A bucket wheel excavator boom pitch detection system and pitch method

Abstract

A pitch detection system and method for the boom of a bucket wheel excavator, belonging to the field of intelligent control technology, is disclosed. It includes a base fixedly connected to the front end of the boom of the bucket wheel excavator, an adjusting bracket connected to the base, and a detection device. Each adjusting bracket is connected to one detection device. The detection device includes a fixed bracket connected to the adjusting bracket, which has multiple bolt holes. The adjusting bracket connects to different bolt holes to adjust the angle of an ultrasonic radar ranging switch located at one end of the fixed bracket. This system has the advantages of simple equipment, ease of implementation, low cost, and convenient deployment and installation, and can be widely promoted in the intelligent control system of open-pit bucket wheel excavators.

Description

Technical Field

[0001] This invention belongs to the field of intelligent control technology, and specifically relates to a bucket wheel excavator boom pitch detection system and pitch method. Background Technology

[0002] The material handling process of a bucket wheel excavator involves using a preset advance distance and the reciprocating rotation angle of the lifting arm. The lifting arm operates in three working angles (tilt and sag) to pick up material, which is then transported to the downstream system via conveyor belts. During the material handling process, the lifting arm alternates between reciprocating rotation and the excavator's walking motion. After each cycle, the excavator retreats to the starting position and lowers to the next working angle (tilt and sag). Once the set angle is reached, the reciprocating rotation and walking motion resume. However, during production, irregular vertical slippage of material on the working face during material handling causes the bucket wheel excavator's automatic material handling system to struggle to adapt to the material conditions. Delayed feedback can result in material handling being either too fast or too slow. Too fast a speed can damage the bucket teeth, increasing maintenance costs and impacting efficiency. Too slow a speed reduces the amount of material handled, affecting production capacity. Reduced material handling leads to energy waste and increased maintenance costs, further increasing operating costs and contradicting the principles of high efficiency, green technology, and energy conservation. Summary of the Invention

[0003] To address the above shortcomings, the purpose of this invention is to provide a bucket wheel excavator boom pitch detection system and pitch method.

[0004] The technical solution adopted in this invention is: a bucket wheel excavator boom pitch detection system, the key technical points of which are: a base fixedly connected to the front end of the bucket wheel excavator boom, an adjustment bracket connected to the base, and a detection device, each adjustment bracket being connected to a corresponding detection device; the detection device includes a fixed bracket connected to the adjustment bracket, the fixed bracket having multiple bolt holes, and the adjustment bracket being used to adjust the angle of an ultrasonic radar ranging switch located at one end of the fixed bracket by connecting to different bolt holes.

[0005] In the above scheme, the detection device also includes a protective cover screwed onto a fixed bracket, a mounting plate disposed inside the protective cover, and an ultrasonic radar ranging switch fixed on the mounting plate.

[0006] In the above scheme, the ultrasonic radar ranging switch is set at different angles below the material picking arm.

[0007] A method for detecting the pitch of the boom of a bucket wheel excavator, implemented using a bucket wheel excavator boom pitch detection system, includes the following steps:

[0008] Step 1: Set the ultrasonic radar ranging switch to output both analog and digital signals. The analog signal fed back by the ultrasonic radar ranging switch displays the actual distance between the ultrasonic radar ranging switch and the edge of the material at the current pitch angle, while the digital signal can be set to the optimal trigger distance.

[0009] Step 2: Adjust the position of the first ultrasonic radar ranging switch G1 of the lifting and retrieving arm to match the horizontal plane of the mining face; adjust the position of the second ultrasonic radar ranging switch G2 to correspond to the middle layer of material on the mining face; and adjust the position of the third ultrasonic radar ranging switch G3 to correspond to the bottom layer of material on the mining face. At the same time, ensure that when the three ultrasonic radar ranging switches reach the starting boundary of the mining face at different heights, the optimal distance detection signals H1, H2, and H3 are always triggered.

[0010] Step 3: During the material handling process, the detection device system is activated, the controller acquires a signal from H1, and the material handling arm is ready to handle the material at this sampling angle.

[0011] Step 4: When H1 In the state of having a trigger action signal H2 and H3 When there is no trigger action signal, the controller determines that the material handling arm is working in the first cutting width. The rotation of the material handling arm and the stepping of the excavator alternate until the total walking distance reaches the total walking distance set by the system and then the reverse is started.

[0012] Step 5: After the excavator retreats to the starting position, the material handling arm begins to descend to the second cutting angle. The controller determines that the material handling arm has reached the second cutting angle normally. The rotation of the material handling arm and the stepping of the excavator begin to alternate until the total walking distance reaches the system-set total walking distance and then the excavator begins to retreat. If H2 has a trigger action signal and H1 or H3 also has a trigger action signal during rotation or walking, the controller determines that there is an irregular slippage area on the working face corresponding to H2. It is necessary to reduce the bucket wheel digging speed and rotation speed until H2 has a trigger action signal and H1 and H3 are both without trigger action signals, then the normal digging speed and rotation speed are restored.

[0013] Step 6: After the excavator retreats to the starting position, the material handling arm begins to descend to the third cutting angle. That is, when H3 has a trigger action signal and H1 and H2 have no trigger action signal, the controller determines that the material handling arm has reached the third cutting angle. The material handling arm rotation and the excavator step movement begin to alternate until the total travel distance reaches the system-set total travel distance. The material handling arm then rises to the first cutting angle. If H3 has a trigger action signal and H1 or H2 also has a trigger action signal during rotation or movement, the controller determines that there is an irregular slippage area on the working face corresponding to H3. It is necessary to reduce the bucket wheel digging speed and rotation speed until H3 has a trigger action signal and H1 and H2 are both without trigger action signals. Then, the normal digging speed and rotation speed are restored.

[0014] Step 7: When H1 is in the state of having a trigger action signal and H2 and H3 are in the state of not having a trigger action signal, the controller determines the first mining angle of the material arm reaching the boundary of the next mining face and returns to execute step 4.

[0015] Step 8: When H1, H2 and H3 are in a state of no trigger action signal, the controller determines that the working surface boundary has been reached and executes step 9;

[0016] Step 9: When H1, H2 and H3 are all in a state of no trigger action signal, stop picking up materials. The display shows that pitch, rotation and travel have stopped, and the picking operation is over.

[0017] The beneficial effects of this invention are as follows: The bucket wheel excavator boom pitch detection system and pitch method include a base fixedly connected to the front end of the bucket wheel excavator boom, an adjustment bracket connected to the base, and a detection device. Each adjustment bracket is connected to a corresponding detection device. The detection device includes a fixed bracket connected to the adjustment bracket. The fixed bracket is provided with multiple bolt holes. The adjustment bracket is used to adjust the angle of the ultrasonic radar ranging switch set at one end of the fixed bracket by connecting to different bolt holes. It has the advantages of simple equipment, easy implementation, low cost, and convenient deployment and installation, and can be widely promoted in the intelligent control system of open-pit bucket wheel excavators. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the bucket wheel excavator structure in an embodiment of the present invention;

[0020] Figure 2This is a schematic diagram of the working state of the bucket wheel excavator in an embodiment of the present invention;

[0021] Figure 3 This is a schematic diagram of the overall structure in this embodiment of the invention;

[0022] Figure 4 Partial structural schematic diagram of the present invention;

[0023] The numbers in the diagram are explained as follows: 10 Detection device, 15 Fixed bracket, 16 Protective cover, 17 Mounting plate, 50 Base, 51 Discharge shield, 52 Bolt hole, 53 Adjustment bracket, 60 Ultrasonic radar ranging switch, 80 Material handling arm, 100 Material working surface, G1 First ranging switch, G2 Second ranging switch, G3 Third ranging switch; 35 Driver's cab, 36 Electrical room, C Data acquisition and processing unit, M Touch screen. Detailed Implementation

[0024] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the following description is provided in conjunction with the accompanying drawings. Figures 1-4 The present invention will be further described in detail below with reference to specific embodiments.

[0025] This embodiment discloses a bucket wheel excavator boom pitch detection system, which includes a base 50, which is fixedly connected to the front end of the bucket wheel excavator boom 80, specifically welded or bolted to the discharge shield 51 at the front end of the boom 80. Three sets of detection devices 10 are arranged on one side of the base 50, and the three sets of boom detection devices are arranged at different angles facing downwards. The detection device 10 includes a fixed bracket 15, a protective cover 16 bolted to the fixed bracket 15, a mounting plate 17 arranged inside the protective cover 16, and an ultrasonic radar ranging switch 60 fixed on the mounting plate 17. Multiple bolt holes 52 are provided on the fixed bracket 15. It also includes an adjustment bracket 53, one end of which is hinged to the base 50, and the other end is connected to the bolt holes 52 of the detection device 10 by bolts.

[0026] In this embodiment, the first sampling detection device and the material picking arm 80 are at a horizontal angle of -40 to -50 degrees, the second sampling detection device and the material picking arm 80 are at a horizontal angle of -25 to -35 degrees, and the third sampling detection device and the material picking arm 80 are at a horizontal angle of -15 to -20 degrees.

[0027] The bucket wheel excavator boom pitch detection system of this embodiment is equipped with three sets of detection devices, which can effectively cope with the impact of irregular slippage areas on normal material handling during the mining process. The distance measuring switches are all located inside the protective cover to prevent material damage. The detection devices are equipped with adjustment brackets to support and adjust the detection devices, ensuring their angle stability.

[0028] The method for detecting the pitch of the boom of a bucket excavator used in this embodiment includes the following steps:

[0029] Step 1: Set the ultrasonic radar ranging switch output to use both analog and digital signals. The analog signal fed back by the ranging switch displays the actual distance between the switch and the edge of the material at the current pitch angle in real time. At the same time, it has a digital signal that can set the optimal trigger distance, i.e., a trigger signal is represented by 1, and no trigger signal is represented by 0. In this embodiment, three ultrasonic radar ranging switches are used, namely the first ultrasonic radar ranging switch G1, the second ultrasonic radar ranging switch G2, and the third ultrasonic radar ranging switch G3.

[0030] Step 2: Adjust the position of the first ultrasonic radar ranging switch G1 of the lifting and retrieving arm to match the horizontal plane of the mining face; adjust the position of the second ultrasonic radar ranging switch G2 to correspond to the middle layer of material on the mining face; and adjust the position of the third ultrasonic radar ranging switch G3 to correspond to the bottom layer of material on the mining face. At the same time, ensure that when the three ultrasonic radar ranging switches reach the starting boundary of the mining face at different heights, the optimal distance detection signals H1, H2, and H3 are always triggered, i.e., the signal is 1.

[0031] Step 3: During the material handling process, the detection device 10 system is started, the controller acquires a signal from H1, and the material handling arm 80 is ready to handle the material at this sampling angle;

[0032] Step 4: When H1 is 1 and H2 and H3 are 0, the controller determines that the material handling arm 80 is working in the first cutting width. The rotation of the material handling arm and the stepping of the excavator alternate until the total walking distance reaches the total walking distance set by the system and then the excavator starts to move backward.

[0033] Step 5: After the excavator retreats to the starting position, the material handling arm 80 begins to descend to the second cutting angle. The controller determines that the material handling arm has reached the second cutting angle normally. The rotation of the material handling arm and the stepping of the excavator begin to alternate until the total walking distance reaches the system-set total walking distance and then the excavator begins to retreat. If H2 is 1 and H1 or H3 is also 1 during the rotation or walking process, the controller determines that there is an irregular slippage area on the working surface corresponding to H2. It is necessary to reduce the bucket wheel digging speed and rotation speed until H2 is 1 and H1 and H3 are both 0, then restore the normal digging speed and rotation speed.

[0034] Step 6: After the excavator retreats to the starting position, the material handling arm 80 begins to descend to the third cutting angle. That is, when H3 is 1 and H1 and H2 are 0, the controller determines that the material handling arm has reached the third cutting angle. The material handling arm rotation and the excavator step movement begin to alternate until the total travel distance reaches the system-set total travel distance. The material handling arm then rises to the first cutting angle. If H3 is 1 and H1 or H2 is also 1 during rotation or movement, the controller determines that there is an irregular slippage area on the working surface corresponding to H3. It is necessary to reduce the bucket wheel digging speed and rotation speed. When H3 is 1 and H1 and H2 are both 0, the normal digging speed and rotation speed are restored.

[0035] Step 7: When H1 is 1 and H2 and H3 are 0, the controller determines the first mining angle of the material arm 80 reaching the boundary of the next mining face, and returns to execute step 4.

[0036] Step 8: When H1, H2 and H3 are all 0, the controller determines that the working surface boundary has been reached and executes step 9;

[0037] Step 9: When H1, H2 and H3 are all 0, stop picking up materials. The display will show that pitch, rotation and travel have stopped, and the picking operation is over.

[0038] The pitch method in this embodiment utilizes ultrasonic radar detection technology to determine the pitch angle of the bucket wheel excavator's boom and material information. Data is collected and logically analyzed by the controller. If the data changes simultaneously, material slippage is quickly assessed. If the data returns to normal but the digging and slewing speeds do not, the material handling speed is deemed too low, and a further instruction is issued promptly to prevent excessively fast or slow material handling, thus saving energy, increasing efficiency, and improving the system's production capacity. This embodiment also features simple equipment, ease of implementation, low cost, and convenient deployment and installation, making it widely applicable in intelligent control systems for open-pit bucket wheel excavators.

[0039] In this embodiment, the data acquisition and processing unit C is housed in the PLC control cabinet in the electrical room 36. It collects distance measurement switch information in real time, performs analysis, calculation, and decision-making, and outputs control information for the material handling arm 80 and the distance value of the material at the working surface. The touch screen display unit M is installed in the driver's cab 35 and is used to display the control information of the material handling arm and the distance signal of the material at the working surface output by the data acquisition and processing unit C. The control information for the material handling arm 80 includes commands to raise, lower, and stop.

[0040] In this embodiment, the bucket wheel excavator's material handling arm 80 steps to pick up material. The safe distance between the material receiving point of the material handling arm's discharge baffle 51 and the material working surface 100 is 350-500mm. Therefore, the ultrasonic radar switch is selected with a detection distance of 6 meters. It has a diffuse reflection function, does not require a baffle, and can be directly projected onto the material for distance detection.

[0041] The data acquisition and processing unit C uses an advanced programmable controller, consisting of a DC power supply, CPU, IO modules, etc., and supports Ethernet interface communication protocol. The controller is installed in the control cabinet in the electrical room 36. The display unit uses an advanced touch screen M, which supports Ethernet interface protocol. The touch screen M is installed in the driver's cab 35. The data acquisition and processing unit C and the touch screen M are connected by a Category 5e shielded network cable, and are respectively connected to switches G1, G2 and G3 by flame-retardant shielded BVR8X1.5 control flexible cables.

[0042] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method of detecting the pitch of a wheel loader's arm, the method being implemented based on a wheel loader's arm pitch detection system, characterized in that, The wheel bucket excavator material taking arm pitch detection system comprises a base fixedly connected with the front end of the wheel bucket excavator material taking arm, adjusting supports connected with the base, and detection devices, each adjusting support being connected with one detection device; the detection device comprises a fixed support connected with the adjusting support, a plurality of bolt holes being arranged on the fixed support, and the adjusting support being connected with different bolt holes for adjusting the angle of the ultrasonic radar ranging switch arranged at one end of the fixed support; the detection device further comprises a protective cover screwed on the fixed support, a mounting plate arranged in the protective cover, and an ultrasonic radar ranging switch fixed on the mounting plate; the ultrasonic radar ranging switch is arranged at different angles below the material taking arm; The wheel bucket excavator material taking arm pitch detection method comprises the following steps: Step 1: setting the output of the ultrasonic radar ranging switch as analog signal and switch signal, and using the analog signal feedback by the ultrasonic radar ranging switch to display the actual distance between the ultrasonic radar ranging switch and the material edge at the current pitch angle in real time, and the switch signal with the best trigger distance; Step 2: adjusting the positions of the first, second and third ultrasonic radar ranging switches G1, G2 and G3 so that the first ultrasonic radar ranging switch G1 is matched with the horizontal plane of the mining working face, the second ultrasonic radar ranging switch G2 corresponds to the middle layer material surface of the mining face, and the third ultrasonic radar ranging switch G3 corresponds to the bottom layer material surface of the mining face; at the same time, the three ultrasonic radar ranging switches reach the starting boundary of the different height mining face, and the best distance detection signals H1, H2 and H3 are always in the trigger action signal; Step 3: when the material taking condition occurs, the detection device system starts, the controller collects the signal H1, and the material taking arm is ready to take material at the current pitch angle; Step 4: When H1 In the triggered action signal H2 and H3 In the non-triggered action signal, the controller determines that the taking arm is working in the first sampling range, the taking arm rotates and the excavator walks alternately until the total walking distance reaches the system set total walking distance to start retreating; Step 5: when the excavator retreats to the starting position, the material taking arm starts to descend to the second pitch angle, the controller judges that the material taking arm normally reaches the second pitch angle, the material taking arm starts to rotate and the excavator starts to walk alternately, until the total walking distance reaches the system set total walking distance and starts to retreat; if H2 is in the trigger action signal and H1 or H3 is also in the trigger action signal during the rotation or walking process, the controller judges that the working face corresponding to H2 has an irregular sliding area, and the bucket wheel excavator speed and the rotation speed need to be reduced; when H2 is in the trigger action signal and H1 and H3 are in the non-trigger action signal, the normal excavator speed and the rotation speed are restored. Step 6: When the excavator retreats to the starting position, the dipper arm starts to descend to the third pitch angle, that is, when H3 is in the trigger action signal and H1 and H2 are in the non-trigger action signal, the controller judges that the dipper arm reaches the third pitch angle, the dipper arm rotation and the excavator walking start to alternate, until the total walking distance reaches the system set total walking distance, the dipper arm starts to rise to the first pitch angle, if H3 is in the trigger action signal and H1 or H2 is also in the trigger action signal during rotation or walking, the controller judges that the working surface corresponding to H3 has irregular sliding area, which needs to reduce the bucket wheel digging speed and the rotation speed, until H3 is in the trigger action signal and H1 and H2 are in the non-trigger action signal, the normal digging speed and rotation speed are restored; Step 7: When H1 is in the trigger action signal and H2 and H3 are in the non-trigger action signal, the controller judges that the dipper arm reaches the first pitch angle of the next mining face boundary, and returns to step 4; Step 8: When H1, H2 and H3 are in the non-trigger action signal, the controller judges that the working face boundary is reached, and step 9 is executed; Step 9: When H1, H2 and H3 are in the non-trigger action signal, stop taking material, the display shows that the pitch, rotation and walking are stopped, and the taking material work is finished.

Images