling the output Z and the power consumption P in unit time sum The current energy consumption E is calculated and,
preferably, the micro-processing module comprises a storage module, an energy consumption calculation module and an energy consumption comparison module; the energy consumption calculation module calculates unit consumption data in the historical unit time, then sorts the unit consumption data and stores the unit consumption data in the storage module; and the energy consumption comparison module compares the real-time energy consumption with the differential parameters of the historical energy consumption according to the energy consumption model and sends the differential parameters to the user interaction terminal for display.
Further, the energy consumption model is:
wherein P is m For a given pressure, A is the roll press equipment constant, S is the roll gap, and ρ is the feed density.
Further, the energy consumption model is:
W feeding device Is the feeding amount, ρ is the feeding density, W Returning to And t is time for powder return.
Further, the energy consumption calculation module selects the lowest historical energy consumption of the previous N bits according to the sorting condition and stores the lowest historical energy consumption into the storage module; the energy consumption comparison module compares the parameters under the lowest energy consumption of the previous N-bit history with the current parameters according to the energy consumption model, highlights the differentiated parameters, and selects the optimal values of all the parameters under the lowest energy consumption of the previous N-bit history as the current parameters, wherein N is more than or equal to 2.
In the energy-saving system, the roll squeezer equipment unit consists of a plurality of roll squeezers, each roll squeezer is respectively and electrically connected with a user interaction terminal and a roll squeezer analysis system in a bidirectional way, and the user interaction terminal displays the current energy consumption of each roll squeezer and the energy parameters under the lowest historical energy consumption.
Compared with the prior art, the invention has the beneficial effects that:
the invention can realize the analysis and comparison of unit consumption under different process parameters, and find out the process parameter range under the condition of lowest energy consumption; the unit consumption is used as an energy-saving management index, and the optimal roll gap difference, the optimal given pressure, the optimal powder return amount and the optimal feeding granularity can be timely adjusted according to the corresponding logic quantity relation by properly selecting the roll gap distance, the given pressure, the feeding amount and the powder return amount data index of the roll squeezer, so that the consumption of idle work of the roll squeezer is reduced under the condition of ensuring the product quality, the yield and the equipment safety, and the aim of saving energy is achieved.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic block diagram of the system of the present invention.
Fig. 2 is a schematic block diagram of a roll squeezer apparatus unit and a roll squeezer analysis system of the present invention.
In the figure: 1. a user interaction terminal; 2. a roll squeezer apparatus unit; 3. a roller press analysis system; 31. a microprocessor module; 32. a roll gap detection module; 33. a pressure detection module; 34. a feeding amount detection module; 35. a feeding granularity detection module; 36. a powder return amount detection module; 37. a finished product yield metering module; 38. and the electric quantity calculating module.
Detailed Description
In order to make the objects, technical solutions and advantageous technical effects of the present invention more apparent, the present invention will be further described in detail with reference to the accompanying drawings and detailed description. It should be understood that the detailed description is intended to illustrate the invention, and not to limit the invention.
Referring to fig. 1-2, an embodiment of the present invention provides an intelligent optimization energy saving system based on a rolling energy efficiency analysis module, which includes a user interaction terminal 1, a rolling machine equipment unit 2 and a rolling machine analysis system 3, wherein the user interaction terminal 1, the rolling machine equipment unit 2 and the rolling machine analysis system 3 are electrically connected in two directions by wires, and two-by-two directions are realized, wherein: the roller press analysis system 3 operates and serves as a server and comprises a micro-processing module 31, a roller gap detection module 32, a pressure detection module 33, a feeding amount detection module 34, a feeding particle size detection module 35, a powder return amount detection module 36, a finished product yield metering module 37 and an electric quantity calculation module 38. The micro-processing module 31 is in bidirectional electrical connection with the roll gap detection module 32, the pressure detection module 33, the feeding amount detection module 34, the powder return amount detection module 35, the finished product yield metering module 36 and the electric quantity calculation module 37 through wires, and the micro-processing module 31 is in bidirectional electrical connection with the roll squeezer equipment unit 2 through wires. The microprocessor module 31 includes a memory module 3101, an energy consumption calculation module 3102 and an energy consumption comparison module 3103,
in the invention, the roll gap detection module 32 detects the roll gap S at the front end and the rear end of the movable fixed roll through an infrared distance sensor, and converts a distance signal into an analog signal to be transmitted to the micro-processing module 31.
The pressure detection module 33 transmits the hydraulic oil pump to the hydraulic oil pressure P of the movable fixed roller through a pressure sensor m The signals are converted into analog signals and transmitted to the microprocessor module 31.
The feeding amount detection module 34 stabilizes the bin flow through the rotor balanceMaterial flow W between movable fixed rolls of roll-in machine Feeding device The detection is performed and the throughput is calculated from the material thickness and transferred to the micro-processing module 31.
The feeding particle size detection module 35 detects the material density and the water content data ρ through a fluorescence online analyzer, and converts the signals into analog signals to be transmitted to the micro-processing module 31.
The powder return amount detection module 36 is used for detecting the material flow W from the outlet of the rotor balance pair roller press to the inlet of the powder selector Returning to The detection is performed and the throughput is calculated from the material thickness and transferred to the micro-processing module 31.
The product yield metering module 37 detects the flow rate of the material flowing into the inlet of the product bin at the product outlet of the powder concentrator through the rotor scale, calculates the obtained yield data Z, and transmits the yield data Z to the micro-processing module 31.
The electricity quantity calculation module 38 realizes the collection of the electricity quantity of the main equipment by installing an electricity metering device on the main equipment, and transmits the electricity quantity to the communication manager to realize the data summarization calculation, thereby obtaining the electricity consumption P in unit time sum And then to the microprocessor module 31.
In the invention, the roller press equipment unit 2 is composed of a plurality of roller press equipment.
The intelligent optimization energy-saving system based on the energy saving of the roller press operation can adjust the unit consumption under the current working condition to be optimal, specifically calculates the current energy consumption through the collected parameters, compares the parameters with the parameters under the historical lowest energy consumption value, adjusts the current parameters to be close to the optimal historical parameters according to the influence relation of the parameters in the energy consumption model on the energy consumption value, observes the energy consumption change and the yield change condition, and can reduce the consumption reduction value. Therefore, under the condition of ensuring the quality and the yield of products and the safety of equipment, the consumption of idle work of the roller press is reduced, so as to achieve the aim of saving energy.
The energy-saving optimization process of the intelligent optimization system based on the rolling machine energy analysis module comprises the following steps:
1. building an energy consumption model: the roll press analysis system 3 collects roll gap, given pressure, feeding amount and powder return amount data of the roll press equipment unit in real time, correlates the process parameter data with the roll press finished product yield data to obtain the yield per hour and corresponding process parameters, establishes a roll press energy consumption model according to the parameter values, calculates an energy consumption value based on the energy consumption model by the energy consumption calculation module 3102, and stores the energy consumption value and the corresponding parameters in the storage module 3101.
Specifically, the roll press apparatus unit collects the roll gap of the roll press motor and the set pressure (P m MPa), feed density (ρ, kg/m) 3 ) Feeding amount (W) Feeding device T/h), the powder return amount (W Returning to T/h) and finished product yield data, correlating the process parameter data with rolling energy consumption (kWh/t) data to obtain energy consumption data and corresponding process parameter values of each hour, and carrying out calculation according to the parameter values and carrying out calculation according to the following formulas 1-3 to establish a rolling energy consumption model.
The rolling energy consumption model calculation process is as follows:
(1) The power of the roller press is as follows:
wherein P is the power of the roller press, P m For a given pressure, L is the roller length, D is the roller diameter, T is the roller torque, n is a constant, pi is a constant; l, D, T are roll squeezer equipment constants.
(2) The productivity of the roller press is determined according to the throughput per unit time,
Q＝3600SLρv＝60πnρDLS (2)
wherein Q is the productivity (t/h), ρ is the material density, kg/m 3 V is the roll linear speed, m/S, L is the roll length, D is the roll diameter, and S is the roll gap.
(3) The unit energy consumption e=p/Q of the roller press, namely:
from equation 3, it can be seen that the given pressure P m The material density rho and the roll gap clearance S can influence the energy consumption of the rolling machineSize of the product.
2. According to the electric quantity calculation formulas of the main machine of the roller press and the auxiliary equipment, the electric quantity calculation module 37 collects data every 5 seconds, counts the electric quantity every 15 minutes, and gathers the electric quantity every hour to obtain the electric consumption P in unit time sum The current energy consumption is calculated according to the energy consumption calculation formula 3,
3. the roll squeezer analysis system 3 correlates the product yield data with the hour yield data, calculates the unit consumption data of each hour, sorts the corresponding process parameters according to the unit consumption from low to high, and stores the sorted unit consumption data into the storage module 3101 in the format of: { sequence number, time t, unit consumption value E, yield Z, power consumption P sum Roll gap S of roll squeezer and given pressure P m Feeding amount W Feeding device The grain size rho of the feed and the powder return quantity W Returning to }. Under a certain working condition, N independent roller press devices are operated simultaneously, data in a certain time are taken, unit consumption of the N independent roller press devices is calculated and then is sequenced independently, energy consumption information of each roller press is output according to an output format, and the serial number is 1,2 and … N.
4. The roll gap distance S and the pressure P of each roll squeezer under the current working condition are respectively collected by the roll squeezer analysis system 3 m Feeding amount W Feeding device The grain size rho of the feed and the powder return quantity W Returning to Yield Z of finished products and power consumption P sum The data is transmitted to an energy consumption calculation module 3102 to calculate the current energy consumption value, an energy consumption comparison module 3103 calls out the historical data in a storage module 3101 to be compared with the parameters under the current energy consumption, specifically, the parameters under the condition that the top 10 list consumes the lowest are taken out, and the output Z and the power consumption P during the running of the single roll squeezer are output sum Roll gap S of roll squeezer and given pressure P m Feeding amount W Feeding device The grain size rho of the feed and the powder return quantity W Returning to And (3) automatically comparing the acquired calculation data with the optimal values under the historical parameters, highlighting the difference data in red, prompting an operator to adjust the process parameters according to the optimal values and realizing energy consumption adjustment.
Table 1 is a comparison of energy consumption before and after parameter adjustment under a certain working condition, energy parameter collection is performed on a plurality of current roller press devices, current and optimal values of parameters are obtained after energy model construction, adjustment is performed according to the optimal values, and energy consumption after optimization is obviously reduced.
Table 1:
the present invention is not limited to the details and embodiments described herein, and thus additional advantages and modifications may readily be made by those skilled in the art, without departing from the spirit and scope of the general concepts defined in the claims and the equivalents thereof, and the invention is not limited to the specific details, representative apparatus and illustrative examples shown and described herein.
Claims (7)
1. The intelligent optimization energy-saving system based on the rolling machine energy analysis module is characterized by comprising user interaction terminals (1), a rolling machine equipment unit (2) and a rolling machine analysis system (3), wherein the user interaction terminals are in bidirectional electrical connection with each other; the roll squeezer analysis system (3) comprises a data acquisition module and a micro-processing module (31), wherein the data acquisition module acquires energy parameters of the roll squeezer equipment unit (2) and transmits the energy parameters to the micro-processing module (31), the micro-processing module (31) calculates current energy consumption and compares historical energy consumption, the current energy consumption and the historical energy consumption are respectively output energy parameters under the lowest current energy consumption and the lowest historical energy consumption, the current energy consumption and the historical energy consumption are transmitted to the user interaction terminal (1) for display, and the user interaction terminal (1) transmits the manual generation instruction to the roll squeezer equipment unit (2) to adjust the current energy parameters;
the data acquisition module comprises a roll gap detection module (32), a pressure detection module (33), a feeding amount detection module (34), a feeding granularity detection module (35) and a return wire which are respectively and electrically connected with the micro-processing module (31) in a bidirectional mannerThe powder quantity detection module (36), the finished product yield metering module (37) and the electric quantity calculation module (38); the roll gap detection module (32), the pressure detection module (33), the feeding amount detection module (34), the feeding granularity detection module (35) and the powder return amount detection module (36) respectively collect roll gaps of the roll press equipment unit (2)SPressure and forceP m Feeding amountW Feeding device The feeding density rho and the powder return quantityW Returning to The method comprises the steps of carrying out a first treatment on the surface of the The yield measurement module (37) is used for calculating the yield of the finished productZThe electricity consumption calculation module (38) is used for collecting and calculating the electricity consumption in unit timeP sum ；
The micro-processing module (31) is based on the outputZAnd the amount of electricity used per unit timeP sum Calculating the current energy consumptionE，
。
2. The energy saving system of claim 1, wherein the power calculation module (38) collects data every 5 seconds, counts power every 15 minutes, and counts power every hour.
3. The energy saving system according to claim 1, characterized in that the micro-processing module (31) comprises a storage module (3101), an energy consumption calculation module (3102) and an energy consumption comparison module (3103); the energy consumption calculation module (3102) calculates unit consumption data in a historical unit time, then sequences the unit consumption data and stores the unit consumption data in the storage module (3101); the energy consumption comparison module (3103) compares the real-time energy consumption with the differential parameters of the historical energy consumption according to the energy consumption model, and sends the differential parameters to the user interaction terminal (1) for display.
4. The energy conservation system of claim 3, wherein the energy consumption model is:
wherein, the method comprises the steps of, wherein,P m for a given pressure to be applied,Ais a constant value of the equipment of the roller press,Sroll gap, ρ is the feed density.
5. The energy conservation system of claim 3, wherein the energy consumption model is:
，W feeding device Is the feeding amount and ρ is the feeding density,W Returning to And t is time for powder return.
6. The energy saving system according to claim 3, characterized in that the energy consumption calculation module (3102) selects the lowest energy consumption of the first N-bit history according to the ordering situation and stores it in the storage module (3101); the energy consumption comparison module (3103) compares the parameters under the lowest energy consumption of the previous N-bit history with the current parameters according to the energy consumption model, highlights the differentiated parameters, and selects the optimal values of all the parameters under the lowest energy consumption of the previous N-bit history as the current parameters, wherein N is more than or equal to 2.
7. The energy saving system according to claim 1, wherein the roll squeezer equipment unit (2) is composed of a plurality of roll squeezers, each roll squeezer is respectively and bi-directionally electrically connected with the user interaction terminal (1) and the roll squeezer analysis system (3), and the user interaction terminal (1) displays the current energy consumption of each roll squeezer and the energy parameters under the lowest historical energy consumption.
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