A coal bunker jam monitoring system based on real-time prediction of coal bunker coal level

Abstract

The application discloses a coal bunker blockage monitoring system based on real-time prediction of coal bunker coal level, which comprises a coal bunker coal replenishment monitoring module and a volume calculation module with double-acting switching, which are constructed by using a coal level gauge signal; the volume calculation module is activated by the coal replenishment signal to update the coal bunker coal storage volume monitoring; the updated coal bunker coal storage volume monitoring module and the coal bunker coal drop volume monitoring module generate a coal bunker coal level prediction signal through the switching reset volume calculation module and a balance compensation module cyclic iteration; the coal bunker coal level prediction signal and the coal level gauge signal constitute a coal bunker blockage early warning module, which outputs a coal bunker blockage alarm signal and a blockage positioning prediction, and activates a coal bunker blockage prevention suppression module to control the bunker wall rapping device or the air cannon at different positions of the coal bunker. The application can realize the whole-process monitoring of the coal bunker operation of the boiler, timely find the coal bunker blockage, position the blockage occurrence position, and execute different intervention measures according to different degrees of blockage.

Description

Technical Field

[0001] This invention relates to the field of coal bunker blockage monitoring, and in particular to a coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker. Background Technology

[0002] Coal bunkers and hoppers in thermal power plants are used to store raw coal and granular materials such as coal slurry. Blockage in these bunkers or hoppers is a common challenge, posing a serious threat to the stable operation and safety of the power plant. Blockage reduces the effective volume within the bunker, creating "rat holes," causing coal feeder interruptions, shortening coal feeding intervals, and increasing the frequency of coal conveying system operation. This leads to large fluctuations in boiler operating conditions and makes it difficult to control environmental indicators. Furthermore, improper handling can even lead to boiler flameout, spontaneous combustion of the coal hopper, or explosion, severely impacting normal production. In particularly severe cases, serious blockages have resulted in major accidents such as bunker collapses during unloading, causing personal injury and millions of yuan in direct economic losses.

[0003] The main causes of blockages are varied. The design structures of raw coal hoppers or bunkers include rectangular cross-section conical, conical, rectangular hyperbolic, and circular hyperbolic designs. While each of these structural types has its own characteristics, they all present varying degrees of blockage problems. For example, in conical raw coal bunkers, the flow cross-sectional area gradually decreases, leading to increased compression pressure and increased friction between coal particles and the bunker walls, resulting in arching and blockage. In rectangular raw coal bunkers, the coal near the four corners of the hopper wall experiences "double-sided friction" and compression, making it prone to sticking to the corners and causing blockages. However, the most significant cause of blockages includes coal quality characteristics (such as moisture content and particle size distribution). Currently, many thermal power plants in my country cannot guarantee the use of a single coal source and require blended coal combustion, making blockages caused by coal quality characteristics unavoidable.

[0004] Coal blockage can take a considerable amount of time to develop from its initial stage to its severe state. Minor blockages in the coal bunker, such as coal adhesion or deposition, may only require the use of vibrators, water spraying, or simple cleaning operations. Minor blockages, if not addressed promptly, can progress to moderate or even severe blockages. For moderate blockages, such as caking or minor arching blockages, equipment like air cannons and hydraulic loosening machines are typically used. If the blockage develops into hard caking or large arching blockages, the treatment time may be several days or even longer, requiring complex operations and equipment, such as large-scale cleaning equipment or blasting operations.

[0005] To prevent and mitigate significant losses, thermal power plants employ various technologies to detect and manage coal bunker blockages. Current monitoring and early warning technologies for coal bunker blockages include using new level gauges as primary sensors to collect real-time data on coal level on the inner surface of the bunker at multiple points. This data is then processed by computer to simulate the actual coal distribution on-site. Alternatively, coal seam pressure sensors are installed to monitor changes in coal pile pressure in real time. Alarms are triggered by abnormal pressure changes to prevent blockages. However, existing technologies have limitations in several aspects. Radar level gauges, as the mainstream and relatively advanced level sensor, may experience signal attenuation when measuring highly conductive materials (such as coal with high moisture content). In environments with high dust concentrations, radar signals may be scattered or absorbed. In conical coal bunkers, radar waves may reflect multiple times on the conical walls, creating false echoes. Internal supports, pipes, or other structures may interfere with radar signal propagation. All of these issues significantly affect measurement accuracy and precision. In terms of monitoring systems, structural modifications to the coal bunker and the installation of numerous monitoring points are required. This increases the structural complexity of the bunker's inner walls, creating new causes of blockages, and the addition of heterogeneous industrial control network security risks due to the new monitoring and early warning computer processing units. Regarding blockage mitigation, most of these heterogeneous monitoring and early warning computer processing units are based on original black-box systems, which not only suffer from delayed execution but also frequently become inaccurate after changes in production processes. This results in anti-blockage measures being mismatched with the specific conditions of the coal bunker or hopper, failing to effectively solve the coal blockage problem, leading to obstructed coal flow and impacting production efficiency. Incorrect triggering of anti-blockage equipment can also cause safety risks; for example, inappropriate vibrator frequencies may damage the coal bunker structure, and excessively strong airflow devices may pose a risk of coal dust explosions. Summary of the Invention

[0006] The main objective of this invention is to overcome the aforementioned deficiencies in the prior art and propose a coal bunker blockage monitoring system based on real-time prediction of coal bunker level. This system can realize full-process monitoring of boiler coal bunker operation, timely detect coal bunker blockage, locate the location of the blockage, and implement different intervention measures for different degrees of blockage.

[0007] The present invention adopts the following technical solution:

[0008] A coal bunker blockage monitoring system based on real-time prediction of coal level includes:

[0009] The coal bunker replenishment monitoring module acquires the coal level gauge signal from the coal bunker. Based on the coal level gauge signal, it determines when coal feeding begins and triggers the coal bunker replenishment start signal, initializing the coal bunker storage volume monitoring module, the coal bunker falling coal volume monitoring module, and the coal bunker blockage early warning module. Based on the coal level gauge signal, it determines when coal feeding ends and activates the coal bunker storage volume monitoring module, the coal bunker falling coal volume monitoring module, and the coal bunker blockage early warning module.

[0010] The coal bunker coal storage volume monitoring module, after activation, switches the input of the volume calculation module to the real-time signal of the coal level gauge and the output of the volume calculation module to the coal storage volume signal after coal loading, updating the initial coal storage volume of the coal bunker to the coal storage volume signal after coal loading is completed; after the update is completed, the updated initial coal storage volume of the coal bunker is output to the balance compensation module as a given value, the input of the volume calculation module is the register output of the balance compensation module, and the output of the volume calculation module is the first input signal of the balance compensation module, performing real-time cyclic prediction of the coal level in the coal bunker;

[0011] The coal bunker coal volume monitoring module starts calculating the real-time coal volume after the coal bunker coal volume monitoring module is activated, and outputs it to the second input signal of the balance compensation module in real time in a loop.

[0012] The balance compensation module iteratively calculates the real-time predicted coal storage volume of the coal bunker. When the sum of the first input signal and the second input signal reaches a balance with the given value, the register output of the subsequent stage of the balance compensation module is activated, and the predicted coal level signal of the coal bunker is output.

[0013] The coal bunker blockage early warning module calculates the difference in coal drop detection height between the predicted coal level signal and the real-time coal level gauge signal. When the difference in coal drop detection height reaches the blockage early warning condition, an alarm signal is issued.

[0014] Preferably, the coal bunker blockage monitoring system based on real-time prediction of coal bunker level is characterized in that it further includes:

[0015] The coal bunker anti-blocking and suppression module is activated after the coal bunker blockage early warning module issues an alarm signal. The coal bunker anti-blocking and suppression module starts a vibrating device or an air cannon to clear the blockage based on the coal drop detection height difference and real-time coal feeding rate signal. The vibrating device and air cannon are distributed at different heights around the bunker wall on the side of the coal bunker.

[0016] Preferably, the coal bunker is divided into two or more sections, and each section is equipped with a coal level gauge; the coal replenishment monitoring module is based on the coal level gauge signals of all sections; the coal storage volume monitoring module, the coal drop volume monitoring module, the balance compensation module, the coal blockage early warning module, and the coal blockage prevention and suppression module all process independently for each section.

[0017] Preferably, in the coal bunker replenishment monitoring module, determining the start of coal feeding based on the coal level gauge signal specifically includes:

[0018] When there is only one coal level gauge, the preset periodic change of the coal level gauge signal is calculated. When the preset periodic change of the coal level gauge signal is greater than the first threshold and the triggering time interval of the signal exceeding the first threshold is less than the second threshold, it is determined that coal feeding has started.

[0019] The end of coal feeding is determined based on the coal level gauge signal, specifically including:

[0020] After the coal bunker starts to replenish coal signal is activated, the preset periodic change of the coal level gauge signal is detected until it is less than the third threshold, at which point it is determined that coal feeding has ended.

[0021] When there are two or more coal level gauges, the preset periodic change amount is calculated for all coal level gauge signals. When the preset periodic change amount of at least two coal level gauge signals is greater than the first threshold and the triggering time interval of exceeding the first threshold is less than the second threshold, it is determined that coal feeding has started.

[0022] The end of coal feeding is determined based on the coal level gauge signal, specifically including:

[0023] After the coal bunker starts to replenish coal signal activation, the preset periodic change of at least two coal level gauge signals is detected until both are less than the third threshold, at which point it is determined that coal feeding has ended.

[0024] Preferably, in the coal bunker volume calculation module, the initial coal storage volume and the real-time predicted coal storage volume of the coal bunker are calculated based on the coal bunker design structural parameters.

[0025] Preferably, in the coal bunker coal falling volume monitoring module, the real-time coal falling volume of the coal bunker is calculated as follows:

[0026]

[0027] Among them, V At The real-time coal drop volume is represented by ρ; the coal particle size density coefficient is represented by ρ; ∈ represents the time interval from the most recent initialization until the activation signal is re-issued; t represents the time interval from the most recent activation until the initialization signal is re-issued; M A The coal feed rate signal represents the integral time of the preset time width dt, and the coal feed rate signal is the coal feed rate signal after multiplying by the preset time width coefficient.

[0028] Preferably, in the balance compensation module, when the difference between the real-time predicted coal storage volume and the initial coal storage volume and the real-time coal falling volume of the coal bunker reaches a balance, it is represented as follows:

[0029]

[0030] Among them, V(h) tn (h) is based on real-time coal bunker level prediction signal. tn And the specific coal bunker design structural parameters, referencing the updated initial coal storage volume V. A0n The real-time predicted coal storage volume of the generated coal bunker, V(h) is calculated. tn The calculation process iterates repeatedly through balance compensation until the difference between the two sides of the formula is less than the fourth threshold, and then outputs the final predicted coal bunker level signal; V At This indicates the real-time volume of coal falling from the coal bunker.

[0031] Preferably, in the coal bunker blockage early warning module, the difference in coal drop detection height between the predicted coal level signal and the real-time coal level gauge signal is calculated. When the coal drop detection height difference reaches the blockage early warning condition, an alarm signal is issued, specifically including:

[0032] When the coal drop detection height difference is greater than or equal to the fifth threshold, a coal bunker blockage alarm signal is output. Based on the coal bunker design structure parameters and the coal drop detection height difference, an empirical constant is superimposed to output blockage location prediction parameters. The empirical constant is generated by multiple iterations of fitting during the normal coal drop process of the calculation loop. The blockage location prediction parameters include the average blockage elevation, the arched blockage sag, and the circumferential location of the blockage.

[0033] Preferably, the coal bunker blockage early warning module is also used to activate the anti-blockage suppression module, and when the coal falling detection height difference is less than the sixth threshold, reset the alarm signal and stop the anti-blockage suppression module.

[0034] Preferably, the coal bunker anti-blocking and suppression module is specifically used to: control the corresponding circumferential parts of the coal bunker and the wall vibration devices that are close to and slightly higher than the arched blockage height, based on the blockage location prediction parameters output by the coal bunker blockage early warning module, to perform initial blockage clearing at a preset frequency; simultaneously, perform real-time calculation and monitoring of the coal drop detection height difference and real-time coal feed rate signals, and when the decrease in the real-time coal feed rate signal is greater than the seventh threshold or the coal drop detection height difference is greater than the eighth threshold, control the corresponding circumferential parts of the coal bunker and the air cannons that are close to and slightly higher than the arched blockage height to start, and perform moderate blockage clearing at a preset frequency.

[0035] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0036] (1) This invention monitors coal feeding in the coal bunker through a coal bunker replenishment monitoring module; after the coal storage volume monitoring module is activated, the volume calculation module is switched to calculate the initial coal storage volume and the real-time predicted coal storage volume; the real-time coal drop volume in the coal bunker is calculated based on the coal drop volume monitoring module; using a balance compensation module, the difference between the real-time predicted coal storage volume and the initial coal storage volume and the real-time coal drop volume in the coal bunker is balanced to obtain a coal level prediction signal in the coal bunker; the coal drop detection height difference is calculated through a coal bunker blockage early warning module, an alarm signal is issued based on the coal drop detection height difference, and blockage location prediction is realized; different interventions are performed for different degrees of blockage through a coal bunker anti-blockage suppression module to ensure the safe and continuous production of the thermal power plant;

[0037] (2) The present invention can bypass the static deviation of the existing coal level measuring points in the coal bunker, and combine the coal feeding metering system to perform data mining on the changing characteristics of the coal falling process in the coal bunker, without generating any network security risks.

[0038] (3) The present invention can be used to optimize and expand the measurement points based on the physical location in various complex coal bunker structures, obtain more accurate blockage location, more effectively judge the coal blockage situation, and obtain the key parts of blockage treatment in the first time, effectively reduce the consumption of manpower and material resources in the coal blending operation of thermal power plants, ensure the continuity and stability of power production, and provide data reference for subsequent coal bunker structure optimization and transformation.

[0039] (3) The coal bunker level prediction signal generated by the system of the present invention can also be used as a calibration signal for replacing or modifying the coal bunker level gauge, and to test the performance and sensitivity of the device. Even if the coal bunker undergoes structural size and volume changes in the future, the system can flexibly adjust the coal bunker design structural parameters in the module (different coal bunker structures can adjust the module calculation function according to the parameters through the component adjustment) and continue to operate stably. Attached Figure Description

[0040] Figure 1 This is a structural block diagram of a coal bunker blockage monitoring system based on real-time prediction of coal level, according to an embodiment of the present invention.

[0041] Figure 2 This is a schematic diagram of the coal bunker structure and parameters according to an embodiment of the present invention. Detailed Implementation

[0042] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0043] See Figure 1As shown, the present invention discloses a coal bunker blockage monitoring system based on real-time prediction of coal level, comprising a coal bunker replenishment monitoring module 11, a volume calculation module 12, a coal storage volume monitoring module 13, a coal drop volume monitoring module 14, a balance compensation module 15, and a coal bunker blockage early warning module 16. Specifically:

[0044] The coal bunker replenishment monitoring module 11 acquires the coal level gauge signal collected from the coal bunker. Based on the coal level gauge signal, when coal feeding begins, it triggers the coal bunker replenishment start signal and initializes the coal bunker storage volume monitoring module 13, the coal bunker falling coal volume monitoring module 14, and the coal bunker blockage early warning module 16. Based on the coal level gauge signal, when coal feeding ends, it activates the coal bunker storage volume monitoring module 13, the coal bunker falling coal volume monitoring module 14, and the coal bunker blockage early warning module 16.

[0045] The coal storage volume monitoring module 13, after being activated, switches the input of the volume calculation module 12 to the real-time signal of the coal level gauge and the output of the volume calculation module 12 to the coal storage volume signal after coal loading, updating the initial coal storage volume of the coal bunker to the coal storage volume signal after coal loading is completed; after the update is completed, the updated initial coal storage volume of the coal bunker is output to the balance compensation module 15 as a given value, the input of the volume calculation module 12 is the pre-stage signal of the balance compensation module register output, and the back end of the volume calculation module 12 is the first input signal of the balance compensation module 15, so as to perform real-time cyclic prediction of the coal level in the coal bunker;

[0046] The coal bunker coal volume monitoring module 14 starts calculating the coal volume after it is activated, and outputs the real-time cyclical input signal to the second input signal of the balance compensation module 15.

[0047] The balance compensation module 15 controls the coal bunker coal level prediction calculation loop to calculate the real-time predicted coal storage volume of the coal bunker. When the sum of the first input signal and the second input signal reaches a balance with the given value, the register output of the subsequent stage of the balance compensation module 15 is activated, and the coal bunker coal level prediction signal is output.

[0048] The coal bunker blockage early warning module 16 calculates the coal level prediction signal and the coal level gauge signal collected in real time in the coal bunker, and issues an alarm signal when the coal level detection height difference reaches the blockage early warning condition.

[0049] The coal bunker anti-blocking and suppression module 17 and the coal bunker blockage early warning module 16 activate the coal bunker anti-blocking and suppression module 1 after issuing an alarm signal; the coal bunker anti-blocking and suppression module 1 starts the vibrating device or air cannon to clear the blockage based on the coal falling detection height difference and real-time coal feeding rate signal; the vibrating device and air cannon are distributed around the bunker wall at different heights on the side of the coal bunker.

[0050] In this embodiment, the coal level gauge signal is acquired by two or more radar-type coal level gauges installed on the top of the coal bunker. The number of radar-type coal level gauges corresponds to the number of divisions within the coal bunker. Furthermore, at least one wall-mounted vibrating device is distributed at different heights along the sidewalls of the coal bunker, along with air cannons arranged in the same manner. A coal feeder control device is connected to the coal outlet of the coal bunker, as well as a DCS distributed control system or PLC control system that connects the control signals of the aforementioned modules.

[0051] The following example illustrates the situation using a coal bunker with two sections, two corresponding radar-type coal level gauges, and a DCS distributed control system.

[0052] A coal bunker blockage monitoring system based on real-time coal level prediction is disclosed. Based on a DCS system software calculation engine, it utilizes a coal replenishment monitoring module 11 (built from coal level gauge signals) and a volume calculation module 12 with dual-function switching. The replenishment signal switches the volume calculation module 12 to activate and update the coal storage volume monitoring. The updated coal storage volume monitoring module 13 and the coal drop volume monitoring module 14, after switching and resetting the volume calculation module 12, iteratively generate a coal level prediction signal through a balance compensation module 15. This prediction signal, along with two sets of radar-type coal level gauge signals, constitutes a coal bunker blockage early warning module 16. The early warning module 16 outputs a blockage alarm signal and blockage location prediction, and activates a coal bunker anti-blockage suppression module 17. This module controls the wall vibration devices and / or air cannons at different locations within the coal bunker, thereby achieving full-process monitoring of the boiler coal bunker operation. The system features static coal quantity reset at the completion of coal feeding, adaptive coal level cyclic correction prediction based on irregular replenishment cycles, and blockage location management.

[0053] The specific implementation of the coal bunker replenishment monitoring module 11 is as follows: Based on the signals of two (or more, taking two as an example) radar coal level gauges, the preset time period change is calculated cyclically. When the preset period change of the signals of both radar coal level gauges is greater than a first threshold, and the trigger time interval between exceeding the first threshold is less than a second threshold, a coal bunker replenishment signal is triggered. This signal initializes the coal bunker storage volume monitoring module 13, the coal bunker falling coal volume monitoring module 14, and the coal bunker blockage early warning module 16. After the coal bunker replenishment signal is activated, the preset period change of the signals of the two radar coal level gauges is detected until both are less than a third threshold, at which point the coal bunker storage volume monitoring module 13 and the coal bunker falling coal volume monitoring module 14 are activated.

[0054] The specific implementation of the coal storage volume monitoring module 13 in the coal bunker is as follows: Independent monitoring loops are constructed based on two (or more, taking two as an example) radar-type coal level gauge signals. Each monitoring loop is based on specific coal bunker design structural parameters and the coal level gauge signal value h at the moment the module is activated. 0n(i.e., the signal values ​​of the two coal level gauges after coal feeding is completed), calculate and output the corresponding coal storage volume signals V of the two coal bunkers. A0n Where n represents the radar-type coal level gauge number, this volume is stored as the coal storage value after this coal loading, and is cleared to zero after the next initialization. See also Figure 2 The figure shows a formula for calculating the coal storage volume based on the structural parameters of a typical conical coal hopper structure, as shown in the embodiment.

[0055]

[0056] It should be noted that, in this embodiment, the volume calculation module 12 has a dual-function switching function, which is used for both the coal storage volume calculation loop and the coal bunker level prediction calculation loop. This does not mean that the module cannot be copied and replaced and used in parallel.

[0057] The specific implementation of the coal bunker coal drop volume monitoring module 14 is as follows: Based on the coal feeder control device connected to the coal bunker's coal outlet, its standard process real-time coal feed rate signal is transformed into an integral time coal feed rate signal M with a preset time width dt. A During the initialization of the coal drop volume monitoring module 14 in the coal bunker, the coal drop volume V output by the module is monitored. At The system resets to zero and begins integrating and calculating the output coal volume V when the coal bunker's coal drop volume monitoring module 14 is activated. At ρ represents the coal particle size density coefficient, which can be corrected through the human-machine interface of the DCS system; ∈ represents the time interval between the module's most recent initialization and reactivation, and t represents the time interval between the most recent initialization and reinitialization. Both are sent out as auxiliary signals by the coal bunker drop volume monitoring module 14 for display.

[0058]

[0059] Among them, V At The real-time coal drop volume is represented by ρ; the coal particle size density coefficient is represented by ρ; ∈ represents the time interval from the most recent initialization until the activation signal is re-issued; t represents the time interval from the most recent activation until the initialization signal is re-issued; M A The coal feed rate signal represents the integral time of the preset time width dt. The coal feed rate signal is the coal feed rate signal after multiplying by the preset time width coefficient. The original coal feed rate signal is in cubic meters per hour.

[0060] Specifically, the balance compensation module 15 iteratively generates the coal bunker coal level prediction signal based on the following balance formula:

[0061]

[0062] The V(h) tnThis is based on real-time coal level prediction signals and specific coal bunker design structural parameters, referencing coal storage volume signals V in different coal bunkers. A0n The calculated real-time predicted coal bunker volume is generated through iterative balancing and compensation until the difference between the two sides of the formula is less than the fourth threshold. The resulting predicted coal level signal h for different coal bunkers is then output. tn In this embodiment, the pseudocode format for the balance compensation is as follows:

[0063]

[0064] As mentioned earlier, the volume calculation module 12 has a dual-function switching capability, V(h) tn Based on a typical cone-shaped coal hopper structure embodiment, fx(h) tn The calculation formula is as follows; the meanings of the symbols in the formula are as follows: Figure 2 As shown.

[0065]

[0066] The specific implementation of the coal bunker blockage early warning module 16 is as follows: Based on the coal bunker coal level prediction signal h... tn The two sets of radar-type coal level gauge signals, together with the coal level gauge signals, constitute the coal falling detection height difference of the coal bunker sections where the radar-type coal level gauges are located. When the coal falling detection height difference of a section is greater than a fifth threshold, a coal bunker blockage alarm signal is output. Based on the coal bunker design structural parameters and the coal falling detection height difference, an empirical constant is superimposed to output blockage location prediction parameters. The empirical constant is generated by multiple iterations of fitting during the normal coal falling process of the calculation loop. The blockage location prediction parameters include the average blockage elevation, the arched blockage sag, and the circumferential location of the blockage. Furthermore, after issuing the alarm signal, the section blockage early warning module activates the anti-blockage suppression module. When the coal falling detection height difference of a section is less than a sixth threshold (the difference between the fifth threshold and the preset return value), the alarm signal is reset and the anti-blockage suppression module is stopped.

[0067] The specific implementation of the coal bunker anti-blocking suppression module 17 is as follows: Based on the blockage location prediction parameters, the module controls the corresponding circumferential parts of the coal bunker and the wall vibration devices that are close to and slightly higher than the arched blockage height to perform initial blockage clearing at a preset frequency. In parallel, the module activates the suppression evaluation module to perform real-time calculation and monitoring of the coal drop detection height difference and real-time coal feed rate signals. When the decrease in the real-time coal feed rate signal is greater than the seventh threshold, or the coal drop detection height difference is greater than the eighth threshold, the moderate blockage alarm signal of the coal bunker is activated, and the air cannons that are corresponding circumferential parts of the coal bunker and close to and slightly higher than the arched blockage height are activated to perform moderate blockage clearing at a preset frequency.

[0068] The above are merely specific embodiments of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention using this concept shall be considered as infringing upon the protection scope of the present invention.

Claims

1. A coal bunker blockage monitoring system based on real-time prediction of coal level, characterized in that, include: The coal bunker replenishment monitoring module acquires the coal level gauge signal from the coal bunker. Based on the coal level gauge signal, it determines when coal feeding begins and triggers the coal bunker replenishment start signal, initializing the coal bunker storage volume monitoring module, the coal bunker falling coal volume monitoring module, and the coal bunker blockage early warning module. Based on the coal level gauge signal, it determines when coal feeding ends and activates the coal bunker storage volume monitoring module, the coal bunker falling coal volume monitoring module, and the coal bunker blockage early warning module. The coal bunker coal storage volume monitoring module, after activation, switches the input of the volume calculation module to the real-time signal of the coal level gauge and the output of the volume calculation module to the coal storage volume signal after coal loading, updating the initial coal storage volume of the coal bunker to the coal storage volume signal after coal loading is completed; after the update is completed, the updated initial coal storage volume of the coal bunker is output to the balance compensation module as a given value, the input of the volume calculation module is the register output of the balance compensation module, and the output of the volume calculation module is the first input signal of the balance compensation module, performing real-time cyclic prediction of the coal level in the coal bunker; The coal bunker coal volume monitoring module starts calculating the real-time coal volume after the coal bunker coal volume monitoring module is activated, and outputs it to the second input signal of the balance compensation module in real time in a loop. The balance compensation module iteratively calculates the real-time predicted coal storage volume of the coal bunker. When the sum of the first input signal and the second input signal reaches a balance with the given value, the register output of the subsequent stage of the balance compensation module is activated, and the predicted coal level signal of the coal bunker is output. The coal bunker blockage early warning module calculates the difference in coal drop detection height between the predicted coal level signal and the real-time coal level gauge signal. When the difference in coal drop detection height reaches the blockage early warning condition, an alarm signal is issued.

2. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, Also includes: The coal bunker anti-blockage suppression module is activated after the coal bunker blockage early warning module issues an alarm signal. The coal bunker anti-blocking and suppression module activates a rapping device or an air cannon to clear blockages based on the coal drop detection height difference and real-time coal feeding rate signal; the rapping device and air cannon are distributed at different heights around the bunker wall on the side of the coal bunker.

3. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, The coal bunker is divided into two or more sections, and each section is equipped with a coal level gauge; the coal replenishment monitoring module is based on the coal level gauge signals of all sections; the coal storage volume monitoring module, the coal drop volume monitoring module, the balance compensation module, the coal blockage early warning module, and the coal blockage prevention and suppression module all process independently for each section.

4. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, The coal bunker replenishment monitoring module determines the start of coal feeding based on the coal level gauge signal, specifically including: When there is only one coal level gauge, the preset periodic change of the coal level gauge signal is calculated. When the preset periodic change of the coal level gauge signal is greater than the first threshold and the triggering time interval of the signal exceeding the first threshold is less than the second threshold, it is determined that coal feeding has started. The end of coal feeding is determined based on the coal level gauge signal, specifically including: After the coal bunker starts to replenish coal signal is activated, the preset periodic change of the coal level gauge signal is detected until it is less than the third threshold, at which point it is determined that coal feeding has ended. When there are two or more coal level gauges, the preset periodic change amount is calculated for all coal level gauge signals. When the preset periodic change amount of at least two coal level gauge signals is greater than the first threshold and the triggering time interval of exceeding the first threshold is less than the second threshold, it is determined that coal feeding has started. The end of coal feeding is determined based on the coal level gauge signal, specifically including: After the coal bunker starts to replenish coal signal activation, the preset periodic change of at least two coal level gauge signals is detected until both are less than the third threshold, at which point it is determined that coal feeding has ended.

5. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, In the coal bunker volume calculation module, the initial coal storage volume and the real-time predicted coal storage volume of the coal bunker are calculated based on the coal bunker design structural parameters.

6. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, The coal bunker falling volume monitoring module calculates the real-time coal falling volume in the coal bunker as follows: Among them, V At The real-time coal drop volume is represented by ρ; the coal particle size density coefficient is represented by ρ; ∈ represents the time interval from the most recent initialization until the activation signal is re-issued; t represents the time interval from the most recent activation until the initialization signal is re-issued; M A The coal feed rate signal represents the integral time of the preset time width dt, and the coal feed rate signal is the coal feed rate signal after multiplying by the preset time width coefficient.

7. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, In the balance compensation module, when the difference between the real-time predicted coal storage volume and the initial coal storage volume and the real-time coal falling volume in the coal bunker reaches a balance, it is represented as follows: Among them, V(h) tn (h) is based on real-time coal bunker level prediction signal. tn And the specific coal bunker design structural parameters, referencing the updated initial coal storage volume V. A0n The real-time predicted coal storage volume of the generated coal bunker, V(h) is calculated. tn The calculation process iterates repeatedly through balance compensation until the difference between the two sides of the formula is less than the fourth threshold, and then outputs the final predicted coal bunker level signal; V At This indicates the real-time volume of coal falling from the coal bunker.

8. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 1, characterized in that, The coal bunker blockage early warning module calculates the difference in coal drop detection height between the predicted coal level signal and the real-time coal level gauge signal. When the coal drop detection height difference reaches the blockage early warning condition, an alarm signal is issued, specifically including: When the coal drop detection height difference is greater than or equal to the fifth threshold, a coal bunker blockage alarm signal is output. Based on the coal bunker design structure parameters and the coal drop detection height difference, an empirical constant is superimposed to output blockage location prediction parameters. The empirical constant is generated by multiple iterations of fitting during the normal coal drop process of the calculation loop. The blockage location prediction parameters include the average blockage elevation, the arched blockage sag, and the circumferential location of the blockage.

9. The coal bunker blockage monitoring system based on real-time prediction of coal level in a coal bunker according to claim 8, characterized in that, The coal bunker blockage early warning module is also used to activate the anti-blockage suppression module, and when the coal drop detection height difference is less than the sixth threshold, it resets the alarm signal and stops the anti-blockage suppression module.

10. The coal bunker blockage monitoring system based on real-time prediction of coal level in the coal bunker according to claim 2, characterized in that, The coal bunker anti-blocking and suppression module is specifically used to: control the corresponding circumferential parts of the coal bunker and the wall vibration devices that are close to and slightly higher than the arched blockage height, based on the blockage location prediction parameters output by the coal bunker blockage early warning module, to perform initial blockage clearing at a preset frequency; at the same time, it performs real-time calculation and monitoring of the coal drop detection height difference and the real-time coal feed rate signal, and when the decrease in the real-time coal feed rate signal is greater than the seventh threshold or the coal drop detection height difference is greater than the eighth threshold, it controls the corresponding circumferential parts of the coal bunker and the air cannons that are close to and slightly higher than the arched blockage height to start, and perform moderate blockage clearing at a preset frequency.

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