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水泥技术, 2025, 1(4): 52-58    doi: 10.19698/j.cnki.1001-6171.20254052
  数字智能 本期目录 | 过刊浏览 | 高级检索 |

石灰石破碎AI+APC智能控制系统的开发与应用

1 中才邦业(杭州)智能技术有限公司,浙江  杭州  310000;

2 湖州槐坎南方水泥有限公司,浙江  长兴  313100;

Development and Application of AI + APC (Advanced Process Control) Intelligent Control in Limestone Crushing

1 Zhongcai Bangye (Hangzhou) Intelligent Technology Co., Ltd. , Hangzhou Zhejiang 310000, China;

2 Huzhou Huaikan Southern Cement Co., Ltd. , Changxing Zhejiang 313100, China

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摘要 

基于湖州槐坎水泥生产线石灰石破碎系统存在的操作依赖人工、大块物料识别滞后、产能优化不足及收尘控制粗放等问题,开发了基于AI视频分析+APC智能控制”的智能化系统解决方案。该技术方案主要包括AI视频分析(在卸车坑部署摄像头,采用YOLO目标检测算法实时识别大块、特大块物料及泥块,触发语音报警并联动控制系统)、APC智能控制(以多变量模型预测控制为核心,构建产能优化与收尘控制回路;动态调整板式喂料机转速,优化电流设定值);基于冒灰识别结果自整定负压值,自动调节收尘风机阀门开度、DCS功能升级(新增一键启停功能,标准化启停时长,主动/被动断料差异化响应,实现APC与组控系统无缝衔接)等功能。该智能化系统投用后,平均电耗降至0.975kW·h/t,综合台时产量提升至877.24t/h,操作员工作量显著降低,堵塞风险减少,产能利用率与环保性能同步优化。

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张闯
顾志彬
马纯辉
李志丹
魏灿
关键词:  石灰石破碎系统  AI视频分析  APC智能控制  一键启停  产能优化    
Abstract: 

To address the issues of manual operation dependence, delayed oversized material identification, insufficient production optimization, and crude dust collection control in the limestone crushing system of a cement production line in Huaikan, Huzhou, an intelligent system solution based on "AI Video Analytics + APC Intelligent Control" was developed. The technical solution primarily includes: AI Video Analytics (Cameras deployed at the unloading pit utilize the YOLO object detection algorithm to identify large/oversized material blocks and mud chunks in real-time, triggering voice alarms and interlocking control with the control system)APC Intelligent Control (Centered on multivariable model predictive control (MPC), it establishes production optimization and dust control loops; dynamically adjusts the speed of the plate feeder and optimizes current setpoints;Automatically sets negative pressure values based on dust escape detection and regulates the dust collector fans damper opening)DCS Function Upgrades (Added one-click start/stop functionality with standardized start/stop durations;Implemented differentiated responses to active/passive material interruptions;Enabled seamless APC-group control handover).After deployment, the system reduced average power consumption to 0.975kW·h/t, increased integrated unit output to 877.24t/h, significantly lowered operator workload, reduced blockage risks, and simultaneously improved capacity utilization and environmental performance.

Key words:  limestone crushing system    AI video analytics    APC(Advanced Process Control) intelligent control    One-Click start/stop    production optimization
收稿日期:  2024-11-16      修回日期:  2025-07-25           出版日期:  2025-07-25      发布日期:  2025-07-25      整期出版日期:  2025-07-25
ZTFLH:  TQ172.632  
基金资助: 

中国建材联合会全国建材行业第二批重大科技攻关“揭榜挂帅”项目(202201JBGS06-01

作者简介:  张 闯(1984—),男,本科,高级工程师,主要从事水泥智能化产品与技术开发。E-mail:lyzhangchuang@163.com
引用本文:    
张闯, 顾志彬, 马纯辉, 李志丹, 魏灿.

石灰石破碎AI+APC智能控制系统的开发与应用 [J]. 水泥技术, 2025, 1(4): 52-58.
ZHANG Chuang, GU Zhibin, MA Chunhui, LI Zhidan, WEI Can.

Development and Application of AI + APC (Advanced Process Control) Intelligent Control in Limestone Crushing . Cement Technology, 2025, 1(4): 52-58.

链接本文:  
http://www.cemteck.com/CN/10.19698/j.cnki.1001-6171.20254052  或          http://www.cemteck.com/CN/Y2025/V1/I4/52
[1] 黄新云.

石灰石破碎系统改造 [J]. 水泥技术, 2025, 1(2): 43-46.

[2] 魏灿, 俞利涛, 童睿, 王纯良.
水泥粉磨智能优化控制系统的应用
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