Installation and early warning method and device for high-fall buffer chute funnel

Abstract

The invention belongs to the technical field of metallurgical equipment, and particularly relates to an installation and early warning method and device for a high-fall buffer chute funnel. Comprising the following steps: (1) mounting a chute funnel: reserving a space for mounting a buffer base plate in the chute funnel, and externally supporting an auxiliary support; (2) fall grading: reasonably and equally dividing the inner wall of the chute funnel according to the fall of the chute funnel and the gravity of conveyed blocky materials; (3) buffer base plates are manufactured and installed, wherein the buffer base plates are installed at proper positions in all fall grading points on the inner wall of the chute funnel in the horizontal spiral direction; and (4) mounting an online monitoring system: analyzing the actual pressure of the side wall of the chute funnel at the mounting position of each buffer base plate through online monitoring. Through reasonable grading and buffering, the problems of material crushing, equipment abrasion and the like in the high-fall blocky material conveying process are solved, and the high-fall efficient conveying requirement of the blocky materials is met.

Description

Technical Field

[0001] The invention belongs to the technical field of metallurgical equipment, and in particular relates to an installation and early warning method and device for a high-drop buffer chute funnel. Background Art

[0002] With the rapid development of science and technology and economy, the production of enterprises is becoming increasingly large-scale and large-scale. In the process of material transportation, there is an increasing demand for conveying materials with a height difference of more than 10 meters. Affected by factors such as the gravity of the material itself, a height difference of more than 10 meters forms a large material impact force, which will cause adverse consequences such as material crushing during the transportation of block materials. At the same time, it also greatly increases equipment loss, such as wear of the chute funnel wall, deformation of the belt bracket of the next process, and shortened service life. For this reason, most companies have made two types of improvements to the high-drop drop point. One is to set up an intermediate belt conveyor, and the other is to change the straight chute funnel to a corner chute funnel. The former has a large investment and operating cost, and has strict requirements on geographical space, so it cannot be widely promoted; the latter aggravates the frequent wear of the funnel, frequent leakage and scattering accidents, and serious accumulation of materials at the corners, which can easily cause the funnel to fall off, thereby causing major safety accidents.

[0003] After inquiry, the high drop material buffer chute with application number CN202310580207.X and announcement number CN116513694A has multiple groups of discharge valve plates inside the chute, which effectively reduces the impact of high drop materials on the lower receiving belt and equipment, and reduces dust. This patented technology mainly uses springs behind the valve plates for buffering. If the reserved discharge port between each group of discharge valve plates is too large, it will affect the conveying efficiency, and if it is too small, the buffering effect will be poor. It is only suitable for small material flow conveying needs.

[0004] After inquiry, the high-drop corner chute funnel with patent number 201821032585.5 uses a movable plug plate to form an impact-resistant working surface, which solves the problem of high-drop material transportation. This patented technology is only suitable for the transportation needs of small-particle bulk materials. The high-drop buffer chute funnel provided by this patented technology can meet the high-drop and efficient transportation needs of bulk materials through reasonable grading and buffering. The high-drop buffer chute funnel provided by this patented technology can take into account both buffering and transportation needs through reasonable grading and buffering, and meet the high-drop and efficient transportation needs of bulk materials. Summary of the invention

[0005] The purpose of the present invention is to provide an installation and early warning method and device for a high-drop buffer chute funnel to solve the problems existing in the prior art.

[0006] The technical solution adopted by the present invention to solve its technical problem is:

[0007] A method for installing and warning a high-drop buffer chute hopper comprises the following steps:

[0008] (1) Install the chute funnel: reserve space inside the chute funnel for installing the buffer pad, and provide external auxiliary support;

[0009] (2) Head classification: According to the head of the chute hopper and the gravity of the transported bulk materials, the inner wall of the chute hopper is reasonably divided into equal parts;

[0010] (3) Making and installing buffer plates: The buffer plates are installed at appropriate positions of each drop grading point on the inner wall of the chute hopper in a horizontal spiral direction;

[0011] (4) Install an online monitoring system: Through online monitoring and analysis, the actual pressure on the side wall of the chute hopper at each buffer pad installation location can be detected.

[0012] Furthermore, step (2) drop classification includes drop point analysis, drop gravity analysis and reasonable equal division;

[0013] The analysis of the drop point is to confirm that the first drop point is the installation location of the first-level buffer pad;

[0014] The drop gravity analysis is to calculate the reasonable number of grades according to the gravity acceleration and material buffering requirements. The calculation formula is: F = T × 2Vn × g × Ln, where F is the free fall impact force that can be sustained, T is the empirical coefficient, Vn is the material conveying speed, and g is the gravity acceleration, which is 9.8m / s 2 , Ln is the height difference between the buffer pad levels;

[0015] Reasonable equal division means dividing the inner wall of the chute hopper equally according to the reasonable number of grades to determine the installation level of the buffer pad. The calculation formula is: S = L 总 / Ln, where S is the reasonable classification number, and the value is taken as an approximate value, L 总 is the vertical effective drop, and Ln is the drop between the buffer pad levels.

[0016] Furthermore, in step (3), the method for making and installing the buffer pad is that the length of the upper material receiving plate of the buffer pad is the length of one side of the inner wall of the chute funnel, and the width is calculated by the formula: (n×L 总斜 ) / (S×cosα), where n is the empirical coefficient, with a value of 0.6-0.8, α is the preset buffer angle, with a value of 15-45°, and L 总斜 is the effective length of the inner wall of the chute hopper, S is the reasonable number of classifications;

[0017] The lower buffer pad of the buffer pad is made of multi-layer rubber pads, and its length is the length of one side of the inner wall of the chute funnel. The calculation formula for the width of the rubber pad at the bottom of the lower buffer pad is: (n×L 总斜) / (S×cosα)+installation width, other rubber pads of the lower buffer pad decrease from bottom to top to form a preset buffer angle, and a support plate is formed by steel plate and bolt consolidation. The support plate is welded and fixed at the angle space between the upper material receiving plate and the inner wall of the chute funnel, and the lower buffer pad is carried on the support plate, and the lower buffer pad is in close contact with the upper material receiving plate.

[0018] Furthermore, in step (4), the pressure sensor of the online monitoring system is installed on the outer wall of the chute funnel of each level of buffer pads, and the early warning system is installed on the relevant industrial control microcomputer. The pressure of each level of buffer pads is monitored online by the pressure sensor. If the pressure exceeds the threshold range, an early warning signal is issued to prompt the on-site personnel to check and handle it.

[0019] Furthermore, the early warning principles of the online monitoring system are as follows:

[0020] If the pressure of less than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, an early warning signal of material accumulation on the x-th level buffer pad is given;

[0021] If the pressure of more than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, a material overload warning signal will be given;

[0022] If the pressure of less than m / 2 pressure sensors is less than the lower limit threshold and greater than 1.1×static pressure and lasts for t, a warning signal for wear of the level x buffer pad is given;

[0023] If the pressure of more than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, a warning signal of too little material will be given;

[0024] Where: t is the duration, which can be set and controlled between 30 and 120 seconds; m is the number of pressure sensors; x is the level where the pressure sensor that exceeds the threshold is located;

[0025] The upper and lower thresholds are obtained through actual testing and empirical values, or:

[0026] The upper threshold is determined according to the formula: the maximum weight of material allowed to be transported per unit time × sinα × V1, where V1 is the upper limit empirical constant, with a value of 1.05 to 1.15;

[0027] The lower limit threshold is determined according to the formula: minimum material weight allowed to be transported per unit time × sin (α / 2) × V2, where V2 is the lower limit empirical constant, with a value of 0.85 to 0.95.

[0028] A high-drop buffer chute funnel comprises a chute funnel, in which a plurality of buffer pads are installed in a spiral arrangement from top to bottom, the buffer pads comprising an upper material welcoming plate, a lower material welcoming plate and a support plate, the upper material welcoming plate is hinged on the inner wall of the chute funnel, the lower material welcoming plate is located between the upper material welcoming plate and the chute funnel, the lower material welcoming pad is supported on a support plate made of a steel plate, the support plate is welded to the inner wall of the chute funnel, and pressure sensors are installed on the chute funnel where the lower material welcoming pad is located, and the pressure sensors are electrically connected to an industrial control microcomputer.

[0029] The present invention has the following beneficial effects:

[0030] 1. Through reasonable classification and buffering, the problems of material breakage and equipment wear in the process of conveying high-drop bulk materials are solved, meeting the needs of high-drop and efficient conveying of bulk materials.

[0031] 2. The wear of buffer facilities can be monitored online, which is convenient for maintenance and has high operating efficiency.

[0032] 3. Low investment, reliable operation, easy to promote and apply by manufacturers in the same industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the steps of the present invention.

[0034] Figure 2 It is a schematic diagram of the structure of the present invention.

[0035] Among them: 1. chute funnel; 2. upper material receiving plate; 3. lower buffer pad; 4. support plate; 5. pressure sensor. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with specific embodiments and drawings. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0037] Embodiment 1: This embodiment provides an installation and early warning method for a high-drop buffer chute hopper, comprising the following steps:

[0038] like Figure 1 As shown, taking the 3800 blast furnace chute funnel 1 as an example, the vertical funnel (L 总斜 =L 总 ), a height of 15m, a cross-section length of 2.2m, a width of 2m, and an upper and lower process belt speed of 2m / s. The specific implementation mode of the present invention is further described below in conjunction with the accompanying drawings.

[0039] (1) Installing the chute funnel 1: A space is reserved inside the chute funnel 1 for installing a buffer pad, and an external auxiliary support is provided.

[0040] The chute funnel 1 under the original trough is sufficient to reserve space for installing a buffer pad according to the graded drop. Externally, auxiliary support is provided by using pull rods and other methods, thickened steel plates and other materials nearby to prepare for the installation of the buffer pad.

[0041] (2) Head classification: According to the head of the chute hopper 1 and the gravity of the transported bulk materials, the inner wall of the chute hopper 1 is reasonably divided into equal parts.

[0042] First, the first drop point of the material transported from the previous process into the chute funnel 1 is collected, recorded and analyzed, and the first-level buffer pad is installed at 1.0m-1.8m vertically on the drop side of the inner wall of the chute funnel 1; secondly, the drop gravity analysis is performed to measure and determine the effective length L of the inner wall of the chute funnel 1 总斜 =Vertical effective height L 总 =15m, according to the gravity acceleration and the material buffering requirement (F≤180N), the reasonable classification number S is calculated to be 5; the inner wall of the chute funnel 1 is divided into five equal parts according to the calculated reasonable classification number to determine the specific level at which the buffer pad is installed on the inner wall of the chute funnel 1. The relevant calculation formula is as follows:

[0043] Can withstand free fall impact force F = T × 2Vn × g × Ln = 1.5 × 2 × 2 × 9.8 × Ln ≤ 180.

[0044] According to the above formula, it is calculated that Ln≤180 / (1.5×2×2×9.8)=3.06.

[0045] Reasonable classification number S = L 总 / Ln=15 / 3.06=4.9≈5.

[0046] (3) Making and installing the buffer pad: The buffer pad is installed at appropriate positions in each drop grading point on the inner wall of the chute funnel 1 in a horizontal spiral direction.

[0047] The buffer pad is mainly composed of an upper material receiving plate 2 and a lower buffer pad 3. The upper material receiving plate 2 can be made of corrosion-resistant steel plate. The length is the length of one side of the inner wall of the chute funnel 1, 2.2m on the front and rear sides, and 2m on the left and right sides; width = (n×L 总斜) / (S×cosα)=(0.7×15) / (5×cos30°)=2.42m, the empirical coefficient n is 0.7, and the preset buffer angle α is 30°. The upper side of the first-level upper material receiving plate 2 is installed at 0.9m vertically downward from the front side of the inner wall of the chute funnel 1, and the other upper material receiving plates 2 are also installed at appropriate positions in each drop grading point on the inner wall of the chute funnel 1 in the horizontal spiral direction. The lower buffer pad 3 is made of multiple layers of rubber-like slightly elastic hard material, with a length equal to the single side length of the inner wall of the chute funnel 1, 2.2m on the front and rear sides, and 2m on the left and right sides; the bottom rubber pad is 2.45m wide (installation width 0.03m), and the other rubber pads decrease in sequence from bottom to top to form a preset buffer angle, which is formed by steel plates and bolts to form a support plate 4, which is welded and fixed to the angle space between the upper material welcoming plate 2 and the inner wall of the chute funnel 1, and the lower buffer pad 3 is carried on the support plate 4, and the lower buffer pad 3 is in close contact with the upper material welcoming plate 2.

[0048] (4) Install an online monitoring system. Install a pressure sensor 5 at an appropriate position on the outer wall of the five-level buffer pad chute funnel 1. The early warning system is installed on the relevant industrial control microcomputer. The five-level buffer pad pressure is extracted online through PLC. If it exceeds the threshold range, an early warning signal is issued to prompt the post personnel to check and handle it. According to actual detection, the upper threshold of the empirical value is 2MPa, the lower threshold is 200KPa, and the static pressure is 0.2KPa. The corresponding early warning examples are as follows:

[0049] If the pressure detected by the first and second level pressure sensors 5 is greater than 2MPa and lasts for 60s, a warning signal "material accumulation on the first and second level buffer pads" is given;

[0050] If the pressure detected by the first, second and third level pressure sensors 5 is greater than 2MPa and lasts for 60s, an early warning signal "material overload" will be given;

[0051] If the pressure detected by the second and third level pressure sensors 5 is less than 200 KPa and greater than 0.2 KPa and lasts for 60 seconds, a warning signal "wear of the second and third level buffer plates" is given;

[0052] If the pressure detected by the third, fourth, and fifth level pressure sensors 5 is less than 200KPa and greater than 0.2KPa and lasts for 60s, an early warning signal "material too small" will be given.

[0053] Practical steps:

[0054] 1) Turn on the industrial control microcomputer, confirm that the pressure sensors 5 at all levels are intact and the static pressure is normal, then set the upper threshold to 2MPa, the lower threshold to 200KPa, the static pressure to 0.2KPa, and the allowed duration to 60 seconds.

[0055] 2) The pressure of buffer pads at all levels is monitored online through PLC. If it exceeds the threshold range, an early warning signal will be issued. The on-site personnel will check and handle it in time according to the early warning prompt until the early warning signal is eliminated.

[0056] Example 2: This example provides a high-drop buffer chute funnel, which is installed and manufactured based on the method of Example 1.

[0057] like Figure 2 As shown, a high-drop buffer chute funnel includes a chute funnel 1, in which a plurality of buffer pads are installed in a spiral arrangement from top to bottom, and the buffer pads include an upper material welcoming plate 2, a lower material welcoming pad 3, and a support plate 4. The upper material welcoming plate 2 is hinged on the inner wall of the chute funnel 1, and the lower material welcoming pad 3 is located between the upper material welcoming plate 2 and the chute funnel 1. The lower material welcoming pad 3 is supported on the support plate 4 made of steel plate, and the support plate 4 is welded to the inner wall of the chute funnel 1. The chute funnel 1 where the lower material welcoming pad 3 is located is equipped with a pressure sensor 5, and the pressure sensor 5 is electrically connected to the industrial control microcomputer.

[0058] The above-described embodiments are merely descriptions of preferred implementations of the present invention, and are not intended to limit the concept and scope of the present invention. Without departing from the design concept of the present invention, various modifications and improvements made by ordinary persons in the art to the technical solution of the present invention should all fall within the scope of protection of the present invention.

[0059] The techniques, shapes, and structural parts not described in detail in the present invention are all well-known techniques.

Claims

1. A method for installing and warning a high-drop buffer chute hopper, characterized in that: The following steps are involved: (1) Install the chute funnel: reserve space inside the chute funnel for installing the buffer pad, and provide external auxiliary support; (2) Head classification: According to the head of the chute hopper and the gravity of the transported bulk materials, the inner wall of the chute hopper is reasonably divided into equal parts; (3) Making and installing buffer plates: The buffer plates are installed at appropriate positions of each drop grading point on the inner wall of the chute hopper in a horizontal spiral direction; (4) Install an online monitoring system: Through online monitoring and analysis, the actual pressure on the side wall of the chute hopper at each buffer pad installation location can be detected.

2. The installation and early warning method of the high drop buffer chute funnel according to claim 1 is characterized in that: The drop classification in step (2) includes drop point analysis, drop gravity analysis and reasonable equal division; The analysis of the drop point is to confirm that the first drop point is the installation location of the first-level buffer pad; The drop gravity analysis is to calculate the reasonable number of grades according to the gravity acceleration and material buffering requirements. The calculation formula is: F = T × 2Vn × g × Ln, where F is the free fall impact force that can be sustained, T is the empirical coefficient, Vn is the material conveying speed, and g is the gravity acceleration, which is 9.8m / s 2 , Ln is the height difference between the buffer pad levels; Reasonable equal division means dividing the inner wall of the chute hopper equally according to the reasonable number of grades to determine the installation level of the buffer pad. The calculation formula is: S = L 总 / Ln, where S is the reasonable classification number, and the value is taken as an approximate value, L 总 is the vertical effective drop, and Ln is the drop between the buffer pad levels.

3. The installation and early warning method of the high drop buffer chute funnel according to claim 2 is characterized in that: The method for making and installing the buffer pad in step (3) is that the length of the upper material receiving plate of the buffer pad is the length of one side of the inner wall of the chute funnel, and the width is calculated by the formula: (n×L 总斜 ) / (S×cosα), where n is the empirical coefficient, with a value of 0.6-0.8, α is the preset buffer angle, with a value of 15-45°, and L 总斜 is the effective length of the inner wall of the chute hopper, S is the reasonable number of classifications; The lower buffer pad of the buffer pad is made of multi-layer rubber pads, and its length is the length of one side of the inner wall of the chute funnel. The calculation formula for the width of the rubber pad at the bottom of the lower buffer pad is: (n×L 总斜 ) / (S×cosα)+installation width, other rubber pads of the lower buffer pad decrease from bottom to top to form a preset buffer angle, and a support plate is formed by steel plate and bolt consolidation. The support plate is welded and fixed at the angle space between the upper material receiving plate and the inner wall of the chute funnel, and the lower buffer pad is carried on the support plate, and the lower buffer pad is in close contact with the upper material receiving plate.

4. The installation and early warning method of the high drop buffer chute funnel according to claim 1 is characterized in that: The pressure sensor of the online monitoring system in step (4) is installed on the outer wall of the chute funnel of each level of buffer pads, and the early warning system is installed on the relevant industrial control microcomputer. The pressure sensor is used to monitor the pressure of each level of buffer pads online. If it exceeds the threshold range, an early warning signal is issued to prompt the on-site personnel to check and handle it.

5. The installation and early warning method of the high drop buffer chute funnel according to claim 4 is characterized in that: The early warning principles of the online monitoring system are as follows: If the pressure of less than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, an early warning signal of material accumulation on the x-th level buffer pad will be given; If the pressure of more than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, a material overload warning signal will be given; If the pressure of less than m / 2 pressure sensors is less than the lower limit threshold and greater than 1.1×static pressure and lasts for t, a warning signal for wear of the level x buffer pad is given; If the pressure of more than m / 2 pressure sensors is greater than the upper threshold value and lasts for t, a warning signal of too little material will be given; Where: t is the duration, which can be set and controlled between 30 and 120 seconds; m is the number of pressure sensors; x is the level where the pressure sensor that exceeds the threshold is located; The upper and lower thresholds are obtained through actual testing and empirical values, or: The upper threshold is determined according to the formula: the maximum weight of material allowed to be transported per unit time × sinα × V1, where V1 is the upper limit empirical constant, with a value of 1.05 to 1.15; The lower limit threshold is determined according to the formula: minimum material weight allowed to be transported per unit time × sin (α / 2) × V2, where V2 is the lower limit empirical constant, with a value of 0.85 to 0.

95.

6. A high drop buffer chute funnel according to any one of claims 1 to 5, characterized in that: It includes a chute funnel, in which a number of buffer pads are installed in a spiral arrangement from top to bottom, the buffer pads include an upper material welcoming plate, a lower buffer pad, and a support plate, the upper material welcoming plate is hinged on the inner wall of the chute funnel, the lower buffer pad is located between the upper material welcoming plate and the chute funnel, the lower buffer pad is carried on a support plate made of steel plate, the support plate is welded to the inner wall of the chute funnel, and pressure sensors are installed on the chute funnel where the lower buffer pad is located, and the pressure sensors are electrically connected to the industrial control microcomputer.

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