Intelligent flat car for bulk materials, car washing device and working method thereof

Abstract

This invention introduces an intelligent flatbed car and car wash system for bulk materials, as well as its operating method. The system includes a flatbed car system, an auxiliary detection system, a car wash system, and a PLC controller. The PLC controller controls the flatbed car system, the auxiliary detection system, and the car wash system, and communicates with the plant's DCS system. This invention integrates the flatbed car and car wash systems, creating a seamless collaboration that reduces vehicle dwell time within the plant and improves commuting efficiency. It also enhances the intelligence and efficiency of the bulk material loading and shipping system, thereby increasing the economic benefits of the bulk material plant.

Description

Technical Field

[0001] The present invention relates to the technical field of sand and gravel bulk material production, and in particular to an intelligent flat car for bulk materials, a car washing device and a working method thereof. Background Art

[0002] In the production of bulk sand and gravel materials, when a vehicle enters the factory and loads the materials in the loading system, the driver stops the car and flattens the pile of gravel in the car, then covers it with canvas and leaves the factory. The length of time the vehicle stays in the factory determines the efficiency of the logistics system. Production companies generally require trucks to enter and exit quickly and shorten their stay in the factory as much as possible. Modern bulk sand and gravel materials, due to environmental protection and other requirements, also require the cleaning of materials attached to the vehicle to avoid scattering during transportation and causing safety hazards. Generally, at the factory gate, a person is required to operate the flattener next to the truck, and then wash the truck in the next parking space. The truck needs to stop twice in two parking spaces, and the existing flatteners have a low degree of intelligence and high manual labor intensity, which is not conducive to improving the efficiency of the logistics system. Summary of the Invention

[0003] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide an intelligent flat car for bulk materials, a car washing device and a working method thereof, which adopts a highly intelligent flat car and car washing integrated system to improve the logistics efficiency of bulk material plants.

[0004] The technical solution adopted in the present invention is:

[0005] An intelligent flat car and car wash device for bulk materials, including a flat car system, an auxiliary detection system, a car wash system, and a PLC controller; the PLC controller controls the flat car system, the auxiliary detection system, and the car wash system, and communicates with the plant-wide DCS system;

[0006] The flat car system includes a support platform, a gantry, an electric hoist, a support beam, a material rake and a material blocking plate; the support platform is arranged at the vehicle exit position, the gantry is vertically arranged on the support platform, the electric hoist is arranged on the support gantry, the support beam is arranged on the hook of the electric hoist, the two ends of the support beam are slidably arranged on both sides of the support gantry, the material rake is arranged in the middle of the lower side of the support beam, and the material blocking plates are respectively arranged at both ends of the material rake;

[0007] The auxiliary detection system includes a material level detection device, a camera, a beam grating, a card reader, and a traffic light. The material level detection device and camera are mounted on a support gantry on the vehicle entrance side. The beam grating and the support gantry are positioned adjacent to each other on a support platform on the vehicle exit side. The card reader and the traffic light are sequentially positioned on the vehicle exit end of the support platform. The material level detection device detects the material level height signal on the vehicle and feeds back the integrated camera image to a PLC controller. The card information read by the card reader is fed back to the PLC controller, which controls the operation of the traffic light.

[0008] The car washing system includes a filter, an electric ball valve, a water tank, a water pump system, a connecting pipe solenoid valve and several water spray pipes; the water inlet pipe of the filter is connected to the external water source, the water outlet pipe of the filter is connected to the water inlet of the water tank, the electric ball valve is arranged on the pipe between the filter and the water tank, and the PLC controller controls the opening and closing of the electric ball valve; the water outlet of the water tank is connected to the water inlet of the water pump system through a connecting pipe, and the water outlet of the water pump system is connected to the water spray pipe through a pipe laid inside the supporting platform, and the several water spray pipes are vertically arranged on both sides of the supporting platform through a bracket, and a plurality of nozzles are evenly arranged on the water spray pipe; the solenoid valve is arranged on the pipe between the water pump system outlet and the water spray pipe, the PLC controller controls the opening and closing of the solenoid valve, and the solenoid valve controls the opening and stopping of the water spray pipe and the flow rate.

[0009] Specifically, the auxiliary detection system also includes a lighting component, which is arranged on the supporting door frame on the vehicle entrance side; the lighting component includes a photometric sensor and a lighting lamp; the outdoor light intensity signal fed back by the photometric sensor is sent to the PLC controller to control the turning on or off of the lighting lamp.

[0010] Specifically, the material level detection device is a radar level meter, a laser line scanning radar and / or an industrial camera with a ranging function; the material level detection device locates the material level height and provides parameters for the flat car system to descend.

[0011] Specifically, the material baffle plate includes an arc-shaped connecting plate and several fan-shaped plates. Several bolt holes are evenly arranged on the surface of the arc-shaped connecting plate, and bolt holes are also arranged on the upper end of the fan-shaped plate. Several fan-shaped plates are connected to the arc-shaped connecting plate through the bolt holes at different angles on the arc-shaped connecting plate corresponding to the bolt holes at the upper end.

[0012] More specifically, the fan-shaped plate is provided with threaded steel reinforcement ribs.

[0013] Specifically, the water tank is integrated with a liquid level gauge, a drain valve and a water outlet ball valve; the liquid level gauge feeds back the water tank liquid level signal to the PLC controller, and the PLC controller controls the opening and closing of the electric ball valve to control the water level in the water tank.

[0014] Specifically, the water pump system includes a water pump, a water pump filter, a pressure gauge, a drain valve and a manual ball valve; the water pump is a pipeline pump or a plunger pump.

[0015] A working method of an intelligent flat car and car washing device for bulk materials, comprising the following specific steps:

[0016] Step 1: After the truck driver registers the vehicle information and takes the card, he drives the vehicle onto the support platform and parks the vehicle. The driver swipes the card at the card reader, which reads the vehicle information and the width of the truck compartment (L). ka , Truck model compartment material limit height H xiandingThe light sensor in the lighting assembly detects that if the light is too dark, the PLC controls the lighting to turn on.

[0017] Step 2: Start the beam grating and set the beam spacing detected at this time to L m Sent to the PLC controller, if the installation distance L between the two beam gratings dui *0.975<(L m +L ka ) < L dui *1.025, it is determined that the carriage is in place and jump to step 3; if this standard is not met, it is determined that the carriage is not in place, and the PLC controller controls the orange light in the traffic light to flash to remind the driver to move the car;

[0018] Step 3: The carriage is in place, and the material level detection device scans the material height at n points near the center axis of the carriage, and sends the data signal to the PLC controller. The PLC controller calculates the material height based on the average value H of the n points. pingjun The height limit H for materials in the truck compartment xianding Compare, if H pingjun <H xianding , and the camera captures the carriage image and recognizes that the carriage is intact and there are no people or debris around, then it is determined that the flat car conditions are met and jump to step 4; if H is not met pingjun <H xianding , it is determined that the conditions for leveling the vehicle are not met, and the PLC controller controls the red light in the traffic light to flash, reminding the driver to drive the vehicle away;

[0019] Step 4: When it is determined that the flat car conditions are met in step 3, the PLC controller controls the green light in the traffic light to light up, the flat car system starts, the PLC controller controls the electric hoist to operate and lower, the supporting beam descends along the gantry, and the material rake is lowered to the average material height H pingjun Position; at the same time, the PLC controller controls the car washing system to start, the water pump runs to pump the water in the water tank to each water spray pipe and spray it out, the driver slowly drives forward, and the car is leveled and washed at the same time;

[0020] Step 5: When the beam grating detects the beam spacing L m Meet L dui *0.975 <Lm< L dui *1.025, determines that the carriage has left the flat car system; the electric hoist of the PLC controller flat car system raises the material rake to the starting position; the water spray system stops, the reflected light barrier stops working, the traffic light turns red, the flat car and car washing machine operations are completed, and wait for the next truck to enter.

[0021] Due to the adoption of the above technical solution, the present invention has the following advantages:

[0022] The intelligent bulk material flat car, car washing device and working method of the present invention can integrate the flat car and car washing, cooperate closely, reduce the vehicle's stay time in the factory area, and improve commuting efficiency; it can improve the intelligence level and efficiency of the bulk material loading and shipping system, thereby improving the economic benefits of the bulk material plant. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the system of the present invention.

[0024] Figure 2 It is a structural schematic diagram of the present invention.

[0025] Figure 3 yes Figure 2 Schematic side view of .

[0026] Figure 4 Schematic diagram of the arc-shaped connecting plate of the present invention.

[0027] Figure 5 Schematic diagram of the fan-shaped plate of the present invention.

[0028] In the figure: 1- flat car system, 11- supporting platform, 12- gantry, 13- electric hoist, 14- supporting beam, 15- material rake, 16- material baffle, 2- auxiliary detection system, 21- material level detection device, 22- camera, 23- beam grating, 24- card reader, 25- traffic light, 26- lighting assembly, 3- car washing system, 31- filter, 32- electric ball valve, 33- water tank, 34- water pump system, 35- connecting pipe, 36- solenoid valve, 37- water spray pipe, 38- nozzle, 4- PLC controller. DETAILED DESCRIPTION

[0029] The present invention will be further explained below with reference to the accompanying drawings and embodiments, which should not be used to limit the scope of protection of the present invention. The purpose of disclosing the present invention is to protect all technical improvements within the scope of the present invention.

[0030] Combined with attachment Figure 1-5 The shown intelligent flat car and car washing device for bulk materials includes a flat car system 1, an auxiliary detection system 2, a car washing system 3 and a PLC controller 4; the PLC controller 4 controls the flat car system 1, the auxiliary detection system 2 and the car washing system 3, and communicates with the DCS system of the entire plant.

[0031] The flat car system 1 includes a supporting platform 11, a gantry 12, an electric hoist 13, a supporting beam 14, a material rake 15 and a material baffle 16; the supporting platform 11 is arranged at the vehicle exit position, the gantry 12 is vertically arranged on the supporting platform 11, the electric hoist 13 is arranged on the supporting gantry 12, the supporting beam 14 is arranged on the hook of the electric hoist 13, the two ends of the supporting beam 14 are slidably arranged on both sides of the supporting gantry 12, the material rake 15 is arranged in the middle of the lower side of the supporting beam 14, and the material baffle 16 are respectively arranged at both ends of the material rake 15.

[0032] The auxiliary detection system 2 includes a material level detection device 21, a camera 22, a beam grating 23, a card reader 24, a traffic light 25 and a lighting assembly 26; the material level detection device 21, the camera 22 and the lighting assembly 26 are all arranged on the support gantry 12 on the vehicle entrance side; the beam grating 23 is adjacent to the support gantry 12 and is arranged on the support platform 11 on the vehicle exit side; the card reader 24 and the traffic light 25 are arranged in sequence on the vehicle exit end of the support platform 11; the material level detection device 21 detects the material level height signal on the vehicle and integrates the image of the camera 22 to feed back to the PLC controller 4; the card information read by the card reader 24 is fed back to the PLC controller 4, and the PLC controller 4 controls the operation of the traffic light 25; the lighting assembly 26 includes a photometric sensor and a lighting lamp; the outdoor light intensity signal fed back by the photometric sensor is fed back to the PLC controller 4 to control the turning on or off of the lighting lamp.

[0033] The car washing system 3 includes a filter 31, an electric ball valve 32, a water tank 33, a water pump system 34, a connecting pipe 35, a solenoid valve 36 and several water spray pipes 37; the water inlet pipe of the filter 31 is connected to the external water source, the water outlet pipe of the filter 31 is connected to the water inlet of the water tank 33, the electric ball valve 32 is arranged on the pipe between the filter 31 and the water tank 33, and the PLC controller 4 controls the opening and closing of the electric ball valve 32; the water outlet of the water tank 33 is connected to the water inlet of the water pump system 34 through the connecting pipe 35, and the water outlet of the water pump system 34 is connected to the water spray pipe 37 through the pipe laid inside the support platform 11. Several water spray pipes 37 are vertically arranged on both sides of the support platform 11 through a bracket, and several nozzles 38 are evenly arranged on the water spray pipe 37; the solenoid valve 36 is arranged on the pipe between the water outlet of the water pump system 34 and the water spray pipe 37, and the PLC controller 4 controls the opening and closing of the solenoid valve 36, and the solenoid valve 36 controls the opening and stopping and flow rate of the water spray pipe 37.

[0034] Preferably, the material level detection device 21 is a radar level meter, a laser line scanning radar and / or an industrial camera with a ranging function; the material level detection device 21 locates the material level height and provides parameters for the flat car system 1 to descend.

[0035] Preferably, the material baffle plate 16 includes an arc-shaped connecting plate and several fan-shaped plates, a plurality of bolt holes are evenly arranged on the surface of the arc-shaped connecting plate, and bolt holes are also arranged on the upper end of the fan-shaped plate. The several fan-shaped plates are connected to the arc-shaped connecting plate through the bolt holes on the upper end corresponding to the bolt holes at different angles on the arc-shaped connecting plate; threaded steel reinforcement ribs are arranged on the fan-shaped plate; the fan-shaped plate is debugged on site to find a suitable angle to avoid material spillage during the flat car process.

[0036] Preferably, the water tank 33 is integrated with a liquid level gauge, a drain valve and a water outlet ball valve; the liquid level gauge feeds back the liquid level signal of the water tank 33 to the PLC controller 4, and the PLC controller 4 controls the opening and closing of the electric ball valve 32 to control the water level of the water tank 33.

[0037] Preferably, the water pump system 34 includes a water pump, a water pump filter 31, a pressure gauge, a drain valve and a manual ball valve; the water pump is a pipeline pump or a plunger pump.

[0038] A working method of an intelligent flat car and car washing device for bulk materials, comprising the following specific steps:

[0039] Step 1: After the truck driver registers the vehicle information and takes the card, he drives the vehicle onto the support platform 11 and parks the vehicle. The driver swipes the card at the card reader 24, which reads the vehicle information and the width of the truck compartment L. ka , Truck model compartment material limit height H xianding and sends the vehicle information to the PLC controller 4; the photometric sensor in the lighting assembly 26 detects that if the light is too dark, the PLC controls the lighting to turn on;

[0040] Step 2: Start the beam grating 23 and set the beam spacing detected at this time to L m Sent to the PLC controller 4, if the installation distance L between the two beam gratings 23 dui *0.975<(L m +L ka ) < L dui *1.025, it is determined that the carriage is in place, and the process goes to step 3; if the standard is not met, it is determined that the carriage is not in place, and the PLC controller 4 controls the orange light in the traffic light 25 to flash, reminding the driver to move the car;

[0041] Step 3: When the carriage is in place, the material level detection device 21 scans the material height at n points near the center axis of the carriage and sends the data signal to the PLC controller 4. The PLC controller 4 calculates the material height based on the average value H of the material height at n points. pingjun The height limit H for materials in the truck compartment xianding Compare, if H pingjun <H xianding, and the camera 22 captures the carriage image and recognizes that the carriage is intact and there are no people or debris around, then it is determined that the flat car conditions are met and jump to step 4; if H is not satisfied pingjun <H xianding , it is determined that the flat car condition is not met, and the PLC controller 4 controls the red light in the traffic light 25 to flash, reminding the driver to drive the vehicle away;

[0042] Step 4: When it is determined that the flat car conditions are met in step 3, the PLC controller 4 controls the green light of the traffic light 25 to light up, the flat car system 1 is started, the PLC controller 4 controls the electric hoist 13 to operate and lower, the supporting beam 14 is lowered along the door frame 12, and the material rake 15 is lowered to the average material height H pingjun position; at the same time, the PLC controller 4 controls the car wash system 3 to open, the water pump operates the water pump in the water tank 33 to each spray pipe 37 to spray out, the driver slowly drives forward, flat car, car wash at the same time;

[0043] Step 5: When the beam grating 23 detects the beam spacing L m Meet L dui *0.975 <Lm< L dui *1.025, determines that the carriage has left the flat car system 1; the electric hoist 13 of the flat car system 1 of the PLC controller 4 raises the material rake 15 to the starting position; the water spray system stops, the reflected light barrier 23 stops working, the traffic light 25 turns red, the operation of the flat car and the car washing machine ends, and waits for the next truck to enter.

[0044] In the above embodiment, flattening and washing are performed simultaneously. However, the present invention can also perform only flattening or washing by registering the truck driver or in other ways.

[0045] In the above implementation, the steps of truck drivers registering vehicle information, taking out the card and swiping the card can also be implemented separately or in combination through online and offline methods such as scanning codes, mini-program registration, smart license plate recognition, etc., or replaced by other methods.

[0046] The parts not described in detail in this invention are prior art.

[0047] The embodiments selected herein for the purpose of disclosing the invention are presently considered suitable, but it should be understood that the invention is intended to include all variations and modifications of the embodiments that fall within the scope of the concept and invention.

Claims

1. An intelligent flat car and car washing device for bulk materials, characterized in that: It includes a flat car system, auxiliary detection system, car wash system and PLC controller; the PLC controller controls the flat car system, auxiliary detection system and car wash system, and communicates with the DCS system of the entire plant; The flat car system includes a supporting platform, a gantry, an electric hoist, a supporting beam, a material rake and a material baffle; the supporting platform is arranged at the vehicle exit position, the gantry is arranged vertically on the supporting platform, the electric hoist is arranged on the supporting gantry, the supporting beam is arranged on the hook of the electric hoist, both ends of the supporting beam are slidably arranged on both sides of the supporting gantry, the material rake is arranged in the middle of the lower side of the supporting beam, and the material baffle plates are respectively arranged at both ends of the material rake; the material baffle plate includes an arc-shaped connecting plate and a plurality of fan plates, a plurality of bolt holes are evenly arranged on the plate surface of the arc-shaped connecting plate, and bolt holes are also arranged on the upper end of the fan plate, and the plurality of fan plates are respectively connected to the arc-shaped connecting plate through the bolt holes at the upper end corresponding to the bolt holes at different angles on the arc-shaped connecting plate; the fan plate is provided with threaded steel reinforcement ribs; The auxiliary detection system includes a material level detection device, a camera, a beam grating, a card reader, a traffic light, and a lighting assembly; the material level detection device and the camera are arranged on the support gantry on the vehicle entrance side; the beam grating and the support gantry are arranged adjacent to each other on the support platform on the vehicle exit side; the card reader and the traffic light are arranged in sequence on the vehicle exit end of the support platform; the material level detection device detects the material level height signal on the vehicle and feeds back the integrated camera image to the PLC controller; the card information read by the card reader is fed back to the PLC controller, and the PLC controller controls the operation of the traffic light; the lighting assembly is arranged on the support gantry on the vehicle entrance side; the lighting assembly includes a photometric sensor and a lighting lamp; the outdoor light intensity signal fed back by the photometric sensor is fed back to the PLC controller to control the turning on or off of the lighting lamp; The car washing system includes a filter, an electric ball valve, a water tank, a water pump system, a connecting pipe solenoid valve and several water spray pipes; the water inlet pipe of the filter is connected to an external water source, the water outlet pipe of the filter is connected to the water tank through an electric ball valve, and the PLC controller controls the opening and closing of the electric ball valve; the water outlet of the water tank is connected to the water inlet of the water pump system through a connecting pipe, and the water outlet of the water pump system is connected to the water spray pipe through a pipe laid inside the supporting platform. Several water spray pipes are vertically arranged on both sides of the supporting platform through a bracket, and several nozzles are evenly arranged on the water spray pipe; the solenoid valve is arranged on the pipe between the water pump system outlet and the water spray pipe, the PLC controller controls the opening and closing of the solenoid valve, and the solenoid valve controls the opening and stopping of the water spray pipe and the flow rate.

2. The intelligent flat car and car washing device for bulk materials according to claim 1 is characterized in that: The material level detection device is a radar level meter, a laser line scanning radar and / or an industrial camera with a ranging function; the material level detection device locates the material level height and provides parameters for the flat car system to descend.

3. The intelligent flat car and car washing device for bulk materials according to claim 1 is characterized in that: The water tank is integrated with a liquid level meter, a sewage valve and a water outlet ball valve; the liquid level meter feeds back the water tank liquid level signal to the PLC controller, and the PLC controller controls the opening and closing of the electric ball valve to control the water level of the water tank.

4. The intelligent flat car and car washing device for bulk materials according to claim 1 is characterized in that: The water pump system comprises a water pump, a water pump filter, a pressure gauge, a drain valve and a manual ball valve; the water pump is a pipeline pump or a plunger pump.

5. A method for operating a bulk material intelligent flat car and car washing device according to any one of claims 1 to 4, comprising the following specific steps: Step 1: After the truck driver registers the vehicle information and takes the card, he drives the vehicle onto the support platform and parks the vehicle. The driver swipes the card at the card reader, which reads the vehicle information and the width of the truck compartment (L). ka , Truck model compartment material limit height H xianding The light sensor in the lighting assembly detects that if the light is too dark, the PLC controls the lighting to turn on. Step 2: Start the beam grating and set the beam spacing detected at this time to L m Sent to the PLC controller, if the installation distance L between the two beam gratings dui *0.975<(L m +L ka ) < L dui *1.025, it is determined that the carriage is in place and jumps to step 3; if the standard is not met, it is determined that the carriage is not in place, and the PLC controller controls the orange light in the traffic light to flash to remind the driver to move the car; Step 3: The carriage is in place, and the material level detection device scans the material height at n points near the center axis of the carriage, and sends the data signal to the PLC controller. The PLC controller calculates the material height based on the average value H of the n points. pingjun The height limit H for materials in the truck compartment xianding Compare, if H pingjun <H xianding , and the camera captures the carriage image and recognizes that the carriage is intact and there are no people or debris around, then it is determined that the flat car conditions are met and jump to step 4; if H is not met pingjun <H xianding , it is determined that the conditions for leveling the vehicle are not met, and the PLC controller controls the red light in the traffic light to flash, reminding the driver to drive the vehicle away; Step 4: When it is determined that the flat car conditions are met in step 3, the PLC controller controls the green light in the traffic light to light up, the flat car system starts, the PLC controller controls the electric hoist to operate and lower, the supporting beam descends along the gantry, and the material rake is lowered to the average material height H pingjun Position; at the same time, the PLC controller controls the car washing system to start, the water pump runs to pump the water in the water tank to each water spray pipe and spray it out, the driver slowly drives forward, and the car is leveled and washed at the same time; Step 5: When the beam grating detects the beam spacing L m Meet L dui *0.975 <Lm< L dui *1.025, determines that the carriage has left the flat car system; the electric hoist of the PLC controller flat car system raises the material rake to the starting position; the water spray system stops, the reflected light barrier stops working, the traffic light turns red, the flat car and car washing machine operations are completed, and wait for the next truck to enter.

Images