Power plant coal intelligent sampling method and system

Abstract

The present application relates to coal sampling and intelligent management technical field, disclose a kind of power plant coal intelligent sampling method and system, comprising: intercepting coal sample from coal flow by automatic sampling equipment, using automatic crushing, screening, sub-division equipment sequentially to the coal sample is handled, by drying equipment to the coal sample after sub-division is dried and handled, and by online total water tester detects moisture content, finally by encapsulation equipment to the coal sample after drying is sealed and encapsulated, and batch loading and unloading and scrap recovery processing are carried out, the whole sampling process is monitored in real time by intelligent control system, to the data uploaded is preprocessed, feature extraction and visual display.The present application realizes the automation and intelligentization of the whole process of sampling, ensures the quality of coal sample while improving sampling efficiency and accuracy, with significant economic benefits and environmental value.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of coal sampling and intelligent management, and particularly relates to a power plant coal intelligent sampling and preparation method and system. BACKGROUND

[0002] In the traditional power plant coal sampling and preparation process, the sampling, crushing, screening, sub-sampling, drying, packaging and other links mostly rely on manual operation or partial automation equipment, which not only is low in efficiency, but also is easily affected by human factors, leading to uneven sampling, inaccurate data and other problems. Although the partial automation equipment improves the efficiency to a certain extent, the lack of collaboration between the links makes it impossible to realize intelligent control and optimization of the whole process.

[0003] In the traditional coal sample drying process, the drying process and moisture detection are usually carried out separately. After the coal sample is treated by the drying equipment, manual sampling is needed and the sample is sent to the laboratory for moisture detection. This process not only consumes time and effort, but also easily leads to changes in moisture content due to sample transfer and changes in detection environment, thereby affecting the accuracy of the detection results. In addition, the traditional drying equipment cannot adjust the drying parameters in real time according to the actual moisture content of the coal sample, which may lead to over-drying or insufficient drying, affecting the quality of the coal sample.

[0004] In the traditional sampling and preparation process, the loading and unloading of the packaged coal sample and the disposal of the waste material mostly rely on manual operation, which not only is low in efficiency, but also easily leads to problems such as confusion of coal sample batches and damage to the coal sample during the loading and unloading process.

[0005] In the traditional sampling and preparation process, the operating personnel can only understand the running state of the equipment through the simple indicator light or display screen of the equipment, and lack comprehensive monitoring and data analysis of the whole sampling and preparation process. This scattered monitoring method not only makes it difficult to find and solve problems in time, but also cannot optimize and trace the sampling and preparation process, leading to difficulty in further improving the sampling and preparation quality and efficiency. SUMMARY

[0006] The present application is proposed to solve the problems in the prior art and provides a power plant coal intelligent sampling and preparation method and system.

[0007] To achieve the above-mentioned purpose, the present application adopts the following technical scheme: a power plant coal intelligent sampling and preparation method and system, comprising the following steps:

[0008] Step S1: intercepting a coal sample from a coal flow through an automatic sampling device;

[0009] Step S2: crushing the coal sample through an automatic crushing device to obtain a crushed coal sample;

[0010] Step S3, the crushed coal sample is screened by an automatic screening device to obtain a screened coal sample;

[0011] Step S4, the screened coal sample is sub-sampled by an automatic sub-sampling device to obtain a sub-sampled coal sample;

[0012] Step S5, the sub-sampled coal sample is dried by a drying device, and the moisture content is detected by an online total water tester to obtain a dried coal sample;

[0013] Step S6, the dried coal sample is sealed and packaged by a packaging device to obtain a packaged coal sample;

[0014] Step S7, the packaged coal sample is batched and unloaded, and the waste generated during the sampling and preparation process is recycled;

[0015] Step S8, the data uploaded during the sampling and preparation process are preprocessed and feature extracted by an intelligent control system, and the sampling and preparation process is visually displayed.

[0016] Further, in step S1, the following sub-steps are further included:

[0017] S1-1, preset the operating parameters of the automatic sampling device, the automatic sampling device includes a sampling head, a sampling arm, a driving device and a sampling control module, the operating parameters include a sampling mode and a sampling frequency, the automatic sampling device intercepts a coal sample from a coal flow according to the preset operating parameters, and the intercepted coal sample is transported to a crushing device;

[0018] S1-2, during the operation of the automatic sampling device, the coal quality data of the coal flow are monitored in real time by a multi-modal sensor, and the coal quality data are transmitted to an intelligent control system, the multi-modal sensor includes a moisture sensor, an ash sensor and a sulfur sensor, and the coal quality data include the moisture content, the ash content and the sulfur content of the coal flow;

[0019] S1-3, the coal quality data are processed and analyzed by a sampling control module to obtain the coal quality change, and the operating parameters of the automatic sampling device are adjusted according to the coal quality change.

[0020] Further, in step S2, the following sub-steps are further included:

[0021] S2-1, an image of the coal sample is captured by an industrial camera, and the image of the coal sample is analyzed by an image analysis method to obtain the initial particle size of the coal sample;

[0022] S2-2, setting operation parameters of the automatic crushing device according to the initial particle size of the coal sample, the automatic crushing device comprising a crusher, a distributing device and a crushing control module, the operation parameters comprising a feeding speed, a distributing device rotating speed, a crusher rotating speed and a crushing intensity;

[0023] S2-3, the automatic crushing device crushing the coal sample according to the set operation parameters to obtain a crushed coal sample and a crushing waste, and the crushing control module monitoring the crushing process in real time to obtain crushing monitoring data and upload the crushing monitoring data to the intelligent control system, the crushing monitoring data comprising a time of inputting the coal sample into the automatic crushing device, the initial particle size of the coal sample, the operation parameters of the automatic crushing device and a time of discharging the crushed coal sample.

[0024] Further, in step S3, the following sub-steps are further included:

[0025] S3-1, presetting operation parameters of the automatic screening device, the automatic screening device comprising a first screen, a second screen, a first discharge port, a second discharge port, a bottom discharge port, a screen vibration device and a screening control module, the operation parameters comprising a screen vibration frequency, a feeding speed and a discharging speed;

[0026] S3-2, the automatic screening device screening the crushed coal sample according to the operation parameters to obtain a screened coal sample and a screening waste, the screened coal sample comprising a large particle size coal sample, a medium particle size coal sample and a small particle size coal sample, the screening process comprising:

[0027] retaining the large particle size coal sample through the first screen and discharging the large particle size coal sample through the first discharge port;

[0028] retaining the medium particle size coal sample through the second screen and discharging the medium particle size coal sample through the second discharge port;

[0029] discharging the small particle size coal sample through the bottom discharge port;

[0030] S3-3, the screening control module monitoring the screening process in real time to obtain screening monitoring data and upload the screening monitoring data to the intelligent control system, the screening monitoring data comprising a time of inputting the crushed coal sample into the automatic screening device, the operation parameters of the automatic screening device and a time of discharging the screened coal sample through each discharge port.

[0031] Further, in step S4, the following sub-steps are further included:

[0032] S4-1, presetting operation parameters of the automatic sample splitting device, the automatic sample splitting device comprising a sample splitter, a vibration device, a collection device and a sample splitting control module, the operation parameters comprising a sample splitting ratio, a vibration frequency, a feeding speed and a discharging speed;

[0033] S4-2, the automatic sizing device performs sizing processing on the screened coal sample according to the operation parameters to obtain sized coal sample and sizing waste, and performs real-time monitoring on the sizing processing to obtain sizing monitoring data and upload the sizing monitoring data to the intelligent control system, the sizing monitoring data including the time when the screened coal sample is input into the automatic sizing device, the operation parameters of the automatic sizing device, and the time when the sized coal sample is discharged.

[0034] Further, in step S5, the following sub-steps are further included:

[0035] S5-1, presetting operation parameters of a drying device, the drying device including a drying box, a hot air device, a stirring device, and a drying control module, the operation parameters including drying temperature, drying time, and hot air flow;

[0036] S5-2, the drying device performing drying processing on the sized coal sample according to the operation parameters to obtain dried coal sample and drying waste, and performing real-time monitoring on the drying processing to obtain drying monitoring data and upload the drying monitoring data to the intelligent control system, the drying monitoring data including the time when the sized coal sample is input into the drying device, the operation parameters of the drying device, and the time when the dried coal sample is discharged;

[0037] S5-3, sampling from the dried coal sample in batches by an automatic sampling device to obtain test samples for moisture detection;

[0038] S5-4, presetting operation parameters of an online total water tester and a moisture content standard for calibration, the operation parameters including test temperature and test time, the online total water tester performing moisture detection on the test samples by infrared absorption method according to the preset operation parameters to obtain sample moisture content;

[0039] S5-5, comparing the sample moisture content with the moisture content standard for calibration to determine whether the sample moisture content is qualified, if yes, the sized coal sample corresponding to the sample is transported to a packaging device, and if no, the sized coal sample corresponding to the sample is sent back to the drying device for re-drying processing.

[0040] Further, in step S6, the following sub-steps are further included:

[0041] S6-1, presetting operation parameters of a packaging device, the packaging device including a packaging container, a sealing device, a filling device, and a packaging control module, the operation parameters including filling speed, sealing pressure, and packaging time;

[0042] S6-2, the encapsulation device seals and encapsulates the dried coal sample according to the operation parameters to obtain an encapsulated coal sample and encapsulated waste, and a sealing and encapsulation process is monitored in real time by a sealing and encapsulation control module to obtain encapsulation monitoring data and upload the encapsulation monitoring data to the intelligent control system, wherein the encapsulation monitoring data includes a time when the dried coal sample is input into the encapsulation device, operation parameters of the encapsulation device, and a time when the encapsulated coal sample is discharged;

[0043] S6-3, a bar code is printed on each batch of encapsulated coal sample by a printer, and the bar code is used to mark the batch of the encapsulated coal sample.

[0044] Further, in step S7, the following sub-steps are further included:

[0045] S7-1, the encapsulated coal sample is temporarily stored in a stock bin, and a batch of the encapsulated coal sample is extracted by a fixed bar code scanner;

[0046] S7-2, the encapsulated coal sample is transferred from the stock bin to a transport vehicle by an automatic loading and unloading robot, and a loading and unloading process is monitored in real time by a sensor to obtain loading and unloading monitoring data, wherein the loading and unloading monitoring data includes a stock bin entry time of each batch of coal sample stored in the stock bin, a transfer time, and operator information and is uploaded to the intelligent control system;

[0047] S7-3, waste generated in the sampling and preparing process is temporarily stored in a waste stock bin, the waste includes crushing waste, screening waste, size-reducing waste, drying waste, and encapsulation waste, and a source and a stock bin entry time of the waste are recorded;

[0048] S7-4, the composition of the waste is analyzed by an infrared spectrum analysis method to determine whether the waste contains valuable components that can be recycled, if yes, the waste containing the valuable components is recycled, and if no, the waste not containing the valuable components is treated in a harmless manner.

[0049] Further, in step S8, the following sub-steps are further included:

[0050] S8-1, the intelligent control system acquires sampling and preparing process data uploaded from the automatic sampling device, the automatic crushing device, the automatic screening device, the automatic size-reducing device, the drying device, the encapsulation device, and the loading and unloading device, wherein the sampling and preparing process data includes coal quality data, crushing monitoring data, screening monitoring data, size-reducing monitoring data, drying monitoring data, encapsulation monitoring data, and loading and unloading monitoring data;

[0051] S8-2, the sampling and preparing process data is subjected to data cleaning and format conversion to obtain formatted sampling and preparing process data, and the sampling and preparing process data is subjected to data analysis and feature extraction by a classification algorithm of a support vector machine to obtain feature information of the sampling and preparing process;

[0052] S8-3, according to the characteristic information of the sampling process, the sampling process is visualized by Tableau.

[0053] An intelligent coal sampling system for power plants, characterized in that it comprises:

[0054] Automatic sampling equipment: for intercepting coal samples from the coal flow;

[0055] Automatic crushing equipment: for crushing the intercepted coal samples to obtain crushed coal samples;

[0056] Automatic screening equipment: for screening the crushed coal samples to obtain screened coal samples;

[0057] Automatic subsampling equipment: for subsampling the screened coal samples to obtain subsampled coal samples;

[0058] Drying equipment: for drying the subsampled coal samples to obtain dried coal samples;

[0059] Sealing and packaging equipment: for sealing and packaging the dried coal samples to obtain packaged coal samples;

[0060] Loading and unloading equipment: for batch loading and unloading of packaged coal samples, and for recycling of waste materials generated during the sampling process;

[0061] Intelligent control system: for receiving sampling process data uploaded by the above equipment and performing data analysis, feature extraction, and visualization of the sampling process.

[0062] The technical solution provided by the present application has at least the following beneficial effects:

[0063] The present application realizes full-process automation from coal flow sampling to packaged coal sample output by tightly integrating each link in the sampling process through full-process automation and intelligent design, which not only greatly improves the sampling efficiency and reduces manual intervention, but also improves the accuracy and reliability of coal sample processing, providing higher quality samples for power plant coal quality analysis.

[0064] The present application integrates drying and moisture detection by organically combining drying equipment and online full-water testing instruments, and the drying equipment dries the coal samples while the online full-water testing instrument detects the moisture content of the coal samples in real time, and automatically determines whether re-drying is needed according to the detection results, which not only shortens the drying and moisture detection time, reduces manual operation, but also improves the accuracy and timeliness of moisture detection, providing a more reliable basis for subsequent coal quality analysis.

[0065] The present application realizes the automation and efficient management of the loading and unloading process by using the automatic loading and unloading robot to batch load and unload the packaged coal samples, and extracting the coal sample batch information through the fixed barcode scanner, and at the same time, the discarded materials generated in the sampling process are classified and recycled, which not only improves the loading and unloading efficiency and reduces the labor intensity, but also embodies the concept of environmental protection and resource recycling, and has significant economic and social benefits.

[0066] The present application collects, analyzes and processes the data of each link in the sampling process through the intelligent control system, and intuitively displays the whole sampling process in the form of graphics or charts through the data visualization tool Tableau, so that the operating personnel can understand the running state, key parameters and equipment operation of the sampling process in real time through the visualization interface, which is convenient for timely finding problems and adjusting operation strategy, improves the controllability and management level of the sampling process, and provides strong support for the optimization and tracing of the sampling process. BRIEF DESCRIPTION OF DRAWINGS

[0067] In order to more clearly illustrate the technical solutions and advantages of the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description, and obviously, the drawings in the following description are only some embodiments of the present application, and those skilled in the art can obtain other drawings according to these drawings without creative labor.

[0068] Figure 1 The method flowchart provided for the embodiments of the present application is provided.

[0069] Figure 2 The system structure diagram provided for the embodiments of the present application is provided. DETAILED DESCRIPTION

[0070] In order to further illustrate the technical means and effects adopted by the present application to achieve the predetermined invention purpose, the following combines the drawings and preferred embodiments to specifically describe the method and system for intelligent sampling of coal in power plant according to the present application, the specific implementation, structure, features and effects thereof, as follows. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. In addition, the specific features, structures or characteristics in one or more embodiments can be combined in any suitable form.

[0071] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs.

[0072] The following embodiments are only for illustrative purposes, and are not intended to limit the scope of the present application.

[0073] The application provides a coal intelligent sampling and preparation method and system for a power plant.

[0074] Please refer to Figure 1 which shows a method flowchart of a coal intelligent sampling and preparation method provided by an embodiment of the application, and the method comprises the following steps.

[0075] Step S1, intercepting a coal sample from a coal flow by an automatic sampling device;

[0076] In step S1, the following substeps are further included.

[0077] S1-1, presetting operation parameters of the automatic sampling device, the automatic sampling device comprising a sampling head, a sampling arm, a driving device and a sampling control module, the operation parameters comprising a sampling mode and a sampling frequency, the automatic sampling device intercepting a coal sample from a coal flow according to the preset operation parameters and conveying the intercepted coal sample to a crushing device;

[0078] S1-2, monitoring coal quality data of the coal flow in real time by a multi-modal sensor during the working process of the automatic sampling device and transmitting the coal quality data to an intelligent control system, the multi-modal sensor comprising a moisture sensor, an ash sensor and a sulfur sensor, the coal quality data comprising moisture content, ash content and sulfur content of the coal flow;

[0079] S1-3, performing data processing and feature analysis on the coal quality data by the sampling control module to obtain a coal quality change condition and adjusting the operation parameters of the automatic sampling device according to the coal quality change condition.

[0080] It should be noted that the sampling head is used to directly contact the coal flow and intercept a coal sample, and the shape and size of the sampling head are designed according to the characteristics of the coal flow and sampling requirements (for example, the shape of the sampling head is shovel-shaped or spoon-shaped), the sampling arm is connected with the sampling head and can be telescopic and rotatable, so that the sampling head can sample at different positions of the coal flow, and the driving device provides power for the movement of the sampling head and the sampling arm, and generally uses a motor or a hydraulic cylinder as a driving mode.

[0081] The moisture sensor is used to measure the moisture content of the coal flow, and the principle is to emit a microwave signal and detect the reflection signal strength in the coal flow, and calculate the moisture content of the coal flow according to the change of the reflection signal.

[0082] The ash sensor is used to measure the ash content of the coal flow, and the principle is to detect the fluorescence intensity of the coal sample under X-ray irradiation to determine the ash content.

[0083] Sulfur content sensor Sulfur content is the content of sulfur element in coal, which has important influence on environmental protection emission and equipment corrosion of power plant, and the sulfur content sensor mainly adopts optical absorption spectrum technology, that is, the sulfur content is determined by measuring the absorption intensity of coal sample to specific wavelength light.

[0084] Step S2, crushing the coal sample by an automatic crushing device to obtain a crushed coal sample;

[0085] In step S2, the following sub-steps are further included:

[0086] S2-1, taking an image of the coal sample by an industrial camera, and analyzing the image of the coal sample by an image analysis method to obtain an initial particle size of the coal sample;

[0087] S2-2, setting operation parameters of the automatic crushing device according to the initial particle size of the coal sample, the automatic crushing device including a crusher, a distributing device and a crushing control module, the operation parameters including a feeding speed, a rotating speed of the distributing device, a rotating speed of the crusher and a crushing intensity;

[0088] S2-3, crushing the coal sample by the automatic crushing device according to the set operation parameters to obtain a crushed coal sample and a crushing waste, and monitoring the crushing process in real time by the crushing control module to obtain crushing monitoring data and upload the crushing monitoring data to the intelligent control system, the crushing monitoring data including a time of inputting the coal sample into the automatic crushing device, the initial particle size of the coal sample, the operation parameters of the automatic crushing device and a time of discharging the crushed coal sample.

[0089] It should be noted that the image analysis method refers to processing and analyzing the image of the coal sample by computer vision technology to obtain the particle size and other characteristic information of the coal sample, in this patent, the image analysis method is used for initial particle size detection of the coal sample before crushing, which provides a basis for subsequent crushing parameter adjustment, so as to realize accurate control of the particle size of the coal sample and ensure that the particle size of the crushed coal sample meets the requirements.

[0090] The crusher is the core component of the automatic crushing device, which is used for crushing the coal sample, common types of crushers include jaw crushers or hammer crushers, wherein the jaw crusher crushes the coal sample by reciprocating movement of the moving jaw and the fixed jaw, and the hammer crusher crushes the coal sample by high-speed rotating hammer heads.

[0091] The function of the distributing device is to uniformly distribute the coal sample at the feeding port of the crusher, so as to ensure that the coal sample can be uniformly fed into the crusher for crushing, which usually includes a distributing hopper, a distributing roller and a distributing vibrator, wherein the distributing hopper is used for receiving and temporarily storing the coal sample, and the distributing roller or the distributing vibrator uniformly spreads the coal sample to the feeding port of the crusher by rotating or vibrating.

[0092] Step S3, the crushed coal sample is screened by an automatic screening device to obtain a screened coal sample;

[0093] In step S3, the following sub-steps are further included:

[0094] S3-1, preset the operating parameters of the automatic screening device, the automatic screening device includes a first screen, a second screen, a first discharge port, a second discharge port, a bottom discharge port, a screen vibration device, and a screening control module, and the operating parameters include screen vibration frequency, feed speed, and discharge speed;

[0095] S3-2, the automatic screening device screens the crushed coal sample according to the operating parameters to obtain a screened coal sample and a screening reject, the screened coal sample includes a large-size coal sample, a medium-size coal sample, and a small-size coal sample, and the screening process includes:

[0096] The large-size coal sample is retained by the first screen and discharged through the first discharge port;

[0097] The medium-size coal sample is retained by the second screen and discharged through the second discharge port;

[0098] The small-size coal sample is discharged through the bottom discharge port after passing through the first screen and the second screen;

[0099] S3-3, the screening control module is used to monitor the screening process in real time, obtain screening monitoring data, and upload the screening monitoring data to the intelligent control system, the screening monitoring data includes the time when the crushed coal sample is input into the automatic screening device, the operating parameters of the automatic screening device, and the time when each discharge port discharges the screened coal sample.

[0100] It should be noted that the screen is the core component of the screening device, which is used for particle size classification of the coal sample, the automatic screening device mentioned in the present patent includes two screens, i.e., a first screen and a second screen, the aperture size of the screen determines the classification standard of the coal sample particle size, which is usually set according to the characteristics of the coal sample and the subsequent processing requirements, for example, if the large-size coal sample needs to be controlled to be greater than 10 mm, the aperture of the first screen can be set to be ≤10 mm, and if the medium-size coal sample needs to be controlled to be between 5 mm and 10 mm, the aperture of the second screen can be set to be ≤5 mm.

[0101] The screen vibration device is used to generate vibration to uniformly distribute the coal sample on the screen and accelerate the coal sample to pass through the screen, the vibration device usually includes a motor, an eccentric block, and a spring, etc., wherein the motor generates vibration through the eccentric block, and the spring is used to support and adjust the vibration frequency.

[0102] Step S4, the screened coal sample is divided by an automatic division device to obtain a divided coal sample;

[0103] wherein in step S4, further comprising the following sub-steps:

[0104] S4-1, preset the operating parameters of the automatic division device, the automatic division device comprising a divider, a vibrating device, a collection device and a division control module, the operating parameters comprising a division ratio, a vibration frequency, a feeding speed and a discharging speed;

[0105] S4-2, the automatic division device performs division processing on the screened coal sample according to the operating parameters to obtain a divided coal sample and a division discard, and performs real-time monitoring on the division processing process to obtain division monitoring data and upload the division monitoring data to the intelligent control system, the division monitoring data comprising a time of inputting the screened coal sample into the automatic division device, the operating parameters of the automatic division device and a time of discharging the divided coal sample.

[0106] It should be noted that the divider is the core component of the automatic division device, which divides the coal sample according to the specified ratio through a specific mechanical structure (such as a rotary structure or a cutting structure).

[0107] The vibrating device is used to uniformly distribute the coal sample in the divider, which is usually composed of a motor and an eccentric block. The motor drives the eccentric block to produce vibration, so that the coal sample is uniformly distributed in the divider, ensuring the uniformity and accuracy of the division process.

[0108] The collection device is used to collect the divided coal sample and the discard, which usually includes a plurality of collection grooves or containers for storing the divided coal sample and the discard, respectively.

[0109] Step S5, drying the divided coal sample by a drying device, and detecting the moisture content by an online total water tester to obtain a dried coal sample;

[0110] wherein in step S5, further comprising the following sub-steps:

[0111] S5-1, preset the operating parameters of the drying device, the drying device comprising a drying box, a hot air device, a stirring device and a drying control module, the operating parameters comprising a drying temperature, a drying time and a hot air flow;

[0112] S5-2, the drying device performs drying processing on the divided coal sample according to the operating parameters to obtain a dried coal sample and a drying discard, and performs real-time monitoring on the drying processing process to obtain drying monitoring data and upload the drying monitoring data to the intelligent control system, the drying monitoring data comprising a time of inputting the divided coal sample into the drying device, the operating parameters of the drying device and a time of discharging the dried coal sample;

[0113] S5-3, sampling from the dried coal sample in batches by an automatic sampling device to obtain a test sample for moisture detection;

[0114] S5-4, presetting the operation parameters of the online total water tester and the moisture content standard for calibration, the operation parameters including the test temperature and the test time, and the online total water tester detecting the moisture content of the test sample by the infrared absorption method according to the preset operation parameters to obtain the moisture content of the sample;

[0115] S5-5, comparing the moisture content of the sample with the moisture content standard for calibration to determine whether the moisture content of the sample is qualified, if yes, then conveying the sub-sampled coal sample of the corresponding batch to the packaging equipment, and if no, then returning the sub-sampled coal sample of the corresponding batch to the drying equipment for re-drying.

[0116] It should be noted that the drying box is the main part of the drying equipment, and a plurality of trays or supports are arranged inside the drying box for placing the sub-sampled coal sample, and the drying box usually has good heat preservation performance.

[0117] The hot air device usually includes a heater and a fan for providing hot air for the drying box to accelerate the evaporation of moisture in the sub-sampled coal sample in the drying box.

[0118] The stirring device is usually driven by a motor to stir the sub-sampled coal sample in the drying box through stirring blades or stirring rods to ensure that the sub-sampled coal sample is uniformly heated during the drying process and improve the drying efficiency.

[0119] The online total water tester is an automatic equipment for real-time detection of the moisture content of coal samples, which can quickly and accurately measure the moisture content of coal samples to provide a basis for the control of the drying process to ensure that the discharged coal sample is fully dried.

[0120] The infrared absorption method is to determine the moisture content of the material by measuring the absorption intensity of the infrared light by the material according to the absorption characteristics of the moisture to the infrared light of a specific wavelength. In the online total water test, the sub-sampled coal sample is irradiated by an infrared light source, and the detector measures the absorption intensity of the infrared light by the sub-sampled coal sample, and finally calculates the moisture content according to the absorption intensity.

[0121] Step S6, sealing and packaging the dried coal sample by the packaging equipment to obtain a packaged coal sample;

[0122] In step S6, the following sub-steps are further included:

[0123] S6-1, presetting the operation parameters of the packaging equipment, the packaging equipment including a packaging container, a sealing device, a filling device and a packaging control module, and the operation parameters including the filling speed, the sealing pressure and the packaging time;

[0124] S6-2, the encapsulation device seals and encapsulates the dried coal sample according to the operation parameters to obtain encapsulated coal samples and encapsulated waste, and the encapsulation control module is used to monitor the sealing and encapsulation process in real time to obtain encapsulation monitoring data and upload the encapsulation monitoring data to the intelligent control system, the encapsulation monitoring data including the time when the dried coal sample is input into the encapsulation device, the operation parameters of the encapsulation device and the time when the encapsulated coal sample is discharged;

[0125] S6-3, a bar code is printed on each batch of encapsulated coal sample by a printer, and the bar code is used to mark the batch of the encapsulated coal sample.

[0126] It should be noted that the encapsulation container is used to contain the dried coal sample, and is usually made of corrosion-resistant and sealing materials (such as polyethylene, polypropylene or glass).

[0127] The sealing device is used to ensure the sealing property of the encapsulation container, prevent the coal sample from being damp or leaking, and usually includes a sealing cover, a sealing ring and a sealing pressure adjusting device, the sealing cover is fixed on the encapsulation container by threads or buckles, the sealing ring ensures the sealing property between the cover and the container, and the sealing pressure adjusting device is used to adjust the sealing pressure.

[0128] The filling device is used to fill the dried coal sample into the encapsulation container, and usually includes a hopper, a conveying pipe and a vibrating device, the hopper is used to receive the coal sample, the conveying pipe conveys the coal sample into the encapsulation container, and the vibrating device uniformly distributes and fills the coal sample into the container by vibration.

[0129] Step S7, the encapsulated coal sample is batched and unloaded, and the waste generated in the sampling process is recycled and treated;

[0130] In step S7, the following sub-steps are further included:

[0131] S7-1, the encapsulated coal sample is temporarily stored in a stock bin, and the batch of the encapsulated coal sample is extracted by a fixed bar code scanner;

[0132] S7-2, the encapsulated coal sample is transferred from the stock bin to a transport vehicle by an automatic loading and unloading robot, and the loading and unloading process is monitored in real time by a sensor to obtain loading and unloading monitoring data, the loading and unloading monitoring data including the stock bin entry time, the transfer time and the operator information of each batch of coal sample stored in the stock bin and uploading to the intelligent control system;

[0133] S7-3, the waste generated in the sampling process is temporarily stored in a waste stock bin, the waste including broken waste, screened waste, divided waste, dried waste and encapsulated waste, and the source and stock bin entry time of the waste are recorded;

[0134] S7-4, analyze the composition of the scrap by infrared spectroscopy to determine whether it contains valuable recyclable components. If yes, recycle the scrap containing valuable components. If not, dispose of the scrap without valuable components.

[0135] It is worth noting that the fixed barcode scanner is an automatic device installed in a fixed position for quickly reading information in barcodes. It is commonly used in logistics, warehousing and production management, and can automatically identify and record batch information of goods. It has the characteristics of high efficiency, high accuracy and high automation, which can reduce manual operation and improve work efficiency.

[0136] The automatic loading and unloading robot is an automatic device that can automatically complete loading and unloading tasks. It is commonly used in logistics, warehousing and production lines. It uses mechanical arms or conveyors, combined with sensors and control systems, to achieve automatic handling and loading of goods. It can automatically complete the transfer of goods from the stockpile to the transport vehicle according to the preset program or real-time instructions, effectively reducing manual labor intensity and improving the accuracy and safety of the loading process.

[0137] Infrared spectroscopy is a spectral analysis technique used to analyze the composition of substances. It determines the chemical composition and structure of a substance by measuring its absorption characteristics of infrared light. The principle is to use infrared light to irradiate the sample, and the detector measures the absorption intensity of the sample to the infrared light. According to the characteristics of the absorption spectrum, the chemical composition and functional groups contained in the sample are determined. It has the characteristics of rapidity, non-destructiveness and non-contact, and can quickly provide composition information of the sample.

[0138] Recycling refers to the process of reprocessing and recycling scrap containing valuable components. The purpose is to extract useful components from scrap and reuse them for production or other purposes. It usually includes steps such as classification, screening, magnetic separation and flotation. The appropriate recycling process should be selected according to the composition and properties of the scrap.

[0139] Harmless treatment refers to the treatment of scrap that does not contain valuable components. The purpose is to remove or convert harmful components in the scrap into harmless substances. It usually includes physical treatment (such as landfill, incineration), chemical treatment (such as neutralization, oxidation-reduction) and biological treatment (such as composting, biodegradation). The appropriate harmless process should be selected according to the composition and properties of the scrap.

[0140] Step S8, pre-process and feature extraction of the data uploaded during the sampling process through the intelligent control system, and visualize the sampling process;

[0141] In step S8, the following sub-steps are included:

[0142] S8-1, the intelligent control system acquires sampling and preparation process data uploaded from the automatic sampling device, the automatic crushing device, the automatic screening device, the automatic splitting device, the drying device, the packaging device and the loading and unloading device, and the sampling and preparation process data includes coal quality data, crushing monitoring data, screening monitoring data, splitting monitoring data, drying monitoring data, packaging monitoring data and loading and unloading monitoring data;

[0143] S8-2, data cleaning and format conversion are performed on the sampling and preparation process data to obtain formatted sampling and preparation process data, data analysis and feature extraction are performed on the sampling and preparation process data by using a support vector machine classification algorithm to obtain feature information of the sampling and preparation process;

[0144] S8-3, according to the feature information of the sampling and preparation process, the Tableau is used to visually display the whole process of the sampling and preparation process.

[0145] It should be noted that data cleaning and format conversion are important steps of data preprocessing, and the purpose is to convert the collected original data into a format suitable for analysis and processing, data cleaning includes removing duplicate data, processing missing values, correcting incorrect data and removing outliers, data format conversion includes data type conversion (converting data to integers, floating-point numbers or strings), data standardization (converting data to a unified range such as [0, 1]), and data encoding (converting categorical data to numerical form such as one-hot encoding or label encoding).

[0146] Support vector machine (SVM) is a powerful machine learning algorithm for data classification and regression analysis, in this patent, SVM is used for classification and feature extraction of sampling and preparation process data, and the working principle is to find the optimal segmentation hyperplane to divide the data into different categories, and to maximize the interval between categories to improve the accuracy and robustness of classification.

[0147] Tableau is a powerful data visualization tool for visually displaying complex data features in the form of graphs or charts, and it supports multiple data sources and provides rich visualization functions.

[0148] Please refer to Figure 2 , which shows a system structure diagram of an intelligent coal sampling and preparation system for a power plant according to an embodiment of the present application, and the system comprises:

[0149] Automatic sampling device: used for intercepting coal samples from coal flow;

[0150] Automatic crushing device: used for crushing the intercepted coal samples to obtain crushed coal samples;

[0151] Automatic screening device: used for screening the crushed coal samples to obtain screened coal samples;

[0152] Automatic division equipment: used for dividing the screened coal sample to obtain a divided coal sample;

[0153] Drying equipment: used for drying the divided coal sample to obtain a dried coal sample;

[0154] Sealing equipment: used for sealing the dried coal sample to obtain a sealed coal sample;

[0155] Loading and unloading equipment: used for batch loading and unloading the sealed coal sample, and recycling the waste generated during the sampling and preparation process;

[0156] Intelligent control system: used for receiving the sampling and preparation process data uploaded by the above equipment and performing data analysis, feature extraction and visual display of the sampling and preparation process.

[0157] The above-described embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacements for part of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.

Claims

1. An intelligent coal sampling method for power plants, characterized in that, The method comprises: Step S1, intercepting a coal sample from a coal flow by an automatic sampling device; Step S2, crushing the coal sample by an automatic crushing device to obtain a crushed coal sample; Step S3, screening the crushed coal sample by an automatic screening device to obtain a screened coal sample; Step S4, sub-sampling the screened coal sample by an automatic sub-sampling device to obtain a sub-sampled coal sample; Step S5, drying the sub-sampled coal sample by a drying device, and detecting the moisture content by an online total water tester to obtain a dried coal sample; Step S6, sealing and packaging the dried coal sample by a sealing and packaging device to obtain a packaged coal sample; Step S7, batch loading and unloading the packaged coal sample, and recycling the waste generated during the sampling and sample preparation process; Step S8, preprocessing and feature extraction of the data uploaded during the sampling and sample preparation process by an intelligent control system, and visualizing the sampling and sample preparation process; In step S1, the following sub-steps are further included: S1-1, presetting the operation parameters of the automatic sampling device, the automatic sampling device comprising a sampling head, a sampling arm, a driving device and a sampling control module, the operation parameters comprising a sampling mode and a sampling frequency, the automatic sampling device intercepting a coal sample from a coal flow according to the preset operation parameters, and the intercepted coal sample being transported to the crushing device; S1-2, monitoring the coal quality data of the coal flow in real time by a multi-modal sensor during the operation of the automatic sampling device, and transmitting the coal quality data to an intelligent control system, the multi-modal sensor comprising a moisture sensor, an ash sensor and a sulfur sensor, the coal quality data comprising the moisture content, ash content and sulfur content of the coal flow; S1-3, performing data processing and feature analysis on the coal quality data by a sampling control module to obtain the coal quality change, and adjusting the operation parameters of the automatic sampling device according to the coal quality change; In step S2, the following sub-steps are further included: S2-1, capturing an image of the coal sample by an industrial camera, and analyzing the image of the coal sample by an image analysis method to obtain the initial particle size of the coal sample; S2-2, setting the operation parameters of the automatic crushing device according to the initial particle size of the coal sample, the automatic crushing device comprising a crusher, a distribution device and a crushing control module, the operation parameters comprising a feeding speed, a distribution device speed, a crusher speed and a crushing intensity; S2-3, the automatic crushing device crushing the coal sample according to the set operation parameters to obtain a crushed coal sample and a crushing waste, and monitoring the crushing process in real time by a crushing control module to obtain crushing monitoring data and upload it to an intelligent control system, the crushing monitoring data comprising the time of the coal sample input into the automatic crushing device, the initial particle size of the coal sample, the operation parameters of the automatic crushing device and the time of the crushed coal sample being discharged; In step S3, the following sub-steps are further included: S3-1, preset the operation parameters of the automatic screening device, the automatic screening device comprising a first screen, a second screen, a first discharge port, a second discharge port, a bottom discharge port, a screen vibration device, and a screening control module, the operation parameters comprising a screen vibration frequency, a feeding speed, and a discharge speed; S3-2, the automatic screening device screens the crushed coal sample according to the operation parameters to obtain a screened coal sample and a screening reject, the screened coal sample comprising a large-size coal sample, a medium-size coal sample, and a small-size coal sample, the screening process comprising: retaining the large-size coal sample through the first screen and discharging the large-size coal sample through the first discharge port; retaining the medium-size coal sample through the second screen and discharging the medium-size coal sample through the second discharge port; discharging the small-size coal sample through the bottom discharge port; S3-3, the screening control module monitors the screening process in real time to obtain screening monitoring data and upload the screening monitoring data to the intelligent control system, the screening monitoring data comprising a time when the crushed coal sample is input into the automatic screening device, the operation parameters of the automatic screening device, and a time when the screened coal sample is discharged from each discharge port.

2. The intelligent coal sampling method for power plants according to claim 1, wherein in step S4, the following sub-steps are further included: S4-1, preset the operation parameters of the automatic quartering device, the automatic quartering device comprising a quartering device, a vibration device, a collection device, and a quartering control module, the operation parameters comprising a quartering ratio, a vibration frequency, a feeding speed, and a discharge speed; S4-2, the automatic quartering device quarters the screened coal sample according to the operation parameters to obtain a quartered coal sample and a quartering reject, and monitors the quartering process in real time to obtain quartering monitoring data and upload the quartering monitoring data to the intelligent control system, the quartering monitoring data comprising a time when the screened coal sample is input into the automatic quartering device, the operation parameters of the automatic quartering device, and a time when the quartered coal sample is discharged.

3. The intelligent coal sampling method for power plants according to claim 1, wherein in step S5, the following sub-steps are further included: S5-1, preset the operation parameters of the drying device, the drying device comprising a drying box, a hot air device, a stirring device, and a drying control module, the operation parameters comprising a drying temperature, a drying time, and a hot air flow rate; S5-2, the drying device dries the quartered coal sample according to the operation parameters to obtain a dried coal sample and a drying reject, and monitors the drying process in real time to obtain drying monitoring data and upload the drying monitoring data to the intelligent control system, the drying monitoring data comprising a time when the quartered coal sample is input into the drying device, the operation parameters of the drying device, and a time when the dried coal sample is discharged; S5-3, the automatic sampling device samples the dried coal sample in batches to obtain a test sample for moisture detection. ​ ​ S5-4, presetting operation parameters of the online total moisture tester and a moisture content standard for calibration, the operation parameters including a test temperature and a test time, and the online total moisture tester detecting moisture of the test sample by infrared absorption method according to the preset operation parameters to obtain a sample moisture content; S5-5, comparing the sample moisture content with the moisture content standard for calibration to determine whether the sample moisture content is qualified, if yes, conveying the sub-sampled coal sample of the sample corresponding batch to the packaging equipment, and if no, returning the sub-sampled coal sample of the sample corresponding batch to the drying equipment for re-drying.

4. The intelligent coal sampling method for power plants according to claim 1, characterized in that: In step S6, the following sub-steps are further included: S6-1, presetting operation parameters of the packaging equipment, the packaging equipment including a packaging container, a sealing device, a filling device and a packaging control module, the operation parameters including a filling speed, a sealing pressure and a packaging time; S6-2, the packaging equipment sealing and packaging the dried coal sample according to the operation parameters to obtain packaged coal samples and packaging waste, and the packaging control module monitoring the sealing and packaging process in real time to obtain packaging monitoring data and upload the same to the intelligent control system, the packaging monitoring data including a time when the dried coal sample is input into the packaging equipment, the operation parameters of the packaging equipment and a time when the packaged coal sample is discharged; S6-3, printing a bar code on each batch of packaged coal sample by a printer, the bar code being used to mark the batch of the packaged coal sample.

5. The intelligent coal sampling method for power plants according to claim 1, characterized in that: In step S7, the following sub-steps are further included: S7-1, temporarily storing the packaged coal sample in a stock bin, and extracting the batch of the packaged coal sample by a fixed bar code scanner; S7-2, transferring the packaged coal sample from the stock bin to a transport vehicle by an automatic loading and unloading robot, and monitoring the loading and unloading process in real time by a sensor to obtain loading and unloading monitoring data, the loading and unloading monitoring data including a stock-in time, a transfer time and operator information of each batch of coal sample stored in the stock bin and uploading the same to the intelligent control system; S7-3, temporarily storing waste generated in the sampling process in a waste stock bin, the waste including crushing waste, screening waste, sub-sampling waste, drying waste and packaging waste, and recording the source and stock-in time of the waste; S7-4, analyzing the composition of the waste by infrared spectrum analysis method to determine whether it contains valuable components that can be recycled, if yes, recycling the waste containing valuable components, and if no, non-hazardous treatment of the waste not containing valuable components.

6. The intelligent coal sampling method for power plants according to claim 1, characterized in that: In step S8, the following sub-steps are further included: S8-1, the intelligent control system acquires sampling and preparation process data uploaded from the automatic sampling device, the automatic crushing device, the automatic screening device, the automatic quartering device, the drying device, the packaging device and the loading and unloading device, wherein the sampling and preparation process data includes coal quality data, crushing monitoring data, screening monitoring data, quartering monitoring data, drying monitoring data, packaging monitoring data and loading and unloading monitoring data; S8-2, the sampling and preparation process data is subjected to data cleaning and format conversion to obtain formatted sampling and preparation process data, and the sampling and preparation process data is subjected to data analysis and feature extraction through a support vector machine classification algorithm to obtain feature information of the sampling and preparation process; S8-3, according to the feature information of the sampling and preparation process, the sampling and preparation process is visualized through Tableau.

7. An intelligent sampling system for coal in power plants, which adopts the intelligent sampling method for coal in power plants according to any one of claims 1-6, characterized in that, The system comprises: an automatic sampling device for intercepting a coal sample from a coal flow; an automatic crushing device for crushing the intercepted coal sample to obtain a crushed coal sample; an automatic screening device for screening the crushed coal sample to obtain a screened coal sample; an automatic quartering device for quartering the screened coal sample to obtain a quartered coal sample; a drying device for drying the quartered coal sample to obtain a dried coal sample; a packaging device for sealing and packaging the dried coal sample to obtain a packaged coal sample; a loading and unloading device for loading and unloading the packaged coal sample in batches and recycling waste generated in the sampling and preparation process; an intelligent control system for receiving sampling and preparation process data uploaded from the above devices and performing data analysis, feature extraction and visualization of the sampling and preparation process.

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