A dual-energy x-ray based ore layer thickness detection system

Abstract

The application relates to the technical field of ore detection, and provides an ore layer thickness detection system based on dual-energy X rays, which comprises a dual-energy X ray ore scanning device and a central control system. X rays are emitted to ores on an ore conveying belt through an X ray source, and X ray transmission high and low energy gray scale images are collected by a linear array detector. The X ray transmission high and low energy gray scale images comprise an X ray transmission high energy gray scale image and an X ray transmission low energy gray scale image. The collected X ray transmission high and low energy gray scale images are transmitted to the central control system. The central control system obtains the layer thickness of the current ores according to a pre-established thickness identification model and in combination with the grade information of the current ores.

Description

Technical Field

[0001] This application relates to the field of ore detection technology, and in particular to an ore layer thickness detection system based on dual-energy X-rays. Background Technology

[0002] As the first processing step in the production of steel from raw ore, mineral processing is a crucial link in ensuring the effective utilization of mineral resources. The mineral processing mainly includes three processes: ore crushing, grinding and classification, and beneficiation. Among these, grinding is the most critical component, playing a pivotal role. Its main task is to use the physical grinding and sorting equipment of ball mills to classify and select ore particles from large to a certain size. Therefore, preliminary analysis of the ore bed thickness during the transfer of ore from the crushing process to the grinding and classification process can provide guiding data for the automatic control of subsequent grinding, classification, and beneficiation processes.

[0003] In existing technologies, non-contact sensors are typically used to continuously and rapidly measure the thickness of moving materials. Non-contact sensors mainly include eddy current thickness sensors, magnetic thickness sensors, capacitive thickness sensors, ultrasonic thickness sensors, and X-ray thickness sensors. For example, an X-ray generator is installed above a conveyor belt transporting ore. The residual intensity of X-rays of a single intensity after passing through the object being measured is approximately exponentially decreasing with the thickness of the object being measured, which is used to predict the thickness of the ore layer being measured.

[0004] However, in actual working conditions, different components of ore have different absorption capabilities for specific energy level particles in X-rays. As a result, the residual intensity of X-rays after passing through the ore does not strictly follow the exponential decrease law with respect to the ore thickness. At the same time, the conveyor belt used to transport the ore can also be transmitted by X-rays, which will generate interference data and make the measurement results inaccurate. Summary of the Invention

[0005] To obtain more accurate ore layer thickness, this application provides an ore layer thickness detection system based on dual-energy X-rays.

[0006] This application provides a dual-energy X-ray ore layer thickness detection system, comprising a dual-energy X-ray ore scanning device and a central control system 100. The dual-energy X-ray ore scanning device is located between the ore crushing system and the grinding and classification system, including an ore conveyor belt 1 and a protective channel 2 that partially encloses a section of the ore conveyor belt 1. An opening communicating with a radiation source chamber 3 is provided above the protective channel 2. An X-ray source 4 is provided at the top of the radiation source chamber 3. A collimator 5 is provided between the X-ray source 4 and the ore conveyor belt 1. A linear array detector 6 is provided directly below the ore conveyor belt 1. The X-rays emitted by the X-ray source 4 are adjusted in beam width by the collimator 5 and then irradiate the ore on the ore conveyor belt 1. The linear array detector 6 is used to acquire high and low energy grayscale images of the ore transmitted by X-rays and to transmit the high and low energy grayscale images of the X-rays transmitted by X-rays to the central control system 100.

[0007] The central control system is configured as follows:

[0008] Obtain the grade information of the current ore layer;

[0009] The grade information and the X-ray transmission high and low energy grayscale images are input into a pre-established thickness recognition model to obtain the ore layer thickness. The thickness recognition model includes the ore layer grade information and the mapping relationship between the ore layer X-ray transmission high and low energy grayscale images and the ore layer thickness. The thickness recognition model is obtained through the following method:

[0010] Multiple sets of known sample data are acquired, including the grade information of the ore layer, the X-ray transmission high and low energy grayscale images of the ore layer, and the corresponding thickness of the ore layer. The X-ray transmission high and low energy grayscale images are obtained using the dual-energy X-ray ore scanning device.

[0011] Based on the multiple sets of known sample data, a thickness recognition model is generated by fitting curves using a cubic spline interpolation function.

[0012] Optionally, the step of fitting the curve using a cubic spline interpolation function to generate a thickness recognition model includes:

[0013] Based on the multiple sets of known sample data, a set of non-intersecting curves is obtained by fitting the data using a cubic spline interpolation function.

[0014] Each curve represents a different material layer thickness.

[0015] Optionally, the step of inputting the grade information and the X-ray transmission high- and low-energy grayscale images into a pre-established thickness recognition model to obtain the ore layer thickness includes:

[0016] Based on the grade information and the X-ray transmission high and low energy grayscale images, the corresponding curves are obtained by least squares matching.

[0017] The thickness of the ore layer can be obtained from the corresponding curve.

[0018] Optionally, a shield 31 is provided inside the X-ray source chamber 3. The shield 31 has a conical structure. The narrow end of the conical structure is connected to the exit port of the X-ray source 4, and the collimator 5 is located at the wide end of the conical structure.

[0019] Optionally, the shielding body 31 includes an inner steel plate and an outer lead plate.

[0020] Optionally, an air conditioning system 32 is also provided inside the radiation source chamber 3.

[0021] Optionally, the central control system 100 further includes an equipment control module, which includes an X-ray source module, a linear array detector module, and an ore transport module.

[0022] The X-ray source module is used to control the system X-ray source 4 to emit X-rays;

[0023] The linear array detector module is used to control the linear array detector 6 to receive X-ray transmission high and low energy grayscale images of the ore.

[0024] The ore conveying module is used to control the start, stop and transport speed of the ore conveyor belt 1.

[0025] Optionally, the central control system 100 further includes an image processing and analysis module connected to the equipment control module, the image processing and analysis module including a thickness recognition module and a real-time display and transmission module;

[0026] The thickness recognition module is used to obtain the thickness of the ore layer based on the thickness recognition model, according to the grade information of the current material layer and the X-ray transmission high and low energy grayscale image.

[0027] The real-time display and transmission module is used for real-time data transmission and display in the system.

[0028] Optionally, the ore layer thickness detection system further includes an electrical control system 7 connected to the equipment control module, the electrical control system 7 being connected to the X-ray source 4, the linear array detector 6, and the ore conveyor belt 1;

[0029] The electrical control system is used to control the transmission and reception of X-ray signals, as well as the start-stop and speed-changing functions of the belt conveyor.

[0030] Optionally, the electrical control system 7 adopts an Omron programmable logic controller.

[0031] As can be seen from the above technical solution, the ore layer thickness detection system based on dual-energy X-rays provided in this application includes a dual-energy X-ray ore scanning device and a central control system 100. X-rays are emitted from the X-ray source 4 onto the ore conveyor belt 1, and the linear array detector 6 acquires high- and low-energy X-ray transmission grayscale images, wherein the high- and low-energy X-ray transmission grayscale images include high-energy X-ray transmission grayscale images and low-energy X-ray transmission grayscale images. The acquired high- and low-energy X-ray transmission grayscale images are transmitted to the central control system 100, which, based on a pre-established thickness recognition model and the current ore grade information, obtains the current ore layer thickness. The thickness recognition model includes the ore layer grade information and the mapping relationship between the high- and low-energy X-ray transmission grayscale images of the ore layer and the ore layer thickness.

[0032] The dual-energy X-ray ore scanning device of this application can acquire ore attribute data based on dual-energy X-rays, with low overall cost and strong versatility. The thickness recognition model algorithm of this application embodiment is based on the current hardware system, which can analyze and detect the thickness of ore layers non-contactly and quickly, achieving rapid response and good compatibility for ores of different grades. Compared with other thickness detection algorithms, the thickness recognition model algorithm of this application embodiment has lower cost and better system compatibility. Both the dual-energy X-ray ore scanning device and the thickness recognition model algorithm of this application embodiment are designed, tested, and developed according to the actual environment of mine production, and can be directly applied to the mine production process, thus having greater practical value. Attached Figure Description

[0033] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 A schematic diagram of the principle structure of a dual-energy X-ray based ore layer thickness detection system provided in this application embodiment;

[0035] Figure 2 A schematic diagram of the main structure of a dual-energy X-ray based ore layer thickness detection system provided in an embodiment of this application;

[0036] Figure 3 A side view of a dual-energy X-ray based ore layer thickness detection system provided in this application embodiment;

[0037] Figure 4This is a schematic diagram of the structure of radiation source end protection and channel protection provided in the embodiments of this application;

[0038] Figure 5 Transmission effect diagram of 160V X-rays through ores of different grades and thicknesses provided for embodiments of this application;

[0039] Figure 6 A schematic diagram illustrating the principle of the thickness recognition model provided in this application embodiment;

[0040] Figure 7 This is a schematic diagram of the electrical control system provided in an embodiment of this application.

[0041] In the diagram, 1-ore conveyor belt, 2-protective passage, 3-radiation source chamber, 31-shielding body, 32-air conditioning system, 4-X-ray source, 5-collimator, 6-linear array detector, 7-electrical control system, 100-central control system. Detailed Implementation

[0042] To obtain more accurate information about the thickness of the ore layer, such as... Figure 1 The diagram shown is a schematic representation of the principle structure of a dual-energy X-ray (DEX) ore layer thickness detection system provided in this application embodiment. The DEX ore layer thickness detection system provided in this application embodiment includes a DEX ore scanning device and a central control system 100. The DEX ore scanning device is located between the ore crushing system and the grinding and classification system, and is used to continuously and in real-time acquire high- and low-energy X-ray transmission grayscale images of the ore on the conveyor belt. These images are then transmitted to the central control system 100, which uses the X-ray transmission grayscale images and combines them with the current ore grade information to determine the ore layer thickness.

[0043] The dual-energy X-ray ore scanning device includes an ore conveyor belt 1, one end of which is connected to the ore crushing system and the other end to the grinding and classification system. It is used to transport the ore crushed by the ore crushing system to the ore crushing system. It should be noted that the purpose of the dual-energy X-ray ore scanning device provided in this application embodiment is to collect data for analyzing the thickness of the ore layer. It is not limited to being installed between the ore crushing system and the grinding and classification system. It can also be installed in other areas or set up and used independently according to actual engineering needs.

[0044] A section of the ore conveyor belt 1 is semi-enclosed with a protective channel 2. An opening connecting to a radiation source chamber 3 is located above the protective channel 2. An X-ray source 4 is positioned at the top of the radiation source chamber 3. A collimator 5 is positioned between the X-ray source 4 and the ore conveyor belt 1. The collimator 5 controls the effective beam width through a collimation slit. The X-rays emitted by the X-ray source 4, after beam width adjustment by the collimator 5, irradiate the ore on the ore conveyor belt 1. A linear array detector 6 is positioned directly below the ore conveyor belt 1, and is located within the protective channel 2. The linear array detector 6 is used to acquire high- and low-energy grayscale images of the ore transmitted via X-ray transmission and transmit them to the central control system 100. These high- and low-energy grayscale images include both high-energy and low-energy X-ray transmission images.

[0045] See Figure 2 and Figure 3 In this embodiment, the X-ray source 4 adopts a top-illuminated structure. The selection of the voltage tube current of the X-ray source 4 is based on compliance with the national Class III radiation source standard, ensuring sufficient penetration capability while maintaining good safety. The radiation source chamber 3 employs a specialized design. In this embodiment, the radiation source is installed in a sealed space, and sealing strips, special slots, and sealant are used to ensure the airtightness of the space, isolating it from the high temperature and high dust environment of actual mining conditions. Furthermore, to ensure that the radiation source operates in a good environment, an air conditioning system 32, such as an IP65-rated industrial air conditioner, is installed in the sealed radiation source chamber 3, which can extend the working life of the radiation source and ensure its data quality.

[0046] To ensure the safety of equipment operators and the public, in some preferred embodiments, the dual-energy X-ray ore scanning device is equipped with a corresponding level of radiation protection system to ensure that the leakage radiation dose inside and outside the controlled area meets national safety standards. The radiation protection system includes source-end protection and channel protection. For example... Figure 4 As shown, Figure 4 Figure (a) shows a schematic diagram of the radiation source end protection structure. The radiation source end protection includes a shielding lead plate covering the outside of the radiation source and a shielding body 31 installed inside the radiation source chamber 3. The shielding body 31 has a conical structure; the narrow end of the conical structure connects to the exit port of the X-ray source 4, and the wide end connects to the collimator 5. The main body of the shielding body 31 is welded from steel plates, and its outer layer is also welded with a lead plate of a certain thickness to provide radiation protection. Furthermore, the shielding body 31 can control the radiation angle of the rays; its opening angle ensures that the rays can completely cover the ore on the ore conveyor belt 1, and the transmitted signal can be detected with high quality at a reasonable angle.

[0047] Figure 4Figure (b) shows a schematic diagram of the channel protection structure. After passing through the shield 31, the radiation enters the protective channel 2. This channel has an open structure, and there is some scattering inside the channel. In this embodiment, a protective lead plate is installed on the outside of the protective channel 2. The protective lead plate includes a top protective lead plate and two side protective lead plates. Based on the calculation of the scattering formula, the top protective lead plate and the two side protective lead plates are made of lead plate with a thickness of 5 mm and 4 mm, respectively. In addition, considering the radiation protection of the linear array detector 6, the protective lead plate also includes a bottom protective lead plate. Based on the extreme case where no ore is transported in the system, the bottom protective lead plate is made of lead plate with a thickness of 7 mm.

[0048] Furthermore, the linear array detector 6 is externally enclosed with a detector housing. The linear array detector 6 is made of GGAG scintillator and is arranged in a linear pattern to detect the dual-energy X-ray transmission signal emitted by the X-ray source 4.

[0049] In this embodiment of the application, after the online array detector 6 collects the X-ray transmission signal of the current ore, it sends it to the central control system 100. The central control system 100 comprehensively analyzes the thickness information of the current ore layer in real time according to the thickness recognition model algorithm encapsulated within it. The thickness recognition model pre-established in this embodiment of the application is described in detail below.

[0050] X-rays have different transmission effects on different materials and on materials of the same type but different thicknesses, such as... Figure 5 As shown, for X-ray sources of the same type and voltage, the image patterns obtained from transmission of different materials and thicknesses show significant differences. For the same material, analysis based on these differences can yield the material's thickness information. Based on this difference, for ore layers of the same grade, scanning ore layers of different thicknesses with X-rays can obtain a set of thickness data related to transmission energy. Based on this data, curve fitting using a cubic spline interpolation function can produce a set of curves that do not intersect in the middle, each curve representing a different thickness, as shown below. Figure 6 The diagram shown illustrates the principle of the thickness recognition model provided in this application embodiment. Specifically, this application embodiment first acquires multiple sets of known sample data, including the grade information of the ore layer, the X-ray transmission high and low energy grayscale images of the ore layer, and the corresponding ore layer thickness. Since the conveyor belts used to transport the ore are also transmitted by X-rays, thus generating interference data, in order to remove noise, the X-ray transmission high and low energy grayscale images in the known sample data of this application embodiment are also obtained using the aforementioned dual-energy X-ray ore scanning device.

[0051] Based on multiple sets of known sample data, a cubic spline interpolation function is used to fit curves and generate a thickness recognition model. After the model is established, it is encapsulated in the central control system 100. In actual applications, when detecting the thickness of the ore layer, the central control system 100 receives X-ray transmission high and low energy grayscale images of the current ore layer in real time. Combining this with the current ore grade, the grade information and the X-ray transmission high and low energy grayscale images are input into the pre-established thickness recognition model. The thickness recognition model uses the least squares method to match and obtain the corresponding curve. Based on the corresponding curve, the thickness of the current ore layer is obtained. It should be noted that the current ore grade information is obtained by the central control system 100. For example, when the ore transported by the system is a batch of gold ore with a stable grade, the grade data corresponding to the gold ore can be pre-input into the central control system 100. Or, for example, when the grade of the ore transported by the system is unstable, the current grade can be detected in real time, and then the grade information can be transmitted to the central control system 100. The existing technology for real-time detection of ore grade is relatively mature and will not be elaborated here.

[0052] Furthermore, in some embodiments of this application, the software architecture of the central control system 100 adopts a modular design, which includes an equipment control module and an image processing and analysis module connected to the equipment control module. The equipment control module includes an X-ray source module, a linear array detector module, and an ore transport module. The X-ray source module is used to control the emission of the system X-ray source 4, the linear array detector module is used to control the signal reception of the linear array detector 6, and the ore transport module is used to control the start, stop, and transport speed of the ore conveyor belt 1.

[0053] The image processing and analysis module includes a thickness recognition module and a real-time display and transmission module. The thickness recognition model is specifically encapsulated in the thickness recognition module. The thickness recognition module is used to obtain the thickness of the ore layer based on the thickness recognition model, the grade information of the current material layer, and the X-ray transmission high and low energy grayscale images. The real-time display and transmission module is used for the real-time transmission and display of data in the system.

[0054] Furthermore, in some embodiments of this application, the ore layer thickness detection system further includes an electrical control system 7 connected to the equipment control module. This electrical control system 7 is simultaneously connected to the X-ray source 4, the linear array detector 6, and the ore conveyor belt 1. (See also...) Figure 7The electrical control system 7 uses an Omron high-performance programmable logic controller (PLC) as the central control unit to control the transmission and reception of radiation system signals and the basic start, stop, and speed regulation functions of the belt conveyor. The PLC is connected to the central control system 100 via fiber optic cable and uses host computer configuration software to remotely send commands to control the system's operation. Furthermore, the electrical control system 7 can display and alarm in case of local emergencies and has local emergency stop and radiation zone intrusion prevention safety interlock functions.

[0055] As can be seen from the above technical solutions, the ore layer thickness detection system based on dual-energy X-rays provided in this application includes a dual-energy X-ray ore scanning device and a central control system 100. X-rays are emitted from the X-ray source 4 onto the ore conveyor belt 1, and the linear array detector 6 acquires high- and low-energy X-ray transmission grayscale images, wherein the high- and low-energy X-ray transmission grayscale images include high-energy X-ray transmission grayscale images and low-energy X-ray transmission grayscale images. The acquired high- and low-energy X-ray transmission grayscale images are transmitted to the central control system 100, which, based on a pre-established thickness recognition model and the current ore grade information, obtains the current ore layer thickness. The thickness recognition model includes the ore layer grade information and a mapping relationship between the high- and low-energy X-ray transmission grayscale images of the ore layer and the ore layer thickness.

[0056] The dual-energy X-ray ore scanning device of this application can acquire ore attribute data based on dual-energy X-rays, with low overall cost and strong versatility. The thickness recognition model algorithm of this application is based on the current hardware system and can analyze and detect the thickness of ore layers non-contactly, achieving rapid response and good compatibility for ores of different grades. Compared with other thickness detection algorithms, the thickness recognition model algorithm of this application has lower cost and better system compatibility. Both the dual-energy X-ray ore scanning device and the thickness recognition model algorithm of this application are designed, tested, and developed according to the actual environment of mine production, and can be directly applied to the mine production process, thus having greater practical value.

[0057] The present application has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present application. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and implementation methods of the present application without departing from the spirit and scope of the present application, and all such modifications and improvements fall within the scope of the present application. The scope of protection of the present application is determined by the appended claims.

Claims

1. A dual-energy X-ray diffraction (DEX) ore layer thickness detection system, characterized in that, The system includes a dual-energy X-ray ore scanning device and a central control system (100). The dual-energy X-ray ore scanning device is located between the ore crushing system and the grinding and classification system. It includes an ore conveyor belt (1) and a protective channel (2) that partially encloses a section of the ore conveyor belt (1). An opening connecting the protective channel (2) to the X-ray source chamber (3) is provided above the protective channel (2). An X-ray source (4) is provided at the top of the X-ray source chamber (3). A collimator (5) is provided between the X-ray source (4) and the ore conveyor belt (1). A linear array detector (6) is provided directly below the ore conveyor belt (1). The X-rays emitted by the X-ray source (4) are irradiated onto the ore on the ore conveyor belt (1) after the beam width is adjusted by the collimator (5). The linear array detector (6) is used to collect high and low energy grayscale images of the ore transmitted by X-rays and to transmit the high and low energy grayscale images of the ore transmitted by X-rays to the central control system (100). The central control system is configured as follows: Obtain the grade information of the current ore layer; The grade information and the X-ray transmission high and low energy grayscale images are input into a pre-established thickness recognition model to obtain the ore layer thickness. The thickness recognition model includes the ore layer grade information and the mapping relationship between the ore layer X-ray transmission high and low energy grayscale images and the ore layer thickness. The thickness recognition model is obtained through the following method: Multiple sets of known sample data are acquired, including the grade information of the ore layer, the X-ray transmission high and low energy grayscale images of the ore layer, and the corresponding thickness of the ore layer. The X-ray transmission high and low energy grayscale images are obtained using the dual-energy X-ray ore scanning device. Based on the multiple sets of known sample data, a thickness recognition model is generated by fitting curves using a cubic spline interpolation function. The step of using a cubic spline interpolation function to fit curves and generate a thickness identification model includes: based on the multiple sets of known sample data, using a cubic spline interpolation function to fit a set of non-intersecting curves; wherein each curve represents a different material layer thickness. The step of inputting the grade information and the X-ray transmission high and low energy grayscale images into a pre-established thickness recognition model to obtain the ore layer thickness includes: matching the grade information and the X-ray transmission high and low energy grayscale images using the least squares method to obtain the corresponding curves; and obtaining the ore layer thickness based on the corresponding curves.

2. The ore layer thickness detection system based on dual-energy X-rays according to claim 1, characterized in that, The X-ray source chamber (3) is equipped with a shield (31), which is a conical structure. The narrow end of the conical structure is connected to the outlet of the X-ray source (4), and the collimator (5) is located at the wide end of the conical structure.

3. The ore layer thickness detection system based on dual-energy X-ray as described in claim 2, characterized in that, The shield (31) includes an inner steel plate and an outer lead plate.

4. The ore layer thickness detection system based on dual-energy X-ray as described in claim 1, characterized in that, An air conditioning system (32) is also installed inside the radiation source chamber (3).

5. The ore layer thickness detection system based on dual-energy X-ray as described in claim 1, characterized in that, The central control system (100) also includes an equipment control module, which includes an X-ray source module, a linear array detector module, and an ore transport module. The X-ray source module is used to control the system X-ray source (4) to emit X-rays; The linear array detector module is used to control the linear array detector (6) to receive X-ray transmission high and low energy grayscale images of the ore. The ore transport module is used to control the start, stop and transport speed of the ore conveyor belt (1).

6. The ore layer thickness detection system based on dual-energy X-ray as described in claim 5, characterized in that, The central control system (100) also includes an image processing and analysis module connected to the equipment control module, the image processing and analysis module including a thickness recognition module and a real-time display and transmission module; The thickness recognition module is used to obtain the thickness of the ore layer based on the thickness recognition model, according to the grade information of the current material layer and the X-ray transmission high and low energy grayscale image. The real-time display and transmission module is used for real-time data transmission and display in the system.

7. The ore layer thickness detection system based on dual-energy X-ray as described in claim 6, characterized in that, The ore layer thickness detection system also includes an electrical control system (7) connected to the equipment control module. The electrical control system (7) is connected to the X-ray source (4), the linear array detector (6), and the ore conveyor belt (1). The electrical control system is used to control the transmission and reception of X-ray signals, as well as the start-stop and speed-changing functions of the belt conveyor.

8. The ore layer thickness detection system based on dual-energy X-ray as described in claim 7, characterized in that, The electrical control system (7) adopts an Omron programmable logic controller.

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