Linkage dust removal device and method based on deposited dust sensor

Abstract

The invention relates to a linkage dust removal device and method based on a deposited dust sensor, and belongs to the technical field of industrial dust removal. Aiming at the problems of response lag and resource waste caused by the fact that a traditional dust removal device cannot monitor the weight of deposited dust in real time, and an existing sensor cannot detect the weight of the deposited dust and is complex in wiring, the device comprises a deposited dust sensor, a linkage control unit, an electric valve, a dust flushing device, an infrared pedestrian detection sensor and a power module; the method comprises the steps of collecting deposited dust weight data in real time, continuously triggering a dust removal instruction in an over-limit manner, and safely interrupting operation when personnel approach. High-pressure flushing is accurately triggered through linkage of deposited dust weight dynamic monitoring and intelligent control; the deployment difficulty is reduced by adopting wireless communication and modular design, and the adaptability is improved by combining multi-mode operation. The dust explosion risk is effectively prevented, and the dust removal operation safety and the resource utilization efficiency are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of industrial dust removal and relates to a linkage dust removal device and method based on a deposited dust sensor. Background Art

[0002] In industrial production environments, the continuous accumulation of deposited dust has become a major safety hazard, causing explosions, shortening equipment lifespan, and endangering the health of workers. Traditional dust removal systems typically utilize timed spray systems or manually operated dust flushing equipment. This passive dust removal method lacks real-time awareness of dust accumulation, resulting in significant lags in cleanup operations. When dust accumulation reaches a critical level, failure to initiate dust removal procedures promptly often leads to safety incidents. Furthermore, fixed-cycle dust removal operations can lead to excessive consumption of water and energy.

[0003] While some existing dust removal equipment incorporates dust monitoring capabilities, the sensors used are primarily designed to detect the concentration of airborne particulate matter and are unable to accurately quantify changes in the mass of deposited dust. Such devices typically utilize wired signal transmission, which presents challenges such as fragility and maintenance difficulties in complex working conditions like coal mine tunnels and chemical plants. Furthermore, conventional systems lack intelligent response mechanisms, making it impossible to monitor dust removal performance in real time after the action is triggered. Furthermore, they lack personnel safety protection features, severely limiting the reliability and adaptability of dust control systems.

[0004] Current industrial scenarios urgently require an integrated dust removal solution with real-time monitoring of deposition quality, intelligent dust removal decision-making, and safety interlock protection. This solution must overcome the bottlenecks of traditional weight detection technology to accurately sense the dynamic changes in deposited dust. Wireless communication and modular design should also simplify deployment, ultimately establishing a dual-security system for preventative dust removal and emergency response. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a linked dust removal device and method based on a deposited dust sensor, which automatically triggers the dust removal action by real-time monitoring of the weight of deposited dust, thereby effectively preventing the risk of dust explosion.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A linked dust removal device based on a dust deposition sensor, comprising:

[0008] The dust deposition sensor 1 is installed in the dust-prone area and is used to detect the weight data of the deposited dust in real time;

[0009] A linkage control unit 2 is communicatively connected to the dust deposition sensor 1 and has a built-in threshold comparison module for receiving and processing the weight data;

[0010] The electric valve 3 is connected to the linkage control unit 2 and is used to receive a dust removal trigger instruction;

[0011] The dust flushing device 4 includes a high-pressure water pipe and a flushing nozzle, and is connected to the fluid source through the electric valve 3;

[0012] an infrared pedestrian detection sensor 5 , which is in communication with the linkage control unit 2 and is used to detect a person approaching signal;

[0013] Power module 6, providing power to each component through cables 7;

[0014] The linkage control unit 2 is configured to trigger the electric valve 3 to open when it detects that the weight data exceeds a preset threshold three times in a row, and to suspend the dust removal operation after receiving an interrupt signal from the infrared pedestrian detection sensor 5 .

[0015] Furthermore, the power module 6 includes an explosion-proof lithium battery pack, supports low-power mode operation, and is equipped with an external wired power supply interface. The cable 7 uses an explosion-proof aviation plug connector to achieve power supply and communication connection between devices.

[0016] Furthermore, the linkage control unit 2 includes three operation modes:

[0017] Automatic mode, triggering dust removal based on real-time data from the dust deposition sensor 1;

[0018] Manual mode: remotely control the dust removal operation via a wireless remote control;

[0019] Inspection mode, the dust flushing device is activated regularly based on the preset time period.

[0020] Furthermore, the preset threshold value is set in a range of 20 to 100 g, and the linkage control unit 2 includes a dust removal termination condition judgment module, which closes the electric valve 3 when it is detected that the weight data drops below 70% of the threshold value.

[0021] Furthermore, the detection range of the infrared pedestrian detection sensor 5 is 3 to 5 meters, and the delayed restart time after the interruption is triggered can be set to 30 to 300 seconds.

[0022] A linked dust removal method based on the device comprises the following steps:

[0023] Data collection steps: periodically obtaining weight data of deposited dust through the deposited dust sensor 1;

[0024] Threshold determination step: the linkage control unit 2 compares the current weight data with the preset threshold value, and triggers the dust removal instruction when the limit is exceeded three times in a row;

[0025] Dust removal execution steps: start the corresponding dust flushing device 4 according to the preset working mode, and activate the self-cleaning function of the dust deposition sensor 1 at the same time;

[0026] Safety interruption step: when the infrared pedestrian detection sensor 5 detects a person approaching, the dust removal is suspended and the delay counter is started;

[0027] Status recovery step: When the safety conditions are met, the interrupted dust removal operation is automatically restored.

[0028] Furthermore, the continuous detection mechanism used in the threshold determination step satisfies the following conditional formula:

[0029]

[0030] Among them, w i It represents the weight value of three consecutive tests, T is the preset threshold parameter, and i is the sequential index of the number of tests, i=1,2,3.

[0031] Furthermore, in the dust removal execution step, the working pressure range of the dust flushing device 4 is 2 to 8 MPa, and the flushing angle is adjustable from 0 to 180° through the electric rotating nozzle.

[0032] Furthermore, the self-cleaning function includes: after each dust removal operation is completed, triggering a compressed air pulse to remove residual dust on the measuring surface of the deposited dust sensor 1.

[0033] Furthermore, the preset working mode includes a graded response mechanism. When the detected weight value exceeds 200% of the threshold, it automatically switches to the pressurized flushing mode and sends an emergency alarm signal.

[0034] The beneficial effects of the present invention are:

[0035] (1) The real-time dynamic monitoring of dust weight by the dust deposition sensor breaks through the limitations of traditional suspended dust detection and realizes direct quantitative analysis of the amount of accumulated dust. When the detection value exceeds the limit continuously, the dust removal action is automatically triggered, fundamentally solving the response lag problem caused by traditional timed dust removal or manual intervention, and significantly reducing the risk of dust explosion accidents.

[0036] (2) Wireless communication and integrated power supply design eliminates wiring problems in complex industrial scenarios. The explosion-proof power module supports wired / wireless dual-mode power supply, and is combined with aviation plug connectors to achieve rapid assembly and disassembly, enabling flexible deployment in harsh environments such as coal mine tunnels and chemical workshops, significantly reducing maintenance costs.

[0037] (3) Innovative integration of infrared personnel detection and dust removal execution links. When human activity occurs in the work area, high-pressure flushing is immediately interrupted and intelligently restarted with a delayed delay. This safety interlock mechanism effectively prevents harm to personnel during dust removal operations while ensuring production continuity.

[0038] (4) It provides three operation modes: automatic response, remote manual, and scheduled inspection, which can be switched dynamically according to the on-site working conditions. By setting the graded dust removal threshold and self-cleaning mechanism, it can reduce water and energy consumption while ensuring the dust removal effect, and achieve the coordinated optimization of preventive maintenance and on-demand response.

[0039] (5) Original real-time verification mechanism for dust removal effect: When the dust weight drops below the safety threshold, the operation is automatically terminated, forming a closed-loop control process of "monitoring-triggering-execution-verification", which completely solves the defect of uncontrollable operation effect of traditional dust removal systems and extends the service life of the equipment.

[0040] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0042] Figure 1 It is a structural schematic diagram of the device of the present invention;

[0043] Figure 2 This is the workflow diagram of the sensor linkage control unit;

[0044] Figure 3 This is the workflow diagram for timing the start of the dust flushing device.

[0045] Reference numerals: 1 - dust deposition sensor, 2 - linkage control unit, 3 - electric valve, 4 - dust flushing device, 5 - infrared pedestrian detection sensor, 6 - power module, 7 - cable. DETAILED DESCRIPTION

[0046] The following describes the embodiments of the present invention by means of specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0047] Among them, the accompanying drawings are only for illustrative purposes and represent only schematic diagrams rather than actual pictures, and should not be understood as limiting the present invention. In order to better illustrate the embodiments of the present invention, some parts of the accompanying drawings may be omitted, enlarged or reduced, and do not represent the dimensions of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted in the accompanying drawings.

[0048] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "front", "back", etc. indicating directions or positional relationships, they are based on the directions or positional relationships shown in the drawings. They 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 direction, be constructed and operate in a specific direction. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0049] 1. Device part

[0050] A linked dust removal device based on a dust deposit sensor comprises a dust deposit sensor (model GFC100(A)), a linked control unit, an electric valve, a dust flushing device, an infrared pedestrian detection sensor, a power module, and cables. The dust deposit sensor is installed in an area prone to dust accumulation and is used to detect the weight of deposited dust in real time and transmit the data to the linked control unit via a communication line. The linked control unit has a built-in threshold comparison module. When the received dust weight data exceeds a set threshold, the electric valve is automatically opened to trigger the dust flushing device. The dust flushing device includes a high-pressure water pipe and a flushing nozzle, which are connected to the linked control unit via the electric valve. The infrared pedestrian detection sensor can detect the approach of a person and automatically stop dust flushing when a person approaches, and restart after a delay. The power module has a built-in battery that can power the linked control unit. At the same time, the dust deposit sensor, the electric valve, and the infrared pedestrian detection sensor can be powered and communicated through the aviation plug connector powered by the linked control unit. The power module uses an explosion-proof lithium battery pack and supports low-power mode. It also supports external wired power supply and can be continuously powered by connecting to other existing power modules. The cable mainly provides power and communication between devices.

[0051] 2. Methods

[0052] The linked dust removal method based on the device comprises the following steps:

[0053] Data collection and transmission: The dust deposition sensor periodically detects the dust weight and sends the data to the linkage control unit through the communication line;

[0054] Threshold judgment: The linkage control unit compares the current dust weight with the preset threshold. If it exceeds the limit, it enters the dust removal mode;

[0055] Dust removal trigger: The linkage control unit selects the dust flushing mode according to the on-site environment, opens the corresponding electric valve to perform dust removal, and simultaneously removes dust from the electronic balance of the deposited dust sensor;

[0056] Dust removal termination: When the dust weight drops below 70% of the threshold, the linkage control unit closes the electric valve and stops dust removal;

[0057] Safety interruption: If a person approaches during the dust removal process, an interruption signal is sent through the infrared pedestrian detection sensor, dust removal is paused and a delayed restart is initiated.

[0058] Furthermore, the linkage control unit supports multi-mode operation:

[0059] Automatic mode: completely dependent on sensor data trigger;

[0060] Manual mode: remotely control dust removal via the remote control;

[0061] Inspection mode: start the dust flushing device regularly to prevent dust accumulation.

[0062] like Figure 1 As shown, the dust accumulation sensor 1 is installed in areas prone to dust accumulation, such as conveyor transfer points, roadway corners, and return air corners. It is connected to the linkage control unit 2 via a communication cable 7. The linkage control unit 2 has a built-in microprocessor and a preset dust weight threshold of 50g (adjustable). When the detection value exceeds the limit, the linkage control unit 2 selects to activate the electric valve 3 according to a preset mode and activates the dust flushing device 4 through the electric valve 3. The power module 6 supplies power to the linkage control unit 2 via cable 7. The linkage control unit 2 also supplies power and communication to the dust accumulation sensor 1, the electric valve 3, and the infrared pedestrian detection sensor 5 through cable 7.

[0063] like Figure 2 As shown, the linkage control unit 2 periodically receives sensor data. If the detection value exceeds the limit three times in a row, the dust removal action is triggered to avoid misjudgment. During the dust removal process, the infrared pedestrian detection sensor 5 monitors human activities in real time, suspends the operation after a trigger interruption, and automatically resumes after one minute (the time can be set).

[0064] This invention adopts an explosion-proof design, suitable for coal mine gas environments; the power module 6 supports wired power supply for charging at any time, extending battery life. Through the above implementation, the thickness of deposited dust can be effectively controlled, dust problems caused by vibration can be prevented, and safe production can be guaranteed.

[0065] Example 1: Automatic mode closed-loop dust removal process

[0066] The dust deposition sensor collects the dust deposition weight at the belt conveyor turning point every 5 minutes;

[0067] The linkage control unit continuously receives detection data and triggers the automatic dust removal mode when the weight values ​​measured for three consecutive times exceed the preset threshold of 50g;

[0068] The opening angle of the electric valve is adjusted in stages according to the over-limit range: when the over-limit is 50%-100%, it is opened 50%, and when the over-limit is more than 100%, it is fully opened;

[0069] The dust flushing device sprays fan-shaped water mist at a pressure of 5MPa and continues flushing until the sensor detection weight drops below 35g;

[0070] After dust removal is completed, the linkage control unit sends a pulse signal to activate the built-in air gun of the deposited dust sensor for self-cleaning.

[0071] Example 2: Personnel safety interruption and recovery process

[0072] After the dust removal operation is started, the infrared sensor scans the human activities within 3 meters of the operation area at a frequency of 2Hz;

[0073] When the human body heat source signal is detected for 0.5 seconds, a third-level interrupt instruction is immediately sent to the linkage control unit;

[0074] The linkage control unit closes the electric valve within 100ms and records the current dust removal progress parameters;

[0075] During the interruption period, a 90-second delay counter is started to detect the personnel retention status every 10 seconds;

[0076] When the personnel leave and the delay ends, the original dust removal program will be automatically restored until the operation is completed.

[0077] Example 3: Multi-mode collaborative operation process

[0078] Daytime operation mode:

[0079] 08:00-18:00: Enable automatic mode to perform real-time monitoring and response;

[0080] When the weight value reaches 150% of the threshold, a text message alarm will be sent to the management personnel simultaneously;

[0081] Nightly maintenance mode:

[0082] Scheduled inspections start at 20:00, and preventive dust removal is performed for 15 minutes every 2 hours;

[0083] The dust removal pressure is reduced to 3MPa to reduce noise pollution;

[0084] Emergency Response Mode:

[0085] After receiving the remote control command, manually start the directional flushing with the pressure increased to 8MPa;

[0086] Disable the safety interrupt function in an emergency state to force the dust removal operation to complete.

[0087] Example 4: Deployment process for adaptability to harsh environments

[0088] In the explosion-proof area of ​​the return air tunnel of a coal mine:

[0089] It is powered by intrinsically safe explosion-proof lithium batteries and the cables are sheathed in metal bellows.

[0090] Data is transmitted wirelessly between the sensor and the control unit via ZigBee;

[0091] When an external power interruption is detected:

[0092] Automatically switch to low power mode, and the sampling frequency is reduced to once per hour;

[0093] When the battery power is lower than 20%, the dust flushing function is turned off and only monitoring and warning are retained;

[0094] When the ambient humidity exceeds 90%:

[0095] Start the sensor heating and dehumidification module to keep the detection surface dry;

[0096] The linkage control unit automatically corrects the weight detection error caused by humidity interference.

[0097] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. A linked dust removal device based on a dust deposition sensor, characterized in that: include: A dust deposition sensor (1) is installed in an area prone to dust accumulation and is used to detect weight data of deposited dust in real time; A linkage control unit (2) is communicatively connected to the dust deposition sensor (1), and has a built-in threshold comparison module for receiving and processing the weight data; An electric valve (3) is control-connected to the linkage control unit (2) and is used to receive a dust removal trigger instruction; A dust flushing device (4), comprising a high-pressure water pipe and a flushing nozzle, connected to a fluid source via the electric valve (3); an infrared pedestrian detection sensor (5), which is in communication with the linkage control unit (2) and is used to detect a person approaching signal; A power module (6) provides power to each component via cables (7); The linkage control unit (2) is configured to trigger the electric valve (3) to open when it detects that the weight data exceeds a preset threshold value three times in a row, and to suspend the dust removal operation after receiving an interrupt signal from the infrared pedestrian detection sensor (5).

2. The linked dust removal device based on the deposited dust sensor according to claim 1, characterized in that: The power module (6) includes an explosion-proof lithium battery pack, supports low-power mode operation, and is equipped with an external wired power supply interface. The cable (7) uses an explosion-proof aviation plug connector to achieve power supply and communication connection between devices.

3. The linked dust removal device based on the deposited dust sensor according to claim 1, characterized in that: The linkage control unit (2) includes three operating modes: Automatic mode, triggering dust removal based on real-time data from the dust deposition sensor (1); Manual mode: remotely control the dust removal operation via a wireless remote control; Inspection mode, the dust flushing device is activated regularly based on the preset time period.

4. The linked dust removal device based on the deposited dust sensor according to claim 1, characterized in that: The preset threshold value has a setting range of 20 to 100 g, and the linkage control unit (2) includes a dust removal termination condition judgment module, which closes the electric valve (3) when it is detected that the weight data drops below 70% of the threshold value.

5. The linked dust removal device based on the deposited dust sensor according to claim 1, characterized in that: The detection range of the infrared pedestrian detection sensor (5) is 3 to 5 meters, and the delayed restart time after triggering the interruption can be set to 30 to 300 seconds.

6. A linked dust removal method based on the device according to any one of claims 1 to 5, characterized in that: The following steps are involved: Data collection steps: periodically obtaining weight data of deposited dust through a deposited dust sensor (1); Threshold determination step: the linkage control unit (2) compares the current weight data with a preset threshold value, and triggers a dust removal instruction when the threshold value is exceeded three times in a row; Dust removal execution steps: starting the corresponding dust flushing device (4) according to the preset working mode, and activating the self-cleaning function of the dust deposition sensor (1); Safety interruption step: when the infrared pedestrian detection sensor (5) detects a person approaching, dust removal is suspended and a delay counter is started; Status recovery step: When the safety conditions are met, the interrupted dust removal operation is automatically restored.

7. The linked dust removal method according to claim 6, characterized in that: The continuous detection mechanism used in the threshold determination step satisfies the following conditional formula: Among them, w i It represents the weight value of three consecutive tests, T is the preset threshold parameter, and i is the sequential index of the number of tests, i=1,2,3.

8. The linked dust removal method according to claim 6, characterized in that: In the dust removal execution step, the working pressure range of the dust flushing device (4) is 2 to 8 MPa, and the flushing angle is adjustable from 0 to 180 degrees through the electric rotating nozzle.

9. The linked dust removal method according to claim 6, characterized in that: The self-cleaning function comprises: after each dust removal operation is completed, triggering a compressed air pulse to clear the residual dust on the measuring surface of the deposited dust sensor (1).

10. The linked dust removal method according to claim 6, characterized in that: The preset working mode includes a graded response mechanism. When the detected weight value exceeds 200% of the threshold value, it automatically switches to the pressurized flushing mode and sends an emergency alarm signal.

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