Anti-wrong material three-dimensional aggregate bin automatic feeding system and control method

Abstract

The present application belongs to the technical field of concrete mixing station, and particularly relates to a three-dimensional aggregate bin automatic feeding system and control method for preventing feeding of wrong materials. The system comprises a feeding mechanism, a visual recognition device, and a two-dimensional code recognition device. The feeding mechanism comprises a feeding hopper, a pipe chain conveyor, a detection box, a discharging pipe, a gate, and an indicator light. The feeding hopper is connected to the three-dimensional aggregate bin through the pipe chain conveyor and the discharging pipe in sequence. The discharging pipe is installed at the discharging end of the pipe chain conveyor. The two-dimensional code recognition device, the gate, and the indicator light are installed at the entrance of the feeding area of the mixing station. The visual recognition device is installed at the entrance of the feeding area of the mixing station and in the detection box. The pipe chain conveyor is provided with a return port. The detection box is installed at a position between the feeding end of the pipe chain conveyor and the return port. The feeding mechanism, the visual recognition device, and the two-dimensional code recognition device are electrically connected to the control host of the mixing station. The whole process from the entry of the transport vehicle to the end of feeding is monitored, the automatic control of the whole process is realized, and the feeding of wrong materials is effectively prevented.

Description

Technical Field

[0001] This invention belongs to the technical field of concrete mixing plants, and particularly relates to an automatic feeding system and control method for three-dimensional aggregate bins to prevent incorrect material feeding. Background Technology

[0002] A concrete batching plant is a combined unit used for centralized mixing of concrete, also known as a precast concrete plant. It has a high degree of mechanization and automation, resulting in high productivity and ensuring concrete quality while saving cement. Aggregates, such as sand and stone, are important raw materials in concrete production. Currently, automated aggregate silos, as a new type of aggregate storage method, have advantages such as small footprint, high conveying efficiency, and environmental friendliness, and are beginning to be used in concrete companies. The current loading process for automated aggregate silos is as follows: vehicles transporting sand and gravel arrive on site; staff take samples for testing to determine if the aggregates are qualified and should be placed in the appropriate silo before allowing them to enter the site; the transport vehicles unload the aggregates into the loading hopper; the aggregates are then conveyed by a conveyor and a placing boom into the corresponding silo; operators need to control the placing boom to the corresponding aggregate silo inlet, and then sequentially start the belt conveyors to transport the aggregates from the receiving hopper to the automated silo.

[0003] The process of incorrectly loading aggregates can easily lead to several issues. The main reasons are as follows: First, improper operation or carelessness by operators can cause aggregates to enter the wrong bins. Second, sampling personnel may not follow sampling procedures. The bumpy ride during transport and the settling of moisture can cause inconsistencies in moisture and particle size distribution between the surface and bottom layers of the aggregates. Furthermore, some suppliers may mix inferior aggregates with significantly different particle sizes, leading to inaccurate test results if only surface sampling is used. This can result in aggregates entering the wrong bins, or even substandard aggregates being incorrectly received and sent to the automated aggregate bins. Third, truck drivers may be unfamiliar with the layout of the mixing plant, entering the wrong discharge port without the staff noticing, resulting in aggregates entering the wrong bins. Once incorrect loading occurs, mixing can occur within the automated aggregate bins. Due to the large volume of the automated aggregate bins, cleaning after mixing is extremely difficult, requiring significant manpower and time. Moreover, if the mixing goes unnoticed, it can severely impact the quality of the concrete. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic feeding system and control method for three-dimensional aggregate bins to prevent incorrect material feeding, so as to solve the problems existing in the prior art.

[0005] The technical solution adopted by this invention to solve its technical problem is: an automatic feeding system for a three-dimensional aggregate bin to prevent incorrect feeding, including a feeding mechanism, a visual recognition device, and a QR code recognition device. The feeding mechanism includes a feeding hopper, a tubular chain conveyor, a detection box, a discharge pipe, a barrier gate, and indicator lights. The feeding hopper is connected to the three-dimensional aggregate bin in sequence through the tubular chain conveyor and the discharge pipe. The discharge pipe is installed at the discharge end of the tubular chain conveyor. The QR code recognition device, the barrier gate, and the indicator lights are installed at the entrance of the feeding area of ​​the mixing plant. The visual recognition device is installed at the entrance of the feeding area of ​​the mixing plant and inside the detection box. The tubular chain conveyor is provided with a return port. The detection box is installed between the inlet end and the return port of the tubular chain conveyor. The feeding mechanism, the visual recognition device, and the QR code recognition device are electrically connected to the main control unit of the mixing plant.

[0006] Furthermore, an online moisture meter for sand and gravel is installed inside the testing box. The online moisture meter for sand and gravel is electrically connected to the main control unit of the mixing plant. The testing box is connected to the pipe chain conveyor. A cover is hinged to the top of the testing box. The visual recognition device and the online moisture meter for sand and gravel are installed on the inner wall of the testing box. A transparent cover is bolted to the inner wall of the testing box outside the visual recognition device. An electric cylinder is installed through the other side of the testing box. A cleaner is connected to the output end of the electric cylinder.

[0007] Furthermore, the three-dimensional aggregate bin is a three-dimensional aggregate bin equipped with a level gauge. The interior of the three-dimensional aggregate bin is divided into several independent compartments, and the discharge end and discharge pipe of the tubular chain conveyor correspond to each compartment.

[0008] A control method for an automated feeding system for three-dimensional aggregate bins to prevent incorrect material feeding includes the following steps:

[0009] (1) Sampling personnel in the sampling area take samples from the transport vehicle. After the samples pass the inspection, they input the vehicle information and test results into the control host to generate a QR code and issue it to the driver.

[0010] (2) Before the transport vehicle enters the site, the QR code is scanned by the QR code recognition device and the transport vehicle is identified by the visual recognition device. If the identification is correct, the indicator light will turn green and the gate will be opened to allow passage. Otherwise, the indicator light will turn red and the vehicle will be prohibited from entering the site.

[0011] (3) The host controller determines the feeding time based on the current operating status of the feeding system, and then switches the relevant valves to feed the material.

[0012] (4) The aggregate loaded on the transport vehicle is unloaded into the feeding hopper, and the tubular chain conveyor is turned on. During the feeding process, the detection box detects the moisture content, aggregate particle size and shape, and performs statistical analysis. If any unqualified situation occurs and the unqualified situation exceeds the preset range, an alarm is issued and the machine is stopped. The staff will then conduct a re-inspection.

[0013] Furthermore, in step (2), the identification of the transport vehicle by the visual recognition device involves collecting the license plate number of the transport vehicle by the visual recognition device, sending it to the control host, and comparing it with the QR code recognition result.

[0014] Furthermore, in step (3), determining the feeding timing based on the current operating status of the feeding system involves confirming whether the tubular chain conveyor is feeding material, determining whether the valve can be switched based on the current material flow in the tubular chain conveyor, calculating the estimated completion time of the current feeding batch based on the conveying speed of the tubular chain conveyor and the feeding start time, and automatically switching the valve to prepare for feeding after the completion time is reached.

[0015] Furthermore, the re-inspection in step (4) involves on-site confirmation and testing by staff. If the material can be fed after the re-inspection, it can continue to be fed. If the feeding compartment needs to be replaced, the corresponding valve should be switched before feeding can continue. If the material needs to be returned, it should be returned to the transport vehicle from the return port of the tubular chain conveyor.

[0016] The present invention has the following beneficial effects:

[0017] 1. By generating a QR code from the aggregate test results and transport vehicle information and issuing it to the driver, if the driver enters the wrong unloading port due to unfamiliarity with the layout, the driver can be refused entry through the QR code recognition device, thereby preventing the situation of loading the wrong material due to the driver mistakenly entering the site.

[0018] 2. The testing box continuously detects the moisture content, particle size, and shape of the aggregates during transportation to prevent aggregates from entering the wrong compartments due to improper sampling or large deviations in test results, or even to prevent unqualified aggregates from being incorrectly received and sent to the three-dimensional aggregate silo.

[0019] 3. The feeding mechanism is electrically connected to the control host. The control host monitors the entire aggregate feeding process, realizes automated feeding, and prevents improper operation or carelessness by operators from causing aggregates to enter the wrong compartment.

[0020] 4. Through continuous monitoring and re-inspection procedures by the testing box, even if unqualified aggregates are found during the feeding process, the aggregates can be returned to the transport vehicle from the return port, thereby preventing mixing.

[0021] 5. Cover the visual recognition device inside the inspection box with a transparent cover and install a cleaner to prevent dust from affecting the visual recognition device and causing unclear image acquisition during the inspection process.

[0022] 6. The visual recognition device is installed inside the detection box and illuminated by its own light source, thus preventing it from being exposed to the outside and affected by ambient light, which could cause deviations in image acquisition.

[0023] 7. The tubular chain conveyor ensures a completely enclosed feeding process, preventing dust pollution and facilitating material return without requiring additional equipment. Attached Figure Description

[0024] Figure 1 This is a flowchart of the control method for the automatic feeding system of the three-dimensional aggregate bin to prevent incorrect material feeding according to the present invention.

[0025] Figure 2 This is a schematic diagram of the elevation structure of the feeding mechanism of the present invention.

[0026] Figure 3 This is a top view schematic diagram of the feeding mechanism of the present invention.

[0027] Figure 4 This is a schematic diagram of the elevation structure of the detection box of the present invention.

[0028] Figure 5 This is a top view of the detection box structure of the present invention.

[0029] The components include: 1. Feeding hopper; 2. Tubular chain conveyor; 3. Detection box; 4. Discharge pipe; 5. Return port; 6. Barrier gate; 7. Indicator light; 8. Visual recognition device; 9. QR code recognition device; 10. Three-dimensional aggregate bin; 11. Online moisture meter for sand and gravel; 12. Cover; 13. Transparent cover; 14. Electric cylinder; 15. Cleaner; 16. Compartment; 17. Feeding area. Detailed Implementation

[0030] The invention will now be described in further detail with reference to the accompanying drawings.

[0031] like Figure 2-5As shown, an automatic feeding system for a three-dimensional aggregate bin to prevent incorrect feeding includes a feeding mechanism, a visual recognition device 8, and a QR code recognition device 9. The feeding mechanism includes a feeding hopper 1, a tubular chain conveyor 2, a detection box 3, a discharge pipe 4, a scanner, a barrier gate 6, and an indicator light 7. The feeding hopper 1 is connected to the three-dimensional aggregate bin 10 in sequence through the tubular chain conveyor 2 and the discharge pipe 4. The discharge pipe 4 is installed at the discharge end of the tubular chain conveyor 2. The QR code recognition device 9, the barrier gate 6, and the indicator light 7 are installed at the entrance of the feeding area 17 of the mixing plant. The visual recognition device 8 is installed at the entrance of the feeding area 17 of the mixing plant and inside the detection box 3. The tubular chain conveyor 2 is provided with a return port 5. The detection box 3 is installed between the inlet end of the tubular chain conveyor 2 and the return port 5. The feeding mechanism, the visual recognition device 8, and the QR code recognition device 9 are electrically connected to the main control unit of the mixing plant. An online moisture meter 11 for sand and gravel is installed inside the testing box 3. The online moisture meter 11 for sand and gravel is electrically connected to the main control unit of the mixing plant. The testing box 3 is connected to the tubular chain conveyor 2. A cover 12 is hinged to the top of the testing box 3. The visual recognition device 8 and the online moisture meter 11 for sand and gravel are installed on the inner wall of the testing box 3. A transparent cover 13 is bolted to the inner wall of the testing box 3 outside the visual recognition device 8. An electric cylinder 14 is installed through the other side of the testing box 3. A cleaner 15 is connected to the output end of the electric cylinder 14. The three-dimensional aggregate bin 10 is a three-dimensional aggregate bin 10 with an internal level gauge. The three-dimensional aggregate bin 10 is divided into several independent compartments 16. The discharge end and discharge pipe 4 of the tubular chain conveyor 2 correspond to each compartment 16.

[0032] like Figure 1 As shown, a control method for an automatic feeding system of a three-dimensional aggregate bin to prevent incorrect material feeding includes the following steps:

[0033] (1) Sampling personnel in the sampling area take samples from the transport vehicle. After the samples pass the inspection, they input the vehicle information and test results into the control host to generate a QR code and issue it to the driver.

[0034] (2) Before the transport vehicle enters the site, the QR code is scanned by the QR code recognition device 9 and the license plate number of the transport vehicle is collected by the visual recognition device 8. After being sent to the control host, it is compared with the QR code recognition result. If it is confirmed to be correct, the indicator light 7 will turn green and the gate 6 will be opened to allow passage. Otherwise, the indicator light 7 will turn red and prohibit entry.

[0035] (3) The control host determines the feeding timing based on the current operating status of the feeding system, confirms whether the tubular chain conveyor 2 is feeding, judges whether the valve can be switched based on the current material flow in the tubular chain conveyor 2, calculates the estimated completion time of the current feeding batch based on the conveying speed of the tubular chain conveyor 2 and the feeding start time, and automatically switches the valve to prepare for feeding after the completion time is reached. After confirming, the relevant valve is switched to feed;

[0036] (4) The aggregate loaded in the transport vehicle is unloaded into the feeding hopper 1, and the tubular chain conveyor 2 is turned on. During the feeding process, the detection box 3 detects the moisture content, aggregate particle size and shape, and performs statistical analysis. If there is a non-conforming situation and the non-conforming situation exceeds the preset range, an alarm is issued and the machine is stopped. The staff conducts a re-inspection, and the staff confirms and tests on site. If the re-inspection is acceptable, feeding can continue. If the feeding compartment 16 needs to be replaced, the corresponding valve is switched and feeding continues. If the material needs to be returned, it is returned to the transport vehicle from the return port 5 of the tubular chain conveyor 2.

[0037] The working principle of this invention is as follows: It monitors every stage from the entry of the transport vehicle to the end of the loading process, and links the feeding hopper 1, tubular chain conveyor 2, detection box 3, discharge pipe 4, scanner, barrier gate 6, indicator lights 7, etc., to achieve fully automated control. The visual recognition device 8 mainly relies on a camera to collect images. However, dust is inevitably generated during aggregate transportation. Direct exposure to dust can cause the camera to become covered with dust, which is difficult to clean. Therefore, a transparent cover 13 is placed over the visual recognition device 8, and a cleaner 15 is installed on the electric cylinder 14. The electric cylinder 14 automatically extends and retracts periodically, pushing the cleaner 15 to clean the surface of the transparent cover 13, preventing dust from adhering to the transparent cover 13 and causing unclear imaging of the visual recognition device 8, resulting in large detection errors.

[0038] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the inventive concept should fall within the protection scope of the present invention.

[0039] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. An automatic feeding system for three-dimensional aggregate bins to prevent incorrect material feeding, characterized in that, The system includes a feeding mechanism, a visual recognition device, and a QR code recognition device. The feeding mechanism includes a feeding hopper, a tubular chain conveyor, a detection box, a discharge pipe, a barrier gate, and indicator lights. The feeding hopper is connected to the three-dimensional aggregate bin in sequence through the tubular chain conveyor and the discharge pipe. The discharge pipe is installed at the discharge end of the tubular chain conveyor. The QR code recognition device, barrier gate, and indicator lights are installed at the entrance of the feeding area of ​​the mixing plant. The visual recognition device is installed at the entrance of the feeding area of ​​the mixing plant and inside the detection box. The tubular chain conveyor is provided with a return port. The detection box is installed between the inlet end and the return port of the tubular chain conveyor. The feeding mechanism, the visual recognition device, and the QR code recognition device are electrically connected to the main control unit of the mixing plant. The detection box is equipped with an online moisture meter for sand and gravel, which is electrically connected to the control host of the mixing plant. The detection box is connected to the pipe chain conveyor. A cover is hinged to the top of the detection box. The visual recognition device and the online moisture meter for sand and gravel are installed on the inner wall of the detection box. A transparent cover is bolted to the inner wall of the detection box outside the visual recognition device. An electric cylinder is installed through the other side of the detection box, and a cleaner is connected to the output end of the electric cylinder. The three-dimensional aggregate bin is a three-dimensional aggregate bin equipped with a level gauge. The three-dimensional aggregate bin is divided into several independent compartments. The discharge end and discharge pipe of the tubular chain conveyor correspond to each compartment. The control method for an automated feeding system for three-dimensional aggregate bins to prevent incorrect material feeding includes the following steps: (1) Sampling personnel in the sampling area take samples from the transport vehicle. After the samples pass the inspection, they input the vehicle information and test results into the control host to generate a QR code and issue it to the driver. (2) Before the transport vehicle enters the site, the QR code is scanned by the QR code recognition device and the transport vehicle is identified by the visual recognition device. If the correct identification is confirmed, the indicator light will turn green and the gate will be opened to allow passage. Otherwise, the indicator light will turn red and the vehicle will be prohibited from entering the site. (3) The host controller determines the feeding time based on the current operating status of the feeding system, and switches the relevant valves to feed the material after the determination is made; (4) The aggregate loaded on the transport vehicle is unloaded into the feeding hopper, and the tubular chain conveyor is turned on. During the feeding process, the detection box detects the moisture content, aggregate particle size and shape, and performs statistical analysis. If there is a non-conforming situation and the non-conforming situation exceeds the preset range, an alarm is issued and the machine is requested to be stopped. If the staff thinks it is necessary, the machine will be stopped and re-inspected. The re-inspection in step (4) is to have staff confirm and test on site. If the material can be fed after the re-inspection, it can continue to be fed. If the feeding compartment needs to be replaced, the corresponding valve should be switched and the material should continue to be fed. If the material needs to be returned, it should be returned to the transport vehicle from the return port of the tubular chain conveyor.

2. The automatic feeding system for preventing incorrect material loading in a three-dimensional aggregate bin according to claim 1, characterized in that, The identification of the transport vehicle by the visual recognition device in step (2) involves collecting the license plate number of the transport vehicle by the visual recognition device, sending it to the control host, and comparing it with the QR code recognition result.

3. The automatic feeding system for preventing incorrect material loading in a three-dimensional aggregate bin according to claim 1, characterized in that, In step (3), determining the feeding time based on the current operating status of the feeding system involves confirming whether the tubular chain conveyor is feeding material, determining whether the valve can be switched based on the current material flow in the tubular chain conveyor, calculating the estimated completion time of the current feeding batch based on the conveying speed of the tubular chain conveyor and the feeding start time, and automatically switching the valve to prepare for feeding after the completion time is reached.

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