JP6245197B2 - Raw material level control method, raw material blending method, raw material level control device and raw material blending device - Google Patents

Description

  The present invention relates to a raw material level control method and a raw material level control device that control raw material levels in a plurality of hoppers, a raw material blending method that blends raw materials in a plurality of hoppers, and a raw material blending device.

  In general, a material handling facility that handles a plurality of types of materials first transports the materials handled by the unloader on a conveyor and loads them on a material yard. Next, the material is discharged from the material yard by the loader and stored in the hopper for each brand. Next, a fixed amount is cut out from each hopper on the same conveyor, mixed, and stacked as a pile pile (mixing yard) by a stacker at the tip of the conveyor. In this way, a large number of brands with different qualities are blended in small amounts and stacked in layers thin and high.

  Conventionally, in order to adjust the amount discharged from the loader to the hopper and perform stable operation, the conveyance amount is calculated from the length and speed of the conveyor and the load amount of the loader, and the raw material level in the hopper is monitored. An invention has been proposed in which the loader is stopped when the raw material is filled up to this position, and the raw material on the conveyor is put into the hopper to control the raw material level (the amount of raw material) at a predetermined upper limit level position. (For example, refer to Patent Document 1).

Japanese Patent Laid-Open No. 58-113032

  However, since the invention proposed in Patent Document 1 does not monitor the amount of cut out from the hopper and only one hopper is monitored, for example, only one of a plurality of hoppers during operation. May become empty and operation may be intermittent. In addition, the invention proposed in Patent Document 1 cannot control the amount of raw material dispensed (replenishment amount) and the amount of cut out for each of a plurality of brands, so that the raw materials cannot be mixed with the intended composition. was there.

  The present invention has been made in view of the above, and is a raw material level control method, a raw material blending method, a raw material level control apparatus, and a raw material blend capable of continuous operation and capable of mixing raw materials in an intended blend. An object is to provide an apparatus.

  In order to solve the above-described problems and achieve the object, the raw material level control method according to the present invention is performed in advance after a plurality of raw materials composed of different components are respectively discharged by a loader and replenished into a plurality of hoppers. A material level control method for controlling a raw material level in each hopper in a loading and unloading process in which the raw material is cut out from each hopper on a conveyor according to a predetermined mixing ratio, and a total amount of cut out from each hopper is An upper limit cutting amount setting step for setting an upper limit cutting amount for the entire hopper, the upper limit cutting amount, and the blending ratio so as to be equal to or less than a predetermined transport amount upper limit value of the conveyor, An initial cutout amount calculating step for calculating an initial cutout amount of each hopper so as to satisfy the upper limit cutout amount of the hopper, and the initial setting Based on the difference between the cutting amount and a predetermined replenishment amount to the hopper, a lower limit weight arrival time that is a time until the raw material weight in the hopper reaches a predetermined lower limit weight is calculated. The lower limit weight arrival time calculating step, and among the hoppers, the hopper having the longest lower limit weight arrival time is defined as a reference hopper, and the other hoppers are determined as correction target hoppers. The lower limit weight arrival time of the correction target hopper is the same as the reference hopper based on the lower limit weight arrival time of the correction target hopper, the raw material weight in the correction target hopper, and the raw material lower limit weight of the correction target hopper A replenishment amount calculating step for calculating a new replenishment amount to the correction target hopper, and a replenishment amount for the correction target hopper to the new replenishment amount Characterized in that it comprises a supply amount correction step of correcting for, the.

  Further, in the raw material level control method according to the present invention, in the replenishment amount calculation step, when the new replenishment amount exceeds a predetermined equipment upper limit payout amount of the loader, the lower limit weight arrival time is shortest. Redefining the hopper as the reference hopper and the other hoppers as the correction target hopper, the amount cut out from the correction target hopper, the longest lower limit weight arrival time, the raw material weight in the correction target hopper, Based on the raw material lower limit weight of the correction target hopper, a new supply amount to the correction target hopper is calculated again so that the lower limit weight arrival time of the correction target hopper becomes the same as the reference hopper, and the supply amount In the correction step, the replenishment amount for the correction target hopper is corrected to the re-calculated new replenishment amount.

  In the raw material level control method according to the present invention, after the replenishment amount calculation step, when the new replenishment amount exceeds a predetermined equipment upper limit payout amount of the loader, the cutout from the correction target hopper is performed. A new cutting amount of the correction target hopper is calculated by decreasing the amount based on a predetermined ratio, and the reference hopper is further calculated based on the new cutting amount of the correction target hopper and the blending ratio. A cutting amount calculation step for calculating a new cutting amount, and a cutting amount correction step for correcting the cutting amount of each hopper to the new cutting amount instead of the replenishment amount correction step, Is further included.

  In order to solve the above-described problems and achieve the object, the raw material blending method according to the present invention is the above-mentioned cut out from each hopper on the conveyor according to the raw material level controlled by the raw material level control method described above. A plurality of raw materials are blended at the blending ratio by a stacker.

  In order to solve the above-described problems and achieve the object, the raw material level control device according to the present invention is configured in advance after a plurality of raw materials made of different components are respectively discharged by a loader and replenished into a plurality of hoppers. In the material handling and transporting process in which the raw material is cut out from each hopper onto a conveyor according to a predetermined blending ratio, the raw material level control device controls the raw material level in each hopper, and the total amount of cut out from each hopper is The upper limit cutting amount setting means for setting the upper limit cutting amount of the entire hopper, the upper limit cutting amount, and the blending ratio so as to be equal to or less than a predetermined transport amount upper limit value of the conveyor An initial set cut amount calculating means for calculating an initial set cut amount of each hopper so as to satisfy the equipment upper limit cut amount of the hopper, and the initial set cut amount A lower limit weight arrival time for calculating a lower limit weight arrival time, which is a time until the weight of the raw material in the hopper reaches a predetermined lower limit weight of the raw material, based on a difference from a predetermined supply amount to the hopper Of the hoppers, the hopper having the longest lower limit weight arrival time is defined as a reference hopper, and the other hoppers are determined as correction target hoppers. The amount cut out from the correction target hopper and the longest lower limit weight Based on the arrival time, the raw material weight in the correction target hopper, and the raw material lower limit weight of the correction target hopper, the correction target hopper has the same lower limit weight arrival time as the reference hopper. Supply amount calculation means for calculating a new supply amount to the hopper, and a supply amount for correcting the supply amount for the correction target hopper to the new supply amount A positive means, characterized in that it comprises a.

  In order to solve the above-mentioned problems and achieve the object, the raw material blending apparatus according to the present invention is cut out on the conveyor from each hopper according to the raw material level controlled by the raw material level control apparatus. A plurality of raw materials are blended at the blending ratio by a stacker.

  According to the present invention, by adjusting the replenishment amount of raw materials to other hoppers in accordance with the hopper with the longest lower limit weight arrival time, the raw material levels of a plurality of hoppers can be controlled at the same time. The balance can be made uniform. Therefore, according to the present invention, only one of the plurality of hoppers is emptied during operation, thereby avoiding a situation in which continuous operation is hindered because the raw materials cannot be mixed at the intended blending ratio, and stable. Can perform operations.

FIG. 1 is a schematic view showing the overall configuration of a cargo handling system including a raw material level control device and a raw material blending device according to an embodiment of the present invention. FIG. 2 is a flowchart showing an example of processing by the raw material level control apparatus according to the first embodiment of the present invention. FIG. 3 is a diagram for explaining a raw material level control method by the raw material level control apparatus according to the embodiment of the present invention. FIG. 4 is a flowchart showing an example of processing by the raw material level control apparatus according to the modification of the first embodiment of the present invention. FIG. 5 is a flowchart showing an example of processing by the raw material level control apparatus according to the second embodiment of the present invention.

  Hereinafter, embodiments of a raw material level control method, a raw material blending method, a raw material level control device, and a raw material blending device according to the present invention will be described. In addition, this invention is not limited to the following embodiment. In addition, constituent elements in the following embodiments include those that can be easily replaced by those skilled in the art or those that are substantially the same.

[First Embodiment]
A first embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, the cargo handling system in the present embodiment includes a loader 1, conveyors 2, 4, 5, a hopper 3, a stacker 6, a raw material level control device 7, and a raw material blending device 8. Composed. And since this cargo handling conveyance system conveys a plurality of raw materials, a plurality of loaders 1, conveyors 2, 4 and hoppers 3 are provided according to the type of raw materials, and the loaders 1 and hoppers 3 correspond one-to-one. ing.

  The loader 1 delivers a plurality of raw materials made of different components onto the conveyor 2 from the raw material yard Ya. The conveyor 2 conveys raw materials to the hopper 3 and replenishes the hopper 3. The raw materials in the hopper 3 are cut out and mixed on the conveyors 4 and 5 in accordance with a predetermined blending ratio. And the stacker 6 piles up the mixed raw material as the compounding yard Yb.

  The raw material level control device 7 controls the raw material level of each hopper 3 in the cargo handling and conveying step in which the raw materials are supplied into the plurality of hoppers 3 and the raw materials are cut out from the plurality of hoppers 3. In the cargo handling and transporting process using the raw material level control device 7, first, before operation, the raw material level control device 7 calculates the raw material cut-out amount of each hopper 3 and the replenishment amount of raw material to each hopper 3, Operation is performed according to the calculated cutout amount and supply amount.

  In addition, the raw material blending device 8 mixes a plurality of raw materials cut out from the hoppers 3 onto the conveyors 4 and 5 according to the raw material level controlled by the raw material level control device 7 by the stacker 6 in advance. Blend in.

  Here, the raw material level control device 7 and the raw material blending device 8 are each means described below, specifically, a general computer including a CPU, a disk device, a memory device, an input device, an output device, a communication device, and the like. This can be realized by operating with a program that functions as:

  Here, the raw material level control device 7 includes functions of an upper limit cut amount setting means, an initial set cut amount calculation means, a lower limit weight arrival time calculation means, a supply amount calculation means, and a supply amount correction means. Hereinafter, the contents of processing in each means will be described with reference to the flowchart of FIG.

  The upper limit cutting amount setting means sets an upper limit of the raw material cutting amount of the plurality of hoppers 3 as a whole. Specifically, the upper limit cutting amount setting means specifically sets the upper limit cutting amount of the entire hopper 3 so that the total cutting amount from each hopper 3 is equal to or less than the predetermined transport amount upper limit value of the conveyors 4 and 5. The amount to be discharged is set (upper limit cutting amount setting step, step S1 in FIG. 2). Thereby, at the time of operation, the cutout amount of the entire hopper 3 does not exceed the transport amount upper limit value of the conveyors 4 and 5 that convey the raw material to the stacker 6.

  The initial set cutting amount calculation means calculates the cutting amount of the raw material of each hopper 3. Specifically, the initial set cutting amount calculation means includes an upper limit cutting amount set by the upper limit cutting amount setting means, a predetermined blending ratio of each raw material, and a predetermined equipment upper limit of the hopper 3. The initial set cut amount of each hopper 3 is calculated so as to satisfy the cut amount (initial set cut amount calculating step, step S2 in FIG. 2).

  The initial set cutting amount calculation means, for example, takes into account the upper limit cutting amount of the entire hopper 3 and the equipment upper limit cutting amount of the hopper 3, and the hopper having the largest raw material blending ratio value among the plurality of hoppers 3. First, an initial cut-out amount of 3 is calculated. Then, the initial cutout amounts of the other hoppers 3 are calculated according to a predetermined blending ratio.

  For example, when the number of hoppers 3 is 2, the upper limit cutting amount of the entire hopper 3 is 25 t / min, the upper limit cutting amount of the hopper 3 is 15 t / min, and the blending ratio of each hopper 3 is 15: 8, the initial The set cutting amount calculation means calculates, for example, the initial setting cutting amount of the hopper 3 having a large blending ratio value (= 15) as 15 t / min, and the initial setting of the hopper 3 having a small blending ratio value (= 8). The cutting amount is calculated as 8 t / min. In this case, the total cutting amount of the entire hopper 3 is 23 t / min, which is equal to or less than the upper limit cutting amount (= 25 t / min) of the entire hopper 3.

Here, for example, when the number of hoppers 3 is N, the value of the blending ratio of each hopper 3 is α _N , and the initial cutout amount of each hopper 3 is Y _N [t / min], the transportation of the conveyors 4 and 5 The amount upper limit value and the total cut amount value of each hopper 3 (that is, the upper limit cut amount of the entire hopper 3) have a relationship as shown in the following expression (1).

Transport amount upper limit ≧ Σ (α _N × Y _N ) (1)

Α _N is the value of the blending ratio of individual raw materials calculated in advance in the raw material blending calculation. Since the cutting amount of each brand is not the same when blending the raw materials of a plurality of brands, the cutting amount from each hopper 3 is equal to the initial cutting amount Y _N as shown in the above formula (1). it is necessary to multiply the value alpha _N compounding ratio.

  The lower limit weight arrival time calculating means calculates the time until the raw material in each hopper 3 reaches the lower limit weight. Specifically, the lower limit weight arrival time calculating means is based on the difference between the initial set cut amount calculated by the initial set cut amount calculating means and a predetermined replenishment amount to the hopper 3. The lower limit weight arrival time, which is the time until the raw material weight reaches the predetermined raw material lower limit weight, is calculated (lower limit weight arrival time calculating step, step S3 in FIG. 2).

  More specifically, the lower limit weight arrival time calculating means extracts the difference between the raw material weight in the hopper 3 and the raw material lower limit weight of the hopper 3 as shown in the following formula (2). The lower limit weight arrival time of each hopper 3 is calculated by dividing by the difference between the amount and the replenishment amount to the hopper 3.

  Lower limit weight arrival time [t] = (raw material weight [t] −raw material lower limit weight [t]) / (initial set cutting amount [t / min] −replenishment amount [t / min]) Equation (2)

  Thus, in the present invention, in order to prevent all raw materials from being cut out from the hopper 3, the raw material lower limit weight, that is, the raw material level lower limit value or more can be maintained. Note that the hopper 3 with “initially set cutting amount [t / min] <replenishment amount [t / min]” is out of the calculation target range, but for example, replenishment after replenishment to the raw material level upper limit value after operation. You may incorporate into the calculation object of said Formula (2) by making quantity into 0.

  The replenishment amount calculation means calculates the replenishment amount of the raw material to the hopper 3. Specifically, the replenishment amount calculation means first determines the hopper 3 having the longest lower limit weight arrival time calculated by the lower limit weight arrival time calculation means among the hoppers 3 as a reference hopper, and sets the other hoppers 3 as the reference hoppers. It is determined as the correction target hopper. Here, the reference hopper indicates the hopper 3 serving as a reference when calculating the replenishment amount of the correction target hopper, and the correction hopper indicates the hopper 3 that is the target of the replenishment amount calculation. Yes. Therefore, as will be described later, the original replenishment amount of the reference hopper (preset replenishment amount) is not corrected and used as it is during operation, the original replenishment amount of the correction target hopper is corrected, and a new replenishment amount during operation Will be used.

  Next, the replenishment amount calculation means calculates the correction target based on the cut-out amount from the correction target hopper, the longest lower limit weight arrival time, the raw material weight in the correction target hopper, and the raw material lower limit weight of the correction target hopper. A new supply amount to the correction target hopper is calculated so that the lower limit weight arrival time of the hopper becomes the same as the reference hopper (supply amount calculation step, step S4 in FIG. 2). That is, the replenishment amount calculating means increases the replenishment amount to the other hoppers 3 (correction target hoppers) in accordance with the hopper 3 (reference hopper) having the longest lower limit weight arrival time, thereby reducing the lower limit of each hopper 3. Match the weight arrival time.

Here, for example, the number of hoppers 3 is two, the raw material weight in the correction target hopper is W ₁ , the raw material lower limit weight is W ₀₁ , the initial cutout amount is Y ₁ , the replenishment amount is X ₁ , and the lower limit weight arrival time. was a T _1, the raw material weight W ₂ in the reference _hopper, material lower weight W _02, initialization switching volume of Y _2, if the supply amount and X _2, the lower weight arrival time T _2, and the Equation (2) can be rewritten as Equation (3) and Equation (4) below.

_{T 1 = (W 1 -W 01} ) / (Y 1 -X 1) ··· (3)
_{T 2 = (W 2 -W 02} ) / (Y 2 -X 2) ··· formula (4)

The supply amount calculation means, the equation (4) T ₂ is substituted into T ₁ of the formula (3) was transformed to the equation (5), a new supply amount X ₁ of the correction target hopper ' Is calculated.

_{X 1 '= Y 1 - (} W 1 -W 01) / T 2 ··· formula (5)

Accordingly, since “original supply amount X ₁ <new supply amount X ₁ ′” to the correction target hopper, the supply amount X to the correction target hopper is matched with the lower limit weight arrival time T ₂ of the reference hopper. The balance of the raw material levels in each hopper 3 can be made uniform.

The supply amount correction means corrects the supply amount of the raw material to the hopper 3. Specifically, the replenishment amount correction means corrects the replenishment amount for the correction target hopper to a new replenishment amount (replenishment amount correction step, step S5 in FIG. 2). That is, the supply amount correction means, by correcting the supply amount X ₁ to a new supply amount X _{1 ',} to increase the supply amount of the correction target hopper.

  Hereinafter, an example of the raw material level control by the raw material level control apparatus 7 according to the present embodiment will be described with reference to FIG. Here, the number of hoppers 3 is two (first hopper and second hopper), processing in the upper limit cutting amount setting means (upper limit cutting amount setting step) and processing in the initial setting cutting amount calculation means (initial setting). The cutting amount calculation step) was omitted, and the conditions of each hopper 3 were set as follows.

<First hopper conditions>
Replenishment amount X ₁ = 10 t / min to the first hopper
Raw material weight in the first hopper W ₁ = 80 t
Raw material lower limit weight W ₀₁ = 10 t of the first hopper
Initial cutout amount Y _{1 of} the first hopper = 15 t / min

<Conditions for second hopper>
Replenishment amount X ₂ = 6 t / min to the second hopper
Raw material weight in the second hopper W ₂ = 120 t
Raw material lower limit weight W ₀₂ = 10 t of second hopper
Initial cutting amount Y _{2 of} the second hopper = 8 t / min

After the upper limit cutting amount setting step and the initial setting cutting amount calculation step, the lower limit weight reaching time calculating means calculates the lower limit weight reaching time T _{1 of} the first hopper and the first weight by the above-described formulas (3) and (4). 2 the lower weight arrival time T ₂ of the hopper is calculated as below (lower weight arrival time calculating step).

Lower limit weight arrival time T ₁ = (80-10) / (15-10) = 14 min
Lower limit weight arrival time T ₂ = (120-10) / (8-6) = 55 min

  From the above calculation results, it can be seen that the raw material in the first hopper reaches the lower limit weight earlier than the raw material in the second hopper. Therefore, as will be described below, processing for increasing the amount of raw material supplied to the first hopper is made larger than the original amount of supply.

That is, supply amount calculation means, among the first hopper and second hopper, defining long lower weight arrival time T ₂ (= 55min) standard hopper a second hopper, the other of the first hopper as the correction target hopper. Then, the replenishment amount calculation means calculates a new replenishment amount X ₁ ′ to the first hopper that is the correction target hopper by the above-described equation (5) as follows (replenishment amount calculation step).

New supply amount X ₁ ′ = 15− (80−10) /55≈13.73 t / min

Based on the calculation result, the new supply amount X ₁ (= 13.73 t / min) of the correction target hopper (first hopper) is larger than the original supply amount X ₁ (= 10 t / min). The amount of replenishment to the hopper will increase.

Then, the replenishment amount correction means corrects the replenishment amount X ₁ (= 10 t / min) for the correction target hopper (first hopper) to a new replenishment amount X ₁ (≈13.73 t / min) (replenishment) Amount correction step), the operation is started under these conditions.

  According to the raw material level control device 7 and the raw material level control method described above, the replenishment amount of the raw material to the other hoppers (correction target hoppers) 3 is adjusted in accordance with the hopper (reference hopper) 3 having the longest lower limit weight arrival time. By adjusting, the raw material levels of the plurality of hoppers 3 can be controlled simultaneously, and the balance of the raw material levels of the hoppers 3 can be made uniform. Therefore, in the raw material level control device 7 and the raw material level control method, only one of the plurality of hoppers 3 is emptied during operation, so that the raw material cannot be mixed at the intended blending ratio and continuous operation is hindered. Can be avoided and stable operation can be performed. Further, according to the raw material blending device 8 and the raw material blending method provided with such a raw material level control device 7, the raw materials can be mixed at the intended blending ratio.

[Modification of First Embodiment]
The modification of 1st Embodiment of this invention is demonstrated referring FIG. 3 and FIG. In the first embodiment described above, the new supply amount to the correction target hopper is calculated in accordance with the longest lower limit weight arrival time, and the supply amount to the correction target hopper is increased. For example, this new supply amount However, when it exceeds the predetermined equipment upper limit payout amount of the loader 1, this new supply amount cannot be used as it is. This modification is for dealing with such a situation. In the following, description will be made on the assumption that the payout amount from the loader 1 = the replenishment amount to the hopper 3.

  As in the first embodiment, the raw material level control device 7 according to the present modification includes an upper limit cut amount setting means, an initial set cut amount calculation means, a lower limit weight arrival time calculation means, a supply amount calculation means, and a supply amount correction. Although the function of the means is provided, the processing of the replenishment amount calculating means is different from that of the first embodiment. Hereinafter, the contents of processing in each means will be described with reference to the flowchart of FIG. Note that steps S11 to S14 in FIG. 4 are the same as steps S1 to S4 already described in FIG.

  After step S14, the replenishment amount calculating means determines whether or not the new replenishment amount exceeds the equipment upper limit payout amount of the loader 1 (step S15). If the new replenishment amount does not exceed the equipment upper limit payout amount of the loader 1 (No in step S15), the replenishment amount correction means sets the replenishment amount for the correction target hopper to a new replenishment as in the first embodiment. By correcting to the amount, the amount of replenishment to the correction target hopper is increased (step S16).

  On the other hand, when the new replenishment amount exceeds the equipment upper limit payout amount of the loader 1 (Yes in step S15), the replenishment amount calculation means uses the hopper 3 having the shortest lower limit weight arrival time as the reference hopper and the other hoppers. 3 is again determined as the correction target hopper, and the correction target is determined based on the cut-out amount from the correction target hopper, the longest lower limit weight arrival time, the raw material weight in the correction target hopper, and the raw material lower limit weight of the correction target hopper. A new supply amount to the correction target hopper is calculated again so that the lower limit weight arrival time of the hopper becomes the same as that of the reference hopper (step S17). That is, the replenishment amount calculation means reduces the replenishment amount to the other hoppers 3 (correction target hoppers) in accordance with the hopper 3 (reference hopper) having the shortest lower limit weight arrival time, thereby reducing the lower limit of each hopper 3. Match the weight arrival time.

Here, for example, the number of the hoppers 3 is two, and contrary to the description in the first embodiment, the raw material weight in the reference hopper is W ₁ , the raw material lower limit weight is W ₀₁ , the initial cutout amount is Y ₁ , The replenishment amount is X ₁ , the lower limit weight arrival time is T ₁ , the raw material weight in the correction target hopper is W ₂ , the raw material lower limit weight is W ₀₂ , the initial cutout amount is Y ₂ , the replenishment amount is X ₂ , the lower limit weight When the arrival time is T ₂ , the replenishment amount calculating means substitutes T ₁ in Equation (3) into T ₂ in Equation (4) and transforms it into Equation (6) below, A new supply amount X ₂ ′ is calculated.

_{X 2 '= Y 2 - (} W 2 -W 02) / T 1 ··· formula (6)

As a result, since “original supply amount X ₂ > new supply amount X ₂ ′” to the correction target hopper, the supply amount to the correction target hopper is reduced in accordance with the lower limit weight arrival time T ₁ of the reference hopper. The balance of the raw material levels in each hopper 3 can be made uniform.

Next, the replenishment amount correcting means corrects the replenishment amount for the correction target hopper to a new replenishment amount recalculated by the above equation (6) (step S18). That is, the supply amount correcting means to correct the replenishing amount X ₂ to a new supply amount X _{2 ',} reduce the replenishing amount to the correction target hopper.

  Hereinafter, an example of the raw material level control by the raw material level control apparatus 7 according to this modification will be described with reference to FIG. Here, the conditions of each hopper 3 are the same as the above-mentioned <first hopper condition> and <second hopper condition>. The description of the processing in the upper limit cut amount setting means (upper limit cut amount setting step) and the process in the initial set cut amount calculation means (initial set cut amount calculation step) will also be omitted.

After the upper limit cutting amount setting step and the initial setting cutting amount calculation step, the lower limit weight reaching time calculating means calculates the lower limit weight reaching time T _{1 of} the first hopper and the first weight by the above-described formulas (3) and (4). 2 the lower weight arrival time T ₂ of the hopper is calculated as below (lower weight arrival time calculating step).

Lower limit weight arrival time T ₁ = (80-10) / (15-10) = 14 min
Lower limit weight arrival time T ₂ = (120-10) / (8-6) = 55 min

Then, supply amount calculation means, among the first hopper and second hopper, set long lower weight arrival time T ₂ (= 55min) standard hopper a second hopper, the other of the first hopper as the correction target hopper The new replenishment amount X ₁ ′ to the first hopper that is the correction target hopper is calculated as follows using the above-described equation (5) (replenishment amount calculating step).

New supply amount X ₁ ′ = 15− (80−10) /55≈13.73 t / min

Up to this point, the process is the same as in the first embodiment. However, for example, when the equipment upper limit payout amount of the loader 1 is 10 t / min, the above-described new supply amount X ₁ ′ exceeds the equipment upper limit payout amount of the loader 1, so the new supply amount X ₁ ′ is It cannot be used as it is.

Therefore, supply amount calculation means, among the first hopper and second hopper defines short lower weight arrival time T ₁ (= 14 min) standard hopper a first hopper, the other second hopper again as the correction target hopper . Then, the replenishment amount calculating means calculates a new replenishment amount X ₂ ′ to the second hopper, which is the correction target hopper, by the above-described equation (6) as follows (replenishment amount calculating step).

New supply amount X ₂ ′ = 8− (120−10) /14≈0.14 t / min

As a result of the above calculation, the new supply amount X ₂ ′ (≈0.14 t / min) of the correction target hopper (second hopper) becomes a value smaller than the original supply amount X ₂ (= 6 t / min). The replenishment amount to 2 hoppers will decrease.

Next, the replenishment amount correction means uses the replenishment amount X ₂ (= 6 t / min) for the correction target hopper (second hopper) as a new replenishment amount X ₂ ′ (≈0.14 t / min). The operation is started under these conditions.

  According to the raw material level control device 7 and the raw material level control method described above, the raw materials in some hoppers 3 are depleted by adjusting the raw material replenishment amount in consideration of the equipment upper limit discharge amount of the loader 1. Can be more reliably prevented, and the balance of the raw material levels of each hopper 3 can be made more uniform.

[Second Embodiment]
A second embodiment of the present invention will be described with reference to FIGS. 3 and 5. In the modified example of the first embodiment described above, when the new replenishment amount exceeds the predetermined equipment upper limit payout amount of the loader 1, the hopper 3 other than the hopper 3 having the shortest lower limit weight arrival time is supplied. Although the replenishment amount has been reduced, it is also possible to adjust the cutout amount from the hopper 3, for example, instead of the replenishment amount to the hopper 3.

  The raw material level control device 7 according to the present embodiment is in addition to the upper limit cut amount setting means, the initial set cut amount calculation means, the lower limit weight arrival time calculation means, the supply amount calculation means, and the supply amount correction means in the first embodiment. Thus, it has functions of a cutout amount calculating means and a cutout amount correcting means. Hereinafter, the contents of processing in each means will be described with reference to the flowchart of FIG. Note that steps S21 to S24 in FIG. 5 are the same as steps S1 to S4 already described in FIG.

  After step S24, the replenishment amount calculating means determines whether or not the new replenishment amount exceeds the equipment upper limit payout amount of the loader 1 (step S25). If the new supply amount does not exceed the equipment upper limit payout amount of the loader 1 (No in step S25), the supply amount correction means supplies the supply amount to the correction target hopper as in the first embodiment and its modification. Is corrected to a new supply amount to increase the supply amount to the correction target hopper (step S26).

  On the other hand, when the new supply amount exceeds the equipment upper limit payout amount of the loader 1 (Yes in step S25), the cutout amount calculating means decreases the cutout amount from the correction target hopper based on a predetermined ratio. Thus, a new cutout amount of the correction target hopper is calculated (cutout amount calculating step, step S27). The predetermined ratio described above is experimentally obtained in advance and is set to 0.8, for example.

  Next, the cutting amount calculation means calculates a new cutting amount of the reference hopper based on the new cutting amount of the correction target hopper and a predetermined blending ratio (cutting amount calculation step, Step S28). That is, since it is necessary to maintain the blending ratio of the cutting amounts from each hopper 3, after obtaining a new cutting amount for the correction target hopper, a new cutting amount is obtained also for the other reference hoppers. . As described above, since the blending ratio is maintained for the cutout amount from each hopper 3, the new cutout amount of the correction target hopper is also a value reduced from the initial cutout amount.

  Next, the cutout amount correction means corrects the initial set cutout amount of each hopper 3 to a new cutout amount instead of the replenishment amount correction step by the replenishment amount correction means of the first embodiment (cutout amount). Output amount correction step, step S29). That is, the cut amount correcting means corrects the initial set cut amount of each hopper 3 to a new cut amount, thereby reducing the cut amount (initial set cut amount) of each hopper 3.

  Thereafter, the process returns to step S23, and the lower limit weight arrival time calculation step (step S23) until the new supply amount calculated in the supply amount calculation step does not exceed the equipment upper limit payout amount of the loader 1 (No in step S25). The replenishment amount calculation step (step S24), the cutout amount calculation step (steps S27 and S28), and the cutout amount correction step (step S29) are repeated. Finally, in all hoppers 3, the cutout amount is adjusted so that the replenishment amount from the loader 1 exceeds the cutout amount from the hopper 3.

  Hereinafter, an example of the raw material level control by the raw material level control apparatus 7 according to the present embodiment will be described with reference to FIG. Here, the conditions of each hopper 3 are the same as the above-mentioned <first hopper condition> and <second hopper condition>, and the mixing ratio of the first hopper and the second hopper is 15: 8. The description of the processing in the upper limit cut amount setting means (upper limit cut amount setting step) and the process in the initial set cut amount calculation means (initial set cut amount calculation step) will also be omitted.

After the upper limit cutting amount setting step and the initial setting cutting amount calculation step, the lower limit weight reaching time calculating means calculates the lower limit weight reaching time T _{1 of} the first hopper and the first weight by the above-described formulas (3) and (4). 2 the lower weight arrival time T ₂ of the hopper is calculated as below (lower weight arrival time calculating step).

Lower limit weight arrival time T ₁ = (80-10) / (15-10) = 14 min
Lower limit weight arrival time T ₂ = (120-10) / (8-6) = 55 min

Then, supply amount calculation means, among the first hopper and second hopper, set long lower weight arrival time T ₂ (= 55min) standard hopper a second hopper, the other of the first hopper as the correction target hopper The new replenishment amount X ₁ ′ to the first hopper that is the correction target hopper is calculated as follows using the above-described equation (5) (replenishment amount calculating step).

New supply amount X ₁ ′ = 15− (80−10) /55≈13.73 t / min

Up to this point, the process is the same as in the first embodiment. However, for example, when the equipment upper limit payout amount of the loader 1 is 10 t / min, the above-described new supply amount X ₁ ′ exceeds the equipment upper limit payout amount of the loader 1, so the new supply amount X ₁ ′ is It cannot be used as it is.

Therefore, the cutting amount calculation means reduces the cutting amount from the first hopper, which is the correction target hopper (here, the initial setting cutting amount Y ₁ ) based on a predetermined ratio, thereby reducing the cutting amount as follows. A new cutting amount Y ₁ ′ of one hopper is calculated. Here, a predetermined ratio = 0.8.

New cutting amount Y ₁ ′ = 15 × 0.8 = 12 t / min

As a result of the above calculation, the new cut-out amount Y ₁ ′ (= 12 t / min) of the correction target hopper (first hopper) is smaller than the initial cut-out amount Y ₁ (= 15 t / min). The cutting amount (initial cutting amount) of one hopper is reduced.

Then, cutting amount calculating means, corrected hopper by multiplying the new cutting amount ratio Y _{1 '(first} hopper), a new cutting amount of the reference hopper (second hopper) Y ₂ 'Is calculated as follows (cutout amount calculation step).

New cutting amount Y ₂ ′ = 12 × (8/15) = 6.4 t / min

As a result of the above calculation, the new cutting amount Y ₂ ′ (= 6.4 t / min) of the reference hopper (second hopper) is also smaller than the initial setting cutting amount Y ₂ (= 8 t / min). Further, the cutting amount of the second hopper (initial setting cutting amount) is also reduced.

Next, the cutting amount correcting means corrects the initial cutting amount Y ₁ (= 15 t / min) for the correction target hopper (first hopper) to a new cutting amount Y ₁ ′ (= 12 t / min). In addition, the initial set cutting amount Y ₂ (= 8 t / min) for the reference hopper (second hopper) is corrected to a new cutting amount Y ₂ ′ (= 6.4 t / min) (cutting amount correction). Step).

  After that, until the new supply amount calculated in the supply amount calculation step does not exceed the equipment upper limit payout amount of the loader 1, the lower limit weight arrival time calculation step, the supply amount calculation step, the cutout amount calculation step, and the cutout amount correction The steps are repeated to adjust the cutout amount so that the replenishment amount from the loader 1 exceeds the cutout amount from the hopper 3, and the operation is started under this condition.

  According to the raw material level control device 7 and the raw material level control method described above, the raw material in some of the hoppers 3 is depleted by adjusting the raw material cutting amount in consideration of the equipment upper limit payout amount of the loader 1. This can be prevented more reliably, and the balance of the raw material levels of the hoppers 3 can be made more surely uniform.

  As mentioned above, the raw material level control method, the raw material blending method, the raw material level control apparatus and the raw material blending apparatus according to the present invention have been described in detail according to the mode for carrying out the invention. Should be construed broadly based on the claims. Needless to say, various changes and modifications based on these descriptions are also included in the spirit of the present invention.

  For example, in the raw material level control method, the raw material blending method, the raw material level control apparatus and the raw material blending apparatus according to the present invention, the supply amount to the hopper 3 and the cut-out amount from the hopper 3 are the facility stoppage, replenishment amount and In consideration of the fact that it changes during the calculation due to the side change of the weigher measuring the cutout amount, the cutout amount and the replenishment amount may be recalculated at an arbitrary time period or at an arbitrary timing. Thereby, for example, it is possible to avoid that the calculation does not converge and the calculation falls into an infinite loop.

1 Loader 2, 4, 5 Conveyor 3 Hopper 6 Stacker 7 Raw material level control device 8 Raw material blending device Ya Raw material yard Yb Blending yard

Claims (6)

In the loading and unloading process in which a plurality of raw materials made of different components are discharged by a loader and replenished into a plurality of hoppers, and then the raw materials are cut out from the hoppers onto a conveyor according to a predetermined blending ratio. A raw material level control method for controlling a raw material level in
An upper limit cutting amount setting step for setting an upper limit cutting amount of the entire hopper so that a total cutting amount value from each hopper is equal to or less than a predetermined transport amount upper limit value of the conveyor;
An initial cutout amount calculating step for calculating an initial cutout amount of each hopper so as to satisfy the upper cutout amount, the blending ratio, and the predetermined facility upper cutout amount of the hopper, respectively. ,
Based on the difference between the initial cutout amount and a predetermined replenishment amount to the hopper, a lower limit weight arrival time, which is a time until the raw material weight in the hopper reaches a predetermined lower limit raw material weight A lower limit weight arrival time calculating step for calculating
Among the hoppers, the hopper with the longest lower limit weight arrival time is defined as a reference hopper, and the other hoppers are determined as correction target hoppers, the amount of cut out from the correction target hopper, and the longest lower limit weight arrival time, Based on the raw material weight in the correction target hopper and the raw material lower limit weight of the correction target hopper, the correction target hopper is renewed so that the lower limit weight arrival time of the correction target hopper becomes the same as the reference hopper. A replenishment amount calculating step for calculating a replenishment amount;
A replenishment amount correction step for correcting the replenishment amount for the correction target hopper to the new replenishment amount;
A raw material level control method comprising: In the replenishment amount calculating step, when the new replenishment amount exceeds a predetermined equipment upper limit payout amount of the loader, the hopper having the shortest lower limit weight arrival time is designated as the reference hopper, and the other hoppers are designated as the hopper. Redefining the correction target hopper, based on the amount of cut from the correction target hopper, the longest lower limit weight arrival time, the raw material weight in the correction target hopper, and the raw material lower limit weight of the correction target hopper, Recalculate a new supply amount to the correction target hopper so that the lower limit weight arrival time of the correction target hopper becomes the same as the reference hopper,
The raw material level control method according to claim 1, wherein the replenishment amount correction step corrects a replenishment amount for the correction target hopper to the recalculated new replenishment amount. After the replenishment amount calculating step,
When the new replenishment amount exceeds a predetermined equipment upper limit payout amount of the loader, a new amount of the correction target hopper is reduced by reducing a cutout amount from the correction target hopper based on a predetermined ratio. A cutting amount calculating step of calculating a cutting amount, and further calculating a new cutting amount of the reference hopper based on the new cutting amount of the correction target hopper and the blending ratio;
Instead of the replenishment amount correction step, a cutout amount correction step for correcting the cutout amount of each hopper to the new cutout amount, respectively.
The raw material level control method according to claim 1, further comprising:   According to the raw material level controlled by the raw material level control method according to any one of claims 1 to 3, the mixing ratio of the plurality of raw materials cut out from each hopper onto the conveyor by the mixing ratio. A raw material blending method characterized by blending in In the loading and unloading process in which a plurality of raw materials made of different components are discharged by a loader and replenished into a plurality of hoppers, and then the raw materials are cut out from the hoppers onto a conveyor according to a predetermined blending ratio. A raw material level control device for controlling the raw material level in
An upper limit cutting amount setting means for setting an upper limit cutting amount of the entire hopper so that a total cutting amount value from each hopper is equal to or less than a predetermined transport amount upper limit value of the conveyor;
An initial cutout amount calculating means for calculating an initial cutout amount of each hopper so as to satisfy the upper cutout amount, the blending ratio, and the predetermined facility upper cutout amount of the hopper, respectively. ,
Based on the difference between the initial cutout amount and a predetermined replenishment amount to the hopper, a lower limit weight arrival time, which is a time until the raw material weight in the hopper reaches a predetermined lower limit raw material weight A lower limit weight arrival time calculating means for calculating
Among the hoppers, the hopper with the longest lower limit weight arrival time is defined as a reference hopper, and the other hoppers are determined as correction target hoppers, the amount of cut out from the correction target hopper, and the longest lower limit weight arrival time, Based on the raw material weight in the correction target hopper and the raw material lower limit weight of the correction target hopper, the correction target hopper is renewed so that the lower limit weight arrival time of the correction target hopper becomes the same as the reference hopper. A replenishment amount calculating means for calculating a replenishment amount;
Replenishment amount correction means for correcting the replenishment amount for the correction target hopper to the new replenishment amount;
A raw material level control apparatus comprising:   6. The raw material characterized in that, according to the raw material level controlled by the raw material level control device according to claim 5, the plurality of raw materials cut out from each hopper onto the conveyor are mixed at a mixing ratio by a stacker. Compounding equipment.

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