CN113643298A - Working condition diagnosis method and device, electronic equipment and computer readable storage medium - Google Patents
Working condition diagnosis method and device, electronic equipment and computer readable storage medium Download PDFInfo
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Abstract
The invention provides a working condition diagnosis method, a working condition diagnosis device, electronic equipment and a computer readable storage medium, wherein the working condition diagnosis method comprises the following steps: acquiring characteristic parameters of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters and foam parameters of the foam image; and diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result. The invention can find the working condition change in time and intervene, ensures the stability of the production process and can improve the accuracy of the diagnosis result.
Description
Technical Field
The invention relates to the technical field of mineral flotation, in particular to a working condition diagnosis method, a working condition diagnosis device, electronic equipment and a computer-readable storage medium.
Background
The flotation is that a surfactant-foaming agent capable of generating a large amount of bubbles is adopted, and the bubbles can take away specified mineral powder in the flotation process, so that the purpose of mineral separation is achieved. The flotation process is a slowly changing physicochemical reaction process, and in the actual production process, the working condition needs to be diagnosed in real time, so that the reagent change and the abnormal event are processed, and the stability of the production process is ensured. In the prior art, the real-time diagnosis of the working condition is usually performed by performing analysis and judgment through visual observation and manual sample panning of an operator, the operator may not find the working condition change at the first time, and the diagnosis result is often influenced by the subjectivity of the operator, so that the diagnosis is not timely and the result is inaccurate.
Disclosure of Invention
In view of the above, the present invention provides a method, an apparatus, an electronic device and a computer-readable storage medium for diagnosing a working condition, which can detect and intervene a working condition change in time, ensure stability of a production process, and improve accuracy of a diagnostic result.
In order to achieve the above purpose, the embodiment of the present invention adopts the following technical solutions:
in a first aspect, an embodiment of the present invention provides a working condition diagnosis method, including: acquiring characteristic parameters of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters and foam parameters of the foam image; and diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
In one embodiment, the step of obtaining characteristic parameters for each operation in the flotation process comprises: determining a froth parameter based on the acquired froth image of each operation in the flotation process; wherein the foam parameters include: foam flow rate, foam number ratio, and foam color.
In one embodiment, the step of determining froth parameters based on the acquired froth images for each operation in the flotation process comprises: determining the coordinates of each target pixel point in a color coordinate system based on the RGB values of the target pixel points in the foam image; the target pixel points comprise pixel points of which the brightness values in the foam image are within a preset brightness interval; determining intersection point coordinates of a vertical line from the target pixel point to a preset straight line and the preset straight line based on coordinates of the target pixel point in a color coordinate system; respectively calculating a first distance from the intersection point coordinate to a first preset point and a second distance from the intersection point coordinate to a second preset point; determining a color value of each target pixel point based on the first distance and the second distance; and determining the foam color based on the color value of each target pixel point.
In one embodiment, the step of determining froth parameters based on the acquired froth images for each operation in the flotation process comprises: segmenting the foam image, and sequencing connected domains in the segmented foam image based on the pixel areas of the connected domains to obtain a connected domain area sequence; determining the number of foams in different preset area intervals based on the connected domain area sequence and a plurality of preset thresholds, and determining a foam number ratio based on the number of foams in different preset area intervals; the preset area interval is divided based on a plurality of preset thresholds.
In one embodiment, the characteristic parameters further include: the filtering value, the instantaneous change rate and the general trend corresponding to the foam parameters, and the filtering value and the general trend corresponding to the grade parameters; the filtering value comprises a current filtering value and a filtering value before a preset time period; after the step of determining the froth parameters based on the acquired froth images of each operation in the flotation process, the method further comprises the following steps: calculating the current filtering value of the foam parameter and the filtering value before the preset time period, and calculating the current filtering value of the grade parameter and the filtering value before the preset time period; and calculating the instantaneous change rate and the general trend of the foam parameters based on the current filtered value of the foam parameters and the filtered value before the preset time period, and calculating the general trend of the grade parameters based on the current filtered value of the grade parameters and the filtered value before the preset time period.
In one embodiment, the production parameters include: the addition amount of the medicament, the thickness of a foam layer and the liquid level aeration quantity; the characteristic parameters further include: the ratio of the metal quantity of the collecting agent to the metal quantity of the raw ore, the single-operation metal yield, the theoretical recovery rate and the accumulated value of the instantaneous color change rate; after the step of obtaining the characteristic parameters of each operation in the flotation process, the method further comprises the following steps:
calculating the ratio of the metal amount of the collecting agent to the metal amount of the raw ore according to the following formula:
wherein,K C representing the ratio of the amount of the collecting agent to the amount of the crude ore metal,
to representxThe total amount of collector addition for each run,
representing the average grade of the raw ore;
the single pass metal yield was calculated according to the following formula:
wherein,M x which represents the yield of the metal in a single operation,
to representxThe average grade of the operation is determined,K m the scale factor is expressed in terms of a scale factor,Ar（t) To representtThe liquid level aeration quantity at the moment,Lf（t) To representtThe thickness of the foam layer at the moment,v x （t) To representxWork intThe foam flow rate at that time;
the theoretical recovery was calculated according to the following formula:
wherein,r R the theoretical recovery rate is shown in the figure,
represents the raw ore grade before the reaction time of the process,G C the quality of the concentrate is shown,G T representing the grade of the tailings;
calculating the accumulated value of the instantaneous change rate of the color according to the following formula:
when T ish>At the time of 0, the number of the first,
when T ish<At the time of 0, the number of the first,
wherein,S h the accumulated value of the instantaneous rate of change of the color is represented,I h indicating the instantaneous rate of change of the foam color,L H the upper limit value is represented by the following numerical value,L HH the upper limit value is represented as an upper limit value,iwhich represents the number of sample points that are to be sampled,T h indicating the general trend of foam color.
In one embodiment, the step of performing condition diagnosis on the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result further includes: determining constraint conditions of preset diagnosis rules based on the characteristic parameters; and (4) performing working condition diagnosis on the flotation process based on the constraint conditions and the characteristic parameters to obtain a diagnosis result.
In a second aspect, an embodiment of the present invention provides a working condition diagnosing apparatus, including: the characteristic parameter acquisition module is used for acquiring the characteristic parameter of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters and foam parameters of the foam image; and the diagnosis module is used for diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
In a third aspect, an embodiment of the present invention provides an electronic device, which includes a processor and a memory, where the memory stores computer-executable instructions capable of being executed by the processor, and the processor executes the computer-executable instructions to implement the steps of any one of the methods provided in the first aspect.
In a fourth aspect, the present invention provides a computer-readable storage medium, on which a computer program is stored, where the computer program is executed by a processor to perform the steps of any one of the methods provided in the first aspect.
The embodiment of the invention has the following beneficial effects:
according to the working condition diagnosis method, the working condition diagnosis device, the electronic equipment and the computer-readable storage medium, the characteristic parameters of each operation in the flotation process are firstly obtained (the characteristic parameters at least comprise production parameters, grade parameters and foam parameters of a foam image); and then, carrying out working condition diagnosis on the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result. The method can be used for carrying out real-time working condition diagnosis on the basis of preset diagnosis rules by combining various characteristic parameters such as production parameters, grade parameters and foam parameters of the foam image of each operation, so that working condition changes can be found and intervened in time, the accumulated time of abnormal occurrence is shortened, and the stability of the production process is ensured; meanwhile, diagnosis is carried out according to preset diagnosis rules, so that the standard can be judged uniformly, subjective influences brought by operators are reduced, and the accuracy of diagnosis results is improved.
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 claims hereof as well as the appended drawings.
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a flow chart of a method for diagnosing operating conditions according to an embodiment of the present invention;
FIG. 2 is a schematic view of a process model according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of a working condition diagnosing apparatus according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of an electronic device according to an embodiment of the present invention.
Detailed Description
To make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are some, but not all embodiments of the present 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.
The copper metal sorting process is the same as that of other nonferrous metal minerals, the real-time diagnosis of the working condition is usually carried out by analyzing and judging through visual judgment and manual sample panning of operators, the requirements on the experience of the operators are very high, and particularly, in the mixed copper flotation process, different operators hardly form the consistent standard on the color and the form of foam, the sample preparation method and the judgment standard. Therefore, the online diagnosis and real-time analysis of the working conditions are always important challenges in the beneficiation process. In addition, due to the offline nature of the manual analysis, the operator is often limited to recognize slow variations in the flotation process during the decision-making of the operating conditions. Therefore, in the prior art, an operator may not find the working condition change in the first time, and the diagnosis result is often influenced by the subjectivity of the operator, so that the diagnosis is not timely and the result is inaccurate.
Based on this, the invention aims to provide a working condition diagnosis method, a working condition diagnosis device, an electronic device and a computer readable storage medium, which can find working condition changes in time and intervene, ensure the stability of a production process and improve the accuracy of a diagnosis result.
To facilitate understanding of the present embodiment, first, a detailed description is given of an operating condition diagnosing method disclosed in the present embodiment, referring to a flowchart of an operating condition diagnosing method shown in fig. 1, where the method may be executed by an electronic device, and the electronic device may be a computer, a mobile phone, or the like, and the method mainly includes the following steps S102 to S104:
step S102: and acquiring characteristic parameters of each operation in the flotation process.
Wherein the characteristic parameters at least include: production parameters, grade parameters, and foam parameters of the foam image. In practical application, one flotation operation process may include a plurality of operations, taking a rough sweeping process of copper flotation as an example, general copper flotation includes 5 to 10 rough sweeping operations, which can be monitored for each operation respectively, a froth image of each operation is obtained through a froth image analyzer, the froth image is further analyzed to obtain froth parameters, such as froth flow rate, froth color and froth number ratio, and the like, a grade parameter of each operation is obtained through the grade analyzer, and production parameters, such as chemical addition amount, froth layer thickness, liquid level aeration amount, and the like, are obtained through a beneficiation machine control system.
Considering that there is a strong coupling relationship between the foam parameters and the production parameters and the grade parameters, and each operation process data of the grade analysis has a direct correlation with the foam overflow condition produced upstream and downstream, therefore, in this embodiment, a basic mathematical equation for condition diagnosis can be obtained according to the historical data and mathematical transformation of the parameters on the basis of the obtained characteristic parameters, then the constant terms in the mathematical equations are solved through experiments for a specific operation flow, so as to obtain constant values of the operation flow, and the constant values are used as the characteristic parameters for condition diagnosis.
Step S104: and diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
In one embodiment, the preset diagnostic rule is to constrain the characteristic parameters through a proportionality coefficient, and the working condition diagnosis is performed according to the and-or logic and causal logic judgment, and the expression of the diagnostic rule of the collecting agent can be:
whereinQthe number ratio of the foam is expressed,r R the theoretical recovery rate is shown in the figure,K c representing the ratio of the collector to the crude metal,T h indicating the general trend of the color of the foam,D f denotes a blowing agent additive which is,S h indicating the color instantaneous change rate integrated value, the upper right hand scale H indicates the upper limit, HH indicates the upper limit, L indicates the lower limit, and LL indicates the lower limit. And when the obtained characteristic parameters meet the expression, determining that the state of the collecting agent is excessive.
The working condition diagnosis method provided by the embodiment of the invention can be used for carrying out working condition diagnosis in real time based on the preset diagnosis rule by combining various characteristic parameters such as production parameters, grade parameters and foam parameters of foam images of each operation, thereby timely finding working condition changes and intervening, reducing the accumulated time of abnormal occurrence and ensuring the stability of the production process; meanwhile, diagnosis is carried out according to preset diagnosis rules, so that the standard can be judged uniformly, subjective influences brought by operators are reduced, and the accuracy of diagnosis results is improved.
In one embodiment, the working condition can be judged according to the characteristics of the color, the size and the like of the foam in the flotation process, and the foam characteristics can be extracted through a foam image of each operation acquired by a foam image analyzer. Based on this, in the embodiment of the present invention, when acquiring the foam parameter, the step S102 further includes: determining a froth parameter based on the acquired froth image of each operation in the flotation process; wherein the foam parameters include: foam flow rate, foam number ratio, and foam color.
For convenience in understanding, for different froth parameters, the embodiment of the present invention further provides a method for extracting different parameters, that is, for the step of determining the froth parameters based on the acquired froth image of each operation in the flotation process, the method mainly includes the following three ways:
the first method is as follows: the foam parameter is foam flow rate
In a particular application, the bubble image analyzer has a certain frequency when acquiring the bubble image, such as: 25 frames of bubble images are acquired every second, so that the time interval between every two adjacent frames of bubble images is 40 milliseconds. Based on this, in this embodiment, the displacement of the same bubble in the overflow weir direction in any one frame of bubble image relative to the bubble in the previous frame or several previous frames of bubble images can be determined, and then the bubble flow rate (unit: mm/s) can be calculated according to the interval time of different bubble images.
The second method comprises the following steps: the foam parameter is foam color
Specifically, the foam color of the foam image is the average value of the color values of the pixel points in the foam image, and the calculating of the foam color in this embodiment mainly includes the following steps a1 to a 5:
step a 1: and determining the coordinates of each target pixel point in the color coordinate system based on the RGB values of the target pixel points in the foam image.
And the target pixel points comprise pixel points in the foam image, wherein the brightness values of the pixel points are within a preset brightness interval. The preset interval can be 20% -90% of the overall brightness, specifically, all pixel points in the foam image can be sequenced from high to low (or from low to high) according to the brightness value, and the pixel points with the brightness values between 20% -90% of the overall brightness are selected as target pixel points, namely the target pixel points are pixel points with the central brightness in the foam image.
In an embodiment, each pixel point may obtain a unique point in a color coordinate system (i.e., CIE coordinate system), and each target pixel point may be calculated according to the following formulaiCoordinates in the color coordinate system (x i ，y i ）：
In the formula (1), the first and second groups,R i 、G i 、B i representing target pixel points in a foam imageiThe RGB value of (a).
Step a 2: and determining the intersection point coordinates of the vertical line from the target pixel point to the preset straight line and the preset straight line based on the coordinates of the target pixel point in the color coordinate system.
In an implementation manner, a color space domain can be formed according to the coordinates of each pixel point under a color coordinate system, that is, a tongue-shaped graph, a preset straight line can be determined according to the distribution of colors in the tongue-shaped graph, and the color values of all the pixel points in the image all fall within the projection range of the preset straight line, so that the color interval to which the pixel point belongs can be determined according to the position of the vertical point of each pixel point to the preset straight line. Based on this, the present embodiment may be based on the coordinates of the target pixel point(s) ((x i ，y i ) And calculating the coordinate of the vertical point from the point to the preset straight line, namely the coordinate of the intersection point of the vertical line from the point to the preset straight line and the preset straight line.
Further, the preset straight lines are different for different selection working conditions. In the copper oxide flotation process, the foam color is mainly green, and the color interval judged by the working condition changes in a yellow-yellow green-blackish green interval; for the change of the working condition in the copper sulfide process mainly changes from grey-light grey-black brown, so that the mapping equations (i.e. the preset straight lines) of different working conditions are different, see table 1 specifically.
TABLE 1 Preset equation of straight line and Preset coordinates under different conditions
Step a 3: and respectively calculating a first distance from the intersection point coordinate to the first preset point and a second distance from the intersection point coordinate to the second preset point.
Wherein the first preset point and the second preset point are fixed points of a preset straight line, and can be determined according to different working conditions, such as shown in table 1 (x1,y1) And (a)x2,y2）。
Step a 4: and determining the color value of each target pixel point based on the first distance and the second distance.
Specifically, the color value of the target pixel point can be calculated according to the following formulah i ：
In the formula (2), the first and second groups,d 1representing a first distance of the intersection coordinates to a first preset point,d 2representing a second distance of the intersection coordinates to a second preset point.
Step a 5: and determining the foam color based on the color value of each target pixel point.
Specifically, the foam color can be calculated according to the following formulah：
In the formula (3), the first and second groups,nthe number of the target pixel points is represented,
whereinROIand representing a target pixel point, namely a pixel point with middle brightness in the foam image.
In one embodiment, the froth color can also be understood as a characteristic parameter of the grey-black difference of the froth color in the copper sulfide flotation process or the yellow-green difference of the froth color in the copper oxide flotation process.
The third method comprises the following steps: the foam parameter is the number ratio of foams
In one embodiment, when the froth parameters include a froth number ratio, determining the froth parameters based on the acquired froth image for each job in the flotation process mainly includes the following steps b1 to b 2:
step b 1: and segmenting the foam image, and sequencing connected domains in the segmented foam image based on the pixel areas of the connected domains to obtain a connected domain area sequence.
In one particular application, a watershed segmentation algorithm with marker control may be employed to segment the foam image. The watershed segmentation algorithm is an image region segmentation method, and in the segmentation process, the similarity between adjacent pixels can be used as an important reference basis, so that pixel points which are close in spatial position and have close gray values (gradient calculation) are connected with each other to form a closed contour. The idea of marker-controlled watershed algorithms is to use some additional knowledge to find some internal and external markers in the original image to guide the algorithm to perform segmentation, preventing over-segmentation.
The segmented bubble image may include a plurality of connected domains (i.e., bubbles), and in order to facilitate statistics of the bubble size, the connected domains may be ordered according to pixel areas from large to small (or from small to large), so as to obtain a connected domain area sequence:C 1,C 2,C 3,…,C n 。
step b 2: determining the number of foams in different preset area intervals based on the connected domain area sequence and a plurality of preset thresholds, and determining a foam number ratio based on the number of foams in different preset area intervals; the preset area interval is divided based on a plurality of preset thresholds.
In one embodiment, the preset threshold may be determined according to the total pixel number of the bubble image, and the preset threshold may be as shown in table 2 assuming that the total pixel number is P.
TABLE 2 parameter threshold table
Based on the preset threshold value in Table 2th1、th2 andth3 four preset area intervals can be divided, because the area is less thanth3, in order to improve the accuracy of statistics and reduce the influence of noise, the embodiment of the invention respectively counts the pixel area larger than the area of the pixelth1, pixel area isth2 toth1 and the pixel area is betweenth3 toth2, the quantity of foam in different preset pixel area intervals can be determined according to the following formula:
wherein,
。
further, the foam number ratio is as follows:
wherein, if L<1，S<1, let L =1 and S = 1.
Considering that the flotation process is a slowly changing physicochemical reaction process, the diagnosis of the working condition also needs to be analyzed by combining the transitional working condition state within a longer time period so as to improve the accuracy of diagnosis and further make an accurate decision. Based on this, the characteristic parameters in the embodiment of the present invention further include: the filtering value, the instantaneous change rate and the general trend corresponding to the foam parameters, and the filtering value and the general trend corresponding to the grade parameters; wherein the filtered value includes a current filtered value and a filtered value prior to a preset time period. After obtaining the foam parameters and the grade parameters, the method also comprises the following steps: calculating the current filtering value of the foam parameter and the filtering value before the preset time period, and calculating the current filtering value of the grade parameter and the filtering value before the preset time period; and calculating the instantaneous change rate and the general trend of the foam parameters based on the current filtered value of the foam parameters and the filtered value before the preset time period, and calculating the general trend of the grade parameters based on the current filtered value of the grade parameters and the filtered value before the preset time period.
In one embodiment, taking the foam flow rate as an example, assuming that the sampling period of the parameter is 2s, if the current time is t302s before t29By analogy, t is before 58s1Therefore, the filtered value of the foam flow rate at the current time (i.e., the current filtered value of the foam flow rate) is the filtered value
Similarly, a filtered value before a predetermined period of time (such as 20 minutes) may be obtainedV -20。
Further, the filtered value may be based on the flow rate of the foam one minute agoV -1Calculating to obtain the instantaneous change rate and the general trend of the foam flow rate, specifically, calculating the instantaneous change rate of the foam flow rate according to the following formula:
in the formula (5), the first and second groups,I v representing the instantaneous rate of change of the foam flow rate,Va current filtered value representing the flow rate of the froth,V -1represents the filtered value of the foam flow rate one minute before.
The general trend of the foam flow rate was calculated according to the following formula:
in the formula (6), the first and second groups,T v indicating the general trend of the foam flow rate,Va current filtered value representing the flow rate of the froth,V -20represents the filtered value of the foam flow rate 20 minutes ago.
Similarly, the foam color can be obtained by the above methodhAnd the number ratio of foamsQThe corresponding current filtered value, the filtered value before 20 minutes, the instantaneous change rate and the general trend, and the corresponding current filtered value, the filtered value before 20 minutes and the general trend of the grade parameter. Since the measurement period of the grade analyzer is generally 20 minutes, the grade parameters have no instantaneous change rate. Specifically, see table 3, where the pulp/froth grade is one of the grade parameters.
TABLE 3 statistical table of characteristic parameters
For process condition diagnostics, it is also desirable to incorporate key parameters associated with flotation production, including: the additive amount of the reagent (the additive amount of the foaming agent and the additive amount of the collecting agent), the thickness of a foam layer and the inflation amount of the liquid level. Before the working condition diagnosis, a plurality of related constant values (namely characteristic parameters) are obtained through a process test, and after the process flow and the selected minerals are determined, the constant values of the same operation are kept unchanged, so that the change of a certain working condition characteristic can be predicted according to the change of the constant values during the working condition diagnosis, and further logical reasoning is carried out.
The constant values, i.e., the characteristic parameters in this embodiment further include: the ratio of the metal quantity of the collecting agent to the metal quantity of the raw ore, the single-operation metal yield, the theoretical recovery rate and the accumulated value of the instantaneous color change rate.
Specifically, the ratio of the amount of the collector to the amount of the raw ore metal can be calculated according to the following formula:
in the formula (7), the first and second groups,K C representing the ratio of the amount of the collecting agent to the amount of the crude ore metal,
to representxThe total amount of collector addition for each run,
the average grade of the raw ore, namely the average grade of the raw ore in the process reaction time is shown. The ratio of the amount of collector to the metal content of the raw ore is suspected to be approximately constant in the cumulative amount of collector to the average grade ratio of the raw ore assuming a constant feed rate.
Further, the single-job metal yield can be calculated according to the following formula:
in the formula (8), the first and second groups,M x representing sheet jobsxThe yield of the metal of (a) is,
to representxAverage grade of operation, i.e.xOperate at [ t0,t1]The average grade over a period of time,Ar（t) To representtThe liquid level aeration quantity at the moment,Lf（t) To representtThe thickness of the foam layer at the moment,v x （t) To representxWork intThe foam flow rate at a momentt 0,t 1]Which represents the reaction time of a flow path,K m indicating the scaling factor, the scaling factor between different jobsK m In contrast, it can be derived in advance from experimental tests. The above equation (8) is expressed as a single jobxMetal yield and foam flow rate ofvAnd average grade
The product is proportional to the square root of the ratio of the liquid level aeration to the foam layer thickness.
Further, the theoretical recovery rate can be calculated according to the following formula:
in the formula (9), the reaction mixture,r R the theoretical recovery rate is shown in the figure,
indicating the grade of the raw ore before the reaction time of the process, e.g. the start time of the process ist 0Then, then
To representt 0The grade of the raw ore before the moment,G C the quality of the concentrate is shown,G T indicating the grade of the tailings. The theoretical recovery remains essentially unchanged without radical changes in the process conditions.
Further, the color instantaneous change rate integrated value may be calculated according to the following formula:
when T ish>At 0, calculate IhThe total change in the color of the sample within 20 minutes is the cumulative value S of the color changehComprises the following steps:
when T ish<When 0, the color change accumulated value S can be obtained according to the same principle of symmetryhIs negative, calculate IhThe total change in the color of the sample within 20 minutes is the cumulative value S of the color changehComprises the following steps:
in the formula (10), the first and second groups,S h the accumulated value of the instantaneous rate of change of the color is represented,I h indicating the instantaneous rate of change of the foam color,L H the upper limit value is represented by the following numerical value,L HH the upper limit value is represented as an upper limit value,iwhich represents the number of sample points that are to be sampled,T h indicating the general trend of foam color.
Considering that the particularity of the flotation process and the characterization of the working conditions, particularly the medicament, are difficult to use in a simple mathematical model to establish a direct mathematical relationship with the detection parameters, a parameter calculation formula is required to be adopted to derive each constant value of the relational expression according to a fixed production process, and the process deviation range is further constrained by a proportionality coefficient. In the actual working condition diagnosis and prediction process, the instantaneous parameter values are brought into the parameter expression, and then AND logic and causal logic judgment are carried out according to the preset diagnosis rule, and a diagnosis result is formed.
Based on this, the step of performing the working condition diagnosis on the flotation process based on the characteristic parameters and the preset diagnosis rule to obtain the diagnosis result provided by the embodiment of the invention specifically includes: determining constraint conditions of preset diagnosis rules based on the characteristic parameters; and (4) performing working condition diagnosis on the flotation process based on the constraint conditions and the characteristic parameters to obtain a diagnosis result.
In one embodiment, using flotation process collector prediction and frother prediction as examples, such as diagnostic task a, see the diagnostic rule expressions for collector state prediction shown in table 4, and see the diagnostic rule expressions for frother state prediction shown in table 5. When the logic and causal judgment results are satisfied, the state of the collecting agent or the foaming agent can be obtained, the current working condition is further determined according to the state of the collecting agent or the foaming agent, and the addition amount of the collecting agent or the additive can be adjusted according to the state of the collecting agent or the foaming agent. For example, the following steps are carried out: diagnosis assuming that the obtained characteristic parameters satisfy the following collector statesBreaking the expression:
if the amount of the collector is insufficient, the amount of the collector can be increased appropriately.
It should be additionally noted that, for the characteristic parameters, the upper right notation H in tables 4 and 5 indicates an upper limit, HH indicates an upper limit, L indicates a lower limit, and LL indicates a lower limit.
Table 4 diagnostic rule expressions for collector state prediction
TABLE 5 diagnostic rule expressions for frother state prediction
In one embodiment, the characteristic parameterK C 、M A 、Df、Ar、r R The data are accumulated through process experiments, and the parameter set values of different processes are different. The set values (constraints) of the characteristic parameters referred to in tables 4 and 5 can be seen from table 6.
TABLE 6 set values for different characteristic parameters
The working condition diagnosis method provided by the embodiment of the invention mainly adopts a grade analyzer, a foam image analyzer and production parameters (foam thickness and air inflation) of the flotation machine, and obtains a basic mathematical equation of the working condition diagnosis through historical values and mathematical transformation of the parameters. And solving constant terms in a basic mathematical equation of working condition diagnosis through experiments according to different operations of a specific process link, and solving constant values belonging to the process in each equation. And further carrying out logic comparison and causal judgment on the characteristics in different optimization intervals to obtain different dosing states in the flotation process, thereby realizing working condition diagnosis.
Compared with the prior art, the method extracts the foam parameters based on the foam image, and processes the parameters of the transition process such as the process parameters of the grade analyzer and the flotation machine, so that the problems of data failure, diagnosis accuracy, serious parameter quantization distortion and the like caused by abnormal working conditions can be solved; secondly, a diagnosis rule is constructed in advance through the instantaneous value, the historical value and the change rate of the key characteristic parameters and the characteristics of the flotation process, and the working condition change can be found as early as possible based on the characteristic parameters and the diagnosis rule in the flotation process, so that intervention can be performed in advance, the accumulated time of abnormal occurrence is shortened, and the production can reach a steady state as fast as possible. The method has important significance for sorting the production process by timely discovering the working condition migration and providing an alarm or warning, and simultaneously makes up the blank of multidimensional data joint analysis of the medicament adding state.
In the flotation process of mixed copper, a sorting sequence of firstly sulfur and then oxygen is generally adopted, and in the actual production process, an operator needs to diagnose the working condition in real time so as to change the chemical and process abnormal events. The series of diagnostic operations mainly occur in the course of the coarse scavenging of the mixed copper flotation process. In order to facilitate understanding, the embodiment of the invention provides another working condition diagnosis method by taking a copper rough sweeping process as an example, and the working condition diagnosis method mainly comprises the following steps 1 to 4:
step 1: and acquiring real-time data of online grade parameters, foam images and production parameters in the flotation process.
Specifically, before acquiring data, a flotation process model needs to be determined, the number of sets of process operations is determined, and for a rough scavenging process of mixed copper flotation, the copper flotation generally comprises 5-10 rough scavenging operations, and a process model schematic diagram shown in fig. 2 is shown, wherein A, B, C represents three operations, and each operation is provided with a grade analysis measuring point and a froth image measuring point. It should be noted that fig. 2 is only an example, mainly illustrates a relationship model of upstream and downstream jobs, and does not limit the number of jobs.
In one embodiment, the production parameters (i.e., the base parameters) include: the foam layer thickness, the liquid level aeration quantity, the medicament additive and the like, the grade parameters comprise ore pulp grade and the like acquired by a special instrument grade analyzer, and parameters such as foam flow rate, foam color, foam number ratio and the like can be acquired based on a foam image acquired by a foam image analyzer.
Furthermore, time-dependent characteristic parameters can also be calculated from the acquired data in combination with historical data, such as: the filtering values, the instantaneous change rates and the general trends corresponding to the parameters such as the foam flow rate, the foam color and the foam number ratio, and the filtering values and the general trends corresponding to the grade parameters; wherein the filtered value includes a current filtered value and a filtered value prior to a preset time period.
Step 2: and establishing a working condition characteristic parameter expression.
In one embodiment, the operating condition characteristic parameters include: the foam flow rate, the foam color, the general trend of the foam color, the instantaneous change rate, the foam number ratio, the ratio of the collecting agent to the metal amount of the raw ore, the single-operation metal yield, the theoretical recovery rate, the accumulated value of the instantaneous change rate of the color and the like can be specifically shown in the formulas (1) to (11).
And step 3: and determining a constant value in the working condition characteristic parameter expression in each operation.
Specifically, according to the actual production situation, the constant value in the working condition characteristic parameter expression in each operation can be comprehensively determined by generally combining the experimental data of the process with the experience of manual operation and taken as the standard value for working condition diagnosis.
And 4, step 4: and obtaining a diagnosis result according to a preset diagnosis rule and the instantaneous value of the characteristic parameter.
Specifically, the working condition judgment result at the current moment can be obtained by referring to the diagnostic expressions shown in the above tables 4 and 5 according to the real-time measurement data of the actual production process.
The method provided by the embodiment of the present invention has the same implementation principle and technical effect as the method embodiment, and for the sake of brief description, no part of the embodiment may refer to the corresponding content in the method embodiment.
In summary, the embodiment of the invention provides a method for predicting the working condition and diagnosing the fault in the mixed copper flotation process, which performs the working condition diagnosis on the real-time medicament adding condition by predicting the flotation state and the property of the raw ore and monitoring the enrichment ratio of the operation metal. The invention adopts the online parameters of two special intelligent instruments of a froth image analyzer and an online grade analyzer which are arranged in the process to carry out real-time calculation and analysis, and combines the upstream and downstream production parameters to obtain the real-time working condition characteristic diagnosis of the copper flotation process. Specifically, three types of characteristic parameters of a froth image and real-time grade analysis data are used for carrying out self-adaptive working condition judgment and diagnosis aiming at a universal copper flotation beneficiation process model, so that the problem of difficult decision of typical working conditions in the mixed copper flotation process is solved, and the control of a medicament and the working condition allocation can be guided in the mixed copper flotation process.
As for the working condition diagnosing method provided in the foregoing embodiment, an embodiment of the present invention further provides a working condition diagnosing apparatus, referring to a schematic structural diagram of a working condition diagnosing apparatus shown in fig. 3, where the apparatus may include the following components:
a characteristic parameter obtaining module 301, configured to obtain a characteristic parameter of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters, and foam parameters of the foam image.
And the diagnosis module 302 is used for diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
The working condition diagnosis device provided by the embodiment of the invention can be used for carrying out working condition diagnosis in real time based on preset diagnosis rules by combining various characteristic parameters such as production parameters, grade parameters and foam parameters of foam images of each operation, so that working condition changes can be found and intervened in time, the accumulated time of abnormal occurrence is shortened, and the stability of a production process is ensured; meanwhile, diagnosis is carried out according to preset diagnosis rules, so that the standard can be judged uniformly, subjective influences brought by operators are reduced, and the accuracy of diagnosis results is improved.
In an embodiment, the characteristic parameter obtaining module 301 is further configured to: determining a froth parameter based on the acquired froth image of each operation in the flotation process; wherein the foam parameters include: foam flow rate, foam number ratio, and foam color.
In an embodiment, when the foam parameter includes a foam color, the characteristic parameter obtaining module 301 is further configured to: determining the coordinates of each target pixel point in a color coordinate system based on the RGB values of the target pixel points in the foam image; the target pixel points comprise pixel points of which the brightness values in the foam image are within a preset brightness interval; determining intersection point coordinates of a vertical line from the target pixel point to a preset straight line and the preset straight line based on coordinates of the target pixel point in a color coordinate system; respectively calculating a first distance from the intersection point coordinate to a first preset point and a second distance from the intersection point coordinate to a second preset point; determining a color value of each target pixel point based on the first distance and the second distance; and determining the foam color based on the color value of each target pixel point.
In one embodiment, when the foam parameter includes a foam number ratio, the characteristic parameter obtaining module 301 is further configured to: segmenting the foam image, and sequencing connected domains in the segmented foam image based on the pixel areas of the connected domains to obtain a connected domain area sequence; determining the number of foams in different preset area intervals based on the connected domain area sequence and a plurality of preset thresholds, and determining a foam number ratio based on the number of foams in different preset area intervals; the preset area interval is divided based on a plurality of preset thresholds.
In one embodiment, the characteristic parameters further include: the filtering value, the instantaneous change rate and the general trend corresponding to the foam parameters, and the filtering value and the general trend corresponding to the grade parameters; the filtering value comprises a current filtering value and a filtering value before a preset time period; the device also comprises a first parameter calculation module, a second parameter calculation module and a filtering module, wherein the first parameter calculation module is used for calculating the current filtering value of the foam parameter and the filtering value before the preset time period, and calculating the current filtering value of the grade parameter and the filtering value before the preset time period; and calculating the instantaneous change rate and the general trend of the foam parameters based on the current filtered value of the foam parameters and the filtered value before the preset time period, and calculating the general trend of the grade parameters based on the current filtered value of the grade parameters and the filtered value before the preset time period.
In one embodiment, the production parameters include: the addition amount of the medicament, the thickness of a foam layer and the liquid level aeration quantity; the characteristic parameters further include: the ratio of the metal quantity of the collecting agent to the metal quantity of the raw ore, the single-operation metal yield, the theoretical recovery rate and the accumulated value of the instantaneous color change rate; the apparatus further comprises a second parameter calculation module configured to:
calculating the ratio of the metal amount of the collecting agent to the metal amount of the raw ore according to the following formula:
wherein,K C representing the ratio of the amount of the collecting agent to the amount of the crude ore metal,
to representxThe total amount of collector addition for each run,
represents the average grade of the raw ore.
The second parameter calculating module is further configured to: the single pass metal yield was calculated according to the following formula:
wherein,M x which represents the yield of the metal in a single operation,
to representxThe average grade of the operation is determined,K m the scale factor is expressed in terms of a scale factor,Ar（t) To representtThe liquid level aeration quantity at the moment,Lf（t) To representtThe thickness of the foam layer at the moment,v x （t) To representxWork intFoam flow rate at the moment.
The second parameter calculating module is further configured to: the theoretical recovery was calculated according to the following formula:
wherein,r R the theoretical recovery rate is shown in the figure,
represents the raw ore grade before the reaction time of the process,G C the quality of the concentrate is shown,G T indicating the grade of the tailings.
The second parameter calculating module is further configured to: calculating the accumulated value of the instantaneous change rate of the color according to the following formula:
when T ish>At the time of 0, the number of the first,
when T ish<At the time of 0, the number of the first,
wherein,S h the accumulated value of the instantaneous rate of change of the color is represented,I h indicating the instantaneous rate of change of the foam color,L H the upper limit value is represented by the following numerical value,L HH the upper limit value is represented as an upper limit value,iwhich represents the number of sample points that are to be sampled,T h indicating the general trend of foam color.
In one embodiment, the diagnostic module 302 is further configured to: determining constraint conditions of preset diagnosis rules based on the characteristic parameters; and (4) performing working condition diagnosis on the flotation process based on the constraint conditions and the characteristic parameters to obtain a diagnosis result.
The device provided by the embodiment of the present invention has the same implementation principle and technical effect as the method embodiments, and for the sake of brief description, reference may be made to the corresponding contents in the method embodiments without reference to the device embodiments.
In the description of the present invention, it should be noted that the terms "first", "second", and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
The embodiment of the invention also provides electronic equipment, which specifically comprises a processor and a storage device; the storage means has stored thereon a computer program which, when executed by the processor, performs the method of any of the above embodiments.
Fig. 4 is a schematic structural diagram of an electronic device 100 according to an embodiment of the present invention, where the electronic device 100 includes: a processor 40, a memory 41, a bus 42 and a communication interface 43, wherein the processor 40, the communication interface 43 and the memory 41 are connected through the bus 42; the processor 40 is arranged to execute executable modules, such as computer programs, stored in the memory 41.
The Memory 41 may include a high-speed Random Access Memory (RAM) and may also include a non-volatile Memory (non-volatile Memory), such as at least one disk Memory. The communication connection between the network element of the system and at least one other network element is realized through at least one communication interface 43 (which may be wired or wireless), and the internet, a wide area network, a local network, a metropolitan area network, etc. may be used.
The bus 42 may be an ISA bus, PCI bus, EISA bus, or the like. The bus may be divided into an address bus, a data bus, a control bus, etc. For ease of illustration, only one double-headed arrow is shown in FIG. 4, but that does not indicate only one bus or one type of bus.
The memory 41 is used for storing a program, the processor 40 executes the program after receiving an execution instruction, and the method executed by the apparatus defined by the flow process disclosed in any of the foregoing embodiments of the present invention may be applied to the processor 40, or implemented by the processor 40.
The processor 40 may be an integrated circuit chip having signal processing capabilities. In implementation, the steps of the above method may be performed by integrated logic circuits of hardware or instructions in the form of software in the processor 40. The Processor 40 may be a general-purpose Processor, and includes a Central Processing Unit (CPU), a Network Processor (NP), and the like; the device can also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other Programmable logic devices, discrete Gate or transistor logic devices, discrete hardware components. The various methods, steps and logic blocks disclosed in the embodiments of the present invention may be implemented or performed. A general purpose processor may be a microprocessor or the processor may be any conventional processor or the like. The steps of the method disclosed in connection with the embodiments of the present invention may be directly implemented by a hardware decoding processor, or implemented by a combination of hardware and software modules in the decoding processor. The software module may be located in ram, flash memory, rom, prom, or eprom, registers, etc. storage media as is well known in the art. The storage medium is located in a memory 41, and the processor 40 reads the information in the memory 41 and completes the steps of the method in combination with the hardware thereof.
The computer program product of the readable storage medium provided in the embodiment of the present invention includes a computer readable storage medium storing a program code, where instructions included in the program code may be used to execute the method described in the foregoing method embodiment, and specific implementation may refer to the foregoing method embodiment, which is not described herein again.
The functions, if implemented in the form of software functional units and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
Finally, it should be noted that: the above-mentioned embodiments are only specific embodiments of the present invention, which are used for illustrating the technical solutions of the present invention and not for limiting the same, and the protection scope of the present invention is not limited thereto, although the present invention is described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: any person skilled in the art can modify or easily conceive the technical solutions described in the foregoing embodiments or equivalent substitutes for some technical features within the technical scope of the present disclosure; such modifications, changes or substitutions do not depart from the spirit and scope of the embodiments of the present invention, and they should be construed as being included therein. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (10)
1. A method of diagnosing an operating condition, comprising:
acquiring characteristic parameters of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters and foam parameters of the foam image;
and diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
2. The method of claim 1, wherein the step of obtaining characteristic parameters of each operation in the flotation process comprises:
determining a froth parameter based on the acquired froth image of each operation in the flotation process; wherein the foam parameters include: foam flow rate, foam number ratio, and foam color.
3. The method of claim 2, wherein the step of determining froth parameters based on the acquired froth images for each operation in the flotation process comprises:
determining the coordinates of each target pixel point in a color coordinate system based on the RGB values of the target pixel points in the foam image; the target pixel points comprise pixel points of which the brightness values are within a preset brightness interval in the foam image;
determining intersection point coordinates of a perpendicular line from the target pixel point to a preset straight line and the preset straight line based on coordinates of the target pixel point in a color coordinate system;
respectively calculating a first distance from the intersection point coordinate to a first preset point and a second distance from the intersection point coordinate to a second preset point;
determining a color value of each of the target pixel points based on the first distance and the second distance;
and determining the foam color based on the color value of each target pixel point.
4. The method of claim 2, wherein the step of determining froth parameters based on the acquired froth images for each operation in the flotation process comprises:
segmenting the foam image, and sequencing connected domains in the segmented foam image based on the pixel areas of the connected domains to obtain a connected domain area sequence;
determining the number of foams in different preset area intervals based on the connected domain area sequence and a plurality of preset thresholds, and determining the number ratio of the foams based on the number of foams in the different preset area intervals; wherein the preset area interval is divided based on a plurality of the preset thresholds.
5. The method of claim 2, wherein the characteristic parameters further comprise: the filtered value, the instantaneous change rate and the general trend corresponding to the foam parameters, and the filtered value and the general trend corresponding to the grade parameters; the filtered values include a current filtered value and a filtered value prior to a preset time period;
after the step of determining the froth parameters based on the acquired froth images of each operation in the flotation process, the method further comprises the following steps:
calculating the current filtering value of the foam parameter and the filtering value before a preset time period, and calculating the current filtering value of the grade parameter and the filtering value before the preset time period;
calculating the instantaneous change rate and the general trend of the foam parameters based on the current filtered values of the foam parameters and the filtered values before the preset time period, and calculating the general trend of the grade parameters based on the current filtered values of the grade parameters and the filtered values before the preset time period.
6. The method of claim 1, wherein the production parameters comprise: the addition amount of the medicament, the thickness of a foam layer and the liquid level aeration quantity; the characteristic parameters further include: the ratio of the metal quantity of the collecting agent to the metal quantity of the raw ore, the single-operation metal yield, the theoretical recovery rate and the accumulated value of the instantaneous color change rate;
after the step of obtaining the characteristic parameters of each operation in the flotation process, the method further comprises the following steps:
calculating the ratio of the amount of the collecting agent to the amount of the raw ore metal according to the following formula:
wherein,K C representing the ratio of the amount of the collecting agent to the amount of the crude ore metal,
to representxCollecting for individual workThe total amount of the additive is added,
representing the average grade of the raw ore;
the single pass metal yield was calculated according to the following formula:
wherein,M x which represents the yield of the metal in a single operation,
to representxThe average grade of the operation is determined,K m the scale factor is expressed in terms of a scale factor,Ar（t) To representtThe liquid level aeration quantity at the moment,Lf（t) To representtThe thickness of the foam layer at the moment,v x （t) To representxWork intThe foam flow rate at that time;
the theoretical recovery was calculated according to the following formula:
wherein,r R the theoretical recovery rate is shown in the figure,
represents the raw ore grade before the reaction time of the process,G C the quality of the concentrate is shown,G T representing the grade of the tailings;
calculating the accumulated value of the instantaneous change rate of the color according to the following formula:
when in useT h >At the time of 0, the number of the first,
when in useT h <At the time of 0, the number of the first,
wherein,S h the accumulated value of the instantaneous rate of change of the color is represented,I h indicating the instantaneous rate of change of the foam color,L H the upper limit value is represented by the following numerical value,L HH the upper limit value is represented as an upper limit value,iwhich represents the number of sample points that are to be sampled,T h indicating the general trend of foam color.
7. The method according to any one of claims 1 to 6, wherein the step of performing working condition diagnosis on the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result further comprises:
determining constraint conditions of the preset diagnosis rules based on the characteristic parameters;
and carrying out working condition diagnosis on the flotation process based on the constraint conditions and the characteristic parameters to obtain a diagnosis result.
8. An operation condition diagnosis device characterized by comprising:
the characteristic parameter acquisition module is used for acquiring the characteristic parameter of each operation in the flotation process; wherein the characteristic parameters at least include: production parameters, grade parameters and foam parameters of the foam image;
and the diagnosis module is used for diagnosing the working condition of the flotation process based on the characteristic parameters and preset diagnosis rules to obtain a diagnosis result.
9. An electronic device comprising a processor and a memory, the memory storing computer-executable instructions executable by the processor, the processor executing the computer-executable instructions to perform the steps of the method of any one of claims 1 to 7.
10. A computer-readable storage medium, on which a computer program is stored, which, when being executed by a processor, carries out the steps of the method according to any one of the claims 1 to 7.
Priority Applications (1)
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