Flat coal control system and method

Abstract

The present invention provides a coal leveling control system and method, which relates to the field of coal leveling technology. The coal leveling control system includes a controller, a laser radar, a speed detection device, and a running device that are respectively connected to the controller. The coal leveling scraper is provided on the running device. When leveling coal, the controller activates the laser radar to detect the flatness of the coal loading in the train car and determine the uneven position of the coal seam in the train car; activates the speed detection device to detect the running speed of the train car and determine the running speed of the train; controls the running device to drive the coal leveling scraper to move according to the uneven position of the coal seam and the running speed of the train, and controls the coal leveling scraper to descend to level the coal seam in the train car. In this way, coal leveling can be performed automatically while the train is running. Compared with the manual coal leveling method, it reduces labor costs and improves coal leveling efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of flat coal, and in particular to a flat coal control system and method. Background Art

[0002] Railways are the primary means of coal transportation. With their vast transport capacity, high train load capacity, and 24 / 7 operation, they are ideal for transporting bulk coal. However, the coal carried in train cars is prone to uneven seams. Currently, this problem requires manual leveling after the train stops. This manual leveling method is costly and inefficient. Summary of the Invention

[0003] The purpose of the present invention is to provide a coal leveling control system and method to reduce labor costs and improve coal leveling efficiency.

[0004] In a first aspect, an embodiment of the present invention provides a coal-leveling control system, comprising a controller, a laser radar, a speed detection device, a traveling device, and a coal-leveling scraper, each connected to the controller, wherein the coal-leveling scraper is disposed on the traveling device;

[0005] The controller is used to detect the flatness of coal loading in the train car by starting the laser radar to determine the uneven position of the coal seam in the train car; to detect the traveling speed of the train car by starting the speed detection device to determine the traveling speed of the train; and to control the traveling device to drive the coal-leveling scraper to move according to the uneven position of the coal seam and the traveling speed of the train, and to level the coal seam in the train car by controlling the coal-leveling scraper to descend.

[0006] Furthermore, the controller includes a programmable logic controller (PLC); the speed detection device includes a through-beam measuring light curtain, which is connected to the PLC via a 485 communication module; the walking device includes a walking trolley, which moves along the walking end beams arranged on both sides of the train track.

[0007] Furthermore, the coal-leveling scraper includes a fixedly connected cage and a lifting scraper; the controller is also used to detect the size of the train car by starting the laser radar to determine the target height position; control the lifting scraper to descend to the target height position, and control the cage to operate at a target speed corresponding to the train travel speed.

[0008] Furthermore, the flat coal control system further includes a server, which is connected to the controller, the laser radar and the speed detection device respectively; the controller is connected to the cage motor of the cage through a first frequency converter;

[0009] The laser radar is used to send the detected laser radar data to the server, wherein the laser radar data includes coal seam height data, carriage width data, and carriage length data; the speed detection device is used to send the detected speed data to the server;

[0010] The server is configured to determine the uneven position of the coal seam based on the coal seam height data; determine the train model based on the carriage width data and the carriage length data; determine the target height position based on the coal seam height data and the train model; determine the train travel speed based on the speed data; determine the train position and a first output frequency based on the train travel speed, and send the uneven position of the coal seam, the target height position, the train position, and the first output frequency to the controller;

[0011] The controller is also used to control the walking device to drive the coal leveling scraper to move according to the uneven position of the coal seam and the position of the train, control the lifting scraper to descend to the target height position, and control the first frequency converter to operate at the first output frequency so that the cage motor drives the cage to operate at the target speed.

[0012] Furthermore, the controller is also used to control the traveling device to move to the rear of the carriage in the opposite direction of the train's travel direction when the uneven position of the coal seam is close to the rear of the carriage; when it is detected that the lifting scraper has descended to the target height position and the cage is operating at the target speed, the traveling device is controlled to move rapidly along the train's travel direction to achieve coal seam leveling.

[0013] Furthermore, the controller is connected to the travel motor of the travel device through a second frequency converter; an encoder is installed on the lifting motor of the lifting scraper, and the encoder is connected to the controller;

[0014] The server is further configured to determine a second output frequency according to the running speed of the train, and send the second output frequency to the controller;

[0015] The controller is also used to detect the descending height of the lifting scraper through the encoder; when the encoder detects that the lifting scraper has descended to the target height position and the cage is running at the target speed, the second inverter is controlled to operate at the second output frequency, so that the traveling device moves rapidly along the traveling direction of the train at the target traveling speed.

[0016] Furthermore, a lifting mechanism is provided on the walking device, and the flat coal scraper is fixed on the lifting mechanism; the controller is also used to control the lifting mechanism and the lifting scraper to descend together, so that the lifting scraper can quickly descend to the target height position.

[0017] Furthermore, a first ultrasonic sensor and a second ultrasonic sensor are respectively provided at the front end and the rear end of the walking device, and the first ultrasonic sensor and the second ultrasonic sensor are respectively connected to the controller;

[0018] The controller is further configured to control the lifting scraper to descend when receiving a first ultrasonic signal sent by the first ultrasonic sensor; and to control the lifting scraper to ascend when receiving a second ultrasonic signal sent by the second ultrasonic sensor.

[0019] Furthermore, the front and rear ends of the walking device are respectively provided with a first proximity switch, the front and rear ends of the coal-leveling scraper are respectively provided with a second proximity switch, the coal-leveling scraper is provided with a torque limiter, and the torque limiter is additionally equipped with a third proximity switch with a set torque, and the first proximity switch, the second proximity switch and the third proximity switch are respectively connected to the controller;

[0020] The controller is also used to control the walking device to stop running when receiving a first proximity signal sent by the first proximity switch; and to control the flat coal scraper to rise when receiving a second proximity signal sent by the second proximity switch or a third proximity signal sent by the third proximity switch.

[0021] In a second aspect, an embodiment of the present invention further provides a flat coal control method, which is applied to the flat coal control system of the first aspect; the flat coal control method includes:

[0022] Activating the laser radar to detect the flatness of coal loading in the train carriage, and determining the uneven position of the coal seam in the train carriage;

[0023] Activating the speed detection device to detect the running speed of the train carriage to determine the running speed of the train;

[0024] According to the uneven position of the coal seam and the traveling speed of the train, the traveling device is controlled to drive the coal-leveling scraper to move, and the coal seam of the train carriage is leveled by controlling the coal-leveling scraper to descend.

[0025] In the coal leveling control system and method provided by the embodiment of the present invention, the coal leveling control system includes a controller, a laser radar, a speed detection device, a traveling device, and a coal leveling scraper connected to the controller respectively, and the coal leveling scraper is set on the traveling device. When leveling coal, the controller activates the laser radar to detect the flatness of the coal loading in the train car and determine the uneven position of the coal seam in the train car; activates the speed detection device to detect the traveling speed of the train car and determine the traveling speed of the train; according to the uneven position of the coal seam and the traveling speed of the train, controls the traveling device to drive the coal leveling scraper to move, and controls the coal leveling scraper to descend to level the coal seam in the train car. In this way, automatic leveling of the coal seam in the train car is achieved, which reduces labor costs and improves coal leveling efficiency compared with manual coal leveling. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0027] Figure 1 A schematic diagram of the module composition of a flat coal control system provided by an embodiment of the present invention;

[0028] Figure 2 A schematic diagram of the module composition of another flat coal control system provided by an embodiment of the present invention;

[0029] Figure 3 A circuit diagram of a flat coal control system provided by an embodiment of the present invention;

[0030] Figure 4 A schematic diagram of the overall structure of a walking device and a flat coal scraper provided in an embodiment of the present invention;

[0031] Figure 5 A schematic structural diagram of a flat coal scraper provided in an embodiment of the present invention;

[0032] Figure 6 A schematic flow chart of a flat coal control method provided in an embodiment of the present invention.

[0033] Icons: 101-controller; 102-laser radar; 103-speed detection device; 104-traveling device; 105-coal scraper; 201-PLC; 202-switch; 203-485 communication module; 204-through-beam measurement light curtain; 205-server; 206-frequency converter; 207-frequency conversion motor; 208-encoder; 209-proximity switch; 301-traveling trolley; 302-traveling end beam; 303-lifting mechanism; 304-cage; 305-lifting scraper; 306-torque limiter; 307-electrical anti-collision device. DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0035] Currently, coal transported in train cars typically requires two to three people to manually level the coal. This manual leveling method is costly, inefficient, and requires the train to stop for leveling. Therefore, embodiments of the present invention provide a coal leveling control system and method that automatically intervenes while the train is moving, automatically following the train's movement and achieving high efficiency and effective leveling. This advanced technology allows for adaptive leveling based on loading conditions.

[0036] To facilitate understanding of this embodiment, a flat coal control system disclosed in an embodiment of the present invention is first introduced in detail.

[0037] See also Figure 1 The schematic diagram of the module composition of a flat coal control system shown in the figure includes a controller 101, and a laser radar 102, a speed detection device 103, a walking device 104 and a flat coal scraper 105 respectively connected to the controller 101, and the flat coal scraper 105 is arranged on the walking device 104.

[0038] The laser radar 102 and speed detection device 103 are both located in front of the traveling device 104. The train car first passes the laser radar 102 and speed detection device 103, and then passes the traveling device 104 equipped with the coal-leveling scraper 105. There is no position requirement between the laser radar 102 and the speed detection device 103; that is, the laser radar 102 can be located in front of or behind the speed detection device 103.

[0039] The controller 101 is used to detect the flatness of coal loading in the train car by starting the laser radar 102 to determine the uneven position of the coal seam in the train car; to detect the traveling speed of the train car by starting the speed detection device 103 to determine the traveling speed of the train; and then, according to the uneven position of the coal seam and the traveling speed of the train, to control the traveling device 104 to drive the coal leveling scraper 105 to move, and to level the coal seam in the train car by controlling the coal leveling scraper 105 to descend.

[0040] When leveling coal, the control system provided by the embodiment of the present invention performs a coal leveling operation. The controller 101 activates the laser radar 102 to detect the flatness of the coal loading in the train car and determine the unevenness of the coal seam. The speed detection device 103 is then activated to detect the travel speed of the train car and determine the train's travel speed. Based on the unevenness of the coal seam and the train's travel speed, the travel device 104 is controlled to move the coal leveling scraper 105, which is then controlled to descend to level the coal seam in the train car. This allows for automatic coal leveling while the train is moving, reducing labor costs and improving efficiency compared to manual leveling.

[0041] Alternatively, as Figure 2 and Figure 3 As shown, the controller 101 may be a PLC 201 , that is, a programmable logic controller (PLC). The following description will be made by taking the controller 101 as the PLC 201 as an example.

[0042] Alternatively, as Figure 2 and Figure 3 As shown, the speed detection device 103 may be a through-beam measurement light curtain 204, which can be communicatively connected to the PLC 201 via a 485 communication module 203. The through-beam measurement light curtain 204 can effectively detect any opaque object. It should be noted that the through-beam measurement light curtain 204 can also be communicatively connected to the PLC 201 via other types of communication modules, and the type of communication module is not limited here. The following description uses the through-beam measurement light curtain 204 as an example of the speed detection device 103.

[0043] The through-beam measuring light curtain 204 detects switching quantities. By using the time corresponding to the switching quantities detected at both ends of the through-beam measuring light curtain 204, the time when the train car passes through the through-beam measuring light curtain 204 (i.e., the difference between the two times) can be determined. Since the length of the through-beam measuring light curtain 204 is fixed, its length divided by the time it takes for the train car to pass through is equal to the train speed.

[0044] Optionally, in order to facilitate the transmission of control instructions and data signals, such as Figure 2 and Figure 3As shown, the above-mentioned flat coal control system also includes a switch 202, and the PLC201, the laser radar 102, and the 485 communication module 203 are all connected to the switch 202 through a network cable, thereby realizing the connection between the PLC201 and the laser radar 102 and the beam-type measurement light curtain 204.

[0045] Optionally, in order to reduce the calculation pressure of PLC201, as Figure 2 and Figure 3 As shown, the above-mentioned coal leveling control system also includes a server 205, which is connected to the PLC 201, the laser radar 102, and the through-beam measurement light curtain 204 via the switch 202. Specifically, the server 205 is connected to the through-beam measurement light curtain 204 via the switch 202 and the 485 communication module 203. The server 205 can receive the laser radar data detected by the laser radar 102 and the speed data detected by the through-beam measurement light curtain 204, calculate the uneven position of the coal seam in the train car and the train running speed, and send them to the PLC 201. For example, the laser radar 102 can transmit the different point values ​​of the scanned train car plane to the server 205; the server 205 uses the point values ​​to calculate a 3D stereogram, draw the coal seam height of the train car, and then determine the uneven position of the coal seam in the train car.

[0046] Alternatively, as Figure 4 As shown, the walking device 104 can be a walking trolley 301, and the walking trolley 301 walks along the walking end beams 302 set on both sides of the train track. The following description is taken as an example that the walking device 104 is the walking trolley 301.

[0047] Alternatively, as Figure 5 As shown, the coal-leveling scraper 105 may include a fixedly connected cage 304 and a lifting scraper 305. The cage 304, also known as a screw conveyor, rotates the coal seam in the train car and is then leveled by the lifting scraper 305. The lifting scraper 305 is normally in the raised position. When it receives a lowering signal from the PLC 201, it descends to level the coal seam. After completing the leveling process, the lifting scraper 305 automatically returns to the raised position.

[0048] Optionally, to achieve automatic descent and ascent of the lifting scraper 305, a first ultrasonic sensor and a second ultrasonic sensor are respectively provided at the front and rear ends of the traveling trolley 301. The first and second ultrasonic sensors are respectively connected to the PLC 201. The PLC 201 is further configured to control the descent of the lifting scraper 305 upon receiving a first ultrasonic signal from the first ultrasonic sensor, and to control the ascent of the lifting scraper 305 upon receiving a second ultrasonic signal from the second ultrasonic sensor. Upon detecting a train car, the first and second ultrasonic sensors transmit corresponding ultrasonic signals to the PLC 201, indicating that the train car has entered or left the area where the traveling trolley 301 is located. Therefore, the first and second ultrasonic sensors are respectively used to trigger the descent and ascent of the lifting scraper 305, thereby providing the PLC 201 with the timing for the descent and ascent of the lifting scraper 305.

[0049] Considering that there are many types of train cars, and the heights of different train cars may vary, PLC201 is also used to detect the dimensions of the train cars by activating the laser radar 102, determine the target height position, and control the lifting scraper 305 to descend to the target height position. The detected train car dimensions can be the car width and car length. In this case, the train model can be determined based on the car width and car length, and then the train height can be determined based on the train model, and then the corresponding target height position is determined. The target height position is generally not higher than the train height. This control of the lifting scraper 305 lowering takes into account the influence of the train car height, and the coal leveling effect is better.

[0050] Based on the width and length of the carriage, multiple matching train models may be found, but the train heights of these matching train models are usually the same, so a unique train height can be determined. For example, the dimensions (length * width * height) corresponding to the train models C62A, C62B, and C62AK are all 12500 * 2900 * 2000 (in mm), and the train heights are all 3083 mm. When the carriage width and carriage length are 12500 mm and 2900 mm, the train height can be determined to be 3083 mm, and the target height position can be 3080 mm. In addition, when determining the target height position, the coal seam height data detected by the laser radar 102 can also be referred to to ensure that the coal will not be scraped out of the carriage during the leveling process.

[0051] Optionally, in order to increase the lifting speed and height, such as Figure 4 As shown, the above-mentioned traveling trolley 301 is also provided with a lifting mechanism 303 connected to the PLC201, and the flat coal scraper 105 is fixed on the lifting mechanism 303; the PLC201 is also used to control the lifting mechanism 303 and the lifting scraper 305 to descend together, so that the lifting scraper 305 can quickly descend to the target height position.

[0052] In one possible implementation, the lifting mechanism 303 may include a lifting body, a motor and a contactor, the flat coal scraper 105 is fixed on the lifting body, the motor is mechanically connected to the lifting body, the contactor is electrically connected to the motor, and the contactor is also communicatively connected to PLC201; after PLC201 sends a start signal to the contactor, the contactor is energized to make the motor rotate forward or reverse, thereby driving the lifting body and the flat coal scraper 105 to rise or fall.

[0053] Furthermore, PLC201 is also used to control the cage 304 to operate at a target speed corresponding to the train's running speed. The cage 304 rotates to distribute the thick coal seam to both sides of the carriage, which can further improve the coal leveling effect.

[0054] The above-mentioned flat coal control system also includes a driving device, which can be multiple sets, such as the driving device corresponding to the cage 304, the driving device corresponding to the lifting scraper 305 and the driving device corresponding to the walking trolley 301. Figure 2 and Figure 3 As shown, the driving device includes a frequency converter 206, a variable frequency motor 207 ( Figure 3 M in the middle) and encoder 208; frequency converter 206 is connected to variable frequency motor 207. Frequency converter 206 is used to convert 50Hz AC power into variable frequency AC power, so that variable frequency motor 207 can obtain different speeds. Variable frequency motor 207 is used to drive the connected equipment to operate (such as move or rotate, etc.); frequency converter 206 is also connected to PLC 201 via a network cable. PLC 201 can control the output frequency of frequency converter 206, thereby controlling the operating speed of the equipment connected to variable frequency motor 207; encoder 208 is connected to variable frequency motor 207 and PLC 201 respectively. Encoder 208 is used to detect the operating distance of the equipment connected to variable frequency motor 207 and send a corresponding signal to PLC 201. Encoder 208 is an optical position detection element. Encoder 208 is directly installed on the rotating shaft of variable frequency motor 207 to measure the rotation angle position and speed change of the shaft. Its output signal is an electrical pulse.

[0055] In some possible embodiments, the drive device corresponding to the cage 304 may include a first inverter and a cage motor. The PLC 201 is connected to the cage motor via the first inverter, and the cage motor drives the cage 304. The server 205 may calculate a target speed for the cage 304 based on the train speed, e.g., the target speed is 1.1-1.3 times the train speed. Based on the target speed of the cage 304, the server 205 calculates a first output frequency corresponding to the first inverter, and controls the first inverter to operate at the first output frequency via the PLC 201, thereby ensuring that the cage 304 operates at the target speed.

[0056] Based on this, a possible operating process of the above-mentioned coal leveling control system is as follows: PLC201 activates the laser radar 102 and the beam-type measurement light curtain 204 through the switch 202. The laser radar 102 and the beam-type measurement light curtain 204 respectively send the detected laser radar data and speed data to the server 205 through the switch 202. The laser radar data may include coal seam height data, car width data, and car length data. Server 205 determines the uneven position of the coal seam based on the coal seam height data; determines the train model based on the car width data and car length data; determines the target height position based on the coal seam height data and the train model; determines the train travel speed based on the speed data; determines the train position and the first output frequency based on the train travel speed, and sends the coal seam uneven position, target height position, train position, and the first output frequency to PLC201. Based on the unevenness of the coal seam and the train's position, PLC 201 controls the traveling trolley 301 to move the coal-leveling scraper 105, lowers the lifting scraper 305 to the target height, and controls the first inverter to operate at a first output frequency, causing the cage motor to drive the cage 304 at the target speed. The train's position is calculated based on the train's speed and time.

[0057] Furthermore, the driving device corresponding to the lifting scraper 305 may include a lifting motor and an encoder installed on the lifting motor, and the encoder is connected to the PLC 201. The PLC 201 can detect the descent height of the lifting scraper 305 through the electrical pulses output by the encoder and determine whether the lifting scraper 305 has descended to the target height position.

[0058] The trolley 301 drives the cage 304 and the lifting scraper 305 forward and backward, scraping the coal seam inside the train carriage. To prevent coal from being scraped outside the train carriage, the PLC 201 also controls the trolley 301 to move in the opposite direction of the train's travel to the rear of the carriage when the uneven coal seam is near the rear of the carriage. When the lifting scraper 305 is detected to have descended to the target height and the cage 304 is operating at the target speed, the trolley 301 is controlled to move rapidly in the direction of the train's travel to achieve coal seam scraping.

[0059] The operation process of the walking trolley 301 can be as follows: the walking trolley 301 first stops at the initial position, detects and calculates the uneven position of the coal seam in the carriage through the laser radar 102, and the laser radar 102 detection is completed. The walking trolley 301 quickly walks in the opposite direction of the train's travel direction to the uneven position of the coal seam, drops the lifting scraper 305, and controls the rotation of the cage 304; then, according to the uneven position of the coal seam, the travel direction of the walking trolley 301 is controlled to achieve the leveling of the coal seam. Specifically, if the coal seam at the head of the carriage is uneven (that is, the uneven position of the coal seam is close to the head of the carriage), the walking trolley 301 can quickly walk in the opposite direction of the train's travel direction to level the coal seam in the train carriage (that is, level it from the head of the carriage to the tail of the carriage); or, the walking trolley 301 can stop and level the coal seam in the train carriage by moving the train carriage. If the coal seam at the rear of the carriage is uneven (i.e., the uneven coal seam is near the rear of the carriage), the trolley 301 moves quickly along the direction of the train's travel to scrape the coal seam in the train carriage flat (i.e., scrape from the rear of the carriage to the front of the carriage). After the scraping is completed, the lifting scraper 305 automatically rises to the raised position, and the trolley 301 returns to its initial position, ready to scrape the next train carriage.

[0060] Furthermore, PLC201 is also connected to the travel motor of the traveling trolley 301 through a second frequency converter; an encoder is installed on the lifting motor of the lifting scraper 305, and the encoder is connected to PLC201; on this basis, the server 205 is also used to determine the second output frequency according to the traveling speed of the train, and send the second output frequency to PLC201; PLC201 is also used to detect the descending height of the lifting scraper 305 through the encoder; when the encoder detects that the lifting scraper 305 descends to the target height position and the cage 304 runs at the target speed, the second frequency converter is controlled to operate at the second output frequency, so that the traveling trolley 301 moves rapidly at the target traveling speed along the traveling direction of the train.

[0061] Alternatively, the target travel speed of the trolley 301 can be determined by multiplying the train travel speed by a preset coefficient, where the coefficient is greater than 1, so that the target travel speed is greater than the train travel speed. For example, the target travel speed of the trolley 301 can be 1.1-1.3 times the train travel speed.

[0062] like Figure 2 and Figure 3 As shown, the above-mentioned flat coal control system further includes a proximity switch 209 connected to the PLC 201. The proximity switch 209 can protect the equipment from traveling beyond a preset range. The proximity switch 209 is described in detail below.

[0063] To prevent damage to the trolley 301, a first proximity switch connected to the PLC 201 is provided at the front and rear ends of the trolley 301. The PLC 201 is also configured to stop the trolley 301 upon receiving a first proximity signal from the first proximity switch. The first proximity switch ensures that the trolley 301 travels within the travel range corresponding to the travel end beam 302, preventing the trolley 301 from exceeding its travel range. Both the lifting scraper 305 and the lifting mechanism 303 can be equipped with limit protection proximity switches connected to the PLC 201 in both the ascending and descending positions to ensure that the lifting scraper 305 and the lifting mechanism 303 remain within their respective travel ranges.

[0064] In order to prevent the flat coal scraper 105 from scratching the train carriage, Figure 5 As shown, the front and rear ends of the coal-leveling scraper 105 are each equipped with an electrical anti-collision device 307. The electrical anti-collision device 307 includes an electrical anti-collision lever and a second proximity switch mounted thereon. The second proximity switch is connected to the PLC 201. When the electrical anti-collision lever contacts the front and rear outer frames of the train car, the second proximity switch activates, sending a second proximity signal to the PLC 201, which controls the coal-leveling scraper 105 to rise. Therefore, this coal-leveling control system provides electrical protection for the train car. When a train car contacts the electrical anti-collision device 307, the coal-leveling scraper 105 immediately rises, preventing the coal-leveling scraper 105 from damaging the train car.

[0065] The flat coal scraper 105 also has a torque protection function, such as Figure 5 As shown, the flat coal scraper 105 is provided with a torque limiter 306, and the torque limiter 306 is equipped with a third proximity switch connected to the PLC201 with a set torque. The PLC201 is also used to control the flat coal scraper 105 to rise when it receives a third proximity signal sent by the third proximity switch.

[0066] The torque limiter 306 can be set on the lifting scraper 305. When the lifting scraper 305 is hung on coal or a train car, the lifting scraper 305 will deform, triggering the torque limiter 306 to operate. At this time, the third proximity switch will send a third proximity signal to PLC201, and PLC201 will control the lifting scraper 305 to rise immediately, thereby avoiding scratching the train car.

[0067] In addition, if Figure 3 As shown, the above-mentioned flat coal control system also includes a switching power supply, which is used to convert three-phase AC power into DC power with a preset voltage value to power the laser radar 102, PLC 201, switch 202, 485 communication module 203, through-beam measurement light curtain 204, and proximity switch 209. The switching power supply can be, but is not limited to, a 24V power supply. The server 205 can directly use two-phase AC power.

[0068] like Figure 3 As shown, the above-mentioned flat coal control system also includes an industrial computer (i.e., a host computer), which is connected to the Ethernet and is connected to the switch 202 via a network cable. The industrial computer can be used to set the preset lifting distance of the lifting scraper 305 (in some cases, the PLC 201 cannot determine the target height position, in which case the lifting scraper 305 can be controlled to move up and down according to the preset lifting distance), set the initial frequency for the frequency converter 206; the industrial computer can display the real-time position value of the lifting scraper 305, equipment faults, etc., and can also control the start and stop of the entire machine.

[0069] For ease of understanding, the embodiment of the present invention also provides the overall operation process of the above-mentioned flat coal control system, as follows:

[0070] 1. All equipment of the flat coal control system is ready and all equipment is in the original position, such as the lifting scraper 305 is in the rising position and the walking trolley 301 is at the front position of the train.

[0071] 2. When the train is about to pass through the Pingmei control system, the start button of the industrial computer is pressed manually, and the start signal is transmitted to PLC201, and PLC201 controls all equipment to start automatic operation.

[0072] 3. PLC 201 starts the cage 304 to run at the preset speed;

[0073] 4. PLC 201 activates the laser radar 102 to detect the train carriage and obtains the laser radar data;

[0074] 5. The laser radar data is transmitted to the server 205;

[0075] 6. The server 205 determines the uneven position of the coal seam in the train carriage, the target descent distance and target height position of the lifting scraper 305 based on the laser radar data, and returns them to the PLC 201;

[0076] 7. PLC201 starts the beam-type measuring light curtain 204 to detect the train carriage and obtain the detection data;

[0077] 8. The detection data is transmitted to the server 205;

[0078] 9. The server 205 calculates the train speed based on the detection data; based on the train speed, it calculates the train position, the first output frequency of the first inverter, and the target speed of the trolley 301, and returns the train position, the first output frequency, and the target speed to the PLC 201;

[0079] 10. PLC201 controls the trolley 301 to move to the position where the coal seam needs to be leveled according to the train position, the uneven position of the coal seam and the target travel speed;

[0080] 11. When the PLC 201 receives the first ultrasonic signal sent by the first ultrasonic sensor, it controls the lifting scraper 305 to descend by the target descending distance. When the encoder detects that the actual position of the lifting scraper 305 has reached the target height, it controls the first frequency converter to operate according to the first output frequency, thereby causing the cage 304 to rotate at the set target speed to achieve coal seam leveling.

[0081] 12. When the PLC 201 receives the second ultrasonic signal sent by the second ultrasonic sensor, it determines that the scraping operation is completed, controls the encoder to detect the current position of the lifting scraper 305, and sends the position detection data to the server 205;

[0082] 13. The server 205 calculates the target lifting distance of the lifting mechanism based on the current position of the lifting scraper 305 and returns it to the PLC 201;

[0083] 14. After the PLC 201 controls the lifting scraper 305 to rise the target lifting distance, it controls the traveling carriage 301 to return to the initial position at a specified speed. The specified speed can be a target traveling speed or a preset traveling speed.

[0084] There is no order requirement for executing steps 4-6 and steps 7-9 above. In other embodiments, steps 7-9 may be executed first, and then steps 4-6. Steps 4 and 7 may also be executed first (there is no order requirement for executing steps 4 and 7), and then steps 5 and 8 (there is no order requirement for executing steps 5 and 8), and finally steps 6 and 9 (there is no order requirement for executing steps 6 and 9).

[0085] In summary, the coal-leveling control system provided in the embodiment of the present invention is an unmanned operating system. Through three-dimensional scanning of the coal-leveling in the train carriage, it can automatically calculate the coal-leveling height of the carriage and determine the type of train. It can automatically calculate the running speed of the train. The coal-leveling scraper 105 can automatically rise and fall, and the walking trolley 301 can automatically move. It also has functions such as lifting limit protection and torque protection of the coal-leveling scraper 105.

[0086] The embodiment of the present invention also provides a flat coal control method, which is applied to the above-mentioned flat coal control system. Figure 6 The flow chart of a flat coal control method shown in FIG. 1 mainly includes the following steps S602 to S606:

[0087] Step S602: Start the laser radar to detect the flatness of the coal loading in the train carriage to determine the uneven position of the coal seam in the train carriage.

[0088] Step S604: Activate a speed detection device to detect the running speed of the train carriage to determine the running speed of the train.

[0089] Step S606: According to the uneven position of the coal seam and the traveling speed of the train, the traveling device is controlled to drive the coal-leveling scraper to move, and the coal seam in the train carriage is leveled by controlling the coal-leveling scraper to descend.

[0090] The flat coal control method provided in this embodiment has the same implementation principle and technical effects as those of the aforementioned flat coal control system embodiment. For the sake of brief description, for matters not mentioned in the flat coal control method embodiment, reference may be made to the corresponding contents in the aforementioned flat coal control system embodiment.

[0091] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0092] In addition, in the description of the embodiments of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0093] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0094] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flat coal control system, characterized in that: It includes a controller, a laser radar, a speed detection device, a traveling device and a flat coal scraper respectively connected to the controller, wherein the flat coal scraper is arranged on the traveling device; The controller is used to detect the flatness of coal loading in the train carriage by activating the laser radar to determine the uneven position of the coal seam in the train carriage; to detect the travel speed of the train carriage by activating the speed detection device to determine the travel speed of the train; and to control the travel device to drive the coal leveling scraper to move according to the uneven position of the coal seam and the travel speed of the train, and to control the coal leveling scraper to descend to level the coal seam in the train carriage; The coal-leveling scraper includes a fixedly connected cage and a lifting scraper; the controller is further configured to detect the size of the train carriage by activating the laser radar to determine a target height position; control the lifting scraper to descend to the target height position, and control the cage to operate at a target speed corresponding to the train's travel speed; the coal-leveling control system further includes a server, which is respectively connected to the controller, the laser radar, and the speed detection device; the controller is connected to the cage motor of the cage via a first frequency converter; The laser radar is used to send the detected laser radar data to the server, wherein the laser radar data includes coal seam height data, carriage width data, and carriage length data; the speed detection device is used to send the detected speed data to the server; The server is used to determine the uneven position of the coal seam according to the coal seam height data; and determine the train model according to the carriage width data and the carriage length data; Determine the target height position according to the coal seam height data and the train model; determine the train travel speed according to the speed data; determine the train position and a first output frequency according to the train travel speed, and send the coal seam unevenness position, the target height position, the train position, and the first output frequency to the controller; The controller is further configured to control the traveling device to drive the coal leveling scraper to move, control the lifting scraper to descend to the target height position, and control the first frequency converter to operate at the first output frequency so that the cage motor drives the cage to operate at the target speed according to the uneven position of the coal seam and the position of the train. The speed detection device includes a beam-type measuring light curtain, and the time when the train carriage passes through the beam-type measuring light curtain is determined by the time corresponding to the switching values ​​detected at both ends of the beam-type measuring light curtain. The length of the beam-type measuring light curtain divided by the time when the train carriage passes through the beam-type measuring light curtain is equal to the train running speed; The laser radar transmits the different point position values ​​of the scanned train carriage plane to the server; the server uses the point position values ​​to calculate a 3D stereogram, draws the coal seam height of the train carriage, and then determines the uneven position of the coal seam in the train carriage.

2. The flat coal control system according to claim 1, characterized in that: The controller includes a programmable logic controller (PLC); the through-beam measuring light curtain is connected to the PLC via a 485 communication module; the traveling device includes a traveling trolley, which travels along the traveling end beams arranged on both sides of the train track.

3. The flat coal control system according to claim 1, characterized in that: The controller is also used to control the traveling device to move to the rear of the carriage in the opposite direction of the train's travel direction when the uneven position of the coal seam is close to the rear of the carriage; and when it is detected that the lifting scraper has dropped to the target height position and the cage is running at the target speed, the controller controls the traveling device to move rapidly along the train's travel direction to achieve coal seam leveling.

4. The flat coal control system according to claim 3, characterized in that: The controller is connected to the travel motor of the travel device through a second frequency converter; an encoder is installed on the lifting motor of the lifting scraper, and the encoder is connected to the controller; The server is further configured to determine a second output frequency according to the running speed of the train, and send the second output frequency to the controller; The controller is also used to detect the descending height of the lifting scraper through the encoder; when the encoder detects that the lifting scraper has descended to the target height position and the cage is running at the target speed, the second inverter is controlled to operate at the second output frequency, so that the traveling device moves rapidly along the traveling direction of the train at the target traveling speed.

5. The flat coal control system according to claim 1, characterized in that: The walking device is also provided with a lifting mechanism, and the coal-leveling scraper is fixed on the lifting mechanism; the controller is also used to control the lifting mechanism and the lifting scraper to descend together, so that the lifting scraper can quickly descend to the target height position.

6. The flat coal control system according to claim 1, characterized in that: The front end and the rear end of the walking device are respectively provided with a first ultrasonic sensor and a second ultrasonic sensor, and the first ultrasonic sensor and the second ultrasonic sensor are respectively connected to the controller; The controller is further configured to control the lifting scraper to descend when receiving a first ultrasonic signal sent by the first ultrasonic sensor; and to control the lifting scraper to ascend when receiving a second ultrasonic signal sent by the second ultrasonic sensor.

7. The flat coal control system according to claim 1, characterized in that: The front end and rear end of the walking device are respectively provided with a first proximity switch, the front end and rear end of the coal-leveling scraper are respectively provided with a second proximity switch, the coal-leveling scraper is provided with a torque limiter, and the torque limiter is additionally equipped with a third proximity switch with a set torque, and the first proximity switch, the second proximity switch and the third proximity switch are respectively connected to the controller; The controller is also used to control the walking device to stop running when receiving a first proximity signal sent by the first proximity switch; and to control the flat coal scraper to rise when receiving a second proximity signal sent by the second proximity switch or a third proximity signal sent by the third proximity switch.

8. A flat coal control method, characterized in that: Applicable to the flat coal control system according to any one of claims 1 to 7; the flat coal control method comprises: Activating the laser radar to detect the flatness of coal loading in the train carriage, and determining the uneven position of the coal seam in the train carriage; Activating the speed detection device to detect the running speed of the train carriage to determine the running speed of the train; According to the uneven position of the coal seam and the traveling speed of the train, the traveling device is controlled to drive the coal-leveling scraper to move, and the coal seam of the train carriage is leveled by controlling the coal-leveling scraper to descend.

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