A system for controlling the flow of material from a hopper outlet by air table

Abstract

This invention provides a system for controlling the outlet flow rate of a feed hopper using an air cushion conveyor, relating to the field of bulk material conveying technology. The system includes a laser material scanner and a control center. The laser material scanner is positioned directly above the center of the air cushion conveyor belt. It scans the belt area and acquires measurement data based on the relative positions of measurement points within the belt area and the laser material scanner itself. The laser material scanner converts the measurement data into measurement signals and sends them to the control center. The control center receives the measurement signals and externally input data, uses a convolutional neural network deep learning algorithm for learning and analysis, and outputs material information. This invention can simulate the material profile at the feed inlet position of the air cushion conveyor in real time using data from multiple single-point measurements.

Description

Technical Field

[0001] This invention relates to the field of bulk material conveying technology, and more particularly to a system for controlling the outlet flow of a feed hopper using an air cushion machine. Background Technology

[0002] In bulk material conveying systems, air cushion conveyors are an important component, capable of transporting various granular, powdery, and other bulk materials. To reduce the impact of dust on the environment and the influence of the natural environment on the conveying system, air cushion conveyors are generally fully enclosed or enclosed at the top and on the side walls, operating in an explosive dust environment.

[0003] During material transport by the air cushion conveyor, factors such as material impact at the discharge port and uneven material accumulation on the air cushion can cause it to deviate from its designated path. This is especially true when multiple hoppers feed the same air cushion simultaneously, as varying hopper gate opening controls can lead to localized overload, spillage, excessive material accumulation, and even motor overload and belt compression. In actual production, methods such as light / heavy deviation switches, instantaneous flow rate weighing on belt scales, and real-time current monitoring of the air cushion motor are generally used to assess and protect the air cushion's reliable operation. Furthermore, to accommodate the varying material and process requirements of different production stages, current conveying systems employ manual or remote gate adjustment on-site. The relationship between air cushion capacity and gate opening is preset based on experience before system startup, minimizing manual adjustments during material transport.

[0004] However, existing hopper outlet flow control methods have certain shortcomings. Control room operators cannot promptly monitor the status of the receiving hopper and air cushion machine. Furthermore, after gate adjustments, the instantaneous flow rate feedback from the existing belt scale exhibits a significant lag, and the air cushion machine motor current cannot monitor localized material overload. Production operations are extremely difficult, resulting in large and prolonged fluctuations in the air cushion machine's material flow rate, posing safety hazards to production. Summary of the Invention

[0005] To address the technical problem mentioned above that existing hopper outlet flow control methods cannot accurately monitor the material composition in real time, this invention provides a system for controlling the hopper outlet flow using an air cushion machine. The main purpose of this invention is to utilize a laser material scanner to detect the material composition on the air cushion machine in real time.

[0006] The technical means employed in this invention are as follows:

[0007] A system for controlling the outlet flow of a feed hopper via an air cushion machine includes: a laser material scanner and a control center;

[0008] The laser material scanner is positioned directly above the center of the air cushion machine's belt surface. The laser material scanner scans the area of ​​the air cushion machine's belt surface and acquires measurement data of the measurement points based on the relative positions of the measurement points within the air cushion machine's belt surface area and the laser material scanner. The laser material scanner converts the measurement data into measurement signals and sends them to the control center.

[0009] The control center receives measurement signals and external data input from the outside world, uses convolutional neural network deep learning algorithms to learn and analyze them, and outputs material information.

[0010] Furthermore, the measurement data includes the distance between the measurement point and the laser material scanner and the angular relationship between the measurement point and the laser material scanner, and the external data includes the air cushion machine belt speed and material density.

[0011] Furthermore, the step of the laser material scanner scanning the surface area of ​​the air cushion machine is as follows:

[0012] The initial scanning reference plane of the laser material scanner is set as the air cushion machine belt surface and the inner surface of the enclosed box;

[0013] The laser material scanner is activated to begin scanning the measurement points. The scanning process involves single-point measurements at regular intervals.

[0014] After the laser shines on the measurement point, the measurement point emits a light spot, and the laser material scanner collects the light spot data and converts it into measurement data.

[0015] Furthermore, the spot data includes the spot diameter and the spot spacing. The laser material scanner calculates the detection distance value based on the spot diameter, using the following formula:

[0016] The spot data includes the spot diameter and the spot spacing. The laser material scanner 1 calculates the detection distance value based on the spot diameter, using the following formula:

[0017] When the laser material scanner uses a high-resolution device

[0018] Spot diameter = Detection distance × 4.6 + 13 mm

[0019] When the laser material scanner uses a standard resolution device.

[0020] Spot diameter = Detection distance × 11 + 13 mm

[0021] The laser material scanner calculates the material shape based on the spot spacing, using the following formula:

[0022] Spot spacing = tan(angular resolution) × detection distance

[0023] The angular resolution is set by adjusting the rotation frequency of the laser material scanner, and the range of the angular resolution is 25 to 100 Hz.

[0024] Furthermore, a dust explosion-proof protective box is provided on the outside of the laser material scanner. The observation surface of the dust explosion-proof protective box is an inclined surface that slopes inward from top to bottom, and a protective box window is provided on the observation surface.

[0025] Furthermore, the angle between the inclined surface and the horizontal line is 45°.

[0026] Furthermore, the upper part of the air cushion machine is provided with a closed box that completely encloses the air cushion machine, and the dust explosion-proof protective box is installed through the upper surface of the closed box.

[0027] Furthermore, the connection between the dust explosion-proof protective box and the enclosed box is sealed with a rubber ring.

[0028] Furthermore, the material information includes:

[0029] The volumetric flow rate of the material is calculated based on the material type and the belt speed of the air cushion conveyor.

[0030] The instantaneous flow rate of a material is calculated based on its volumetric flow rate and density.

[0031] The cumulative flow of materials is calculated based on the instantaneous flow rate and the material handling time;

[0032] The center of gravity of the material is determined by statistically analyzing its position on the air cushion conveyor belt and its offset from the center of the overall conveyor line, based on the obtained material shape. Compared with existing technologies, this invention has the following advantages:

[0033] 1. The laser material scanner provided by this invention realizes the function of real-time detection of the material shape on the air cushion machine by collecting light spot data.

[0034] 2. The present invention has a dust explosion-proof protective box on the outside of the laser material scanner to prevent dust from entering the equipment. At the same time, in order to prevent the laser from producing mirror reflection on the window of the protective box, an inclined surface is set at a 45° angle with the horizontal line.

[0035] 3. This invention can simulate the material shape of the air cushion machine at the feed port position in real time through data measured at multiple single points. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is a schematic diagram showing the position of the laser material scanner of the present invention.

[0038] Figure 2 This is a front view of the dust explosion-proof protective box of the present invention.

[0039] Figure 3 This is a side view of the dust explosion-proof protective box of the present invention.

[0040] Figure 4 This is a top view of the dust explosion-proof protective box of the present invention.

[0041] In the diagram: 1. Laser material scanner; 2. Belt conveyor; 3. Enclosed box; 4. Dust explosion-proof protective box; 5. Observation surface; 6. Protective box viewing window. Detailed Implementation

[0042] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0045] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0046] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0047] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0048] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0049] like Figures 1-4As shown, the present invention provides a system for controlling the outlet flow of a feed hopper by means of an air cushion machine flow control, comprising: a laser material scanner 1 and a control center;

[0050] To achieve real-time acquisition of the material pattern on the air cushion machine, the laser material scanner 1 is positioned directly above the center of the air cushion machine belt surface 2, approximately 4 meters from the feed inlet. The laser material scanner 1 scans the area of ​​the air cushion machine belt surface 2 and acquires measurement data of the measurement points based on their relative positions within the area. The measurement data is in polar coordinates. The laser material scanner 1 converts the measurement data into measurement signals and sends them to the control center.

[0051] The measurement data includes the distance between the measurement point and the laser material scanner 1 and the angular relationship between the measurement point and the laser material scanner 1. The external data includes the air cushion machine belt speed and the material density.

[0052] The steps for the laser material scanner 1 to scan the surface area of ​​the air cushion machine are as follows:

[0053] To achieve accurate data collection and comparison, an initial scanning reference plane is set for the laser material scanner 1. The initial scanning reference plane is the air cushion machine belt surface 2 and the inner surface of the enclosed box 3.

[0054] Start the laser material scanner 1 to begin scanning the measurement points. The scanning process involves single-point measurement at regular intervals, and the diverging light spot at each point is determined based on the installation distance.

[0055] After the laser shines on the measurement point, the measurement point emits a light spot, and the laser material scanner 1 collects the light spot data and converts it into measurement data.

[0056] The spot data includes the spot diameter and the spot spacing. The laser material scanner 1 calculates the detection distance value based on the spot diameter, using the following formula:

[0057] When the laser material scanner 1 uses a high-resolution device

[0058] Spot diameter = Detection distance × 4.6 + 13 mm

[0059] When the laser material scanner 1 uses a standard resolution device

[0060] Spot diameter = Detection distance × 11 + 13 mm

[0061] The laser material scanner 1 calculates the material shape based on the spot spacing, using the following formula:

[0062] Spot spacing = tan angular resolution × detection distance

[0063] The angular resolution is set by adjusting the rotation frequency of the laser material scanner 1, and the range of the angular resolution is 25 to 100 Hz.

[0064] The control center receives measurement signals and external data input from the outside world, uses convolutional neural network deep learning algorithms to learn and analyze them, and outputs material information.

[0065] The material information includes:

[0066] The volumetric flow rate of the material is calculated based on the material type and the belt speed of the air cushion conveyor.

[0067] The instantaneous flow rate of a material is calculated based on its volumetric flow rate and density.

[0068] The cumulative flow of materials is calculated based on the instantaneous flow rate and the material handling time;

[0069] The center of gravity of the material is statistically analyzed using a slicing method based on the obtained material shape, focusing on the offset of the center of gravity of the material on the air cushion conveyor belt surface from the center of the overall conveyor line.

[0070] Air cushion machine belt edge detection, real-time monitoring of the overall belt offset;

[0071] By analyzing the material and conveyor belt offset based on the center of gravity, the software provides real-time analysis and feedback on the air cushion conveyor's deviation and material overloading. Using machine learning algorithms, potential deviations of the air cushion conveyor are predicted and fed back to the intelligent control system for bulk material unloading or to operators in the central control room for timely pre-emptive action, preventing accidents.

[0072] The flow rate output from the model can be fed back to the gate control system in real time to adjust the gate opening and thus control the flow rate at the hopper gate outlet. The model can be used to verify in real time whether the controlled gate outlet flow rate meets the requirements and improve the accuracy of control.

[0073] The area where the scanner is installed on the air cushion machine is an explosive dust environment. To prevent interference from strong light, rain, and direct sunlight, a dust explosion-proof protective box 4 is installed on the outside of the laser material scanner 1. The observation surface 5 of the dust explosion-proof protective box 4 is an inclined surface sloping inwards from top to bottom, and a protective box window 6 is provided on the observation surface 5. To prevent specular reflection of the laser on the protective box window 6, the angle between the inclined surface and the horizontal line is 45°. The laser beam is directed onto the conveyor belt surface 2 through the protective box window 6.

[0074] The air cushion machine is equipped with a sealed box 3 that completely encloses the air cushion machine at its upper part, and a dust explosion-proof protective box 4 is installed through the upper surface of the sealed box 3. The connection between the dust explosion-proof protective box 4 and the sealed box 3 is sealed with a rubber ring.

[0075] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions 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 system for controlling the outlet flow rate of a feed hopper using an air cushion machine, characterized in that, include: Laser material scanner (1) and control center; The laser material scanner (1) is positioned directly above the center of the air cushion machine belt surface (2). The laser material scanner (1) scans the area of ​​the air cushion machine belt surface (2) and obtains measurement data of the measurement points based on the relative positions of the measurement points within the area of ​​the air cushion machine belt surface (2) and the laser material scanner (1). The laser material scanner (1) converts the measurement data into measurement signals and sends them to the control center. The measurement data includes the distance between the measurement point and the laser material scanner (1) and the angular relationship between the measurement point and the laser material scanner (1). The external data includes the air cushion machine belt speed and the material density. The control center receives measurement signals and external data input from the outside, uses convolutional neural network deep learning algorithms for learning and analysis, and outputs material information. The steps of the laser material scanner (1) scanning the surface area of ​​the air cushion machine are as follows: The initial scanning reference plane of the laser material scanner (1) is set as the air cushion machine belt surface (2) and the inner surface of the enclosed box (3); Start the laser material scanner (1) to begin scanning the measurement points. The scanning process involves single-point measurement at certain angles. After the laser irradiates the measurement point, the measurement point emits a light spot, and the laser material scanner (1) collects the light spot data and converts it into measurement data; The spot data includes the spot diameter and the spot spacing. The laser material scanner (1) calculates the detection distance based on the spot diameter using the following formula: When the laser material scanner (1) uses a high-resolution device, Spot diameter = Detection distance × 4.6 + 13mm When the laser material scanner (1) uses a standard resolution device, Spot diameter = Detection distance × 11 + 13 mm The laser material scanner (1) calculates the material shape based on the spot spacing, using the following formula: Spot spacing = tan (angular resolution) × detection distance The angular resolution is set by adjusting the rotation frequency of the laser material scanner (1), and the range of the angular resolution is 25°~100°.

2. The system for controlling the outlet flow rate of the feed hopper via an air cushion machine according to claim 1, characterized in that, The laser material scanner (1) is provided with a dust explosion-proof protective box (4) on its outside. The observation surface (5) of the dust explosion-proof protective box (4) is an inclined surface that slopes from top to bottom inward. The observation surface (5) is provided with a protective box window (6).

3. The system for controlling the outlet flow rate of the feed hopper via an air cushion machine according to claim 2, characterized in that, The angle between the observation surface (5) and the horizontal line is 45°.

4. The system for controlling the outlet flow rate of the feed hopper via an air cushion machine according to claim 2, characterized in that, The upper part of the air cushion machine is provided with a closed box (3) that completely encloses the air cushion machine, and the dust explosion-proof protective box (4) is provided through the upper surface of the closed box (3).

5. The system for controlling the outlet flow rate of the feed hopper via an air cushion machine according to claim 4, characterized in that, The connection between the dust explosion-proof protective box (4) and the enclosed box (3) is sealed with a rubber ring.

6. The system for controlling the outlet flow rate of the feed hopper via an air cushion machine according to claim 1, characterized in that, The material information includes: The volumetric flow rate of the material is calculated based on the material type and the belt speed of the air cushion conveyor. The instantaneous flow rate of a material is calculated based on its volumetric flow rate and density. The cumulative flow of materials is calculated based on the instantaneous flow rate and the material handling time; The center of gravity of the material is statistically analyzed using a slicing method based on the obtained material shape, focusing on the offset of the center of gravity of the material on the air cushion conveyor belt surface from the center of the overall conveyor line.

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