CN114707255A - Industrial screening effect dynamic evaluation method based on digital twinning - Google Patents
Industrial screening effect dynamic evaluation method based on digital twinning Download PDFInfo
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Abstract
The invention relates to a dynamic evaluation method for industrial screening effect based on digital twins, belongs to the technical field of mineral screening, and solves the problem that the online dynamic observation and real-time evaluation of the industrial screening effect cannot be carried out in the prior art. The evaluation method comprises the following steps: step 1, acquiring structural parameters, material parameters, particle group component parameters, load parameters in a screening process and information of an environment around equipment operation; step 2, establishing a three-dimensional structure model of the screening machine; step 3, establishing a screening machine digital twin simulation model; step 4, correcting a digital twin simulation model of the screening machine; step 5, constructing a cloud database based on the corrected screening machine digital twin simulation model, and acquiring the real-time running state of the equipment through the terminal equipment; and 6, evaluating the screening effect in real time based on the acquired real-time running state of the equipment. The invention can acquire working condition parameters of the screening machine in the screening process in real time, and realize real-time detection on the structure, the running state, the fault early warning and the screening result of the screening machine.
Description
Technical Field
The invention relates to the technical field of screening, in particular to a dynamic evaluation method for industrial screening effect based on digital twinning.
Background
The screening is a separation technology for separating the bulk mixed materials with different particle sizes into materials with different particle size ranges according to the particle sizes through screen holes. The industrial screening refers to large-scale screening operation for continuously producing materials as a key link of an industrial production process in a factory or a mine mining and processing process.
Traditional screening effect evaluation is mainly to the material that carries out single screening operation, carries out static sampling and assesses screening effect. For industrial screening, in the continuous operation production process, the traditional screening effect evaluation system can only carry out random sampling evaluation, and real-time online accurate measurement cannot be realized; meanwhile, the operating condition change of the screening machine is very complex, the timeliness of the traditional screening effect evaluation system is poor, and the operating condition of the screening machine cannot be reflected in real time.
Disclosure of Invention
In view of the above analysis, the present invention aims to provide a dynamic evaluation method for industrial screening effect based on digital twin, so as to solve the technical problem that the industrial screening effect cannot be evaluated in real time in the prior art.
The purpose of the invention is mainly realized by the following technical scheme:
the invention provides a dynamic evaluation method of industrial screening effect based on digital twins, which comprises the following steps: step 1, collecting structural parameters, material parameters, particle group component parameters, load parameters in a screening process and environmental information around equipment operation;
step 2, establishing a three-dimensional structure model of the screening machine according to the structural parameters, the material parameters and the particle group division parameters of the screening machine acquired in the step 1;
step 3, obtaining a screening machine digital twin simulation model based on the established screening machine three-dimensional structure model;
step 4, correcting the digital twin simulation model of the screening machine according to the virtual test data and the actual production data of the digital twin simulation model of the screening machine;
step 5, constructing a cloud database based on the corrected screening machine digital twin simulation model, and acquiring the real-time running state of the equipment through the terminal equipment;
and 6, evaluating the screening effect in real time based on the acquired real-time running state of the equipment.
Further, the step 3 includes: carrying out mesh division on the established three-dimensional structure model of the screening machine, calculating a plurality of divided small units, selecting a corresponding interpolation algorithm for synthesis, controlling the motion state of the screening machine by adopting terminal equipment according to the acquired acceleration information to be consistent with the actual operation, further obtaining the integral structure characteristic of the screening machine, carrying out monitoring and overload early warning on key components of the screening machine, and finally obtaining a digital twin simulation model;
further, in step 4, the virtual test data includes stress and strain information of the structure of the screening machine, information of the rotation speed and temperature change of the motor, information of the acceleration of the key part of the screening machine and information of the process parameters of the material;
the method comprises the steps of collecting virtual test data of a screening machine digital twin simulation model under a working condition in real time, comparing the collected virtual test data with test data collected in actual production at the same moment, and correcting the digital twin simulation model to accurately reflect an actual industrial screening process.
Further, in step 2, the process of establishing the three-dimensional structure model of the screening machine comprises the following steps:
uploading the acquired structural parameters of the screening machine to the same industrial personal computer for processing and analysis;
adding the material parameters and particle group parameters processed and analyzed by the industrial personal computer, the load parameters in the screening process and the environment information around the operation of the equipment;
and operating through a visual platform to obtain a three-dimensional structure model of the screening machine.
Further, in step 6, the real-time evaluation comprises evaluation of screening efficiency, processing capacity, mismatch content, upper limit rate and lower limit rate;
and testing and collecting the operation condition of the screening machine in real time while evaluating in real time, and regulating and controlling the vibration parameters of the screening machine through a digital end.
Further, the method further comprises: when the screening effect is evaluated in real time, monitoring and overload early warning are carried out on the screening machine; and when the abnormality occurs, early warning and reporting are carried out, and the actual production screening machine is stopped and maintained in time.
Further, in the step 1, the structural parameters of the screening machine include structural size of the screening machine, stress strain, acceleration, motor speed and temperature variation parameters;
the material parameters comprise density, elastic modulus, Poisson's ratio, hardness, tensile strength and yield strength;
particle group parameters: particle size composition, particle shape, ash content and water content.
Further, in the step 1, the load parameter in the screening process refers to the impact of the material particles on the screen surface; the device operation ambient environment information includes temperature and humidity information around the device.
Further, in step 1, the acquisition process of the structural parameters of the screening machine comprises the following steps:
respectively arranging a stress strain sensor and a first acceleration sensor on a screen frame and an excitation beam of the screen machine, and acquiring stress strain and acceleration of the screen machine;
arranging a temperature sensor and a rotating speed sensor on the excitation motor, and monitoring the rotating speed and the temperature change condition of the excitation motor;
and sequentially arranging a plurality of groups of second acceleration sensors on the screen surface along the motion direction of the screened material, and acquiring acceleration information of the screen surface in the screening process.
Further, in step 1, the collection process of the particle group component parameters includes: a vision sensor and an X-ray are respectively arranged at the periphery of the feeding end and the discharging end of the screening machine; at the feeding end of the screening machine, a corresponding visual sensor is used for collecting the granularity composition and the particle size of the fed material, and a corresponding X-ray is used for collecting the ash content and the water content of the fed material;
at the discharge end department of screen (ing) machine, its vision sensor that corresponds is used for gathering the material granularity composition and the particle shape of the ejection of compact, and its X ray that corresponds is used for gathering the material ash content and the moisture content of the ejection of compact.
Compared with the prior art, the invention can realize at least one of the following beneficial effects:
(1) the dynamic evaluation method for the industrial screening effect based on the digital twin can dynamically evaluate the screening effect of a large-scale industrial screening process of materials in real time, simultaneously detects the operation condition of a screening machine in real time, and is suitable for evaluating the screening effect in industrial production processes such as a mining and processing process, a sandstone aggregate preparation process, industrial solid waste disposal and the like.
(2) Compared with the conventional evaluation system, the dynamic evaluation method for the industrial screening effect based on the digital twin has the following advantages that: the method comprises the steps of simulating an industrial screening process by establishing a digital twin simulation model, realizing real-time dynamic evaluation on an industrial screening effect, and simultaneously realizing real-time detection on the structural reliability of a screening machine according to the working condition parameters of the screening machine in the screening process collected in real time; the invention can effectively solve the problem that the real-time dynamic evaluation on the industrial screening effect cannot be carried out in the prior art.
(3) The dynamic evaluation method for the industrial screening effect based on the digital twin has the characteristics of high real-time performance, accuracy, matching degree and the like; aiming at the real-time property: the system can realize real-time evaluation; in the traditional screening evaluation, representative sampling is carried out on equipment running at a certain moment in industrial production, screening effect evaluation is carried out according to the sampled products, certain time delay is achieved, and real-time sampling cannot be achieved. For accuracy: the invention can carry out all analysis and evaluation on the screening effect of a certain section or a certain section of material above the screen surface, and is more accurate than the traditional random sampling. For the degree of matching: the result of the screening effect obtained by the invention is consistent with the current working condition of the screening machine, has good matching degree, and is convenient for carrying out feedback adjustment on the equipment in operation according to the evaluation result of the screening effect. The traditional screening evaluation is based on the two points, and the good matching degree of the evaluation result and the working condition of the invention cannot be achieved.
In the invention, the technical schemes can be combined with each other to realize more preferable combination schemes. Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and drawings.
Drawings
The drawings are only for purposes of illustrating particular embodiments and are not to be construed as limiting the invention, wherein like reference numerals are used to designate like parts throughout.
FIG. 1 is a process flow diagram of the dynamic evaluation method of material screening effect based on digital twinning according to the present invention;
FIG. 2 is a flow chart of the dynamic evaluation system for material screening effect based on digital twinning.
Detailed Description
The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form a part hereof, and which together with the embodiments of the invention serve to explain the principles of the invention and not to limit its scope.
The digital twin is to fully utilize data such as a physical model, sensor updating, operation history and the like to construct a simulation process and complete mapping in a virtual space so as to reflect the full life cycle process of corresponding entity equipment. Traditional screening effect evaluation is mainly to the material that carries out single screening operation, carries out static sampling and assesses screening effect. For industrial screening, in the continuous operation production process, the traditional screening effect evaluation system can only carry out random sampling evaluation, and real-time online accurate measurement cannot be realized; meanwhile, the operating condition change of the screening machine is very complex, the timeliness of the traditional screening effect evaluation system is poor, and the operating condition of the screening machine cannot be reflected in real time. Therefore, the development of a dynamic evaluation method for industrial screening effect based on digital twins is of great significance.
The invention provides a dynamic evaluation method for industrial screening effect based on digital twins, the flow of which is shown in figure 1, and the method comprises the following steps:
step 1, acquiring structural parameters, material parameters, particle group component parameters, load parameters in a screening process and information of an environment around equipment operation;
step 2, establishing a digital twinning simulation model by using the structural parameters, the material parameters and the particle group component parameters of the screening machine;
step 3, obtaining a screening machine digital twin simulation model based on the established screening machine three-dimensional structure model;
step 4, correcting the digital twin simulation model of the screening machine according to the virtual test data and the actual production data of the digital twin simulation model of the screening machine;
step 5, constructing a cloud database based on the corrected screening machine digital twin simulation model, and acquiring the real-time running state of the equipment through the terminal equipment;
and 6, evaluating the screening effect in real time based on the acquired real-time running state of the equipment.
Compared with the prior art, the dynamic evaluation method for the industrial screening effect based on the digital twin can dynamically evaluate the screening effect of the large-scale industrial screening process of the material in real time, simultaneously detects the operation condition of the screening machine in real time, and is suitable for evaluating the screening effect in industrial production processes such as a mining and processing process, a sandstone aggregate preparation process, industrial solid waste disposal and the like.
Specifically, in step 1, the structural parameters of the screening machine include the structural size of the screening machine itself, stress strain, acceleration, motor speed and temperature change. The material parameters are the self-attributes of various structures, including density, elastic modulus, poisson's ratio, hardness, tensile strength, and yield strength. Particle group parameters: particle size composition, particle shape, ash content and water content.
It should be noted that, in step 1, the material parameters are obtained without testing and can be obtained by standard inquiry.
In the step 1, the acquisition process of the structural parameters of the screening machine comprises the following steps: respectively arranging a stress strain sensor and a first acceleration sensor on a screen frame and an excitation beam of the screen machine, and acquiring stress strain and acceleration of the screen machine; arranging a temperature sensor and a rotating speed sensor on the excitation motor, and monitoring the rotating speed and the temperature change condition of the excitation motor; and sequentially arranging a plurality of groups of second acceleration sensors on the screen surface along the motion direction of the screened material, and acquiring acceleration information of the screen surface in the screening process.
In the step 1, the collection process of the particle group component parameters comprises: a vision sensor and an X-ray are respectively arranged at the periphery of the feeding end and the discharging end of the screening machine; at the feeding end of the screening machine, a corresponding visual sensor is used for acquiring the granularity composition and the particle shape of the fed material, and a corresponding X-ray is used for acquiring the ash content and the water content of the fed material; at the discharge end department of screen (ing) machine, its vision sensor that corresponds is used for gathering the material granularity composition and the particle size of the ejection of compact, and its X ray that corresponds is used for gathering the material ash content and the moisture content of the ejection of compact.
It should be noted that, in the step 1, the load parameter in the screening process refers to the impact of the material particles on the screen surface; the ambient environment information of the equipment operation comprises temperature and humidity information around the equipment.
In the step 2, the specific establishment process of the digital twin simulation model is as follows: establishing a three-dimensional structure model of the screening machine according to the structural parameters of the screening machine acquired in the step 1, wherein the establishing process comprises the following steps: the acquired screening machine structure parameters are uploaded to the same industrial personal computer for processing and analysis, and the purpose of processing and analysis is to obtain corresponding physical information including a series of parameters such as acceleration vibration frequency and the like through processing and analysis because the acquired signals are digital signals, and output the parameters from the twin model and feed back the parameters to a user. Adding the material parameters and particle group parameters processed and analyzed by the industrial personal computer, the load parameters in the screening process and the environment information around the operation of the equipment; and running through the visual platform.
Meanwhile, the established three-dimensional structure model of the screening machine is subjected to grid division, the divided small units are calculated, a corresponding interpolation algorithm is selected for synthesis, the motion state of the screening machine is controlled by terminal equipment according to the acquired acceleration information, the motion state is consistent with the actual operation, the integral structural characteristics (which refer to real-time screening machine structural parameters such as stress strain, acceleration, rotating speed, temperature change and the like) of the screening machine are further obtained, the monitoring and overload early warning of key components (including a screening surface, a side plate and an excitation beam) of the screening machine are facilitated, and a digital twin simulation model is obtained at the moment.
In addition, the step 3 includes: and carrying out mesh division on the established three-dimensional structure model of the screening machine, calculating a plurality of divided small units, selecting a corresponding interpolation algorithm for synthesis, controlling the motion state of the screening machine by adopting terminal equipment according to the acquired acceleration information to be consistent with the actual operation, further obtaining the integral structure characteristic of the screening machine, carrying out monitoring and overload early warning on key components of the screening machine, and finally obtaining a digital twin simulation model. Wherein, the specific control process is as follows: in order to make the digital twin simulation model consistent with the actual operation parameters of the screening machine, the physical information obtained by acquisition and analysis needs to be displayed on the digital twin simulation model of the screening machine in a simulation mode.
In the step 3, the specific process of correcting the digital twin simulation model is as follows: under a certain working condition, acquiring t by utilizing the digital twin simulation model established in the step 2iThe method comprises the following steps of (1) constantly testing virtual test data, wherein the virtual test data comprise stress and strain information of a screening machine structure, rotating speed and temperature change information of a motor, acceleration information of key parts (comprising a screening surface, a side plate and an excitation beam) of the screening machine and particle group component parameter information (comprising granularity composition, particle shape, ash content and water content); will be at tiMoment, virtual test data acquired by digital twin simulation model and tiTime of dayRepeatedly comparing the repeatability of the test data acquired in the corresponding actual production, and judging the reliability of the test data; and when the credibility of the numerical twin simulation model does not meet the requirement, modifying the structural parameters of the screening machine input in the step 2 so as to modify the numerical twin simulation model of the screening machine, and repeating the process to continuously modify the numerical twin simulation model until the numerical twin simulation model can accurately reflect the actual industrial screening process.
It should be noted that, when the digital twin simulation model of the screening machine is modified, the modification is directly performed in the source file of the input parameters, and the basis of the modification is tiData actually measured at a moment need to be measured for multiple times in the correction process, and i is a moment serial number; in addition, the structural parameters (the structural size, stress strain, acceleration, motor speed and temperature change of the screening machine) are obtained by testing corresponding measuring equipment.
In the step 4, the virtual test data comprises stress and strain information of the structure of the screening machine, the rotating speed and temperature change information of the motor, acceleration information of key parts of the screening machine and process parameter information of the material; the method comprises the steps of collecting virtual test data of a screening machine digital twin simulation model under a working condition in real time, comparing the collected virtual test data with test data collected in actual production at the same moment, and correcting the digital twin simulation model to accurately reflect an actual industrial screening process.
In the step 5, a cloud database is built based on the corrected screening machine digital twin simulation model, a cloud platform is built, and a user can obtain the real-time running state of the equipment through terminal equipment such as a computer and a mobile phone; meanwhile, a screening machine digital twin simulation model is adopted to evaluate the screening effect in real time, and the real-time evaluation comprises the evaluation of screening efficiency, processing capacity, mismatch content, upper limit rate and lower limit rate. Meanwhile, the operation condition of the screening machine is tested and collected in real time, and the vibration parameters of the screening machine can be regulated and controlled through a digital end.
In the step 6, the screening effect includes screening efficiency, processing capacity, mismatch content, upper limit rate and lower limit rate indexes. When the screening effect is evaluated in real time, monitoring and overload early warning are carried out on the screening machine; and when the abnormality occurs, early warning and reporting are carried out, and the actual production screening machine is stopped and maintained in time.
When the screening efficiency is evaluated, the evaluation calculation formula of the specific indexes is as follows:
upper limit rate UcLower limit rate UfThe calculation of (2):
Uc＝1-Of (1)
Uf＝1-Oc (2)
wherein, UcRepresents the upper limit ratio (%), UfRepresents a lower limit ratio (%), OfDenotes the ratio (%) of fine material in the undersize product, OcThe ratio (%) of coarse material in the oversize product is indicated.
Calculating the screening efficiency eta:
η＝Ec+Ef-100 (5)
wherein eta represents the sieving efficiency (%), EcThe positive proportion (%) of coarse grains, EfThe positive proportion (%) of the fine particles is represented byoThe yield (%) of the product on the sieve is shown, γuThe yield (%) of the undersize product, McThe ratio (%) of coarse particles in the undersize product to the feed, MfRepresents the ratio (%) of fines to feed in the oversize product;
the proportion of fine fraction in the material fed into the screening machine is (%);
the proportion (%) of the coarse fraction in the feed to the screen.
Total mismatch content MtThe calculation of (2):
Mc＝100γuUc (6)
Mf＝100γoOf (7)
Mt＝Mc+Mf (8)
Mtthe total mismatch content (%) is expressed, McThe ratio (%) of coarse particles in the undersize product to the feed, MfThe ratio (%) of fines to feed in the oversize product is expressed, γuThe yield (%) of undersize product, UcRepresents the upper limit ratio (%), OfMeans the ratio (%) of fine material in the undersize product, gammaoThe yield (%) of the product on the sieve is indicated.
Calculation of the processing capacity Q:
Q＝q×S (9)
q represents a processing capacity (t/h), and Q represents a unit area processing capacity (t/(h m)2) S represents a sieving area (m)2)。
It is emphasized that the data of each index of screening efficiency, processing capacity, mismatch content, upper limit rate and lower limit rate are obtained by the index calculation formula, the screening performance of the equipment is evaluated, and whether the granularity and the yield (processing capacity) of screened products meet the industrial production requirement is mainly determined; if the deviation is larger than the production requirement (the deviation is determined according to the condition and has no unified standard), the equipment parameters and the material parameters can be adjusted to meet the industrial production requirement, and meanwhile, the digital twin simulation model is modified according to the adjusted parameters.
It should be noted that, the method for dynamically evaluating the effect of the industrial screening according to the present invention further includes:
it should be noted that, when monitoring and overload early warning the screen machine, need monitor and early warning the operating mode parameter of shale shaker, its specific process is:
(i) under a certain condition, defining the time as t0First, the screen machine t is aligned0Stress strain, acceleration, rotating speed and temperature at the moment and acceleration information of the screen surface are collected.
(ii) Will t0Corresponding to timeAnd comparing the force strain, the acceleration, the rotating speed, the temperature and the acceleration information of the screen surface with the cloud database data interval established in the previous period, and judging whether the range of the interval is exceeded by +/-5%.
(iii) If the vibration sieve operation is beyond the range of +/-5% of the interval, the vibration sieve operation is possible to have faults, the faults are fed back to the operation process of the actual sieve machine in time, and then the actual production sieve machine is stopped for maintenance.
In above-mentioned step 5, when monitoring and overload early warning the material, need monitor and the early warning to the material parameter, its concrete process is:
(i) the method comprises the steps of collecting the granularity composition, the particle shape, the ash content and the moisture content index of the fed coal, and the granularity composition of the oversize product and the undersize product at the discharge end.
(ii) According to the grain size composition of the three materials of the feeding end, the oversize discharge end and the undersize discharge end and the self processing capacity of the equipment, the yield of the oversize products, the undersize products and the materials with different grain sizes is obtained.
(iii) And calculating the screening efficiency (comprehensive separation index), the content of the mismatch, the upper limit rate and the lower limit rate indexes of the equipment.
Compared with the prior art, the dynamic evaluation method for the industrial screening effect based on the digital twinning, provided by the invention, has the following advantages: simulating an industrial screening process through a digital twin simulation model to realize real-time dynamic evaluation on an industrial screening effect, and meanwhile, realizing real-time detection on the structural reliability of a screening machine according to the working condition parameters of the screening machine in the screening process acquired in real time; the invention can effectively solve the problem that the real-time dynamic evaluation on the industrial screening effect cannot be carried out in the prior art.
On the other hand, as shown in fig. 2, the invention also provides a dynamic evaluation system for industrial screening effect based on digital twins, as shown in fig. 1, the evaluation system comprises a digital twins simulation unit and a real-time screening effect evaluation unit which are connected with each other; the digital twin simulation unit is used for simulating an actual industrial screening process and comparing virtual test data obtained by the simulation unit with actual industrial screening data so as to reflect the actual industrial screening process; the effect real-time evaluation unit is used for evaluating the screening efficiency, the processing capacity, the content of mismatching substances, the upper limit rate and the lower limit rate; the screening effect real-time evaluation unit carries out real-time test and acquisition on the operation condition of the screening machine while carrying out real-time evaluation, and regulates and controls the vibration parameters of the screening machine through the digital twin simulation unit.
The evaluation system also comprises a data acquisition unit, wherein the parameter acquisition unit is connected with the digital twin simulation unit; the parameter acquisition unit is used for acquiring structural parameters, material parameters, particle group component parameters, load parameters in the screening process and the information of the environment around the operation of the equipment.
It is explained that the structural parameters of the screening machine comprise the structural size, stress strain, acceleration, motor rotating speed and temperature change parameters of the screening machine; the material parameters comprise density, elastic modulus, Poisson's ratio, hardness, tensile strength and yield strength; the particle group classification parameters include particle size composition, particle shape, ash content and water content.
It should be noted that the load parameter in the screening process refers to the impact of the material particles on the screen surface; the device operation ambient environment information includes temperature and humidity information around the device.
It should be noted that the digital twin simulation unit includes a screening machine digital twin simulation model, the digital twin simulation module is established through a screening machine three-dimensional structure model, and the establishing process is as follows: and carrying out mesh division on the three-dimensional structure model of the screening machine, calculating a plurality of divided small units, selecting a corresponding interpolation algorithm for synthesis, controlling the motion state of the screening machine according to the acquired acceleration information to be consistent with the actual operation, further obtaining the integral structure characteristic of the screening machine, carrying out monitoring and overload early warning on key components of the screening machine, and finally obtaining the digital twin simulation model of the screening machine.
The establishment process of the three-dimensional structure model of the screening machine comprises the following steps:
uploading the acquired structural parameters of the screening machine to the same industrial personal computer for processing and analysis; adding the material parameters and particle group parameters processed and analyzed by the industrial personal computer, the load parameters in the screening process and the environment information around the operation of the equipment; and operating through a visual platform to obtain a three-dimensional structure model of the screening machine.
In order to accurately reflect the actual industrial screening process, the virtual test data obtained by the digital twin simulation model of the screening machine comprises stress and strain information of the screening machine structure, the rotating speed and temperature change information of a motor, acceleration information of key parts of the screening machine and process parameter information of materials; the method comprises the steps of collecting virtual test data of a screening machine digital twin simulation model under a working condition in real time, comparing the collected virtual test data with test data collected in actual production at the same moment, further obtaining a corrected screening machine digital twin simulation model, and ensuring that an actual industrial screening process is accurately reflected.
In order to more conveniently control the running state of the screening machine, the evaluation system further comprises terminal equipment, and the running state of the screening machine is displayed through the terminal equipment.
It should be noted that the evaluation system of the invention further comprises an early warning unit, wherein the early warning unit comprises a monitor and an audible and visual alarm; when the screening effect is evaluated in real time, a monitor and an audible and visual alarm are utilized to monitor and perform overload early warning on the screening machine; and when the abnormality occurs, early warning and reporting are carried out, and the actual production screening machine is prompted to be stopped for maintenance.
In conclusion, compared with the existing evaluation system, the dynamic evaluation system for the industrial screening effect provided by the invention has the following advantages: simulating an industrial screening process through a screening machine digital twin simulation model to realize real-time dynamic evaluation on the industrial screening effect, and meanwhile, realizing real-time detection on the structural reliability of the screening machine according to the screening machine working condition parameters acquired in real time in the screening process; the invention can effectively solve the problem that the real-time dynamic evaluation on the industrial screening effect cannot be carried out in the prior art.
Example 1
Taking a vibrating screen for screening coal by 6mm as an example, when the vibrating screen in a model system stably operates, the working condition parameters and the material parameters of the vibrating screen are collected at any time. The method comprises the following specific steps:
for the working condition parameters of the vibrating screen, (i) firstly, the screen machine t is checked0Stress strain at time, accelerationAnd acquiring the information of the degree, the rotating speed, the temperature and the acceleration of the screen surface.
(ii) Will t0Stress strain, acceleration, rotating speed, temperature and acceleration information of the screen surface corresponding to the moment are acquired, current stress strain, acceleration, rotating speed, temperature and acceleration information of the screen surface are compared with cloud database data intervals established in the previous period, and whether the stress strain, acceleration, rotating speed, temperature and acceleration information exceed the interval range by +/-5% is judged.
(iii) If the vibration sieve operation is beyond the range of +/-5% of the interval, the operation of the vibration sieve is possibly failed, the failure is fed back to the operation process of the actual sieve machine in time, and then the actual production sieve machine is stopped for maintenance.
For material parameters, (1) the indexes of granularity composition, particle shape, ash content and water content of the fed coal are collected, and the granularity composition of oversize products and undersize products at the discharge end is collected. (2) According to the grain size composition of the three materials of the feeding end, the oversize discharge end and the undersize discharge end and the self processing capacity of the equipment, the yield of the oversize products, the undersize products and the materials with different grain sizes is obtained.
(3) And calculating the screening efficiency (comprehensive separation index), the content of the mismatch, the upper limit rate, the lower limit rate and other indexes of the equipment.
Based on the results, the operation condition and the screening effect of the screening machine can be evaluated in real time, and meanwhile, the vibration parameters of the screening machine can be regulated and controlled through digital end feedback by constructing a digital twin screening simulation system.
In conclusion, the dynamic evaluation method for the industrial screening effect based on the digital twins has the characteristics of high real-time performance, accuracy, matching degree and the like; in the aspect of real-time performance, the system can realize real-time evaluation; in the traditional screening evaluation, representative sampling is carried out on equipment running at a certain moment in industrial production, screening effect evaluation is carried out according to the sampled products, certain time delay is achieved, and real-time sampling cannot be achieved. In the aspect of accuracy, the invention can carry out all analysis and evaluation on the screening effect of a certain section or a certain section of material above the screen surface, and is more accurate than the traditional random sampling. In the aspect of matching degree, the result of the screening effect obtained by the invention is consistent with the current working condition of the screening machine, and the invention has good matching degree, and is convenient for carrying out feedback adjustment on the equipment in operation according to the evaluation result of the screening effect. The traditional screening evaluation is based on the two points, and the good matching degree of the evaluation result and the working condition of the invention cannot be achieved.
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.
Claims (10)
1. A dynamic evaluation method for industrial screening effect based on digital twinning is characterized by comprising the following steps:
step 1, acquiring structural parameters, material parameters, particle group component parameters, load parameters in a screening process and information of an environment around equipment operation;
step 2, establishing a three-dimensional structure model of the screening machine according to the structural parameters, the material parameters and the particle group division parameters of the screening machine acquired in the step 1;
step 3, obtaining a screening machine digital twin simulation model based on the established screening machine three-dimensional structure model;
step 4, correcting the digital twin simulation model of the screening machine according to the virtual test data and the actual production data of the digital twin simulation model of the screening machine;
step 5, constructing a cloud database based on the corrected screening machine digital twin simulation model, and acquiring a real-time running state through terminal equipment;
and 6, evaluating the screening effect in real time based on the acquired real-time running state.
2. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 1, wherein said step 3 comprises: and carrying out mesh division on the established three-dimensional structure model of the screening machine, calculating a plurality of divided small units, selecting a corresponding interpolation algorithm for synthesis, controlling the motion state of the screening machine by adopting terminal equipment according to the acquired acceleration information to be consistent with the actual operation, further obtaining the integral structure characteristic of the screening machine, carrying out monitoring and overload early warning on key components of the screening machine, and finally obtaining a digital twin simulation model.
3. The dynamic evaluation method for the industrial screening effect based on the digital twin as claimed in claim 1, wherein in the step 4, the virtual test data comprises stress and strain information of a screening machine structure, information of the rotation speed and temperature change of a motor, information of the acceleration of key parts of the screening machine and information of process parameters of materials;
the method comprises the steps of collecting virtual test data of a screening machine digital twin simulation model under a working condition in real time, comparing the collected virtual test data with test data collected in actual production at the same moment, and further correcting the digital twin simulation model to accurately reflect an actual industrial screening process.
4. The dynamic evaluation method for industrial screening effect based on digital twinning as claimed in claim 1, wherein in the step 2, the establishment process of the three-dimensional structure model of the screening machine comprises the following steps:
uploading the acquired structural parameters of the screening machine to the same industrial personal computer for processing and analysis;
adding the material parameters and particle group grouping parameters processed and analyzed by the industrial personal computer, the load parameters in the screening process and the environment information around the operation of equipment;
and operating through a visual platform to obtain a three-dimensional structure model of the screening machine.
5. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 2, wherein in the step 6, the real-time evaluation comprises evaluation of screening efficiency, processing capacity, mismatch content, upper limit rate and lower limit rate;
and testing and collecting the operation condition of the screening machine in real time while evaluating in real time, and regulating and controlling the vibration parameters of the screening machine through a digital end.
6. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 1, characterized in that the method further comprises: when the screening effect is evaluated in real time, monitoring and overload early warning are carried out on the screening machine; and when abnormity occurs, early warning and reporting are carried out, and shutdown maintenance is carried out on the actual production screening machine in time.
7. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 1, wherein in the step 1, the structural parameters of the screening machine include structural size of the screening machine, stress strain, acceleration, motor speed and temperature variation parameters;
the material parameters comprise density, elastic modulus, Poisson's ratio, hardness, tensile strength and yield strength;
the particle group parameters are as follows: particle size composition, particle shape, ash content and water content.
8. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 1, wherein in the step 1, the screening process load parameter refers to impact of material particles on a screening surface; the ambient environment information of the equipment operation comprises temperature and humidity information around the equipment.
9. The dynamic evaluation method for industrial screening effect based on digital twin as claimed in claim 6, wherein in the step 1, the collection process of the screening machine structural parameters comprises:
respectively arranging a stress strain sensor and a first acceleration sensor on a screen frame and an excitation beam of the screen machine, and acquiring stress strain and acceleration of the screen machine;
arranging a temperature sensor and a rotating speed sensor on the excitation motor, and monitoring the rotating speed and the temperature change condition of the excitation motor;
and sequentially arranging a plurality of groups of second acceleration sensors on the screen surface along the motion direction of the screened material, and acquiring acceleration information of the screen surface in the screening process.
10. The dynamic evaluation method for industrial screening effect based on digital twinning as claimed in claim 1 to 9, wherein in step 1, the collection process of the particle group component parameters comprises:
a vision sensor and an X-ray are respectively arranged at the periphery of the feeding end and the discharging end of the screening machine;
at the feeding end of the screening machine, a corresponding visual sensor is used for collecting the granularity composition and the particle size of the fed material, and a corresponding X-ray is used for collecting the ash content and the water content of the fed material;
at the discharge end department of screen (ing) machine, its vision sensor that corresponds is used for gathering the material granularity composition and the particle shape of the ejection of compact, and its X ray that corresponds is used for gathering the material ash content and the moisture content of the ejection of compact.
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