Coal storage silo blockage removal device, blockage removal system and blockage removal method

Abstract

The present invention discloses a coal storage silo unblocking device, an unblocking system and an unblocking method. The coal storage silo of the unblocking device comprises a cylindrical upper silo and a frustum-shaped lower silo. A main shaft is provided in the lower silo. A plurality of circular links of different sizes are provided on the main shaft. The circular links are distributed from large to small from top to bottom. The circular links are connected to the main shaft through connecting rods. The circular links are connected to a plurality of fan blades. The fan blades are tilted and connected to the plurality of circular links distributed from top to bottom. The fan blades are connected to a connecting flying disc. The connecting flying disc has teeth on the outside. A transmission gear is provided outside the coal storage silo. The connecting flying disc is meshed with the transmission gear through teeth. The transmission gear is driven by a power device. The unblocking system comprises a monitoring system, a processing system, a control system and a rotation system. The unblocking system has an automatic adjustment function of the unblocking device by online monitoring of the coal falling flow rate in the silo. The system can work independently and issue early warning according to a digital model, thereby providing a system with short-stroke all-round cleaning and realizing cleaning without dead angles.

Description

Technical Field

[0001] The present invention relates to a coal silo unblocking device for cleaning the coal silo, belonging to the technical field of coal silo cleaning. The present invention also relates to an unblocking system and an unblocking method of the coal silo unblocking device. Background Art

[0002] Coal silos are widely used by coal companies and downstream enterprises due to their large storage capacity and simple structure. These cylindrical upper and conical lower structures, with a larger upper portion and a smaller lower portion, rely on the coal's own weight to flow, which is bound to cause blockage and poor coal flow. Especially in conditions of small coal particles, high humidity, and low temperature, the lower conical structure is prone to problems such as coal blockage, sticking to the wall, and frozen coal, which seriously restricts production and safe operations. Currently, coal silo blockages require manual inspection and cleaning, which is labor-intensive, slow, and inefficient. It is also difficult to accurately determine the time and location of the blockage, which can easily lead to further blockages, disrupting production activities, causing unplanned shutdowns, and even safety accidents.

[0003] Patent document with publication number CN112389880A discloses a coal storage silo cleaning device, which adopts several box-shaped frames, with a guide rail groove in the middle of the box-shaped frame, a slider in the guide rail groove, a scraper fixed on the slider, a pressure plate between the bottom end of the box-shaped frame and the slider, and a central control system cooperates with a hydraulic cylinder and a hydraulic hammer cylinder.

[0004] Patent document with publication number CN112605072A discloses a mechanical hammering device for dredging coal storage silos. At the coal outlet of the coal storage silo, a steel wire rope is passed through the box cover and the tower spring in sequence to be fixedly connected to the hammer head. The steel wire rope sleeve mounted on the steel wire rope passes through the tower spring to be fixedly connected to the C-shaped slider and is driven by an air cylinder or an oil cylinder. By hammering the steel plate, the frozen coal material stuck to the inner wall of the steel plate is directly shaken off, thereby quickly and effectively achieving the purpose of cleaning the frozen wall.

[0005] Patent document with publication number CN114148640A discloses a steel coal-breaking cone for a coal storage silo equipped with a ring feeder, which includes a radial steel frame, an annular steel frame, a steel plate, wear-resistant material, a cast steel diverter cone and embedded parts. The radial steel frame and the annular steel frame are evenly distributed and cross-welded to form a ribbed ring-type frustum-shaped steel frame. The cast steel diverter cone is welded or fixed to the top of the steel frame frustum by bolts. The steel plate is welded to the steel frame. Wear-resistant material is laid on the surface of the steel plate to form a coal-breaking cone. The coal-breaking cone is welded to the embedded parts embedded in the center column of the silo through the radial steel frame.

[0006] Patent document with publication number CN112537552A discloses a hydraulic hammering device for unblocking coal storage silos, wherein a box-shaped frame is fixedly installed on the inner side of the coal bunker funnel, a scraper is provided on the inner side of the box-shaped frame, and a hydraulic hammering cylinder connected to the scraper is provided on the side of the box-shaped frame, a fork is installed on the top of the hydraulic hammering cylinder, and the bottom of the hydraulic hammering cylinder is connected to the output end of the hydraulic cylinder; the first and second sliders are fixedly connected on the upper and lower sides of the scraper through a stop, and a long notch is provided on the pressure plate for the first and second sliders to slide up and down, and the protrusion of the first slider is inserted into the groove of the fork; a sensor assembly is provided on one side of the hydraulic cylinder and is fixed to the bottom of the box-shaped frame, which can directly act on the part of the silo most prone to coal loosening and freezing, and can hammer to break the ice to achieve rapid unblocking.

[0007] Although the device disclosed in the above patent document can achieve blockage relief, it cannot effectively predict coal silo blockage and issue early warnings, and cannot perform autonomous regulation based on different signals. In addition, it cannot effectively clean the location where blockage is most likely to occur at the junction of the upper and lower parts of the silo in the present invention. After multiple operations, the inner wall of the coal silo will be damaged, which seriously restricts its life and service life. In particular, most hammering devices are bound to threaten the stability of large storage equipment such as coal silos. Summary of the Invention

[0008] The purpose of the present invention is to provide a coal storage silo unblocking device, unblocking system and unblocking method, which adopts sensors to monitor the coal falling flow of the silo in real time, timely issue silo blockage warning and automatically control the intelligent adjustment system to unblock, effectively improving the inefficient work of manual inspection, manual unblocking and so on.

[0009] To achieve the above object, the technical solution of the present invention is:

[0010] A coal storage silo unblocking device, the coal storage silo includes a cylindrical upper silo and a frustum-shaped lower silo, a main shaft is provided in the lower silo, and a plurality of circular links of different sizes are provided on the main shaft, the circular links are distributed from large to small from top to bottom, the circular links are connected to the main shaft through connecting rods, the circular links are connected to a plurality of fan blades, the fan blades are placed at an angle, the fan blades are connected to a plurality of circular links distributed from top to bottom, the fan blades are connected to a connecting flying disc, the connecting flying disc has teeth on the outside, a transmission gear is provided on the outside of the coal storage silo, the connecting flying disc is engaged with the transmission gear through teeth, and the transmission gear is driven by a power device.

[0011] Specifically, the connecting flying disc is tapered and wide at the top and narrow at the bottom, and the thickness of the teeth of the connecting flying disc is greater than the thickness of the teeth of the transmission gear.

[0012] Preferably, the power device is a motor, and the fan blades are evenly distributed.

[0013] The coal storage silo is provided with two or more sets of transmission gears, with at least one set of transmission gears and the other sets of transmission gears being arranged on either side of the lower silo. When there are two sets of transmission gears, the two sets of transmission gears are symmetrically arranged on either side of the lower silo. The transmission gears are horizontally movable and are conical gears, with the teeth of the connecting disc being conical. When the transmission gears move horizontally inward (toward the rotation system), due to the conical gear structure, the transmission gears "compress" the connecting disc, driving the rotation system upward. When the transmission gears move horizontally outward, the transmission gears no longer "compress" the connecting disc, driving the rotation system downward. Specifically, the power unit is disposed on a rail, and the horizontal movement of the power unit on the rail enables horizontal movement of the transmission gear connected to the power unit. Movement of a power unit (such as a motor) on a rail is conventional technology and can be achieved by adopting conventional drive and movement schemes, which will not be elaborated on here.

[0014] The unblocking system of the coal storage silo unblocking device includes a monitoring system, a processing system, a control system and a rotation system, among which:

[0015] The monitoring system monitors the coal falling flow rate through sensors installed at the lower part of the lower silo and sends the sensor signals to the processing system; the sensors include ultrasonic sensors and infrared sensors, but are not limited to them.

[0016] The processing system counts the sensor data parameters under different coal falling conditions, establishes a digital model of coal falling, analyzes different databases under normal coal falling conditions and abnormal coal falling conditions, and forms an online monitoring and early warning model; receives the sensor signals of the monitoring system, analyzes and processes them in the digital model of coal falling, and issues alarms through the monitoring and early warning model, and issues control instructions to the control system.

[0017] The control system includes a power unit and a transmission gear. The processing system regulates the speed of the power unit of the control system and the distance between the lower silo and the transmission gear.

[0018] The rotating system includes a circular linkage, a main shaft, fan blades, a connecting disc and a connecting rod to achieve unblocking of the coal storage silo.

[0019] The blockage unblocking method of the blockage unblocking system comprises the following steps:

[0020] The first step is to install sensors at the bottom of the coal storage silo to monitor coal falling; set different parameters in the processing system, count the sensor data parameters under different coal falling conditions, establish a digital model of coal falling, analyze different databases under normal and abnormal coal falling conditions, and form an online monitoring and early warning model.

[0021] The second step is to analyze and process the data continuously transmitted from the monitoring system to the processing system. When any sensor data reaches the warning critical value, an early warning will be issued, and the processing system will issue instructions to the control system in a timely manner.

[0022] In the third step, based on the data model established in the first step and according to different silo blockage conditions, the speed of the power unit of the control system and the distance between the lower silo and the transmission gear are adjusted to achieve control of the rotation and horizontal movement of the rotating system.

[0023] In the fourth step, the transmission gear of the control system is engaged with the connecting disc of the rotation system through gears, and the up and down movement of the rotation system is achieved by controlling the distance between the lower silo and the transmission gear.

[0024] The fifth step is to compare the sensor data with the database. If the comparison result is normal coal falling, the alarm is cancelled.

[0025] Currently, coal silo blockages require manual inspections and cleaning, which are labor-intensive, slow to react, and inefficient. They are unable to accurately determine the time and location of blockages, which can easily lead to further blockages, disrupting production activities, causing unplanned shutdowns, and even safety accidents. In response to the inability of existing technologies to autonomously control and clean silo blockages, the data monitoring and early warning model and coal drop digital model of the present invention enable unmanned automated cleaning, capable of operating autonomously and issuing early warnings based on the digital model. Furthermore, existing cleaning devices have limited cleaning methods and cannot achieve full-range cleaning of the entire coal silo's lower coal drop location. The present invention provides a system with short-stroke, all-round cleaning capabilities, achieving cleanliness without blind spots.

[0026] Beneficial technical effects of the present invention:

[0027] (1) Online monitoring of the coal flow rate in the silo effectively improves the slow response and accident-proneness of manual inspections, and promptly curbs the further development of internal blockages, alleviating problems such as unplanned production stoppages caused by blockages and increased costs caused by replacing other raw materials.

[0028] (2) The automatic adjustment function of the unblocking device through online monitoring of the coal falling flow in the silo can effectively reduce the energy consumption of the unblocking device, achieve the needs of low energy and low consumption to ensure production, and comply with the national strategic policy of energy conservation and emission reduction.

[0029] (3) The conical integrated unblocking device has a large area, is easy to operate, and is suitable for any blockage location, especially for extreme conditions such as large frozen coal clumps, and does not affect normal coal production during maintenance and shutdown.

[0030] (4) The system realizes the unmanned automatic control function, effectively improves the efficiency of manual inspection, manual unblocking, etc., effectively reduces the labor intensity of workers and ensures construction safety, which is of great significance for the realization of intelligent unmanned factories. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] Figure 1 This is a schematic diagram of the installation of the coal silo unblocking device (the distance between the coal silo and the transmission gear is the farthest).

[0033] Figure 2 This is a schematic diagram of the installation of the coal silo unblocking device (the distance between the coal silo and the transmission gear is the shortest).

[0034] Figure 3 for Figure 1 Middle AA section view.

[0035] Figure 4 This is a schematic diagram of the congestion relief process of the congestion relief system. DETAILED DESCRIPTION

[0036] Coal storage silo unblocking device, such as Figure 1-3 As shown, the coal storage silo includes a cylindrical upper silo 7 and a frustum-shaped lower silo 6, a main shaft 4 is provided in the lower silo 6, and a number of circular links 3 of different sizes are provided on the main shaft 4, the circular links 3 are distributed from large to small from top to bottom, and the circular links 3 are connected to the main shaft 4 through a connecting rod 9, the circular links 3 are connected to a number of fan blades 5, the fan blades 5 are evenly distributed, the fan blades 5 are tilted, and the fan blades 5 are connected to a number of circular links 3 distributed from top to bottom, and the fan blades 5 are connected to a connecting flying disc 8, the connecting flying disc 8 has teeth on the outside, and the connecting flying disc 8 is a cone-shaped one that is wide at the top and narrow at the bottom. A transmission gear 2 is provided outside the coal storage silo, and the tooth thickness of the connecting flying disc 8 is greater than the tooth thickness of the transmission gear 2. The connecting flying disc 8 is engaged with the transmission gear 2 through teeth, and the transmission gear 2 is driven by a power device, and the power device is preferably a motor 1.

[0037] The circular joint 3, main shaft 4, fan blades 5, connecting disc 8, and connecting rod 9 are all welded and fixedly connected, wherein the main shaft 4 is arranged perpendicular to the center of the silo. The circular joint 3 and the connecting rod 9 are mainly used to fix the fan blades 5 to ensure stability under long-term coal gravity operation conditions. The circular joint 3 is arranged perpendicular to the main shaft 4 of the silo center ring to connect the fan blades 5. The circular joint 3 is connected to the main shaft 4 through the connecting rod 9 and is perpendicular to the main shaft. The fan blades 5 are arranged parallel to the inner wall of the lower part 6 of the silo, and a certain distance is reserved, generally 10mm. The outside of the connecting disc 8 is a bevel gear structure (wide at the top and narrow at the bottom), which is connected to the transmission gear 2 through the gear structure. The transmission gear 2 is also a bevel gear structure (narrow at the top and wide at the bottom). The connecting disc 8 links the entire rotating system Z4 through the fan blades 5. The width of the external gear of the connecting disc 8 is higher than the width of the transmission gear 2. The motor 1 is connected to the entire rotating system Z4 through the transmission gear 2 and drives it to move. As Figure 1-3 As shown, there are a total of 2 circular links 3, 1 main shaft 4, 4 fan blades 5 and 4 connecting rods 9.

[0038] Two sets of transmission gears 2 (not limited to two sets) are arranged outside the coal storage silo, and the two sets of transmission gears 2 are symmetrically arranged on both sides of the lower silo 6.

[0039] Described transmission gear 2 can be horizontally moved and is provided with, and specifically, power unit is arranged on bail, and described power unit horizontally moves on bail and realizes that the transmission gear 2 that is connected with power unit horizontally moves.Power unit (as motor) moves on bail and belongs to prior art, as long as adopting the drive mobile scheme of the prior art all can be realized, as rack is set on bail, power unit arranges gear, and gear is driven by stepping motor, and gear moves along rack like this, realizes that power unit, transmission gear move on bail.Simultaneously, described transmission gear 2 is a conical gear, and the tooth that is connected flying disc 8 is conical.When transmission gear 2 horizontally moves inward (to rotation system direction), due to conical gear structure, transmission gear 2 " extrudes " and connects flying disc 8, connects flying disc 8 and drives rotation system to move upward, and when transmission gear 2 horizontally moves to the outside, transmission gear 2 no longer " extrudes " and connects flying disc, connects flying disc 8 and drives rotation system to move downward.

[0040] The unblocking system of the coal storage silo unblocking device, such as Figure 4 As shown, it includes a monitoring system Z1, a processing system Z2, a control system Z3 and a rotation system Z4, wherein:

[0041] Monitoring system Z1 utilizes sensors installed beneath the lower silo, including, but not limited to, ultrasonic and infrared sensors. To ensure data accuracy during unmanned inspections, a variety of sensors can be selected to ensure detection accuracy. These sensors monitor the coal flow rate and transmit sensor signals to the processing system.

[0042] Processing system Z2 collects sensor data parameters for different coal-dropping scenarios, builds a digital coal-dropping model, analyzes different databases for normal and abnormal coal-dropping scenarios, and forms an online monitoring and early warning model. It receives sensor signals from the monitoring system, analyzes and processes them within the digital coal-dropping model, and issues alarms through the monitoring and early warning model, issuing control instructions to the control system. If a silo blockage or other condition occurs, the processing system issues a timely warning. To ensure on-site safety, an alarm is triggered if any sensor reaches a critical warning value.

[0043] The control system Z3 includes a power unit and a transmission gear 2. The processing system regulates the speed of the power unit of the control system and the distance between the lower silo and the transmission gear 2.

[0044] The rotating system Z4 includes a circular linkage 3, a main shaft 4, fan blades 5, a connecting disc 8 and a connecting rod 9, which realizes the unblocking of the coal storage silo.

[0045] The blockage unblocking method of the blockage unblocking system comprises the following steps:

[0046] The first step is to install sensors at the bottom of the coal storage silo (such as silo 6 below) to monitor coal falling; set different parameters in the processing system Z2, count the sensor data parameters under different coal falling conditions, establish a digital model of coal falling, analyze different databases under normal coal falling conditions and abnormal coal falling conditions, and form an online monitoring and early warning model.

[0047] The second step is to analyze and process the data continuously transmitted from the monitoring system Z1 to the processing system. When any sensor data reaches the warning critical value, an early warning is issued, and the processing system Z2 issues instructions to the control system in a timely manner.

[0048] In the third step, based on the data model established in the first step and according to different silo blockage conditions, the speed of the power device of the control system Z3 and the distance between the lower silo 6 and the transmission gear 2 are adjusted to achieve control of the rotation and horizontal movement of the rotation system Z4.

[0049] In the fourth step, the transmission gear of the control system Z3 is engaged with the connecting disc 8 of the rotation system Z4 through gears, and the up and down movement of the rotation system Z4 is achieved by controlling the distance between the lower silo 6 and the transmission gear 2.

[0050] The fifth step is to compare the sensor data with the database. If the comparison result is normal coal falling, the alarm is cancelled.

[0051] Repeat the above five steps continuously to achieve real-time monitoring and cleaning of the coal silo.

[0052] The above embodiments do not limit the present invention in any way, and any technical solutions obtained by equivalent replacement or equivalent transformation fall within the protection scope of the present invention.

Claims

1. A coal silo unblocking device, wherein the coal silo comprises a cylindrical upper silo and a frustum-shaped lower silo, characterized in that: A main shaft is provided in the lower silo, and a plurality of circular links of different sizes are provided on the main shaft, and the circular links are distributed from large to small from top to bottom, and the circular links are connected to the main shaft through a connecting rod, and the circular links are connected to a plurality of fan blades, and the fan blades are placed obliquely, and the fan blades are connected to the plurality of circular links distributed from top to bottom, and the fan blades are connected to a connecting disc, and the connecting disc has teeth on the outside, and a transmission gear is provided on the outside of the coal storage silo, and the connecting disc is engaged with the transmission gear through teeth, and the transmission gear is driven by a power device; The connecting flying disc is tapered and wide at the top and narrow at the bottom; The coal storage silo is provided with two or more sets of transmission gears, at least one set of transmission gears and the other sets of transmission gears are respectively arranged on both sides of the lower silo; when there are two sets of transmission gears, the two sets of transmission gears are symmetrically arranged on both sides of the lower silo; The transmission gear can be arranged to move horizontally, the transmission gear is a conical gear, and the teeth connected to the flying disc are conical; The power device is arranged on the rail, and the power device moves horizontally on the rail to realize the horizontal movement of the transmission gear connected with the power device.

2. The coal storage silo blockage removal device according to claim 1, characterized in that: The thickness of the teeth of the connecting flying disc is greater than the thickness of the teeth of the transmission gear.

3. The coal storage silo blockage removal device according to claim 1, characterized in that: The power device is an electric motor.

4. The coal storage silo blockage removal device according to claim 1, characterized in that: The fan blades are evenly distributed.

5. The blockage clearing system of the coal storage silo blockage clearing device according to any one of claims 1 to 4, characterized in that It includes monitoring system, processing system, control system and rotation system, among which: The monitoring system monitors the coal flow rate through sensors installed at the bottom of the lower silo and sends sensor signals to the processing system; the sensors include ultrasonic sensors and infrared sensors; The processing system counts the sensor data parameters under different coal-dropping conditions, establishes a digital model of coal-dropping, analyzes different databases under normal and abnormal coal-dropping conditions, and forms an online monitoring and early warning model; receives sensor signals from the monitoring system, analyzes and processes them in the digital model of coal-dropping, and issues alarms through the monitoring and early warning model, and issues control instructions to the control system; the control system includes a power unit and a transmission gear, and the processing system controls the speed of the power unit of the control system and the distance between the lower silo and the transmission gear; the rotation system includes a circular linkage, a main shaft, fan blades, a connecting flying disc and a connecting rod to realize the unblocking of the coal storage silo.

6. The method for clearing a blockage according to claim 5, characterized in that The following steps are involved: The first step is to install sensors under the coal storage silo to monitor coal falling. Different parameters are set in the processing system to collect sensor data parameters under different coal falling conditions, establish a digital model of coal falling, analyze different databases of normal and abnormal coal falling conditions, and form an online monitoring and early warning model. The second step is to analyze and process the data continuously transmitted from the monitoring system to the processing system. If any sensor data reaches the warning threshold, an early warning will be issued, and the processing system will promptly issue instructions to the control system. In the third step, the data model established in the first step is used to adjust the speed of the control system's power unit and the distance between the lower silo and the transmission gear according to different silo blockage conditions, thereby achieving control over the rotation and horizontal movement of the rotation system. In the fourth step, the transmission gear of the control system is engaged with the connecting disc of the rotation system through gears, and the up and down movement of the rotation system is achieved by controlling the distance between the lower silo and the transmission gear; The fifth step is to compare the sensor data with the database. If the comparison result is normal coal falling, the alarm is cancelled.

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