CN115167307A

CN115167307A - Intelligent cement grinding system and working method thereof

Info

Publication number: CN115167307A
Application number: CN202210860850.3A
Authority: CN
Inventors: 张象刚; 文成忠; 李鹏斌; 唐宇军
Original assignee: Chengdu Design & Research Institute Of Building Materials Industry Co ltd
Current assignee: Chengdu Design & Research Institute Of Building Materials Industry Co ltd
Priority date: 2022-07-21
Filing date: 2022-07-21
Publication date: 2022-10-11

Abstract

The invention provides an intelligent cement grinding system and a working method thereof, wherein the system comprises a central control system, a cement grinding APC server, a video monitoring system, an intelligent detection system and a production management system which are connected through a terminal bus; the central control system comprises an operation station, an engineer station and a DCS redundant server which are connected with a terminal bus, a cement mill controller which is connected with the DCS redundant server through a factory bus, and field intelligent equipment which is connected with the cement mill controller through a control bus; the video monitoring system comprises a camera integration station, a switch and a camera which are connected in sequence; the intelligent detection system comprises an air volume detector, an online particle size analyzer, a carbon-sulfur analyzer and a mill load detector; the production management system comprises an all-purpose card system, an energy management system and an equipment management system. The invention can accurately monitor and finely control the production process in real time.

Description

Intelligent cement grinding system and working method thereof

Technical Field

The invention relates to the technical field of intelligent manufacturing in the cement industry, in particular to an intelligent cement grinding system and a working method thereof.

Background

With the improvement of the foundation of the modern cement industry, the intellectualization of the cement industry becomes an inevitable trend for realizing the breakthrough of a production management mode. The intelligent cement production system integrates high and new technologies such as big data and the Internet of things, realizes the intellectualization of detection, control, optimization and management in the production process, and enables the cement industry to continuously advance to digitalization, intellectualization and high level.

The current cement mill system is a large energy consumer in cement plants.

In the system starting and stopping process, an operator starts and stops each process group according to a logic sequence, the next group can be started and stopped after the start and stop of all equipment in the group are completed, and process parameters such as frequency of a frequency converter, valve opening, air volume, pressure and the like are adjusted after the start and stop of all the groups are completed. The start-stop process is complicated in operation and long in time due to the logical relationship among groups, so that the waste of labor and energy is caused.

In the production process, sampling, testing and analyzing are carried out by sampling equipment within specified time intervals to obtain results, and then the results are sent to a controller to adjust the ratio and the equipment operation parameters, so that the product quality is improved. The production process can not be stopped in the sampling analysis process, and once the product quality is unqualified, the whole product quality is influenced.

In the aspect of equipment management, the system functions still only monitor the equipment state and archive the equipment parameters. The situation of the equipment cannot be estimated through complex data, the fault reason cannot be analyzed autonomously, and a diagnosis report cannot be pushed. In fact, the operation parameters of the equipment contain abundant mechanical operation information, such as mechanical vibration parameters of the equipment, and scientific analysis is carried out on the operation parameters, so that the faults of unbalance, misalignment, bearing fault, gear fault, poor lubrication, blade damage, cavitation, resonance, looseness and the like of the mechanical equipment can be diagnosed. The running parameters of the equipment are monitored and scientifically analyzed in real time on line, so that the equipment can be efficiently, quickly and timely ensured to effectively run.

Data interaction among various systems in a cement mill workshop has certain closure and functional limitations. For example, a video monitoring system is limited to video integration, and an operator cannot effectively view the video in a large number of videos and the operation is tedious. Through data interaction with a control system, linkage of video and equipment start and stop and faults is achieved, effective video windows are automatically screened and popped, and the effective utilization rate of the video is increased. The same is true between systems for production control, production management, shipment, etc.

In summary, the existing cement mill workshop system is not digital and intelligent enough in functions of perception, control, decision making, execution and the like. The complete intellectualization and the unmanned solution in the aspects of production management, product quality, energy efficiency, labor productivity and the like are urgently needed.

Disclosure of Invention

The invention aims to provide an intelligent cement grinding system and a working method thereof, and aims to solve the problem that the existing cement grinding workshop system is not digitalized and intelligentized in functions of perception, control, decision, execution and the like.

The invention provides an intelligent cement grinding system which comprises a central control system, a cement mill APC server, a video monitoring system, an intelligent detection system and a production management system, wherein the central control system, the cement mill APC server, the video monitoring system, the intelligent detection system and the production management system are connected through a terminal bus;

the central control system comprises an operation station, an engineer station and a DCS redundant server which are connected with a terminal bus, a cement mill controller which is connected with the DCS redundant server through a factory bus, and field intelligent equipment which is connected with the cement mill controller through a control bus;

the video monitoring system comprises a camera integration station, a switch and a camera which are connected in sequence;

the intelligent detection system comprises an air volume detector, an online particle size analyzer, a carbon-sulfur analyzer and a mill load detector;

the production management system comprises an all-purpose card system, an energy management system and an equipment management system.

Further, the working method of the intelligent cement grinding system comprises the following steps:

the cement mill controller collects data of field intelligent equipment and carries out logic processing, and then transmits the data to the DCS redundant server; the DCS redundancy server processes and files the data; the operating station and the engineer station read and write data in the DCS redundant server and the cement mill controller, and realize monitoring of the operation state of the on-site intelligent equipment, control of start and stop of the on-site intelligent equipment and adjustment of the operation parameters of the on-site intelligent equipment in a man-machine interaction mode;

detecting product quality information by an online particle size analyzer and a carbon-sulfur analyzer; the cement grinding APC server reads the field intelligent equipment operation parameters of the DCS redundant server and the product quality information in the online granularity analyzer and the carbon-sulfur analyzer, optimizes the field intelligent equipment operation parameters through a related intelligent control loop, writes the optimized field intelligent equipment parameters into the DCS redundant server, and then automatically adjusts the field intelligent equipment operation parameters to realize intelligent production control;

the method comprises the steps that an equipment management system monitors on-site intelligent equipment start-stop signals and fault signals and transmits the on-site intelligent equipment start-stop signals and the fault signals to a DCS redundant server; the video monitoring system reads a start-stop signal and a fault signal of the field intelligent equipment in a camera shooting area of the DCS redundant server, so that a monitoring picture is linked with the start-stop and fault of the field intelligent equipment, and an effective monitoring picture is provided for an operator.

In some embodiments, the operator station and the engineer station start the field intelligent device with one key; one-key activation is initiated in the following order:

cooling fan and lubricating system → cement conveying → external circulation of cement mill → exhaust system of cement mill → rolling machine system → feeding group → transmission of cement mill;

and automatically feeding materials after the field intelligent equipment operates, automatically feeding an APC expert system after the rated output is reached, and adjusting the operation parameters of the field equipment to carry out optimization control.

In some embodiments, the intelligent control loop comprises:

(1) Warehousing to obtain finished products, namely, fineness specific surface area and granularity screen residue: adjusting the rotating speed amplitude of the powder concentrator according to the current result and the historical trend of the online particle analyzer;

(2) A mill load control loop: adjusting the rotating speed of the circulating fan according to the current feedback result and the historical trend of the mill outlet hoister:

if the current of the hoister is larger than the current value corresponding to the rated load, reducing the rotating speed of the circulating fan;

if the current of the hoister is smaller than the current value corresponding to the rated load, the rotating speed of the circulating fan is increased;

(3) The steady flow weighs the storehouse and weighs the control circuit: adjusting the feeding amount of the system according to the weight result and the historical trend of the steady-flow weighing bin:

the bin weight is reduced, and the feeding amount is increased;

the bin weight is increased to reduce the feeding amount;

(4) The current control loop of the roller press comprises: adjusting the opening of an inlet electric regulating valve according to the current and the historical trend of the roller press;

(5) Grinding head negative pressure control loop: adjusting the rotation speed of a tail grinding exhaust fan according to the negative pressure feedback result of the grinding head and the historical trend;

(6) Grinding aid control loop: after the material is ground, the grinding aid is injected, the injection amount of the grinding aid is adjusted according to the feeding amount of the system, and the proportion of the grinding aid to the feeding amount is kept.

In some embodiments, the video monitoring system performs AI machine vision intelligent analysis on the camera image, and performs early warning display on personnel safety operation, illegal production and dangerous area prevention near the starting and running equipment.

In some embodiments, the equipment management system establishes an effective mechanism model through equipment mechanism analysis, optimizes a mechanism model diagnosis conclusion by an expert, automatically intercepts fault samples, and gradually accumulates the fault samples into an expert knowledge base.

In some embodiments, the production management system analyzes and sorts the energy distribution condition in the energy management system, the sales records in the one-card system, the production condition of intelligent equipment on the cement mill site and the product inventory condition, automatically produces the ingredient list and makes a production plan.

In some embodiments, the systems of the intelligent cement grinding system adopt an OPC protocol for data transmission.

In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:

1. by adopting the technology of the invention, the production process is accurately monitored and finely controlled in real time. The timeliness of the adjusting measures can obviously reduce the probability of unqualified products, and greatly improve the comprehensive quality of the products;

2. by adopting the technology of the invention, the indexes such as actual output of the production line are effectively improved, the labor intensity from the production line to the post of enterprise management and the like is obviously reduced, and the requirement of the enterprise on personnel is reduced. Meanwhile, enterprises can benefit in the aspects of unit product energy consumption, equipment maintenance cost and the like;

3. by adopting the technology of the invention, the starting time is reduced by 5-8 minutes, namely the effective running time is improved by 5-8 minutes, about 25 t-30 t of cement can be produced by starting up the machine every time compared with the prior art according to the output accounting of 280t/h, about 350 yuan/ton of PO425 cement can be produced, and 8750-10500 yuan can be saved by starting up and stopping the machine every time.

4. By adopting the technology of the invention, the continuity of system operation is effectively improved, the operation parameters are optimized, and the intelligent expert control system, the production management system, the quality management system, the energy management system, the equipment management system and the like are cooperatively implemented, so that the cement yield can be improved by 0.5-1% in expectation;

5. by adopting the technology of the invention, the failure rate of the equipment is reduced and the service life of the equipment is prolonged. The inspection quality is expected to be improved, the equipment management level is improved, the equipment fault shutdown can be reduced, and the production is stable;

6. by adopting the technology of the invention, the starting time and the idle running of the equipment are reduced, the electric energy consumption is saved, the energy utilization rate is improved, and the production cost is reduced.

7. By adopting the technology of the invention, the shipping management operation cost is reduced, the weighing efficiency is improved, and the optimization of the shipping work effect is ensured.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention, and therefore should not be considered as limiting the scope, and it is obvious for those skilled in the art that other related drawings can be obtained according to these drawings without inventive efforts.

Fig. 1 is an architecture diagram of an intelligent cement grinding system in an embodiment of the present invention.

FIG. 2 is a process flow diagram of an on-site intelligence apparatus in accordance with an embodiment of the present invention.

FIG. 3 is a flowchart illustrating a one-touch start-up procedure according to an embodiment of the present invention.

FIG. 4 is a diagram of the control structure of the APC expert system in the embodiment of the present invention.

FIG. 5 is a diagram of a fineness-specific surface area and particle size screen residue control loop of a warehousing finished product in the embodiment of the invention.

FIG. 6 is a diagram of a load control loop of the mill in an embodiment of the present invention.

FIG. 7 is a structural diagram of a current-stabilizing weighing bin weight control loop and a current control loop of a roller press in the embodiment of the invention.

Fig. 8 is a structural diagram of a grinding head negative pressure control circuit in the embodiment of the invention.

Icon: 1-feeding scale, 2-auxiliary equipment, 3-feeding belt, 4-warehousing elevator, 5-roller press circulating elevator, 6-roller press, 7-feeding pneumatic valve, 8-three-separation powder concentrator, 9-circulating fan, 10-efficient double-grading powder concentrator, 11-bag type dust collector, 12-first waste gas fan, 13-chute fan, 14-second waste gas fan, 15-bag type dust collector, 16-solid flow meter, 17-cold air valve, 18 electric adjusting louver valve, 19-first air volume detector, 20-second air volume detector, 21-first particle size analyzer, 22-third air volume detector, 23-tube mill, 24-mill load detector, 25-high-speed plate chain elevator, 26-carbon-sulfur analyzer and 27-second particle size analyzer.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the present invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Examples

As shown in fig. 1, the present embodiment provides an intelligent cement grinding system, which includes a central control system, a cement grinding APC server, a video monitoring system, an intelligent detection system, and a production management system, which are connected by a terminal bus;

In this embodiment, as shown in fig. 2, the on-site intelligent device and the intelligent detection system, which are arranged according to the cement grinding production process, specifically include:

the device comprises a feeding scale 1, auxiliary equipment 2 (comprising a roller press oil station, a three-separation efficient powder concentrator thin oil station, a motor cooling fan, a cement grinding oil station, an oil station cooling water pump, medium-pressure cabinet air-water cooling and the like), a feeding belt 3, a warehousing elevator 4, a roller press circulating elevator 5, a roller press 6, a feeding pneumatic valve 7, a three-separation powder concentrator 8, a circulating fan 9, an efficient double-grading powder concentrator 10, a bag type dust collector 11, a first waste gas fan 12, a chute fan 13, a second waste gas fan 14, a bag type dust collector 15, a solid flow meter 16, a cold air valve 17, an electric adjusting louver valve 18, a first air volume detector 19, a second air volume detector 22, a first particle size meter 21, a second particle size meter 27, a tube mill 23, a mill load detector 24, a high-speed plate chain elevator 25 and a carbon-sulfur analyzer 26.

The working process of the field intelligent device is as follows: grinding materials (mixed materials, gypsum, limestone and clinker) pass through a feeding scale 1, then sequentially pass through a feeding belt 3 and a warehousing elevator 4, then enter a steady flow weighing bin, the materials formed after extrusion by a roller press 6 enter a V-shaped powder concentrator through a bucket elevator 5, coarse particles return to the steady flow weighing bin from the lower part of the V-shaped powder concentrator, air flow carries smaller particles, the smaller particles enter a three-separation powder concentrator 8 from an air outlet of the V-shaped powder concentrator, and then finished products (with the specific surface area of 350-450 m) generated in the extrusion process of the roller press are separated through a double-rotating-drum ² And/kg), metering the powder into a cement warehouse through a finished product chute by a solid flow meter 16, conveying the separated finished medium coarse powder into a ball mill 23 for grinding, returning the coarse powder to the roller press 6 for continuous extrusion, sorting the ground material by a high-efficiency powder sorter 10, returning the qualified finished product into the finished product cement warehouse through a finished product chute 13, and returning the coarse powder to the ball mill 23 for continuous grinding.

The data acquisition, advanced control and production management in the whole intelligent cement grinding system are as follows:

1. data acquisition

(1) Air volume detector

Mounting position 1 (first air volume detector 19 in fig. 2): the air inlet pipe of the circulating fan is straight;

measurement contents are as follows: measuring the air quantity value in the air pipe;

the purpose of use is as follows: the corresponding relation between the opening of the fan and the air quantity of the three separation powder separators is determined by measuring the air quantity value in the air pipes, and a basis is provided for adjusting the air quantity of the system.

Mounting position 2 (second air volume detecting instrument 20 in fig. 2): the air inlet pipe of the circulating fan is straight;

the purpose of use is as follows: the corresponding relation between the opening degree of the fan and the air quantity is determined by measuring the air quantity value in the air pipe, and a basis is provided for adjusting the air quantity of the system.

Mounting position 3 (second air volume detecting instrument 22 in fig. 2): the air inlet pipe of the system exhaust fan is straight;

the measurement content is as follows: measuring the air quantity value in the air pipe;

the use purpose is as follows: through measuring the air quantity value in the air pipe, the corresponding relation between the opening degree of the fan and the powder selecting air quantity of the efficient double-grading powder selecting machine is determined, and a basis is provided for adjusting the air quantity of the system.

(2) Particle size analyzer

Mounting position 1 (second granulometer 27 in fig. 2): feeding chute of finished product warehousing hoister;

measurement contents are as follows: granularity and specific surface area of a cement finished product;

the purpose of use is as follows: and providing a basis for a quality control loop of the warehousing finished product according to the specific surface area and the sifting result measured by the on-line particle size analyzer.

Mounting position 2 (first particle sizer 27 in fig. 2): separating to a tube mill scraper-trough conveyer;

measurement contents are as follows: the granularity of the semi-finished product of the cement powder grinding head;

the purpose of use is as follows: and controlling the rotating speed of the three-separation powder concentrator according to the granularity of the semi-finished product measured by the on-line granularity analyzer.

(3) Carbon and sulfur analyzer 26

Mounting position: finished product warehouse entry lifting machine feeding chute.

The measurement content is as follows: the mass contents of CO2 and SO3 in the cement finished product.

The use purpose is as follows: the proportion of limestone and gypsum in the cement ingredients is adjusted through the feedback value of the mass contents of CO2 and SO3 in the cement finished product.

The using method comprises the following steps:

1) Limestone conditioning

According to the quality requirement of ordinary silica cement, the maximum doping amount of the non-active mixed material is not more than 10% of the cement, and the doping amount of limestone in the project is determined to be less than or equal to 10%.

According to the quality requirement of ordinary portland cement, the loss on ignition of the cement finished product cannot be more than 5%, the loss on ignition of the limestone accounts for less than or equal to 4% in proportion to 1% of the loss on ignition of clinker and other mixed materials, the loss on ignition of the limestone is 40.99% according to a material balance table, and the requirement on the mixing amount of the limestone is determined to be less than or equal to 9.75%.

Determining that the content of the limestone in the cement proportion is not more than 9.75 percent, and the content of CO2 in the carbon-sulfur analyzer is not more than 3.86. The CO2 content in the carbon-sulfur analyzer can be set to exceed 3.5 for alarming, and the limestone mixing amount needs to be reduced in proportion.

2) Gypsum adjustment

According to the quality requirement of ordinary silicon cement, the SO3 content in the cement is not more than 3.5%. The general factory is controlled at 2.5% -3%, the SO3 content in the carbon-sulfur analyzer can be set to be 2.8 +/-0.2, if the SO3 content exceeds 3, an alarm is given, the gypsum proportion is reduced, and if the SO3 content is lower than 2.6, the gypsum proportion is increased.

(4) Mill load detector 24

Mounting positions: on the mill cylinder

Measurement contents are as follows:

1) Feeding out mill load according to the mill sound;

2) Measuring the temperature of the partition

The purpose of use is as follows:

1) And determining the working state of the mill according to the load feedback of the mill, and providing a basis for a load control loop of the mill.

2) When the load values given by the first bin and the second bin are different during operation, whether the material blockage phenomenon occurs on the grinding tail discharging grate plate and the bin separating plate can be judged in time, for example, when the load of the first bin is obviously greater than the load of the second bin, whether the bin separating plate is blocked is considered, and when the load of the second bin is obviously greater than the load of the first bin, whether the grinding tail discharging grate plate is blocked is considered. If the bin separation plate and the mill tail discharge grate plate are not blocked, the difference of the loads of the first bin and the second bin needs to consider whether the ball loading amount of the first bin or the second bin needs to be adjusted.

3) The temperature condition in the mill is determined according to the temperature display of the partition plate, and a basis is provided for a partition plate temperature control loop.

(3) Equipment management system

Traditional on-line monitoring triggers the warning through setting up the threshold value, and the control personnel carry out operations such as timely point inspection maintenance through reporting to the police, go to get rid of unusual and trouble. With the development of intelligent manufacturing, the monitoring data volume is increased on a large scale, and the traditional online monitoring has many problems. Firstly, large-scale data monitoring, simple threshold setting and a large amount of false reports and false reports are missed; second, fatigue is prone to manual through remote monitoring; thirdly, the plant lacks engineers for professional fault diagnosis and analysis, and the monitoring and diagnosis of a large amount of data poses a huge challenge to the engineers; the traditional online monitoring has a plurality of problems, and with the development of artificial intelligence, the problems can be effectively solved by means of artificial intelligence and the like.

The equipment management system of the embodiment establishes the effective mechanism model through equipment mechanism analysis, optimizes the mechanism model diagnosis conclusion by experts, automatically intercepts fault samples, gradually accumulates the fault samples into the expert knowledge base, can diagnose common faults, and helps monitoring and fault analysis personnel to reduce workload. Along with accumulation of fault samples and expert knowledge experiences, a manual analysis and mechanism model diagnosis mode is gradually changed into a data-driven machine learning-based diagnosis mode, the fault diagnosis efficiency and the fault diagnosis precision are improved, the manual workload is reduced, the production stability and the intelligent manufacturing level are improved, the unplanned shutdown is reduced, the safety accidents are reduced, and spare parts and maintenance plans are guided.

(4) Video identification

The video monitoring system can play a great role in the safety production aspect of cement plants. In this embodiment, a display of the camera integration station is divided into 4 areas, namely, an area a, an area B, an area C, and an area D. In the process of starting, stopping and operating the equipment, when a video monitoring system reads signals of start early warning, delayed operation, faults and the like of the equipment in a DCS redundant server through an OPC protocol, a camera in a current signal area is displayed in an area A, after a new signal is collected, the current signal is displayed in the area A, the current signal is displayed in an area B at the previous moment, and the like in sequence, so that the inheritance station is ensured to always display 4 area pictures of the current latest signal. The camera shooting picture is subjected to AI machine vision intelligent analysis, early warning display is carried out on personnel safety operation (without safety helmets, smoking and the like), illegal production (material blockage, material leakage, material breakage and the like) and dangerous area precaution (belt breakage, smoke and the like) near the starting and running equipment, after-the-fact follow-up is upgraded to advance early warning, and safe driving and protection are carried out for stable production.

The primary plan for monitoring point locations and AI scene recognition is shown in table 1.

Table 1:

2. advanced control

The working method of the intelligent cement grinding system comprises the following steps:

the cement mill controller collects data of field intelligent equipment and carries out logic processing, and then transmits the data to the DCS redundant server; the DCS redundancy server processes and files the data; the operating station and the engineer station read and write data in the DCS redundant server and the cement mill controller, and realize monitoring the running state of the on-site intelligent equipment, controlling the on-site intelligent equipment to start and stop and adjusting the running parameters of the on-site intelligent equipment in a man-machine interaction mode;

The operation station and the engineer station start the field intelligent equipment by one key; as shown in fig. 3, one-touch activation is activated in the following order:

and the material is automatically fed after the field intelligent equipment operates, the APC expert system automatically feeds after the rated output is reached, and the operation parameters of the field equipment are adjusted to carry out optimization control.

In this embodiment, with reference to fig. 2, the processes of starting, controlling, and stopping the field intelligent device are as follows:

before the field intelligent devices are started, all the field intelligent devices are detected to enter a ready-to-start state, a feeding scale of required raw materials is selected according to cement labels, operation parameters of the field intelligent devices for producing corresponding cement products are set, and as shown in table 2, whether coarse powder and fine powder are put into a bin or ground is determined, and feeding amount and raw material ratio are set. After receiving a starting command, firstly starting auxiliary equipment at the same time, and giving initial given parameters A1-F1 set in the table 1 to the frequency converter. The field intelligent device then starts itself according to the one-key start-up procedure of fig. 3. And simultaneously, after the frequency conversion equipment operates and the feedback reaches the initial setting, setting the delay setting parameters A2-F2 to the frequency converter, and after the delay setting parameters are reached, setting the parameters A3-F3 to the frequency converter according to the feeding setting parameters A3-F3 required by the output, operating the feeding scale when the system reaches the feeding state (namely the frequency conversion equipment is accelerated to finish without any fault), starting the pneumatic valve to operate the corresponding feeding scale when the steady flow weighing bin is more than the grade steady flow value, and when the steady flow weighing bin reaches the preset steady flow value, entering the production operation by the pneumatic gate valve.

Table 2:

and after the system receives the shutdown command, the feeding is stopped firstly, and after the materials are emptied, the field intelligent equipment is stopped according to the reverse process sequence of the starting process. When the system fails, the system is shut down according to the following principle that the interlocking condition is met:

(1) The upstream transport equipment of the downtime or equipment that can block incoming material is immediately shut down in a chain.

(2) Equipment that cannot intercept material upstream of the failed shutdown equipment may not shut down (e.g., roller presses, powder sorters).

(3) The main blower (circulating blower, system exhaust blower, tail grinding exhaust blower) does not participate in the chain jump stop of other equipment, but the opening degree can be reduced to maintain the negative pressure of the system.

(4) If the equipment fault is judged to be processed within 15 minutes (set according to requirements), the tube mill needs to be stopped.

(5) And (4) stopping any equipment, immediately closing the feeding equipment of the system, and stopping the addition of the grinding aid.

In the process of starting, stopping and operating the equipment, the video monitoring system reads signals of operation, faults and the like of field intelligent equipment in the DCS redundant server through an OPC protocol, and dynamically displays video pictures in corresponding equipment areas on a specified display in a stacking mode.

After the system is operated to 80% of the rated output (set according to the requirement), as shown in fig. 4, the operating parameters of the equipment are intelligently adjusted by an APC expert system, and the intelligent control loop of the quality of the finished products which are mainly warehoused comprises:

(1) Warehousing to obtain finished products, namely, fineness specific surface area and granularity screen residue: and adjusting the rotating speed amplitude of the powder concentrator according to the current result and the historical trend of the online particle analyzer, as shown in fig. 5.

and if the current of the hoisting machine is smaller than the current value corresponding to the rated load, increasing the rotating speed of the circulating fan.

As shown in FIG. 6, this ensures that the mill is always operating at full load, and no empty or full grinding occurs, maximizing the efficiency of the mill.

the bin weight is reduced, and the feeding amount is increased;

the bin weight is increased to reduce the feeding amount.

As shown in fig. 7, thereby keeping the bin weight always within the set range.

(4) The current control loop of the roller press comprises: the opening of the inlet electric control valve is adjusted according to the current of the roller press and the historical trend, as shown in fig. 7, so that the working current of the roller press is increased as much as possible (within 85% of the rated current).

(5) Grinding head negative pressure control loop: and adjusting the rotation speed of the exhaust fan at the grinding tail according to the grinding head negative pressure feedback result and the historical trend, as shown in figure 8, so as to ensure that the grinding head negative pressure is close to a set value.

(6) Grinding aid control loop: after the materials are ground, the grinding aid is injected, the injection amount of the grinding aid is adjusted according to the feeding amount of the system, and the proportion of the grinding aid to the feeding amount is kept.

After the system is stabilized, an APC expert system is input for automatic parameter optimization, and as shown in Table 3, for example, the feeding amount is reduced when the weight of the steady-flow weighing bin is increased, and the feeding amount is increased when the bin level is reduced, so that the balance is gradually realized. The same is true for other equipment and parameter control relationships in the table.

Table 3:

after the system receives the stop command, the feeding is stopped firstly, the set time is delayed, and after the logistics are emptied, the system gives the stop given parameters A4-F4 in the table 2 to the frequency converter. After the weight of the steady-flow weighing bin is lower than a set limit value, the stop range is determined according to stop reasons (such as fault stop, one-key stop and the like) after the grinding of the main machine is stopped, and the stop is delayed according to a stop principle and a stop sequence.

3. Production management

The production management system analyzes and arranges the energy distribution condition in the energy management system, the sales record in the one-card system, the production condition of intelligent equipment on the cement mill site and the product inventory condition, automatically produces a batching list and formulates a production plan.

(1) Energy management

The cement mill controller reads power consumption information stored in the MCU and the low-voltage multifunctional table of each device on site through a Profibus DP communication protocol, and transmits the power consumption information to the DCS redundant server for storage and filing. The production management system reads information such as energy consumption, yield, product specification, storage space and the like in the DCS redundant server through the terminal bus, calculates the station hour, yield, process power consumption, system power consumption and the like of each team and generates a series of reports such as days, months, seasons, years and the like. And the production condition and the product inventory condition are reflected through the report and the sales information, and the ingredient list is automatically produced. Analyzing the energy distribution defects and making a production plan.

(2) Device management

The equipment management system establishes an equipment operation and maintenance system which comprises a plurality of management processes such as planning, routing inspection, lubrication, operation and maintenance, spare parts and the like, and an equipment archive is used as a basic knowledge base for daily management. By associating with the production data, a daily maintenance work plan is automatically generated according to time, an operation cycle or yield and the like, and automatic pushing is carried out according to a management flow through the mobile terminal. Reading data archived by the redundant server through a terminal bus, analyzing a mechanical fault of equipment and carrying out intelligent alarm; the equipment management system establishes an effective mechanism model through equipment mechanism analysis, diagnoses a conclusion through an expert optimization mechanism model, automatically intercepts fault samples and gradually accumulates the fault samples into an expert knowledge base. The main modules are as follows:

the equipment comprehensive management module comprises: and establishing an equipment operation and maintenance system which comprises a plurality of management processes such as planning, routing inspection, lubrication, operation and maintenance, spare parts and the like, and taking the equipment file as a basic knowledge base for daily management.

The device master data management module: by utilizing the equipment management information system, the service processes of real-time monitoring of the process, daily production management, dynamic operation and maintenance management of the equipment, performance assessment of personnel and the like are realized, and meanwhile, closed-loop management is realized. And the synchronous automatic updating of basic file information, codes, inventory and contracts of the equipment is realized.

Equipment archive digitalization module: and establishing a basic file model by taking the equipment maintenance operation instruction as a prototype. Automatic updating of parameters is realized by docking with an asset system; the automatic updating or supplement of the related file information is realized through the association with the processes of routing inspection, lubrication, maintenance and spare parts. And carrying out online monitoring and diagnosis on equipment related to the cement mill, and storing an equipment electronic basic file and a diagnosis file record.

The self-service maintenance management module: the method comprises the steps of establishing an automatic maintenance standard by taking a maintenance operation guide book as a prototype, integrating various field detection device data (such as an inspection system, an equipment vibration system, an automatic lubrication system and the like) according to a standard requirement system, integrating data such as equipment operation parameters, a scheduled inspection cycle requirement, a spare part life cycle and the like, establishing comprehensive maintenance judgment logic, automatically triggering a maintenance plan, dispatching a work order, performing standardized acceptance and standard operation flow according to abnormal change of the comprehensive data, submitting a spare part requirement list, safety precautions and the like, and realizing automatic updating, automatic early warning and automatic publishing of the maintenance plan.

Intelligent spare part management module: the spare part storeroom and the storeroom are managed, the operation of adding, deleting, modifying and checking the spare parts can be carried out, the consumption of the spare parts is linked with the operation and maintenance work of the equipment, and the information synchronization of the equipment ledger and the spare parts is ensured.

The equipment operation statistical module: the method comprises the steps of accessing data of equipment start-stop, important process parameters and the like of a cement mill part into a factory data center, automatically counting the start-stop time of the equipment by a factory intelligent platform, establishing a corresponding shutdown reason analysis flow, and realizing rapid entry or automatic associated acquisition of the shutdown reason.

Intelligent efficient inspection system module: data of DCS redundant servers or intelligent detection equipment are collected uniformly through an information platform, and inspection content needing to be detected is directly written in.

Hidden danger automatic analysis module: the directly collected detection data of the central control system automatically corresponds to the inspection standard, and the exceeding automatic alarm is given. And the temperature and vibration measuring sensors can be arranged at the speed reducer, the bearing and other positions of the main on-site intelligent equipment, and the equivalent temperature and vibration of the running equipment are collected into an equipment management system. By technical methods such as time domain waveform analysis, envelope demodulation technology, frequency domain analysis method and the like, analysis and diagnosis results are automatically given, the running state of mechanical equipment is reported, maintenance and overhaul suggestions are provided, equipment management engineers are assisted to make scientific overhaul plan decisions, and problems are identified by self-learning and updating functions, data review and logical reasoning.

(3) Product shipment

The production management system accesses bulk cement and a rotor scale in a cement mill workshop into the all-purpose card system, and automatically identifies vehicle information through machine vision intelligent analysis of an entry camera AI; recording the entrance weight of the vehicle through the platform scale, automatically issuing an electronic information card, swiping the card to automatically charge when the vehicle enters a bulk area, and taking out the platform scale to weigh and then receiving a receipt after the vehicle is finished; the vehicle is detected by infrared rays, whether the vehicle is completely pressed or not is detected, and cheating is prevented; the WIFI is accessed to realize remote monitoring and parameter adjustment of a mobile terminal by radar smashing prevention, ensuring the safety of people and vehicles entering the field and the like; and through voice recognition, the transport personnel are remotely guided to perform standard operation.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An intelligent cement grinding system is characterized by comprising a central control system, a cement grinding APC server, a video monitoring system, an intelligent detection system and a production management system which are connected through a terminal bus;

2. The working method of the intelligent cement grinding system according to claim 1, comprising the steps of:

the method comprises the steps that an equipment management system monitors on-site intelligent equipment start-stop signals and fault signals and transmits the on-site intelligent equipment start-stop signals and the fault signals to a DCS redundant server; the video monitoring system reads a start-stop signal and a fault signal of the field intelligent equipment in a camera shooting area of the DCS redundant server, so that a monitoring picture is linked with the start-stop and fault of the field intelligent equipment, and an effective monitoring picture is provided for operators.

3. The working method of the intelligent cement grinding system according to claim 2, wherein the operation station and the engineer station start the field intelligent device by one key; one-key activation is initiated in the following order: cooling fan and lubricating system → cement conveying → external circulation of cement mill → exhaust system of cement mill → roller press system → feeding group → transmission of cement mill;

and the material is automatically fed after the field equipment operates, the APC expert system automatically feeds after the rated output is reached, and the operation parameters of the field equipment are adjusted to carry out optimization control.

4. The working method of the intelligent cement grinding system according to claim 3, wherein the intelligent control circuit comprises:

(1) Warehousing to obtain a finished product, namely, the fineness specific surface area and the granularity screen residue: adjusting the rotating speed amplitude of the powder concentrator according to the current result and the historical trend of the online particle analyzer;

(2) A mill load control loop: adjusting the rotating speed of the circulating fan according to the current feedback result and the historical trend of the mill discharging hoister:

if the current of the hoister is smaller than the current value corresponding to the rated load, increasing the rotating speed of the circulating fan;

the bin weight is reduced, and the feeding amount is increased;

the bin weight is increased to reduce the feeding amount;

(5) Grinding head negative pressure control loop: adjusting the rotating speed of a tail grinding exhaust fan according to the negative pressure feedback result of the grinding head and the historical trend;

5. The working method of the intelligent cement grinding system according to claim 2, wherein the video monitoring system performs AI machine vision intelligent analysis on the shot picture, and performs early warning display on personnel safety operation, illegal production and dangerous area prevention near the start and operation equipment.

6. The working method of the intelligent cement grinding system according to claim 2, wherein the equipment management system establishes an effective mechanism model through equipment mechanism analysis, and automatically intercepts fault samples by expert optimization mechanism model diagnosis conclusion, and gradually accumulates into an expert knowledge base.

7. The working method of the intelligent cement grinding system according to claim 2, wherein the production management system analyzes and collates the energy distribution condition in the energy management system, the sales record in the one-card system, the production condition of the intelligent equipment on the cement grinding site and the product inventory condition, automatically produces the ingredient list, and makes a production plan.

8. The working method of the intelligent cement grinding system according to claim 2, wherein data transmission is performed between the systems of the intelligent cement grinding system by using an OPC protocol.