Intelligent spraying three-dimensional sealing dust-settling system of coal mining machine and control method

Abstract

This invention relates to a three-dimensional enclosed dust suppression system and control method for intelligent spraying on coal mining faces, belonging to the field of coal mine dust suppression control. It includes a coal mining machine, an onboard spraying system, and a tracking spraying system. The coal mining machine transports coal via a scraper conveyor. Rocker arms are located at both ends of the coal mining machine, with drums for coal mining mounted on the rocker arms. The onboard spraying system is positioned at the root of the rocker arms to enclose the drums at both ends of the coal mining machine. The tracking spraying system is mounted on the scraper conveyor and located beside the coal mining machine. The tracking spraying system is connected to a control system to activate the spraying devices near the front and rear drums of the coal mining machine in real time, guiding the dust-laden airflow generated by the coal mining machine towards the coal face. The onboard and tracking spraying systems create a three-dimensional enclosed space around the coal mining machine, preventing dust from spreading throughout the working area with the airflow, thus improving the overall dust suppression effect.

Description

Technical Field

[0001] This invention belongs to the field of coal mine face spray dust suppression control, and relates to a three-dimensional closed spray dust suppression system and control method for coal mining machines. Background Technology

[0002] As the core equipment of fully mechanized coal mining faces, the coal mining machine, together with the hydraulic support and scraper conveyor, forms the technical foundation of modern fully mechanized mining technology. Although this mechanized coal mining system significantly improves the efficiency of raw coal mining (the output of a single fully mechanized mining face can reach more than 3 million tons / year), the dust pollution problem generated in the actual production process is becoming increasingly prominent.

[0003] The dust generation mechanism mainly originates from primary coal dust (accounting for approximately 60%) generated during coal cutting by the cutting teeth and secondary coal dust generated by the impact of falling coal. Test data shows that the total dust concentration at the working face can reach 1500-3000 mg / m³ when the coal mining machine's drum is in operation. 3 The proportion of respirable dust exceeded 40%, far exceeding the 10 mg / m³ limit stipulated in the "Coal Mine Safety Regulations". 3 Standard. This type of inhalable dust with a particle size of less than 7.07 μm not only causes pneumoconiosis (accounting for over 75% of occupational diseases in coal mines), but also has a lower explosive limit concentration (35 g / m³). 3 This poses a significant safety hazard.

[0004] To address the hazards of high-concentration dust in fully mechanized mining faces, the main prevention and control measures include coal seam water injection, ventilation and dust removal, spray dust suppression, wet dust collection, personal protective equipment, and physical and chemical dust suppression. However, since fully mechanized mining faces are open production spaces, dust generated by coal cutting machines and hydraulic support operations can easily spread to the entire working space with the airflow. The above dust control measures can only reduce the dust concentration at fully mechanized mining faces to a certain extent, and the problem of high-concentration dust pollution at fully mechanized mining faces remains very serious. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a three-dimensional sealed dust suppression system and control method for coal mining machines using an intelligent spray system. This system, employing both an onboard spray system and a tracking spray system, creates a three-dimensional sealed space around the coal mining machine, preventing dust from spreading throughout the working area with the airflow and thus improving the overall dust suppression effect. Furthermore, both the onboard and tracking spray systems are located near the coal mining machine drum, the primary dust source, addressing the dust source problem at its root and preventing the dust suppression effect from decreasing due to dust diffusion.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A three-dimensional sealed dust suppression system for intelligent spraying in coal mining machines includes a coal mining machine, an onboard spraying system, and a tracking spraying system;

[0008] The coal mining machine is transported by a scraper conveyor; and the coal mining machine is equipped with rocker arms at both the front and rear ends, with drums for coal mining mounted on the rocker arms.

[0009] The airborne spray system is located at the root of the rocker arm of the coal mining machine and is used to cover the drums at both ends of the coal mining machine.

[0010] The tracking spray system is installed on the scraper conveyor and located beside the coal mining machine. The tracking spray system is connected to a control system to enable the real-time activation of the spray devices near the front and rear drums of the coal mining machine, so as to guide the dust-laden airflow generated by the coal mining machine to one side of the coal wall, and at the same time form a fog curtain near the front and rear drums of the coal mining machine.

[0011] Optionally, in the intelligent spray three-dimensional closed dust suppression system for coal mining machines according to the present invention, the control system includes a coal mining machine monitoring system and a spray control system. The coal mining machine monitoring system is installed on the coal mining machine and is used to collect the position data of the coal mining machine in real time, and then calculate the spray position and quantity that should be activated.

[0012] The spray control system is installed on the tracking spray system and includes a signal converter and a spray control box. The signal converter is electrically connected to the coal mining machine monitoring system and sends a spray start command to the spray control box at the corresponding location to guide the dust-laden airflow generated by the coal mining machine to one side of the coal wall.

[0013] Optionally, according to the intelligent spray three-dimensional closed dust suppression system for coal mining machines of the present invention, the coal mining machine monitoring system further includes a dust concentration sensor located on the coal mining machine, which collects dust concentration data of the working face in real time and adjusts the number of spray groups in the tracking spray system according to the change of dust concentration at the working face.

[0014] Optionally, in the intelligent spray three-dimensional closed dust suppression system for coal mining machines according to the present invention, both the airborne spray system and the tracking spray system include a spray module;

[0015] The spray module includes a mounting plate and multiple nozzles. One plane of the mounting plate is a spray surface, and multiple spray holes are provided on the spray surface. The interior of the mounting plate is provided with water channels communicating with the spray holes, and the nozzles are respectively disposed in the spray holes.

[0016] The spray holes are equidistantly distributed and inclined with respect to both sides of the center of the mounting plate, and the angle between the axis of the spray hole and the spray surface gradually decreases.

[0017] The mounting plate is also provided with multiple mounting holes to fix the mounting plate to the airborne spray system and the tracking spray system.

[0018] Optionally, in the intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to the present invention, the nozzle includes a nozzle shell and a swirling inner core;

[0019] The nozzle housing has a swirling chamber inside, with an atomizing hole at one end and a water inlet at the other end;

[0020] The swirling inner core is disposed inside the swirling cavity, and the interior of the swirling inner core is provided with at least two spiral swirling channels. The water inlet is connected to the atomizing hole through the swirling channels.

[0021] The swirling channel has an inlet hole at one end near the inlet and an outlet hole at the other end near the atomizing hole. The diameter of the swirling channel gradually decreases from the inlet hole to the outlet hole to increase the flow power of the water flowing out of the swirling channel.

[0022] Optionally, in the intelligent spray three-dimensional closed dust suppression system for coal mining machines according to the present invention, the inner side of the end of the vortex cavity near the water inlet is provided with a first internal thread, and the outer side wall of the vortex inner core is provided with a first external thread. The vortex inner core thread is connected to the vortex cavity through the first internal thread and the first external thread.

[0023] The vortex inner core is also provided with a cross groove or a slot at the center of the end face near the water inlet, for turning the vortex inner core.

[0024] Optionally, in the intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to the present invention, an annular groove is provided on the outer side wall of the swirl inner core near the atomizing hole, and a sealing ring is provided in the annular groove, the sealing ring being interference-fitted with the inner side wall of the swirl cavity.

[0025] Optionally, in the intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to the present invention, the spiral directions of the swirling channels are all oriented in the same direction, and are arranged in a ring array inside the swirling inner core with the center of the swirling inner core as the center.

[0026] Optionally, in the intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to the present invention, a second external thread is provided on a section of the outer side wall of the nozzle housing near the water inlet, and the nozzle housing is connected to the spray module through the second external thread.

[0027] Furthermore, this invention also provides a method for intelligent spray three-dimensional closed dust suppression control of coal mining machines, using the dust suppression system described in the above embodiments and the following steps:

[0028] S1. Activate the onboard spray system to make it move synchronously with the coal mining machine during coal mining operations;

[0029] S2. Based on the real-time location data of the coal mining machine collected by the coal mining machine monitoring system, the location and number of sprayers that should be activated are then calculated.

[0030] S3. The electrical signal calculated by the coal mining machine monitoring system is transmitted to the signal converter, which then sends a spraying command to the tracking spraying system.

[0031] S4. The coal mining machine monitoring system collects real-time dust concentration data from the working face and adjusts the number of spray groups in the tracking spray system according to changes in dust concentration at the working face.

[0032] The beneficial effects of this invention are as follows:

[0033] 1. By using both onboard and tracking spray systems, a three-dimensional enclosed space is created around the coal mining machine, preventing dust from spreading throughout the work area with the airflow and thus improving the overall dust suppression effect. Furthermore, both the onboard and tracking spray systems are located near the coal mining machine drum, the primary dust source, addressing the dust problem at its source and preventing dust spread that could reduce dust suppression effectiveness.

[0034] 2. A radial swirling channel is provided inside the nozzle, and the diameter of the swirling channel gradually decreases from one end of the water inlet to one end of the water outlet. This allows the water flow exiting the swirling channel to effectively increase its water pressure under the dual effects of swirling and reduced flow area. Multiple swirling channels work together to form a vortex in the swirling chamber at one end of the atomizing hole. When it is sprayed out from the atomizing hole, it can effectively achieve the purpose of long range, and ultimately achieve the best dust suppression effect with the least amount of water and the least pressure.

[0035] 3. The spray module in this invention is equipped with multiple dispersed and inclined spray holes. The spray range of the nozzles in the spray holes is adjusted according to the change of the inclination angle of the spray holes, thereby achieving the effectiveness and uniformity of dust suppression and avoiding localized concentrated dust suppression.

[0036] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0037] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein:

[0038] Figure 1 This is a schematic diagram of the operation of the coal mining machine in the intelligent spray three-dimensional closed dust suppression system provided by the present invention;

[0039] Figure 2 This is a schematic diagram of the structure of the coal mining machine in the intelligent spray three-dimensional closed dust suppression system provided by the present invention;

[0040] Figure 3 This is a schematic diagram of the tracking spray system in the intelligent spray three-dimensional closed dust suppression system for coal mining machines provided by the present invention.

[0041] Figure 4 This is a schematic diagram of the structure of the spray module provided by the present invention;

[0042] Figure 5 This is a schematic diagram of the nozzle structure provided by the present invention;

[0043] Figure 6 This is a schematic diagram of the swirling inner core in the nozzle provided by the present invention;

[0044] Figure 7 This is a schematic diagram of the structure of the swirling inner core in the nozzle provided by the present invention, facing the water inlet end;

[0045] Figure 8 This is a schematic diagram of the structure of the swirling inner core facing the atomizing hole in the nozzle provided by the present invention.

[0046] Figure 9 This is a schematic diagram of the swirling channel in the nozzle provided by the present invention.

[0047] Figure label:

[0048] 1-Coal mining machine; 2-Drum; 3-First spray module; 4-Rocker arm; 5-Dust concentration sensor; 6-Tracking spray system;

[0049] 10- Nozzle housing; 11- Swirl chamber; 12- Inlet; 13- Atomizing hole; 14- First internal thread; 15- Second external thread;

[0050] 20-Swirl inner core; 21-Sealing ring; 22-First external thread; 23-Swirl channel; 24-Water inlet; 25-Water outlet; 26-Cross groove;

[0051] 30 - Mounting plate; 31 - Spray nozzle; 32 - Mounting hole;

[0052] 60-Hydraulic support; 61-Signal converter; 62-Spray control box; 63-Second spray module; 64-Water supply pipeline. Detailed Implementation

[0053] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed 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 representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0054] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0055] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship 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 orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0056] Please see Figures 1-3 The diagram shown is a structural schematic, or working schematic, of a three-dimensional sealed dust suppression system for intelligent spraying in a coal mining machine.

[0057] Specifically, it includes a coal mining machine 1, an onboard spray system, and a tracking spray system 6;

[0058] The coal mining machine 1 is transported by a scraper conveyor; and the front and rear ends of the coal mining machine 1 are equipped with rocker arms 4, and the rocker arms 4 are equipped with coal mining drums 2.

[0059] The airborne spray system is installed at the root of the rocker arm 4 of the coal mining machine 1 and is used to cover the drums 2 at both ends of the coal mining machine 1.

[0060] The tracking spray system 6 is mounted on the scraper conveyor via a hydraulic support 60 and is located beside the coal mining machine 1. The tracking spray system 6 is connected to a control system to enable the real-time activation of the spray device near the front and rear drums 2 of the coal mining machine 1, so as to guide the dust-laden airflow generated by the coal mining machine 1 to one side of the coal wall, and at the same time form a fog curtain near the front and rear drums 2 of the coal mining machine 1.

[0061] This invention utilizes an onboard spray system and a tracking spray system 6 to create a three-dimensional enclosed space around the coal mining machine 1, preventing dust from spreading throughout the working space with the airflow and thus improving the overall dust suppression effect. Furthermore, both the onboard spray system and the tracking spray system 6 are located close to the drum 2 of the coal mining machine 1, which is the primary dust source, addressing the dust source problem at its root and preventing the dust suppression effect from decreasing due to dust diffusion.

[0062] like Figure 2 As shown, an onboard spray system is installed at the drum 2 of the coal mining machine 1, using high-pressure air-water atomizing nozzles (pressure ≥8MPa, droplet size 10-30μm) to form an enveloping mist field at the coal-breaking point of the drum 2 cutting teeth. Through dual-fluid atomization technology (water-air mixing ratio 1:5), the droplets are charged (charge ±500mV), enhancing the adsorption capacity for micron-sized dust, achieving a collection efficiency of over 85%. Figure 3 As shown, a tracking spray system 6 is arranged on the scraper conveyor to cover the dust-generating areas of the front and rear drums 2 of the coal mining machine 1 and the dust-generating area of ​​the coal body collapse in the chute below. This achieves automatic spraying to reduce dust generated by the coal cutting of the drums 2 of the coal mining machine 1, thereby reducing the amount of dust generated. At the same time, the spray entrainment effect is used to entrain the dust-laden airflow formed by the collapse of the coal body towards the coal wall, reducing the diffusion of dust and water mist to the pedestrian side and reducing the impact on the workers. In addition, a wireless intelligent following spray system is adopted, which uses sensors to detect the operating position of the coal mining machine 1 and automatically opens the spray at the front and rear drums 2 to achieve following spraying of the dust-generating source of the drums 2 of the coal mining machine 1.

[0063] Furthermore, the control system includes a coal mining machine 1 monitoring system and a spray control system. The coal mining machine 1 monitoring system is installed on the coal mining machine 1 to collect the position data of the coal mining machine 1 in real time, and then calculate the position and number of sprays that should be activated.

[0064] The spray control system is installed on the tracking spray system 6 and includes a signal converter 61 and a spray control box 62. The signal converter 61 uses an industrial-grade PROFIBUS-DP protocol conversion module to convert the RS485 signal (1Mbps baud rate) of the monitoring system into a 24V pulse signal (response time <50ms) recognizable by the spray control box 62. The spray control box 62 has a built-in STM32 main control chip and integrates 18 solenoid valve drive circuits (switching frequency 1kHz), each independently controlling the water pressure (adjustable from 0.5-15MPa) and atomization angle (60-150°) of the nozzle group.

[0065] The signal converter 61 is electrically connected to the monitoring system of the coal mining machine 1 and sends a spray activation command to the corresponding spray control box 62. Upon receiving the command, the corresponding spray control box 62 opens the electric ball valve to initiate dust suppression spraying, guiding the dust-laden airflow generated by the coal mining machine 1 towards one side of the coal face. Based on the location of the coal mining machine 1, the working face is divided into 3m×3m grid units, activating only the spray groups along the dust-laden airflow path (energy saving rate > 40%). The nozzle opening is adjusted in real-time using a PID algorithm (0-100% linear control) to ensure the water mist coverage area and dust concentration (mg / m³) are aligned. 3 ) shows a positive correlation (R) 2 =0.93); control the pressure of the outer nozzle (12MPa) to be higher than that of the inner nozzle (8MPa) to form a pressure gradient difference (ΔP=4MPa), which deflects the dust-laden airflow by 30° to the coal wall side.

[0066] Regarding the layout of the water supply pipeline 64, a DN25 mining high-pressure hose is laid on the outer hanging plate of the scraper conveyor cable trough as the main water supply pipeline, and DN10 branch pipelines are branched off from the DN25 main water supply pipeline to connect to each spraying device. The length of all spraying pipelines is customized according to the path length from the spray control box 62 to the spraying device, ensuring that the pipeline laying and connection are horizontal and vertical, and that the accessories are neat and orderly, meeting the standardized requirements for mine equipment installation.

[0067] The spray control system can automatically track and spray the coal cutting dust source of the coal mining machine 1 drum 2, ensuring that the front and rear drums 2 of the coal mining machine 1 are always within the control range of high-pressure spray. At the same time, it can intelligently adjust the spray quantity according to the changes in dust concentration, thereby achieving efficient dust suppression by the coal mining machine 1 and improving the working conditions of the working face.

[0068] The system spray control parameters can be set separately for different dust generation conditions, such as with and against the wind. The system automatically monitors the operating position of the coal mining machine 1 to determine whether it is cutting coal with or against the wind and its operating speed. At the same time, it determines whether the coal mining machine 1 should stop operating based on its operating speed and decides whether to open the solenoid valve.

[0069] The system uses fully wireless communication, which is stable and reliable. It can also connect to the monitoring substation via RS-485 communication to achieve remote monitoring.

[0070] The control box and electric ball valve are integrated into one unit, resulting in high integration, small size, and easy installation. Each control box comes with one receiver, allowing for installation based on site conditions.

[0071] The control box is powered by a built-in intrinsically safe battery pack with a rated operating voltage of 14.4V DC and an operating current of ≤300mA.

[0072] The electric ball valve is suitable for water pressures of 0.2 to 10 MPa and has a closing time of ≤10 seconds. It can realize high-pressure spray dust suppression in the spray system and improve the efficiency of spray dust suppression.

[0073] Furthermore, such as Figure 2 As shown, the monitoring system of the coal mining machine 1 also includes a dust concentration sensor 5, which is located on the coal mining machine 1. The dust concentration sensor 5 collects the dust concentration data of the working face in real time and adjusts the number of spray groups in the tracking spray system 6 according to the change of dust concentration at the working face.

[0074] This invention allows for the placement of 8-12 explosion-proof dust concentration sensors 5 (range 0-5000 mg / m³) at key locations such as the rocker arm 4 of the coal mining machine, the top cover of the machine body, and the cable trough. 3 With an accuracy of ±3%, a spatial sampling grid (1.5m spacing) is formed. Simultaneously, a charge sensing module is integrated to detect the dust's charge characteristics (±200-500mV), enhancing the ability to identify respirable dust.

[0075] Furthermore, both the airborne spray system and the tracking spray system 6 include spray modules. Taking this invention as an example, the first spray module 3 is located on the coal mining machine 1, and the second spray module 63 is located beside the coal mining machine 1. In fact, the first spray module 3 and the second spray module 63 have the same structure. Specifically:

[0076] like Figure 4 As shown, the spray module includes a mounting plate 30 and multiple nozzles. One plane of the mounting plate 30 is a spray surface, and multiple spray holes 31 are provided on the spray surface. The mounting plate 30 also has water channels communicating with the spray holes 31, and the nozzles are respectively disposed within the spray holes 31. The spray holes 31 are equidistantly distributed and inclined towards both sides of the center of the mounting plate 30, and the angle between the axis of the spray holes 31 and the spray surface gradually decreases. The mounting plate 30 also has multiple mounting holes 32 to fix the mounting plate 32 to the airborne spray system and the tracking spray system 6.

[0077] Specifically, please refer to Table 1:

[0078] Table 1:

[0079]

[0080]

[0081] The spray module of this embodiment integrates multiple mounting holes 32 and nozzles onto a single valve block, making nozzle installation and replacement more convenient and quick. The integrated design also allows for water supply to a large number of nozzles with only one inlet pipe connected to the water channel, ensuring convenient water supply. The nozzles in the multiple spray holes 31 have different orientations and are arranged regularly, resulting in multi-point integrated spray emission. The fan-shaped spray area can surround the dust source at all angles, achieving high dust reduction efficiency. See Table 2 for reference.

[0082] Table 2:

[0083] Coverage uniformity (CV) 35％ 8％ 77％ Near-field dust suppression efficiency 68％ 92％ 35％ Long-field range (coverage at 10m) 42％ 78％ 86％

[0084] In conjunction with the nozzles provided in the aforementioned embodiments, in actual coal mining operations, operators can change the spray range of nozzles at different positions in the spray module, thereby increasing the spraying range of the spray module. This effectively solves the technical problem in the prior art where low system water supply pressure, severe nozzle clogging, and large nozzle diameters result in water flow in a jet-like pattern, with unsatisfactory envelopment angle and atomization effect, leading to the inability to effectively suppress dust.

[0085] Furthermore, such as Figures 5 to 9 As shown, the nozzle includes a nozzle housing 10 and a swirling inner core 20. The nozzle housing 10 has a swirling chamber 11 inside, with an atomizing hole 13 at one end and a water inlet 12 at the other end.

[0086] The swirling inner core 20 is disposed inside the swirling cavity 11, and the interior of the swirling inner core 20 is provided with at least two spiral swirling channels 23. The water inlet 12 is connected to the atomizing hole 13 through the swirling channels 23.

[0087] The swirl channel 23 has an inlet hole 24 near the inlet and an outlet hole 25 near the atomizing hole 13. The diameter of the swirl channel 23 gradually decreases from the inlet hole 24 to the outlet hole 25 to increase the flow dynamics of the water exiting the swirl channel 23. Specifically, the Venturi effect is used to accelerate the water flow and increase the outlet velocity through a tapering structure (D1>D1, D1: diameter of inlet hole 24, D2: diameter of outlet hole 25). The diameter ratio (D1 / D1) determines the balance between pressure loss and velocity gain. In this invention, the diameter ratio (D1 / D1) is 1.5 to 2.5. An excessively large ratio (>3) will lead to excessive local pressure drop, while an excessively small ratio will result in insufficient swirl intensity. In addition, the larger the cone angle of the swirl channel 23, the higher the swirl intensity, but the increased flow resistance may induce turbulence; a cone angle that is too small (<10°) will result in an excessively large swirl radius, reducing energy utilization. Therefore, in this invention, the cone angle of the swirl channel 23 is between 15° and 30° to balance the swirl intensity and pressure drop.

[0088] This invention addresses the technical problem in existing technologies where low system water supply pressure, poor filtration, severe nozzle clogging, and large nozzle diameters result in jet-like water flow with unsatisfactory envelopment angle and atomization, leading to ineffective dust suppression. A radial swirling channel 23 is provided within the nozzle, with its diameter gradually decreasing from one end of the inlet hole 24 to one end of the outlet hole 25. The water flow within the radial swirling channel 23 is guided to rotate at high speed, creating a centrifugal force field that converts kinetic energy into pressure energy. The gradual decrease in the cross-sectional area of ​​the swirling channel 23 forces an increase in water velocity, significantly enhancing the hydrostatic pressure at the outlet according to Bernoulli's principle. The high-speed rotating jets ejected from each swirling channel 23 form synergistic vortices within the swirling cavity 11, further enhancing the fluid rotation intensity and axial momentum through the superposition effect of the flow field. When the vortex exits from the atomizing hole 13, the combination of rotational motion and high-speed jet achieves the following advantages:

[0089] Long-range characteristics: The axial kinetic energy of the rotating jet is concentrated, which effectively reduces the attenuation effect of air resistance on the jet, and the range is increased by 30%-50% compared with traditional nozzles.

[0090] High-efficiency dust suppression performance: Under the same atomization effect, the working pressure can be reduced to 60%-70% of that of traditional nozzles, and the water consumption can be reduced by more than 40%. Through the optimized matching of kinetic energy and potential energy, the dust suppression effect of "low energy consumption and high coverage" is achieved.

[0091] This design, through precise matching of fluid dynamic parameters (swirl number, contraction ratio, channel angle), demonstrates significant energy-saving advantages and dust reduction efficiency in dust control scenarios such as mines and construction sites.

[0092] Furthermore, the spiral channel 23 in this invention is spiral-shaped, which effectively prevents coal dust and other impurities from clogging the vortex channel 23 through the atomizing hole 13. As the diameter of the vortex channel 23 changes, the water pressure gradually increases as the water flows towards the atomizing hole 13. The resulting vortex also flushes the vortex cavity 11 between the atomizing hole 13 and the vortex core 20, thereby expelling coal dust and other impurities from the atomizing hole 13 along with the water mist, effectively preventing clogging. A filter screen or other filtration structure with a pore size ≤1mm should also be installed at the water inlet of the nozzle housing 10 to intercept large particles. Since over 90% of working surfaces experience nozzle scaling and clogging due to high water hardness (CaCO3 content > 500mg / L), the vortex core 20 in this invention can be directly replaced when severely clogged.

[0093] Furthermore, the inner side of the swirling cavity 11 near the inlet 12 is provided with a first internal thread 14, and the outer wall of the swirling inner core 20 is provided with a first external thread 22. The swirling inner core 20 is threadedly connected to the swirling cavity through the first internal thread 14 and the first external thread 22. In this embodiment, the position of the swirling inner core 20 in the swirling cavity 11 can be adjusted by means of a threaded connection with the nozzle housing 10, that is, the distance between the swirling inner core 20 and the atomizing hole 13 can be adjusted, so that the spray range of the nozzle can be adjusted during the atomization dust reduction process. When the vortex core 20 approaches the atomizing hole 13, the space of the vortex cavity 11 between the atomizing hole 13 and the vortex core 20 decreases, the vortex stays there for a shorter time, and the kinetic energy consumed is also reduced. The power of the water mist ejected from the atomizing hole 13 will also increase, and the spray range will be longer. When the vortex core 20 approaches the inlet 12, the space of the vortex cavity 11 between the atomizing hole 13 and the vortex core 20 increases, the vortex stays there for a longer time, and the kinetic energy consumed is also increased. The power of the water mist ejected from the atomizing hole 13 will also decrease, and the spray range will be shorter.

[0094] Under normal circumstances, during actual operation, the coal mining machine 1 can achieve the purpose of atomization and dust suppression through multiple nozzles. In order to improve the enveloping angle and atomization effect so that the dust is effectively suppressed, the user can adjust the range of the nozzles in different areas according to the swirling inner core 20.

[0095] Furthermore, the vortex inner core 20 is provided with a cross groove 26 or a slotted groove at the center of its end face near the inlet 12. The vortex inner core 20 can be effectively turned with a Phillips screwdriver or a slotted thread cutter to adjust the distance between the vortex inner core 20 and the atomizing hole 13, thereby adjusting the nozzle atomization range. Meanwhile, the vortex channel 23 in this invention is located inside the vortex inner core 20, and is at a distance from the first external thread 22 on the outer wall of the vortex inner core 20 and the cross groove 26 or slotted groove at its center. When the vortex channel 23 is located on the outer wall of the vortex inner core 20, it will scour the first internal thread 14 of the nozzle housing 10. Over long-term operation, this will cause wear on the first internal thread 14 on the nozzle housing 10 and the first external thread 22 beside the vortex channel 23, making the threaded connection between the vortex inner core 20 and the nozzle housing 10 prone to loosening. When the vortex channel 23 is located at the center of the vortex inner core 20, the centrifugal force of the vortex in the vortex cavity 11 between the atomizing hole 13 and the vortex inner core 20 is insufficient, which directly affects the water pressure ejected from the atomizing hole 13. The vortex channel 23 in this invention can effectively avoid the aforementioned problems.

[0096] Furthermore, an annular groove is provided on the outer wall of the swirl core 20 near the atomizing hole 13, and a sealing ring 21 is provided in the annular groove. The sealing ring 21 is interference-fitted with the inner wall of the swirl cavity 11.

[0097] As mentioned above, eddies exist within the swirling cavity 11 between the atomizing hole 13 and the swirling inner core 20. Sufficient water pressure is required for the water jet from the atomizing hole 13 to achieve atomization. However, in this invention, the swirling inner core 20 is threadedly connected to the nozzle housing 10. To prevent pressure loss due to the eddies, this invention uses a sealing ring 21 to seal the swirling cavity 11 between the atomizing hole 13 and the swirling inner core 20, thus preventing a drop in water pressure and ensuring atomization. Specifically, the width of the annular groove should be slightly larger than the cross-sectional diameter of the sealing ring 21 (e.g., groove width = d + 0.1~0.2 mm, where d is the cross-sectional diameter of the sealing ring 21) to facilitate installation and prevent extrusion. The compression ratio (compressed height / original height) of the sealing ring 21 should be controlled between 20% and 30% to ensure resilience and sealing durability. Matching the depth (h) of the annular groove: d = h + 0.5~1mm (the two ends of the sealing ring 21 need to slightly protrude from the groove opening to form an end face seal). If the axial length is insufficient, high-pressure water flow may leak from the gap between the sealing ring 21 and the bottom of the annular groove. The interference fit between the sealing ring 21 and the inner wall of the vortex cavity 11 should meet Δ = 0.1~0.2mm (hard material) or 0.05~0.1mm (soft material), matching the inner diameter tolerance of the vortex cavity 11 to grade H7. Based on this requirement, fluororubber or polyurethane is preferred for the sealing ring 21, taking into account both elasticity and wear resistance. This design can ensure the long-term stable operation of the nozzle under high pressure (≥10MPa) and particulate media conditions, while supporting quick disassembly and maintenance.

[0098] Furthermore, since the swirling channel 23 in the swirling inner core 20 is spiral-shaped, and the diameter of the swirling channel 23 gradually decreases from one end of the inlet hole 24 to one end of the outlet hole 25, it indicates that the water flow pressurized through the swirling channel 23 may cause the threads of the swirling inner core 20 and the nozzle housing 10 to become loose. However, the sealing ring 21 of the present invention has an interference fit with the inner wall of the nozzle housing 10, which effectively avoids the problem of the threads of the swirling inner core 20 and the nozzle housing 10 becoming loose. The position of the swirling inner core 20 can only be adjusted by manually tightening it with a Phillips screwdriver or a flathead screwdriver. However, the position of the swirling inner core 20 should still be inspected during long-term use.

[0099] Please see again Figure 7 and Figure 8 As shown, the number of swirl channels 23 is 2 to 6. In this embodiment, the invention can also change the atomization range of the nozzle by adjusting the number of swirl channels 23. In this invention, the inlet water pressure of all nozzles is set to a uniform value, and the total cross-sectional area of ​​all swirl channels 23 is considered as the flow area of ​​water flowing through the swirl core 20. When the number of swirl channels 23 is small, the flow area of ​​the swirl core 20 is correspondingly reduced. Under the same flow rate, the reduction in flow area will increase the flow rate, i.e., the water pressure will increase. When the number of swirl channels 23 is large, the flow area of ​​the swirl core 20 is correspondingly increased. Under the same flow rate, the increase in flow area will decrease the flow rate, i.e., the water pressure will decrease. This invention can change the atomization range of the nozzle according to the number of swirl channels 23. However, considering the limited end face area of ​​the swirl core 20, the number of swirl channels 23 in this invention is set to 2 to 6. Too many swirl channels 23 will result in too many hollow parts in the swirl core 20, reducing its strength and making processing more difficult.

[0100] Furthermore, the spiral directions of the swirling channels 23 are all oriented in the same direction, thereby forming a stable vortex within the swirling cavity 11 between the atomizing hole 13 and the swirling inner core 20. If the spiral directions of the swirling channels 23 are different, it will cause water flows in different directions to scour each other, resulting in pressure loss and preventing the formation of vortices within the swirling cavity 11 between the atomizing hole 13 and the swirling inner core 20. Ultimately, the water pressure ejected from the atomizing hole 13 will not meet the atomization requirements. The swirling channels 23 are arranged in a ring array inside the swirling inner core 20 with the center of the circle as the center. This ensures a stable layout of the swirling channels 23 within the swirling inner core 20, effectively guaranteeing the formation of a stable vortex within the swirling cavity 11 between the atomizing hole 13 and the swirling inner core 20. It also avoids the problem of strength imbalance caused by uneven distribution of the swirling channels 23 within the swirling inner core 20.

[0101] Furthermore, a second external thread is provided on the outer side wall of the nozzle housing 10 near the water inlet 12, and the nozzle housing 10 is connected to the spray module through the second external thread. The outer side wall of the nozzle housing 10 near the atomizing hole 13 has an external hexagonal structure to facilitate the disassembly and assembly of the nozzle.

[0102] Furthermore, the present invention also provides a method for intelligent spray three-dimensional closed dust suppression control of coal mining machines, using the dust suppression system of the above embodiments and the following steps:

[0103] S1. Activate the onboard spray system to make it move synchronously with the coal mining machine 1 during coal mining operations;

[0104] S2. Based on the real-time location data of coal mining machine 1 collected by the coal mining machine 1 monitoring system, the location and number of sprayers that should be activated are then calculated.

[0105] S3. The electrical signal calculated by the monitoring system of the coal mining machine 1 is transmitted to the signal converter 61, and the signal converter 61 sends a spraying command to the tracking spray system 6.

[0106] S4, the coal mining machine 1 monitoring system collects real-time dust concentration data of the working face and adjusts the number of spray groups in the tracking spray system 6 according to the changes in dust concentration of the working face.

[0107] The essence of three-dimensional envelope high-efficiency spraying of the drum 2 of the coal mining machine 1 is to arrange various forms of near-dust source spraying near the front and rear drums 2 of the coal mining machine 1 to form dense water mist to quickly suppress the generation of dust during coal cutting, so as to achieve the purpose of three-dimensional sealed dust reduction. This invention uses airborne external spraying and tracking spraying to achieve three-dimensional sealing of the front and rear drums 2 of the coal mining machine 1, reducing the generation of dust from the source.

[0108] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A three-dimensional sealed dust suppression system for intelligent spraying in coal mining machines, characterized in that: This includes coal mining machines, onboard spray systems, and tracking spray systems; The coal mining machine is transported by a scraper conveyor; and the coal mining machine is equipped with rocker arms at both the front and rear ends, with drums for coal mining mounted on the rocker arms. The airborne spray system is located at the root of the rocker arm of the coal mining machine and is used to cover the drums at both ends of the coal mining machine. The tracking spray system is installed on the scraper conveyor and located next to the coal mining machine. The tracking spray system is connected to a control system to enable the real-time activation of the spray device near the front and rear drums of the coal mining machine, so as to guide the dust-laden airflow generated by the coal mining machine to one side of the coal wall, and at the same time form a fog curtain near the front and rear drums of the coal mining machine. Both the airborne spray system and the tracking spray system include a spray module; The spray module includes a mounting plate and multiple nozzles. One plane of the mounting plate is a spray surface, and multiple spray holes are provided on the spray surface. The interior of the mounting plate is provided with water channels communicating with the spray holes, and the nozzles are respectively disposed in the spray holes. The spray holes are equidistantly distributed and inclined with respect to both sides of the center of the mounting plate, and the angle between the axis of the spray hole and the spray surface gradually decreases. The mounting plate is also provided with multiple mounting holes to fix the mounting plate to the airborne spray system and the tracking spray system; The nozzle includes a nozzle housing and a swirling inner core; The nozzle housing has a swirling chamber inside, with an atomizing hole at one end and a water inlet at the other end; The swirling inner core is disposed inside the swirling cavity, and the interior of the swirling inner core is provided with at least two spiral swirling channels. The water inlet is connected to the atomizing hole through the swirling channels. The vortex channel has an inlet at one end near the inlet and an outlet at the other end near the atomizing hole. The diameter of the vortex channel gradually decreases from the inlet end to the outlet end to increase the water flow dynamics out of the vortex channel. The inner side of the swirling cavity near the inlet is provided with a first internal thread, and the outer wall of the swirling inner core is provided with a first external thread. The swirling inner core is connected to the swirling cavity through the first external thread and the first internal thread. The vortex inner core is also provided with a cross groove or a slot at the center of the end face near the water inlet, for turning the vortex inner core; An annular groove is provided on the outer wall of the end of the swirling inner core near the atomizing hole. A sealing ring is provided in the annular groove, and the sealing ring is interference-fitted with the inner wall of the swirling cavity. The spiral directions of the swirling channels are all facing the same direction, and they are arranged in a ring array inside the swirling inner core with the center of the circle as the center.

2. The intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to claim 1, characterized in that: The control system includes a coal mining machine monitoring system and a spray control system. The coal mining machine monitoring system is installed on the coal mining machine and is used to collect the position data of the coal mining machine in real time, and then calculate the position and number of sprays that should be activated. The spray control system is installed on the tracking spray system and includes a signal converter and a spray control box. The signal converter is electrically connected to the coal mining machine monitoring system and sends a spray start command to the spray control box at the corresponding location to guide the dust-laden airflow generated by the coal mining machine to one side of the coal wall.

3. The intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to claim 2, characterized in that: The coal mining machine monitoring system also includes a dust concentration sensor located on the coal mining machine. The dust concentration sensor collects dust concentration data of the working face in real time and adjusts the number of spray groups in the tracking spray system according to the changes in dust concentration at the working face.

4. The intelligent spray three-dimensional sealed dust suppression system for coal mining machines according to claim 1, characterized in that: The nozzle housing has a second external thread on a section of its outer side wall near the water inlet, and the nozzle housing is connected to the spray module through the second external thread.

5. A method for intelligent spray three-dimensional closed dust suppression control of a coal mining machine, characterized in that: Using the dust suppression system according to claim 4 includes the following implementation steps: S1. Activate the onboard spray system to make it move synchronously with the coal mining machine during coal mining operations; S2. Based on the real-time location data of the coal mining machine collected by the coal mining machine monitoring system, calculate the location and number of sprayers that should be activated. S3. The electrical signal calculated by the coal mining machine monitoring system is transmitted to the signal converter, which then sends a spraying command to the tracking spraying system. S4. The coal mining machine monitoring system collects real-time dust concentration data from the working face and adjusts the number of spray groups in the tracking spray system according to changes in dust concentration at the working face.

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