A material conveying device with detection function and its detection method

Abstract

This invention relates to the field of material production equipment technology, and more particularly to a material conveying device and its detection method with detection function. The device includes: a material conveying line, an online sampling mechanism, a metering hopper, a screening mechanism, a detection module, and a sample conveying mechanism. A portion of the material is sampled on the material conveying line as an inspection sample, which is then passed through the screening mechanism to be screened into the metering hopper. The metering hopper discharges material to the sample conveying mechanism, where it passes through the detection module to detect the sample data. The weight of the metering hopper and the particle size distribution of the sample measured by the detection module provide feedback on the quality of the particulate material based on the ratio of the individual volume quantity data to the sample data. This invention enables automatic sampling, separation, filtering, and detection of materials, thereby quickly and accurately obtaining the quality index of the proportion of non-compliant particles in the material, facilitating the monitoring and control of particulate material quality.

Description

Technical Field

[0001] This invention relates to the field of material production equipment technology, and in particular to a material conveying device with detection function and its detection method. Background Technology

[0002] In the production, processing, and transportation of granular materials, effective monitoring of particle size distribution is crucial for ensuring product quality and process stability. Excessively large particles often negatively impact the final product's appearance, performance, and even potentially damage subsequent processing equipment. Therefore, accurately and efficiently detecting and controlling the content of excessively large particles in materials is essential. Currently, the main methods for detecting excessively large particles in granular materials include manual sampling and online detection.

[0003] Manual sampling is the most traditional method of inspection. This method typically involves manually taking small samples periodically from the material conveyor line, then sieving them visually or using a standard sieve, weighing the material remaining on the sieve, and calculating its proportion of the total sample. While simple and easy to implement, this method has several inherent drawbacks. Manual sampling is random, making it difficult to guarantee that each sample accurately reflects the particle size distribution of the entire batch of material, especially when the material has uneven flowability, leading to greater errors and insufficient representativeness. Manual sieving and weighing are time-consuming and labor-intensive, making it difficult to meet the real-time monitoring needs of continuous production processes, hindering the timely detection and correction of anomalies, and resulting in low inspection efficiency. The results of manual visual inspection and sieving are easily influenced by the operator's subjective judgment and skill level, leading to deviations in the test results, a lack of objectivity and consistency, and significant human error. Furthermore, the long hours and repetitive nature of sampling and sieving work increase the labor intensity of workers.

[0004] With the development of automation technology, some online detection technologies have been applied to the quality monitoring of particulate materials. For example, image processing-based particle size analysis systems can capture material images through cameras and then use image processing algorithms to analyze the particle size distribution. However, these systems still have certain limitations in detecting oversized particles. At high particle concentrations, image processing systems struggle to accurately segment and identify overlapping particles, potentially leading to inaccurate counting or size measurement of oversized particles and difficulty in accurately identifying overlapping particles. Image acquisition quality is significantly affected by lighting conditions; unstable lighting environments can cause deviations in image analysis results, making them sensitive to lighting conditions. High-precision image processing systems are typically expensive, requiring complex image processing algorithms and hardware support, resulting in complex maintenance and operation. Image-based systems primarily acquire particle size information, making it difficult to directly obtain the weight percentage of oversized particles, which is often a crucial indicator for assessing material quality. Furthermore, some online detection devices based on weighing principles can infer material flow rate or density by measuring weight changes in specific areas of the conveyor line, but these devices typically struggle to directly distinguish between particles of different sizes, making selective detection and quantification of oversized particles impossible. Summary of the Invention

[0005] To address the technical problems of the prior art, this invention provides a material conveying device and its detection method with detection function, which can automatically sample, separate, filter and detect materials, thereby quickly and accurately obtaining the quality index of the proportion of non-compliant particles in the material, so as to realize the monitoring and control of the quality of particulate materials.

[0006] This invention provides a material conveying device with detection function, comprising:

[0007] Material conveyor line, used for conveying granular materials;

[0008] An online sampling device is installed above the material conveyor line;

[0009] Measuring hopper, used to load test samples of particulate materials;

[0010] A screening mechanism is provided inside the metering hopper, and the screening mechanism is used to filter out particles that are too large in the test sample.

[0011] The detection module is used to detect data from the test samples;

[0012] A sample conveying mechanism is used to receive and convey qualified particle samples of volume that have been screened out by the screening mechanism and fall from the metering hopper.

[0013] The online sampling mechanism collects a portion of particulate material from the material conveying line as an inspection sample and transports the inspection sample to the metering hopper. The detection module detects the initial inspection sample data entering the metering hopper, as well as the data of excessively large particles in the inspection sample that have been filtered by the screening mechanism and are retained in the metering hopper. The quality of the material is fed back based on the ratio of the data of excessively large particles to the initial inspection sample data.

[0014] According to a material conveying device with detection function according to the present invention, the detection module includes:

[0015] The weighing module supports the bottom of the metering hopper.

[0016] The weighing module measures the total weight of the test samples entering the metering hopper, and the weight of the oversized particles that have been filtered by the screening mechanism and are retained in the metering hopper.

[0017] The system provides feedback on the material quality based on the ratio of the weight data of excessively large particles to the weight data of the initial test sample.

[0018] According to a material conveying device with detection function according to the present invention, the detection module includes:

[0019] The first vision module is used to detect volume-qualified particles in the test sample that have passed through the screening mechanism; the first vision module detects image data of volume-qualified particles in the test sample.

[0020] The system calculates the weight of particles with acceptable volume based on the difference between the total weight of the test sample and the weight of particles with excessive volume.

[0021] The system calculates the total volume of the qualified particles based on their size values ​​and the image data from the first vision module.

[0022] The system calculates the density ρ of the qualified particles based on the weight data of the qualified particles and the total volume data;

[0023] The system provides feedback on the material's quality based on the density ρ of qualified particles.

[0024] According to a material conveying device with detection function according to the present invention, the detection module includes:

[0025] The second vision module is located above the metering hopper and is used to collect image data of the test samples inside the metering hopper.

[0026] The system calculates the number of particles with excessive volume using image data from the second vision module, and calculates the number of particles with acceptable volume using image data from the first vision module.

[0027] The system provides feedback on the material quality based on the ratio between the number of particles with acceptable volume and the number of particles with excessive volume.

[0028] According to a material conveying device with detection function according to the present invention, the sample conveying mechanism includes a first inclined unloading channel, a return conveyor belt and a second inclined unloading channel;

[0029] The return material conveyor belt is located below the first vision module and between the first inclined unloading channel and the second inclined unloading channel;

[0030] One end of the first inclined unloading channel extends upward at an angle to the bottom discharge port of the metering hopper, and the other end extends downward at an angle to the top of the return conveyor belt.

[0031] One end of the second inclined unloading channel extends upward at an angle to below the return conveyor belt, and the other end extends downward at an angle to above the material conveying line.

[0032] According to a material conveying device with detection function of the present invention, the first inclined unloading channel is provided with an unloading port at one end near the return conveyor belt, and a limiting baffle is rotatably provided at the unloading port;

[0033] The discharge port is closed by the limiting baffle so that qualified particles in the test sample that have passed through the filter screen fall into the first inclined discharge channel and are then restricted by the limiting baffle within the first inclined discharge channel.

[0034] The weighing module is supported upwards by the first inclined unloading channel and the metering hopper, so as to obtain the total weight data of the test sample by measuring the excessively large particles left in the metering hopper and the qualified particles left in the first inclined unloading channel.

[0035] By controlling the material limiting baffle to deflect at a certain angle, a discharge slit is formed between the lower edge of the material limiting baffle and the discharge port; the opening size of the discharge slit is adapted to match the diameter of qualified particles in terms of volume, so as to allow qualified particles in terms of volume to leave the first inclined discharge channel.

[0036] According to a material conveying device with detection function of the present invention, the limiting baffle is liftable, and the system adjusts the opening of the discharge slit by the deflection angle of the limiting baffle so that the height of the discharge slit is suitable for matching qualified particles of different diameters.

[0037] According to a material conveying device with detection function of the present invention, a horizontally arranged cleaning scraper and cleaning sponge are provided below the return material conveyor belt, and the cleaning scraper and cleaning sponge scrape the surface of the return material conveyor belt upward in sequence.

[0038] According to a material conveying device with detection function according to the present invention, the online sampling mechanism includes:

[0039] A vertical guide rail is positioned above the material conveying line;

[0040] The lifting slider is slidably mounted on the vertical guide rail;

[0041] The horizontal guide rail is perpendicular to the vertical guide rail;

[0042] A translation slider is slidably mounted on the horizontal guide rail and connected to the vertical guide rail. The translation slider drives the vertical guide rail and causes the lifting slider to move laterally along the horizontal guide rail.

[0043] The bottom of the lifting slider is rotatably equipped with a material-collecting shovel;

[0044] The system controls the scooping shovel to rotate upward at a certain angle to scoop up granular material from the material conveying line, and controls the scooping shovel to rotate downward at a certain angle to pour granular material into the top opening of the metering hopper.

[0045] The present invention discloses a detection method for a material conveying device with detection function, comprising:

[0046] Sample collection procedure: Collect a certain amount of particulate material from the material conveyor line as a sample for testing, and place the sample in the metering hopper;

[0047] Weighing and recording total weight steps: Measure the total weight A of the test sample using the weighing module, and send A to the control system;

[0048] Separation steps for oversized particle samples: Oversized particles in the sample are blocked and retained by the screening mechanism, while particles of acceptable size pass through the screening mechanism and fall into the conveying channel.

[0049] Weighing and recording the weight of oversized particle samples: Measure the weight A1 of the oversized particle samples remaining on the screening mechanism again using the weighing module, and send A1 to the control system;

[0050] The steps for calculating and plotting curve X are as follows: The control system calculates the ratio R of A1 to A based on A and A1, and obtains multiple sets of ratios R after repeated detection. Based on the R values ​​of each detection, curve X is plotted to reflect the proportion of excessively large particles in the batch of material.

[0051] A detection method for a material conveying device with detection function according to the present invention is characterized by comprising:

[0052] Steps for calculating the weight of qualified particles: The control system calculates the weight of qualified particle samples A2 = A - A1 based on the total weight A of the test samples and the weight A1 of the oversized particle samples.

[0053] Steps for obtaining the size value of qualified volume particles: Obtain the diameter value D of the qualified volume particles, wherein the size value D is a preset value or determined by image analysis of the first vision module;

[0054] Steps for calculating the total volume of qualified particles: Using the image data obtained by the first vision module, the volume of qualified particle samples that have passed through the screening mechanism and are laid flat on the return conveyor belt is calculated to obtain the total volume V of the qualified particle samples.

[0055] The density ρ calculation step: The system calculates the density ρ = A2 / V of the qualified particles based on A2 and the total volume V;

[0056] Step Z for plotting the curve: After repeated testing, obtain multiple sets of densities ρ, and plot the curve Z based on the ρ values ​​from each test to reflect the overall quality of the batch of materials.

[0057] A detection method for a material conveying device with detection function according to the present invention includes:

[0058] Steps for detecting the number of particles with excessive volume: The second vision module set above the metering hopper collects image data of the particles with excessive volume, and the control system analyzes the image to obtain the number of particles with excessive volume B2.

[0059] Steps for detecting the number of particles in a qualified volume particle sample: The first vision module set above the return conveyor belt collects image data of the qualified volume particle sample, and the control system analyzes the image to obtain the number of particles B1 in the qualified volume particle sample.

[0060] Calculation steps: The control system calculates the ratio Q = B1 / B2 of B1 based on B1 and B2, and obtains multiple sets of ratios Q by repeating the detection multiple times;

[0061] Steps for plotting curve Y: Plot curve Y based on Q from each test to reflect the ratio of qualified particles to excessively large particles in this batch of material.

[0062] In operation, the material conveying device of the present invention, with a detection function, carries and transports particulate material forward along the material conveying line. During the entire operation of the device, the particulate material moves first along the material conveying line, providing an accessible material source for subsequent sampling. The online sampling mechanism is positioned above the material conveying line. Driven by the control system or a corresponding drive mechanism, the online sampling mechanism can acquire a portion of the particulate material from the material conveying line. A "sampling-transportation" relationship is formed between the online sampling mechanism and the material conveying line. The sample acquired by the online sampling mechanism is the "detection" material that subsequently enters the metering hopper. The online sampling mechanism transports the acquired samples to the metering hopper. The metering hopper, in conjunction with the detection module and screening mechanism, performs detection and particle separation. Since the screening mechanism is located within the metering hopper, when the test sample falls into it, particles that are too large in volume or size are blocked or retained. Particles of acceptable size can pass through the screening mechanism and fall to the lower layer or be further processed. The screening mechanism and the metering hopper are integrated, allowing for "size sieving" of the test sample, thus distinguishing and detecting particles of different sizes. The detection module collects data from the material within the metering hopper (including the initial sample stage and the post-filtration stage). For example, it can detect total weight, particle quantity, or other images / sizes. The detection module reads or statistically analyzes data from both the "initial test sample data" and "oversized particle data" stages, and then the system performs ratio calculations to ultimately determine the quality of the particulate material. The detection module may include a weighing unit, a vision unit, or other data acquisition components; the specific form can vary according to implementation requirements. During operation, particulate material is conveyed forward via a material conveyor line. When testing is required, the online sampling mechanism performs a sampling operation, collecting a portion of the particulate material from the material conveyor line and feeding it into the metering hopper. This input material is the "initial inspection sample." The testing module then acquires data from the "initial inspection sample" (e.g., weight, quantity, size). Next, the screening mechanism sieves the sample based on particle size, leaving oversized particles on the screening mechanism or in its upper area. These particles are then re-tested or weighed / counted by the testing module to obtain "oversized particle data." Finally, the testing module calculates the ratio between the "oversized particle data" and the "initial inspection sample data" to output the quality status of the particulate material (e.g., determining if there is a high proportion of oversized particles, or whether production process adjustments are needed), and feeds this test result back to subsequent systems or personnel.It is understood that in the technical solution of this invention, since an online sampling mechanism is set above the conveyor belt, representative inspection samples can be extracted without affecting the mass production and conveying, thus improving sampling efficiency. After the inspection sample is put into the metering hopper, the detection module first collects the "initial inspection sample data" to obtain the initial quality characteristics of the sampled material. The setting of the screening mechanism allows particles that are too large to be naturally filtered and retained, and the "oversized particle data" is measured again by the detection module. The ratio of the "oversized particle data" to the "initial inspection sample data" can be calculated to intuitively reflect the proportion of large particles in the granular material, and give an intuitive judgment on the quality of the granular material. The whole process is completed in an automated manner, realizing accurate, fast and real-time quality monitoring of granular materials and reducing errors or delays caused by manual intervention. The technical solution of this invention organically combines material conveying, sampling, screening and testing, which not only simplifies the operation process, but also obtains graded testing data, and ultimately achieves the effect of rapid screening and evaluation of particulate material quality. Therefore, it realizes the ability to automatically sample, separate, filter and test materials, thereby quickly and accurately obtaining the quality index of the proportion of non-compliant particles in the material, so as to realize the monitoring and control of particulate material quality. Attached Figure Description

[0063] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0064] Figure 1 This is a perspective view of the present invention;

[0065] Figure 2 This is a simplified structural diagram of the present invention.

[0066] Figure label:

[0067] 100. Material conveying line;

[0068] 200. Online sampling mechanism; 201. Vertical guide rail; 202. Lifting slider; 203. Horizontal guide rail; 204. Translation slider; 205. Material shovel.

[0069] 300. Measuring hopper;

[0070] 400. Screening agencies;

[0071] 500 Weighing module; 501 First vision module; 502 Second vision module;

[0072] 600. First inclined unloading channel; 601. Unloading port; 602. Material limiting baffle; 603. Discharge joint;

[0073] 700. Return material conveyor belt; 701. Cleaning scraper; 702. Cleaning sponge;

[0074] 800. Second inclined unloading channel. Detailed Implementation

[0075] The embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention. In the description of the present invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present invention.

[0076] like Figure 1 and Figure 2As shown in the figure, this embodiment of a material conveying device with detection function mainly includes a material conveying line 100, an online sampling mechanism 200, a metering hopper 300, a filtering screen screening mechanism 400, a detection module, a sample conveying mechanism, and a control system. In this embodiment, the screening mechanism 400 is a filtering screen. The material conveying line 100 is used to convey particulate materials. The online sampling mechanism 200 is installed above the material conveying line 100. The metering hopper 300 is used to load test samples of particulate materials. The screening mechanism 400 is fixed inside the metering hopper 300 and is used to filter out excessively large particles from the test samples. The detection module detects the test sample data inside the metering hopper 300. The sample conveying mechanism is used to receive and convey qualified particulate samples that have been screened out by the screening mechanism 400 and fall from the metering hopper 300. During operation, the online sampling mechanism 200 collects a portion of the particulate material on the material conveying line 100 as an inspection sample and transports the inspection sample to the metering hopper 300. The detection module detects the initial inspection sample data entering the metering hopper 300, as well as the data of excessively large particles in the inspection sample that have been filtered by the screening mechanism 400 and are retained in the metering hopper 300. The quality of the material is fed back based on the ratio of the data of excessively large particles to the data of the initial inspection sample.

[0077] It is understood that in the operation of the material conveying device of this embodiment, the material conveying line 100 carries and conveys particulate material forward. During the entire operation of the device, the particulate material moves first on the material conveying line 100, providing an accessible material source for subsequent sampling. The online sampling mechanism 200 is set above the material conveying line 100. Driven by the control system or the corresponding drive mechanism, the online sampling mechanism 200 can obtain a portion of the particulate material from the material conveying line 100. A "sampling-conveying" relationship is formed between the online sampling mechanism 200 and the material conveying line 100. The sample obtained by the online sampling mechanism 200 is the "test sample" that subsequently enters the metering hopper 300. The sampling mechanism 200 transports the acquired sample to the metering hopper 300. The metering hopper 300 can work with the detection module and the screening mechanism 400 to complete the detection and particle separation. Since the screening mechanism 400 is arranged inside the metering hopper 300, when the test sample falls into the metering hopper 300, particles that are too large in volume or size are blocked or retained by the screening mechanism 400; while particles with qualified volume and size can pass through the screening mechanism 400 and fall to the lower layer or be further processed. The screening mechanism 400 and the metering hopper 300 are installed as a whole. The presence of the screening mechanism 400 allows the test sample to complete the "size screening" operation here, thereby realizing the differentiation and detection of particles of different sizes. The detection module can collect data on the material within the metering hopper 300 (including the initial sample stage and the post-filtration stage). For example, it can detect total weight, particle quantity, or other images / sizes. The detection module reads or statistically analyzes data from two stages: "initial inspection sample data" and "oversized particle data." Subsequently, the system performs ratio calculations to ultimately determine the quality of the particulate material. The detection module may include a weighing unit, a vision unit, or other components capable of data acquisition; the specific form can vary according to implementation requirements. During operation, the particulate material is conveyed forward via the material conveyor line 100. When detection is required, the online sampling mechanism 200 performs a sampling operation, collecting a portion of the particulate material from the material conveyor line 100 and feeding it into the metering hopper 300. At this point, the material input is the "initial inspection sample." Then, the detection module acquires data from the "initial inspection sample" (e.g., weight, quantity, size, etc.). Next, the screening mechanism 400 sieves the inspection sample by particle size, leaving oversized particles on the filter screen or in the upper area of ​​the filter screen. These particles are then detected or weighed / counted again by the detection module to obtain "oversized particle data." Finally, the detection module calculates the ratio between the "oversized particle data" and the "initial inspection sample data" to output the quality status of the particulate material (e.g., determining whether there is a high proportion of oversized particles, whether the production process needs to be adjusted, etc.) and feeds the detection result back to the subsequent system or personnel.It is understood that in the technical solution of the present invention, since an online sampling mechanism 200 is set above the conveyor belt, representative inspection samples can be extracted without affecting the mass production and conveying, thus improving sampling efficiency. After the inspection sample is put into the metering hopper 300, the detection module first collects the "initial inspection sample data" to obtain the initial quality characteristics of the sampled material. The setting of the screening mechanism 400 allows particles with excessive volume to be naturally filtered and retained, and the "excessive volume particle data" is measured again by the detection module. The ratio of the "excessive volume particle data" to the "initial inspection sample data" can be calculated to intuitively reflect the proportion of large particles in the granular material and give an intuitive judgment on the quality of the granular material. The whole process is completed in an automated manner, realizing accurate, fast and real-time quality monitoring of granular materials and reducing errors or delays caused by manual intervention. The technical solution of this invention organically combines material conveying, sampling, screening and testing, which not only simplifies the operation process, but also obtains graded testing data, and ultimately achieves the effect of rapid screening and evaluation of particulate material quality. Therefore, it realizes the ability to automatically sample, separate, filter and test materials, thereby quickly and accurately obtaining the quality index of the proportion of non-compliant particles in the material, so as to realize the monitoring and control of particulate material quality.

[0078] In one embodiment, the detection module includes a weighing module 500. The weighing module 500 supports the bottom of the metering hopper 300. The weighing module 500 measures the total weight of the test sample entering the metering hopper 300, and also measures the weight of the oversized particles remaining in the metering hopper 300 after being filtered by the screening mechanism 400. The system provides feedback on the material quality based on the ratio of the weight of the oversized particles to the weight of the initial test sample. It can be understood that the weighing module 500 is installed at the bottom of the metering hopper 300, enabling real-time weighing of the hopper 300 through support. The screening mechanism 400 is located inside the metering hopper 300 and is used for volume classification after the sample falls into the hopper 300. At this time, the weighing module 500 can obtain the weight data before and after filtration. The system obtains the weight of the initial test sample and the weight of the oversized particles from the weighing module 500 through a signal connection for subsequent ratio calculation. When the online sampling mechanism 200 feeds particulate material into the metering hopper 300, the weighing module 500 first measures the total weight of the "initial inspection sample." The screening mechanism 400 retains oversized particles above the cylinder or screen. Then, the weighing module 500 measures the weight of the "oversized particles" inside the metering hopper 300. Based on these two weight measurements, the system calculates the ratio of the weight of the oversized particles to the total weight of the initial inspection sample, reflecting the proportion of large particles in the material. By configuring the weighing module 500 at the bottom of the metering hopper 300, the overall weight of the sample and the weight of large particles can be accurately measured and compared, providing a quantitative basis for further judging material quality and the proportion of large particles. This solution helps to achieve automatic detection and timely feedback of material quality, improving detection efficiency and accuracy. In summary, the above structure uses a weighing module to measure the weight of the inspection sample, obtaining the mass ratio between the initial sample and the oversized particles, thus providing a weight proportion parameter for material quality evaluation.

[0079] In one embodiment, the detection module further includes a first vision module 501. The first vision module 501 is used to detect the volume-qualified particles in the inspection sample that have passed through the screening mechanism 400, thereby detecting image data of the volume-qualified particles in the inspection sample. The control system calculates the weight data of the volume-qualified particles based on the difference between the total weight of the inspection sample and the weight of the oversized particles. It also calculates the total volume of the volume-qualified particles based on their size and the image data from the first vision module 501. The system then calculates the density ρ of the volume-qualified particles based on their weight and total volume data, and finally provides feedback on the material's mass based on the density ρ. It can be understood that the first vision module 501 collects image data of the volume-qualified particles that fall onto the return conveyor belt 700 after passing through the screening mechanism 400, enabling continuous imaging. The weighing module 500 focuses on mass measurement, while the first vision module 501 focuses on image acquisition and volume estimation. These two modules complement each other, providing necessary parameters for the system to calculate the density of the qualified particles. The control system analyzes the images from the first vision module 501 using existing image recognition technology to identify the number of particles, particle shape, or projected area, thereby estimating the total particle volume. After qualified particles pass through the screening mechanism 400, the first vision module 501 acquires images of their shape. Based on the weight of the qualified particles provided by the weighing module 500 and the total volume of the qualified particles provided by the first vision module 501, the system calculates the particle density ρ. For materials from different batches or time periods, the system can continuously collect this density ρ data, thereby dynamically reflecting the fluctuations and trends in material quality. It can be understood that, based on the same weight and volume, density more intuitively reflects the internal quality characteristics of particulate materials. Combining volume detection by the first vision module 501 with quality detection by the weighing module 500 not only allows for quantitative analysis of the proportion of large particles but also enables in-depth evaluation of the density of qualified particles, significantly improving the detection dimensions and reliability. In summary, the above structure, through the joint detection of the vision module and the weighing module, obtains accurate data on the volume and weight of qualified particles, thereby deriving and mastering particle density, providing a more comprehensive indicator for material quality.

[0080] In one embodiment, the detection module further includes a second vision module 502, which is installed above the metering hopper 300. The control system uses the second vision module 502 to acquire image data of the inspection sample inside the metering hopper 300. The control system calculates the total number of particles in the inspection sample using the image data from the second vision module 502, and calculates the number of qualified particles by volume using the image data from the first vision module 501. Finally, the quality of the material is fed back based on the ratio between the number of qualified particles by volume and the number of particles in the initial inspection sample. It can be understood that in this embodiment, the second vision module 502 is installed above the metering hopper 300, enabling direct image capture of the initial inspection sample falling into the hopper to obtain the total number of particles in the inspection sample. The first vision module 501 focuses on qualified particles passing through the filter screen, while the second vision module 502 focuses on the entire inspection sample within the metering hopper 300. A comparison of "total quantity - qualified quantity" can be formed between the two. The system uses the image data from the second vision module 502 to identify and count the entire batch of particles, and then uses the image data from the first vision module 501 to identify and count qualified particles by volume. The combination of these two methods reflects the pass rate or fail rate. In other words, after the test sample is fed into the metering hopper 300, the second vision module 502 captures an image of the test sample. The system identifies and counts the number of particles in the entire sample (i.e., the total number of particles). Next, the test sample is separated into large particles and qualified particles by a filter screen. The qualified particles are captured and counted by the first vision module 501 to obtain the number of qualified particles. The system compares the ratio between the "number of qualified particles" and the "total number of particles" to generate a quality assessment reference value. This scheme can quickly obtain the total number of particles and the number of qualified particles, thereby obtaining statistical indicators such as the pass rate or fail rate. Combined with the density and weight detection described in claim 3, it can further comprehensively grasp the particle quantity distribution and morphological characteristics of the material, greatly improving the reliability and comprehensiveness of the test results. In summary, this scheme aims to expand the dimensions of visual inspection. In addition to weighing, the second vision module 502 obtains the total number of particles in the initial test sample, and the first vision module 501 obtains the data information of qualified particles, realizing quality judgment based on particle quantity distribution.

[0081] Furthermore, the structure of this embodiment also includes a first inclined unloading channel 600, a return conveyor belt 700, and a second inclined unloading channel 800. The return conveyor belt 700 is located below the first vision module 501 and between the first inclined unloading channel 600 and the second inclined unloading channel 800. The right end of the first inclined unloading channel 600 extends inclined upward to the bottom discharge port of the metering hopper 300, and the left end extends inclined downward to the top of the return conveyor belt 700. The right end of the second inclined unloading channel 800 extends inclined upward to the bottom of the return conveyor belt 700, and the left end extends inclined downward to the top of the material conveying line 100. In the above structure, the first inclined unloading channel 600 and the bottom discharge port of the metering hopper 300 are used to receive qualified particles that fall after passing through the filter screen. The inclined design of this channel is to use gravity to guide the qualified particles to the return conveyor belt 700. The return conveyor belt 700 is positioned below the first vision module 501, allowing the first vision module 501 to capture images of qualified particles as they move flat on the return conveyor belt 700, thus enabling image detection of particle quantity or size. The left end of the return conveyor belt 700 connects to a second inclined discharge channel 800, which re-transports the detected qualified particles back to the material conveyor line 100, achieving a cyclical return process. Specifically, during the detection process, qualified particles fall onto the return conveyor belt 700 through the first inclined discharge channel 600, forming a flat surface. The first vision module 501 captures images of these flattened particles above the return conveyor belt 700, obtaining information such as particle quantity or size. At the end of the conveying process, the return conveyor belt 700 returns the qualified particles to the material conveyor line 100 via the second inclined discharge channel 800, achieving material recycling. The coordination of the first inclined unloading channel 600 and the return conveyor belt 700 ensures that qualified particles can pass through the visual inspection position stably and in a photographic manner. The qualified particles are then returned to the material conveying line 100 via the second inclined unloading channel 800. This not only saves material resources but also tightly integrates the overall inspection process with the production process, improving production continuity and inspection efficiency. In summary, the purpose of the above structure is to construct a conveying and return path for qualified particles and effectively integrate the inspection station of the first vision module 501 into the conveying process, enabling on-site online inspection and subsequent recycling of qualified particles.

[0082] In one embodiment, the first inclined discharge channel 600 has a discharge port 601 at one end near the return conveyor belt 700, and a limiting baffle 602 is rotatably installed at the discharge port 601. The limiting baffle 602 closes the discharge port 601, allowing qualified particles from the test sample that have passed through the filter screen to fall into the first inclined discharge channel 600 and be temporarily contained within it. The weighing module 500 supports both the first inclined discharge channel 600 and the metering hopper 300 upwards, obtaining the total weight data of the test sample by simultaneously measuring the excessively large particles remaining in the metering hopper 300 and the qualified particles remaining in the first inclined discharge channel 600. By controlling the material limiting baffle 602 to deflect at a certain angle, a discharge slot 603 is formed between the lower edge of the material limiting baffle 602 and the discharge port 601. This is equivalent to the control system controlling the material limiting baffle 602 to rotate at a certain angle and open the discharge port 601, allowing qualified particles to flow out of the first inclined discharge channel 600 through the discharge slot 603. The opening size of the discharge slot 603 is suitable for matching the diameter of the qualified particles, allowing them to leave the first inclined discharge channel 600. It can be understood that the material limiting baffle 602 is connected to the upper side of the discharge port 601 by a hinge or pivot, allowing the material limiting baffle 602 to deflect and swing at the discharge port 601. By controlling the rotation and swing, the opening of the discharge port 601 is controlled, and the control system can open the discharge port 601 of the first inclined discharge channel 600 by controlling the material limiting baffle 602. During material inspection, if the limiting baffle 602 is closed, the discharge port 601 is blocked, and qualified particles will accumulate in the first inclined discharge channel 600 and will not fall onto the return conveyor belt 700. When it is necessary to discharge, by controlling the deflection angle of the limiting baffle 602, a discharge gap 603 matching the particle diameter will appear between its lower edge and the discharge port 601, thereby realizing the orderly discharge of qualified particles in a single layer, making it easier for qualified particles to spread evenly on the surface of the return conveyor belt 700. The weighing module 500 is installed on the support structure below the metering hopper 300 and the first inclined discharge channel 600. It supports the metering hopper 300 and the first inclined discharge channel 600 as a whole through the same metering plane or the same base. When the limiting baffle 602 closes the discharge port 601, the qualified particles are left in the first inclined discharge channel 600, and the oversized particles are left in the metering hopper 300. The weighing module 500 can measure the total weight of these two parts of the material at one time, that is, the total weight data of the test sample. When the discharge slit 603 is opened, so that all the qualified particles leave the first inclined discharge channel 600, the weighing module 500 can measure the weight data of the oversized particles left in the metering hopper 300.The limiting baffle 602 can be driven by a motor or cylinder to perform a deflection action. By controlling the limiting baffle 602 to deflect at a certain angle, a discharge slit 603 is formed between the lower edge of the limiting baffle 602 and the discharge port 601, allowing qualified particles to be discharged onto the return conveyor belt 700. This discharge slit 603 serves as a "quantitative screening" or "single-layer passage" function when particles are discharged. When the height of the discharge slit 603 is similar to the particle diameter, it can prevent multiple layers of particles from stacking and ensure that particles pass through in an orderly manner, facilitating subsequent image detection by the first vision module 501. During the detection process, when qualified particles slide along the first inclined discharge channel 600 towards the discharge port 601, the limiting baffle 602 only allows particles that meet the set diameter to pass through the discharge slit 603 in a single row or with a limited thickness. After discharge, the particles automatically fall onto the return conveyor belt 700, ensuring that the images captured by the first vision module 501 are more accurate and easier for subsequent algorithm recognition. This solution ensures that qualified particles fall in a neat and orderly manner during discharge, significantly reducing particle stacking or aggregation on the return conveyor belt 700. It also improves the accuracy of the visual inspection module, reduces problems such as jamming and material accumulation, enhances inspection stability, and improves the overall automation and reliability of the device.

[0083] In one embodiment, preferably, a horizontally arranged cleaning scraper 701 and a cleaning sponge 702 are installed below the return conveyor belt 700. The cleaning scraper 701 and the cleaning sponge 702 scrape the surface of the return conveyor belt 700 upwards in sequence. It can be understood that the cleaning scraper 701 and the cleaning sponge 702 are both installed below the return conveyor belt 700, usually close to the surface of the conveyor belt, so that the conveyor belt can be cleaned in real time as it runs. During the counterclockwise rotation of the return conveyor belt 700, the cleaning scraper 701 can scrape off larger particles and stubborn debris; the cleaning sponge 702 can further wipe the surface of the conveyor belt to remove fine dust or particles, thereby obtaining a cleaner and flatter shooting background. The accuracy of the image captured by the first vision module 501 is affected by the cleanliness of the conveyor belt surface. If there are attached substances, they can easily interfere with the recognition and measurement of the image algorithm. Therefore, the cleaning mechanism plays an important role in ensuring the detection accuracy. During the inspection process, the return conveyor belt 700 undergoes initial cleaning by the cleaning scraper 701 and then fine wiping by the cleaning sponge 702 as it circulates. After cleaning, the surface of the return conveyor belt 700 maintains a high level of cleanliness within the imaging range of the first vision module 501, resulting in smaller image errors acquired by the system. Therefore, through the successive actions of the cleaning scraper 701 and the cleaning sponge 702, the return conveyor belt 700 maintains a continuously clean state, greatly reducing the interference of impurities and dirt on particle image recognition. This makes the system's detection results in terms of weight, volume, and particle count more stable and reliable. In summary, the technical objective of the above solution is to ensure the cleanliness and purity of the return conveyor belt surface, thereby providing a high-quality background for image recognition by the first vision module 501, ultimately improving the accuracy of detecting the size and quantity of qualified particles.

[0084] In one embodiment, the structure of the online sampling mechanism 200 specifically includes a vertical guide rail 201, a lifting slider 202, a horizontal guide rail 203, and a translation slider 204. The vertical guide rail 201 is fixed above the material conveying line 100. The lifting slider 202 is slidably mounted on the vertical guide rail 201. The horizontal guide rail 203 is perpendicular to the vertical guide rail 201. The translation slider 204 is slidably mounted on the horizontal guide rail 203 and fixedly connected to the vertical guide rail 201. The translation slider 204 drives the vertical guide rail 201 and the lifting slider 202 to move laterally along the horizontal guide rail 203. In addition, a material scooping shovel 205 is rotatably mounted on the bottom of the lifting slider 202. The material scooping shovel 205 is driven to rotate by a motor, which is mounted on the lifting slider 202. The control system can control the material scooping shovel 205 to rotate upward at a certain angle to scoop up the granular material on the material conveying line 100, or control the material scooping shovel 205 to rotate downward at a certain angle to pour the granular material into the top opening of the metering hopper 300. Under the command of the control system, the translation slider 204 moves along the transverse guide rail 203, thereby driving the vertical guide rail 201 and the lifting slider 202 to approach or move away from the specific sampling point on the material conveying line 100 in the horizontal direction. After reaching the target transverse position, the control system drives the lifting slider 202 to descend, so that the scooping shovel 205 approaches or inserts into the granular material layer on the material conveying line 100. When the scooping shovel 205 reaches the appropriate lower position, it begins to rotate upward or flip at a certain angle, thereby realizing the "scooping" action of the granular material to form an inspection sample. Subsequently, the system controls the lifting slider 202 to move upward and drives it through the translation slider 204, so that the scooping shovel 205, together with the scooped granular material, moves to the top of the metering hopper 300. Directly above the top opening of the metering hopper 300, the scooping shovel 205 flips downward, pouring the granular material it contains into the metering hopper 300, completing the sampling and sending the inspection sample to the subsequent testing process. On the one hand, the combined structure of the dual-rail vertical guide rail 201, the horizontal guide rail 203, the lifting slider, the translation slider, and the scooping shovel allows for multi-dimensional control of the sampling process, achieving automated and accurate material handling. On the other hand, the controllable rotation angle of the scooping shovel 205 ensures more uniform and stable scooping of granular materials, avoiding uncertainties caused by manual or fixed online sampling mechanisms. Furthermore, this solution provides structural assurance for the precise introduction of test samples into the metering hopper 300. Improved sample repeatability and accuracy provide higher reliability and data precision for subsequent weight-based, visual, and sieving processes. Precisely pouring samples into the metering hopper 300 provides uniform and repeatable sampling conditions for subsequent weighing, visual inspection, and filtration operations.

[0085] It should also be noted that in practical applications, the volume of qualified particles may vary among different batches or types of granular materials. The opening speed of the limiting baffle 602 at the discharge port 601 needs to be adjusted accordingly. If the opening speed of the limiting baffle 602 at the discharge port 601 is too fast, that is, if the discharge slit 603 is opened too quickly, the granular materials temporarily stored in the first inclined discharge channel 600 are prone to pile up and enter the return conveyor belt 700. This means that it is impossible to ensure that the granular materials are laid flat in a single layer on the surface of the return conveyor belt 700, thereby affecting the first vision module 501's ability to detect qualified particles. Particle count recognition accuracy: If the opening speed of the limiting baffle 602 to the discharge port 601 is too slow, that is, when the discharge slit 603 is opened too slowly, some slightly larger particles will be temporarily stuck and accumulated in the first inclined discharge channel 600. This will cause the particle spacing on the return conveyor belt 700 to be uneven and have large gaps, resulting in a loose overall arrangement. The particles will be difficult to spread evenly on the surface of the return conveyor belt 700, making it difficult for the system to calculate the total volume V of the qualified particle sample from the image data of the qualified particles by the first vision module 501, thus affecting the accuracy of detection. To solve this problem as much as possible, this embodiment further adds the following technical solution:

[0086] The control system of the material conveying device is also equipped with a data processing unit and a control unit;

[0087] The data processing unit calculates the stacking rate O of the particulate material on the surface of the return conveyor belt 700 based on the image information acquired by the first vision module 501. n and spacing rate G n ;

[0088] The control unit adjusts the opening speed v of the material limiting baffle 602 on the discharge port 601 according to the following mathematical model. n+1 ;

[0089]

[0090] In the formula, v n For the current opening speed of the detection work, v n+1 To improve the opening speed for the next inspection, O ref and G ref These are the preset thresholds for stacking rate and spacing rate, respectively, and k1 and k2 are control adjustment coefficients.

[0091] It is understandable that in the above scheme, the control system consists of a data processing unit and a control unit. Utilizing image data from the first vision module 501, it dynamically adjusts the opening speed of the limiting baffle 602 to adapt to different batches and types of granular materials, ensuring that the arrangement of the granular materials on the return conveyor belt 700 meets the detection requirements. During operation, the data processing unit receives image information collected by the first vision module 501 and calculates the stacking rate O of the granular materials on the return conveyor belt using image processing algorithms. n and spacing rate G n Stacking ratio O n This indicates the degree of accumulation of particulate material on the return conveyor belt, which can be calculated by detecting the number or area of ​​overlapping particles in the image. The spacing ratio G... n This represents the average spacing of granular materials on the return conveyor belt. The deviation from the ideal spacing can be obtained by measuring the distance between adjacent particles and calculating the average value.

[0092] The control unit calculates the stacking ratio O based on the data processing unit. n and spacing rate G n and the preset threshold O ref and G ref Using the mathematical model established above, the opening speed v of the material limiting baffle 602 in the next detection operation is calculated. n+1 The specific control logic is as follows:

[0093] When O is detected n >O ref At this time: The system automatically determines that the granular material on the return conveyor belt 700 is severely piled up, and it is necessary to reduce the opening speed of the limiting baffle 602 to reduce the pile-up. The control unit calculates the adjustment amount of the opening speed as follows:

[0094] v n+1 =v n -k1×(O n -O ref );

[0095] The goal is to reduce the number of particles falling into the return conveyor belt per unit time, thereby reducing the probability of stacking. Through dynamic adjustment, detection errors caused by the stacking of particulate materials are avoided.

[0096] When G n >G ref At this time: The system automatically determines that the spacing between the granular materials on the return conveyor belt 700 is too large, and it is necessary to increase the opening speed of the limiting baffle 602 to reduce the spacing. The control unit calculates the adjustment amount of the opening speed as follows:

[0097] v n+1 =v n +k2×(G n -Gref );

[0098] The purpose is to increase the number of particles falling into the return conveyor belt 700 per unit time, reduce the particle spacing, ensure that the particle material is tightly arranged, and facilitate the accurate calculation of the total volume V of qualified particles.

[0099] When O n ≤O ref And G n ≤G ref At this time, the system automatically determines that the granular material on the return conveyor belt 700 is arranged normally, and maintains the current opening speed of the limiting baffle 602:

[0100] v n+1 =v n ;

[0101] At the same time, the control unit must also ensure that the opening speed is within the physical limit, that is, meet v min ≤v n+1 ≤v max .

[0102] In summary, during each testing operation, the material limiting baffle 602 operates at a speed v. n When the discharge port 601 is opened, the granular material falls into the return conveyor belt 700 through the discharge slot 603. The first vision module 501 captures images of the return conveyor belt, and the data processing unit calculates the stacking rate O. n and spacing rate G n The control unit adjusts the opening speed v for the next detection operation based on the calculation results. n+1 Through the above cycle, the control system achieves dynamic adaptive adjustment of the opening speed of the limiting baffle 601. This scheme ensures, to a certain extent, that the granular material is laid out in a single layer with uniform spacing on the return conveyor belt. The first vision module 501 can accurately identify the number of particles and acquire clear image data. The system performs quality assessment based on accurate data, improving the reliability of the detection results. Furthermore, to adapt the equipment to the characteristics of different materials, control adjustment coefficients k1 and k2 are introduced into the above mathematical model. This allows the control system to set parameters according to different material characteristics, enhancing the system's adaptability. The entire adjustment process requires no manual intervention, reducing the impact of human factors on the detection results. It can automatically adapt to material conveying devices for different batches and types of granular materials. By dynamically adjusting the opening speed of the limiting baffle, it ensures that the granular material is laid out in a single layer, tightly arranged, and with uniform spacing on the return conveyor belt, improving detection accuracy and efficiency. The following is a specific calculation example for the above improvement scheme:

[0103] Assume that in a continuous production batch, multiple rounds of inspection are performed on the same particulate material, and the speed is adjusted based on visual data after each round of inspection. The control system has a preset opening speed range for the material limiting baffle: v min =0.20m / s, v max =2.0m / s, stacking ratio and spacing ratio thresholds are respectively: O ref =0.20, G ref =0.25, and the control adjustment coefficients are: k1=0.30 and k2=0.40.

[0104] During execution, after each round of detection, the first vision module 501 calculates the stacking rate O of the granular material on the current return conveyor belt 700 using image algorithms. n and spacing rate G n The table below lists the process from the first and second detections, assuming a stacking rate O in each round of detection. n and spacing rate G n The control logic calculates the opening speed of the limiting baffle 601 for the next time, as shown in the following table:

[0105]

[0106] As can be seen from the list above, the stacking rate O detected visually is... n and spacing rate G n

[0107] The system can dynamically and flexibly adjust the opening speed v of the material limiting baffle 602 on the discharge port 601. n+1 This ensures that the particulate material is better laid out in a single layer on the surface of the return conveyor belt 700 during the next inspection, improving the recognition accuracy of the first vision module 501 for particle number and volume data. In summary, by utilizing the aforementioned mathematical model and control logic, the system can continuously iterate, effectively controlling the distribution of particulate material on the return conveyor belt. This provides a solid foundation for the accurate detection by the first vision module 501 and further improves the overall accuracy and efficiency of material quality inspection.

[0108] In addition, this embodiment also implements a detection method for a material conveying device with detection function, the steps of which include:

[0109] S1-1, Sample Collection Steps: A certain amount of particulate material is collected from the material conveying line as a sample for testing, and the sample is placed in the metering hopper; (This step is achieved in conjunction with the vertical guide rail, lifting slider, and material shovel in the "online sampling mechanism 200" of the device structure: by controlling the material shovel to insert into the conveying particulate material and rotate to collect the material, a particulate material sample of predetermined mass or volume is obtained. This process ensures that the material sample is automatically collected without stopping the machine and sent to the metering hopper for subsequent testing).

[0110] S1-2, Weighing and Recording Total Weight Steps: Measure the total weight A of the test sample using the weighing module and send A to the control system; (This step is executed by the weighing module 500. This step achieves the initial mass (weight) measurement of the collected test sample to obtain the total weight A. This measurement data is recorded and saved by the control system for subsequent calculation of the ratio between excessively large particles and the total population).

[0111] S1-3, Separation of oversized particles: Oversized particles in the test sample are blocked and retained on the filter screen, while particles of acceptable size pass through the filter screen and fall into the conveying channel; (In this step, particles exceeding the screen mesh size are retained on the filter screen, while the remaining particles of acceptable size pass through the filter screen and fall into the lower first inclined discharge channel 600, achieving automatic separation of large and acceptable particle sizes).

[0112] S1-4. Weighing and recording the weight of the oversized particle sample: Use the weighing module again to measure the weight A1 of the oversized particle sample remaining on the filter screen, and send A1 to the control system; (In this step, the weighing module 500 continues to support the metering hopper 300 to measure the oversized particles remaining on the filter screen again, obtain the weight A1, and then send A1 to the control system to calculate the ratio of oversized particles to all samples, thus reflecting the content of large particles more intuitively).

[0113] S1-5, Calculation and plotting curve X: The control system calculates the ratio R = A1 / A based on A and A1. After repeated detection, multiple sets of ratios R are obtained, and curve X is plotted based on the R values ​​from each detection to reflect the proportion of excessively large particles in the batch of material; (The control system calculates the ratio R based on the measured A and A1 using the formula...) The system calculates the percentage R of excessively large particles in each test and uses this as an important indicator for monitoring the quality of the batch of materials. As multiple tests accumulate, the system plots a curve X, showing the trend of this percentage over time or batch, providing a basis for production or quality control.

[0114] As can be seen from the above execution method, by continuously or intermittently executing the detection method on the production line, the weight percentage of large particles in the current batch of materials can be quickly determined. The detection results are presented intuitively on the curve X, facilitating timely understanding and corresponding process or equipment adjustments by quality control personnel. This method automates the assessment of the weight percentage of excessively large particles in materials, reducing errors and time costs caused by manual steps. By monitoring this percentage in real time through the curve X, batch quality fluctuations can be quickly detected and corresponding measures can be taken to improve the quality of the final product. Compared with traditional manual sampling and sieving methods, this method improves detection accuracy and efficiency while reducing manpower input.

[0115] As a further improvement to the above detection method, this embodiment also includes the following steps:

[0116] S2-1, Step 1: Calculating the weight of qualified particles by volume: The control system calculates the weight of qualified particles A2 = A - A1 based on the total weight A of the test sample and the weight A1 of the oversized particles. (It can be understood that this step, based on the A (total weight of the test sample) and A1 (weight of oversized particles) obtained in the previous steps, uses A2 = A - A1 to obtain the actual weight A2 of qualified particles after passing through the filter screen. This weight A2 can eliminate the influence of abnormally large particles and better represent the material quality attributes within the normal particle size range.)

[0117] S2-2, Step 1: Obtain the diameter value D of the qualified volume particles. The diameter value D can be a preset value or determined by image analysis of the first vision module 501. (It can be understood that the particle characteristic size required for volume measurement in this step can be preset (applicable to specific materials and known particle size distribution), or it can be calibrated by real-time image analysis of the first vision module 501. The diameter value D of the qualified volume particles can provide a basis for subsequent calculation of the total volume V and more in-depth statistical analysis.)

[0118] S2-3, Step 1: Calculate the total volume of qualified particles: Using the image data acquired by the first vision module 501, calculate the volume of qualified particle samples that have passed through the filter screen and are laid flat on the return conveyor belt to obtain the total volume V of the qualified particle samples; (It can be understood that this step uses the qualified particle image data captured by the first vision module 501, and combines the fixed angle between the module and the return conveyor belt 700 and the known calibration parameters to realize the algorithm analysis of particle volume or total particle accumulation volume. The system obtains the total volume V of qualified particles through image recognition and geometric conversion (such as treating the particles as approximate spheres, cylinders or other approximate shapes).

[0119] S2-3, Steps for calculating density ρ: The system calculates the density ρ = A2 / V of qualified particles based on A2 and the total volume V;

[0120] S2-4, Step Z: After repeated testing, obtain multiple density values ​​ρ, and plot a curve Z based on the ρ values ​​from each test to reflect the overall quality of the batch of material; (This step can be understood as being based on the formula...) Obtaining the density of qualified particles and plotting a curve Z by accumulating multiple test results can reflect the stability or fluctuation of the overall quality of the batch of materials from a macroscopic perspective.

[0121] As can be seen from the above implementation method, after identifying and removing excessively large particles, further attention is paid to the density of particles with acceptable volume to obtain more comprehensive particle quality indicators. The trend of this density value is visually displayed through a curve Z, which allows for precise adjustments to upstream or downstream processes, enabling continuous process control. Furthermore, the density ρ can determine whether there are voids or excessive irregularities within the particles, thereby further identifying potential quality problems. Density data is crucial for many granular products (food, chemical, pharmaceutical, etc.), directly affecting subsequent ingredient preparation, packaging, and performance. Combined with existing automated sampling, sieving, and image calculation steps, manual intervention or subjective judgment is significantly reduced, facilitating long-term batch monitoring and statistical analysis.

[0122] As a further improvement to the above detection method, this embodiment also includes the following steps:

[0123] S3-1, Step 1: Detecting the number of oversized particles: The second vision module 502, located above the metering hopper, acquires image data of the test sample. The control system analyzes the images to obtain the number of oversized particles, B2. (It can be understood that in this step, the second vision module 502, installed above the metering hopper 300, can photograph the oversized particles that remain on the filter screen after screening, and use a particle image recognition algorithm to count the number of oversized particles, B2. This number of particles, B2, corresponds to the weight A1 measured in the aforementioned detection method steps, thus constructing a two-way monitoring system of particle number and weight, further improving the comprehensive analysis capability of the material.)

[0124] S3-2, Steps for detecting the number of particles in a qualified volume particle sample: The first vision module 501, located above the return conveyor belt, acquires image data of the qualified volume particle sample. The control system analyzes the image to obtain the number of particles B1 in the qualified volume particle sample. (It can be understood that the detection position is different from that of the number of particles B2 for excessively large particles. The qualified volume particles are photographed when they fall onto the return conveyor belt 700 after passing through the filter screen. At this time, the first vision module 501 captures the image of the particles in a flat state and performs particle recognition and counting. B1 is obtained through this recognition result to represent the number of most normal-sized particles that have passed through the screen.)

[0125] S3-3, Ratio Calculation Steps: The control system calculates the ratio Q = B1 / B2 based on B1 and B2, and obtains multiple sets of ratios Q by repeating the detection multiple times; (This can be understood as comparing B1 and B2 to obtain...) ).

[0126] S3-4, Plotting Curve Y: Based on the Q values ​​from each test, plot curve Y to reflect the ratio of qualified particles to oversized particles in this batch of material; (It can be understood that this step uses the Q values ​​obtained from multiple tests to plot curve Y on the ordinate, which can clearly show whether the ratio between the number of qualified particles and the number of oversized particles is stable or fluctuates as the production or testing batch progresses, providing refined guidance for production process control).

[0127] It is understandable that the above-mentioned detection method, in addition to quality (weight) detection, also incorporates a quantity dimension to assess the ratio of qualified particles to excessively large particles in the material, thereby enriching the quality judgment criteria. By accumulating data over a long period using the curve Y, it can quickly identify when abnormal pass rates occur and comprehensively locate the source of the problem by combining other detection data. This method complements the two aforementioned detection methods, which focus on the proportion of mass (weight) and the latter on density and volume calculations. This method emphasizes the assessment of quantity ratios, and quantity detection often reveals the dispersion and uniformity of particle distribution, compensating for the limitations of pure weight detection. Furthermore, the automatic identification of particle count through a vision module reduces the risk of human intervention and ensures the stability and traceability of the detection data.

[0128] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A material conveying device with detection function, characterized in that, include: Material conveyor line (100) is used to convey granular materials; An online sampling device (200) is disposed above the material conveying line (100); Measuring hopper (300) is used to load test samples of particulate materials; A screening mechanism (400) is disposed inside the metering hopper (300), and the screening mechanism (400) is used to filter out particles that are too large in the test sample; The detection module is used to detect data from the test samples; A sample conveying mechanism is used to receive and convey volume-qualified particle samples that have been screened out by the screening mechanism (400) and fall from the metering hopper (300). The online sampling mechanism (200) collects a portion of particulate material on the material conveying line (100) as an inspection sample and transports the inspection sample to the metering hopper (300). The detection module detects the initial inspection sample data entering the metering hopper (300), as well as the data of excessively large particles in the inspection sample that have been filtered by the screening mechanism (400) and are retained in the metering hopper (300). The quality of the material is fed back based on the ratio of the data of excessively large particles to the data of the initial inspection sample. The detection module includes: The weighing module (500) supports the bottom of the metering hopper (300) upwards; The weighing module (500) measures the total weight of the test sample entering the metering hopper (300) and the weight of the oversized particles that are filtered by the screening mechanism (400) and left in the metering hopper (300). The control system provides feedback on the material quality based on the ratio of the weight data of excessively large particles to the weight data of the initial test sample. The detection module includes: The first vision module (501) is used to detect volume-qualified particles in the test sample that have passed through the screening mechanism (400); the first vision module (501) detects image data of volume-qualified particles in the test sample. The control system calculates the weight data of the qualified particles based on the difference between the total weight of the test sample and the weight of the oversized particles. The control system calculates the total volume of the qualified particles based on the size value of the qualified particles and the image data from the first vision module (501). The control system calculates the density ρ of the qualified particles based on the weight data of the qualified particles and the total volume data. The control system provides feedback on the material's quality based on the density ρ of the qualified particles.

2. The material conveying device with detection function according to claim 1, characterized in that, The detection module includes: The second vision module (502) is disposed above the metering hopper (300) and is used to collect image data of the test samples in the metering hopper (300); The control system calculates the number of particles with excessive volume using image data from the second vision module (502) and calculates the number of particles with acceptable volume using image data from the first vision module (501). The control system provides feedback on the material quality based on the ratio between the number of particles with acceptable volume and the number of particles with excessive volume.

3. The material conveying device with detection function according to claim 1, characterized in that, The sample conveying mechanism includes a first inclined unloading channel (600), a return conveyor belt (700), and a second inclined unloading channel (800). The return conveyor belt (700) is located below the first vision module (501) and between the first inclined unloading channel (600) and the second inclined unloading channel (800); One end of the first inclined unloading channel (600) extends upward at an angle to the bottom discharge port of the metering hopper (300), and the other end extends downward at an angle to the top of the return conveyor belt (700). One end of the second inclined unloading channel (800) extends upward at an angle to below the return conveyor belt (700), and the other end extends downward at an angle to above the material conveying line (100).

4. The material conveying device with detection function according to claim 3, characterized in that, The first inclined unloading channel (600) is provided with an unloading port (601) at one end near the return conveyor belt (700), and a limiting baffle (602) is rotatably provided at the unloading port (601). The discharge port (601) is closed by the limiting baffle (602) so that the qualified particles in the test sample that have passed the screening mechanism (400) fall into the first inclined discharge channel (600) and are restricted by the limiting baffle (602) within the first inclined discharge channel (600). The weighing module (500) is supported upward by the first inclined unloading channel (600) and the metering hopper (300) to obtain the total weight data of the test sample by measuring the excessively large particles in the metering hopper (300) and the qualified particles in the first inclined unloading channel (600). By controlling the material limiting baffle (602) to deflect at a certain angle, a discharge slit (603) is formed between the lower edge of the material limiting baffle (602) and the discharge port (601); the opening size of the discharge slit (603) is suitable for matching the diameter of the qualified volume particles, so as to allow the qualified volume particles to leave the first inclined discharge channel (600).

5. The material conveying device with detection function according to claim 1, characterized in that, The online sampling facility (200) includes: A vertical guide rail (201) is disposed above the material conveying line (100); The lifting slider (202) is slidably mounted on the vertical guide rail (201); The horizontal guide rail (203) is perpendicular to the vertical guide rail (201); The translation slider (204) is slidably disposed on the horizontal guide rail (203) and connected to the vertical guide rail (201). The translation slider (204) drives the vertical guide rail (201) and the lifting slider (202) to move laterally along the horizontal guide rail (203). The bottom of the lifting slider (202) is rotatably provided with a material shovel (205). The control system controls the material scoop (205) to rotate upward at a certain angle to scoop up the granular material on the material conveying line (100), and controls the material scoop (205) to rotate downward at a certain angle to pour the granular material into the top opening of the metering hopper (300).

6. A detection method for a material conveying device with detection function as described in any one of claims 1-5, characterized in that, include: The steps for collecting test samples are as follows: a certain amount of particulate material is collected from the material conveying line as a test sample, and the test sample is placed in the metering hopper; The steps for weighing and recording the total weight are as follows: The total weight A of the test sample is measured using the weighing module, and the total weight A of the test sample is sent to the control system; Separation steps for oversized particle samples: Oversized particles in the sample are blocked and retained by the screening mechanism, while particles of acceptable size pass through the screening mechanism and fall into the conveying channel. The steps for weighing and recording the weight of the oversized particle sample are as follows: The weight A1 of the oversized particle sample remaining on the screening mechanism is measured again using the weighing module, and the weight A1 of the oversized particle sample is sent to the control system. The steps for calculating and plotting curve X are as follows: The control system calculates the ratio R = A1 / A of the weight of the oversized particle sample to the total weight of the test sample based on the total weight A of the test sample and the weight A1 of the oversized particle sample. After repeated testing, multiple sets of ratios R are obtained, and curve X is plotted based on the ratios R of each test to reflect the proportion of oversized particles in the batch of materials.

7. The detection method of the material conveying device with detection function according to claim 6, characterized in that, include: The steps for calculating the weight of qualified particles are as follows: The control system calculates the weight of qualified particle samples A2 = A - A1 based on the total weight A of the test samples and the weight A1 of the oversized particle samples. The steps for obtaining the size value of qualified volume particles are as follows: obtain the diameter value D of the qualified volume particles, wherein the size value D is a preset value or determined by image analysis of the first vision module (501); The steps for calculating the total volume of qualified particles are as follows: using the image data obtained by the first vision module (501), the volume of qualified particle samples that have passed through the screening mechanism and are laid flat on the return conveyor belt is calculated to obtain the total volume V of the qualified particle samples. The steps for calculating density ρ are as follows: The control system calculates the density ρ = A2 / V of the qualified particle sample based on the weight A2 of the qualified particle sample and the total volume V. The steps for plotting curve Z are as follows: After repeated testing, multiple sets of densities ρ are obtained, and curve Z is plotted based on the density ρ of each test to reflect the overall quality of the batch of materials.

8. The detection method of the material conveying device with detection function according to claim 6, characterized in that, include: The steps for detecting the number of particles with excessive volume are as follows: image data of the particles with excessive volume is acquired by the second vision module (502) set above the metering hopper, and the control system analyzes the image to obtain the number of particles with excessive volume B2. The steps for detecting the number of particles in a qualified volume particle sample are as follows: image data of the qualified volume particle sample is acquired by the first vision module (501) set above the return conveyor belt, and the control system analyzes the image to obtain the number of particles B1 of the qualified volume particle sample. The steps for calculating the ratio are as follows: The control system calculates the ratio Q = B1 / B2 of the number of particles in the qualified particle sample and the number of particles in the excessively large particle sample based on the number of particles B1 and B2 of the qualified particle sample. Multiple sets of ratios Q are obtained after repeated testing. The steps for plotting curve Y are as follows: Plot curve Y based on Q from each test to reflect the ratio of qualified particles to excessively large particles in this batch of material.

Images