Visual voice intercom system for coal transportation

Abstract

The invention discloses a coal conveying visual voice intercom system. The system comprises a central control module, a video acquisition module, an audio acquisition module, a voice intercom module, a video analysis module, a data storage module, a network communication module, an alarm module, a mobile terminal access module and a power management module. By fusing high-definition video monitoring, intelligent analysis and real-time voice intercom technologies, the safety and operation efficiency of the coal conveying system are remarkably improved. The system adopts a deep learning algorithm to monitor the state of the belt in real time, faults such as deviation, coal blockage and tearing can be recognized in advance, and sudden accidents are reduced; the full-duplex noise reduction voice intercom function ensures efficient communication between the site and the control center, and the emergency response speed is greatly improved. In addition, the system supports mobile terminal access and digital twinning technologies, remote monitoring and predictive maintenance are facilitated, and the operation and maintenance cost is effectively reduced.

Description

Technical Field

[0001] The present application relates to the technical field of visual voice intercom systems, and in particular to a visual voice intercom system for coal transportation. Background Art

[0002] Currently, monitoring of coal transportation systems relies primarily on manual inspections and basic sensors, which present significant technical shortcomings. Manual inspections struggle to achieve 24 / 7 coverage, and traditional sensors have a limited monitoring range. This makes it difficult to detect faults such as belt deviation, coal blockage, and tearing in a timely manner. These faults are often only addressed after they escalate, severely impacting production safety and operational efficiency. Furthermore, communication between on-site personnel and the control center often relies on walkie-talkies or telephones. The high-noise environment of coal transportation sites results in poor call quality and inefficient communication, severely impacting emergency response speed. Existing video surveillance systems mostly offer only simple recording capabilities, lacking intelligent analysis and voice collaboration capabilities, and are unable to meet the intelligent management requirements of modern coal transportation systems.

[0003] With the development of Industry 4.0, traditional monitoring methods are no longer able to meet the coal industry's higher demands for safety and efficiency. Especially in long-distance, complex coal transportation scenarios, a comprehensive solution integrating intelligent monitoring, real-time communication, and data analysis is urgently needed to enhance the automation level and safety management capabilities of coal transportation systems. Summary of the Invention

[0004] To this end, the present application provides a coal transportation visual voice intercom system to solve the problems of poor call quality and low communication efficiency in the prior art.

[0005] In order to achieve the above objectives, this application provides the following technical solutions:

[0006] In the first aspect, a visual voice intercom system for coal transportation includes a central control module, a video acquisition module, an audio acquisition module, a voice intercom module, a video analysis module, a data storage module, a network communication module, an alarm module, a mobile terminal access module, and a power management module;

[0007] The central control module is used to coordinate the operation of each module in the system, process data communication, and provide a human-computer interaction interface;

[0008] The video acquisition module includes multiple high-definition cameras, which are deployed at key locations along the coal conveyor belt and are used to collect real-time video data of the coal conveying site;

[0009] The audio acquisition module includes multiple noise reduction microphones, which are used to collect live voice signals and have echo cancellation function;

[0010] The voice intercom module supports full-duplex communication, enabling real-time voice interaction between the control center and on-site personnel;

[0011] The video analysis module uses a deep learning algorithm to monitor the operating status of the coal conveyor belt in real time to identify coal flow anomalies, belt deviation, coal blockage, and tearing faults;

[0012] The data storage module is used to store video, audio and system operation logs, and can support historical data backtracking;

[0013] The network communication module uses a combination of industrial Ethernet and 5G wireless communication to ensure the real-time and reliability of data transmission;

[0014] The alarm module is used to send out sound and light alarm information. When an abnormal situation is detected during the coal transportation process, the alarm module is triggered;

[0015] The mobile terminal access module is used to support mobile devices such as mobile phones and tablets to access the system and realize remote monitoring and intercom;

[0016] The power management module provides a redundant power supply solution to ensure that the system can maintain key functions in the event of a power outage.

[0017] Preferably, the video acquisition module adopts an infrared fill light camera, has high-definition imaging capabilities in low-light environments, and supports H.265 encoding compression to reduce bandwidth occupancy.

[0018] Preferably, the voice intercom module adopts an adaptive noise reduction algorithm, which can clearly extract human voices in a high-noise environment, and supports voice command recognition to achieve voice control of some operations.

[0019] Preferably, the video analysis module includes a coal flow monitoring submodule, a belt status monitoring submodule, a foreign object recognition submodule and a fire warning submodule;

[0020] The coal flow monitoring submodule is used to detect coal flow anomalies;

[0021] The belt status monitoring submodule is used to identify belt deviation, slippage, and tearing faults;

[0022] The foreign object recognition submodule is used to detect non-coal foreign objects on the conveyor belt;

[0023] The fire warning submodule uses thermal imaging analysis to detect conveyor belt overheating or fire hazards in advance.

[0024] Preferably, the network communication module adopts a dual-network redundant architecture, and automatically switches to the 5G wireless network when the wired network fails to ensure uninterrupted communication.

[0025] Preferably, the alarm module supports a hierarchical alarm mechanism, specifically including:

[0026] Level 1 alarm, representing a minor abnormality, only records the log and notifies the operator;

[0027] Level 2 alarm, representing a medium risk, triggers an audible and visual alarm and notifies relevant personnel;

[0028] Level 3 alarm indicates a serious fault, which will automatically cause the system to shut down for protection and push the alarm information to the management level.

[0029] Preferably, the mobile terminal access module adopts an encrypted communication protocol to ensure data transmission security, and supports role-based authority management to limit the access scope of different users.

[0030] Preferably, the power management module includes a battery, a solar auxiliary power supply unit and an intelligent power consumption management submodule;

[0031] The battery provides at least 2 hours of backup power;

[0032] The solar auxiliary power supply unit is used to supplement power when there is sufficient sunlight;

[0033] The intelligent power consumption management submodule dynamically adjusts the power supply strategy of each module according to the system load.

[0034] Compared with the prior art, this application has at least the following beneficial effects:

[0035] This invention significantly improves the safety and operational efficiency of the coal conveying system by integrating high-definition video monitoring, intelligent analysis, and real-time voice intercom technology. The system uses a deep learning algorithm to monitor belt status in real time, proactively identifying faults such as deviation, coal blockage, and tearing, mitigating unexpected incidents. Full-duplex, noise-reducing voice intercom functionality ensures efficient communication between the site and the control center, significantly accelerating emergency response. Furthermore, the system supports mobile terminal access and digital twin technology, facilitating remote monitoring and predictive maintenance, effectively reducing operational costs.

[0036] The system's innovation lies in its closed-loop management of "intelligent monitoring - real-time warning - coordinated response," making it suitable for a variety of coal transportation scenarios, including power plants, coal mines, and ports. Compared with traditional methods, it significantly improves fault identification accuracy and greatly shortens average fault resolution time, delivering significant economic and social benefits, providing a reliable intelligent solution for the coal transportation industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] To more intuitively illustrate the prior art and the present application, exemplary drawings are provided below. It should be understood that the specific shapes and structures shown in the drawings should not generally be considered as limiting conditions for implementing the present application; for example, based on the technical concepts disclosed in this application and the exemplary drawings, those skilled in the art are capable of easily making routine adjustments or further optimizations to the addition / reduction / attribution division, specific shapes, positional relationships, connection methods, dimensional ratios, etc. of certain units (components).

[0038] Figure 1 This is a module diagram of a visual voice intercom system for coal transportation in this application. DETAILED DESCRIPTION

[0039] The present application will be further described below in detail through specific embodiments in conjunction with the accompanying drawings.

[0040] like Figure 1 As shown, a visual voice intercom system for coal transportation includes a central control module, a video acquisition module, an audio acquisition module, a voice intercom module, a video analysis module, a data storage module, a network communication module, an alarm module, a mobile terminal access module and a power management module;

[0041] The central control module is used to coordinate the operation of each module in the system, process data communication, and provide a human-computer interaction interface;

[0042] The video acquisition module includes multiple cameras, which are deployed at key locations along the coal conveyor belt, such as the belt drive pulley location and locations prone to failure. The cameras can also be arranged according to the on-site conditions and are used to collect real-time video data of the coal conveyor. The cameras are high-definition cameras to ensure the clarity of the image acquisition.

[0043] The audio acquisition module includes multiple noise-canceling microphones, which are arranged along the coal conveyor belt. The noise-canceling microphones are used to collect on-site voice signals and have an echo cancellation function.

[0044] The voice intercom module supports full-duplex communication (i.e., two-way real-time communication between the control center and on-site personnel), enabling real-time voice interaction between the control center and on-site personnel;

[0045] The video analysis module uses a deep learning algorithm to monitor the operating status of the coal conveyor belt in real time to identify faults such as abnormal coal flow, belt deviation, coal blockage, and tearing.

[0046] The data storage module is used to store video, audio and system operation logs, and can support historical data backtracking;

[0047] The network communication module uses a combination of industrial Ethernet and 5G wireless communication to ensure the real-time and reliability of data transmission;

[0048] The alarm module is used to send out sound and light alarm information. When an abnormal situation is detected during the coal transportation process, the alarm module is triggered;

[0049] The mobile terminal access module is used to support mobile devices such as mobile phones and tablets to access the system, so that staff can achieve remote monitoring and intercom functions;

[0050] The power management module provides redundant power supply solutions (multiple power supply modes) to ensure that the system can maintain key functions in the event of a power outage.

[0051] The central control unit serves as the brain of the system, coordinating the operation of each module and providing a human-machine interface. The video acquisition module uses a high-definition camera to monitor the coal conveyor belt in real time, ensuring coverage without blind spots. The audio acquisition module uses a noise-canceling microphone to clearly pick up audio even in noisy environments. The voice intercom module enables real-time, two-way communication between the control center and on-site personnel. The video analysis module uses existing video algorithms to automatically identify abnormal conditions such as belt deviation and coal blockage. The data storage module stores operational data over the long term for retrospective analysis. The network communication module ensures data transmission reliability through dual wired / wireless channels. The alarm module implements intelligent hierarchical early warning, the mobile terminal access module supports remote monitoring, and the power management module ensures uninterrupted system operation. This architecture enables intelligent monitoring and emergency response during the coal conveying process.

[0052] The video acquisition module uses an infrared fill-light camera, which has high-definition imaging capabilities in low-light environments and supports H.265 encoding compression to reduce bandwidth usage. The hardware configuration of video surveillance was optimized during the implementation of this solution. The use of an infrared fill-light camera can maintain high-definition imaging quality in low-light environments such as underground coal mines. H.265 encoding technology increases the video stream compression rate by 50%, significantly reducing network bandwidth requirements. The camera has a wide dynamic range of 120dB and can clearly present details in both dark and bright areas of the belt. The dustproof and waterproof casing design adapts to the harsh environment of the coal transportation site, and the pan-tilt mechanism supports remote control of rotation and zoom. This solution solves the pain points of traditional monitoring in dark environments, such as blurred imaging and excessive data volume, and provides high-quality video sources for subsequent intelligent analysis.

[0053] The voice intercom module adopts an adaptive noise reduction algorithm, which can clearly extract human voices in high-noise environments, and supports voice command recognition to achieve voice control of some operations.

[0054] This technical solution has improved voice communication quality during implementation. The system utilizes multiple microphones combined with beamforming technology to effectively suppress the steady-state noise generated by the conveyor belt. An adaptive noise reduction algorithm separates human voices from ambient noise in real time. The voice intercom module also features echo cancellation, which prevents repeated pickup of speaker sound. The voice command recognition function allows operators to control the system with voice commands such as "Start belt 3" and "Pause conveying," improving operational convenience. This technology maintains voice clarity even in 90dB noise levels, fundamentally reversing the poor communication performance of traditional intercoms.

[0055] The video analysis module includes a coal flow monitoring submodule, a belt status monitoring submodule, a foreign object recognition submodule and a fire warning submodule;

[0056] The coal flow monitoring submodule is used to detect coal flow anomalies;

[0057] The belt status monitoring submodule is used to identify belt deviation, slippage, and tearing faults;

[0058] The foreign object recognition submodule is used to detect non-coal foreign objects on the conveyor belt;

[0059] The fire warning submodule uses thermal imaging analysis to detect conveyor belt overheating or fire hazards in advance.

[0060] The coal flow monitoring submodule calculates coal flow through image recognition and triggers alarms when anomalies occur. The belt status monitoring submodule employs an edge detection algorithm to identify belt deviation with an accuracy of ±2cm. The foreign object recognition submodule detects foreign objects such as metal and stone through material analysis with an accuracy rate exceeding 95%. The fire warning submodule combines visible light and thermal imaging cameras to provide 10-minute advance warning of overheating risks. Each submodule shares GPU computing resources, resulting in analysis latency of less than 200ms, achieving a technological leap from passive monitoring to active prevention.

[0061] The network communication module adopts a dual-network redundant architecture, and automatically switches to the 5G wireless network when the wired network fails to ensure uninterrupted communication. The system deploys industrial Ethernet and 5G wireless networks at the same time, and detects the network status in real time through heartbeat packets. The specific parameters can be implemented as follows: When a wired network interruption is detected, it automatically switches to the 5G channel within 50ms, and the switching process does not affect the video stream transmission. The 5G module supports NSA / SA dual-mode and can still maintain a transmission rate of more than 80Mbps in complex industrial environments. Network encryption uses IPsec VPN tunnels to prevent data from being eavesdropped to meet the strict real-time requirements of the coal transportation system.

[0062] The alarm module supports a hierarchical alarm mechanism, specifically including:

[0063] Level 1 alarm, representing a minor abnormality, only records the log and notifies the operator;

[0064] Level 2 alarm, representing a medium risk, triggers an audible and visual alarm and notifies relevant personnel;

[0065] Level 3 alarm indicates a serious fault, which will automatically cause the system to shut down for protection and push the alarm information to the management level.

[0066] As one of the implementation methods of the alarm module, it has the following features: Level 1 alarm is for conditions such as slight uneven coal flow, which only makes log records; Level 2 alarm is such as belt deviation of 5-10cm, which triggers on-site sound and light alarms and notifies the team leader by SMS; Level 3 alarm is such as belt tearing or fire, which immediately links to shutdown and calls the emergency team.

[0067] The mobile terminal access module adopts an encrypted communication protocol to ensure data transmission security, and supports role-based authority management to limit the access scope of different users.

[0068] For example, the encrypted communication protocol uses the national SM4 encryption for data transmission, and each login requires a dynamic verification code. Permission management is broken down into six roles, including monitor, maintenance worker, and administrator, with restrictions on camera access and intercom permissions for each role. The mobile app supports an electronic fence function, automatically disconnecting devices when they leave the plant area. Access logs record complete operation traces, meeting the requirements of Information Security Protection 2.0. This solution strikes a balance between convenience and security, allowing managers to monitor coal transportation status anytime, anywhere.

[0069] The power management module includes a battery, a solar auxiliary power supply unit and an intelligent power consumption management submodule;

[0070] The battery provides at least 2 hours of backup power;

[0071] The solar auxiliary power supply unit is used to supplement power when there is sufficient sunlight;

[0072] The intelligent power consumption management submodule dynamically adjusts the power supply strategy of each module according to the system load.

[0073] After a utility power outage, the battery can maintain system operation for two hours (or other durations depending on demand, cost, and specific requirements). Key modules utilize a dual-power design. The solar power supply unit includes a maximum power point tracking (MPPT) controller. The power management submodule prioritizes power supply for each device based on its importance, prioritizing the operation of cameras and communication modules during an alarm. Real-time battery health monitoring provides early warning of energy storage degradation. This design enables the system to maintain basic monitoring capabilities for 72 hours even in extreme power conditions.

[0074] The technical features of the above embodiments can be combined arbitrarily (as long as there is no contradiction in the combination of these technical features). In order to make the description concise, not all possible combinations of the technical features in the above embodiments are described; these embodiments that are not explicitly written should also be considered to be within the scope of this specification.

Claims

1. A visual voice intercom system for coal transportation, characterized in that: It includes central control module, video acquisition module, audio acquisition module, voice intercom module, video analysis module, data storage module, network communication module, alarm module, mobile terminal access module and power management module; The central control module is used to coordinate the operation of each module in the system, process data communication, and provide a human-computer interaction interface; The video acquisition module includes multiple cameras, which are deployed at key locations along the coal conveyor belt and are used to collect real-time video data of the coal conveying site; The audio acquisition module includes multiple noise reduction microphones, which are used to collect live voice signals and have echo cancellation function; The voice intercom module supports full-duplex communication, enabling real-time voice interaction between the control center and on-site personnel; The video analysis module uses a deep learning algorithm to monitor the operating status of the coal conveyor belt in real time to identify coal flow anomalies, belt deviation, coal blockage, and tearing faults; The data storage module is used to store video, audio and system operation logs, and can support historical data backtracking; The network communication module uses a combination of industrial Ethernet and 5G wireless communication to ensure the real-time and reliability of data transmission; The alarm module is used to send out sound and light alarm information. When an abnormal situation is detected during the coal transportation process, the alarm module is triggered; The mobile terminal access module is used to support mobile devices such as mobile phones and tablets to access the system and realize remote monitoring and intercom; The power management module provides a redundant power supply solution to ensure that the system can maintain key functions in the event of a power outage.

2. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The video acquisition module uses an infrared fill light camera, has the imaging capability in low-light environments, and supports H.265 encoding compression to reduce bandwidth usage.

3. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The voice intercom module adopts an adaptive noise reduction algorithm, which can clearly extract human voices in high-noise environments, and supports voice command recognition to achieve voice control of some operations.

4. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The video analysis module includes a coal flow monitoring submodule, a belt status monitoring submodule, a foreign object recognition submodule and a fire warning submodule; The coal flow monitoring submodule is used to detect coal flow anomalies; The belt status monitoring submodule is used to identify belt deviation, slippage, and tearing faults; The foreign object recognition submodule is used to detect non-coal foreign objects on the conveyor belt; The fire warning submodule uses thermal imaging analysis to detect conveyor belt overheating or fire hazards in advance.

5. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The network communication module adopts a dual-network redundant architecture, which automatically switches to the 5G wireless network when the wired network fails to ensure uninterrupted communication.

6. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The alarm module supports a hierarchical alarm mechanism, specifically including: Level 1 alarm, representing a minor abnormality, only records the log and notifies the operator; Level 2 alarm, representing a medium risk, triggers an audible and visual alarm and notifies relevant personnel; Level 3 alarm indicates a serious fault, which will automatically cause the system to shut down for protection and push the alarm information to the management level.

7. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The mobile terminal access module adopts an encrypted communication protocol to ensure data transmission security, and supports role-based authority management to limit the access scope of different users.

8. The visual voice intercom system for coal transportation according to claim 1 is characterized in that: The power management module includes a battery, a solar auxiliary power supply unit and an intelligent power consumption management submodule; The battery provides at least 2 hours of backup power; The solar auxiliary power supply unit is used to supplement power when there is sufficient sunlight; The intelligent power consumption management submodule dynamically adjusts the power supply strategy of each module according to the system load.

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