Editor's note: High-quality development has become the main theme and core task of the sand and gravel and equipment industry, at present, the downward pressure on China's economy is increasing, and the sand and gravel industry is facing a "drop in volume and price".It depends on innovation, especially technological innovation!
Different from the current mainstream sand making equipment, Zhejiang Shuangjin has been developing and exploring the preparation and application of cone sand making machine. Mr. Shi Xiaofeng explored the arduous process and current achievements of the cone sand making machine according to the research and development of Zhejiang Shuangjin, especially with the blessing of intelligent technology, the cone sand making machine has made new breakthroughs, and wrote the article "Application of Intelligent Sensing Technology in Cone Sand Making Machine". Today, the China Sand and Gravel Association will share the articles contributed by Mr. Shi Xiaofeng on the financial platform, and everyone is welcome to read and participate in the discussion.
Application of intelligent sensing technology in cone sand making machineShi XiaofengCan the cone machine be used for sand making?This is a topic of discussion with many opinions, but it is actually a global problem. As we all know, the cone machine can meet the production of sand and gravel aggregates, but it is indeed very difficult to turn sand and gravel aggregates into machine-made sand that meets the requirements. There are two major problemsFirst, the crushing ratio is largeTo make sand and gravel aggregate into sand, its crushing ratio is generally 15-20 times higher, and the pressure of the machine is several times that of the usual cone machine. Second, the ultra-small closed-edge discharge port forces the density of the rolled and laminated aggregate in the cavity to increase, resulting in the cone machine subjected to the rigidity test is extremely powerful. In other words, the service conditions of the cone machine in the sand making process are extremely strict. Zhejiang Shuangjin began to develop a cone sand making machine in 2010, and based on the above two difficult considerations, several improvements were made under the premise of ordinary cone machine. Replace springs with multi-cylinder hydraulics to improve machine rigidity. Thicken the spindle to improve its compressive capacity. Reduction of the crushing chamber and reduction of the (conventional) machine load. High chromium cast iron is used to replace high manganese steel for rolling and crushing walls to improve the wear resistance of the material. It was a success in 2013. Compared with conventional impact crushing sand, conical machine-made sand has various advantages, such as low power consumption, good particle shape, low production cost, low maintenance cost, and high sand yield (the one-time yield can reach more than 60%). However, unexpectedly, in the marketing promotion, almost hit a wall, customers have asked for returns, and some simply change the function of the plastic machine or transfer it to other uses. Although the cone sand making machine is obviously better than impact crushing in many aspects, people are still generally willing to use impact crushing for sand making. The reason for thisIt is a double gold cone sand making machine that is difficult to controlWhen the closed-edge discharge port is adjusted to a suitable clearance, once it encounters too much blanking or is suddenly doped with some superhard materials, it will cause a stuffy machine accident. It is undeniable that this kind of machine has extremely strict requirements for the on-site operator, requiring strong and sensitive control and adjustment ability, and must be very focused. However, this is almost the wind in the sand making industry. In other words, it's almost impossible. Today, when natural sand is increasingly depleted and machine-made sand is completely replacing natural sand, people have adopted impact crushing to make sand. Although it is known that the impact crusher consumes a lot of power and is frequently maintained, and its sand particle size and gradation are not ideal, it still chooses the impact crusher to make sand. In order to ensure the grain shape and gradation, some are also equipped with roller machines and rod mills to participate in sand making, which pushes up the cost of machine-made sand. The overall idea of the research and development of this round of double gold cone sand making machine is:By reducing the cavity type and controlling the appropriate output, the parts of the ordinary cone machine can meet the rigid requirements required for sand making。In fact, it is the idea of a large horse-drawn trolley, which solves the problem of cone sand making. However, due to the shortcomings of the control system, it is extremely difficult to operate on site, so that the product cannot be successfully promoted. Shuangjin Machinery re-established the project in 2019, restarted the research and development project of sand making machine and sand making complete equipment, and adopted the new idea of single-cylinder hydraulic cone machine-made sand. As we all know, there are three major advantages of single-cylinder hydraulic cone machine:The spindle is floating, with a supporting structure at both ends, and the spindle has a strong radial bearing capacityThe cavity is steep, and the blanking is fasterThe discharge port can be adjusted without stopping, which brings great convenience to the on-site operation. On the basis of summing up the successful experience and the lessons of failure, the following improvements have been made. The design of the cavity type, on the basis of satisfying the extrusion and rolling of ultra-fine materials, strengthens the design and discussion of the bottom edge of the crushing wall, because the material is easy to slip out of the cavity when passing through the bottom edge, so the wear failure of the bottom line is far less than that of other parts in the cavity, and soon it will accumulate into a hurdle because of less wear, and the free fall of the material is blocked after the hurdle, and if it is not treated in time, it is easy to form a vortex in the upper part of the bottom edge, which affects the normal production. In response to this difficult problem, we are interested in:Pre-failure measures were taken at the bottom of the crushing wall, forcing the wear of the first line of the bottom edge to fail in sync with the rest of the crushing wallIt forms a constant discharge oral type, which makes the service life of the crushing wall and the rolling wall longer, and ensures the normal operation of the machine. The sand making machine has to withstand greater pressure than other cone machines during operation, and the spindle, copper sleeve, and lubricating oil have undergone great tests. When the pressure cannot be changed, reducing the speed of the eccentric shaft is also an option, so as to adjust the PV value of the sliding bearing (copper sleeve), control the increase in oil temperature, and maintain effective lubricationSo that production can be carried out normally. The balanced feeding of the sand making machine is also an important part of the control, and the operators in the control room pay close attention to the production dynamics and regulate them at any time through various instruments and monitoring. After satisfying the above elements, a production line for the production of medium and coarse manufactured sand can basically operate normally, and can also be used for shaping and road fabric production. In the dry production of sand and gravel aggregate production line, when the cone sand making machine is equipped to implement tailings sand making (dry sand making), it is only necessary to be equipped with dust removal equipment to capture dust, which is an economical choice to meet the needs of environmental protection. If it is used in wet production or construction waste production, it is necessary to pay attention to the moisture of the material in the crushing chamberTo avoid this section of 3%-9% (because the crushed sand within this range is very sticky and cannot fall properly), it is necessary to increase the amount of flushing waterThe sand production can be carried out normally. To sum up, the cone sand making machine produced by Shuangjin has achieved breakthrough success from being able to make sand but difficult to control to the current controllable. However, it needs to be further improved, through the actual situation of the operation of the sand production line in the experimental base, there are three major deficiencies: the production of machine-made sand is still in the range of medium and coarse sand, and it cannot meet the needs of advanced distribution for the time beingIn the case of manual negligence control, the feeding speed is fast or slow: when the feeding speed is too fast, there will be too much material in the hopper of the sand making machine, and there will be a full discharge phenomenon;The feeding speed is too slow, the material in the cavity of the sand making machine is too small, the operation efficiency of the sand making machine is low, the sand making capacity is low and the quality of the machine-made sand is poorIn the production process, it is difficult to deal with the motor stall (stuffy machine) accident, so in order to avoid accidents, the operator uses relatively low efficiency to operate and drive the Taiping car, and the average power only reaches 60%. The so-called bottleneck is that the power output of the machine cannot reach the ideal state, and the production capacity and quality of machine-made sand are essentially exchanged for electric power, and the semi-automatic production line controlled by manual control is restricted due to human reasons. Because the natural inertia of human beings always chooses to operate within the range of a large safety factor, it objectively forms a bottleneck. In order to overcome these bottlenecks, the Shuangjin R&D team realized that it was necessary to make the cone sand making machine fully efficientIt is necessary to adopt advanced technologies of digital intelligenceZhejiang Shuangjin and Hangzhou Dianzi University signed a cooperation agreement on "intelligent equipment" joint innovation laboratory, the school is responsible for software design, the factory is responsible for resource provision and hardware support, and the two sides actively strive to cooperate in research and development. Through the intelligent control of the production line, the production efficiency of the machine-made sand production line is improved。A variety of advanced sensing technologies are used to apply to the intelligence of cone sand making machine and sand making production line. The biggest advantage of intelligent control is:The size of the discharge port, the feeding speed and the eccentric shaft speed of the cone sand making machine can be automatically adjusted and accurately controlled by the intelligent control system, improve the efficiency of sand making and the quality of sand, eliminate motor stall (stuffy machine) under the premise of full power, and improve production efficiency. This is also a major breakthrough and qualitative leap in the technology of sand making machine and sand making production line. 1. The intelligent control points of the sand making production line are mainly through the following aspects:1.Current Control Points:In the process of sand making, if the load of the sand making machine becomes larger, the current will fluctuate abnormally, and the sensor signal will immediately issue a command, and the sand making machine will react instantly to enlarge the discharge port to prevent the motor from stalling (stuffy) accident. After that, according to the constant power setting, the intelligent controller slowly narrows the discharge port through the instructions of the intelligent controller and continues to operate efficiently. The intelligent control value is generally set between 90% and 95% of the full load。After the adoption of intelligent technology, the work efficiency and advantages of the cone sand making machine are fully exerted, and the output, gradation, particle shape and other aspects are obviously better than other various sand making machines of the same power. 2.Level Control Point:The feeding speed is automatically controlled by issuing instructions through sensor signals to ensure uniform feeding and balanced production. Prevent the feeding speed from being too fast, the hopper of the sand making machine from being full, the feeding speed from being too slow, the operation efficiency of the sand making machine from being low, the sand making capacity from being low and the quality of the machine-made sand from being poor. 3.Temperature Control Points:When the temperature of the lubricating oil rises too fast or the temperature is close to the upper limit, the sensor signal immediately sends a command to reduce the speed of the eccentric shaft to maintain the normal PV value of the sliding bearing (copper sleeve), and control the output within a reasonable range. 4.Pressure Control Point:In the process of sand making, when the pressure of the hydraulic cylinder is too large, the sensor signal sends a command to open the regulating valve to control the pressure within the normal range. 2. The intelligent control system, method and process of sand making production line mainly include the following steps:1.Sensor Signal Acquisition:Through the sensors installed on the sand making machine, such as current sensor, material level sensor, temperature sensor, pressure sensor, etc., the working status data of the sand making machine is collected in real time. 2.Data Processing & Analysis:The data collected by the sensor is processed and analyzed, and whether the sand making machine needs to be adjusted is judged according to the working status of the sand making machine. 3.Smart Controller:According to the results of data processing and analysis, the sand making machine is automatically adjusted through program control and artificial intelligence algorithms. 4.Sand making machine adjustment:According to the instructions of the intelligent controller, the sand making machine is adjusted accordingly, such as adjusting the size of the discharge port, feeding speed, eccentric shaft speed, etc., to ensure the constant power and full load operation, so as to achieve the maximum sand making efficiency. 5.Feedback device:The feedback device installed on the sand making machine can monitor the output and quality of the sand in real time, and feed these data back to the intelligent control system. 6.System Optimization:According to the feedback data, the intelligent control system is continuously optimized to improve the efficiency of sand making and the quality of sand. Through the implementation of the intelligent control scheme of the above-mentioned sand production lineIt can greatly reduce the labor cost of the production line, replace manual operation with intelligence, and realize unmanned sand making plants. Shuangjin Machinery has been like a day for decades, respecting science, being brave in innovation, and daring to challenge. In the process of developing the cone sand making machine, we have always adhered to it after repeated setbacks, and have been working hard to overcome various difficulties and explore solutions, and have always believed that the idea of using the cone machine for sand making is feasible. At present, the implementation of the programme has achieved initial results and is bound to be successful. Shuangjin Machinery first put forward the concept of using conical machine-made sand in the industry, which is correct and feasible. The success of Shuangjin mechanical sand making will make a great contribution to the progress of the industry. Editor-in-charge |Zhai Wenjing · Review |Zhang peng.
*: China Sand and Gravel Association.