Semi-autogenous mill blockage detection device based on wireless non-contact mode and detection method of semi-autogenous mill blockage detection device

Abstract

The invention provides a semi-autogenous mill blockage detection device based on a wireless non-contact mode and a detection method thereof. The semi-autogenous mill blockage detection device comprises a microwave sensor, a radar sensor, a PLC and an audible and visual alarm, and the PLC is electrically connected with the microwave sensor, the radar sensor and the audible and visual alarm through a wireless gateway and an RS485 network; the radar sensor is vertically installed above the feeding hopper and does not make direct contact with materials, and the radar sensor emits radar waves in the vertical direction and is used for detecting the longitudinal material blocking state in the feeding hopper; the two microwave sensors are installed on the two sides of the feeding hopper respectively, do not make direct contact with materials, emit microwaves in the horizontal direction and are used for detecting the stacking state of the materials in the feeding hopper. The radar sensor and the microwave sensor are matched with the PLC to perform longitudinal and transverse detection and blockage state judgment on the feeding end of the semi-autogenous mill, so that the effects of accurate detection and accurate judgment are achieved, production accidents are reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of detection devices, and in particular to a wireless non-contact semi-autogenous grinding mill blockage detection device and a detection method thereof. Background Art

[0002] Blockage detection is mainly used for hopper detection of hard ores and large ores, which are subject to adverse factors such as harsh working conditions, large vibration, large dust, large impact, and large electromagnetic interference.

[0003] The existing Chinese patent with publication number CN110294286B discloses a material blockage detection device, wherein the material blockage detection device includes a sensing probe with one end extending into the material flow; a rotating shaft rotatably connected to the sensing probe; a proximity switch selectively contacting the other end of the sensing probe; and a controller electrically connected to the proximity switch and including a timing module and an alarm module.

[0004] The shortcomings of the existing technology are: the sensor is a contact electrode, which is easily impacted by materials, interfered by dust, has poor reliability and is easily damaged, and is suitable for detecting powders with small particle sizes; the transmission medium is a twisted pair, which cannot suppress interference or avoid false signals caused by electromagnetic interference, and cannot be used in places with strong magnetic interference and high dust; it has a large amount of wiring and many components, resulting in high costs, and poor applicability to scenes where wiring is not possible. It can only use contact detection methods and wired network transmission, and cannot accurately judge the blockage status, nor can it issue different alarm categories.

[0005] Therefore, it is necessary to provide a wireless non-contact semi-autogenous mill blockage detection device and a detection method thereof, which can accurately judge the blockage status and issue different alarm categories through non-contact detection means and wireless network transmission. Summary of the invention

[0006] In view of the defects in the prior art, the object of the present invention is to provide a wireless non-contact semi-autogenous grinding mill blockage detection device and a detection method thereof.

[0007] According to the present invention, a wireless non-contact semi-autogenous mill blockage detection device includes: a microwave sensor, a radar sensor, a PLC and an acoustic and optical alarm, wherein the PLC is electrically connected to the microwave sensor, the radar sensor and the acoustic and optical alarm through a wireless gateway and an RS485 network respectively;

[0008] The radar sensor is vertically installed above the feed hopper and does not directly contact the material. The radar sensor emits radar waves in the vertical direction to detect the longitudinal material blocking state inside the feed hopper;

[0009] The two microwave sensors are respectively installed on both sides of the feed hopper and are not in direct contact with the material. The microwave sensors emit microwaves in a horizontal direction to detect the accumulation state of the material inside the feed hopper.

[0010] Preferably, there is a 0.5 m installation space between the radar sensor and the top of the hopper.

[0011] Preferably, the sensing distance of the radar sensor is 0-10m.

[0012] Preferably, mounting holes for mounting the microwave sensor are respectively provided on both sides of the feed hopper, and the mounting position deviation of the two microwave sensors on both sides of the feed hopper is less than 2 mm.

[0013] Preferably, the sensing distance of the microwave sensor is 0-5m.

[0014] Preferably, the radar sensor, PLC, sound and light alarm and two microwave sensors are all independently connected to a wireless gateway.

[0015] Preferably, the radar sensor and the microwave sensor are both provided with an RS485 communication interface for connecting to a wireless gateway.

[0016] Preferably, the sound and light alarm is 2m above the ground.

[0017] A detection method for a wireless non-contact SAG mill blockage detection device provided by the present invention is applied to the above-mentioned wireless non-contact SAG mill blockage detection device, comprising the following steps:

[0018] Step S1, when a microwave sensor or a radar sensor detects a material blocking signal, the material blocking signal is transmitted to the PLC;

[0019] Step S2, the PLC analyzes and determines the material blocking state, and if the alarm suppression time is exceeded, it is determined to be a real material blocking state, and sends an alarm command to the sound and light alarm;

[0020] Step S3, the sound and light alarm emits different states according to different alarm instructions of the PLC.

[0021] Preferably, in step S3, when longitudinal material blockage occurs, the sound and light signal emitted by the sound and light alarm is an alarm state of 1 second of sound and 1 second of strong light;

[0022] When lateral blockage occurs, the sound and light alarm emits a 5-second sound and 5-second strong light alarm signal.

[0023] When both longitudinal and transverse alarms sound simultaneously, it is a serious material blockage state. At this time, the sound and light alarm emits continuous sound and strong light, and sends a stop command to the semi-autogenous grinding feeding equipment to cut off the ore entering the mill in time.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention adopts two non-contact detection sensors, radar sensor and microwave sensor, and cooperates with PLC to perform real-time longitudinal and lateral detection and blockage status judgment on the feed end of the semi-autogenous mill, thereby solving the problem that manual inspections cannot timely detect blockage of the feed port of the semi-autogenous mill and cannot understand the material situation of the feed port of the semi-autogenous mill in real time, and solves the problem of sensor failure caused by material flow interference and equipment vibration, achieving the effect of accurate detection and precise judgment, reducing the occurrence of production accidents, improving the working environment of workers, and improving production efficiency.

[0026] 2. The present invention uses PLC and sound and light alarms to issue different alarm states for different blockage states, solving the problem that a single device cannot issue different alarm states. Workers on the job can understand the blockage information more intuitively, achieving the effect of quickly handling faults and efficiently operating.

[0027] 3. The present invention solves the problems of difficult wiring, high cost and large electromagnetic interference of traditional wired networks through the wireless RS485 network structure, and achieves the effects of stable and efficient transmission and easy maintenance. The wireless network coverage also improves the level of the Internet of Things, and can interact with the full-process control system, advanced control system or expert system for data, providing a reliable interface for intelligent manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0029] Figure 1 This is a system topology diagram of a wireless non-contact semi-autogenous mill blockage detection device mainly embodied in the present invention;

[0030] Figure 2 The present invention mainly embodies the structural schematic diagram of a wireless non-contact semi-autogenous mill blockage detection device.

[0031] As shown in the figure:

[0032] Microwave sensor 1 Radar sensor 2 Wireless gateway 3

[0033] PLC4 RS485 network 5 Sound and light alarm 6 DETAILED DESCRIPTION

[0034] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several changes and improvements can also be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0035] Example 1

[0036] like Figure 1-2 As shown, a wireless non-contact semi-autogenous grinding mill blockage detection device provided according to the present invention includes: a microwave sensor 1, a radar sensor 2, a PLC4 and an audible and visual alarm 6, wherein the PLC4 is electrically connected to the microwave sensor 1, the radar sensor 2 and the audible and visual alarm 6 respectively; the radar sensor 2 is vertically installed above the feed hopper and is not in direct contact with the material, and the radar sensor 2 emits radar waves in the vertical direction to detect the longitudinal blockage state inside the feed hopper; two microwave sensors 1 are respectively installed on both sides of the feed hopper and are not in direct contact with the material, and the microwave sensor 1 emits microwaves in the horizontal direction to detect the material accumulation state inside the feed hopper.

[0037] The present application is a device for detecting the blocking state of the feed port of a semi-autogenous mill, so as to prevent the feed port from being blocked due to large particle size of the ore or too much ore feeding, thereby causing production accidents. The present application combines a radar sensor 2 with a microwave sensor 1, connects the radar signal and the microwave signal to a PLC 4, and performs a logical operation in the PLC 4, so that the feed port state of the semi-autogenous mill can be accurately detected in real time. In the event of an abnormality, the PLC 4 drives the sound and light alarm 6 to send out an alarm signal.

[0038] The radar sensor 2 is electrically connected to the PLC4 through the wireless gateway 3 and the RS485 network 5. The radar sensor 2 is provided with an RS485 communication interface for connecting to the wireless gateway 3. The radar sensor 2 is vertically installed on the feed hopper, does not directly contact the material, and leaves a 0.5m installation space at the top of the feed hopper. The sensing distance is 0-10m. It is used to detect the material height by emitting large-angle radar waves. Because the radar sensor 1 will not be damaged by the impact or vibration of the material, it has the characteristics of large detection surface and anti-material interference. Its installation position avoids the interference of material splash as much as possible. At the same time, the radar sensor 2 uses radar waves with high-frequency characteristics and strong penetration. It has the ability to resist material flow interference, which can minimize the misjudgment caused by longitudinal material splash. At the same time, a longitudinal time filtering function is set in PLC4. Only when the set time threshold is exceeded, the blocking state is considered to be valid, not material flow interference. In view of material splash interference, this application adopts dual judgment in the radar sensor 2 and PLC4 to avoid interference, effectively preventing longitudinal material splash interference. Since the material accumulation surface in the longitudinal direction of the feed hopper is large, the radar sensor 1 is suitable for longitudinal detection of the feed port of the semi-autogenous mill. At the same time, it has an RS485 communication interface to communicate with the wireless gateway 3.

[0039] The microwave sensor 1 is electrically connected to the PLC4 through the wireless gateway 3 and the RS485 network 5. The microwave sensor 1 is provided with an RS485 communication interface for connecting to the wireless gateway 3. Holes are opened on both sides of the feed hopper for installation, and the installation position deviation of the two microwave sensors 1 on both sides of the feed hopper is required to be less than 2mm. The sensing distance of the microwave sensor 1 is 0-5m. The microwave sensor 1 is used to detect the state of material accumulation by emitting small-angle microwaves. The installation position of the microwave sensor 1 needs to avoid the normal material flow interval side and the instrument is installed outside the hopper, so that the microwave sensor 1 will not be damaged by material impact or vibration. Its installation position avoids the interference of material flow splash as much as possible. At the same time, the microwave sensor 1 adopts a microwave detection source, and its transmitting end beam angle is only 1°, which can effectively avoid the interference caused by the horizontal material flow splash. At the same time, the horizontal time filtering function is set in the PLC4. Only when the set time threshold is exceeded, the blocking state is considered to be valid, not the material flow interference. In view of the material splash interference, this application adopts the microwave sensor 1 and PLC4 to double-judge and avoid interference, effectively preventing the horizontal material splash interference. Since the lateral detection of the feed hopper needs to prevent the interference of falling materials in the longitudinal material flow, its small emission angle is more suitable for lateral detection of the feed port of the semi-autogenous mill. At the same time, it has an RS485 communication interface to communicate with the wireless gateway 3.

[0040] The sound and light alarm 6 is installed near the feed hopper, 2m above the ground to avoid being blocked by the equipment. It has the characteristics of high-power sound broadcast, high-intensity light, and is not affected by dust and noise. It is used to broadcast the blocking signal of the semi-automatic machine.

[0041] PLC4 is the core component of the logic control of this application. It is used for data collection, logical operations, and output instructions. It has optocoupler isolation characteristics, strong anti-interference ability, and is not affected by electromagnetic interference. It is also resistant to high temperature, dust, and water vapor. It is suitable for harsh working conditions and has RS485 communication interface and RS485 network communication.

[0042] Radar sensor 2, PLC4, sound and light alarm 6 and two microwave sensors 1 are all independently connected to wireless gateway 3. Wireless gateway 3 connected to radar sensor 2 and microwave sensor 1 is electrically connected to wireless gateway 3 connected to PLC4 through RS485 network 5. Sound and light alarm 6 can be directly connected to wireless gateway 3 connected to PLC4. Wireless gateway 3 has high transmission rate and anti-interference ability, is not affected by obstructions and bad working conditions, has a transmission distance of 0-1000m and a transmission frequency of 2100MHz. Because of its high transmission frequency and long transmission distance, it will not be affected by interference from steel structure, wall, electrical equipment, etc. of the factory building, and is the carrier of RS485 network 5.

[0043] The RS485 network 5 is the transmission medium of the present application and is used to connect various components. It has a universal interface transmission protocol, adopts a standard communication protocol, supports communication between 247 master and slave devices, and can wirelessly transmit with the radar sensor 2, microwave sensor 1, wireless gateway 3, PLC4, and sound and light alarm 6 through the RS485 network 5.

[0044] When the material level at the feed inlet of the semi-autogenous mill is high due to the large particle size of the incoming ore or the excessive amount of ore fed, it is easy to cause a blockage state. The present application detects the longitudinal blockage state of the feed inlet of the semi-autogenous mill through a radar sensor 2, and performs a lateral detection of the feed inlet of the semi-autogenous mill through a microwave sensor 1. The detected data is transmitted to the PLC4 through a wireless gateway 3 and an RS485 network 5. The PLC4 performs logical judgment based on the longitudinal detection of the radar sensor 2 and the lateral detection of the microwave sensor 1.

[0045] The present application adopts two types of non-contact detection sensors, radar sensor 2 and microwave sensor 1, to perform real-time detection of the longitudinal and lateral directions of the semi-autogenous mill feed end, and makes real-time judgment on the blockage status through PLC4, thereby solving the problems that manual inspections cannot promptly detect blockage of the semi-autogenous mill feed port and cannot understand the material situation at the semi-autogenous mill feed port in real time, and solves the problem of sensor failure caused by material flow interference and equipment vibration, thereby achieving the effect of accurate detection and precise judgment, reducing the occurrence of production accidents, improving the working environment of workers, and improving production efficiency.

[0046] The present application uses PLC4 and sound and light alarm 6 to issue different alarm states for different blockage states, thereby solving the problem that a single device cannot issue different alarm states. Workers on the job can understand the blockage information more intuitively, achieving the effect of quickly handling faults and efficiently operating.

[0047] This application solves the problems of difficult wiring, high cost and large electromagnetic interference of traditional wired networks through the wireless RS485 network 5 structure, and achieves the effect of stable and efficient transmission and easy maintenance. The wireless network coverage also improves the level of the Internet of Things, and can interact with the full-process control system, advanced control system or expert system for data, providing a reliable interface for intelligent manufacturing.

[0048] Example 2

[0049] Based on Example 1, a detection method based on a wireless non-contact semi-autogenous mill blockage detection device provided by the present invention comprises the following steps:

[0050] Step S1, using radar sensor 2 to detect the longitudinal blocking state of the feed end of the semi-autogenous mill in real time, and using microwave sensor 1 to detect the transverse blocking state of the feed end of the semi-autogenous mill in real time, and the detected data is transmitted to PLC4 in real time. When the microwave sensor 1 or the radar sensor 2 detects a blocking signal, the blocking signal is transmitted to PLC4;

[0051] Step S2, in order to suppress the interference of multiple factors such as material flow or vibration, dust and electromagnetic, PLC4 analyzes and judges the material blocking state. When the longitudinal radar sensor 2 exceeds the set threshold height and the transverse microwave sensor receiving end exceeds the set time and still cannot receive the transmitting end signal, it is considered a serious material blocking state. The connection delay timer is set inside PLC4. When the serious material blocking state does not reach the setting time of the connection delay timer, the alarm suppression does not output the alarm. Only when the serious state exceeds the setting time of the connection delay timer, the alarm suppression is released and the alarm is output. It is judged to be a real material blocking state, and according to the material blocking situation detected by the radar sensor 2 and the microwave sensor 1, an alarm instruction is sent to the sound and light alarm 6;

[0052] Step S3, the sound and light alarm 6 emits different states according to different alarm instructions of PLC4.

[0053] In step S3, different alarm instructions are used to distinguish between the lateral blockage state and the longitudinal blockage state or the serious blockage state of both; when longitudinal blockage occurs, the sound and light signal emitted by the sound and light alarm 6 is an alarm state of 1 second sound and 1 second strong light; when lateral blockage occurs, the sound and light signal emitted by the sound and light alarm 6 is an alarm state of 5 seconds sound and 5 seconds strong light; when both longitudinal and lateral alarms are in a serious blockage state, the sound and light alarm 6 emits continuous sound and strong light, and sends a shutdown command to the semi-autogenous grinding feeding equipment, and cuts off the grinding ore in time, so as to achieve real-time and accurate judgment of semi-autogenous grinding and feeding end blockage, prevent production accidents, improve production efficiency, and reduce the labor intensity of workers on the job.

[0054] In the description of the present application, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0055] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which does not affect the essence of the present invention. In the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. A wireless non-contact semi-autogenous mill blockage detection device, characterized in that: include: A microwave sensor (1), a radar sensor (2), a PLC (4) and an audible and visual alarm (6), wherein the PLC (4) is electrically connected to the microwave sensor (1), the radar sensor (2) and the audible and visual alarm (6) respectively via a wireless gateway (3) and an RS485 network (5); The radar sensor (2) is vertically mounted above the feed hopper and is not in direct contact with the material. The radar sensor (2) emits radar waves in a vertical direction to detect a longitudinal material blocking state inside the feed hopper. The two microwave sensors (1) are respectively installed on both sides of the feed hopper and are not in direct contact with the material. The microwave sensor (1) emits microwaves in a horizontal direction to detect the accumulation state of the material inside the feed hopper.

2. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: There is a 0.5 m installation space between the radar sensor (2) and the top of the feed hopper.

3. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: The sensing distance of the radar sensor (2) is 0-10m.

4. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: Mounting holes for mounting the microwave sensor (1) are respectively provided on both sides of the feed hopper, and the mounting position deviation of the two microwave sensors (1) on both sides of the feed hopper is less than 2 mm.

5. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: The sensing distance of the microwave sensor (1) is 0-5m.

6. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: The radar sensor (2), PLC (4), sound and light alarm (6) and two microwave sensors (1) are all independently connected to a wireless gateway (3).

7. The wireless non-contact SAG mill blockage detection device according to claim 6, characterized in that: The radar sensor (2) and the microwave sensor (1) are both provided with an RS485 communication interface for connecting to a wireless gateway (3).

8. The wireless non-contact SAG mill blockage detection device according to claim 1, characterized in that: The sound and light alarm (6) is 2 m above the ground.

9. A detection method based on a wireless non-contact semi-autogenous mill blockage detection device, characterized in that: The wireless non-contact SAG mill blockage detection device applied to any one of claims 1 to 8 comprises the following steps: Step S1, when the microwave sensor (1) or the radar sensor (2) detects a material blocking signal, the material blocking signal is transmitted to the PLC (4); Step S2, the PLC (4) analyzes and determines the material blocking state, and if the alarm suppression time is exceeded, it is determined to be a real material blocking state, and sends an alarm command to the sound and light alarm (6); Step S3, the sound and light alarm (6) emits different states according to different alarm instructions of the PLC (4).

10. The detection method based on the wireless non-contact SAG mill blockage detection device according to claim 9, characterized in that: In the step S3, when longitudinal material blockage occurs, the sound and light alarm (6) emits a sound and light signal of 1 second of sound and 1 second of strong light as an alarm state; When lateral material blocking occurs, the sound and light alarm (6) emits a sound and light signal of 5 seconds of sound and 5 seconds of strong light alarm; When both longitudinal and transverse alarms are given, it is a serious material blocking state. At this time, the sound and light alarm (6) emits a continuous sound and strong light, and sends a stop command to the semi-autogenous grinding feeding equipment to cut off the ore entering the grinding mill in time.

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