CN115293377A - Method for managing service life of blades of mixing machine - Google Patents
Method for managing service life of blades of mixing machine Download PDFInfo
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- CN115293377A CN115293377A CN202210954889.1A CN202210954889A CN115293377A CN 115293377 A CN115293377 A CN 115293377A CN 202210954889 A CN202210954889 A CN 202210954889A CN 115293377 A CN115293377 A CN 115293377A
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- 238000000034 method Methods 0.000 title claims abstract description 29
- 239000000463 material Substances 0.000 claims abstract description 32
- 238000013461 design Methods 0.000 claims abstract description 17
- 238000012423 maintenance Methods 0.000 claims abstract description 13
- 230000008569 process Effects 0.000 claims abstract description 13
- 238000007619 statistical method Methods 0.000 claims abstract description 4
- 230000000007 visual effect Effects 0.000 claims abstract description 4
- 230000001186 cumulative effect Effects 0.000 claims abstract description 3
- 230000008859 change Effects 0.000 claims description 20
- 238000012545 processing Methods 0.000 claims description 14
- 238000005516 engineering process Methods 0.000 claims description 13
- 230000036541 health Effects 0.000 claims description 12
- 238000011156 evaluation Methods 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 230000002159 abnormal effect Effects 0.000 claims description 7
- 230000003993 interaction Effects 0.000 claims description 5
- 230000000694 effects Effects 0.000 claims description 4
- 238000007689 inspection Methods 0.000 claims description 2
- 238000012797 qualification Methods 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 2
- 238000012937 correction Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000001360 synchronised effect Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical group [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
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Abstract
The invention relates to a method for managing the service life of a mixer blade, and belongs to the field of automation. The method comprises the following steps: s1: theoretical service life T of input blade factory design 0 And theoretical treatment amount M 0 Respectively defined as the initial values of the theoretical life index 1 and the theoretical life index 2 of the blade; s2: recording the initial profile dimension V of the blade 0 (ii) a S3: establishing a blade quality basic attribute library; s4: recording the cumulative operating time T of the blades i Accumulating the amount of the processed material M i And the external dimension V measured at the time of intermediate setting i (ii) a S5: synchronously acquiring the running state parameters of the process of the mixing machine, and marking the blades in the same batch; s6: accumulating to form a historical database and an expert knowledge base of the blade life, and carrying out statistical analysis on historical life values; s7: and establishing a visual billboard for dynamic presentation. By using the present inventionThe automatic prediction and fine management of the service life of the blades of the rotary hearth furnace mixer can be realized, the maintenance cost of the mixer is reduced, and the stable operation is guaranteed.
Description
Technical Field
The invention belongs to the field of automation, and relates to a method for managing the service life of a mixer blade.
Background
The rotary hearth furnace process is mainly used for the environment-friendly treatment of iron-containing zinc-containing dust and sludge of iron and steel enterprises and generates metallized pellets and secondary zinc oxide powder, and the process is gradually accepted and accepted in China. With the progress of production practice, new problems are also exposed in the new process, for example, iron-containing dust and mud with one physical property is used as raw materials processed by a rotary hearth furnace, and a mixer is required to be used for fully and uniformly mixing in order to facilitate the subsequent process treatment, but the blades of the mixer are rapidly worn and need to be replaced regularly due to the strong grinding performance of the raw materials and the complex and severe working conditions.
As the rotary hearth furnace is continuously operated for 24 hours, once the abrasion of the blades is too serious, the uniform mixing effect of the raw materials is directly influenced, the stability and the quality of downstream production are influenced, and even the production needs to be stopped when the abrasion is serious. In order to guarantee production, the service life of the blade is estimated mostly according to manual experience at present, and then the blade is replaced regularly in advance, and the blade is expensive in manufacturing cost and poor in accuracy of manual judgment, so that the blade is very easy to replace too early to cause waste or is not replaced in time to cause difficulty in production, and the requirement of fine management cannot be supported.
Disclosure of Invention
In view of the above, the object of the present invention is to provide a method for managing the life of a mixer blade,
In order to achieve the purpose, the invention provides the following technical scheme:
a method of mixer blade life management, the method comprising the steps of:
s1: theoretical service life T of input blade factory design 0 And theoretical treatment amount M 0 Respectively defined as the initial values of the theoretical life index 1 and the theoretical life index 2 of the blade;
s2: recording the initial profile dimension V of the blade 0 The length, the width and the height are defined as initial values of the health characteristic values of the blades;
s3: synchronously recording material characteristic information of the blades of the batch, including material quality, hardness, processing technology and supplier information, and establishing a blade quality basic attribute library;
s4: recording the accumulated operation time T of the blade i And accumulating the processed material amount M i And the external dimension V measured at the time of intermediate setting i Acquiring a life index and a health characteristic value of the intermediate process state, wherein the life index refers to the theoretical service life T 0 The health characteristic value refers to the theoretical treatment amount M 0 And calculating and comparing the change rates of the two types of the data, wherein the change rates respectively comprise the change rate K of the theoretical service duration T ＝T i /T 0 The change rate K of the amount of the treated material M ＝M i /M 0 And rate of change of blade size K V ＝V i /V 0 Calculating and comparing; if the rate of change of blade size K V And the theoretical use time length change rate K T Or rate of change of treatment amount K M Out of synchronism, by the rate of change of blade size K V Correcting theoretical age T 0 And theoretical treatment amount of material M 0 Two indicators of life, i.e. T 0 ＝T i *K v ，M 0 ＝M i *K v (ii) a When any remaining life t i Or m i When the preset level 1 threshold value is reached, namely 10% of the theoretical life after correction, an early warning is sent out, and when the level 2 threshold value is reached, namely 0, the life returns to zero;
s5: synchronously acquiring the running state parameters of the process of the mixing machine, including current, rotating speed, vibration and temperature, classifying according to normal working conditions and abnormal working conditions, specifically, counting the running time and the treated material amount under different rules respectively, and then marking the blades of the same batch;
s6: accumulating to form historical database and expert knowledge base of blade life, performing statistical analysis on historical life values, taking average value to feed back and correct theoretical service duration T of new blade 0 And theoretical treatment amount of material M 0 ；
S7: and establishing a visual billboard to dynamically present the real-time service life, health state and working condition parameters of the blade, and providing functions of risk early warning, maintenance suggestion, data interaction and report display.
Optionally, the normal working condition is not greater than a maximum operation value allowed by equipment factory design;
the abnormal working condition is as follows: the operation maximum value and the unplanned shutdown allowed by the equipment factory design are exceeded, and the operation maximum value and the unplanned shutdown are classified into a mild grade, a moderate grade and a severe grade according to the exceeding amplitude, and the operation maximum value and the unplanned shutdown are specifically as follows:
mild: the exceeding amplitude is less than or equal to 1.1 times of the maximum operation value;
medium: the exceeding amplitude is 1.1 to 1.2 times of the maximum operation value;
and (3) severe degree: the exceeding amplitude is more than or equal to 1.2 times of the maximum operation value;
unplanned shutdown: i.e. the plant is shut down.
Optionally, the historical database is designed for each batch of leaves to leave a factory, and is synchronized with the basic attribute library of leaf quality recorded in S3, wherein the theoretical use duration and the theoretical use amount of the leaves, and the actual use duration and the theoretical use amount of the leaves during scrapping are synchronized;
the expert knowledge base forms classification evaluation according to the blade service life statistical data under different attribute conditions and the actual service duration, and simultaneously establishes statistical rules of the expert knowledge base, the material, the hardness and the processing technology, and the statistical rules are as follows:
the method has the advantages that: the actual service life is more than or equal to the design service life multiplied by 110 percent;
good: the designed service life value is less than the actual service life and less than or equal to the designed service life value multiplied by 110 percent;
and (4) qualification: the design service life value = actual service life;
unqualified: the design service life value is less than or equal to the actual service life;
and accumulating and establishing rules of corresponding use effects under the blade quality basic attribute libraries of different suppliers, materials, hardness and processing technologies according to excellent, good and unqualified classifications, and matching according to basic attributes before a new batch of blades are put into use to replace the design life with the average value of the corresponding historical statistical life.
Optionally, the risk pre-warning includes:
the system background carries out reminding and early warning when the statistical mean value of the historical life is unqualified through the matching of the basic attributes of the blades;
in the using process, when the residual service life reaches the level 1 threshold value, reminding that the service life is about to return to zero;
the maintenance recommendations include case one and case two:
the first condition is as follows: providing a push of a maintenance strategy based on changes in state parameters such as operating current, rotational speed, amplitude or temperature, comprising:
(a) When the abnormal condition is mild, a prompt is pushed to an operator, so that the production load is reduced;
(b) When the equipment is in moderate anomaly, except for the operation in the step (a), simultaneously pushing a reminder to equipment maintenance personnel for field observation and inspection;
(c) When the equipment is in severe abnormity, except for the operation in the step (b), a prompt and a spare part inventory state are simultaneously pushed to a manager, and the replacement of the spare part is suggested in time;
case two: according to the historical classification evaluation of the actual service life of the blade, a selection suggestion of spare part purchasing is provided, and the selection suggestion comprises the following steps:
(a) When the historical evaluation is qualified and the times are more than 80%, the name, the material, the hardness and the technical requirements of the processing technology of the supplier are met;
(b) The name of a supplier, the material, the hardness and the technical requirements of the processing technology are met when the historical evaluation is more than 70 percent and the times are less than or equal to 80 percent;
(c) The name of a supplier, the material, the hardness and the technical requirements of the processing technology are met when the historical evaluation is more than or equal to 60 percent and the times are more than or equal to 70 percent;
the data interaction and report form is displayed by graphically displaying and man-machine interacting risk early warning and maintenance suggestions at a computer end so as to be convenient for production management personnel to monitor.
The invention has the beneficial effects that: the invention is completely different from the traditional manual management mode, can realize the automatic prediction and the fine management of the service life of the blades of the rotary hearth furnace mixer, reduces the maintenance cost of the mixer and ensures the stable operation.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from 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 thereof.
Drawings
For the purposes of promoting a better understanding of the objects, aspects and advantages of the invention, reference will now be made to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram of a system for managing the life of a mixing blade of a rotary hearth furnace according to the present invention;
FIG. 2 is a life state diagram of the invention suitable for rotor blade life management.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention in a schematic way, and the features in the following embodiments and embodiments may be combined with each other without conflict.
Wherein the showings are for the purpose of illustrating the invention only and not for the purpose of limiting the same, and in which there is shown by way of illustration only and not in the drawings in which there is no intention to limit the invention thereto; for a better explanation of the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The same or similar reference numerals in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there is an orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", "front", "rear", etc., based on the orientation or positional relationship shown in the drawings, it is only for convenience of description and simplification of description, but it is not an indication or suggestion that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes, and are not to be construed as limiting the present invention, and the specific meaning of the terms may be understood by those skilled in the art according to specific situations.
Referring to fig. 1 and 2, a method and a system for managing the service life of a mixer blade of a rotary hearth furnace are provided, which comprises the following steps:
1) Theoretical service life T of input blade factory design 0 And theoretical treatment amount M 0 And are respectively defined as initial values of a theoretical life index 1 and an index 2 of the blade.
2) Record the initial profile V of the blade 0 (including length, width, height) is defined as the initial value of the blade health characteristic value.
3) And synchronously recording material characteristic information of the batch of blades, such as material quality, hardness, processing technology and the like, and supplier details, and establishing a blade quality basic attribute library.
4) Recording the cumulative operating time T of the blades i And an accumulation partAmount of material to be treated M i And the external dimension V measured at the time of intermediate setting i Acquiring the life index and health characteristic value of the intermediate process state, and adjusting the change rate K of the life index and the health characteristic value T 、K M 、K V Calculating and comparing, and then calculating the change rate K of the blade size V Two service life indexes of correction duration and treatment material amount are obtained; when the remaining life index t i Or m i And sending out early warning when the preset level 1 threshold is reached, and enabling the service life to return to zero when the level 2 threshold is reached.
5) The method comprises the steps of synchronously collecting operation state parameters of the process of the mixing machine, such as current, rotating speed, vibration, temperature and the like, classifying according to two expert rules of normal working conditions and abnormal working conditions, respectively counting operation time and processing material amount under different rules, and then marking blades of the same batch.
6) And accumulating to form a historical database and an expert knowledge base of the blade service life, carrying out statistical analysis on historical service life values of the blades, and taking an average value of the historical service life values to feed back and correct theoretical service life indexes of a new batch of blades.
7) And establishing a visual billboard to dynamically present the real-time service life, health state and working condition parameters of the blade, and providing functions of risk early warning, maintenance suggestion, data interaction, report display and the like.
Finally, the above embodiments are only intended to illustrate the technical solutions of the present invention and not to limit the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it will be understood by those skilled in the art that modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions, and all of them should be covered by the claims of the present invention.
Claims (4)
1. A method of mixer blade life management, characterized by: the method comprises the following steps:
s1: theoretical service life T of input blade factory design 0 And theoretical treatment amount of material M 0 Respectively defined as the initial values of the theoretical life index 1 and the theoretical life index 2 of the blade;
s2: recording the initial profile dimension V of the blade 0 The length, the width and the height are defined as initial values of the health characteristic values of the blades;
s3: synchronously recording material characteristic information of the blades of the batch, including material quality, hardness, processing technology and supplier information, and establishing a blade quality basic attribute library;
s4: recording the cumulative operating time T of the blades i And accumulating the processed material amount M i And the external dimension V measured at the time of intermediate setting i Acquiring a life index and a health characteristic value of the intermediate process state, wherein the life index refers to the theoretical service life T 0 The health characteristic value refers to the theoretical treatment material quantity M 0 And calculating and comparing the change rates of the two types of the data, wherein the change rates respectively comprise the change rate K of the theoretical service duration T ＝T i /T 0 The change rate K of the amount of the treated material M ＝M i /M 0 And rate of change of blade size K V ＝V i /V 0 Calculating and comparing; if the rate of change of blade size K V And the change rate K of the theoretical use duration T Or rate of change of treatment amount K M Out of step, at the rate of blade size change K V Correcting theoretical age T 0 And theoretical treatment amount M 0 Two life indicators, i.e. T 0 ＝T i *K v ，M 0 ＝M i *K v (ii) a When any remaining life t i Or m i When the preset level 1 threshold value is reached, namely 10% of the corrected theoretical life is reached, an early warning is sent out, and when the level 2 threshold value is reached, namely 0, the life returns to zero;
s5: synchronously acquiring the running state parameters of the process of the mixing machine, including current, rotating speed, vibration and temperature, classifying according to normal working conditions and abnormal working conditions, specifically, counting the running time and the treated material amount under different rules respectively, and then marking the blades of the same batch;
s6: accumulating to form historical database and expert knowledge base of blade life, carrying out statistical analysis on historical life values, taking average value to feed back and correct theoretical service time T of new blade 0 And theoretical treatment amount M 0 ；
S7: and establishing a visual billboard to dynamically present the real-time service life, health state and working condition parameters of the blade, and providing functions of risk early warning, maintenance suggestion, data interaction and report display.
2. A method of mixer blade life management according to claim 1, wherein: the normal working condition is not more than the maximum operation value allowed by equipment factory design;
the abnormal working condition is as follows: the operation maximum value and the unplanned shutdown allowed by the equipment factory design are exceeded, and the operation maximum value and the unplanned shutdown are classified into a mild grade, a moderate grade and a severe grade according to the exceeding amplitude, and the operation maximum value and the unplanned shutdown are specifically as follows:
mild: the exceeding amplitude is less than or equal to 1.1 times of the maximum operation value;
moderate: the exceeding amplitude is 1.1 to 1.2 times of the maximum operation value;
and (3) severe degree: the exceeding amplitude is more than or equal to 1.2 times of the maximum operation value;
unscheduled shutdown: i.e. the plant is shut down.
3. A method of mixer blade life management according to claim 1, wherein: the historical database is used for synchronizing the theoretical use duration and the theoretical use material amount of each batch of leaves factory design, the actual use duration and the theoretical use material amount during scrapping with the leaf quality basic attribute library recorded in the S3;
the expert knowledge base forms classification evaluation according to the blade service life statistical data under different attribute conditions and the actual service duration, and simultaneously establishes statistical rules of the expert knowledge base, the material, the hardness and the processing technology, and the statistical rules are as follows:
the advantages are that: the actual service life is more than or equal to the design service life multiplied by 110 percent;
good: the designed service life value is less than the actual service life and less than or equal to the designed service life value multiplied by 110 percent;
and (4) qualification: the design service life value = actual service life;
unqualified: the design service life value is less than or equal to the actual service life;
and accumulating and establishing rules of corresponding use effects under the blade quality basic attribute libraries of different suppliers, materials, hardness and processing technologies according to excellent, good, qualified and unqualified classifications, and matching according to basic attributes before a new batch of blades are put into use to replace the design life by the average value of the corresponding historical statistical life.
4. A method of mixer blade life management according to claim 1, wherein: the risk early warning comprises the following steps:
the system background carries out reminding and early warning when the statistical mean value of the historical service life is unqualified through the matching of the basic attributes of the blades;
in the using process, when the residual service life reaches the level 1 threshold value, reminding that the service life is about to return to zero;
the maintenance recommendations include case one and case two:
the first condition is as follows: providing a push of a maintenance strategy based on changes in state parameters such as operating current, rotational speed, amplitude or temperature, comprising:
(a) When the abnormal condition is mild, a prompt is pushed to an operator, so that the production load is reduced;
(b) When the equipment is in moderate abnormity, except for the operation in the step (a), simultaneously pushing a prompt to equipment maintenance personnel for field observation and inspection;
(c) When the equipment is in severe abnormity, except for the operation in the step (b), a prompt and a spare part inventory state are simultaneously pushed to a manager, and the replacement of the spare part is suggested in time;
case two: according to the historical classification evaluation of the actual service life of the blade, a selection suggestion of spare part purchase is provided, and the selection suggestion comprises the following steps:
(a) When the historical evaluation is qualified and the times are more than 80%, the name, the material, the hardness and the technical requirements of the processing technology of the supplier are met;
(b) The name of a supplier, the material, the hardness and the technical requirements of the processing technology are met when the historical evaluation is more than 70 percent and the times are less than or equal to 80 percent;
(c) The name of a supplier, the material, the hardness and the technical requirements of the processing technology are met when the historical evaluation is more than or equal to 60 percent and the times are more than or equal to 70 percent;
the data interaction and report form is displayed by graphically displaying and man-machine interacting risk early warning and maintenance suggestions at a computer end so as to be convenient for production management personnel to monitor.
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| CN202210954889.1A CN115293377A (en) | 2022-08-10 | 2022-08-10 | Method for managing service life of blades of mixing machine |
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| CN202210954889.1A CN115293377A (en) | 2022-08-10 | 2022-08-10 | Method for managing service life of blades of mixing machine |
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