Coal bunker inspection robot system and coal bunker comprising same

Abstract

This invention relates to a coal bunker inspection robot system and a coal bunker including the same. The inspection robot system includes: an inspection robot equipped with sensors and a built-in battery pack, capable of moving in and out of the coal bunker from a machine room at the top; a motion control device including a lifting device controlled by a servo motor to raise and lower the inspection robot, thus allowing it to enter and exit the coal bunker; a remote control center and data processing center receiving and processing sensor signal data transmitted from the inspection robot via a fiber optic network, and sending corresponding control commands based on the sensor signal data to achieve the inspection robot's inspection; and an auxiliary and decision-making system enabling communication between the inspection robot and detection devices within the coal bunker, including millimeter-wave radar, lidar, an image acquisition device, and a signal transceiver. This coal bunker inspection robot system can replace manual labor for comprehensive inspections of the coal bunker, thereby ensuring the safety of the coal bunker.

Description

[Technical Field]

[0001] This invention relates to the field of coal mining equipment technology; more specifically, this invention relates to a coal bunker inspection robot system and a coal bunker including the same. [Background Technology]

[0002] In coal production, various coal bunkers need to be set up at the main transportation links above and below ground in coal mines to alleviate the uneven hoisting and transportation caused by production at different stages.

[0003] Because the coal bunker is a closed space, it is impossible to inspect the damage to the bunker walls, the amount of coal stuck to the walls, the humidity, the temperature of the coal, the coal accumulation, and the distribution of harmful gases. Abnormalities can only be detected when there is damage to the bunker body, high coal temperature, or alarms for harmful gas overflow.

[0004] Therefore, there is an urgent need to provide a coal bunker inspection robot system that can replace manual labor in conducting comprehensive inspections of coal bunkers. [Summary of the Invention]

[0005] In view of this, the present invention provides a coal bunker inspection robot system and a coal bunker including the same, thereby solving or at least alleviating one or more of the above-mentioned problems and other problems existing in the prior art.

[0006] To achieve the aforementioned objectives, a first aspect of the present invention provides a coal bunker inspection robot system, wherein the inspection robot system comprises:

[0007] An explosion-proof inspection robot is equipped with sensors and a built-in battery pack. The sensors are used for data acquisition, and the inspection robot is connected to an external power source. Its power cable is connected to the external power supply interface of the inspection robot through a cable retraction device. The power cable can be raised and lowered together with the inspection robot from the machine room on the top of the coal bunker to enter and exit the interior of the coal bunker.

[0008] A motion control device, comprising a lifting device fixed to the ceiling of the machine room, the lifting device being connected to the inspection robot via a stabilizer, the lifting device being controlled by a servo motor to raise and lower the inspection robot, thereby allowing the inspection robot to enter and exit the interior of the coal bunker;

[0009] A remote control center and a data processing center are provided. The control center and the data processing center receive and process the sensor signal data transmitted back by the inspection robot through a fiber optic network, and send corresponding control commands according to the sensor signal data to realize the inspection of the inspection robot.

[0010] An auxiliary and decision-making system is provided, which enables detection within the coal bunker and communication with the inspection robot through a detection device. The detection device includes a millimeter-wave radar for detecting the bunker's height, a lidar for detecting cracks in the inner wall of the coal bunker, an image acquisition device for acquiring images inside the coal bunker, and a signal transceiver for amplifying signals inside the coal bunker and communicating with the inspection robot. The millimeter-wave radar periodically detects the bunker's height, the lidar periodically detects cracks in the inner wall of the coal bunker, and the image acquisition device periodically acquires images inside the coal bunker.

[0011] In the inspection robot system described above, optionally, the sensors include a gas sensor, a smoke sensor, a temperature sensor, and a humidity sensor, so that the inspection robot system issues an alarm when the gas parameter, smoke parameter, temperature parameter, or humidity parameter exceeds the standard.

[0012] In the inspection robot system described above, optionally, the control center includes a PLC control system and a host computer interface display system to send instructions and realize the control of various working modes of the inspection robot and the acquisition and display of data.

[0013] In the inspection robot system described above, optionally, the data processing center uses a server to process the data collected by the sensors and detection devices of the inspection robot.

[0014] In the inspection robot system described above, optionally, the lifting device is a pulley-wire rope device, which includes a fixed pulley fixed to the top wall of the machine room by a bracket, a movable pulley connected to the inspection robot, and a wire rope passing over the fixed pulley and the movable pulley. One end of the wire rope is connected to the servo motor, and the other end of the wire rope is connected to the bracket of the fixed pulley.

[0015] In the inspection robot system described above, optionally, an infrared camera and a first lidar are installed inside the inspection robot to detect and mark wear and cracks on the inner wall of the coal bunker.

[0016] In the inspection robot system described above, optionally, a second lidar and an infrared thermal imager are installed on the inspection robot. The second lidar is used to detect the coal level, and the infrared thermal imager is used to detect the temperature of the coal and issue an alarm when the detected coal temperature exceeds the standard.

[0017] In the inspection robot system described above, optionally, the inspection robot includes a supplementary light to assist in the inspection and manual maintenance work of the inspection robot.

[0018] In the inspection robot system described above, optionally, the inspection robot is equipped with a microphone and a speaker for two-way voice communication with on-site personnel and for sound and light alarms in case of abnormalities.

[0019] To achieve the aforementioned objective, a second aspect of the present invention provides a coal bunker, wherein the top of the coal bunker has a machine room, an opening with a door is provided between the machine room and the coal bunker, and an inspection robot of the inspection robot system as described in any one of the first aspects is provided in the machine room, and:

[0020] When inspection is required, the warehouse door opens and the inspection robot enters the coal warehouse to conduct inspection.

[0021] After the inspection is completed, the inspection robot returns to the machine room and the door is closed.

[0022] According to the present invention, the coal bunker inspection robot system and the coal bunker including it are controlled by a control center and a data processing center. The control center processes and displays the signal data of the internal conditions of the coal bunker detected by the inspection robot and the auxiliary and decision-making system. Based on the processed signal data, the control center sends control commands to the inspection robot to realize the inspection robot's inspection of the coal bunker. This realizes the control of the inspection robot and the collection of data. When the inspection robot issues an alarm, the control center notifies the relevant personnel to handle the situation. This realizes the comprehensive inspection of the coal bunker and ensures the safety of the coal bunker. [Attached Image Description]

[0023] The disclosure of this invention will become more apparent from the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings:

[0024] Figure 1 This is a schematic diagram of an embodiment of the coal bunker inspection robot system of the present invention, which also shows the internal structure of the coal bunker; and

[0025] Figure 2 for Figure 1 A schematic diagram of the internal structure of the inspection robot.

[0026] Attached reference numerals: 10-Coal bunker; 11-Machine room; 12-Floor; 13-Machine room ceiling; 14-Opening; 20-Inspection robot; 21-Sensor; 22-Built-in battery pack; 23-Infrared camera device; 24A-First lidar; 24B-Second lidar; 25-Infrared imager; 26-Supplemental light; 27-Pickup unit; 28-Speaker; 29-Control board; 31-Bracket; 32-Fixed pulley; 33-Modible pulley; 34-Wire rope; 35-Servo motor; 40-Control center and data processing center; 41-Control cabinet; 42-Fiber optic cable; 51-Millimeter-wave radar; 52-LiDAR; 53-Image acquisition device; 54-Signal transceiver.

Detailed Implementation Methods

[0027] Referring to the accompanying drawings, the structural composition, features, and advantages of the coal bunker inspection robot system according to the present invention and specific embodiments of the coal bunker including the system will be described below. However, all descriptions should not be construed as limiting the scope of protection of the present invention in any way.

[0028] Furthermore, for any single technical feature described or implied in the embodiments mentioned herein, or any single technical feature shown or implied in the various figures, the present invention still allows for any combination or deletion of these technical features (or their equivalents) without any technical obstacle, and thus these further embodiments according to the present invention should also be considered within the scope of this description.

[0029] It should also be noted that the terms "upper" and "lower" indicate the orientation or positional relationship based on the vertical orientation or positional relationship of the coal bunker inspection robot system shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.

[0031] Figure 1 This is a schematic diagram of an embodiment of the coal bunker inspection robot system of the present invention, which also shows the internal structure of the coal bunker.

[0032] As shown in the diagram, a machine room 11 is located on top of the coal bunker 10. An opening 14 with a door is provided in the floor 12 between the machine room 11 and the coal bunker 10. Some electrical equipment of the inspection robot system and the inspection robot 20 are housed inside the machine room 11. When inspection is required, the door opens, and the inspection robot 20 enters the coal bunker 10 through the opening 14 to perform the inspection. After the inspection, the inspection robot 20 returns to the machine room 11 through the opening 14, and the door closes to prevent coal dust and other contaminants from the coal bunker 10 from entering the machine room 11 and affecting the electrical equipment inside.

[0033] In the illustrated embodiment, the inspection robot system may include an inspection robot 20, a motion control device (e.g., a servo motor 35), a control center and a data processing center 40, and an auxiliary and decision-making system (e.g., a millimeter-wave radar 51 or other detection device).

[0034] As shown in the figure, the inspection robot 20 is used to comprehensively inspect the interior of the coal bunker 10 and transmits the inspection data to the control center and data processing center 40 via the control cabinet 41 located in the machine room 11. The robot also receives instructions from the control center and data processing center 40 through the control cabinet 41 to proceed with the next inspection. During inspection, the inspection robot 20 moves in and out of the coal bunker 10 through an opening 14 in the floor 12 of the machine room 11 at the top of the coal bunker. It should be noted that the inspection robot 20 is designed as an explosion-proof robot to meet the national standard GB3836 General Requirements for Explosion-Proof Electrical Equipment for Explosive Atmospheres. It has obtained coal mine safety certification, thus isolating the internal electrical equipment of the inspection robot 20 from contact with various gases and dust inside the external coal bunker 10 to prevent combustion and explosion.

[0035] The motion control device may include a lifting device and a servo motor 35. In the illustrated example, the lifting device may be a pulley-wire rope device, which includes a bracket 31, a fixed pulley 32, a movable pulley 33, and a wire rope 34. Figure 1 In this embodiment, the bracket 31 is fixedly supported on the floor 12, and its upper end can be fixedly located at the top wall 13 of the machine room 11. The lower end of the bracket 31 is connected to a fixed pulley 32 to fix it at the top wall 13 of the machine room 11. One end of the steel wire rope 34 is connected to the servo motor 35, passes over the fixed pulley 32 and the movable pulley 33, and its other end is connected to the bracket 31. The inspection robot 20 can be connected to the lower part of the movable pulley 33 through a stabilizer (not shown in the figure). The combination of the fixed pulley 32 and the movable pulley 33 can change the direction of the tension of the steel wire rope 34, enabling the servo motor 35 to raise or release the inspection robot 20 through the pulley combination. Therefore, the inspection robot 20 can stably move in and out of the coal bunker with the pulley combination. In addition, the pulley combination can also save the tension of the servo motor 35.

[0036] During inspection, servo motor 35 releases wire rope 31, which passes through fixed pulley 32 and downwards to release movable pulley 33. This controls the inspection robot 20, connected below movable pulley 33, to descend and enter the coal bunker 10 through the opening 14 of the open door, thus performing a comprehensive inspection of the interior of the coal bunker 10. After the inspection, servo motor 35 pulls up wire rope 31, which passes through fixed pulley 32 and upwards to pull movable pulley 33. This controls the inspection robot 20, connected below movable pulley 33, to ascend and enter the machine room 11 through the opening 14 of the open door.

[0037] The auxiliary and decision-making system assists the inspection robot 20 in achieving comprehensive inspection within the coal bunker 10 through a detection device, and communicates with the inspection robot 20, which then transmits the collected signal data in a unified manner. This detection device may include a millimeter-wave radar 51, a lidar 52, an image acquisition device 53, and a signal transceiver 54. As shown in the figure, these detection devices can be suspended and installed below the floor 12 of the machine room 11 and on the roof of the coal bunker 10 to continuously monitor the interior of the coal bunker 10.

[0038] The millimeter-wave radar 51 is used to detect coal piles within the coal bunker 10, assisting the inspection robot 20 in creating a 3D model of the coal pile to obtain the coal accumulation status and quantity within the coal bunker 10. In an optional embodiment, regardless of whether the inspection robot 20 enters the coal bunker 10, the millimeter-wave radar 51 periodically scans, for example, but not limited to, the surface of the coal pile every minute, and models it, simultaneously calculating the coal accumulation status and coal storage quantity within the coal bunker 10. By detecting the coal accumulation status, the coal pile can be adjusted to achieve good porosity and ventilation conditions, preventing spontaneous combustion. The coal storage quantity data is uniformly transmitted by the inspection robot 20 to the control center and data processing center 40, and then fed back to the coal preparation process control system by the control center and data processing center 40, thereby controlling the subsequent coal preparation production process and ensuring continuous coal mine production and output measurement. Furthermore, the millimeter-wave radar 51 also has explosion-proof and self-cleaning functions to ensure the safety of detection and the coal bunker 10.

[0039] The lidar 52 is used to assist the inspection robot 20 in detecting various wear and cracks on the inner wall of the coal bunker 10, and to accurately locate and display the specific position of cracks or wear in three dimensions. In an optional embodiment, regardless of whether the inspection robot 20 enters the coal bunker 20, the lidar 52 will periodically scan, for example, but not limited to, once every minute, the inner wall surface and perform modeling to obtain real-time detection signal data of the inner wall. Based on the signal data, the inner wall of the coal bunker 10 is repaired to prevent water leakage, carbonization, and corrosion, thereby making the inner wall of the coal bunker 10 more robust and extending the service life of the coal bunker 10.

[0040] The image acquisition device 53 is used to assist the inspection robot 20 in taking images of the inside of the coal bunker 10 at regular intervals or in real time. It can be combined with other detection devices to better detect the condition of the coal pile and inner wall inside the coal bunker 10.

[0041] The transceiver 54 is used to receive signals from other detection devices inside the coal bunker 10 and amplify them. The transceiver 54 can communicate with the inspection robot 20, transmitting the received signals, which are then uniformly sent out by the inspection robot 20. The transceiver 54 can also receive instructions from the inspection robot 20, amplify the instruction signals, and transmit them to other detection devices, which then perform inspections inside the coal bunker 10 according to the received instructions.

[0042] In the embodiment shown in the figure, the control center and data processing center 40 are network-connected to the control cabinet 41 located in the computer room 11 via optical fiber 42. The control center receives and processes the signal data transmitted back by the inspection robot 20 through the control cabinet 41. This control center and data processing center 40 provides remote monitoring, facilitating real-time remote monitoring and unified management of the coal bunker 10. In an optional embodiment, the signal data processed by the control center and data processing center 40 can be synchronized to a handheld inspection terminal, facilitating real-time monitoring by staff.

[0043] It should be noted that the data processing center utilizes a server to process and manipulate the signal data received from the inspection robot 20. The control center includes a PLC control system and a host computer interface display system. The host computer interface display system shows the processed signal data, and the PLC control system sends corresponding instructions to the inspection robot 20 based on the processed signal data. This enables the inspection robot 20 to perform various operating modes, such as scheduled inspections, fixed-point inspections, designated special task inspections, remote control inspections, or remote inspections, thereby achieving control of the inspection robot 20 and data acquisition. In different embodiments, the PLC control system can automatically or manually issue instructions through a preset program to control the inspection robot 20 and the auxiliary and decision-making system.

[0044] Figure 2 for Figure 1 A schematic diagram of the internal structure of the inspection robot.

[0045] As shown in the figure, the inspection robot 20 has a built-in battery pack 22 for powering it. This built-in battery pack 22 can be a high-capacity lithium rechargeable battery, which can achieve rapid charging and discharging, has high output power, and a long service life, thus meeting the power supply requirements of the inspection robot 20.

[0046] In an optional embodiment, the inspection robot 20 can also be connected to an external power source (not shown in the figure), enabling dual-mode power supply. The external power source can directly supply power to the inspection robot 20, and its power cable can be connected to the external power supply interface of the inspection robot 20 via a cable retraction device. This power cable, along with the inspection robot 20, can move in and out of the coal bunker 10 through the opening 14 of the machine room 11 at the top of the coal bunker 10, facilitating power supply to the inspection robot 20. The external power source can also charge the built-in battery pack 22, further ensuring power supply to the inspection robot 20.

[0047] As can be seen from the figure, the inspection robot 20 is equipped with a sensor 21, which is used to collect data inside the coal bunker 10. In optional embodiments, the sensor 21 may include a gas sensor for detecting gas parameters such as CH4, CO, and CO2 inside the coal bunker 10, a smoke sensor for detecting smoke parameters inside the coal bunker 10, a temperature sensor for detecting temperature parameters inside the coal bunker 10, and a humidity sensor for detecting humidity parameters inside the coal bunker 10. When the aforementioned parameters exceed the limits, the inspection robot system will issue an alarm to notify the staff to take action, thereby preventing spontaneous combustion of the coal pile.

[0048] In an optional embodiment, the inspection robot 20 may be equipped with an infrared thermal imager 25, which is used to detect the temperature of the coal pile. It can work in conjunction with the aforementioned temperature sensor to detect the temperature of the coal pile more accurately, and issue an alarm when the detected temperature of the coal pile exceeds the standard to notify the staff to handle the situation, thereby preventing the coal pile from spontaneously combusting.

[0049] According to the embodiment shown in the figure, the inspection robot 20 is also equipped with a second lidar 24B. This second lidar 24B is used to detect the coal level in the coal pile. It can be used alone or in conjunction with the millimeter-wave radar 51 of the auxiliary decision-making system to create a three-dimensional map of the coal pile, thereby obtaining the coal accumulation and storage volume within the coal bunker 10. By detecting the coal accumulation, the coal pile can be adjusted to achieve optimal porosity and ventilation, further preventing spontaneous combustion. Furthermore, this coal storage volume data will be fed back from the control center and data processing center 40 to the coal preparation process control system, thereby controlling the subsequent coal preparation production process and ensuring continuous coal mine production and output measurement.

[0050] As can be seen from the embodiment shown in the figure, an infrared camera 23 and a first lidar 24A are installed inside the inspection robot 20 to detect wear and cracks on the inner wall of the coal bunker 10 and mark the specific locations of the wear and cracks. The infrared camera 23 and the first lidar 24A can be used alone or in conjunction with the lidar 52 of the auxiliary decision-making system to achieve precise positioning and three-dimensional display of wear and cracks on the inner wall of the coal bunker 10. This allows workers to repair the inner wall of the coal bunker 10 based on the positioning, preventing water leakage, carbonization, and corrosion, thereby making the inner wall of the coal bunker 10 more robust and extending its service life.

[0051] To better inspect the conditions inside the coal bunker 10, the inspection robot 20 may also include a supplementary light 26. This supplementary light 26 provides additional illumination to the coal bunker 10, offering a uniform lighting environment to facilitate the robot's inspections and providing illumination during manual maintenance work. It should be noted that this supplementary light 26 is an explosion-proof light, further ensuring the safety of both the inspection robot 20 and the coal bunker 10.

[0052] As can also be seen from the embodiment shown in the figure, the inspection robot 20 is equipped with a microphone 27 and a speaker 28 for two-way voice communication between personnel in the control center and data processing center 40 and staff in the coal bunker 10; and for sound and light alarms when abnormal situations occur, such as when parameters such as gas, smoke, temperature, and humidity in the coal bunker exceed the standard.

[0053] According to the coal bunker inspection robot system of the present invention, the inspection robot enters the interior of the coal bunker to conduct unmanned inspections and automatically alarm for abnormal situations, thereby realizing effective and comprehensive inspection of the interior of the coal bunker.

[0054] The inspection robot system of this invention uses a control center and a data processing center to process and display the signal data of the inspection robot and the auxiliary and decision-making system detecting the internal conditions of the coal bunker. Based on the processed signal data, control commands are sent to the inspection robot to realize the inspection of the robot, thereby realizing the control of the inspection robot and the collection of data. When the inspection robot issues an alarm, the relevant personnel are notified to handle it, thereby realizing a comprehensive inspection of the coal bunker to ensure the safety of the coal bunker.

[0055] The technical scope of this invention is not limited to the contents of the above specification. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the scope of this invention.

Claims

1. A coal bunker inspection robot system, characterized in that, The coal bunker has a machine room on its roof, and a floor is installed between the machine room and the coal bunker. The floor has an opening with a bunker door. The inspection robot system includes: An explosion-proof inspection robot is equipped with sensors and a built-in battery pack. The sensors are used for data acquisition, and the inspection robot is connected to an external power source. Its power cable is connected to the external power supply interface of the inspection robot through a cable retraction device. The power cable can be raised and lowered together with the inspection robot from the machine room on the top of the coal bunker to enter and exit the interior of the coal bunker. A motion control device, comprising a lifting device fixed to the top wall of the machine room, the lifting device being connected to the inspection robot via a stabilizer, the lifting device being controlled by a servo motor to raise and lower the inspection robot so that the inspection robot can enter and exit the interior of the coal bunker through the opening; A remote control center and a data processing center are provided. The control center and the data processing center receive and process the sensor signal data transmitted back by the inspection robot through a fiber optic network, and send corresponding control commands according to the sensor signal data to realize the inspection of the inspection robot. An auxiliary and decision-making system is provided, which uses a detection device to achieve detection within the coal bunker and communication with the inspection robot. The detection device includes a millimeter-wave radar for detecting the bunker's height, a lidar for detecting cracks in the bunker's inner walls, an image acquisition device for acquiring images of the bunker's interior, and a signal transceiver for amplifying signals within the bunker and communicating with the inspection robot. The millimeter-wave radar periodically detects the bunker's height and calculates the amount of coal stored within. The lidar periodically detects cracks in the bunker's inner walls, and the image acquisition device periodically or in real-time acquires images of the bunker's interior. The lifting device is a pulley-wire rope device, which includes a fixed pulley fixed to the top wall of the machine room by a bracket, a movable pulley connected to the inspection robot, and a wire rope passing around the fixed pulley and the movable pulley. One end of the wire rope is connected to the servo motor, and the other end of the wire rope is connected to the bracket of the fixed pulley.

2. The inspection robot system as described in claim 1, wherein, The sensors include a gas sensor, a smoke sensor, a temperature sensor, and a humidity sensor, enabling the inspection robot system to issue an alarm when the gas parameter, smoke parameter, temperature parameter, or humidity parameter exceeds the standard.

3. The inspection robot system as described in claim 1, wherein, The control center includes a PLC control system and a host computer interface display system, which sends commands and realizes the control of the inspection robot in various working modes and the collection and display of data.

4. The inspection robot system as described in claim 1, wherein, The data processing center uses a server to process the data collected by the sensors and detection devices of the inspection robot.

5. The inspection robot system as described in claim 1, wherein, An infrared camera and a first lidar are installed inside the inspection robot to detect and mark wear and cracks on the inner wall of the coal bunker.

6. The inspection robot system as described in claim 1, wherein, The inspection robot is equipped with a second lidar and an infrared thermal imager. The second lidar is used to detect the coal level, and the infrared thermal imager is used to detect the coal temperature and issue an alarm when the detected coal temperature exceeds the standard.

7. The inspection robot system as described in claim 1, wherein, The inspection robot includes supplementary lighting to assist in its inspection and manual maintenance work.

8. The inspection robot system as described in claim 1, wherein, The inspection robot is equipped with a microphone and a speaker for two-way voice communication with on-site personnel and for sound and light alarms in case of abnormalities.

9. A coal bunker, characterized in that, The coal bunker has a machine room on its roof, a floor is provided between the machine room and the coal bunker, the floor has an opening with a bunker door, and an inspection robot of the inspection robot system as described in any one of claims 1 to 8 is provided in the machine room, and: When inspection is required, the warehouse door opens, and the inspection robot enters the coal warehouse through the opening to conduct inspection. After the inspection is completed, the inspection robot returns to the machine room through the opening, and the warehouse door is closed.

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