A method of using a railway container bulk loading system

Abstract

The application discloses a kind of railway container bulk material loading system's use method, it is related to railway container technical field.The railway container bulk material loading system's use method, specific operation is as follows: step S1: measuring train container in length direction distribution distance, including the length of container, the interval (small gap) of two containers on car flat and the interval (large gap) of two flat containers are measured and recorded, and multiple groups of measurement are averaged.The railway container bulk material loading system's use method uses the method of system control, keeps train running in the process of container loading, avoids material falling between containers by controlling the start-stop of vibrating feeder and belt conveyor, and realizes the maximum utilization of container volume by adjusting the discharging amount of vibrating feeder and the given frequency of shunting winch.Improving the upper limit of transport capacity, and then providing conditions for improving capacity.

Description

Technical Field

[0001] This invention relates to the field of railway container technology, specifically to a method for using a railway container bulk loading system. Background Technology

[0002] Railways are an effective mode of transporting bulk goods, playing a crucial role, especially in intra-factory and mine transportation. With the implementation of containerized unloading, the loading time for bulk materials has become a bottleneck restricting transportation efficiency. In particular, production line logistics often rely on the capacity of a single railway line, and loading time impacts the release of production line capacity.

[0003] Currently, the method for loading bulk materials using railway containers is as follows: each flatcar at the rear of the train carries two containers. After the locomotive delivers the flatcar to the designated location, it is uncoupled and drives away. Then, a shunting winch is hooked up to the containers and pulls them one by one to the unloading point for loading.

[0004] Materials are continuously transported from the production line to the top buffer silo. When the container is aligned with the discharge port (with two position detection signals: an infrared position detector and a rotary encoder), the vibrating feeder at the bottom of the buffer silo starts to load the material. After a certain feeding time, the vibrating feeder stops, completing the loading of the current container. Then, the shunting winch is started to pull the next container below the discharge port.

[0005] Modern shunting winches use variable frequency motors and brake-operated controls, increasing the vehicle's load from zero to full capacity during loading. While accurate positioning is possible when the car is empty, slippage often occurs under heavy loads, causing bulk material to fall from between containers onto the tracks, requiring manual recovery. Because of the fixed-point unloading, the drop point is often located at the center of the container, causing the bulk material to accumulate in a cone shape, wasting valuable space in front of and behind the container. Furthermore, the vehicle starts from zero speed and stops loading while in motion, resulting in a short effective loading time for the vibrating feeder.

[0006] Search expression: container + bulk materials + railway, retrieved 15 documents, among which the closest are "CN218319520U-Container tipping machine and container loading and unloading system for railway transportation-disclosure" and "CN217263368U-A container filling device for bulk fertilizer-disclosure".

[0007] CN218319520U - Container Tilting Machine and Container Loading and Unloading System for Railway Transportation - Publication:

[0008] The process involves handling the already loaded containers as a whole, with the loading of materials inside the containers completed in advance. This cannot absorb the time spent lifting and lowering the containers and the additional land area occupied, and is not included in the innovation of this invention.

[0009] CN217263368U - A containerized bulk fertilizer filling device - Publication:

[0010] The purpose is to allow for the simultaneous use of dry bulk containers and general-purpose railway containers, making full use of general-purpose railway containers. This also requires completing the loading process inside the containers in advance. This invention primarily provides a method for efficiently and accurately loading bulk materials directly into the interior of railway containers. Summary of the Invention

[0011] (a) Technical problems to be solved

[0012] To address the shortcomings of existing technologies, this invention provides a method for using a railway container bulk material loading system. This solves the problem that current shunting winches, which use variable frequency motors and brakes for control, experience a significant increase in vehicle load from zero to full load during loading. While accurate positioning is possible when the car is empty, slippage often occurs under heavy loads, causing bulk material to fall from between containers onto the tracks, requiring manual recovery. Because the loading is done at a fixed point, the material falls at the center of the container, causing it to accumulate in a cone shape, wasting valuable space in front of and behind the container. Furthermore, the vehicle starts from zero speed and stops loading while in motion, resulting in a short effective loading time for the vibratory feeder.

[0013] (II) Technical Solution

[0014] To achieve the above objectives, the present invention provides the following technical solution: a method for using a railway container bulk material loading system, the specific operation of which is as follows:

[0015] Step S1: Measure the distribution distance of the train containers along the length direction.

[0016] This includes measuring and recording the length of the container, the distance between two containers on the flatbed (small gap), and the distance between containers between two flatbed sections (large gap), and taking the average of multiple measurements.

[0017] Step S2: Set the initial values ​​for the rotary encoder.

[0018] The origin is a large gap ahead of the first container. The rotation value and coefficient of the rotary encoder are set according to the site conditions.

[0019] Step S3: Establish a function to calculate the distance between the two ends of the train container and the origin.

[0020] Based on the container length, the small gap, the large gap, and the number of train cars, the distances from both ends of each container to the origin can be calculated. For example, the distance from D1 to D0 is d1; the distance from D2 to D0 is d2, and so on.

[0021] Step S4: Determine the specific location of the material drop outlet within the train container.

[0022] Obviously, when the feedback distance of the rotary encoder (e.g., represented by S) is: 0 to d1, d4 to d5, d8 to d9 is a large gap; d2 to d3, d6 to d7, d10 to d11 is a small gap; and d1 to d2, d3 to d4, d5 to d6 is a container.

[0023] Step S5: Vibrating feeder operating rules.

[0024] The system starts when the feedback distance S equals d1 and stops when it equals d2; it starts when the feedback distance S equals d3 and stops when it equals d4...

[0025] Step S6: Calculate the operating frequency of the shunting winch during synchronous loading.

[0026] The operating speed of the shunting winch during synchronous loading is obtained by calculating the loading time and length of a single container. Multiplying this speed by the speed ratio coefficient yields the operating frequency (LHz) of the shunting winch during loading.

[0027] Step S7: Shunting winch speed control rules.

[0028] When the feedback distance S is less than d1, the speed operates at HHz; when it is equal to d1, the speed decreases to LHz. When the feedback distance S is equal to d4, the speed increases to HHz; when it is equal to d5, the speed decreases to LHz...

[0029] Step S8: Software programming.

[0030] Implement the functions of steps S5 and S7 through programming, and open the setting windows for small gap, large gap, and container length.

[0031] Step S9: Adapt to different train numbers.

[0032] Nested functions are used to adapt to changes in the number of train cars, allowing operators to simply input the number of train cars.

[0033] Step S10: Continuous tracking and optimization.

[0034] (III) Beneficial Effects

[0035] This invention provides a method for using a bulk cargo loading system for railway containers. It has the following beneficial effects:

[0036] The operation of this railway container bulk cargo loading system employs a system control approach. During container loading, the train remains running, and material is prevented from falling between containers by controlling the start and stop of the vibrating feeder and belt conveyor. The maximum utilization of container volume is achieved by adjusting the material feeding rate of the vibrating feeder and the set frequency of the shunting winch. This increases the upper limit of transport capacity, thereby providing conditions for increasing production capacity and effectively achieving the following results:

[0037] 1. Implement overall coordinated control of the bulk material feeding device and the train transportation system to control the loading time of a single container based on the train's running speed.

[0038] 2. Based on the pattern of container placement on the train, a function was established, and the position feedback signal of the incremental rotary encoder was used to accurately determine the specific position of the train container at the unloading port.

[0039] 3. The feeding device is started and stopped based on the specific location of the train container, thus preventing material spillage in the empty space of the container.

[0040] 4. A control loop is formed by the vibrating feeder, belt conveyor and electronic belt scale to achieve stable feeding.

[0041] 5. During the loading process, the train speed is uniform and the bulk material feeding rate is stable, which realizes the flat laying of the material pile inside the container and effectively improves the container's volume ratio. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the structure of the present invention. Detailed Implementation

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] Please see Figure 1 This invention provides a technical solution: a method for using a railway container bulk material loading system, the specific operation of which is as follows:

[0045] Step S1: Measure the distribution distance of the train containers along the length direction.

[0046] This includes measuring and recording the length of the container, the distance between two containers on the flatbed (small gap), and the distance between containers between two flatbed sections (large gap), and taking the average of multiple measurements.

[0047] Step S2: Set the initial values ​​for the rotary encoder.

[0048] The origin is a large gap ahead of the first container. The rotation value and coefficient of the rotary encoder are set according to the site conditions.

[0049] Step S3: Establish a function to calculate the distance between the two ends of the train container and the origin.

[0050] Based on the container length, the small gap, the large gap, and the number of train cars, the distances from both ends of each container to the origin can be calculated. For example, the distance from D1 to D0 is d1; the distance from D2 to D0 is d2, and so on.

[0051] Step S4: Determine the specific location of the material drop outlet within the train container.

[0052] Obviously, when the feedback distance of the rotary encoder (e.g., represented by S) is: 0 to d1, d4 to d5, d8 to d9 is a large gap; d2 to d3, d6 to d7, d10 to d11 is a small gap; and d1 to d2, d3 to d4, d5 to d6 is a container.

[0053] Step S5: Vibrating feeder operating rules.

[0054] The system starts when the feedback distance S equals d1 and stops when it equals d2; it starts when the feedback distance S equals d3 and stops when it equals d4...

[0055] Step S6: Calculate the operating frequency of the shunting winch during synchronous loading.

[0056] The operating speed of the shunting winch during synchronous loading is obtained by calculating the loading time and length of a single container. Multiplying this speed by the speed ratio coefficient yields the operating frequency (LHz) of the shunting winch during loading.

[0057] Step S7: Shunting winch speed control rules.

[0058] When the feedback distance S is less than d1, the speed operates at HHz; when it is equal to d1, the speed decreases to LHz. When the feedback distance S is equal to d4, the speed increases to HHz; when it is equal to d5, the speed decreases to LHz...

[0059] Step S8: Software programming.

[0060] Implement the functions of steps S5 and S7 through programming, and open the setting windows for small gap, large gap, and container length.

[0061] Step S9: Adapt to different train numbers.

[0062] Nested functions are used to adapt to changes in the number of train cars, allowing operators to simply input the number of train cars.

[0063] Step S10: Continuous tracking and optimization.

[0064] In summary, the operation of this railway container bulk loading system employs a system control approach. During container loading, the train remains running, and material is prevented from falling between containers by controlling the start and stop of the vibrating feeder and belt conveyor. The maximum utilization of container volume is achieved by adjusting the material feeding rate of the vibrating feeder and the set frequency of the shunting winch. This increases the upper limit of transport capacity, thereby providing conditions for increasing production capacity and effectively achieving the following results:

[0065] 1. Implement overall coordinated control of the bulk material feeding device and the train transportation system to control the loading time of a single container based on the train's running speed.

[0066] 2. Based on the pattern of container placement on the train, a function was established, and the position feedback signal of the incremental rotary encoder was used to accurately determine the specific position of the train container at the unloading port.

[0067] 3. The feeding device is started and stopped based on the specific location of the train container, thus preventing material spillage in the empty space of the container.

[0068] 4. A control loop is formed by the vibrating feeder, belt conveyor and electronic belt scale to achieve stable feeding.

[0069] 5. During the loading process, the train speed is uniform and the bulk material feeding rate is stable, which realizes the flat laying of the material pile inside the container and effectively improves the container's volume ratio.

[0070] This invention employs a system control method. When the train container passes the drop point, the train continues to run and the vibrating feeder is started to load material. When passing through the drop point in the gap between the train containers, the vibrating feeder is stopped to avoid dropping material between the containers. When passing through a large gap, the speed is increased to pass quickly. The maximum utilization of the container volume is achieved by adjusting the material feeding amount of the vibrating feeder and the given frequency of the shunting winch.

[0071] This avoids frequent train starts and stops, reducing the failure rate of the shunting winch power system; it also reduces the insufficiency of manual cleaning of loose materials and secondary dust caused by inaccurate shunting winch positioning; it changes the shape of loose material accumulation inside the container, effectively utilizing the container volume; and it allows for simultaneous loading of materials while the container is open below the unloading point, accelerating its passage through large gaps and increasing the proportion of effective loading time. This effectively increases the upper limit of railway container transport capacity, thus providing the necessary conditions for releasing production capacity.

[0072] The hardware equipment described in this invention includes electronic belt scales, vibrating feeders, belt conveyors, shunting winches, rotary encoders, infrared position detectors, frequency converters, DCS control systems, and database servers, etc.; the software includes programming software, screen editing software, and database software, etc.

[0073] This invention mainly achieves continuous, efficient, and precise loading of bulk materials in train containers by dynamically controlling the start and stop of the vibrating feeder and belt conveyor, as well as the train's running speed.

[0074] First, the length of the container, the distance between two containers on the flatbed, and the distance between containers between two flatbed sections are measured and recorded. The measurement origin is set, and a calculation function is established to calculate the distance between the two ends of the train container and the origin.

[0075] An incremental rotary encoder is installed on the drive reducer of the shunting winch to measure the position of the train. The initial value of the rotary encoder is set, and the position feedback signal of the rotary encoder is used to determine which position of the train container is below the material drop port.

[0076] Alternatively, a function can be established to measure the distance a train container travels from its origin, based on the frequency and operating time of the shunting winch. The calculated distance is then compared with the distance provided by the rotary encoder to ensure timely detection of encoder malfunctions. Furthermore, infrared position detectors are used to verify the movement of passing containers and the gaps between them.

[0077] The above functions are implemented through software programming, which allows for the measurement and prediction of the train's position at the material drop point, thereby controlling the start and stop times of the vibrating feeder. Bulk material is fed from the vibrating feeder, transported by belt conveyor to the drop point for loading. The belt conveyor and vibrating feeder start and stop synchronously, thus avoiding residual vibration during material discharge after the vibrating feeder stops.

[0078] Based on the loading time and length of each container, the operating speed of the shunting winch can be calculated backwards, thus determining the operating frequency of the shunting winch during loading, such as LHz. Regarding the gaps between containers, the gaps between two containers on the same wagon are smaller (e.g., 19cm), while the gaps between two containers on adjacent wagons are larger (e.g., 115cm). Considering the train's acceleration and deceleration time, the operating frequency of the shunting winch can be set to a higher frequency, such as HHz, only when passing through large gaps.

[0079] The feed rate of bulk materials can be adjusted by the excitation frequency of the vibrating feeder and the amplitude of the eccentric block, and measured by an electronic belt scale. When the transport capacity is insufficient, the feed rate of the vibrating feeder is adjusted to the maximum. The optimal feed rate can also be adjusted according to the specific gravity of different materials, and combined with the adjustment of the shunting winch running speed, the container volume utilization rate can be controlled. This achieves the effect of increasing the upper limit of transport capacity, avoiding bulk materials falling due to inaccurate positioning, and accurately controlling the container volume ratio.

[0080] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0081] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for using a railway container bulk cargo loading system, characterized in that: The specific steps are as follows: Step S1: Measure the distribution distance of the train containers along the length direction; This includes measuring and recording the container length, the small gap between two containers on the flatbed, and the large gap between containers between two flatbed sections, and taking the average of multiple measurements. Step S2: Set the initial values ​​for the rotary encoder; The origin is a large gap ahead of the first container. The rotation value and coefficient of the rotary encoder are set according to the site conditions. Step S3: Establish a function to calculate the distance between the two ends of the train container and the origin; Based on the container length, small gap, large gap, and number of train cars, the distances between the two ends of each container and the origin can be calculated. The distance from D1 to D0 is d1; the distance from D2 to D0 is d2; and the distance from Dn to D0 is dn, where n is a non-zero natural number. Step S4: Determine the specific location of the material drop outlet within the train container; When the feedback distance S of the rotary encoder is in the range of: large neutral when it is from d(4m) to d(4m+1); small neutral when it is from d(4m+2) to d(4m+3); and container when it is from d(2m+1) to d(2m+2), where m is a natural number; Step S5: Vibrating feeder operating rules; The system starts when the feedback distance S equals d(2i+1) and stops when it equals d(2i+2), where i is a natural number. Step S6: Calculate the operating frequency of the shunting winch during synchronous loading; The operating speed of the shunting winch during synchronous loading is obtained by calculating the loading time and length of a single container. Multiplying this speed by the speed ratio coefficient yields the operating frequency (LHz) of the shunting winch during loading. Step S7: Shunting winch speed control rules; When the feedback distance S is less than d1, the speed is reduced to HHz; when it is equal to d1, the speed is reduced to LHz. When the feedback distance S is equal to d(4x), the speed is increased to HHz; when it is equal to d(4x+1), the speed is reduced to LHz, where x is a non-zero natural number. Step S8: Software programming; Implement the functions of steps S5 and S7 through programming, and open the setting windows for small gap, large gap and container length; Step S9: Adapt to different train numbers; Nested functions are used to adapt to changes in the number of train cars; operators only need to input the number of train cars. Step S10: Continuous tracking and optimization.

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