Research On Simulation Of Artificial Colored Sand Production Process And Optimization For Production Line

In recent years,stone-like paint with colored sand as the raw material has been increasingly used for the spraying of exterior walls and roofs of highrise buildings due to its advantages of green environmental protection and rich colors.In this context,the demand for artificial colored sand,which is made of quartz sand particles,mixed with inorganic pigments and sintered at high temperature,is increasing rapidly year by year.Meanwhile,the optimization design technology of production line has become a research focus.The production line of artificial colored sand has a large number of equipment,and its layout is relatively scattered,and the control of each equipment is relatively isolated.During the process of continuous production,material accumulation is easy to occur due to the incongruity of material rate between manual operation and equipment processing,which leads to frequent shutdown of production line,directly affecting the production efficiency and stability of product quality.Therefore,according to the equipment layout,production process and equipment operation parameters of the production line,a production process simulation model is established in this dissertation,which is running in a continuous simulated production environment.By analyzing the simulation results,the factors affecting production line efficiency and product quality stability is obtained.According to the production equipment and control process,an optimal design scheme is proposed and applied to the actual production line.The main research work of this dissertation is as follows.(1)Combined with production technology of the artificial colored sand,the production process,equipment composition and layout of four sections of the colored sand production line,including the feeding coloring,preheating calcination,cooling and finished product measurement and packaging,are analyzed in detail.The output of the production line and the downtime rate of some equipment are obtained through production data.The operation parameters of the line body conveyor belt,drying machinery and other key equipment are obtained through field experiments,including the maximum flow rate of material and the maximum capacity of the equipment.(2)According to the equipment layout,actual production process and specific equipment parameters of artificial colored sand production line,the entities in Flexsim corresponding to the production line equipment are found and the production process model is built by the entities connection and parameters configuration;The rationality of the simulation model is verified by the comparative analysis of the simulation operation results and the production line operation data;The factors affecting the production efficiency and product quality stability of the existing production line are analyzed,and an optimization scheme is proposed for the equipment and control process of the production line,and the effectiveness of the optimization scheme is verified by simulation.(3)In order to realize the proposed control process optimization scheme and meet characteristics of the production line with mass equipment and scattered layout,the distributed control network of the production line was constructed based on CC-Link bus,which realizes the data transmission between PLC and each device;The PLC program of the control system is developed according to the control process,which ensures the continuous and coordinated operation of the production line;The upper computer software of the control system is developed by Qt Creator.Key functions of the artificial colored sand production line are realized,including real-time monitoring of the production process,automatic switching of the target silo and automatic adjustment of the inverter parameters.(4)The optimized scheme and control system are applied to the new production line,the installation and debugging of field equipment are completed,and the reliability of the control system and the correctness of the optimized scheme are verified by repeated operation.The field trial operation shows that the optimization scheme of artificial colored sand production line proposed in this dissertation ensures the stability of product quality,and downtime rate of the feeding and coloring section and finished product metering and packaging section is reduced by 42% and 45%,respectively.Furthermore,improve production efficiency by 71%.Thus,this dissertation provides a reference for the simulation optimization of continuous production line.