Coal flow monitoring device and system for driving face belt conveyor

Abstract

The invention relates to the technical field of image processing, and discloses a driving working face belt conveyor coal flow monitoring device and system.The driving working face belt conveyor coal flow monitoring system comprises an intelligent coal flow monitoring and sampling module, a data processing module and a data processing module, the belt tensioning adjusting module is used for monitoring and automatically adjusting the tensioning degree of a belt, the belt deviation correcting module is used for monitoring the running direction of the belt, the coal dust cooling and dust falling control module is used for monitoring the coal dust concentration and temperature, and the data collecting and processing module is used for collecting and preliminarily processing data of all the modules. The intelligent monitoring and early warning module is used for monitoring the running state of the system in real time, and the data transmission and communication module is used for transmitting data among the modules. By means of high-precision sensors such as laser ranging, an image sensor and an automatic sampling device, errors caused by manual observation are avoided, comprehensive and automatic sampling can be carried out on coal flow, uneven sample selection caused by human factors is avoided, and representativeness and objectivity of data are ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of image processing, and in particular to a coal flow monitoring device and system for a belt conveyor on an excavation working face. Background Art

[0002] Most coal mining in my country is done underground. The transportation of coal from the tunneling face to the ground is a key link to ensure efficient and reliable use of coal. As the core equipment for coal flow transportation, the operation stability and safety of the tunneling face belt conveyor are crucial to the production efficiency and safety of coal mines. Traditional coal flow monitoring methods rely on manual observation, which is not only inefficient, but also easily affected by human subjective factors, resulting in insufficient accuracy of monitoring data. In addition, existing coal flow monitoring methods are mostly local static detection, which cannot meet the intelligent and automated production needs of modern coal mines, limiting production efficiency and safety assurance levels.

[0003] At present, although there are some coal flow monitoring devices, most of them cannot comprehensively consider multiple factors such as coal flow, coal flow thickness, coal dust concentration, belt tension, etc., and lack efficient and automated monitoring and adjustment methods. Therefore, there is an urgent need for an intelligent coal flow monitoring system that can perform comprehensive, real-time and accurate monitoring to improve the safety, reliability and automation level of coal flow transportation. Summary of the invention

[0004] In view of the shortcomings of the prior art, the present invention provides a coal flow monitoring device and system for a belt conveyor at an excavation working face to solve the shortcomings of coal flow monitoring. The lack of automation, precision and intelligence requires technicians to use visual inspection for inspection, resulting in low efficiency and insufficient safety during coal flow transportation.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a coal flow monitoring system for a belt conveyor of an excavation working face, comprising: Coal flow intelligent monitoring and sampling module, belt tensioning and adjustment module, belt deviation correction module, coal dust cooling and dust reduction control module, data acquisition and processing module, intelligent monitoring and early warning module, intelligent analysis and decision support module and data transmission and communication module; The coal flow intelligent monitoring and sampling module is used to monitor the thickness, image characteristics and coal sample data of the coal flow; The belt tension adjustment module is used to monitor and automatically adjust the tension of the belt to prevent the belt from being loose or too tight; The belt deviation correction module is used to monitor the running direction of the belt and automatically correct the deviation to allow the belt to operate normally; The coal dust cooling and dust reduction control module is used to monitor the coal dust concentration and temperature and automatically start the dust reduction device; The data acquisition and processing module is used to acquire and preliminarily process the data of each module; The intelligent monitoring and early warning module is used to monitor the system operation status in real time, generate early warning information, and remind operators to handle abnormalities; The intelligent analysis and decision support module is used to analyze data, provide optimization decisions and fault prediction, and automatically adjust system parameters; The data transmission and communication module is used to transmit data between modules, allowing information to be shared and transmitted in real time.

[0006] Preferably, the coal flow intelligent monitoring and sampling module includes a thickness measuring unit, an image capture unit and an automatic sampling unit. The thickness measuring unit is used to measure the thickness of the coal flow in real time and provide information related to the volume of the coal flow. The image capture unit is used to capture the image of the coal flow, analyze the coal flow morphology and information on abnormal coal blocks, and assist in judging the state of the coal flow. The automatic sampling unit is used to automatically extract coal samples from the coal flow to make the extracted coal samples representative.

[0007] Preferably, the belt tensioning adjustment module includes a tension detection unit, a hydraulic adjustment unit and a guide adjustment unit. The tension detection unit is used to detect the tensioning state of the conveyor belt to ensure stable operation of the belt. The hydraulic adjustment unit is used to automatically adjust the tension of the belt through the hydraulic system according to the feedback result of the tension detection unit to ensure stable operation of the belt. The guide adjustment unit is used to adjust the path of the conveyor belt to ensure that the belt does not deviate from the normal track and maintains smooth operation during operation.

[0008] Preferably, the belt correction module includes a position monitoring unit, an image recognition unit and a drive correction unit. The position monitoring unit is used to monitor the position and trajectory of the belt and whether it is offset, so that the belt can run on the correct track. The image recognition unit is used to assist in detecting the offset of the belt through image recognition technology and provide additional data verification. The data verification is used for secondary verification of the data and the accuracy of the correction operation. The drive correction unit is used to automatically perform the belt correction action according to the information provided by the position monitoring and image recognition units to allow the belt to run normally.

[0009] Preferably, the coal dust cooling and dust reduction control module includes a coal dust concentration monitoring unit, a temperature monitoring unit and a dust reduction and cooling control unit. The coal dust concentration monitoring unit is used to monitor the coal dust concentration in real time to ensure that the coal dust concentration is within a safe range. The temperature monitoring unit is used to monitor the temperature of the coal flow and the surrounding environment in real time to prevent excessive temperature from affecting equipment operation or causing a fire. The dust reduction and cooling control unit is used to automatically start the dust reduction spray system or temperature adjustment device based on the monitoring results. The dust reduction spray is used to maintain the ambient temperature and coal dust concentration within a safe range.

[0010] Preferably, the data acquisition and processing module includes a data acquisition unit, a data processing unit and a data storage unit. The data acquisition unit is used to collect data from each monitoring unit in real time to provide input for data analysis. The collected data includes thickness, image, tension, and temperature. The data processing unit is used to perform preliminary processing on the collected data to confirm the data quality and accuracy. The preliminary processing includes filtering, formatting, and correction. The data storage unit is used to store real-time data and historical data, support data tracing and historical analysis, and provide decision support and optimization basis.

[0011] Preferably, the intelligent monitoring and early warning module includes a real-time monitoring unit, an abnormality detection unit and an early warning response unit. The real-time monitoring unit is used to monitor various operating parameters of the system in real time, and the operating parameters include belt status and coal flow conditions. The abnormality detection unit is used to monitor the data in real time for analysis, detect whether any abnormal phenomenon occurs, and generate alarm information. The early warning response unit is used to automatically or manually start response measures according to the early warning information provided by the abnormality detection unit. The response measures include sound and light alarms and operation prompts.

[0012] Preferably, the intelligent analysis and decision support module includes a data analysis unit, a fault prediction unit and a decision support unit. The data analysis unit is used to perform in-depth analysis on real-time and historical data, extract key operating laws, and predict equipment status and fault trends. The key operating laws include equipment working status change patterns, periodic operating laws, and abnormal pattern recognition. The fault prediction unit is used to analyze the operating status of the equipment, predict potential faults, and make preventive maintenance suggestions in advance. The decision support unit is used to provide optimized operation suggestions and decisions based on the analysis results. The preventive maintenance suggestions include maintenance suggestions for equipment overtemperature, small deviations, and abnormal equipment vibration.

[0013] Preferably, the data transmission and communication module includes a data transmission unit, a communication management unit and a security encryption unit. The data transmission unit is responsible for transmitting data between modules so that information can be shared in real time to avoid data delay or loss. The communication management unit is used to manage the communication interfaces of all devices and modules in the system to ensure smooth and stable data transmission. The security encryption unit is used to encrypt the transmitted data to ensure the security of information during transmission and prevent data leakage or tampering.

[0014] A coal flow monitoring device for a belt conveyor of an excavation working face comprises a mounting plate, the upper surface of the mounting plate is fixedly connected with a connecting block, the outer wall of the connecting block is fixedly connected with a motor, the output end of the motor is fixedly connected with a driving rod, the outer wall of the driving rod is fixedly connected with a worm, the tooth end of the worm is meshingly connected with a worm wheel, the outer wall of the worm wheel is rotatably connected with a supporting frame, the lower surface of the supporting frame is fixedly connected with the upper surface of the mounting plate, the top of the worm wheel is fixedly connected with a threaded rod, the outer wall of the threaded rod is rotatably connected to the inner wall of the supporting frame, the outer wall of the threaded rod is threadedly connected with a limiting slider, the middle part of the limiting slider is fixedly connected with a rotating table, the outer wall of the rotating table is rotatably connected with a half-scale wheel, the outer wall of the supporting frame is fixedly connected with an electric slide rail, the outer wall of the electric slide rail is slidably connected with an electric slide rail, the outer wall of the electric slide rail is fixedly connected with a toothed plate, the tooth end of the toothed plate is meshed with the tooth end of the half-scale wheel, the outer wall of the half-scale wheel is fixedly connected with a stabilizing shaft, and the outer wall of the stabilizing shaft is fixedly connected to the outer wall of the rotating table; The inner wall of the rotating table is fixedly connected to a mounting seat, the outer wall of the mounting seat is slidably connected to a slide, the lower surface of the slide is fixedly connected to an electric push rod, the output end of the electric push rod is fixedly connected to the left outer wall of the mounting seat, the middle part of the mounting seat is rotatably connected to a connecting rod, the outer wall of the connecting rod is rotatably connected to the inner wall of the slide, the upper surface of the slide is fixedly connected to a splint, and the outer wall of the splint is slidably connected to a camera.

[0015] The present invention provides a coal flow monitoring device and system for a belt conveyor on a tunneling working face. It has the following beneficial effects: 1. The present invention avoids the error of manual observation through high-precision sensors such as laser ranging, image sensors and automatic sampling devices, improves the accuracy and objectivity of coal flow monitoring, and uses automatic sampling devices to perform comprehensive and automatic sampling of coal flows, avoiding uneven sample selection caused by human factors and ensuring the representativeness and objectivity of the data.

[0016] 2. The present invention ensures the efficient and stable operation of the belt conveyor through intelligent belt tension adjustment and automatic deviation correction system, reduces the occurrence of belt loosening, falling off and deviation and other faults, and improves the operation efficiency and safety of the equipment. Combined with temperature, coal dust concentration sensors and intelligent control devices, real-time monitoring of coal dust concentration is achieved, and environmental safety during coal flow transportation is ensured. The intelligent control of the dust suppression device can automatically start and stop, reducing manual intervention. At the same time, the system conducts comprehensive analysis based on real-time data, automatically generates early warning information, and promptly discovers and handles abnormal conditions in coal flow transportation, reducing the probability of accidents.

[0017] 3. The present invention can extend the camera during use by moving the slider upward. It can extend and retract the camera during use. The electric slider and the electric slide rail drive the toothed plate to move up and down and engage with the half-scale wheel. The angle of the camera can be adjusted during use. The longitudinal angle of the camera can be adjusted according to the needs of use to better capture images.

[0018] 4. The present invention drives the slide on the other side of the slide under the limit of the connecting rod when the electric push rod pushes the mounting seat. During use, the connecting rod drives the clamping plate so that cameras of different sizes can be installed and disassembled quickly and adapted for use. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a system architecture diagram of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Figure 2 This is a schematic diagram of the coal flow intelligent monitoring and sampling module of a coal flow monitoring system for a belt conveyor on a tunneling working face of the present invention; Figure 3 This is a diagram of the belt tensioning adjustment module architecture of a coal flow monitoring system for a belt conveyor on a tunneling working face of the present invention; Figure 4 This is a relationship architecture diagram of the coal flow intelligent monitoring and sampling modules of a coal flow monitoring system for a belt conveyor on a tunneling working face of the present invention; Figure 5 This is a diagram of the belt deviation correction module architecture of a coal flow monitoring system for a belt conveyor on a tunneling working face of the present invention; Figure 6 This is a schematic diagram of the coal dust cooling and dust reduction control module of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Figure 7 This is a relationship architecture diagram of a coal dust cooling and dust reduction control module of a coal flow monitoring system for a belt conveyor on a tunneling working face of the present invention; Figure 8 This is a data acquisition and processing module architecture diagram of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Fig. 9 This is a diagram of the intelligent monitoring and early warning module architecture of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Fig.10 This is a diagram of the intelligent analysis and decision support module architecture of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Fig.11 This is a relationship architecture diagram of the intelligent analysis and decision support modules of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Fig.12 This is a data transmission and communication module architecture diagram of a coal flow monitoring system for a belt conveyor on a tunneling working face according to the present invention; Fig.13 A three-dimensional diagram of a coal flow monitoring device for a belt conveyor of a tunneling working face according to the present invention; Fig.14 It is a partial schematic diagram of a driving rod of a coal flow monitoring device for a belt conveyor on a tunneling working face of the present invention; Fig.15 It is a partial schematic diagram of a support frame of a coal flow monitoring device for a belt conveyor on a tunneling working face according to the present invention; Fig.16 It is a partial schematic diagram of a mounting base of a coal flow monitoring device for a belt conveyor on an excavation working face according to the present invention.

[0020] Among them, 1. Mounting plate; 2. Connecting block; 3. Motor; 4. Driving rod; 5. Worm; 6. Worm wheel; 7. Support frame; 8. Threaded rod; 9. Limit slider; 10. Half-size wheel; 11. Electric slide rail; 12. Electric slider; 13. Tooth plate; 14. Stabilizing shaft; 15. Turntable; 16. Mounting seat; 17. Electric push rod; 18. Slide; 19. Connecting rod; 20. Clamp; 21. Camera. DETAILED DESCRIPTION

[0021] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings 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.

[0022] Example: Please see attached Figure 1 -Attached Fig.12 The embodiment of the present invention provides a coal flow monitoring system for a belt conveyor of a tunneling working face, comprising: Coal flow intelligent monitoring and sampling module, belt tensioning and adjustment module, belt deviation correction module, coal dust cooling and dust reduction control module, data acquisition and processing module, intelligent monitoring and early warning module, intelligent analysis and decision support module and data transmission and communication module; The coal flow intelligent monitoring and sampling module is used to monitor the thickness, image characteristics, and coal sample data of the coal flow; The belt tension adjustment module is used to monitor and automatically adjust the belt tension to prevent the belt from being loose or too tight; The belt deviation correction module is used to monitor the running direction of the belt and automatically correct the deviation to ensure the normal operation of the belt; The coal dust cooling and dust reduction control module is used to monitor the coal dust concentration and temperature and automatically start the dust reduction device; The data acquisition and processing module is used to collect and preliminarily process the data of each module; The intelligent monitoring and early warning module is used to monitor the system operation status in real time, generate early warning information, and remind operators to handle abnormalities; The intelligent analysis and decision support module is used to analyze data, provide optimization decisions and fault prediction, and automatically adjust system parameters; The data transmission and communication module is used to transmit data between modules, allowing information to be shared and transmitted in real time.

[0023] The intelligent coal flow monitoring and sampling module includes a thickness measurement unit, an image capture unit and an automatic sampling unit. The thickness measurement unit is used to measure the thickness of the coal flow in real time and provide information related to the coal flow volume. The image capture unit is used to capture the image of the coal flow, analyze the coal flow morphology and information on abnormal coal blocks, and assist in judging the coal flow status. The automatic sampling unit is used to automatically extract coal samples from the coal flow to make the extracted coal samples representative.

[0024] Specifically, laser distance measuring sensors, image sensors and automatic sampling devices are installed on the belt conveyor of the excavation working face to collect the thickness, image features and coal sample data of the coal flow in real time. The laser distance measuring sensor measures the thickness of the coal flow, the image sensor captures the image features of the coal flow, and the sampling device automatically samples from the coal flow. All data are uploaded to the central control system in real time. The thickness measurement unit is based on laser ranging technology. It measures the thickness of the coal flow in real time through a laser sensor installed above the conveyor belt. The sensor emits laser light and receives reflected light, and calculates the thickness value based on the time difference of the optical path. Combined with the conveyor belt speed, the system can estimate the volume of the coal flow in real time, ensure the accuracy and continuity of the data, and provide support for production statistics and scheduling optimization; The image capture unit uses a high-definition industrial camera to capture coal flow images in real time, analyze the coal flow morphology through image processing technology (such as edge detection and target recognition), and identify abnormal coal blocks and accumulation phenomena. The image data is transmitted to the control system for analysis to assist in judging the coal flow status, effectively reducing the workload of manual inspections and improving the efficiency of abnormal handling; The automatic sampling unit consists of a sampling device and a drive system. It automatically extracts coal samples according to the set conditions to ensure the representativeness of the samples. The unit obtains samples at different positions through a sampling rod or a mechanical arm to avoid sampling errors. The samples are used for quality inspection after pretreatment. The system can adjust the sampling frequency and position according to real-time data to improve the accuracy and automation level of coal quality management; Through the linked monitoring of thickness, image and sample data, the accuracy and real-time performance of coal flow management are improved, overcoming the low efficiency and large errors of traditional manual methods.

[0025] The belt tensioning adjustment module includes a tension detection unit, a hydraulic adjustment unit and a guide adjustment unit. The tension detection unit is used to detect the tensioning state of the conveyor belt to ensure stable operation of the belt. The hydraulic adjustment unit is used to automatically adjust the tension of the belt through the hydraulic system according to the feedback from the tension detection unit to ensure stable operation of the belt. The guide adjustment unit is used to adjust the path of the conveyor belt to ensure that the belt does not deviate from the normal track and maintains smooth operation during operation.

[0026] Specifically, by installing tension sensors and displacement sensors, the tension and position of the coal conveyor belt are monitored in real time. The central control system intelligently designs and adjusts the belt tension based on the belt's historical operation data and real-time sensor data, and uses hydraulic telescopic rods and guide wheels to automatically adjust the belt tension to ensure stable operation of the belt. The tension detection unit monitors the tension status of the belt in real time through the tension sensors installed on both sides of the belt. The sensor measures the pull or tension change of the belt, and the data is transmitted to the central control system so that the system can determine whether the belt is in normal operation. The detection accuracy is usually within ±2%, which can detect insufficient or excessive tension in time to prevent the belt from loosening, slipping or damage. The hydraulic adjustment unit adjusts the belt tension through the hydraulic telescopic rod or hydraulic cylinder according to the feedback provided by the tension detection unit. The system automatically calculates the tension adjustment amount, and the hydraulic device responds to the command in a short time to change the belt stress state. The telescopic range of hydraulic adjustment is usually 0~1000 mm, and the adjustment accuracy meets the required standard for safe operation of the system, thereby maintaining the smooth and reliable operation of the belt; The guide adjustment unit includes a guide wheel or adjustment mechanism, which is installed at a key position of the conveyor belt to assist in stabilizing the belt path during operation. The guide wheel automatically adjusts the angle and position according to the real-time position of the belt, so that the belt avoids deviating from the track during operation and prevents abnormal deviation caused by external interference or load changes; Through the coordinated work of tension detection, hydraulic adjustment and guide adjustment, this module realizes automatic monitoring and adjustment of the belt tensioning state, effectively prevents belt loosening, deviation and other problems, improves the operation stability of the conveyor, and reduces equipment failure rate and the need for manual intervention.

[0027] The belt correction module includes a position monitoring unit, an image recognition unit and a drive correction unit. The position monitoring unit is used to monitor the position and trajectory of the belt and whether it is offset, so that the belt can run on the correct track. The image recognition unit is used to assist in detecting the offset of the belt through image recognition technology and provide additional data verification. The data verification is used for secondary verification of data and the accuracy of the correction operation. The drive correction unit is used to automatically perform belt correction actions based on the information provided by the position monitoring and image recognition units to ensure the normal operation of the belt.

[0028] Specifically, position sensors or image recognition devices are installed on both sides of the coal conveyor belt to monitor the running direction of the belt in real time. Once the belt deviation is detected, the central control system performs automatic deviation correction operations through bidirectional drive motors, worms, worm gears and other components to ensure the correctness of the belt operation; The position monitoring unit monitors the position and track of the conveyor belt in real time through displacement sensors installed on both sides of the conveyor belt to detect whether the belt is offset. It can accurately collect the belt edge position data and transmit the position information to the central control system. The monitoring accuracy is usually within the range of ±3 mm, which can promptly detect slight track deviations and ensure that the belt continues to run on the correct track. The image recognition unit uses a high-definition camera or industrial vision device, and uses image processing technology such as edge detection and morphological analysis to assist in detecting the running status of the belt. By collecting real-time images of the belt and comparing them with the data of the position monitoring unit, a data verification mechanism is formed. Image recognition technology can detect abnormalities such as the edge status, offset angle and deposits of the belt, providing higher detection reliability and ensuring the accuracy of the correction operation; The drive correction unit consists of a bidirectional drive motor and a mechanical transmission device (such as a worm and a worm wheel), and automatically performs correction operations based on the comprehensive data provided by the position monitoring unit and the image recognition unit. When the belt deviates, the drive device quickly adjusts the position of the guide device or the belt support system to restore the belt to its normal operating track. The response time of the drive correction system is usually within 0.5 seconds, ensuring timely and efficient deviation correction; Through the coordinated control of position monitoring, image recognition and drive correction, the precise monitoring and automatic adjustment of the belt position can effectively prevent the occurrence of belt deviation, jamming and other problems, improve the operating stability and safety of the conveying system, reduce equipment downtime and maintenance costs, and provide guarantee for the long-term stable operation of the coal mine conveying system.

[0029] The coal dust cooling and dust reduction control module includes a coal dust concentration monitoring unit, a temperature monitoring unit and a dust reduction and cooling control unit. The coal dust concentration monitoring unit is used to monitor the coal dust concentration in real time to ensure that the coal dust concentration is within a safe range. The temperature monitoring unit is used to monitor the temperature of the coal flow and the surrounding environment in real time to prevent excessive temperature from affecting equipment operation or causing a fire. The dust reduction and cooling control unit is used to automatically start the dust reduction spray system or temperature adjustment device based on the monitoring results. The dust reduction spray is used to maintain the ambient temperature and coal dust concentration within a safe range.

[0030] Specifically, the coal dust concentration monitoring unit monitors the coal dust content in the air in real time through coal dust concentration sensors installed in the coal flow channel and the working area. It can accurately measure the coal dust concentration and maintain it within the safety standard. The coal dust concentration sensor usually adopts the laser scattering principle or electrochemical principle, has high sensitivity and stability, and can timely feedback the changes in coal dust concentration and transmit it to the control system for data analysis. Once the coal dust concentration exceeds the preset safety threshold, the system will immediately trigger an early warning and automatically start the dust reduction device; The temperature monitoring unit monitors the temperature changes of the coal flow surface and the surrounding environment in real time through temperature sensors installed in the coal flow and working environment. It can accurately measure the ambient temperature and ensure that the temperature does not exceed the safe working range of the equipment and operators. The temperature monitoring unit usually includes a thermocouple or an infrared sensor, which has a fast response speed and high accuracy, and can detect temperature anomalies in time to avoid safety accidents such as high temperature affecting the normal operation of the equipment or causing fires; The dust reduction and temperature control unit automatically adjusts the temperature and coal dust concentration of the working environment according to the data provided by the coal dust concentration monitoring unit and the temperature monitoring unit. When it is detected that the coal dust concentration or temperature exceeds the standard, the control unit will start the dust reduction spray system or the temperature adjustment device (such as a cooling fan or a water mist injection system). The dust reduction spray system sprays water mist into the air through a high-pressure water mist nozzle to reduce the coal dust particles in the air and reduce the coal dust concentration; while the temperature adjustment device reduces the working environment temperature through cooling measures to prevent the equipment from overheating. The control unit can intelligently adjust the start and stop of these devices according to real-time data to ensure that the coal dust concentration and temperature in the working environment are always within a safe range.

[0031] Through the coordinated action of coal dust concentration monitoring, temperature monitoring and dust reduction and cooling control, the problems of coal dust pollution and excessive temperature can be effectively controlled, which not only ensures the long-term stable operation of the equipment, but also effectively protects the health of the miners, reduces the occurrence of equipment failures and accidents, and improves the safety and efficiency of coal mine operations.

[0032] The data acquisition and processing module includes a data acquisition unit, a data processing unit and a data storage unit. The data acquisition unit is used to collect data from each monitoring unit in real time and provide input for data analysis. The collected data includes thickness, image, tension and temperature. The data processing unit is used to perform preliminary processing on the collected data to confirm the data quality and accuracy. The preliminary processing includes filtering, formatting and correction. The data storage unit is used to store real-time data and historical data, support data tracing and historical analysis, and provide decision support and optimization basis.

[0033] Specifically, the data acquisition unit is responsible for real-time data collection from various monitoring units, including coal flow thickness, coal flow image, belt tension, coal flow temperature and other key parameters. The data acquisition unit is usually connected to sensors, image capture devices and other monitoring devices in the system, and collects and transmits real-time data to the control system through wired or wireless networks. Through the data acquisition unit, the system can monitor the coal flow status, belt status and temperature of the working environment in real time, providing comprehensive real-time data input for the operation of the system; The data processing unit is responsible for the preliminary processing of the collected data to ensure the data quality and accuracy. The preliminary processing operations performed by this unit include steps such as data filtering, formatting and correction to ensure the consistency and accuracy of the data. The work of the data processing unit ensures the quality of the data and avoids erroneous judgments and decisions caused by data anomalies; The data storage unit is used to store processed real-time data and historical data, and supports data tracing and historical analysis. It can not only provide data support for real-time operations, but also provide historical data basis for long-term operations and optimization decisions. The design of the data storage unit allows the system to access historical data, perform trend analysis and performance backtracking, and support decision-making analysis such as system optimization, fault diagnosis, and production efficiency improvement; Through the collaborative work of the data acquisition unit, data processing unit and data storage unit, this module can ensure the efficient and accurate collection, processing and storage of real-time data during coal mine operations, thereby improving the intelligence level of the system, optimizing production decisions, reducing the occurrence of failures and improving safety.

[0034] The intelligent monitoring and early warning module includes a real-time monitoring unit, an abnormality detection unit and an early warning response unit. The real-time monitoring unit is used to monitor the various operating parameters of the system in real time. The operating parameters include belt status and coal flow conditions. The abnormality detection unit is used to monitor the data in real time for analysis, detect whether there are abnormal phenomena, and generate alarm information. The early warning response unit is used to automatically or manually start response measures according to the early warning information provided by the abnormality detection unit. The response measures include sound and light alarms and operation prompts.

[0035] Specifically, the real-time monitoring unit is responsible for real-time monitoring of various operating parameters of the system. The unit obtains the values ​​of various monitoring indicators in real time by connecting multiple sensors such as belt status monitoring equipment, coal flow monitoring equipment, and temperature monitoring equipment. The real-time monitoring parameters include the operating status of the belt (such as tension, running speed, position, etc.), the thickness, flow rate, temperature of the coal flow, and environmental parameters such as coal dust concentration. It provides real-time data for the system and displays it to operators through the central control system to help timely discover potential problems with equipment and the environment. The anomaly detection unit performs real-time analysis based on the data provided by the real-time monitoring unit to detect whether any abnormal phenomena occur. By comparing and analyzing various parameters, the anomaly detection unit can identify data that exceeds the preset threshold or deviates from the normal operating mode. When the system detects an abnormal situation (such as low belt tension, excessive coal dust concentration, abnormal coal flow, etc.), the unit will promptly generate an alarm message and transmit it to the early warning response unit. The anomaly detection unit can use rule algorithms, pattern recognition algorithms, or machine learning models to analyze data to ensure accurate detection of any potential faults or safety hazards.

[0036] The early warning response unit automatically or manually initiates response measures based on the early warning information provided by the abnormality detection unit. After receiving the alarm information, the unit immediately takes action to allow the system to take timely and effective response measures. Response measures include but are not limited to sound and light alarms, operation prompts, and emergency shutdowns. When the abnormality detection unit finds that the data is abnormal, the system will trigger an sound and light alarm to alert the operator; at the same time, the system can automatically generate operation prompts to guide the operator to take necessary repair or adjustment measures. For more serious abnormal situations, the early warning response unit can also automatically start the emergency shutdown or safety protection mode to avoid accidents; Through the collaboration of three units, namely real-time monitoring, anomaly detection and early warning response, the safety of coal mine operations can be fully guaranteed. During operation, the system can automatically detect and handle potential problems, reduce human intervention, improve monitoring efficiency and response speed, and reduce the risk of accidents.

[0037] The intelligent analysis and decision support module includes a data analysis unit, a fault prediction unit and a decision support unit. The data analysis unit is used to conduct in-depth analysis of real-time and historical data, extract key operating laws, and predict equipment status and fault trends. Key operating laws include equipment working status change patterns, periodic operating laws, and abnormal pattern recognition. The fault prediction unit is used to analyze the operating status of the equipment, predict potential faults, and make preventive maintenance recommendations in advance. The decision support unit is used to provide optimized operation recommendations and decisions based on the analysis results. Preventive maintenance recommendations include maintenance recommendations for equipment overtemperature, small deviations, and abnormal equipment vibration.

[0038] Specifically, the data analysis unit extracts key operating rules through in-depth analysis of real-time and historical data. Through data mining, statistical analysis and machine learning algorithms, the system extracts the equipment working status change pattern, periodic operation rules and abnormal patterns. The system can analyze the long-term operation data of the equipment, identify the changes of the equipment under different working conditions, and discover potential abnormalities, thereby providing data support for subsequent maintenance and operation optimization; The fault prediction unit uses real-time and historical data to predict equipment failures and make preventive maintenance recommendations in advance. By continuously monitoring the equipment's operating conditions, the system can identify potential problems such as overtemperature, small deviations, abnormal equipment vibrations, and give timely recommendations, such as checking the cooling system, adjusting belt tension, or checking drive components, to avoid equipment failures. The decision support unit provides optimized operation suggestions and decision support based on data analysis results and fault predictions. By analyzing the data provided by the system, it automatically generates optimization suggestions for operators and adjusts equipment parameters or operating methods based on these suggestions to improve work efficiency and equipment stability.

[0039] The data transmission and communication module includes a data transmission unit, a communication management unit and a security encryption unit. The data transmission unit is responsible for transmitting data between modules so that information can be shared in real time to avoid data delays or losses. The communication management unit is used to manage the communication interfaces of all devices and modules in the system to ensure smooth and stable data transmission. The security encryption unit is used to encrypt the transmitted data to ensure the security of information during transmission and prevent data leakage or tampering.

[0040] Specifically, the data transmission unit is responsible for real-time data transmission between modules, ensuring smooth sharing of information within the system. Through efficient communication protocols and network architecture, data can be transmitted from one module to another without lag or loss. The data transmission unit supports multiple communication methods, such as wired (such as CAN bus, Ethernet) or wireless communication (such as Wi-Fi, ZigBee), and can process input data from each monitoring unit in real time to ensure smooth information transmission; The communication management unit is responsible for managing and coordinating the communication interfaces of all devices and modules in the system, ensuring that data can be transmitted stably and efficiently between modules. Through intelligent routing, load balancing and fault recovery mechanisms, data transmission is guaranteed not to be affected by network problems, avoiding communication interruption or information loss. At the same time, it ensures that different devices and modules in the system can exchange information quickly and accurately, ensuring the reliable operation of the overall system. The security encryption unit encrypts the transmitted data to ensure the security of the information during transmission and prevent the data from being accessed, leaked or tampered with by unauthorized personnel during transmission. The security encryption unit can protect sensitive information, such as operating instructions and real-time monitoring data, prevent security issues caused by data leakage, and ensure information security during coal mine operations.

[0041] Please see attached Fig.13 -Attached Fig.16A coal flow monitoring device for a belt conveyor of an excavation working face, comprising a mounting plate 1, a connecting block 2 is fixedly connected to the upper surface of the mounting plate 1, a motor 3 is fixedly connected to the outer wall of the connecting block 2, a driving rod 4 is fixedly connected to the output end of the motor 3, a worm 5 is fixedly connected to the outer wall of the driving rod 4, a tooth end of the worm 5 is meshingly connected to a worm wheel 6, an outer wall of the worm wheel 6 is rotatably connected to a support frame 7, a lower surface of the support frame 7 is fixedly connected to the upper surface of the mounting plate 1, a threaded rod 8 is fixedly connected to the top of the worm wheel 6, and an outer wall of the threaded rod 8 is rotatably connected to the support frame 7 The inner wall of the threaded rod 8 is threadedly connected to the limit slider 9, the middle part of the limit slider 9 is fixedly connected to the rotating table 15, the outer wall of the rotating table 15 is rotatably connected to the half-scale wheel 10, the outer wall of the support frame 7 is fixedly connected to the electric slide rail 11, the outer wall of the electric slide rail 11 is slidably connected to the electric slider 12, the outer wall of the electric slider 12 is fixedly connected to the tooth plate 13, the tooth end of the tooth plate 13 is meshed with the tooth end of the half-scale wheel 10, the outer wall of the half-scale wheel 10 is fixedly connected to the stabilizing shaft 14, and the outer wall of the stabilizing shaft 14 is fixedly connected to the outer wall of the rotating table 15; The inner wall of the rotating table 15 is fixedly connected to a mounting seat 16, the outer wall of the mounting seat 16 is slidably connected to a slide 18, the lower surface of the slide 18 is fixedly connected to an electric push rod 17, the output end of the electric push rod 17 is fixedly connected to the left outer wall of the mounting seat 16, the middle part of the mounting seat 16 is rotatably connected to a connecting rod 19, the outer wall of the connecting rod 19 is rotatably connected to the inner wall of the slide 18, the upper surface of the slide 18 is fixedly connected to a splint 20, and the outer wall of the splint 20 is slidably connected to a camera 21.

[0042] Specifically, the camera 21 is first placed on the mounting seat 16, and then the electric push rod 17 is started to push the mounting seat 16. Because the mounting seat 16 is fixed on the rotating shaft 15, the electric push rod 17 drives the slide 18 to slide on the outer wall of the mounting seat 16 under its own push, so that during use, the slide 18 drives the connecting rod 19 to drive the slide 18 on the other side to move, which plays a role in centering and clamping, and adapts to the installation and use of cameras 21 of different sizes; Then the mounting plate 1 is installed. The mounting plate 1 can be installed on the oblique upper side of the conveyor belt of the working surface or on the wall by means of bolts or other installation methods for use. Then the motor 3 drives the driving rod 4 to rotate inside the connecting block 2. During the rotation of the driving rod 4, the worm gear 6 is driven to rotate through the worm 5. The threaded rod 8 is driven by the worm gear 6 to rotate when the inner wall of the support frame 7 is rotated to drive the limit slider 9 to move up and down. During use, the stabilizing shaft 14 and the rotating shaft 15 are combined with the toothed plate 13 to prevent the rotating shaft 15 from rotating itself during use according to the needs of use. The toothed plate 13 and the half-size wheel 10 are meshed to achieve a self-locking effect. During use, the toothed plate 13 is used to lock the belt of the electric slider 12 and the electric slide rail 11 The movement plays a role in rotating the half-scale wheel 10, thereby playing a role in longitudinally adjusting the angle of the camera 21 during use, so that the collection position can be adjusted according to the needs of use, and the electric slider 12 moves up and the limit slider 9 moves up at the same time, which can play a role in protruding the camera 21 during use, so that the camera 21 has room to move and better collect data in complex environments. When moving inward, the support frames 7 on both sides simultaneously play a role in protecting the camera 21, thereby further protecting the camera 21. When the electric slider 12 is moved alone to drive the toothed plate 13, it plays a role in driving the half-scale wheel 10 alone to adjust the angle of the rotating shaft 15 during use, thereby adjusting the angle of the camera 21.

[0043] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A coal flow monitoring system for belt conveyor of excavation working face, characterized in that: include: Coal flow intelligent monitoring and sampling module, belt tensioning and adjustment module, belt deviation correction module, coal dust cooling and dust reduction control module, data acquisition and processing module, intelligent monitoring and early warning module, intelligent analysis and decision support module and data transmission and communication module; The coal flow intelligent monitoring and sampling module is used to monitor the thickness, image characteristics and coal sample data of the coal flow; The belt tension adjustment module is used to monitor and automatically adjust the tension of the belt to prevent the belt from being loose or too tight; The belt deviation correction module is used to monitor the running direction of the belt and automatically correct the deviation to allow the belt to operate normally; The coal dust cooling and dust reduction control module is used to monitor the coal dust concentration and temperature and automatically start the dust reduction device; The data acquisition and processing module is used to acquire and preliminarily process the data of each module; The intelligent monitoring and early warning module is used to monitor the system operation status in real time, generate early warning information, and remind operators to handle abnormalities; The intelligent analysis and decision support module is used to analyze data, provide optimization decisions and fault prediction, and automatically adjust system parameters; The data transmission and communication module is used to transmit data between modules, allowing information to be shared and transmitted in real time.

2. A coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The coal flow intelligent monitoring and sampling module includes a thickness measurement unit, an image capture unit and an automatic sampling unit. The thickness measurement unit is used to measure the thickness of the coal flow in real time and provide information related to the coal flow volume. The image capture unit is used to capture the image of the coal flow, analyze the coal flow morphology and information on abnormal coal blocks, and assist in judging the state of the coal flow. The automatic sampling unit is used to automatically extract coal samples from the coal flow to make the extracted coal samples representative.

3. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1 is characterized by: The belt tensioning adjustment module includes a tension detection unit, a hydraulic adjustment unit and a guide adjustment unit. The tension detection unit is used to detect the tension state of the conveyor belt to ensure stable operation of the belt. The hydraulic adjustment unit is used to automatically adjust the tension of the belt through the hydraulic system according to the feedback result of the tension detection unit to ensure stable operation of the belt. The guide adjustment unit is used to adjust the path of the conveyor belt to ensure that the belt does not deviate from the normal track and maintains stable operation during operation.

4. A coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The belt correction module includes a position monitoring unit, an image recognition unit and a drive correction unit. The position monitoring unit is used to monitor the position and trajectory of the belt and whether it is offset, so that the belt can run on the correct track. The image recognition unit is used to assist in detecting the offset of the belt through image recognition technology and provide additional data verification. The data verification is used for secondary verification of the data and the accuracy of the correction operation. The drive correction unit is used to automatically perform the belt correction action according to the information provided by the position monitoring and image recognition units to ensure the normal operation of the belt.

5. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The coal dust cooling and dust reduction control module includes a coal dust concentration monitoring unit, a temperature monitoring unit and a dust reduction and cooling control unit. The coal dust concentration monitoring unit is used to monitor the coal dust concentration in real time to ensure that the coal dust concentration is within a safe range. The temperature monitoring unit is used to monitor the temperature of the coal flow and the surrounding environment in real time to prevent excessive temperature from affecting equipment operation or causing a fire. The dust reduction and cooling control unit is used to automatically start the dust reduction spray system or temperature adjustment device based on the monitoring results. The dust reduction spray is used to maintain the ambient temperature and coal dust concentration within a safe range.

6. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The data acquisition and processing module includes a data acquisition unit, a data processing unit and a data storage unit. The data acquisition unit is used to collect data from each monitoring unit in real time to provide input for data analysis. The collected data includes thickness, image, tension, and temperature. The data processing unit is used to perform preliminary processing on the collected data to confirm the data quality and accuracy. The preliminary processing includes filtering, formatting, and correction. The data storage unit is used to store real-time data and historical data, support data tracing and historical analysis, and provide decision support and optimization basis.

7. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The intelligent monitoring and early warning module includes a real-time monitoring unit, an abnormality detection unit and an early warning response unit. The real-time monitoring unit is used to monitor various operating parameters of the system in real time. The operating parameters include belt status and coal flow conditions. The abnormality detection unit is used to monitor the data in real time for analysis, detect whether any abnormal phenomenon occurs, and generate alarm information. The early warning response unit is used to automatically or manually start response measures according to the early warning information provided by the abnormality detection unit. The response measures include sound and light alarms and operation prompts.

8. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The intelligent analysis and decision support module includes a data analysis unit, a fault prediction unit and a decision support unit. The data analysis unit is used to perform in-depth analysis on real-time and historical data, extract key operating laws, and predict equipment status and fault trends. The key operating laws include equipment working status change patterns, periodic operating laws, and abnormal pattern recognition. The fault prediction unit is used to analyze the operating status of the equipment, predict potential faults, and make preventive maintenance suggestions in advance. The decision support unit is used to provide optimized operation suggestions and decisions based on the analysis results. The preventive maintenance suggestions include maintenance suggestions for equipment overtemperature, small deviations, and abnormal equipment vibration.

9. The coal flow monitoring system for belt conveyor of tunneling working face according to claim 1, characterized in that: The data transmission and communication module includes a data transmission unit, a communication management unit and a security encryption unit. The data transmission unit is responsible for transmitting data between modules so that information can be shared in real time to avoid data delay or loss. The communication management unit is used to manage the communication interfaces of all devices and modules in the system to ensure smooth and stable data transmission. The security encryption unit is used to encrypt the transmitted data to ensure the security of information during transmission and prevent data leakage or tampering.

10. A coal flow monitoring device for a belt conveyor on a tunneling working face, applied to a coal flow monitoring system for a belt conveyor on a tunneling working face as claimed in any one of claims 1 to 9, comprising a mounting plate (1), characterized in that: The upper surface of the mounting plate (1) is fixedly connected to a connecting block (2); the outer wall of the connecting block (2) is fixedly connected to a motor (3); the output end of the motor (3) is fixedly connected to a driving rod (4); the outer wall of the driving rod (4) is fixedly connected to a worm (5); the tooth end of the worm (5) is meshingly connected to a worm wheel (6); the outer wall of the worm wheel (6) is rotatably connected to a support frame (7); the lower surface of the support frame (7) is fixedly connected to the upper surface of the mounting plate (1); the top end of the worm wheel (6) is fixedly connected to a threaded rod (8); the outer wall of the threaded rod (8) is rotatably connected to the inner wall of the support frame (7); the outer wall of the threaded rod (8) is rotatably connected to the inner wall of the support frame (7); A limit slider (9) is threadedly connected to the wall, a rotating table (15) is fixedly connected to the middle of the limit slider (9), a half-scale wheel (10) is rotatably connected to the outer wall of the rotating table (15), an electric slide rail (11) is fixedly connected to the outer wall of the support frame (7), an electric slider (12) is slidably connected to the outer wall of the electric slide rail (11), a tooth end of the tooth plate (13) meshes with the tooth end of the half-scale wheel (10), a stabilizing shaft (14) is fixedly connected to the outer wall of the rotating table (15); The inner wall of the rotating table (15) is fixedly connected to a mounting seat (16), the outer wall of the mounting seat (16) is slidably connected to a slide table (18), the lower surface of the slide table (18) is fixedly connected to an electric push rod (17), the output end of the electric push rod (17) is fixedly connected to the left outer wall of the mounting seat (16), the middle part of the mounting seat (16) is rotatably connected to a connecting rod (19), the outer wall of the connecting rod (19) is rotatably connected to the inner wall of the slide table (18), the upper surface of the slide table (18) is fixedly connected to a clamping plate (20), and the outer wall of the clamping plate (20) is slidably connected to a camera (21).

Images