An intelligent dust removal system and method for a rapid quantitative loading station

Abstract

The present invention relates to an intelligent dust removal system and method for a fast quantitative loading station, including: a dust collector, a dry fog sprayer, a belt conveyor speed sensor, a buffer bin dust concentration sensor is provided at the inlet of the buffer bin, a quantitative bin dust concentration sensor is provided at the inlet of the quantitative bin, a chute dust concentration sensor is provided at the outlet of the chute, and the belt conveyor speed sensor, the buffer bin dust concentration sensor, the quantitative bin dust concentration sensor, and the chute dust concentration sensor are electrically connected to a dust control unit. The present invention uses dust concentration sensors to be set at locations where dust is easily generated, such as the buffer bin, the quantitative bin, and the chute, to monitor the dust concentration at each location in real time, and to open and control the dry fog sprayer according to the dust concentration. In order to ensure the quality of bulk cargo, the present invention strictly controls the dry fog spraying amount by obtaining the humidity of the material, and obtains the maximum dust reduction effect with the minimum dry fog spraying amount while trying to maintain the material humidity required by the cargo type.

Description

Technical Field

[0001] The present invention relates to an intelligent dust removal system and method for a rapid quantitative loading station, which is an auxiliary environmental protection facility and method for an automated loading device for bulk goods, and is a facility and method for automatically reducing dust in bulk goods. Background Art

[0002] Currently, rapid quantitative loading stations have been widely used in the field of rapid quantitative loading of bulk materials. With the continuous improvement of environmental protection requirements, higher requirements have been put forward for rapid quantitative loading stations. Existing rapid quantitative loading stations mainly prevent dust generated during the flow of bulk materials in a blocking manner, that is, some enclosing structures are set up to block the dispersion of dust into the air. However, this leakage dust removal is not very intelligent. Generally, an absorption type dust collector is installed on the head layer, which has a certain effect on dust removal of the head layer. However, dust will be generated during the whole process from the head layer to the buffer bin, from the buffer bin to the quantitative bin, from the quantitative bin to the chute, and from the chute to the carriage. The fine dust fills the station, affecting the operation of the equipment and the health of the station staff. In addition, the overall sealing of the rapid quantitative loading station is not high, resulting in a large amount of dust in the loading station that will overflow outside the station and affect the surrounding environment. Existing loading stations only have simple dust removal devices, such as installing dust suction or dry fog spraying devices at the belt head unloading place. These dust removal devices are only manually turned on when the dust is large, but the generation of dust is random. Therefore, in most cases, the dust removal devices are running empty, which not only wastes energy but also cannot achieve the desired effect. Therefore, how to control the dust concentration in the loading station is a problem that needs to be solved. Summary of the Invention

[0003] In order to overcome the problems of the prior art, the present invention provides an intelligent dust removal system and method for a rapid quantitative loading station. The system and method realize automatic dust removal without manual startup by installing sensors at multiple locations in the loading station to monitor the dust concentration in real time, which not only improves the dust removal efficiency but also saves energy.

[0004] The object of the present invention is achieved as follows: An intelligent dust removal system for a rapid quantitative loading station includes an absorption type dust collector installed at the head of the belt conveyor, dry fog sprayers installed at the inlet of the buffer bin, the inlet of the quantitative bin, and the outlet of the chute. A belt speed sensor is provided on the belt conveyor, a buffer bin dust concentration sensor is provided at the inlet of the buffer bin, a quantitative bin dust concentration sensor is provided at the inlet of the quantitative bin, a chute dust concentration sensor is provided at the outlet of the chute. The belt speed sensor, the buffer bin dust concentration sensor, the quantitative bin dust concentration sensor, and the chute dust concentration sensor are electrically connected to a dust control unit. The dust control unit is electrically connected to the dry fog sprayers provided at various locations, and the dust control unit is electrically connected to the upper computer of the loading station.

[0005] Further, the loading station is also provided with an environmental humidity sensor, and a material falling sensor is arranged in the buffer bin; the environmental humidity sensor and the material falling sensor are electrically connected to a material humidity analysis unit, and the material humidity analysis unit is electrically connected to a belt conveyor speed sensor, a buffer bin dust concentration sensor, and a dust control unit. The material humidity analysis unit is provided with a material type database.

[0006] Further, the dust control unit and the material humidity analysis unit are arranged in the same electronic digital processing facility with computing and storage capabilities.

[0007] Further, the absorption type dust collector is a bag type dust collector, including: a dust suction head installed at the discharge end of the belt conveyor, the dust suction head is connected to the upper end of the adsorption cylinder through a pipeline, a discharge pipe is arranged at the bottom end of the adsorption cylinder, and the outlet of the discharge pipe is arranged in the buffer bin.

[0008] Further, the dry fog sprayer arranged at the inlet of the buffer bin is provided with at least two spray nozzles, and each spray nozzle is evenly surrounded at the inlet of the buffer bin.

[0009] Further, the dry fog sprayer arranged at the inlet of the metering bin is provided with at least two spray nozzles, and each spray nozzle is evenly surrounded at the inlet of the metering bin.

[0010] Further, the dry fog sprayer arranged at the outlet of the chute is provided with at least two spray nozzles, and each spray nozzle is evenly surrounded at the outlet of the chute.

[0011] An intelligent dust removal method for a rapid quantitative loading station using the above dust removal system, the steps of the method are as follows:

[0012] Step 1, monitor the belt conveyor: the belt conveyor speed sensor monitors whether the belt conveyor is started. If it is monitored that the belt conveyor is started, the dust control unit is started;

[0013] Step 2, start dust monitoring: the dust control unit starts each dust concentration sensor and starts to monitor the dust concentration at the inlet of the buffer bin, the inlet of the metering bin, and the outlet of the chute;

[0014] Step 3, start the absorption type dust collector: when the buffer bin dust concentration sensor senses that the dust concentration at the inlet of the buffer bin reaches the threshold value, the absorption type dust collector is started;

[0015] Step 4, dry fog spraying in the buffer bin: after the absorption type dust collector is started, if the dust concentration at the inlet of the buffer bin continues to rise, the dry fog sprayer at the outlet of the buffer bin is started to reduce dust, and the spraying amount of the dry fog sprayer is adjusted or the dry fog spraying is stopped according to the dust concentration at the inlet of the buffer bin;

[0016] Step 5, dry fog spraying in the metering bin: When preparing to open the buffer bin gate, first turn on the dry fog sprayer in the metering bin; before opening the buffer bin gate, the dry fog spraying volume of the dry fog sprayer at the inlet of the metering bin is determined according to the material humidity; after opening the buffer bin gate, the dust concentration sensor in the metering bin monitors the dust concentration at the inlet of the metering bin and adjusts the spraying volume of the dry fog sprayer according to the dust concentration; after closing the buffer bin gate, the dry fog sprayer at the outlet of the metering bin is closed according to the degree of reduction of the dust concentration monitored by the dust concentration sensor in the metering bin at the inlet of the metering bin;

[0017] Step 6, dry fog spraying in the chute: When opening the chute discharge gate, turn on the dry fog sprayer at the outlet of the chute at the same time; before opening the chute gate, the dry fog spraying volume of the dry fog sprayer at the outlet of the chute is determined according to the material humidity; after opening the chute gate, the dust concentration sensor in the chute monitors the dust concentration at the outlet of the chute during unloading and adjusts the spraying volume of the dry fog sprayer at the outlet of the chute according to the dust concentration at the outlet of the chute; when closing the chute discharge gate, the dry fog sprayer at the outlet of the chute is closed at the same time;

[0018] Step 7, turn off the absorption type dust collector: When the belt conveyor speed sensor monitors that the belt conveyor stops rotating, then turn off the absorption type dust collector;

[0019] Step 8, turn off the dust control unit: When the loading station upper computer indicates that there is no more loading operation, then turn off the dust control unit and end the task.

[0020] Furthermore, when starting the dust control unit in Step 1, start the material humidity analysis unit to analyze the material humidity at the same time, and send the analysis result to the dust unit as a control factor for controlling the dry fog spraying volume: or enter Step 5 to determine the dry fog spraying volume of the dry fog sprayer at the inlet of the metering bin before opening the buffer bin gate; or enter Step 6 to determine the dry fog spraying volume of the dry fog sprayer at the outlet of the chute before opening the chute gate; at the same time, upload it to the loading station upper computer as a control factor for controlling the loading speed.

[0021] Furthermore, the material humidity analysis includes the following sub-steps:

[0022] Sub-step 1, the ambient humidity sensor monitors the ambient humidity;

[0023] Sub-step 2, the belt conveyor speed sensor monitors the material conveying volume;

[0024] Sub-step 3, the material falling sensor monitors the height of the material falling;

[0025] Sub-step 4, monitor the opening states of the absorption type dust collector and the dry fog sprayer at the outlet of the chute;

[0026] Sub-step 5, the buffer bin dust concentration sensor monitors the dust concentration at the buffer bin outlet;

[0027] Sub-step 6, setting the weight of ambient humidity, material conveying volume, material falling height, dust collection and dry fog, and dust concentration, comprehensively calculating the material humidity state probability, and comparing the humidity state probabilities of similar materials in the material type database to obtain the current material humidity.

[0028] The advantages and beneficial effects of the present invention are as follows: the present invention uses dust concentration sensors to be set at locations where dust is easily generated, such as buffer bins, quantitative bins and chutes, to monitor the dust concentration at each location in real time, and to start and control the dry fog sprayer according to the dust concentration. In order to ensure the quality of bulk goods, the present invention strictly controls the dry fog spraying amount by obtaining the humidity of the material, and obtains the maximum dust reduction effect with the minimum dry fog spraying amount while trying to maintain the material humidity required by the type of goods. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the position of the system described in the first embodiment of the present invention in a loading station;

[0030] Figure 2 is a structural principle block diagram of the system described in Embodiment 1 of the present invention;

[0031] Figure 3 This is a principle block diagram of a system with online material moisture analysis according to the second embodiment of the present invention;

[0032] Figure 4 is a schematic diagram of the process of the intelligent dust removal method according to the eighth embodiment of the present invention;

[0033] Figure 5 It is a flow chart of the method for online moisture analysis of materials described in Embodiment 9 of the present invention. DETAILED DESCRIPTION

[0034] Embodiment 1:

[0035] This embodiment is a fast quantitative loading station intelligent dust removal system, such as Figure 1 , 2 As shown, Figure 1 is a schematic diagram of the positions of various sensors and dust removal facilities in the loading station in this embodiment, Figure 2This is a principle block diagram of this embodiment. This embodiment includes an absorption dust collector 2 installed at the head 1 of the belt conveyor, dry mist sprayers 301, 401, 501 installed at the inlet of the buffer bin 3, the inlet of the quantitative bin 4 and the outlet of the chute 5, a belt conveyor speed sensor 101 is provided on the belt conveyor, a buffer bin dust concentration sensor 302 is provided at the inlet of the buffer bin, a quantitative bin dust concentration sensor 402 is provided at the inlet of the quantitative bin, and a chute dust concentration sensor 502 is provided at the outlet of the chute, the belt conveyor speed sensor, the buffer bin dust concentration sensor, the quantitative bin dust concentration sensor, and the chute dust concentration sensor are electrically connected to the dust control unit, the dust control unit is electrically connected to the absorption dust collector and the dry mist sprayers installed at various locations, and the dust control unit is electrically connected to the loading station host computer. Figure 1 The dry mist sprayer and dust concentration sensor in the figure are schematic and the actual size is much smaller. Figure 1 This cannot be displayed in such a proportion, so it is explained here.

[0036] The system described in this embodiment includes three main parts arranged at multiple locations of the loading station, including: various sensors for monitoring the operation of the loading station, a dust control unit for processing the monitored data and converting them into control instructions to control the dust reduction equipment, and various dust reduction facilities, including absorption dust collectors and dry mist sprayers distributed in buffer bins, metering bins and chutes.

[0037] The loading station described in this embodiment is a traditional layout loading station in which a belt conveyor head, a buffer bin, a quantitative bin, and a chute are arranged from top to bottom, and it can also be a loading station of other forms. For other forms of loading stations, the layout of various sensors, controllers, and dust reduction facilities as described in this embodiment is set according to the needs of dust reduction. The steel structure frame of the loading station supports all the chambers and is provided with an enclosure structure, but the enclosure structure does not have strict sealing measures. Therefore, when the dust concentration in the loading station reaches a certain amount, it will overflow and affect the surrounding environment, and the dust diffused in the loading station will also affect the normal operation of the loading station.

[0038] Due to the location of the buffer bin and the top of the loading station, the dust generated is easy to spread throughout the loading station. Therefore, this embodiment sets up two dust reduction facilities in the buffer bin: an absorption dust collector and a dry fog sprayer. The absorption dust collector uses vacuum adsorption to absorb dust and treat it to a state that is not easy to scatter and diffuse. It has a good inhibitory effect on the dust generated when the material is scattered at the outlet of the belt conveyor. However, the absorption dust removal device cannot be too strong, otherwise it may also absorb the fine particles in the material. Therefore, the absorption capacity of the absorption dust removal device must be limited to a certain range. Therefore, when the dust concentration cannot be controlled by the absorption dust removal device, dry fog spraying can also be used for dust reduction.

[0039] A dry mist sprayer is a facility that sprays water into extremely fine mist-like water droplets and uses the fine water droplets to adsorb dust particles diffused in the air for dust reduction. Its advantage is that the equipment is simple. However, the wetted particles for dust reduction need to return to the original material, otherwise certain pollution will still be generated. It is suitable for dust reduction in each bin. In this embodiment, the dry mist sprayer is arranged on the buffer bin, metering bin and chute, minimizing the pollution to the external environment.

[0040] To ensure uniform dry mist spraying, multiple spray nozzles of the dry mist sprayer are usually set and evenly arranged in a circular pattern around the inlet of the buffer bin, the inlet of the metering bin and the outlet of the chute. The generation of dust is inevitable. After the dust is generated, since it is heavier than air, the dust is always in a downward trend. When the dust amount is small in the buffer bin or metering bin, the dust generally only appears and accumulates at the bottom of the bin. Only when the dust amount is large will it overflow the bin and pollute the surroundings. The function of the dry mist sprayer in the buffer bin and metering bin is to inhibit the dust from overflowing the bin. Therefore, the dry mist spraying amount can be relatively small, and the spray nozzles of the dry mist sprayer can be set relatively sparsely. The function of the dry mist sprayer for the chute is to suppress the dust from rising when discharging materials into the carriage. Therefore, a larger dry mist spraying amount is required, and the spray nozzles of the dry mist sprayer can be set relatively densely.

[0041] The dust control unit in this embodiment is an electronic digital processing device, which can be an industrial PC, or hardware facilities such as an embedded system or a single-chip microcomputer, or a software system embedded in the loading station control system (the upper computer of the loading station).

[0042] This embodiment can also be provided with a material analysis unit to perform on-line humidity measurement on the material being transported. Since the generation of dust is closely related to the humidity of the material, the humidity of the material being transported can be obtained through a certain operation using the dust concentration value. The humidity parameter is very important for the transportation of bulk materials. Especially for bulk goods such as coal as a commodity, there are clear regulations on the humidity of the material to avoid disputes between the buyer and the seller. Therefore, at the loading station, excessive spraying of dry mist on the material should be avoided as much as possible to maintain the dry-wet degree of the material. Knowing the dry-wet degree of the current material can control the spraying amount of the dry mist. Obtaining the humidity parameter of the current material can also improve the loading quality and load the carriage more full and evenly.

[0043] Embodiment 2:

[0044] This embodiment is an improvement of Embodiment 1 and a refinement of Embodiment 1 in terms of humidity analysis. The loading station described in this embodiment is also provided with an ambient humidity sensor, and a material falling sensor is arranged in the buffer bin; the ambient humidity sensor and the material falling sensor are electrically connected to the material humidity analysis unit, and the material humidity analysis unit is electrically connected to the belt conveyor speed sensor, the buffer bin dust concentration sensor, and the dust control unit. The material humidity analysis unit is provided with a material type database, such as Figure 3 as shown

[0045] The humidity of the material affects the quality of the material as a commodity. Therefore, it needs to be maintained during the loading process. Dry fog dust suppression is equivalent to spraying water into the material. Although the amount is very small, it should also be controlled in terms of quantity and cannot be sprayed randomly. Online detection of the material humidity is a prerequisite for accurately controlling the dry fog spraying amount.

[0046] This embodiment estimates the humidity of the material by combining the obtained dust concentration with the humidity of the current external environment, as well as factors such as the conveying amount of the material, the falling height, and the particles of the material, to obtain the current humidity of the material. Therefore, this embodiment is provided with an ambient humidity sensor, a material falling sensor, and a material type database. The ambient humidity sensor can be installed outside the enclosure structure of the loading station to sense the humidity of the current external environment, which is an important factor affecting the current humidity of the material. Especially during the transportation process of the long belt conveyor, it is equivalent to spreading out the material. When the external environment is dry, the moisture in the material will quickly evaporate and the material will become very dry. On the contrary, if the humidity in the environment is relatively high, the material will maintain its original humidity during transportation.

[0047] The material falling sensor is mainly used to monitor the falling distance of the material. A radar sensor can be used to measure the fullness of the material in the buffer bin, that is, the height from the material pile surface to the outlet of the belt conveyor, to evaluate the impact and splash degree generated when the material falls. Some existing relatively advanced loading stations also install sensors to detect the fullness of the material to control the conveying speed of the material. In this way, this type of sensor can be directly used as the material falling sensor, achieving a good technical effect with multiple benefits.

[0048] The material type database is actually a database storing various technical indicators of various materials. Of course, the system described in this embodiment is particularly concerned about parameters such as the humidity of the material and the particle size of the material that cause dust. Some modern advanced loading stations are equipped with such databases of material parameters, and this embodiment can borrow these existing data for analysis.

[0049] The material humidity analysis unit can be a software system installed in an electronic device for digital processing, such as an industrial PC or an embedded system. Of course, it can also be a specially designed professional chip hardware. However, the component system can be directly installed in a general-purpose chip and even arranged in the upper computer of the loading station, making the hardware device simpler and the utilization rate of hardware resources higher.

[0050] As described above, this embodiment actually uses some existing sensors for analysis. Therefore, the equipment cost increased for material humidity analysis is actually very little. Only an environmental humidity sensor is added, and other facilities can be implemented by software. The overall cost is very low, but it can produce a good effect of controlling the material humidity.

[0051] Embodiment Three:

[0052] This embodiment is an improvement of the above embodiment and a refinement of the control hardware in the above embodiment. The dust control unit and the material humidity analysis unit described in this embodiment are arranged in the same electronic digital processing facility with computing and storage capabilities.

[0053] The electronic digital processing facility with computing and storage capabilities refers to common electronic digital processing software and hardware systems such as industrial PCs or embedded systems. It can be a separate hardware system or a software system embedded in the control system of the loading station (the upper computer of the loading station).

[0054] Embodiment Four:

[0055] This embodiment is an improvement of the above embodiment and a refinement of the absorption type dust collector in the above embodiment. The absorption type dust collector described in this embodiment is a bag type dust collector, including: a dust suction head installed at the discharge end of the belt conveyor, the dust suction head is connected to the upper end of the adsorption cylinder through a pipeline, a discharge pipe is arranged at the bottom end of the adsorption cylinder, and the outlet of the discharge pipe is arranged in the buffer bin.

[0056] The bag type dust collector described in this embodiment is equivalent to a vacuum cleaner, which absorbs the dust scattered in the air in the form of dust absorption and sends it into the dust bag, and then after water spraying treatment, the dust turns into mud and is thrown into the buffer bin.

[0057] The dust suction head is centered on the material dropping port of the belt conveyor where dust is most likely to be generated, so that the dust is sucked away as soon as it appears and will not diffuse in the air. There can be multiple dust suction heads, which are respectively arranged at different positions.

[0058] Embodiment Five:

[0059] This embodiment is an improvement of the above embodiment and is a refinement of the dry fog sprayer provided at the inlet of the buffer bin in the above embodiment. The dry fog sprayer provided at the inlet of the buffer bin in this embodiment is provided with at least two spray nozzles, and each spray nozzle is evenly arranged around the inlet of the buffer bin.

[0060] The dry fog sprayer has multiple nozzles for spraying dry fog, and these nozzles are arranged around the inlet of the buffer bin. The so-called inlet of the buffer bin is actually the wide bin opening at the top of the buffer bin. Generally, no cover plate is provided at the top of the buffer bin, that is to say, the size of the inlet at the top of the buffer bin is the part surrounded by the side wall of the buffer bin, that is to say, each nozzle of the dry fog sprayer is arranged at the top of the side wall of the buffer bin. Some loading stations set flexible cover cloths at the top of the buffer bin to prevent dust, and there is a gap for inserting the belt conveyor in the middle of the cover cloth. However, the inlet of the buffer bin described in this embodiment is not the gap of the cover cloth, but the top of the side wall of the buffer bin.

[0061] The even arrangement of the spray nozzles mentioned above means that the spray nozzles are arranged at a certain interval on the top of the side wall of the buffer bin and are symmetrically distributed with respect to the vertical axis of the buffer bin.

[0062] Embodiment Six:

[0063] This embodiment is an improvement of the above embodiment and is a refinement of the dry fog sprayer provided at the inlet of the metering bin in the above embodiment. The dry fog sprayer provided at the inlet of the metering bin in this embodiment is provided with at least two spray nozzles, and each spray nozzle is evenly arranged around the inlet of the metering bin.

[0064] The arrangement state of the spray nozzles of the dry fog sprayer provided at the outlet of the metering bin in this embodiment is similar to that of the spray nozzles of the dry fog sprayer of the buffer bin.

[0065] Embodiment Seven:

[0066] This embodiment is an improvement of the above embodiment and is a refinement of the dry fog sprayer provided at the outlet of the chute in the above embodiment. The dry fog sprayer provided at the outlet of the chute in this embodiment is provided with at least two spray nozzles, and each spray nozzle is evenly arranged around the outlet of the chute.

[0067] The dry fog sprayer in this embodiment is mainly aimed at the dust generated when the material falls from the chute into the carriage and impacts the carriage floor or the material pile. Therefore, the spray nozzles should be as close as possible to the outlet of the chute of the material to approach the dust generated by the impact of the material.

[0068] The arrangement of the spray nozzles of the dry fog sprayer in this embodiment is similar to the even arrangement of the buffer bin or the metering bin.

[0069] Embodiment Eight:

[0070] This embodiment is a fast quantitative loading station intelligent dust removal method using the above-mentioned dust removal system. The main process of this embodiment is to detect the dust concentration in various places through dust concentration sensors installed in various places, and start the dry fog sprayer at the right time. Since the dry fog sprayer is a method of using water to form fine water droplets, and using the small water droplets to absorb dust particles to produce dust removal, excessive dry fog will also affect the variety of materials. Therefore, this embodiment strictly controls the spraying amount of dry fog, and obtains the maximum dust reduction effect with the minimum spraying amount.

[0071] The specific steps of the method are as follows: Figure 4 As shown:

[0072] Step 1, monitoring the belt conveyor: The belt conveyor speed sensor monitors whether the belt conveyor is started. If the belt conveyor is detected to be started, the dust control unit is started.

[0073] When the loading station is started, the belt conveyor is not necessarily started. The belt conveyor can only be started when the goods to be loaded have been determined and various parameters of the goods have been obtained. Therefore, this embodiment uses the start of the belt conveyor as the starting point for the dust removal system.

[0074] The belt conveyor speed sensor is mainly used to monitor the speed of the belt conveyor conveying materials. Of course, it has the ability to monitor whether the belt conveyor is started. Therefore, as an efficiency-enhancing function, the belt conveyor speed sensor is used to monitor the start of the belt conveyor as the starting point of the dust removal system.

[0075] Step 2, start dust monitoring: The dust control unit starts each dust concentration sensor and starts monitoring the dust concentration at the inlet of the buffer bin, the inlet of the quantitative bin, and the outlet of the chute.

[0076] After the dust removal system is started, each sensor is first tested to see if it can work normally, and then normal monitoring is carried out.

[0077] Step 3, start the absorption dust collector: when the dust concentration sensor of the buffer bin senses that the dust concentration at the inlet of the buffer bin reaches a threshold, the absorption dust collector is turned on.

[0078] Since dust is particularly easy to be generated when materials fall from the belt conveyor, and the belt conveyor is at the highest point of the loading station, the dust generated will affect the internal space of the entire loading station. Therefore, this embodiment first turns on the absorption dust collector and keeps the absorption dust collector in working state to keep dust removal on the materials output after the belt conveyor is turned on, absorb all the dust generated when the materials fall as much as possible, and reduce the dust concentration in the loading vehicle.

[0079] Step 4, dry mist spraying in the buffer bin: If the dust concentration at the inlet of the buffer bin continues to rise after the absorption dust collector is started, start the dry mist sprayer at the outlet of the buffer bin to reduce dust, and adjust the spraying amount of the dry mist sprayer or stop the dry mist spraying according to the dust concentration at the inlet of the buffer bin.

[0080] Although the absorption dust collector is started, a large amount of dust will still be generated when the material falls into the buffer bin, especially when the material is relatively fine and dry, dust is easily generated. When there is not much material in the buffer bin, the feeding distance of the material is relatively large, and the impact of the feeding material on the material at the bottom of the bin is relatively large, making it easier to generate dust. The bag type dust collector is limited by the size of the absorbed particles and cannot absorb all the dust when the dust concentration is relatively high. Therefore, it is necessary to start the dry mist sprayer to further reduce dust. If the dust concentration sensor in the buffer bin finds that the dust concentration in the buffer bin once exceeds a certain threshold, such as the dust concentration exceeds 50%, the dry mist spraying will be started to reduce the dust concentration. The spraying amount is controlled according to the dust concentration, and the minimum amount of spraying is used to reduce the dust concentration.

[0081] Step 5, dry mist spraying in the metering bin: When preparing to open the gate of the buffer bin, start the dry mist sprayer at the inlet of the metering bin first; before the gate of the buffer bin is opened, the dry mist spraying amount of the dry mist sprayer at the inlet of the metering bin is determined according to the material humidity; after the gate of the buffer bin is opened, the dust concentration sensor in the metering bin monitors the dust concentration at the inlet of the metering bin and adjusts the spraying amount of the dry mist sprayer according to the dust concentration; after the gate of the buffer bin is closed, the dry mist sprayer at the outlet of the metering bin is closed according to the reduction degree of the dust concentration monitored by the dust concentration sensor in the metering bin at the inlet of the metering bin.

[0082] Since the metering bin is completely empty when the gate of the metering bin is just opened, and there is no material at the bottom and side walls of the bin for buffering, a large amount of dust is particularly easy to be generated. Therefore, in this step, the timing of starting the dry mist sprayer at the inlet of the metering bin is selected before the gate of the buffer bin is about to be opened to unload the material into the metering bin. In this way, a certain amount of dry mist can be formed in the metering bin in advance to reduce the dust generated by the initial unloading.

[0083] The sprayer of the metering bin is turned on before the buffer bin gate is opened, and the dry fog spraying amount when it is turned on is determined according to the humidity of the material. When the material is relatively dry, the spraying amount can be appropriately smaller, and when the material is relatively wet, the spraying amount is appropriately increased. Since the material is a commodity, there are generally clear regulations on the dry-wet degree of the material, neither too dry nor too wet, and it must be within a certain range. Therefore, the dry-wet degree of the material can be obtained from the original parameters of the material. However, the dry-wet degree of the material may change during storage and belt conveyor transportation. This change in the dry-wet degree will affect the loading quality and the dust concentration during loading. Therefore, real-time detection of the dry-wet degree of the material can reduce the dry fog spraying amount and ensure the loading quality. In this embodiment, some sensors in the buffer bin can be used to detect the dust situation generated when the belt conveyor enters the buffer bin. Through monitoring operations such as probability and comparison with past existing data, the current dry-wet degree of the material can be obtained on-site and used as a factor for dry fog spraying control, that is, the dry fog spraying amount is determined according to the current dry-wet degree of the material monitored on-site.

[0084] The closing of the dry fog sprayer of the metering bin is not immediately closed after the buffer bin gate is closed, but is closed after a short delay after the buffer bin gate is closed. This is because after the buffer bin gate is closed, the dust in the metering bin will not leave and disperse, and there is still some dust diffused in the air. Therefore, dry fog dust reduction is still needed, and the continuous time is very short, generally about 1 - 2 seconds.

[0085] Step 6, chute dry fog spraying: When the chute discharge gate is opened, the dry fog sprayer at the chute outlet is opened at the same time; the dry fog spraying amount of the dry fog sprayer at the chute outlet before the chute gate is opened is determined according to the material humidity; after the chute gate is opened, the dust concentration sensor at the chute outlet monitors the dust concentration at the chute outlet during unloading, and adjusts the spraying amount of the dry fog sprayer at the chute outlet according to the dust concentration at the chute outlet; when the chute discharge gate is closed, the dry fog sprayer at the chute outlet is closed at the same time.

[0086] The dry fog spraying of the chute is similar to that of the metering bin. The difference is that when the chute gate is closed, the dry fog spraying stops immediately. This is because after the chute gate is closed, the chute will be quickly lifted, and it doesn't make much sense to continue dry fog spraying. In practice, when the chute is lifted to the top of the loaded material pile, the impact on the material pile in the carriage from the falling material pile is very small, and the generated dust is also relatively small. Therefore, the dry fog sprayer has been opened very small and is close to being closed.

[0087] Step 7, turn off the absorption type dust collector: When the belt conveyor speed sensor monitors that the belt conveyor has stopped rotating, the absorption type dust collector is turned off.

[0088] Both the above steps 5 and 6 involve the opening and closing cycle of the dry fog sprayer during the loading process of one carriage, while in this step, after a train is fully loaded, the belt conveyor stops supplying materials, the absorption dust collector stops working, and when the next train arrives, the belt conveyor is started again, and at the same time, the absorption dust collector is started.

[0089] Step 8, close the dust control unit: When the loading station host computer indicates that there is no more loading operation, close the dust control unit to end the task.

[0090] When the host computer issues an instruction that there is no more loading operation, close the entire loading station system, including the dust removal system.

[0091] Embodiment Nine:

[0092] This embodiment is an improvement of Embodiment Eight and is a refinement of the method for analyzing the material humidity in Embodiment Eight. In this embodiment, when step 1 starts the dust control unit, the material humidity analysis unit is started simultaneously to analyze the material humidity, and the analysis result is sent to the dust unit as a control factor for controlling the dry fog spraying amount: either enter step 5 to determine the dry fog spraying amount of the dry fog sprayer at the inlet of the quantitative bin before the buffer bin gate is opened; or enter step 6 to determine the dry fog spraying amount of the dry fog sprayer at the outlet of the chute before the chute gate is opened, as Figure 5 shown, and at the same time upload it to the loading station host computer as a control factor for controlling the loading speed.

[0093] As a commodity, the humidity of materials is a very important indicator. Especially for fuels like coal, a large amount of water is used in the mining and sorting processes, and the water mixed in the coal increases its weight, which can easily lead to disputes between buyers and sellers. Determining a certain humidity of the materials and maintaining this humidity during transportation is an important aspect of ensuring the quality of the materials. At the same time, for bulk materials like coal, their humidity affects the loading quality. Modern automatic loading stations have reached a fully automated level, and their loading capacity has reached or nearly reached the full-load level. The meaning of full-load is that the goods in the carriage have reached the level of being completely filled, one less would be insufficient, and one more would overflow. To achieve the full-load level, it is necessary to know the current angle of repose of the materials so that the materials are piled up just right, neither underloaded nor overloaded and overflowing. However, the angle of repose of bulk materials is related to the dryness and wetness of the materials. Therefore, obtaining the current humidity of the materials on-site can not only guide dust suppression but also affect the loading quality. Therefore, it is very necessary to detect the current humidity of the materials online (on-site). This embodiment adopts the method of using a dust sensor as the main monitoring means, combined with multiple other sensors for probability calculation, and at the same time combined with past data to determine the current dryness and wetness of the materials online. Such monitoring can be said to be the most accurate and realistic, and will not affect the loading quality due to the humidity changes that occur during the transfer of the materials and will not change the quality of the goods during the dust removal process.

[0094] To maintain the quality of the goods, the dry fog spraying amount should be restricted to prevent the humidity of the materials from increasing due to excessive spraying of dry fog. For this purpose, the current material humidity parameter obtained by online detection is sent to the dust control unit as the main data for restricting the dry fog spraying amount, and the dry fog spraying amounts at the buffer bin, metering bin, and chute are restricted to obtain the maximum dust suppression effect with the minimum spraying amount.

[0095] There are various methods for humidity analysis: such as probability analysis method, comparison analysis method, regression analysis, and other methods.

[0096] Embodiment Ten:

[0097] This embodiment is an improvement of Embodiment Nine and is a refinement of Embodiment Nine regarding the humidity analysis method. The material humidity analysis described in this embodiment includes the following sub-steps:

[0098] Sub-step 1, the ambient humidity sensor monitors the ambient humidity;

[0099] Sub-step 2, the belt conveyor speed sensor monitors the material conveying volume;

[0100] Sub-step 3, the material falling sensor monitors the height of the material falling;

[0101] Sub-step 4: Monitor the opening status of the dry fog sprayer at the outlet of the absorption dust collector and the chute.

[0102] Sub-step 5: The dust concentration sensor in the buffer bin monitors the dust concentration at the outlet of the buffer bin.

[0103] Sub-step 6: Set the environmental humidity weight, material conveying volume weight, material falling height weight, dust collection and dry fog weight, and dust concentration weight, comprehensively calculate the probability of the material humidity state, and compare the humidity state probability of the same type of material in the material type database to obtain the current material humidity.

[0104] For the online humidity analysis of the current material, this embodiment adopts the probability analysis method: perform weighted correlation calculations on the dust concentration sensor or the obtained dust concentration parameters, the dust concentration in the surrounding environment, and each condition of material conveying, exclude the interference of other factors, compare the calculation results with the empirical data stored in the database, and finally obtain the humidity of the current material.

[0105] Finally, it should be noted that the above is only used to illustrate the technical solution of the present invention and not to limit it. Although the present invention has been described in detail with reference to the preferred arrangement, those of ordinary skill in the art should understand that the technical solution of the present invention (such as the form of the loading station, the form of the sensor, the sequence of steps, etc.) can be modified or equivalently replaced without departing from the spirit and scope of the technical solution of the present invention.

Claims

1. A method for intelligent dust removal in a rapid quantitative loading station. The system used in this method includes an absorption dust collector installed at the head of the belt conveyor, dry mist sprayers installed at the inlet of the buffer bin, the inlet of the quantitative bin, and the outlet of the chute. There is a belt speed sensor on the belt conveyor, a buffer bin dust concentration sensor at the inlet of the buffer bin, a quantitative bin dust concentration sensor at the inlet of the quantitative bin, and a chute dust concentration sensor at the outlet of the chute. The belt speed sensor, buffer bin dust concentration sensor, quantitative bin dust concentration sensor, and chute dust concentration sensor are electrically connected to the dust control unit. The dust control unit is electrically connected to the dry mist sprayers installed at various locations, and the dust control unit is electrically connected to the upper computer of the loading station; The loading station also has an environmental humidity sensor, and a material falling sensor is installed in the buffer bin. The environmental humidity sensor and the material falling sensor are electrically connected to the material humidity analysis unit. The material humidity analysis unit is electrically connected to the belt speed sensor, buffer bin dust concentration sensor, and dust control unit. The material humidity analysis unit has a material type database; The dust control unit and the material humidity analysis unit are arranged in the same electronic digital processing facility with computing and storage capabilities; The absorption dust collector is a bag filter, including: a dust suction head installed at the discharge end of the belt conveyor. The dust suction head is connected to the upper end of the adsorption cylinder through a pipeline. There is a discharge pipe at the bottom of the adsorption cylinder, and the outlet of the discharge pipe is arranged in the buffer bin; The dry mist sprayer installed at the inlet of the buffer bin has at least two spray nozzles, and each spray nozzle evenly surrounds the inlet of the buffer bin; The dry mist sprayer installed at the inlet of the quantitative bin has at least two spray nozzles, and each spray nozzle evenly surrounds the inlet of the quantitative bin; The dry mist sprayer installed at the outlet of the chute has at least two spray nozzles, and each spray nozzle evenly surrounds the outlet of the chute; It is characterized in that the steps of the method are as follows: Step 1, Monitor the belt conveyor: The belt speed sensor monitors whether the belt conveyor starts. If it is detected that the belt conveyor starts, the dust control unit is started; Step 2, Start dust monitoring: The dust control unit starts each dust concentration sensor and begins to monitor the dust concentrations at the inlet of the buffer bin, the inlet of the quantitative bin, and the outlet of the chute; Step 3, Start the absorption dust collector: When the buffer bin dust concentration sensor senses that the dust concentration at the inlet of the buffer bin reaches the threshold, the absorption dust collector is started; Step 4, Dry mist spraying in the buffer bin: After the absorption dust collector is started and the dust concentration at the inlet of the buffer bin continues to rise, the dry mist sprayer at the outlet of the buffer bin is started to reduce dust, and the spraying amount of the dry mist sprayer is adjusted or the dry mist spraying is stopped according to the dust concentration at the inlet of the buffer bin; Step 5, dry fog spraying in the metering bin: When preparing to open the buffer bin gate, first turn on the dry fog sprayer in the metering bin; before the buffer bin gate is opened, the dry fog spraying volume of the dry fog sprayer at the inlet of the metering bin is determined according to the material humidity; after the buffer bin gate is opened, the dust concentration sensor in the metering bin monitors the dust concentration at the inlet of the metering bin and adjusts the spraying volume of the dry fog sprayer according to the dust concentration; after the buffer bin gate is closed, the dry fog sprayer at the outlet of the metering bin is closed according to the reduction degree of the dust concentration monitored by the dust concentration sensor in the metering bin at the inlet of the metering bin. Step 6, dry fog spraying in the chute: When opening the chute discharge gate, turn on the dry fog sprayer at the outlet of the chute at the same time; before the chute gate is opened, the dry fog spraying volume of the dry fog sprayer at the outlet of the chute is determined according to the material humidity; after the chute gate is opened, the dust concentration sensor in the chute monitors the dust concentration at the outlet of the chute during unloading and adjusts the spraying volume of the dry fog sprayer at the outlet of the chute according to the dust concentration at the outlet of the chute; when the chute discharge gate is closed, the dry fog sprayer at the outlet of the chute is closed at the same time. Step 7, turn off the absorption type dust collector: When the belt conveyor speed sensor monitors that the belt conveyor stops rotating, then turn off the absorption type dust collector. Step 8, turn off the dust control unit: When the loading station host computer indicates that there is no more loading operation, then turn off the dust control unit to end the task.

2. According to the method described in claim 1, characterized in that, when starting the dust control unit in step 1, start the material humidity analysis unit to analyze the material humidity at the same time, and send the analysis result to the dust unit as a control factor for controlling the dry fog spraying volume: or enter step 5 to determine the dry fog spraying volume of the dry fog sprayer at the inlet of the metering bin before the buffer bin gate is opened; or enter step 6 to determine the dry fog spraying volume of the dry fog sprayer at the outlet of the chute before the chute gate is opened; at the same time, upload it to the loading station host computer as a control factor for controlling the loading speed.

3. According to the method described in claim 2, characterized in that, the material humidity analysis includes the following sub-steps: Sub-step 1, the ambient humidity sensor monitors the ambient humidity; Sub-step 2, the belt conveyor speed sensor monitors the material conveying volume; Sub-step 3, the material falling sensor monitors the height of the material falling; Sub-step 4, monitor the opening states of the absorption type dust collector and the dry fog sprayer at the outlet of the chute; Sub-step 5, the buffer bin dust concentration sensor monitors the dust concentration at the outlet of the buffer bin; Sub-step 6, set the ambient humidity weight, material conveying volume weight, material falling height weight, dust absorption and dry fog weight, dust concentration weight, comprehensively calculate the material humidity state probability, and compare the humidity state probability of the same type of material in the material type database to obtain the current material humidity.

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