A real-time monitoring device and method for the reclaiming mechanism of a screw ship unloader

Abstract

The present invention belongs to the technical field of material reclaiming structure monitoring, and specifically discloses a real-time monitoring device and method for the material reclaiming mechanism of a screw ship unloader, including: a material information monitoring module, a monitoring layout setting module, an environmental information importing module, a material reclaiming adjustment analysis module, a material reclaiming adjustment execution terminal and a material reclaiming monitoring verification module. The present invention monitors the material composition through the material information monitoring module to understand the material characteristics, and the monitoring layout setting module monitors the humidity, viscosity and pressure at the turning point of the screw machine, which makes up for the shortcomings of the existing monitoring of local areas. At the same time, the environmental information importing module takes environmental factors into consideration, and improves the adaptability to complex port environments. The material reclaiming adjustment analysis module performs adjustment demand analysis based on multi-source information to make the adjustment more targeted; the material reclaiming monitoring verification module performs secondary adjustment through vibration frequency and motor current analysis to form a closed-loop control to ensure that the reclaiming mechanism is in the best operating state.

Description

Technical Field

[0001] The invention belongs to the technical field of reclaiming structure monitoring, and in particular relates to a real-time monitoring device and method for a reclaiming mechanism of a screw ship unloader. Background Art

[0002] With the rapid development of the economy, the volume of bulk cargo transportation continues to grow. The loading and unloading efficiency of bulk cargo such as coal, ore, and grain directly affects the port's operating capacity and logistics costs. The screw unloader is an important equipment for bulk cargo terminals to unload bulk materials. Its material reclaiming process occupies a key position in the entire unloading operation, so it is necessary to monitor its material reclaiming.

[0003] Prior art, such as the Chinese invention patent application with application number 202411052393.0, discloses an unattended screw ship unloader material blockage monitoring and early warning system, including a material flow monitoring module, which uses at least one high-precision flow meter installed at the feed hopper of the screw ship unloader, and monitors the material flow in real time through sensors. A pressure monitoring module, which uses at least one pressure sensor. Installed on the spiral blade shaft of the screw ship unloader, the pressure changes of the spiral blade shaft are monitored in real time through sensors. A vibration monitoring module, which uses at least one vibration sensor, is installed at a key part of the screw ship unloader. A control system, which uses a real-time operating system, receives signals from a material flow monitoring device, a pressure monitoring device, and a vibration monitoring device. An early warning module, which uses at least one set of sound and light alarm devices and a wireless communication unit, sends an alarm when the control system determines that a blockage occurs. This solves the problem that the traditional blockage monitoring method relies on manual inspections, has slow response speeds, and has low monitoring accuracy.

[0004] Another example of the prior art is a continuous ship unloader and monitoring method that determines the material retrieving position through amplitude monitoring and angle calibration, as disclosed in the Chinese invention patent application with application number 202411335695.9. The method includes a position monitoring system and an angle calibration system. The position monitoring system is installed at the boom pitch hinge position, and is used to monitor the boom pitch angle and calculate the position of the material retrieving device. The angle calibration system is used to calculate the actual boom angle change in real time through the stroke of the pitch cylinder to complete the calibration of the position monitoring system. The present invention solves various problems of the continuous ship unloader equipment, such as unstable material retrieving and chain wear caused by position monitoring deviation. The angle calibration system can directly calculate through the displacement of the cylinder, ensuring the accuracy of the pitch angle.

[0005] With regard to the above technical solutions, it is obvious that the current subway construction safety risk assessment still has the following deficiencies: 1. The monitoring data dimension is limited. The existing monitoring methods mainly focus on material flow, spiral blade shaft pressure and vibration to judge the material blockage phenomenon. However, this data collection method is relatively single. For special materials with complex and changeable characteristics, such as materials with large fluctuations in humidity and viscosity, it is difficult to make accurate and targeted material blockage judgments based on these limited data alone. In addition, the existing scheme does not take the distribution of materials in the cabin into consideration at all, which may make it impossible for the material reclaiming device to make timely adjustments to the material reclaiming when faced with uneven material distribution, thereby interfering with the smooth progress of the material reclaiming work.

[0006] 2. Insufficient attention is paid to the structural status of the equipment. The current monitoring focuses on the overall material flow, the screw blade shaft pressure and the vibration of the key parts of the equipment, but little attention is paid to the status of some key local areas inside the screw unloader. For example, the pressure state at the corner of the screw conveyor, which is subjected to unique pressure changes during the material conveying process and has an important impact on the overall material conveying, has not received enough attention, and the existing monitoring system lacks effective monitoring of this key factor. This will not only lead to deviations in the assessment of material flow abnormalities, but also easily ignore subtle but important abnormal changes in material flow.

[0007] 3. Ignoring the influence of environmental factors. The port operation environment is complex, and the sea breeze may cause the arm of the ship unloader to shake and deform, thus affecting the accuracy of the reclaiming position. The existing monitoring system does not fully consider the interference of these environmental factors on the reclaiming mechanism, making it impossible to fully guarantee the stability of the reclaiming process. Under harsh environmental conditions, it is difficult to ensure the efficient and accurate reclaiming work. Summary of the invention

[0008] In view of this, in order to solve the problems raised in the above background technology, a real-time monitoring device and method for a screw ship unloader reclaiming mechanism is proposed.

[0009] The object of the present invention can be achieved through the following technical solutions: The present invention provides a real-time monitoring device for a material taking mechanism of a screw ship unloader, comprising: a material information monitoring module for monitoring material composition information in a material placement area.

[0010] The monitoring layout setting module is used to install humidity sensors and viscosity sensors at the feed port to monitor the humidity and viscosity of the incoming material in real time, and obtain the real-time material humidity and real-time material viscosity. At the same time, pressure sensors are added at each turning point of the screw machine to monitor the pressure value at each turning point in real time and obtain the real-time pressure value at each turning point.

[0011] The environmental information import module is used to import real-time environmental information in the material collection site.

[0012] The material picking adjustment analysis module is used to analyze the material picking setting adjustment needs based on material composition information, real-time material humidity, real-time material viscosity, real-time pressure values ​​at each turning point and real-time environmental information. If the analysis result is a demand adjustment, the adjustment index is confirmed.

[0013] The material taking adjustment execution terminal is used to adjust the material taking setting of the material taking mechanism according to the adjustment index.

[0014] The material picking monitoring and verification module is used to perform real-time vibration frequency monitoring through the vibration sensor carried by the material picking mechanism, and at the same time import the real-time current of the corresponding associated motor of the material picking mechanism to determine whether the material picking settings are consistent with expectations. If the judgment is no, confirm the secondary adjustment indicators and feedback to the material picking adjustment execution terminal for secondary material picking setting adjustment. If the judgment is yes, continue to execute the material picking instruction.

[0015] The present invention also provides a real-time monitoring method for a material taking mechanism of a screw ship unloader, the method comprising: S1, material information monitoring: monitoring material composition information in a material placement area.

[0016] S2. Monitoring layout setting: Humidity and viscosity sensors are installed at the feed port to measure the humidity and viscosity of the incoming materials in real time. At the same time, pressure sensors are added at each turning point of the screw conveyor to monitor the pressure value at each turning point in real time.

[0017] S3. Environmental information import: import the real-time environmental information in the material collection site.

[0018] S4. Material adjustment analysis: Conduct material setting adjustment demand analysis. If the analysis result is a demand adjustment, confirm the adjustment index.

[0019] S5, material retrieving adjustment execution: adjust the material retrieving setting of the material retrieving mechanism according to the adjustment index described in step S4.

[0020] S6, material picking monitoring and verification: The vibration frequency is monitored by the vibration sensor carried by the material picking mechanism, and the current of the corresponding motor of the material picking mechanism is imported to determine whether the material picking setting is consistent with the expectation. If it is judged as no, confirm the secondary adjustment index and return to step S5 to make a secondary adjustment to the material picking setting. If it is judged as yes, continue to execute the material picking instruction.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention monitors the material composition through the material information monitoring module to understand the material characteristics, and the monitoring layout setting module monitors the humidity, viscosity and pressure at the turning point of the screw machine, which makes up for the shortcomings of the existing monitoring of local areas. At the same time, the environmental information import module takes environmental factors into consideration and improves the adaptability to complex port environments. The material reclaiming adjustment analysis module performs adjustment demand analysis based on multi-source information to make the adjustment more targeted. The material reclaiming monitoring and verification module performs secondary adjustments through vibration frequency and motor current analysis to form a closed-loop control to ensure that the reclaiming mechanism is in the best operating state. These settings can fully grasp the reclaiming status, prevent failures, improve reclaiming efficiency and quality, extend the service life of equipment and reduce costs.

[0022] (2) The present invention effectively solves the problem of limited dimensions of current detection data by detecting the humidity and viscosity of the material, avoids the shortcomings of the current single data collection method, and can well adapt to the material handling operation of special materials with complex and changeable characteristics. At the same time, it also provides powerful assistance for accurate and targeted material blockage judgment. In addition, by detecting the material composition, the distribution of the material in the cabin is fully considered, thereby providing a data basis for the timely adjustment of subsequent material handling and facilitating the smooth progress of subsequent material handling work.

[0023] (3) The present invention adds pressure sensors at each turning point of the screw conveyor to monitor the pressure value at each turning point in real time, thereby making up for the current problem of insufficient attention to the structural status of the equipment, increasing the attention and importance paid to the status of some key local areas inside the ship unloader, and filling the gap in the current detection system at the monitoring level of this key factor, thereby improving the accuracy of subsequent assessments of material flow anomalies, and also avoiding the neglect of subtle but important abnormal changes in material flow.

[0024] (4) The present invention analyzes the interference degree of the material picking environment state based on wind speed and wind direction, and confirms the adjustment items and adjustment indicators accordingly, fully considering the interference of environmental factors on the material picking mechanism, thereby avoiding the current neglect of the influence of the switching factors. At the same time, it also ensures the accuracy of subsequent material picking setting adjustments, the stability of subsequent material picking and the accuracy of the material picking position, and also provides a strong guarantee for the efficient and accurate material picking work under harsh environmental conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0026] Figure 1It is a schematic diagram of the structural connection of the device of the present invention.

[0027] Figure 2 The present invention is a schematic flow chart of the steps for implementing the method.

[0028] Figure 3 This is a schematic diagram of the material taking monitoring and verification process of the present invention. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] See also Figure 1 As shown, the present invention provides a real-time monitoring device for a screw ship unloader reclaiming mechanism, comprising: a material information monitoring module, a monitoring layout setting module, an environmental information importing module, a reclaiming adjustment analysis module, a reclaiming adjustment execution terminal and a reclaiming monitoring verification module.

[0031] In the above, the material fetching adjustment analysis module is respectively connected with: the material information monitoring module, the monitoring layout setting module, the environmental information import module and the material fetching adjustment execution terminal, and the material fetching adjustment execution terminal is also connected with the material fetching monitoring verification module.

[0032] The material information monitoring module is used to monitor the material composition information of the logistics placement area.

[0033] Specifically, the material composition information includes the particle size intervals of each material corresponding to each monitoring sub-area, the distribution ratio of each material particle size interval, and the regularity and similarity of the corresponding materials in each monitoring sub-area.

[0034] It should be added that the specific monitoring process of monitoring the corresponding material particle size intervals and the distribution ratios of the material particle size intervals in each monitoring sub-area includes: 1) dividing the material placement area into various monitoring sub-areas, and installing a high-definition camera above each monitoring sub-area.

[0035] It should be noted that the area division needs to be divided into several representative monitoring sub-areas according to the actual layout of the logistics placement area and the material collection requirements. These sub-areas should be able to cover the main range of material placement.

[0036] It should also be noted that when installing a high-definition camera, it is necessary to ensure that the field of view of the device can completely cover the corresponding monitoring sub-area and have sufficient resolution and frame rate to clearly capture the image information of the material. At the same time, it is necessary to adjust the angle and focal length of the device to ensure that the shape and details of the material in the captured image can be clearly presented. And before officially starting the monitoring, the image acquisition device should be calibrated. Use a standard object of known size and collect its image to determine the proportional relationship between the pixels in the image and the actual size, so as to ensure the accuracy of the subsequent material particle size measurement.

[0037] 2) Start the high-definition cameras installed in each monitoring sub-area to collect material images of each monitoring sub-area in real time, enhance the collected material images, and use image segmentation technology to separate the material particles in the image from the background.

[0038] It should be noted that during the acquisition process, it is important to maintain the stability of the ambient light to avoid image quality degradation due to changes in light, which can affect subsequent analysis. If the ambient light cannot be guaranteed to be stable, consider using auxiliary lighting equipment to provide a uniform light source.

[0039] Understandably, the collected material image is enhanced to improve the clarity and contrast of the image. This can be achieved through some image processing algorithms, such as histogram equalization, filtering, etc. Through image enhancement, the boundaries of material particles are clearer, which is convenient for subsequent identification and measurement. The example image processing algorithms are all relatively mature existing technologies, and their specific processing processes are not repeated here.

[0040] In a specific embodiment, the commonly used methods for separating material particles from the background in the image include threshold segmentation, edge detection, region growing, etc. According to the characteristics of the material and the actual situation of the image, a suitable segmentation method is selected to ensure that each material particle can be accurately segmented from the background to prepare for the subsequent particle size measurement. It can be understood that the image segmentation technology is a relatively mature technology, and its specific segmentation process is not described in detail here.

[0041] 3) In the segmented image, each separated material particle is identified and marked, and the particle size of each marked material particle is measured based on the ratio between the pixel and the actual size obtained by the previous calibration.

[0042] Understandably, the identification and marking of each separated material particle can determine the contour and position information of each particle through some morphological operations and algorithms. The marked particles are convenient for subsequent individual measurement of their particle size. For example, for particles with regular shapes, the particle size can be expressed by measuring their longest diameter or equivalent diameter. For particles with irregular shapes, some approximate algorithms, such as the equivalent circle diameter method and the Feret diameter method, can be used to calculate the equivalent particle size that can reflect the particle size.

[0043] 4) Divide the measured material particle size into several particle size intervals, and count the material particles in each monitoring sub-area, that is, count the material particle size intervals existing in the corresponding monitoring finger area, and count the number of particles falling into each particle size interval. By counting the number of particles in each interval, the number of material particles in different particle size intervals is obtained, and the proportion of the number of particles in each particle size interval to the total number of particles is calculated, and used as the particle size distribution ratio of the particle size interval.

[0044] Exemplarily, for example, the particle size can be divided into different particle size intervals such as 0-5 mm, 5-10 mm, 10-15 mm, etc. in order from small to large.

[0045] It should also be added that there are many methods for detecting the regularity and similarity of material shapes. Specifically, methods based on image analysis and methods based on machine learning can be used. The specific examples are as follows: 1. Using methods based on image analysis: Use a high-definition camera to shoot the material from different angles to obtain a two-dimensional image of the material. Through image preprocessing techniques such as grayscale, filtering, edge detection, etc., the contour information of the material is extracted. Then, shape descriptors such as Hu moments and Zernike moments are used to quantify the shape characteristics of the material. These descriptors can convert the shape information of the material into a set of values. By comparing the shape descriptor values ​​of different materials, the shape similarity between them can be evaluated. For the detection of shape regularity, it can be measured by calculating the relationship between the perimeter and area of ​​the contour, the aspect ratio and other geometric parameters. For example, the perimeter and area ratio of a regular circle or square has a specific numerical range. The greater the deviation from this range, the more irregular the shape.

[0046] 2. Machine learning-based methods: Use machine learning algorithms to extract features and classify images or physical measurement data of materials. First, collect a large amount of sample data of materials with known shape regularity and similarity and label them. Then, use these sample data to train machine learning models, such as convolutional neural networks and support vector machines. During the training process, the model automatically learns the characteristic patterns of the material shape. When the data of the material to be tested is input, the model can classify and evaluate the shape regularity and similarity of the material based on the learned characteristic patterns. For example, by classifying material images with a trained CNN model, it is possible to determine whether the material shape is regular and its similarity to other materials of known shapes.

[0047] The monitoring layout setting module is used to install a humidity sensor and a viscosity sensor at the feed port to monitor the humidity and viscosity of the incoming material in real time to obtain real-time material humidity and real-time material viscosity. At the same time, a pressure sensor is added at each turning point of the screw machine to monitor the pressure value at each turning point in real time to obtain the real-time pressure value at each turning point.

[0048] It should be added that when the humidity of the material is low, the viscosity between the material particles is small, the particles are relatively independent of each other, and the fluidity is better. During the material reclaiming and conveying process of the screw unloader, the material can pass through the feed port, spiral blades and other parts relatively smoothly, and it is not easy to agglomerate and blockage. For example, dry sand can flow quickly in a screw conveyor, and there is rarely a problem of material blockage. However, when the humidity exceeds a certain limit, the fluidity of the material will drop sharply. Excessive moisture will fill the gaps between the material particles, greatly increasing the material flow resistance. In the screw unloader, this high-humidity material is difficult to be pushed by the spiral blades, and it is easy to accumulate in local areas, which will cause material blockage. Therefore, it is necessary to monitor the humidity and viscosity in real time so that abnormal conditions in the reclaiming process can be detected in time, reduce the probability of subsequent material blockage, and ensure the efficiency of reclaiming.

[0049] The embodiments of the present invention effectively solve the problem of limited dimensions of current detection data by detecting material humidity and viscosity, avoid the shortcomings of the current single data collection method, and can well adapt to the material handling operations of special materials with complex and changeable characteristics. At the same time, it also provides powerful assistance for accurate and targeted material blockage judgment, and also fully considers the distribution of materials in the cabin by detecting material composition, thereby providing a data basis for the timely adjustment of subsequent material handling, and facilitating the smooth progress of subsequent material handling work.

[0050] The embodiment of the present invention also compensates for the current problem of insufficient attention to the structural status of the equipment by adding pressure sensors at each turning point of the screw conveyor to monitor the pressure value at each turning point in real time, increases the attention and emphasis on the status of some key local areas inside the ship unloader, fills the gap in the current detection system at the monitoring level of this key factor, thereby improving the accuracy of subsequent assessments of material flow abnormalities, and also avoids ignoring subtle but important abnormal changes in material flow.

[0051] The environmental information importing module is used to import the real-time environmental information in the material taking place.

[0052] Specifically, the real-time environmental information includes real-time measurement of wind speed and real-time measurement of wind direction, etc., which can be monitored by a wind speed and direction measuring instrument.

[0053] The material fetching adjustment analysis module is used to analyze the material fetching setting adjustment needs based on material composition information, real-time material humidity, real-time material viscosity, real-time pressure values ​​at each turning point and real-time environmental information. If the analysis result is a demand adjustment, the adjustment index is confirmed.

[0054] Specifically, the material collection setting adjustment demand analysis is performed, including: A1, extracting the corresponding material particle size intervals and the distribution ratios of each material particle size interval in each monitoring sub-area from the material composition information, marking each material particle size interval on the number axis, and counting the number of times each material particle size interval is marked.

[0055] A2. Filter out the maximum particle size distribution ratio from the distribution ratios of the corresponding material particle size ranges in each monitoring sub-area.

[0056] A3. Extract the regularity and similarity of the corresponding materials in each monitoring sub-area from the material composition information, and analyze the material composition interference .

[0057] A4. Process the real-time material humidity, real-time material viscosity and real-time pressure values ​​at each turning point, and output the material transmission status interference degree , and at the same time analyze the real-time environmental information to obtain the interference degree of the material collection environment status.

[0058] A5. If any of the material composition interference, material transmission state interference and material collection environment state interference is greater than the corresponding set reference value, the need for adjustment will be taken as the analysis result, otherwise no adjustment will be taken as the analysis result.

[0059] Furthermore, in step A3, the material composition interference is analyzed, including: A31, calculating the average regularity of the materials corresponding to each monitoring sub-area to obtain the average regularity of the materials, which is recorded as , and filter out the maximum regularity and minimum regularity ,Will As target regularity , is a natural constant, The regularity of the reference to be set.

[0060] A32. Calculate the average similarity of the materials corresponding to each monitoring sub-area to obtain the average similarity of the materials , and filter out the maximum similarity and minimum similarity , according to the target regularity, define the target similarity, denoted as .

[0061] A33. Extract the highest and lowest marking times from the marking times of each material particle size range, and make the difference to get the standard frequency difference. At the same time, based on the maximum particle size distribution ratio corresponding to each monitoring sub-area, according to The target particle size distribution ratio is defined in the same way. , statistics of material particle size distribution uniformity .

[0062] A34. Set the target regularity, target similarity and material particle size distribution uniformity coefficients, calculate the material composition consistency through weighted average, and take the difference between 1 and the material composition consistency as the material composition interference.

[0063] In a specific embodiment, The value can be 0.3, and the proportion coefficients of target regularity, target similarity and material particle size distribution uniformity can be 0.3, 0.3 and 0.4 respectively.

[0064] It should be added that the particle size distribution of the material will affect the monitoring of blockages. If there are both large and small particles in the material, during the transportation process, the fine particles may fill the gaps between the large particles, resulting in an increase in the packing density of the material and poor fluidity. When large particles gather in narrow areas or corners, it is easy to cause blockages. Traditional blockage monitoring methods may not be able to identify this potential blockage risk caused by changes in particle size distribution in a timely manner. The particle size and distribution of the material have a significant impact on the blockage risk. When the particle size distribution is uneven and there are a large number of large or small particles, it is easy to form blockages during material collection and transportation. By analyzing the particle size distribution, the proportion of materials of different particle sizes in the overall material can be evaluated, thereby judging the potential risk of blockage, thereby avoiding focusing only on the overall material flow and pressure changes, while ignoring the impact of particle size distribution on material flow.

[0065] Furthermore, the output process of the material transmission state interference degree in step A4 is as follows: the current material humidity is filtered out from A41 and the real-time material humidity , calculate the average value of the real-time material viscosity to obtain the average material viscosity .

[0066] A42. Filter out the maximum pressure value from the real-time pressure values ​​at each bend , Indicates the turning number.

[0067] A43. Using time as the horizontal coordinate and pressure value as the vertical coordinate, construct a pressure change curve at each turning point, extract the number of fluctuation points and the slope from the pressure change curve, normalize the number of fluctuation points and the slope, use the normalized result as the evaluation variable, and import it into the Sigmoid function to output the pressure compensation factor at each turning point. .

[0068] A44. Statistics on material transmission status interference , , , and They are respectively the preset interference humidity value, interference viscosity value and reference pressure value.

[0069] It should be added that, in a specific embodiment, the normalization processing of the number of fluctuation points and the slope can be carried out through the maximum-minimum value normalization processing method, which is a relatively common normalization processing method, and the specific processing process will not be repeated here.

[0070] In a specific embodiment, for some materials with a high humidity tolerance, such as some ores, the humidity may reach 30%-40% before it is considered to cause interference. The value can be 40%. For some semi-solid materials, their normal working viscosity may be around several thousand centipoises. When the viscosity increases significantly, such as exceeding 10,000 centipoises, it may affect the transmission, that is, The value can be 10000 centipoise. For a screw conveyor with a certain pipe diameter and turning angle, when conveying a material of a certain density, the theoretical pressure at the turning point is 100kPa. Past experience shows that the normal pressure fluctuation range is between 80-120kPa. So the reference pressure value It can be initially set to 100 kPa.

[0071] Furthermore, step A4 analyzes the real-time environmental information, including: extracting the real-time measured wind speed from the real-time environmental information, constructing a wind speed change curve with time as the horizontal coordinate and wind speed as the vertical coordinate, and locating the total length of the curve above the set reference first interference wind speed and the reference second interference wind speed, respectively, and dividing them by the total length of the wind speed change curve to obtain the first wind speed interference ratio and the second wind speed interference ratio.

[0072] The real-time measured wind direction is extracted from the real-time environmental information, the cumulative number of measured wind directions is counted, and the number is divided by the current cumulative measurement time to obtain the wind direction change rate.

[0073] If the wind direction change rate is greater than or equal to the set reference interference wind direction change rate, the wind direction interference ratio is assigned a value of 1; otherwise, the ratio of the two is used as the wind direction interference ratio.

[0074] The weight coefficients of the first wind speed interference ratio, the second wind speed interference ratio and the wind direction interference ratio are set, and the interference degree of the material collection environment state is obtained by weighted average calculation.

[0075] In a specific embodiment, the first interfering wind speed may be set to 5 m / s, the set reference second interfering wind speed may be set to 8 m / s, and the set reference interfering wind direction change rate may be set to 15 times per hour.

[0076] In another specific embodiment, the weight coefficients of the first wind speed interference ratio, the second wind speed interference ratio and the wind direction interference ratio may be 0.35, 0.4 and 0.25 respectively.

[0077] In another specific embodiment, the adjustment index is confirmed, including: B1. If the material composition interference or the material transmission state interference is greater than the corresponding set reference value, the material quantity adjustment is used as the adjustment item; if the material environment state interference is greater than the corresponding set reference value, the moving speed is used as the adjustment item.

[0078] B2. When the adjustment item is the material taking amount, set the adjustment compensation factor , and correct the pre-set material taking amount. If the corrected material taking amount is lower than the set benchmark material taking amount, the benchmark material taking amount will be used as the adjusted material taking amount. Otherwise, the corrected material taking amount will be used as the adjusted material taking amount, and the adjusted material taking amount will be used as the adjustment parameter.

[0079] B3. When the adjustment item is moving speed, if the second wind speed interference ratio reaches the warning value, the material collection suspension instruction will be started as the adjustment parameter.

[0080] B4. If the second wind speed interference ratio does not reach the warning value, the product of the preset initial moving speed and the inverse of the interference degree of the material collection environment state is used as the adjusted moving speed and as the adjustment parameter, and then the adjustment item and the adjustment parameter under the adjustment item are combined into an adjustment indicator.

[0081] It should be added that the correction of the initial material taking amount is to multiply the initial material taking amount by the difference between 1 and the adjustment compensation factor, and illustratively, the reference value corresponding to the interference degree of the material taking environment state can be set to 0.5.

[0082] It should be added that different material particle sizes behave differently during the reclaiming process. If the material composition does not match the preset reclaiming settings, it is necessary to consider adjusting the reclaiming speed to ensure that the material can enter the reclaiming mechanism smoothly.

[0083] It should also be added that if the high degree of interference in material composition is due to uneven particle size distribution, such as too much large-size material that is prone to blockage, the material reclaiming speed can be reduced to allow the equipment more time to process large-particle materials through the feed port. If the wind speed interference is high, when the wind speed exceeds the first interference wind speed, the moving speed of the reclaiming arm can be reduced to increase its stability. If the wind speed exceeds the second interference wind speed, the reclaiming operation may need to be suspended to reduce the impact of wind on materials and equipment. Similarly, if the wind direction change rate causes interference, it is also necessary to appropriately reduce the moving speed of the reclaiming arm to maintain the stability of reclaiming as much as possible.

[0084] The embodiment of the present invention analyzes the interference degree of the material picking environment state based on wind speed and wind direction, and confirms the adjustment items and adjustment indicators accordingly, fully considering the interference of environmental factors on the material picking mechanism, thereby avoiding the current neglect of the influence of the switching factors, while also ensuring the accuracy of subsequent material picking setting adjustments, the stability of subsequent material picking and the accuracy of the material picking position, and also providing a strong guarantee for the efficient and accurate material picking work under harsh environmental conditions.

[0085] Furthermore, in step B2, the adjustment compensation factor is set, including: if only the material composition interference is greater than the corresponding set reference value, As an interference factor, if the interference degree of the material transmission state is greater than the corresponding set reference value, As interference factors, if both are greater than the corresponding set reference value, As interference factor, we can get the interference factor , The values ​​are or or , .

[0086] Setting the adjustment compensation factor , , and They are respectively used to set the reference material composition interference degree and material transmission state interference degree.

[0087] It should be added that , and The values ​​may be 0.3, 0.4 and 0.8 respectively, and in a specific embodiment, the reference material composition interference value may be set to 0.5, and the reference material transmission state interference value may be set to 0.6.

[0088] The material taking adjustment execution terminal is used to adjust the material taking setting of the material taking mechanism according to the adjustment index.

[0089] See also Figure 3 As shown, the material picking monitoring and verification module is used to perform real-time vibration frequency monitoring through the vibration sensor carried by the material picking mechanism, and at the same time import the real-time current of the corresponding associated motor of the material picking mechanism to determine whether the material picking setting is consistent with the expectation. If it is judged as no, the secondary adjustment index is confirmed and fed back to the material picking adjustment execution terminal for secondary material picking setting adjustment. If it is judged as yes, the material picking instruction continues to be executed.

[0090] Specifically, judging whether the material taking setting is consistent with the expectation includes: D1, calculating the mean of the vibration frequency monitored in real time to obtain the average vibration frequency .

[0091] D2. Filter out the maximum current from the real-time current , and use time as the horizontal axis and current as the vertical axis to construct a current change curve, and extract the slope of the current change curve as the current change rate .

[0092] D3. Make the average vibration frequency greater than or equal to the set reference vibration frequency As condition 1, the maximum current is greater than or equal to the set reference current. As condition 2, the maximum current is Lower than the set reference current ,and and The difference in setting the reference current difference At the same time, the current change rate Exceeds the set reference current change rate As condition 3.

[0093] D4. Determine whether any of the conditions 1, 2, and 3 are met. If so, take "no" as the result, otherwise "yes" as the result.

[0094] In a specific embodiment, in the operation monitoring of material reclaiming equipment such as screw unloaders, parameters such as average vibration frequency and current are crucial to judging the operating status of the equipment, and the setting of relevant reference values ​​needs to comprehensively consider multiple factors such as equipment characteristics, operating experience, and safety requirements. For example, the normal vibration frequency range of material reclaiming equipment of different types and structures is different. For small material reclaiming equipment with a relatively compact structure and good stability, the vibration frequency during normal operation is relatively low, and the reference vibration frequency is set It can be set to 30Hz. When the reclaimer processes materials with different characteristics, the vibration frequency will also change. At this time, the reference vibration frequency is set. It can be set to 40Hz. Generally speaking, the reference current can be set slightly lower than the rated current of the equipment to ensure that the equipment operates within a safe range. For example, the rated current of a ship unloader is 200 amperes. Considering the long-term stable operation of the equipment and a certain safety margin, the reference current is set It can be set to 180 amps. At the same time, by analyzing the equipment's operating history data, we can understand the current consumption of the equipment under different working conditions. If the average current of the equipment fluctuates between 150 amps and 160 amps during normal material reclaiming operations, and occasionally reaches 170 amps, then set the reference current It can be set to 170 amps to detect abnormal current changes that may occur in the equipment in a timely manner. Set the reference current difference The value can be 10 amperes, and different reclaiming equipment has different response speeds. When setting the reference current change rate, this characteristic of the equipment needs to be considered. For equipment with a faster response speed, it can quickly adapt to changes in current and set the reference current change rate. It can be relatively high, such as a change rate of 10 amperes per minute. For devices with slower response speeds, excessive current change rates may cause damage to the device. Can be set to 5 amps per minute.

[0095] In another specific embodiment, the second adjustment index is determined, including: if condition 1 is met, the adjustment moving speed is recorded as , and then As a secondary adjustment of movement speed and as a secondary adjustment indicator.

[0096] If condition 2 or 3 is met, the adjusted material quantity and the reference material quantity are recorded as and , calculate the secondary adjustment material quantity , ,Will As a secondary adjustment indicator.

[0097] The embodiment of the present invention monitors the material composition through the material information monitoring module to understand the material characteristics. The monitoring layout setting module monitors the humidity, viscosity and pressure at the turning point of the screw machine, which makes up for the shortcomings of the existing monitoring of local areas. At the same time, the environmental information import module takes environmental factors into consideration to improve the adaptability to complex port environments. The material reclaiming adjustment analysis module performs adjustment demand analysis based on multi-source information to make the adjustment more targeted. The material reclaiming monitoring and verification module performs secondary adjustments through vibration frequency and motor current analysis to form a closed-loop control to ensure that the reclaiming mechanism is in the best operating state. These settings can fully grasp the material reclaiming status, prevent failures, improve material reclaiming efficiency and quality, extend the service life of equipment and reduce costs.

[0098] See also Figure 2 As shown, the present invention also provides a real-time monitoring method for a material taking mechanism of a screw ship unloader, comprising: S1, material information monitoring: monitoring material composition information in a material placement area.

[0099] S2. Monitoring layout setting: Humidity and viscosity sensors are installed at the feed port to measure the humidity and viscosity of the incoming materials in real time. At the same time, pressure sensors are added at each turning point of the screw conveyor to monitor the pressure value at each turning point in real time.

[0100] S3. Environmental information import: import the real-time environmental information in the material collection site.

[0101] S4. Material adjustment analysis: Conduct material setting adjustment demand analysis. If the analysis result is a demand adjustment, confirm the adjustment index.

[0102] S5, material retrieving adjustment execution: adjust the material retrieving setting of the material retrieving mechanism according to the adjustment index described in step S4.

[0103] S6, material picking monitoring and verification: The vibration frequency is monitored by the vibration sensor carried by the material picking mechanism, and the current of the corresponding motor of the material picking mechanism is imported to determine whether the material picking setting is consistent with the expectation. If it is judged as no, confirm the secondary adjustment index and return to step S5 to make a secondary adjustment to the material picking setting. If it is judged as yes, continue to execute the material picking instruction.

[0104] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. A real-time monitoring device for the material taking mechanism of a screw ship unloader, characterized in that: include: Material information monitoring module, used to monitor the material composition information of the material placement area; The monitoring layout setting module is used to install a humidity sensor and a viscosity sensor at the feed port to monitor the humidity and viscosity of the incoming material in real time, and obtain the real-time material humidity and real-time material viscosity. At the same time, a pressure sensor is added at each turning point of the screw machine to monitor the pressure value at each turning point in real time and obtain the real-time pressure value at each turning point; Environmental information import module, used to import real-time environmental information in the material collection site; The material reclaiming adjustment analysis module is used to analyze the demand for reclaiming setting adjustment based on material composition information, real-time material humidity, real-time material viscosity, real-time pressure values ​​at each turning point, and real-time environmental information. If the analysis result indicates that adjustment is required, the adjustment index is confirmed. A material taking adjustment execution terminal is used to adjust the material taking setting of the material taking mechanism according to the adjustment index; The material taking monitoring and verification module is used to monitor the real-time vibration frequency through the vibration sensor carried by the material taking mechanism, and at the same time import the real-time current of the corresponding motor of the material taking mechanism to determine whether the material taking setting is consistent with the expectation. If it is judged as no, the secondary adjustment index is confirmed and fed back to the material taking adjustment execution terminal for secondary material taking setting adjustment. If it is judged as yes, the material taking instruction is continued to be executed; The material taking setting adjustment demand analysis includes: Extract the corresponding material particle size intervals and the distribution ratios of the material particle size intervals in each monitoring sub-area from the material composition information, mark the material particle size intervals on the number axis, and count the number of times each material particle size interval is marked; The maximum particle size distribution ratio is selected from the distribution ratios of the corresponding material particle size intervals in each monitoring sub-area; Extract the regularity and similarity of the corresponding materials in each monitoring sub-area from the material composition information, and analyze the material composition interference ; Process the real-time material humidity, real-time material viscosity and real-time pressure values ​​at each bend, and output the interference degree of material transmission status , and analyze the real-time environmental information at the same time to obtain the interference degree of the material collection environment state; If any of the material composition interference, material transmission state interference and material collection environment state interference is greater than the corresponding set reference value, the need for adjustment will be taken as the analysis result, otherwise no adjustment will be taken as the analysis result.

2. A real-time monitoring device for a screw ship unloader reclaiming mechanism according to claim 1, characterized in that: The analysis of material composition interference includes: The regularity of the materials corresponding to each monitoring sub-area is averaged and the average regularity of the materials is obtained, which is recorded as , and filter out the maximum regularity and minimum regularity ,Will As target regularity , is a natural constant, The regularity of the reference set; Calculate the average similarity of the materials in each monitoring sub-area to obtain the average similarity of the materials , and filter out the maximum similarity and minimum similarity , according to the target regularity, define the target similarity, denoted as ; Extract the highest and lowest marked times from the marked times of each material particle size range, and make the difference to get the standard frequency difference At the same time, based on the maximum particle size distribution ratio corresponding to each monitoring sub-area, according to The target particle size distribution ratio is defined in the same way. , statistics of material particle size distribution uniformity ; Set the target regularity, target similarity and material particle size distribution uniformity coefficients, calculate the material composition consistency through weighted average, and take the difference between 1 and the material composition consistency as the material composition interference.

3. A real-time monitoring device for a screw ship unloader reclaiming mechanism according to claim 1, characterized in that: The output process of the material transmission state interference degree is as follows: Filter the current material humidity from the real-time material humidity , calculate the average value of the real-time material viscosity to obtain the average material viscosity ; Filter out the maximum pressure value from the real-time pressure values ​​at each bend , Indicates the number of the turning point; With time as the horizontal coordinate and pressure value as the vertical coordinate, a pressure change curve at each bend is constructed, the number of fluctuation points and the slope are extracted from the pressure change curve, the number of fluctuation points and the slope are normalized, the result of the normalization is used as the evaluation variable, and is imported into the Sigmoid function to output the pressure compensation factor at each bend ; Statistics of material transmission status interference , , , and They are respectively the preset interference humidity value, interference viscosity value and reference pressure value.

4. A real-time monitoring device for a screw ship unloader reclaiming mechanism according to claim 1, characterized in that: The analysis of real-time environmental information includes: The real-time measured wind speed is extracted from the real-time environmental information, and a wind speed change curve is constructed with time as the horizontal coordinate and wind speed as the vertical coordinate, and the total length of the curve located above the set reference first interference wind speed and the reference second interference wind speed is located respectively, and the first wind speed interference ratio and the second wind speed interference ratio are obtained by dividing the total length of the wind speed change curve respectively; Extract the real-time measured wind direction from the real-time environmental information, count the cumulative number of measured wind directions, and divide it by the current cumulative measurement time to obtain the wind direction change rate; If the wind direction change rate is greater than or equal to the set reference interference wind direction change rate, the wind direction interference ratio is assigned a value of 1; otherwise, the ratio of the two is used as the wind direction interference ratio; The weight coefficients of the first wind speed interference ratio, the second wind speed interference ratio and the wind direction interference ratio are set, and the interference degree of the material collection environment state is obtained by weighted average calculation.

5. A real-time monitoring device for a screw ship unloader reclaiming mechanism as claimed in claim 2, characterized in that: The confirmation adjustment indicators include: If the material composition interference or material transmission state interference is greater than the corresponding set reference value, the material quantity adjustment is used as the adjustment item; if the material environment state interference is greater than the corresponding set reference value, the moving speed is used as the adjustment item; When the adjustment item is the material taking amount, set the adjustment compensation factor , and correct the pre-set material taking amount. If the corrected material taking amount is lower than the set reference material taking amount, the reference material taking amount is used as the adjusted material taking amount. Otherwise, the corrected material taking amount is used as the adjusted material taking amount, and the adjusted material taking amount is used as the adjustment parameter; When the adjustment item is the moving speed, if the second wind speed interference ratio reaches the warning value, the material suspending instruction will be started as the adjustment parameter; If the second wind speed interference ratio does not reach the warning value, the product of the preset initial moving speed and the inverse of the interference degree of the material collection environment state is used as the adjusted moving speed and as the adjustment parameter, and then the adjustment item and the adjustment parameter under the adjustment item are combined into an adjustment indicator.

6. A real-time monitoring device for a screw ship unloader reclaiming mechanism as claimed in claim 5, characterized in that: The setting and adjusting the compensation factor includes: If only the material composition interference is greater than the corresponding set reference value, As an interference factor, if the interference degree of the material transmission state is greater than the corresponding set reference value, As interference factors, if both are greater than the corresponding set reference value, As interference factor, we can get the interference factor , The values ​​are or or , ; Setting the adjustment compensation factor , , and They are respectively used to set the reference material composition interference degree and material transmission state interference degree.

7. A real-time monitoring device for a screw ship unloader reclaiming mechanism as claimed in claim 5, characterized in that: The step of judging whether the material taking setting is consistent with the expectation includes: Calculate the mean of the real-time monitored vibration frequency to obtain the average vibration frequency ; Filter the maximum current from the real-time current , and use time as the horizontal axis and current as the vertical axis to construct a current change curve, and extract the slope of the current change curve as the current change rate ; The average vibration frequency is greater than or equal to the set reference vibration frequency As condition 1, the maximum current is greater than or equal to the set reference current. As condition 2, the maximum current is Lower than the set reference current ,and and The difference in setting the reference current difference At the same time, the current change rate Exceeds the set reference current change rate As condition 3; Determine whether any of the conditions 1, 2, and 3 are met. If so, take "no" as the result, otherwise "yes" as the result.

8. A real-time monitoring device for a screw ship unloader reclaiming mechanism according to claim 7, characterized in that: The adjustment indicators confirmed for the second time include: If condition 1 is met, the adjusted moving speed is recorded as , and then As a secondary adjustment of movement speed, and as a secondary adjustment indicator; If condition 2 or 3 is met, the adjusted material quantity and the reference material quantity are recorded as and , calculate the secondary adjustment material quantity , ,Will As a secondary adjustment indicator.

9. A real-time monitoring method for a screw ship unloader reclaiming mechanism, performed by a real-time monitoring device according to any one of claims 1 to 8, characterized in that: The method includes: S1. Material information monitoring: monitoring the material composition information in the material placement area; S2. Monitoring layout setting: install humidity sensors and viscosity sensors at the feed inlet to measure the humidity and viscosity of the incoming materials in real time. At the same time, add pressure sensors at each turning point of the screw conveyor to monitor the pressure value at each turning point in real time. S3, environmental information import: import the real-time environmental information in the material collection site; S4. Material adjustment analysis: perform material setting adjustment demand analysis. If the analysis result indicates demand adjustment, confirm the adjustment index. S5, material reclaiming adjustment execution: adjusting the material reclaiming setting of the reclaiming mechanism according to the adjustment index described in step S4; S6, material picking monitoring and verification: The vibration frequency is monitored by the vibration sensor carried by the material picking mechanism, and the current of the corresponding motor of the material picking mechanism is imported to determine whether the material picking setting is consistent with the expectation. If it is judged as no, confirm the secondary adjustment index and return to step S5 to make a secondary adjustment to the material picking setting. If it is judged as yes, continue to execute the material picking instruction.

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