A train carriage residual coal cleaning device, control method and system

Abstract

The present disclosure provides a train carriage residual coal cleaning device, a control method and a system, the scheme comprising: collecting carriage image information in a preset cleaning area, determining the position information of the carriage to be cleaned in the cleaning area based on the image information; when the cleaning condition is met, according to the position information, controlling the cleaning device to reach the inside bottom of the carriage to be cleaned; obtaining the position information of the front and rear of the carriage to be cleaned where the cleaning device is located, and then determining the parking state of the carriage in the cleaning area; wherein the parking state includes parking a complete carriage and only parking two half carriages; based on the parking state of the carriage, residual coal cleaning is carried out according to the corresponding strategy.

Description

Technical Field

[0001] This disclosure belongs to the field of railway car coal cleaning technology, and particularly relates to a railway car coal cleaning device, control method and system. Background Technology

[0002] The statements in this section are merely background information relating to this disclosure and do not necessarily constitute prior art.

[0003] Coal-fired power plants are facing tight coal supplies, high coal prices, and stringent energy-saving targets. "Environmental protection requirements are urgent, and under the new circumstances, there is an urgent need for power plants to quickly achieve intelligent control in terms of safety, environmental protection, and energy conservation in all aspects."

[0004] Coal-fired power plants typically use tippers to unload coal from railcars. Tippers are large, efficient, and highly automated mechanized devices capable of automating unloading operations. However, because the tipping angle is generally only around 160°, and the pressure beams obstruct the railcars, coupled with coal adhesion in some railcars, a certain amount of residual coal remains in the railcars after unloading—ranging from tens to 100-200 kg. If this is not cleaned, the coal loss can amount to 14.6 million yuan annually. Furthermore, residual coal significantly impacts energy consumption during empty railcar transport, failing to meet the requirements of the railway transport system. Railway authorities will not release railcars with unremoved residual coal. Therefore, secondary cleaning of the residual coal in the railcars is necessary.

[0005] Currently, most coal-fired power plants use manual cleaning to remove residual coal from the car bodies. A small number of plants use cleaning methods such as high-pressure water jets and electromagnetic vibrations, but these methods are relatively complex to operate and control, and have shortcomings in terms of cleaning efficiency, repeatability, and safety, resulting in poor cleaning effects. In particular, these solutions are not well adapted to situations where the car bodies are not in fixed locations. Summary of the Invention

[0006] To address the aforementioned problems, this disclosure provides a coal cleaning device, control method, and system for train carriages. The solution effectively reduces safety risks for workers, improves the working environment, reduces labor intensity, and increases work efficiency. Simultaneously, it enhances the automation level of the coal unloading production line, reduces the failure rate, and effectively ensures the safe and stable operation of the system. This is of great significance in effectively solving the problems of long cleaning times and high intensity of cleaning frozen coal in winter and sticky coal during the rainy season, laying the foundation for further unmanned and automated operation of the tippler coal unloading system.

[0007] According to a first aspect of the present disclosure, a coal cleaning device for train carriages is provided, comprising: a mobile trolley and a cleaning device; the mobile trolley is based on a bridge crane structure and can realize movement along three axes: X-axis, Y-axis and Z-axis; the cleaning device includes a perimeter cleaning mechanism, a floor cleaning mechanism, a coal collection mechanism, a reciprocating mechanism and an unloading mechanism;

[0008] The mobile trolley is located on two supports parallel to the empty car track of the tipper within the cleaning area. The cleaning device is installed at the end of the Z-axis of the mobile trolley. The bottom cleaning mechanism is installed on the left and right sides of the bottom of the cleaning device to clean the residual coal at the bottom of the car and collect it in the middle. The residual coal collection mechanism is installed in the middle of the cleaning device, with its actuator end installed in the middle of the bottom of the cleaning device to collect the residual coal into the collection box of the residual coal collection mechanism. The unloading mechanism is installed at the bottom of the collection box of the residual coal collection mechanism to unload the collected residual coal when it is full. The reciprocating mechanism is installed on the front and rear sides of the cleaning device to drive the car perimeter cleaning mechanism to reciprocate. The car perimeter cleaning mechanism is installed on the motion actuator of the reciprocating mechanism to clean the inner wall of the car.

[0009] Furthermore, the bottom of the cleaning device is equipped with guide wheels, and the guide wheels are connected to the cleaning device by a pressure-adjustable spring structure to adapt to the unevenness of the train undercarriage, and to guide and support the cleaning device.

[0010] Furthermore, the main body of the reciprocating mechanism is a screw-slide structure, the motion actuator of the reciprocating mechanism is a slide, and the slide is connected to the vehicle perimeter cleaning mechanism through a pressure-adjustable spring structure to adapt to different widths of the vehicle compartment and to adjust the pressure on the inner wall of the vehicle compartment.

[0011] Furthermore, the main body of the vehicle perimeter cleaning mechanism is a unidirectional spiral brush, which, by controlling its direction, sweeps the remaining coal on the inner wall of the vehicle downwards.

[0012] According to a second aspect of the present disclosure, a method for controlling the cleaning of residual coal in train carriages is provided, comprising:

[0013] Collect image information of the carriages within a preset cleaning area, and determine the location information of the carriages to be cleaned within the cleaning area based on the image information;

[0014] When the cleaning conditions are met, the cleaning device is controlled to reach the bottom of the inner side of the compartment to be cleaned, based on the location information.

[0015] The location information of the front and rear of the carriage to be cleaned by the cleaning device is obtained, and then the parking status of the carriage in the cleaning area is determined; wherein, the parking status includes parking one complete carriage and parking only two half carriages.

[0016] When the car is parked with one complete car, and neither the car in front nor behind the current car meets the cleaning conditions, the cleaning mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front of the car, and then from the front of the car to the rear of the car. After cleaning one car, the cleaning device is lifted to wait for the next car to be cleaned to enter the cleaning area.

[0017] When the car is parked with only two and a half cars, the remaining coal in the two and a half cars is cleaned in sequence, and then the cleaning device is lifted to wait for the next car to be cleaned to enter the cleaning area.

[0018] Furthermore, the step of obtaining the position information of the front and rear of the carriage to be cleaned by the cleaning device specifically involves: obtaining the distance information of the cleaning device to the front and rear of the carriage based on the distance sensors set on the front and rear sides of the cleaning device; and obtaining the position coordinates of the front and rear of the carriage based on the distance information and the position information of the cleaning device.

[0019] Furthermore, determining the parking status of the carriages within the cleaning area specifically involves: based on the position information of the front and rear of the carriage to be cleaned, when both positions are within the cleaning area, the parking status is that one complete carriage is parked; when either position is outside the cleaning area, the parking status is that only two half carriages are parked.

[0020] Furthermore, the cleaning condition is met specifically when the residual coal cleaning permission signal is received from the air conditioning unit of the tippler system;

[0021] Furthermore, when the car is parked in a state where one complete car is parked, and any one of the cleaning conditions of the two cars before and after the current car is met, after the cleaning of the current car is completed, the remaining coal in the cleaning area of ​​the adjacent car that meets the cleaning conditions is cleaned.

[0022] or,

[0023] When the car is parked in a state where there is one complete car and the cleaning conditions of the two cars in front of and behind the current car are met, after the cleaning of the current car is completed, the remaining coal in the cleaning areas of the two adjacent cars will be cleaned in sequence.

[0024] Furthermore, the sequential cleaning of residual coal in two and a half carriages is specifically performed as follows: after cleaning the residual coal in the current carriage's cleaning area, the cleaning device is raised; and according to the direction of the next carriage that meets the cleaning conditions relative to the current carriage, the cleaning device is controlled to reach the limit position in the current direction; the cleaning device is controlled to reach the bottom of the carriage, the sweeping mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front or rear of the carriage to achieve residual coal cleaning;

[0025] Alternatively, the cleaning device is connected to a horizontally suspended trolley via pulleys and wire ropes, and the horizontal movement of the cleaning device is achieved by the horizontal movement of the trolley; the vertical movement of the cleaning device is achieved by the control of the wire ropes and pulleys.

[0026] Furthermore, the acquisition of carriage image information within the preset cleaning area is achieved by using industrial cameras installed in the cleaning area. Multiple industrial cameras are installed to achieve complete coverage of the entire cleaning area.

[0027] According to a third aspect of the present disclosure, a train car residual coal cleaning control system is provided, comprising:

[0028] A data acquisition unit is used to acquire image information of the carriages within a preset cleaning area, and to determine the location information of the carriages to be cleaned within the cleaning area based on the image information.

[0029] The parking status determination unit is used to control the cleaning device to reach the bottom of the inner side of the carriage to be cleaned according to the location information when the cleaning conditions are met; to obtain the location information of the front and rear of the carriage to be cleaned where the cleaning device is located, and then to determine the parking status of the carriage in the cleaning area; wherein, the parking status includes parking one complete carriage and parking only two half carriages.

[0030] The residual coal cleaning unit is used when the car is parked with one complete car and the cleaning conditions for cleaning are not met, by activating the cleaning mechanism located at the bottom and around the cleaning device, controlling the cleaning device to move to the front of the car, and then from the front to the rear of the car, completing the cleaning of one car, and then lifting the cleaning device to wait for the next car to be cleaned to enter the cleaning area; when the car is parked with only two half cars, the residual coal is cleaned in sequence for the two half cars, and then the cleaning device is lifted to wait for the next car to be cleaned to enter the cleaning area.

[0031] According to a fourth aspect of the present disclosure, an electronic device is provided, including a memory, a processor, and a computer program stored in the memory and running on the memory, wherein the processor executes the program to implement the aforementioned method for controlling the cleaning of residual coal in train carriages.

[0032] According to a fifth aspect of the present disclosure, a non-transitory computer-readable storage medium is provided, on which a computer program is stored, which, when executed by a processor, implements the aforementioned method for controlling the cleaning of residual coal in train carriages.

[0033] Compared with the prior art, the beneficial effects of this disclosure are:

[0034] (1) The present disclosure provides a coal cleaning device, control method and system for train carriages. The solution effectively reduces the safety risks of workers, improves the working environment, reduces the labor intensity of workers and improves work efficiency. At the same time, it improves the automatic control level of the coal unloading production line, reduces the failure rate, and effectively ensures the safe and stable operation of the system. It is of great significance to effectively solve the problem of long time and high intensity of cleaning frozen coal in winter and sticky coal in the plum rain season, and lays the foundation for further unmanned and automated unloading of tipper coal unloading system.

[0035] (2) The proposed solution fully considers that there are various types of carriages in the coal train. The length, width and height of each type of carriage are different. However, since the air conditioner of the tipper system pushes the carriage to a fixed position each time, there will be two half empty carriages in the residual coal cleaning area. Therefore, by pre-judging the parking status of the carriages in the cleaning area, different cleaning strategies are executed based on different parking statuses, which effectively improves the robustness of the proposed solution.

[0036] Advantages of this disclosure in additional aspects will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this disclosure. Attached Figure Description

[0037] The accompanying drawings, which form part of this disclosure, are used to provide a further understanding of this disclosure. The illustrative embodiments of this disclosure and their descriptions are used to explain this disclosure and do not constitute an undue limitation of this disclosure.

[0038] Figure 1 This is a simplified diagram of the mechanical structure used in the train car residual coal cleaning and control method described in this embodiment of the present disclosure;

[0039] Figure 2 This is a schematic diagram of a complete carriage within the cleaning area described in this embodiment of the disclosure;

[0040] Figure 3 This is a schematic diagram of the two empty carriages in the clearing area described in this embodiment of the disclosure;

[0041] Figure 4 This is a block diagram of the hardware structure used in the train car residual coal cleaning control method described in the embodiments of this disclosure;

[0042] Figure 5 This is a flowchart of the method for controlling the cleaning of residual coal in train carriages as described in the embodiments of this disclosure;

[0043] Figure 6 This is a flowchart of a method for controlling the cleaning of residual coal in train carriages as described in this embodiment of the present disclosure;

[0044] Figure 7 This is a flowchart of a second method for controlling the cleaning of residual coal in train carriages, as described in this embodiment of the present disclosure.

[0045] Figure 8 This is a flowchart of a method for controlling residual coal cleaning in train carriages as described in this embodiment;

[0046] Among them, 1. Limit switch, 2. Moving trolley, 3. Laser rangefinder sensor, 4. Reciprocating mechanism, 5. Spring structure, 6. Around-the-car cleaning mechanism, 7. Guide wheel and spring structure, 8. Cleaning device parking area, 9. Rail, 10. Under-car cleaning mechanism, 11. Unloading mechanism, 12. Collection box, 13. Residual coal collection mechanism, 14. Encoder, 15. Wire rope, 16. Fixed pulley, 17. Carriage hook, 18. Empty carriage No. 1, 19. Wheel, 20. Cleaning area, 21. Empty carriage No. 2, 22. Empty carriage No. 3, 23. Industrial camera No. 2, 24. Industrial camera No. 1. Detailed Implementation

[0047] The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

[0048] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0049] 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 exemplary embodiments according to this disclosure. 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.

[0050] Where there is no conflict, the embodiments and features described herein can be combined with each other.

[0051] Terminology explanation;

[0052] Tippler: A tippler is a large mechanical device used to unload bulk materials from open railway wagons. It can tilt or tilt rail vehicles to unload materials.

[0053] Air Conditioner: The full name of the air conditioner is empty car shunting machine. It is a shunting equipment in the tippler operation line. It is used to work with the car transfer platform in the tippler system. After the car transfer platform carries the unloaded cars and aligns them with the empty car line, the air conditioner pushes the empty cars out and assembles them into a line on the empty car line.

[0054] Example 1:

[0055] The purpose of this embodiment is to provide a device for cleaning residual coal in train carriages.

[0056] A device for cleaning residual coal in train carriages, comprising:

[0057] A cleaning area is set up along the empty car track of the tippler; within the cleaning area, a coal cleaning device for train cars is installed; the coal cleaning device for train cars includes a moving trolley and a cleaning device; the moving trolley is based on a bridge crane structure and can realize the movement of three axes: X-axis, Y-axis and Z-axis; the cleaning device includes a car perimeter cleaning mechanism, a car bottom cleaning mechanism, a coal collection mechanism, a reciprocating mechanism and a unloading mechanism;

[0058] The mobile trolley is installed on two supports parallel to the empty car track of the tipper within the cleaning area, and moves along the track on the supports in the X-axis direction, moves along the bridge of the mobile trolley in the Y-axis direction, and takes the direction perpendicular to the ground as the Z-axis direction of movement.

[0059] The cleaning device is installed at the end of the Z-axis of the mobile trolley; the undercarriage cleaning mechanism is installed on the left and right sides of the bottom of the cleaning device, used to clean the residual coal at the bottom of the carriage and collect the residual coal in the middle position; the residual coal collection mechanism is installed in the middle of the cleaning device, and its actuator end is installed in the middle position of the bottom of the cleaning device, used to collect the residual coal into the collection box of the residual coal collection mechanism; the unloading mechanism is installed at the bottom of the collection box of the residual coal collection mechanism, used to unload the collected residual coal when the box is full; the reciprocating mechanism is installed on the front and rear sides of the cleaning device, used to drive the circumferential cleaning mechanism to perform reciprocating motion; the circumferential cleaning mechanism is installed on the motion actuator of the reciprocating mechanism, used to clean the inner wall of the carriage.

[0060] In practice, the bottom of the cleaning device is equipped with guide wheels, and the guide wheels are connected to the cleaning device by a pressure-adjustable spring structure to adapt to the unevenness of the train undercarriage and to guide and support the cleaning device.

[0061] In specific implementation, the main body of the reciprocating mechanism is a screw slide structure, the motion actuator of the reciprocating mechanism is a slide, and the slide is connected to the vehicle perimeter cleaning mechanism through a pressure-adjustable spring structure to adapt to different widths of the carriage and to adjust the pressure on the inner wall of the carriage.

[0062] In practice, the main body of the vehicle perimeter cleaning mechanism is a unidirectional spiral brush. By controlling its direction, the residual coal on the inner wall of the vehicle is swept downwards.

[0063] For ease of understanding, the following detailed description of the solution in this embodiment is provided in conjunction with the accompanying drawings:

[0064] Figure 1 This is a simplified mechanical structure diagram of a train carriage residual coal cleaning control scheme described in this embodiment. The mobile trolley includes three axes: X, Y, and Z. The trolley can move in the X, Y, and Z directions, and limit switches are installed at the extreme positions of each axis. The X-axis moves along the supports on both sides of the cleaning area via a rack and pinion drive; the Y-axis moves along the trolley bridge via a rack and pinion drive; and the Z-axis suspends the cleaning device for vertical movement via a wire rope and fixed pulley. The cleaning device mainly includes a perimeter cleaning mechanism, a floor cleaning mechanism, a residual coal collection mechanism, a reciprocating mechanism, and an unloading mechanism. The vehicle perimeter cleaning mechanism uses a unidirectional spiral brush structure to effectively sweep residual coal downwards; the vehicle bottom cleaning mechanism uses a brush structure to effectively sweep residual coal towards the center, facilitating collection by the residual coal collection mechanism; the residual coal collection mechanism uses a negative pressure adsorption device to effectively collect straw, foam, woven bags, and other debris while collecting residual coal; the reciprocating mechanism uses a screw-slide structure, with an adjustable pressure spring connecting the slide to the vehicle perimeter cleaning mechanism, effectively adapting to different widths of the vehicle body; the unloading mechanism is installed at the bottom of the collection box of the residual coal collection mechanism, effectively unloading the collected residual coal; the bottom of the cleaning device is equipped with guide wheels and an adjustable pressure spring structure, effectively adapting to uneven conditions at the bottom of the vehicle body; laser rangefinders are installed on the front and rear sides of the cleaning device, X and Y axis encoders are installed on the wheel axles, and the Z axis encoder is installed on the wire rope winch shaft.

[0065] Example 2:

[0066] The purpose of this embodiment is to provide a method for controlling the cleaning of residual coal in train carriages.

[0067] A method for controlling residual coal cleaning in train carriages includes:

[0068] Collect image information of the carriages within a preset cleaning area, and determine the location information of the carriages to be cleaned within the cleaning area based on the image information;

[0069] When the cleaning conditions are met, the cleaning device is controlled to reach the bottom of the inner side of the compartment to be cleaned, based on the location information.

[0070] The location information of the front and rear of the carriage to be cleaned by the cleaning device is obtained, and then the parking status of the carriage in the cleaning area is determined; wherein, the parking status includes parking one complete carriage and parking only two half carriages.

[0071] When the car is parked with one complete car, and neither the car in front nor behind the current car meets the cleaning conditions, the cleaning mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front of the car, and then from the front of the car to the rear of the car. After cleaning one car, the cleaning device is lifted to wait for the next car to be cleaned to enter the cleaning area.

[0072] When the car is parked with only two and a half cars, the remaining coal in the two and a half cars is cleaned in sequence, and then the cleaning device is lifted to wait for the subsequent cars to be cleaned to enter the cleaning area.

[0073] In specific implementation, obtaining the position information of the front and rear of the carriage to be cleaned by the cleaning device involves: obtaining the distance information of the cleaning device to the front and rear of the carriage based on the distance sensors set on the front and rear sides of the cleaning device; and obtaining the position coordinates of the front and rear of the carriage based on the distance information and the position information of the cleaning device.

[0074] In specific implementation, determining the parking status of the carriages within the cleaning area is as follows: based on the position information of the front and rear of the carriage to be cleaned, when both position information is within the cleaning area, the parking status is that one complete carriage is parked; when either position information is outside the cleaning area, the parking status is that only two half carriages are parked.

[0075] In specific implementation, the cleaning condition is met when the residual coal cleaning permission signal of the tippler system air conditioner is received;

[0076] In specific implementation, when the car is parked in a state where there is a complete car, and any one of the cleaning conditions of the two cars in front of and behind the current car is met, after the cleaning of the current car is completed, the remaining coal in the cleaning area of ​​the adjacent car that meets the cleaning conditions is cleaned.

[0077] When the car is parked in a state where there is one complete car and the cleaning conditions of the two cars in front of and behind the current car are met, after the cleaning of the current car is completed, the remaining coal in the cleaning areas of the two adjacent cars will be cleaned in sequence.

[0078] The process of sequentially cleaning the remaining coal in two and a half car carriages is as follows: after cleaning the remaining coal in the current car carriage area, the cleaning device is raised; and according to the direction of the next car carriage that meets the cleaning conditions relative to the current car carriage, the cleaning device is controlled to reach the limit position in the current direction; the cleaning device is controlled to reach the bottom of the car carriage, the sweeping mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front or rear of the car carriage to achieve the cleaning of the remaining coal.

[0079] In specific implementation, the cleaning device is connected to a horizontally suspended mobile trolley via pulleys and steel wire ropes. The horizontal movement of the cleaning device is achieved by the horizontal movement of the mobile trolley. The vertical movement of the cleaning device is achieved by the control of the steel wire ropes and pulleys. The acquisition of the carriage image information within the preset cleaning area is achieved by the acquisition of images through industrial cameras installed in the cleaning area. Multiple industrial cameras are installed to achieve complete coverage of the entire cleaning area.

[0080] For ease of understanding, the following detailed description of the solution in this embodiment is provided in conjunction with the accompanying drawings:

[0081] like Figure 4 As shown, the hardware implementation of the method in this embodiment includes an industrial control computer, a switch, a programmable logic controller (PLC), a vision system, a data acquisition module, a control module, and a database. The industrial camera and monitoring camera of the vision system, the PLC, and the switch are connected via network cables, and the switch and the industrial control computer transmit data via network cables. The industrial camera transmits the acquired images of the car number to the industrial control computer for number recognition and displays the recognized car model and the location coordinates of the positioned car on the host computer interface. The monitoring camera is used to monitor the movement of the mobile trolley and the cleaning status of the cleaning device in real time. The data acquisition module mainly includes a tension sensor, a laser rangefinder, a proximity switch, a limit switch, a rotary paddle level switch, and an encoder. The data acquisition module is directly connected to the PLC, or connected to an analog input module, or a remote control module. The control module includes the X, Y, and Z axis frequency converters of the mobile trolley and the frequency converters of the cleaning device's perimeter cleaning mechanism, bottom cleaning mechanism, and residual coal collection mechanism, as well as contactors for the reciprocating mechanism and unloading mechanism. The PLC controls the actions of the residual coal cleaning control system of the car through instructions. The data acquisition module transmits the collected sensor information to the programmable logic controller (PLC). The PLC processes the sensor information and transmits the processed information to the host computer software in the industrial control computer. The information can also be displayed through a display device. The database is used to store information about the coal cleaning system in the car body, mainly including system alarm log table, system anomaly log table, service log table, data read / write table, and vehicle model information table.

[0082] Figure 2 This is a schematic diagram of the parking status of a complete train carriage within the cleaning area of ​​one embodiment. The diagram shows the parking position of the empty carriages within the cleaning area and the installation position of the industrial cameras. In the diagram, empty carriage No. 2 is completely within the cleaning area, while empty carriages No. 1 and No. 3 are partially within the cleaning area. Since the cleaning area is large, the field of view of one industrial camera cannot cover the entire cleaning area, so two industrial cameras are needed to identify the carriage numbers.

[0083] Figure 3 This is a schematic diagram of a train car cleaning area where only two and a half carriages are in the cleaning area in one embodiment. The diagram shows that empty carriages 1 and 2 are in the cleaning area, while empty carriage 3 is not. In this case, the distance from the cleaning device to the front and rear of the carriages needs to be measured by a laser rangefinder sensor. After data calculation, it is determined whether carriages 1 and 2 meet the cleaning conditions.

[0084] Figure 5 This is an overall flowchart of the specific implementation of the train carriage residual coal cleaning control method described in this embodiment. In this embodiment, before starting the operation, the local / remote mode is selected as needed. If the local mode is selected, it is necessary to operate on-site. Turn on the corresponding switch on the electrical cabinet to control the forward or backward movement of the X-axis of the moving trolley, the forward and backward movement of the Y-axis of the moving trolley, the upward or downward movement of the Z-axis of the moving trolley, the forward or reverse rotation of the circumferential cleaning mechanism, the forward or reverse rotation of the undercarriage cleaning mechanism, the operation or stop of the residual coal collection mechanism, the forward or reverse rotation of the reciprocating mechanism, and the operation or stop of the unloading mechanism. If remote mode is selected, you need to log in to the host computer software and select remote manual mode / remote automatic mode on the host computer interface. The functions of remote manual mode are the same as local mode, both are manual operation. If you enter automatic mode, you need to click the initialization button first to raise the cleaning device from the parking position to the safe height. At this time, the coal cleaning system and tipper system are interlocked. The coal cleaning system can only operate when the tipper system's air conditioner gives an allow signal. If this condition is not met, the coal cleaning system will not be allowed to operate. When the condition is met, click the identification and positioning button, and then industrial cameras 1 and 2 will transmit the captured images of the car number to the industrial control computer. The host computer software on the industrial control computer will then call up the captured images. Image recognition and positioning: If industrial camera 1 captures an image of the carriage number and successfully identifies and positions it, then there is no need to identify the image captured by industrial camera 2; otherwise, the image captured by industrial camera 2 needs to be used for number identification and carriage position positioning; if neither industrial camera 1 nor industrial camera 2 successfully identifies the carriage, manual intervention is required. Manually control the X-axis of the moving trolley to move it to a position where the cleaning device can be lowered into the carriage, then click the start button to automatically clean the remaining coal in the carriage. After cleaning is completed, the air conditioner pushes the next empty carriage into the cleaning area, and the above actions are repeated until all carriages of the train are cleaned. After completion, the cleaning device is placed in the parking position.

[0085] Preferably, when the mobile trolley is moving, the on-site audible and visual alarm will sound an alarm to warn personnel to stay away from the cleaning area and ensure the personal safety of the staff; when the system alarms, the host computer interface of the industrial control computer will display alarm information, prompting the operator to indicate that there is an abnormality in the system and the cause, and to press the emergency stop button in time to ensure safety.

[0086] Preferably, since a coal train contains various types of carriages, each with different length, width, and height information, and since the air conditioning unit of the tipper system pushes the carriage to a fixed position each time, this results in two empty half-carriages appearing in the residual coal cleaning area. The solution described in this embodiment fully considers this situation. For cleaning the two empty half-carriages, a laser rangefinder is used to measure the distance between the front and rear of the carriage. Then, combined with information such as the current position of the moving trolley's X-axis, the travel distance of the moving trolley's X-axis, the length of the cleaning device in the X-axis direction of the moving trolley, and the distance between the two carriages, calculations are performed to determine whether the cleaning device can be placed in the front half or the rear half of the carriage, thereby determining whether the conditions for cleaning the front half or the rear half of the carriage are met.

[0087] Figure 6 This is a flowchart of the first control method in automatic mode of the train carriage residual coal cleaning control method described in this embodiment. This process mainly focuses on a complete carriage within the cleaning area, such as... Figure 2 The specific steps are as follows: (The text abruptly ends here, likely due to an incomplete sentence or a formatting error.)

[0088] Upon entering the host computer system, the programmable logic controller (PLC) will first automatically initialize the program, detect any abnormal information in the system, and perform maintenance or debugging as needed. When entering remote automatic mode, the initialization button needs to be clicked to raise the cleaning device from its parking position to a position higher than the car body. At this time, the car body coal cleaning system and the tipper system are interlocked for protection. After the tipper system's air conditioner pushes the empty car body to the cleaning area, it waits for the air conditioner's permission signal. When the cleaning conditions are met, the identification and positioning button is clicked, and industrial cameras 1 and 2 transmit the images of the car body numbers captured to the industrial control computer. The host computer software on the industrial control computer then calls up the captured images for further processing. For identification and positioning, if industrial camera 1 captures an image of the carriage number and successfully identifies and positions it, there's no need to use the image from industrial camera 2; otherwise, the image from industrial camera 2 must be used for number identification and carriage positioning. If neither industrial camera 1 nor industrial camera 2 succeeds in identification, the failed images are saved on the industrial control computer for operator review. Based on the identification results, targeted training on carriage numbering can be conducted. Additionally, manual intervention is required for identification and positioning failures. The X-axis of the mobile trolley is moved to a position where the cleaning device can be lowered into the carriage, and the current X-axis coordinates are written to the programmable controller. Clicking the start button controls the X, Y, and Z axes of the mobile trolley to move to the bottom of the carriage. The laser rangefinder of the cleaning device measures the distance, performs numerical calculations, and obtains the position coordinates of the front and rear of the carriage, determining the carriage's parking position. Figure 2 still Figure 3 If the air conditioner malfunctions during the cleaning process, causing the signal for the residual coal cleaning system to be unavailable, the system will issue an alarm. The Z-axis of the moving trolley will then raise the cleaning device to a safe height to prevent accidents. Additionally, if the rotary paddle level switch on the collection box detects that it is full during the cleaning process, the moving trolley will control its X, Y, and Z axes to move to the unloading position, activate the unloading mechanism, execute the unloading procedure, and after unloading, raise it to a safe height before re-performing the identification and positioning processes.

[0089] Preferably, this occurs when empty car number 2 is completely within the cleaning area, and empty cars number 1 and 3 do not meet the cleaning conditions. First, the frequency converters of the cleaning device's perimeter cleaning mechanism, undercarriage cleaning mechanism, and residual coal collection mechanism are activated. Based on numerical calculations, the front and rear position coordinates of empty car No. 2 are obtained. Then, the X-axis of the moving trolley moves to the front of the car. During this movement, the perimeter cleaning mechanism and undercarriage cleaning mechanism clean the residual coal around the car and the bottom of the car, while the residual coal collection mechanism collects the residual coal and stores it in the collection box. When the cleaning device moves to the front of the car, the reciprocating mechanism is activated to clean the residual coal on the front wall of the car. Then, the X-axis of the moving trolley moves to the rear of the car to clean. After reaching the rear of the car, the reciprocating mechanism is activated to clean the residual coal on the rear wall of the car. After cleaning is completed, the X-axis moves to the lowered position of the cleaning device. Then, the frequency converters of the perimeter cleaning mechanism, undercarriage cleaning mechanism, and residual coal collection mechanism of the cleaning device stop working. Finally, the Z-axis raises the cleaning device to a safe height. The residual coal in empty car No. 2 is cleaned, and the car awaits the next empty car.

[0090] Figure 7 This is a flowchart of the second control method in automatic mode for the train carriage coal cleaning control method described in this embodiment. This flowchart is used for cleaning the first half of the carriage. Figure 2 The empty carriage number 1.

[0091] Preferably, based on numerical calculations, it is determined that empty car number 1 meets the cleaning conditions, while empty car number 3 does not. After empty car number 2 is cleaned, it will proceed to... Figure 7 Control process method. First, the X-axis moves to its minimum travel position. After the Z-axis descends to the bottom of the carriage, the cleaning device's perimeter and bottom cleaning mechanisms are activated, as is the residual coal collection mechanism. Then, the rear laser rangefinder of the cleaning device measures the distance to the rear wall of the carriage. After numerical processing, the absolute coordinates of the rear of the carriage are obtained. The X-axis then moves to the rear of the carriage, activating the reciprocating mechanism to clean the residual coal on the rear wall. After that, it moves back to the minimum travel position of the X-axis, stopping the frequency converters of the perimeter and bottom cleaning mechanisms and the residual coal collection mechanism. Finally, the Z-axis raises the cleaning device to a position above the carriage. This control process solves... Figure 2 The remaining coal in half of the empty carriage No. 1 was cleaned up.

[0092] Figure 8 This is a flowchart of control method three in automatic mode of the train car residual coal cleaning control method described in this embodiment. This process is applicable to cleaning the latter half of the car. Its control process method is similar to... Figure 7 Similarly. The process is complete. Figure 3 The remaining coal in the rear half of the empty No. 2 car was cleaned up.

[0093] Preferably, this method for controlling residual coal cleaning in the car is applicable to... Figure 2The following applies to the situation where empty carriage No. 2 is completely within the cleanup area, empty carriage No. 1 is not within the area, and empty carriage No. 3 is partially within the cleanup area and meets the cleanup conditions. Figure 2 The empty carriages No. 1, No. 2, and No. 3 all meet the conditions for cleaning, and will not be elaborated here.

[0094] Preferably, while the mobile trolley is moving, the monitoring camera records the entire process of cleaning the remaining coal in the carriage so that the operator can view it; the database records the system's historical alarm information, personnel operation records, and other information.

[0095] Example 3:

[0096] The purpose of this embodiment is to provide a control system for cleaning up residual coal in train carriages.

[0097] A control system for cleaning residual coal in train carriages, comprising:

[0098] A data acquisition unit is used to acquire image information of the carriages within a preset cleaning area, and to determine the location information of the carriages to be cleaned within the cleaning area based on the image information.

[0099] The parking status determination unit is used to control the cleaning device to reach the bottom of the inner side of the carriage to be cleaned according to the location information when the cleaning conditions are met; to obtain the location information of the front and rear of the carriage to be cleaned where the cleaning device is located, and then to determine the parking status of the carriage in the cleaning area; wherein, the parking status includes parking one complete carriage and parking only two half carriages.

[0100] The residual coal cleaning unit is used when the car is parked with one complete car and the cleaning conditions for the two cars in front and behind it are not met. It activates the cleaning mechanism located at the bottom and perimeter of the cleaning device, controls the cleaning device to move to the front of the car, and then from the front to the rear of the car. After cleaning one car, it lifts the cleaning device to wait for the next car to be cleaned to enter the cleaning area. When the car is parked with only two half-cars, it sequentially cleans the residual coal from the two half-cars, then lifts the cleaning device to wait for the subsequent car to be cleaned to enter the cleaning area.

[0101] Furthermore, the system described in this embodiment corresponds to the method described in Embodiment 2, and its technical details have been described in detail in Embodiment 2, so they will not be repeated here.

[0102] In further embodiments, the following is also provided:

[0103] An electronic device includes a memory and a processor, as well as computer instructions stored in the memory and running on the processor. When executed by the processor, the computer instructions perform the method described in Embodiment 2. For brevity, further details are omitted here.

[0104] It should be understood that in this embodiment, the processor can be a central processing unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor, etc.

[0105] Memory may include read-only memory and random access memory, and provides instructions and data to the processor. A portion of memory may also include non-volatile random access memory. For example, memory may also store information about the device type.

[0106] A computer-readable storage medium for storing computer instructions, which, when executed by a processor, perform the method described in Embodiment 2.

[0107] The method in Example 2 can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor. The software modules can reside in readily available storage media in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, or registers. This storage medium is located in memory; the processor reads information from the memory and, in conjunction with its hardware, completes the steps of the above method. To avoid repetition, a detailed description is not provided here.

[0108] Those skilled in the art will recognize that the units, i.e., algorithm steps, of the various examples described in connection with this embodiment can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this disclosure.

[0109] The above embodiments provide a train carriage residual coal cleaning device, control method, and system that can be implemented and have broad application prospects.

[0110] The above description is merely a preferred embodiment of this disclosure and is not intended to limit this disclosure. Various modifications and variations can be made to this disclosure by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A control method for a coal residue cleaning device for train carriages, wherein the coal residue cleaning device for train carriages comprises: A mobile trolley and a cleaning device; the mobile trolley is based on a bridge crane structure and can realize movement along three axes: X, Y, and Z; the cleaning device includes a trolley perimeter cleaning mechanism, a trolley bottom cleaning mechanism, a residual coal collection mechanism, a reciprocating mechanism, and a unloading mechanism; The mobile trolley is located on two supports parallel to the empty car track of the tipper within the cleaning area. The cleaning device is installed at the end of the Z-axis of the mobile trolley. The bottom cleaning mechanism is installed on the left and right sides of the bottom of the cleaning device to clean the residual coal at the bottom of the car and collect it in the middle. The residual coal collection mechanism is installed in the middle of the cleaning device, with its actuator end installed in the middle of the bottom of the cleaning device to collect the residual coal into the collection box of the residual coal collection mechanism. The unloading mechanism is installed at the bottom of the collection box of the residual coal collection mechanism to unload the collected residual coal when it is full. The reciprocating mechanism is installed on the front and rear sides of the cleaning device to drive the car perimeter cleaning mechanism to reciprocate. The car perimeter cleaning mechanism is installed on the motion actuator of the reciprocating mechanism to clean the inner wall of the car. The control method is characterized by comprising: Collect image information of the carriages within a preset cleaning area, and determine the location information of the carriages to be cleaned within the cleaning area based on the image information; When the cleaning conditions are met, the cleaning device is controlled to reach the bottom of the inner side of the compartment to be cleaned, based on the location information. The location information of the front and rear of the carriage to be cleaned by the cleaning device is obtained, and then the parking status of the carriage in the cleaning area is determined; wherein, the parking status includes parking one complete carriage and parking only two half carriages. When the car is parked with one complete car, and neither the car in front nor behind the current car meets the cleaning conditions, the cleaning mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front of the car, and then from the front of the car to the rear of the car. After cleaning one car, the cleaning device is lifted to wait for the next car to be cleaned to enter the cleaning area. When the car is parked with only two and a half cars, the remaining coal in the two and a half cars is cleaned in sequence, and then the cleaning device is lifted to wait for the subsequent cars to be cleaned to enter the cleaning area.

2. The control method for a train carriage residual coal cleaning device as described in claim 1, characterized in that, The bottom of the cleaning device is equipped with guide wheels, which are connected to the cleaning device by a pressure-adjustable spring structure to adapt to the unevenness of the train undercarriage and to guide and support the cleaning device.

3. The control method for a train carriage residual coal cleaning device as described in claim 1, characterized in that, The main body of the reciprocating mechanism is a screw and slide structure, and the motion actuator of the reciprocating mechanism is a slide. The slide is connected to the vehicle perimeter cleaning mechanism through a pressure-adjustable spring structure to adapt to different widths of the vehicle compartment and to adjust the pressure on the inner wall of the vehicle compartment. or, The main body of the vehicle perimeter cleaning mechanism is a unidirectional spiral brush. By controlling its direction, it sweeps the remaining coal on the inner wall of the vehicle downwards.

4. The control method for a train carriage residual coal cleaning device as described in claim 1, characterized in that, The step of obtaining the position information of the front and rear of the carriage to be cleaned by the cleaning device specifically involves: obtaining the distance information of the cleaning device to the front and rear of the carriage based on the distance sensors set on the front and rear sides of the cleaning device; and obtaining the position coordinates of the front and rear of the carriage based on the distance information and the position information of the cleaning device. or, The determination of the parking status of the carriages within the cleaning area is specifically as follows: based on the position information of the front and rear of the carriage to be cleaned, when both position information is within the cleaning area, the parking status is that one complete carriage is parked; when either position information is outside the cleaning area, the parking status is that only two half carriages are parked.

5. The control method for a train carriage residual coal cleaning device as described in claim 1, characterized in that, The cleaning conditions are met, specifically, the residual coal cleaning permission signal is received from the air conditioning unit of the tippler system; or, When the car is parked in a state where there is one complete car, and any one of the cleaning conditions of the two cars in front of and behind the current car is met, after the cleaning of the current car is completed, the remaining coal in the cleaning area of ​​the adjacent car that meets the cleaning conditions is cleaned. or, When the car is parked in a state where there is one complete car and the cleaning conditions of the two cars in front of and behind the current car are met, after the cleaning of the current car is completed, the remaining coal in the cleaning areas of the two adjacent cars will be cleaned in sequence.

6. The control method for a train carriage residual coal cleaning device as described in claim 1, characterized in that, The process of sequentially cleaning the remaining coal in two and a half car carriages is as follows: after cleaning the remaining coal in the current car carriage area, the cleaning device is raised; and according to the direction of the next car carriage that meets the cleaning conditions relative to the current car carriage, the cleaning device is controlled to reach the limit position in the current direction; the cleaning device is controlled to reach the bottom of the car carriage, the sweeping mechanism located at the bottom and around the cleaning device is activated, and the cleaning device is controlled to move to the front or rear of the car carriage to achieve the cleaning of the remaining coal. or, The cleaning device is connected to a horizontally suspended moving trolley via pulleys and wire ropes. The horizontal movement of the cleaning device is achieved by the horizontal movement of the moving trolley; the vertical movement of the cleaning device is achieved by the control of the wire ropes and pulleys. or, The acquisition of carriage image information within the preset cleaning area is achieved by using industrial cameras installed in the cleaning area. Multiple industrial cameras are installed to achieve complete coverage of the entire cleaning area.

7. A control system for cleaning residual coal in train carriages, employing the control method of a train carriage residual coal cleaning device as described in any one of claims 1-6, characterized in that, include: A data acquisition unit is used to acquire image information of the carriages within a preset cleaning area, and to determine the location information of the carriages to be cleaned within the cleaning area based on the image information. The parking status determination unit is used to control the cleaning device to reach the bottom of the inner side of the carriage to be cleaned according to the location information when the cleaning conditions are met; to obtain the location information of the front and rear of the carriage to be cleaned where the cleaning device is located, and then to determine the parking status of the carriage in the cleaning area; wherein, the parking status includes parking one complete carriage and parking only two half carriages. The residual coal cleaning unit is used when the car is parked with one complete car and the cleaning conditions for the two cars in front and behind it are not met. It activates the cleaning mechanism located at the bottom and perimeter of the cleaning device, controls the cleaning device to move to the front of the car, and then from the front to the rear of the car. After cleaning one car, it lifts the cleaning device to wait for the next car to be cleaned to enter the cleaning area. When the car is parked with only two half-cars, it sequentially cleans the residual coal from the two half-cars, then lifts the cleaning device to wait for the subsequent car to be cleaned to enter the cleaning area.

8. An electronic device comprising a memory, a processor, and a computer program stored in the memory and running thereon, characterized in that, When the processor executes the program, it implements a control method for a train car coal cleaning device as described in any one of claims 1-6.

9. A non-transitory computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by the processor, the program implements a control method for a train car coal cleaning device as described in any one of claims 1-6.

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