Claims:WE CLAIM:
A device for determining and controlling the circumferential balance in charging burden material inside blast furnace, the device comprising:
A control system (A), for acquiring data from field devices and transmitting data to computer device, being coupled with plurality of sensors (P1 – P5) wherein the plurality of sensors (P1 – P5) senses parameters which include vibration of hopper, LMG opening (L), chute rotation angle (r), tilt angle (t) and changing matrix and transmit to the control system (A);
A data cleaning and sampling system (B);
A data processing system (C) to quantify the performance of learning logic program for preparing the data and filtering the database on control limit and estimating circumferential balance of blast furnace; a computation module for communication for feedback system;
A visualization system (D); and
A control room feedback system (E).
The device as claimed in claim 1, wherein the visualization means (D) comprises of charts and graphs.
The device as claimed in claim 1, wherein the sensors (P1 – P5) are tilt angle and gate opening proximity sensor, rotation encoder and the like.
The device as claimed in claim 1, wherein the data processing system (C) comprises of two filters (F1 and F2), wherein filter F1 is configured to remove to hopper filling signal from the vibration signal and filter F2 is configured to remove noise to obtain a pure square wave signal.

A method for determining and controlling uniformity in distribution of the material in a blast furnace the method comprising the steps of:
- obtaining data of parameters including vibration of hopper, LMG opening (L), chute rotation angle (r), tilt angle (t) and changing matrix from plurality of sensors (P1, P2, P3, P4, P5) coupled to associated electronic devices;
- transferring the data to the control system (A) which is coupled to the data cleaning and sampling system (B) and the data processing system (C);
- processing the data through the data processing system (C) to generate learning logic performance index; and
- determining the values generated with a predefined value to obtain the desired result such that the control feedback system (E) coupled to the processing means generates the resultant value and displays on the visualization system (D).
The method as claimed in claim 5, wherein the value of randomness index for charging start-up is equal to zero.
The method as claimed in claim 5, wherein the value of randomness index for charging excess in ring is equal to zero.
The method as claimed in claim 5, wherein the value of randomness index for charging recess in ring is equal to zero.
The method as claimed in claim 5, wherein a decision matrix is generated in the control feedback means (E) and corrective measures are taken.
The method as claimed in claim 5, wherein the data processing system (C) passes the vibration signal through filters (F1 and F2), wherein filter F1 removes the hopper filling signal from the vibration signal and filter F2 removes noise to obtain a pure square wave signal.
The method as claimed in claim 5, wherein the data processing system (C) is configured to pass the vibration signal through two filters (F1 and F2) wherein Filter F1 is configured to remove to hopper filling signal from the vibration signal and Filter F2 is configured to remove noise to obtain a pure square wave signal;
a start and ends point of the timestamp of this signal are used as discharge start (DS) and end (DE) points of the timestamp of a charge, wherein the difference between DS and DE is total discharge time (TDT) of the dump; and
for the generation of data to visualize randomness in start point of charge (R_(Start.point)), randomness in excess (R_excess), randomness in (R_recess)recess (in dump and Total rings per dump.
The method as claimed in claim 11, wherein the data processing system (C) being coupled to data sampling system (B) is configured to calculate randomness in start point index (R_(Start.point) ) using:
R_(Start.point)=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 1)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_sp= number of start points in a sector,
µ_(N_sp )=mean of N_sp in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
The method as claimed in claim 12, wherein the control room feedback system (E) being coupled to processing system (C) is configured to make following decision:
if? R?_(Start.point)>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_(Start.point)=0 or close to zero.
The method as claimed in claim 12, wherein the control room feedback system (E) being coupled to processing system (C) is configured to make following decision: If? R?_(Start.point)=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
The method as claimed in claim 11, wherein the data processing system (C) is configured randomness in excess (R_excess) using:
R_excess=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 2)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_spex= number of points where excess of charge is dumped,
µ_(N_spex )=mean of N_spex in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
The method as claimed in claim 15, wherein the control room feedback system (E) being coupled to processing means (C) it is configured to make following decision:
if? R?_excess>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_(Start.point)=0 or close to zero.
The method as claimed in claim 15, wherein the control room feedback system (E) being coupled to processing means (C) it is configured to make following decision:
If? R?_excess=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
The method as claimed in claim 11, wherein the data processing system (C) is configured to determine an index called as randomness in excess or recess (R_recess) using:
R_recess=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 3)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_spre= number of points where there is recess of charge in dump ,
µ_(N_spre )=mean of N_spre in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
The method as claimed in claim 18, wherein, the control room feedback system (E) being coupled to processing system (C) it is configured to make following decision:
if? R?_recess>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_recess=0 or close to zero.
The method as claimed in claim 18, wherein, the control room feedback system (E) being coupled to processing system (C) it is configured to make following decision:
if? R?_recess=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
, Description:FIELD OF INVENTION:
The invention relates to learning performance of Burden Distribution system in a blast furnace. Particularly the invention relates to a device and a method to determine the circumferential balance using the vibration signals of the hopper.
BACKGROUND AND PRIOR ART:
Blast furnace is a counter current reactor in which coke, metallics are charged from the top, and oxygen is blown from the bottom. Indirect reduction of metallics from the flowing gas is one of the most important factors for achieving high efficiency in the blast furnace. Gas which is injected from the bottom part of the furnace ascends taking the path of least resistance. Gas flow depends on the void fraction of the solids being charged from the top. Therefore, the radial distribution of the coke and metallics becomes important. To achieve desired symmetric distribution bell-less top is used in modern blast furnaces. This provides the ability to charge the material at the desired location and ensures symmetry. However, bell less top operates on some logic and takes input from various sensors for ensuring symmetry.
Asymmetry in gas flow in blast furnace leads to instability of operation, less utilization of fuel and less productivity. There are few patents available which address the circumferential balance in gas distribution.
A Japanese patent, Patent no JP 1297155 of year 1981 provides a methodology to detect the deviation in circumferential distribution of blast furnace by analyzing top gas from four uptakes of the blast furnace.
A Japanese patent, Patent no JP57070209 of year 1982 describes a method of determining the circumferential distribution of gas in blast furnace by using top gas temperature, gas constituents, gas flow rate, gas pressure and tapping data.
The prior art determine circumferential balance is by measuring the gas temperature and composition. Variation in the temperature and composition can be the effect of many parameters which influences it. Here in the present invention a device and methodology is developed by taking direct response of Vibration signal of hopper in the material distribution device instead of hopper weight to monitor the uniformity in distribution.

OBJECTS OF THE INVENTION:
The principal objective of the present invention is to provide a device for determining and controlling the circumferential balance in charging burden material inside blast furnace using the hopper vibrations.
Another object of the present invention is to provide a method for determining and controlling the circumferential balance in charging burden material inside blast furnace using the hopper vibrations.
SUMMARY OF THE INVENTION:
A device and method for determining and controlling the circumferential balance in charging burden material inside blast furnace using the hopper vibrations according to the present invention comprises of a control system (A) for acquiring data from field devices and transmitting data to computer device and is being coupled with plurality of sensors (P1 – P5) to sense the parameters of hopper vibrations? (Hp?_Wt), Lower Material Gate (LMG) opening (L), chute rotation angle (r), tilt angle (t) and charging matrix. Said sensed values are being sent to a data cleaning and sampling means (B) for cleansing of the data which in turn is further forwarded to a data processing means (C) to quantify the performance of learning logic program for preparing the data and filtering the database on control limit and estimating circumferential balance of blast furnace; a computation module for communication for feedback system. A Visualization means (D) is being coupled to processing means (C) and control room feedback means (E) and is configured to visualizeR_peras so that operator can monitor it.

BRIEF DESCRIPTION OF THE DRAWINGS
It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
Fig 1 - shows a block diagram of a predicting device with its various components in accordance with an embodiment of the invention.
Fig-2 - Schematic for Data processing means.
Fig 3 – Schematic for Visualization means
Fig. 4a - Visualization for data passed through filter F1 and F2
Fig. 4b - Visualization for randomness in start point shown by visualization means
Fig. 5 - Visualization for excess of ring with respect to set point.
Fig. 6 - Visualization means configuration to display excess or recess of a dump
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAIL DESCRIPTION OF THE INVENTION
The present invention will be described in detail below with reference to an embodiment as shown in the drawing.
Various embodiments of the invention provide a charging uniformity check device for determining and controlling the charging in a blast furnace equipped with bell-less top charging system.
Various embodiments of the invention provide a charging uniformity check device for determining and controlling the charging in a blast furnace equipped with bell-less top charging system.
The circumferential balance predicting device comprising a plurality of sensors (P1, P2, P3, P4, P5), the plurality of sensors being placed at various location in the bell less top charging system, the plurality of sensors (P1, P2, P3, P4, P5) being configured to sense values corresponding to parameters of hopper Vibration? (Hp?_Wt), LMG opening (L), chute rotation angle(r), tilt angle (t) and skip weight with respect to time and forward the sensed values to a control system (A), the control system (A) being coupled to the plurality of sensors, and configured to store and forward the sensed values to a data cleaning and sampling systems (B).
The data cleaning and sampling system (B) is coupled to data processing system (C).
Data processing system (C) is configured to pass the vibration signal through two filters (F1 and F2) as shown in Fig-2. Filter F1 is configured to remove to hopper filling signal from the vibration signal as shown actual data sample visualization in Fig-4a. Filter F2 is configured to remove noise, if any, to obtain a pure square wave signal. The start and end points of the timestamp of this signal are used as discharge start and end points of the timestamp of a charge. The difference between these two timestamps is termed as total discharge time of a dump. Module-3 of data processing system (C) is configured to determine this discharge time for all dumps.
The data processing system (C) is further configured for the generation of data to visualize randomness in start point of charge, randomness in excess/recess in dump and Total rings per dump. The total rings per dump are calculated when the counters starts at the start pf vibration measuring degree of rotation and as soon as 360 deg completes, it considers one complete circle. Data visualization system (E) is configured to visualize randomness in start point, randomness in excess/recess in dump and total number of rings per dump shown in Fig-3

Randomness in start point index ( R_(Start.point))
Data processing system (C) being coupled to data sampling system (B) it is configured to calculate randomness in start point index (R_(Start.point)). Data visualization system is configured to visualize this randomness in start point as shown in Fig 4b. This visualization system provides an additional information on randomness in metallic charge and coke charge across the circumference.
R_(Start.point)=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 1)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_sp= number of start points in a sector,
µ_(N_sp )=mean of N_sp in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
Control room feedback system (E) being coupled to processing system (C) it is configured to make following decisions.
Case-1: If? R?_(Start.point)>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_(Start.point)=0 or close to zero.
Case-2: If? R?_(Start.point)=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
Randomness of excess of ring in dump (R_excess)
Data processing system (C) is configured to system start point and end point excess/recess. Data processing means (C) is further configured to determine an index called as randomness in excess (R_excess). Visualization means is configured to visualize number of excess rings with respect to set number of rings for visual guideline for operator in Fig 5. Visualization system is also configured to display the online status of excess of dump in radial co-ordinates as shown in Fig-6
R_excess=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 2)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_spex= number of points where excess of charge is dumped,
µ_(N_spex )=mean of N_spex in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
Control room feedback system (E) being coupled to processing means (C) it is configured to make following decisions.
Case-1: If? R?_excess>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_(Start.point)=0 or close to zero.
Case-2: If? R?_excess=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
Randomness of recess of ring in dump (R_recess)
Data processing system (C) is configured to identify start point and end point excess/recess. Data processing system (C) is further configured to determine an index called as randomness in excess or recess (R_recess).
R_recess=v(1/N_sec ?_(i=1)^(N_sec)¦(N_(sp i)-µ_(N_sp ) )^2 ), (Eq. 3)
N_sec=360/n_(sec.mod) .where N_sec=number of permisible sectors
Where N_spre= number of points where there is recess of charge in dump ,
µ_(N_spre )=mean of N_spre in all sectors
(Where n_sec=360.N/(S_f 60),n_(sec.mod)=?(n?_sec+C),such that reminder of (360/n_(sec.mod) )=0).
Control room feedback system (E) being coupled to processing system (C) it is configured to make following decisions.
Case-1: If? R?_recess>0, distribution of ore is not uniform in all sectors, thereby a value alteration of parameters is needed to bring R_recess=0 or close to zero.
Case-2: If? R?_recess=0, distribution of ore is uniform in all sectors, thereby no value alteration of parameters is needed.
Based on three indices mentioned above a decision matrix is developed as shown below in Table-1. The response for an index is ok (v) if it belongs to case-1, While it is not ok (×) if it belongs to case-1. Based on any of the six conditions in the matrix, it is decided if any action is needed or not. If action signal is ‘0’ no action is needed or if action signal is ‘1’ action is needed, i.e. there is need in value alteration of parameters. This decision matrix is generated in control feedback system (E).
Table-1: Final decision matrix for block E i.e. control room feedback system
Index Nos. Response
1 v v v × × ×
2 v v × × v v
3 v × v × v ×
Action Signal 0 1 0 1 0 1
Case-1 Case-2 Case-3 Case-4 Case-5 Case-6

Illustration for decision matrix:
An illustrating example for final decision matrix is explained in Table-2. For case-2,4 and 5 where action signal is 1, operator need value alteration of parameters of burden distribution system such that action signal is 0 i.e. case-1 or case-3. Here when the burden distribution system belongs to case-1 or case-3, we can say that burden distribution performed by burden distribution system is circumferentially balanced.
Table-2: Illustration for decision matrix operation in control room feedback system.
Case No Index-1 (R_(Start.point)) Index-2 (R_excess) Index-3 R_recess) Action Signal
1 0 0 0 0
2 0 0 0.1 1
3 0 0.1 0 1
4 0.1 0.1 0.1 1
5 0.1 0 0 0
6 0.1 0 0.1 1

It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various assembly that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.