CN-122006860-A - Intelligent self-adaptive regulation and control system and method for filling rate of ball mill

CN122006860ACN 122006860 ACN122006860 ACN 122006860ACN-122006860-A

Abstract

The invention belongs to the technical field of ball mill control, in particular to an intelligent self-adaptive regulation and control system and method for the filling rate of a ball mill, comprising a data acquisition module, a data processing module, a self-adaptive regulation and control module and a user interaction terminal, the data acquisition module is internally provided with a sensor unit which is used for monitoring the filling condition in the ball mill in real time, including the weight, particle size and fluidity of materials. The invention can monitor and adjust the filling rate of the ball mill in real time through the intelligent self-adaptive regulation and control system, so that the grinding process of the materials is more efficient, the energy waste and the time loss caused by improper filling are reduced, meanwhile, the filling rate and the operation parameters can be precisely controlled, the grinding uniformity of the materials can be obviously improved, the quality of the final product is further improved, the higher market demand is met, and the system can effectively avoid excessive grinding and energy waste and meet the requirement of green production through the real-time monitoring and intelligent regulation and control of the sensor group.

Inventors

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Assignees

山东鑫华技术有限公司

Dates

Publication Date: 20260512
Application Date: 20260129

Claims (7)

1. An intelligent self-adaptive regulation and control system for the filling rate of a ball mill, which is characterized by comprising: The data acquisition module is internally provided with a sensor linkage group which is used for monitoring the filling condition in the ball mill in real time, including the weight, the particle size and the fluidity of materials; The data processing module is used for processing various data collected by the data acquisition module, effectively processing and analyzing the data and identifying the change trend of the filling rate; The self-adaptive regulation and control module is used for automatically regulating various operation parameters of the ball mill, including the rotating speed and the feeding rate, according to the result of the data processing module so as to achieve the optimal filling rate; the self-optimizing lifting module can optimize a filling rate adjusting strategy based on historical operation data and real-time feedback; the user interaction terminal is connected with the self-adaptive regulation and control module through wireless communication and is used for monitoring and displaying the running state and filling rate data of the ball mill in real time, and an early warning module is arranged in the self-adaptive regulation and control module, so that when abnormality is detected, operators can be prompted through the audible and visual alarm system in time.
2. The intelligent self-adaptive regulation and control system for the filling rate of the ball mill according to claim 1, wherein the sensor group comprises a weight sensor, an ultrasonic sensor, a laser sensor and a temperature sensor, and wherein: The weight sensor is arranged at the bottom of the ball mill to accurately measure the weight and filling state of materials in the barrel of the ball mill; The ultrasonic sensor is used for monitoring the height change of the material surface and reflecting the change of filling conditions; the laser sensor is used for accurately measuring the particle size and distribution of the material, and is convenient for adjusting parameters to adapt to the material characteristics; the temperature sensor is used for monitoring the internal temperature of the ball mill so as to avoid equipment damage and energy consumption increase caused by excessive temperature.
3. The intelligent self-adaptive regulation and control system for the filling rate of the ball mill according to claim 1, wherein the data processing module is internally provided with a signal processing module, a data analysis module and a trend prediction module; The signal processing module adopts a Kalman filtering algorithm to process each item of data acquired by the sensor set, and the specific flow is as follows: 1) The state of the current moment is predicted by using the state estimation of the last moment, and the state transition formula is as follows: Wherein, the To be at the moment Is used for the state prediction of (1), Is a state transition matrix, which describes the dynamic characteristics of the system, For the moment of time Is used for the state estimation of (a), To control the effect of the output; the covariance prediction formula is as follows: Wherein, the For the moment of time Is used for the prediction covariance matrix of (a), Reflecting uncertainty of a system model for a process noise covariance matrix; 2) The state estimate is updated with the new prediction data, and the Kalman gain calculation formula is as follows: Wherein, the Which is the kalman gain, determines the degree of influence of the new observation data, For an observation matrix, which connects the real state and the observation data, The covariance matrix is an observation noise, and reflects the observation noise in the measurement process; The state update formula is as follows: Wherein, the Is the moment of time Is a real observation data of the (b); The covariance update equation is as follows: Wherein, the Is a unit matrix; 3) Setting initial state estimation and covariance matrix, setting according to available historical data and experience values, completing the collection of state data in the ball mill through a data collection module, predicting the current state according to a state transition equation, and updating state covariance; 4) And each time new observation data are obtained, calculating Kalman gain, updating state and state covariance, outputting the filtered filling rate estimation in real time, and providing the filtered filling rate estimation to a data processing module.
4. An intelligent adaptive control system for the filling rate of a ball mill according to claim 3, wherein the data analysis module is based on machine learning to analyze, model and predict the filling state of historical data and real-time data, thereby identifying the pattern of filling change, wherein: The machine learning is performed by a random forest algorithm, and the specific flow is as follows: 1) Combining the data processed by the signal processing modules to form a training set, and randomly extracting samples from the training set in a put-back way so as to construct different subsets; 2) When each node splits, a part of the features are randomly selected from all the features, the optimal splitting point is found, and a decision tree is constructed by using the selected samples and the features until a stopping condition is met, wherein the specific formula is as follows: Wherein, the In order to input the characteristics of the feature, Is the first The prediction function of the tree, the final random forest prediction is obtained by the following formula: Regarding classification problems: Wherein, the For the number of trees to be used, Is an indication function; for regression problems: in line with the classification problem, Is the number of trees; The trend prediction module can predict the change trend of the filling rate in a future period by using a time sequence analysis method.
5. The intelligent self-adaptive regulation and control system for the filling rate of the ball mill according to claim 1, wherein the self-adaptive regulation and control module can adaptively adjust various operation parameters of the ball mill according to a data analysis result generated by the data processing module so as to maintain the optimal filling rate; the self-adaptive regulation and control module is internally provided with a fuzzy controller, and can determine the amplitude and direction of adjustment according to the feedback filling rate information, the target value and the historical data through a fuzzy control rule so as to realize smooth regulation; the fuzzy controller is composed of the following parts: input variables including current fill rate, target fill rate, and possibly historical fill rate, the input variables defining specifically: The current filling rate range is controlled to be 0-100%, and the fuzzy set is low, medium and high; the target filling rate range is controlled to be 0-100%, and the fuzzy set is low, medium and high; the history filling rate is controlled to be 0-100%, and the fuzzy set is descending, stable and ascending; the fuzzification module converts the input variable into a fuzzy set so as to facilitate fuzzy reasoning; presetting the current filling rate to be 70%, wherein the current filling rate is low=0, medium=0.6 and high=1; the fuzzy rule base is used for storing a preset fuzzy control rule and describing the relation between input and output, and the relation is as follows: the current filling rate is low and the target filling rate is high, and the filling quantity is increased; if the current filling rate is medium and the target filling rate is medium, keeping the filling rate unchanged; the current fill rate is high and the target fill rate is low, the fill rate is reduced When the historical filling rate is low and the current filling rate is high, the filling amount is reduced by a small amount; The reasoning engine is used for reasoning according to the fuzzy rule base and the input fuzzy value to generate fuzzy output; the defuzzification module converts the fuzzy output into a clearer control signal so as to realize control action, and the defuzzification is carried out by adopting a gravity center method, and the formula is as follows: Wherein, the In order to control the amount of the liquid, Is a membership function of fuzzy output.
6. The intelligent self-adaptive regulation and control system for the filling rate of the ball mill according to claim 1, wherein a visual user interface and an early warning module are arranged in the user interaction terminal, and the visual user interface displays real-time data by adopting a graphical interface and comprises the filling rate, the rotating speed and the feeding amount.
7. The intelligent self-adaptive regulation and control method for the filling rate of the ball mill is characterized by comprising the following steps of: the method comprises the steps of monitoring various parameters in the ball mill in real time through a sensor set built in a data acquisition module, and then transmitting collected data to a data processing module in real time; Step two, the data acquisition module transmits the collected data to the data processing module, and the signal processing module arranged in the data acquisition module carries out Kalman filtering processing on the sensor data to remove noise, so that the accuracy and stability of the signal are improved; inputting the data subjected to signal processing into a data analysis module, analyzing and modeling historical data and real-time data by adopting machine learning (random forest algorithm), identifying a mode of filling state change, extracting important features and preparing for subsequent trend prediction; in the trend prediction module, predicting the future filling rate change trend based on the result of the data analysis module, and calculating a possible filling rate interval in a future period of time so as to provide a basis for self-adaptive regulation and control; step five, the self-adaptive regulation and control module receives the analysis result of the data processing module and decides whether to adjust various operation parameters of the ball mill according to the change trend of the filling rate; Step six, converting the fuzzy output result into a clear control signal, and adjusting the operation parameters of the ball mill to realize the optimal filling rate, and simultaneously monitoring the adjusted effect to ensure that the filling rate is within a set range and continuously optimizing; And step seven, a worker can know real-time data through the user interaction terminal, wherein the real-time data comprises the filling rate, the rotating speed and the feeding amount in the ball mill, and meanwhile, an early warning module arranged in the ball mill can monitor abnormal conditions, and when the abnormal conditions are found, the worker can be prompted through an audible and visual warning system in time.

Description

Intelligent self-adaptive regulation and control system and method for filling rate of ball mill Technical Field The invention relates to the technical field of ball mill control, in particular to an intelligent self-adaptive regulation and control system and method for filling rate of a ball mill. Background The ball mill is a key device for crushing materials after the materials are crushed. In the ore mill of the type, a certain number of steel balls are filled in a cylinder body of the ore mill to serve as grinding media; It is widely used in cement, silicate products, novel building materials, refractory materials, chemical fertilizers, mineral processing of black and nonferrous metals, glass ceramics and other production industries, and carries out dry or wet grinding on various ores and other grindability materials. The ball mill is suitable for grinding various ores and other materials, is widely used in the industries of mineral separation, building materials, chemical industry and the like, and can be divided into dry type and wet type ore grinding modes. According to different ore discharging modes, the two types of the grid type and the overflow type can be realized. The prior art has the following defects or problems: The traditional ball mill is operated by relying on manual experience, so that accurate control of the filling rate is difficult to realize, and the material is uneven and high in energy consumption in the grinding process; the existing ball mill lacks of a real-time monitoring means, and cannot acquire the running state in time, so that equipment failure or low efficiency is caused; The traditional ball mill can not effectively control the energy consumption during operation, and the situation of excessive grinding often occurs; In the prior art, due to the lack of a perfect monitoring and early warning system, equipment faults and safety accidents can be caused. The foregoing is not necessarily a prior art, and falls within the technical scope of the inventors. Disclosure of Invention Aiming at the defects of the prior art, the invention provides an intelligent self-adaptive regulation and control system and method for the filling rate of a ball mill, which solve the existing problems. In order to achieve the purpose, the invention provides the following technical scheme that the intelligent self-adaptive regulation and control system for the filling rate of the ball mill comprises the following components: The data acquisition module is internally provided with a sensor linkage group which is used for monitoring the filling condition in the ball mill in real time, including the weight, the particle size and the fluidity of materials; The data processing module is used for processing various data collected by the data acquisition module, effectively processing and analyzing the data and identifying the change trend of the filling rate; The self-adaptive regulation and control module is used for automatically regulating various operation parameters of the ball mill, including the rotating speed and the feeding rate, according to the result of the data processing module so as to achieve the optimal filling rate; the self-optimizing lifting module can optimize a filling rate adjusting strategy based on historical operation data and real-time feedback; the user interaction terminal is connected with the self-adaptive regulation and control module through wireless communication and is used for monitoring and displaying the running state and filling rate data of the ball mill in real time, and an early warning module is arranged in the self-adaptive regulation and control module, so that when abnormality is detected, operators can be prompted through the audible and visual alarm system in time. In some embodiments, the sensor set is composed of a weight sensor, an ultrasonic sensor, a laser sensor, and a temperature sensor, wherein: The weight sensor is arranged at the bottom of the ball mill to accurately measure the weight and filling state of materials in the barrel of the ball mill; The ultrasonic sensor is used for monitoring the height change of the material surface and reflecting the change of filling conditions; the laser sensor is used for accurately measuring the particle size and distribution of the material, and is convenient for adjusting parameters to adapt to the material characteristics; the temperature sensor is used for monitoring the internal temperature of the ball mill so as to avoid equipment damage and energy consumption increase caused by excessive temperature. In some embodiments, the data processing module is internally provided with a signal processing module, a data analysis module and a trend prediction module; The signal processing module adopts a Kalman filtering algorithm to process each item of data acquired by the sensor set, and the specific flow is as follows: 1) The state of the current moment is predicted by using the state estimation of the last