Anti-blocking and anti-sample-mixing method, system and equipment for coal sampling equipment
By employing real-time monitoring and intelligent switching methods, combined with microwave radar sensors and automated cleaning devices, the problems of clogging and sample mixing in coal sampling equipment have been solved, ensuring continuous and accurate sampling while reducing equipment maintenance and water consumption.
Patent Information
- Application Number
- CN202511176027.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-21
- Publication Date
- 2025-11-11
AI Technical Summary
Existing coal sampling equipment is prone to clogging and sample mixing, resulting in inaccurate sampling results, increased equipment maintenance and power generation costs, and existing solutions have limited effectiveness or consume large amounts of water resources.
By monitoring the moisture content in the main sampling channel in real time, the system uses microwave radar sensors and intelligent judgment mechanisms to switch to the bypass sampling channel, and employs automated operations such as vibration unblocking, high-pressure cleaning, and purging to prevent blockage and sample mixing.
This ensured the continuity and accuracy of sampling, reduced equipment failures and maintenance costs, ensured that coal samples reflected the quality of coal entering the plant, and reduced equipment wear and water consumption.
Smart Images
Figure CN120927337A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the technical field of coal sampling equipment, specifically relating to a method, system, and equipment for preventing blockage and mixing of coal samples. Background Technology
[0002] In the power industry, coal is the core fuel for thermal power generation. Its quality is closely linked to power generation efficiency and cost control. Accurately understanding the various indicators of incoming coal is crucial for scientifically guiding boiler combustion adjustments and effectively controlling power generation costs. Sampling machines, as key equipment for sampling incoming coal, provide important data for thermal power plants' production decisions by sampling and analyzing its various indicators.
[0003] However, the sampling machines currently in operation have revealed a series of problems that urgently need to be addressed. Regarding clogging, when the moisture content of the coal is too high or it contains impurities, key components of the sampling machine, such as the sampling head, crusher, and divider, are prone to clogging. Once clogging occurs, it not only directly forces the sampling work to be interrupted, severely affecting the continuity and representativeness of the sampling, making the collected coal samples unable to accurately reflect the overall quality of the coal entering the plant, but also significantly increases the workload and cost of equipment maintenance. Long-term clogging can also cause irreversible damage to the equipment, reducing its service life and increasing the power plant's investment in equipment upgrades and maintenance.
[0004] Regarding the issue of sample mixing, during the alternating sampling of different batches of coal, the presence of residual samples from previous batches within the sampling system can easily lead to mixing between different batches. This mixing phenomenon makes the sampling analysis results unable to truly and accurately reflect the actual quality of each batch of coal, causing significant misguidance for the production decisions of thermal power plants. For example, in critical decision-making stages such as determining coal procurement plans and adjusting boiler combustion parameters, relying on inaccurate sampling analysis results may lead to a series of adverse consequences, such as increased coal procurement costs and reduced combustion efficiency.
[0005] Currently, although there are some solutions on the market for the problems of sampler clogging and sample mixing, most of these solutions have obvious defects and are difficult to achieve the desired effect. Some solutions reduce clogging by optimizing the structure of the sampling equipment, but this optimization method often fails to effectively solve the problem of sample mixing, resulting in deviations in the sampling analysis results. Other solutions use cleaning devices to remove residual coal samples, which can reduce sample mixing to some extent, but not only does it consume a lot of water resources and increase the production cost of power plants, but also, due to the limited cleaning effect, it is difficult to completely eliminate sample mixing. Summary of the Invention
[0006] The purpose of this invention is to provide a method, system and equipment for preventing clogging and mixing of coal samples, in order to solve the technical defects of existing cleaning devices when removing residual coal samples. Although they can reduce the mixing phenomenon to a certain extent, they not only consume a lot of water resources and increase the production cost of power plants, but also have limited cleaning effect and cannot completely eliminate the mixing situation.
[0007] To achieve the above objectives, the present invention employs the following technical solution: Firstly, a method for preventing blockage and sample mixing in a coal sampling device is provided, including: Obtain the moisture content value in the main sampling channel; Based on the obtained moisture content value, determine whether to switch to the bypass sampling channel; When switching to the bypass sampling channel, a cleaning mechanism is used to clear the sampling equipment in the bypass sampling channel.
[0008] Furthermore, before obtaining the moisture content value in the main sampling channel, the method further includes: Pre-set the sampling period and channel switching conditions for moisture content values.
[0009] Furthermore, the pre-set sampling period for moisture content values specifically includes: The sampling period is set to once every two seconds.
[0010] Furthermore, the channel switching conditions specifically include: A preset sampling equipment blockage risk threshold is set. When the obtained moisture content value exceeds the risk threshold, the main coal sampling channel is switched to a bypass sampling channel.
[0011] Furthermore, obtaining the moisture content value within the main sampling channel specifically includes: The microwave radar moisture sensor is used to sample the moisture content of coal in the current main sampling channel in real time. The microwave radar moisture sensors are arranged in multiple units.
[0012] Further, based on the acquired moisture content value, it is determined whether to switch to the bypass sampling channel, specifically including: If the moisture content values obtained three times consecutively reach the channel switching condition and the duration is five minutes, it is determined that the current coal mining channel needs to be switched from the main sampling channel to the bypass sampling channel.
[0013] Furthermore, when switching to the bypass sampling channel, a cleaning mechanism is used to unclog the sampling equipment in the bypass sampling channel, specifically including: Vibration was used to clear blockages from the inner wall of the sampling equipment; After the vibration unblocking is completed, the sampling equipment is cleaned using a high-pressure water pump; Blow up the cleaned sampling equipment until there is no obvious dust at the air outlet of the sampling equipment.
[0014] Secondly, a coal sampling equipment anti-clogging and anti-mixing system is provided, characterized in that it includes: The acquisition module is used to acquire the moisture content value in the main sampling channel; The judgment module is used to determine whether to switch to the bypass sampling channel; The cleaning module is used to clear blockages in the sampling equipment in the bypass acquisition channel.
[0015] Thirdly, a mobile device is provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the coal sampling device anti-blocking and anti-mixing method as described above.
[0016] Fourthly, a computer-readable storage medium is provided, the computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the coal sampling equipment anti-blocking and anti-mixing method as described above.
[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. By acquiring the moisture content value in the main sampling channel and determining whether to switch to the bypass sampling channel based on this value, this real-time monitoring and intelligent switching mechanism can predict the risk of blockage in advance. When the main sampling channel may be blocked due to excessive moisture content, it can switch to the bypass sampling channel in time to avoid the sampling work being interrupted due to blockage, ensure the continuity and representativeness of the sampling, and enable the collected coal samples to accurately reflect the overall quality of the coal entering the plant.
[0018] 2. A reasonable sampling cycle can quickly respond to changes in moisture content. When the moisture content approaches or reaches the critical value that may cause blockage or sample mixing, timely measures can be taken to reduce the risk of sampling interruption and inaccurate coal samples caused by moisture problems.
[0019] 3. High-frequency sampling helps reduce monitoring errors caused by excessively long sampling intervals and more accurately reflects the actual moisture content of coal. This provides more reliable data support for subsequent operations such as channel switching decisions based on moisture content.
[0020] 4. Switching channels when the moisture content exceeds the risk threshold can prevent inaccurate coal samples from being collected due to blockage or abnormality of the main sampling channel, ensuring that the collected coal samples can truly reflect the overall quality of the coal entering the plant.
[0021] 5. Microwave radar moisture sensors utilize the principle of interaction between microwaves and moisture in coal to accurately measure the moisture content of coal. Compared with other measurement methods, microwave radar technology is less affected by factors such as the size and density of coal particles, resulting in more accurate and reliable measurement results.
[0022] 6. By requiring three consecutive moisture content values to meet the channel switching condition, rather than relying on only one or two measurement results, abnormal data caused by these accidental factors can be effectively filtered out, avoiding incorrect channel switching decisions due to individual outliers, and improving the accuracy and reliability of the decision.
[0023] 7. Integrating vibration unblocking, high-pressure cleaning, and purging into the automated control process of the sampling system can achieve automatic unblocking and cleaning of the equipment. Attached Figure Description
[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.
[0025] Figure 1 Flowchart of the anti-clogging and anti-mixing method for coal sampling equipment provided by the present invention; Figure 2 The schematic diagram of the anti-clogging and anti-mixing system for coal sampling equipment provided by the present invention. Detailed Implementation
[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0027] To address the technical deficiencies mentioned in the background section, this embodiment provides a method, system, and device for preventing blockage and sample mixing in coal sampling equipment. The invention will be further described in detail below with reference to the accompanying drawings: In a first aspect, embodiments of the present invention provide a method for preventing blockage and mixing of samples in a coal sampling device, such as... Figure 1 As shown, it includes: S101. Obtain the moisture content value in the main sampling channel. For example, to improve the real-time performance and accuracy of moisture content acquisition, the moisture content sampling period and channel switching conditions need to be preset before acquiring the moisture content value. Specifically, the sampling period is set to once every two seconds, and a sampling equipment blockage risk threshold is preset. When the acquired moisture content value exceeds the risk threshold, the main coal sampling channel is switched to a bypass sampling channel. Acquiring the moisture content value once every two seconds enables high-frequency data acquisition, allowing for real-time and accurate monitoring of the dynamic changes in coal moisture content within the main sampling channel. This real-time monitoring is crucial for timely detection of abnormal fluctuations in moisture content and can quickly capture potential risks that may cause blockage or sample mixing. Furthermore, high-frequency sampling helps reduce monitoring errors caused by excessively long sampling intervals, more accurately reflecting the actual situation of coal moisture content, and providing more reliable data support for subsequent channel switching decisions based on moisture content.
[0028] During the coal entry process, the moisture content may change at any time. Multiple microwave radar moisture sensors are installed at the front end of the sampling machine. During coal sampling, these sensors utilize the interaction principle between microwaves and moisture in the coal to sample the moisture content of the coal in the current main sampling channel in real time. Compared with other measurement methods, microwave radar technology is less affected by factors such as coal particle size and density, resulting in more accurate and reliable measurement results. At the same time, multiple microwave radar moisture sensors can work simultaneously to measure coal moisture from different positions and angles, further improving measurement accuracy and providing precise data support for subsequent channel switching and other operations.
[0029] During the measurement process, the arrangement of multiple microwave radar moisture sensors forms a redundant system. Even if individual sensors fail or have large measurement errors, other sensors can still work normally and provide accurate data, thus ensuring the reliability of the entire measurement system. This redundant design reduces the risk of inaccurate measurement data or system failure due to sensor failure, and improves the stability and availability of the system.
[0030] In addition, multiple sensors collect data from different locations, and these data can complement and verify each other. By analyzing and comparing the measurement results of multiple sensors, abnormal data can be detected and processed in a timely manner, further improving the reliability of the measurement results. If the measurement result of a certain sensor differs significantly from that of other sensors, the sensor can be fault-diagnosed or recalibrated to ensure the accuracy of the measurement data.
[0031] By setting a pre-defined clogging risk threshold for the sampling equipment, a clear standard for judging clogging risk is provided. When the obtained moisture content value exceeds this risk threshold, the risk of clogging of the sampling equipment can be predicted in advance, allowing timely measures to be taken to switch the main coal sampling channel to a bypass sampling channel. This advance prediction and intervention mechanism can effectively prevent clogging of the sampling equipment during actual operation, ensuring the continuity of sampling and ensuring that thermal power plants can continuously and stably obtain accurate coal sample data. At the same time, by switching channels in a timely manner, sampling work is not interrupted due to clogging of the main sampling channel, reducing equipment downtime.
[0032] When the moisture content is too high, coal is prone to accumulate and clump in the sampling equipment, leading to increased wear and tear. By switching channels in a timely manner, the main sampling equipment is prevented from operating for a long time when the moisture content exceeds the standard, reducing the losses caused by blockage and abnormal wear, and lowering the frequency and cost of equipment maintenance.
[0033] S102. Based on the acquired moisture content value, determine whether to switch to the bypass sampling channel. For example, if the moisture content value acquired three times consecutively meets the channel switching condition and the duration is five minutes, it is determined that the current coal mining channel needs to be switched from the main sampling channel to the bypass sampling channel. In actual production environments, the moisture content of coal may fluctuate briefly due to various accidental factors, such as localized accumulation of coal during transportation or brief changes in ambient humidity. By requiring three consecutive moisture content values to meet the channel switching condition, rather than relying solely on one or two measurement results, abnormal data caused by these accidental factors can be effectively filtered out. This avoids making incorrect channel switching decisions due to individual abnormal values, improving the accuracy and reliability of the decision-making process.
[0034] In addition, the five-minute duration setting further enhances the reliability of the judgment, helping to confirm that the trend of increasing moisture content is real and stable, rather than a short-term fluctuation. This ensures that the operation is only carried out when it is really necessary to switch channels, avoiding unnecessary switching and ensuring the continuity and stability of the sampling work.
[0035] In practical applications, when the moisture content of coal remains excessively high, key components such as the sampling head, crusher, and divider of the main sampling channel are prone to blockage. By using the above judgment conditions, abnormal increases in moisture content can be detected in a timely and accurate manner, and the system can switch to the bypass sampling channel at an appropriate time. This effectively prevents blockage of the main sampling channel, reduces the probability of equipment failure, ensures the normal operation of the equipment, reduces equipment maintenance costs and downtime, and ensures that the collected coal samples can truly reflect the overall quality of the coal entering the plant.
[0036] S103. When switching to the bypass sampling channel, the sampling equipment in the bypass sampling channel is cleared using a cleaning mechanism. For example, when switching to the bypass sampling channel, the sampling equipment in the main sampling channel stops operating and is in standby mode. Then, a vibration clearing device, a high-pressure water pump, and a drying device are installed at the easily blocked points of the sampling equipment in the bypass sampling channel. The vibration clearing device is preferably a vibrator, and the drying device is preferably an air blowing nozzle. The high-pressure water pump is connected to an external water supply device. After a batch of coal mining operations is completed, in order not to affect the normal operation of subsequent batches of coal mining, the coal at the easily blocked points of the coal mining equipment is shaken off by remote control of the vibration clearing device. Then, the high-pressure water pump is driven to flush the coal mining equipment and the easily blocked points. After flushing, the air blowing nozzle is used to blow clean, drying the coal mining equipment and removing coal ash adhesion.
[0037] Compared to existing solutions on the market, this method comprehensively considers both anti-clogging and anti-mixing aspects, overcoming the shortcomings of some solutions that can only solve the anti-clogging problem but cannot effectively solve the mixing problem, and the shortcomings of some solutions that use cleaning devices to reduce mixing but consume a lot of water resources, have limited cleaning effect and cannot completely eliminate mixing. This method achieves anti-clogging while also preventing mixing, providing a more comprehensive and effective anti-clogging and anti-mixing solution for coal sampling equipment for thermal power plants.
[0038] Secondly, a system for preventing clogging and mixing of samples in a coal sampling device is provided, characterized in that, as Figure 2 As shown, it includes: The acquisition module is used to acquire the moisture content value in the main sampling channel; The judgment module is used to determine whether to switch to the bypass sampling channel; The cleaning module is used to clear blockages in the sampling equipment in the bypass acquisition channel.
[0039] In the system, the acquisition module, judgment module, and cleaning module can all be intelligently and automatically controlled by the central controller in the remote control center. The acquisition module uses microwave radar moisture sensors. Three microwave radar moisture sensors are installed at intervals at the front end of the conveyor belt feed inlet and the sampling machine inlet to cover the entire coal flow cross section, avoiding single-point detection deviation. Then, the microwave radar moisture sensors are preset to collect moisture data once every two seconds. The dielectric constant difference is calculated through the TDR principle and converted into moisture content data in real time. The data processing module simultaneously plots the moisture fluctuation curve.
[0040] The judgment module uses a PLC programmable logic controller. By pre-editing the moisture content threshold and judgment logic program in the PLC controller, when it receives a signal from the acquisition module that any sensor detects a moisture content ≥15% for five consecutive minutes, it is judged as a high-risk state. The judgment module then sends the high-risk state information to the central controller. The central controller then drives the electric valve on the bypass sampling channel to move the switching baffle located in the bypass sampling channel into the main sampling channel, blocking the main sampling channel and putting it into standby mode. The coal mining operation is then carried out by the anti-blocking vertical high-power continuous screenless crusher in the bypass sampling channel.
[0041] The cleaning module uses a vibratory cleaner, a high-pressure water pump, and air nozzles. The vibratory cleaner is installed at easily clogged locations on the anti-clogging vertical high-power continuous screenless crusher and other coal mining equipment. One end of the high-pressure water pump is connected to an external water supply device, and the other end is divided into multiple branches connected to nozzles. The nozzles are installed on the coal mining equipment and can rotate 360 degrees. After each batch of coal sampling is completed, the vibratory cleaner in the cleaning module is activated to shake off the clogged coal sample. Then, the air nozzles are activated to purge the sampling equipment. During the purging process, compressed air is first used to initially purge the inside of the equipment to blow out most of the residual coal sample. Then, high-pressure air-water mixed cleaning and secondary compressed air purging are performed to further remove residual coal sample from the inside of the equipment and prevent mixing of coal samples from different batches. The high-pressure air-water mixed cleaning pressure is between 20-30 MPa, and the cleaning time is 5-8 minutes per cycle. The compressed air purging pressure is 0.6-0.8 MPa, and the purging time is 2-3 minutes per cycle.
[0042] Finally, an independent sampling device is used to retain samples from each batch of coal. The sampling device is equipped with a special sealed container and transmission pipeline to ensure that the coal samples do not mix with other batches of coal samples during the sampling and transmission process. At the same time, the sampling device and transmission pipeline are cleaned and inspected regularly to ensure their sealing and cleanliness.
[0043] Thirdly, a mobile device is provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the coal sampling device anti-blocking and anti-mixing method as described above.
[0044] Fourthly, a computer-readable storage medium is provided, the computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the coal sampling equipment anti-blocking and anti-mixing method as described above.
[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit its scope of protection. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that after reading the present invention, they can still make various changes, modifications or equivalent substitutions to the specific implementation of the invention, but these changes, modifications or equivalent substitutions are all within the scope of protection of the pending claims of the invention.
Claims
1. A method for preventing blockage and sample mixing in a coal sampling device, characterized in that, include: Obtain the moisture content value in the main sampling channel; Based on the obtained moisture content value, determine whether to switch to the bypass sampling channel; When switching to the bypass sampling channel, a cleaning mechanism is used to clear the sampling equipment in the bypass sampling channel.
2. The method for preventing blockage and mixing of samples in a coal sampling device according to claim 1, characterized in that, Before obtaining the moisture content value in the main sampling channel, the method further includes: Pre-set the sampling period and channel switching conditions for moisture content values.
3. The method for preventing blockage and mixing of coal samples in a coal sampling device according to claim 2, characterized in that, The preset sampling period for moisture content values specifically includes: The sampling period is set to once every two seconds.
4. The method for preventing blockage and mixing of samples in a coal sampling device according to claim 2, characterized in that, The channel switching conditions specifically include: A preset sampling equipment blockage risk threshold is set. When the obtained moisture content value exceeds the risk threshold, the main coal sampling channel is switched to a bypass sampling channel.
5. The method for preventing blockage and mixing of samples in a coal sampling device according to claim 1, characterized in that, The acquisition of the moisture content value in the main sampling channel specifically includes: The microwave radar moisture sensor is used to sample the moisture content of coal in the current main sampling channel in real time. The microwave radar moisture sensors are arranged in multiple units.
6. The method for preventing blockage and mixing of samples in a coal sampling device according to claim 1, characterized in that, Based on the acquired moisture content value, determine whether to switch to the bypass sampling channel, specifically including: If the moisture content values obtained three times consecutively reach the channel switching condition and the duration is five minutes, it is determined that the current coal mining channel needs to be switched from the main sampling channel to the bypass sampling channel.
7. The method for preventing blockage and mixing of samples in a coal sampling device according to claim 1, characterized in that, When switching to the bypass sampling channel, a cleaning mechanism is used to clear any blockages in the sampling equipment within the bypass sampling channel, specifically including: Vibration was used to clear blockages from the inner wall of the sampling equipment; After the vibration unblocking is completed, the sampling equipment is cleaned using a high-pressure water pump; Blow up the cleaned sampling equipment until there is no obvious dust at the air outlet of the sampling equipment.
8. A coal sampling equipment anti-clogging and anti-mixing system, characterized in that, include: The acquisition module is used to acquire the moisture content value in the main sampling channel; The judgment module is used to determine whether to switch to the bypass sampling channel; The cleaning module is used to clear blockages in the sampling equipment in the bypass acquisition channel.
9. A mobile device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the coal sampling equipment anti-blocking and anti-mixing method as described in any one of claims 1-7.
10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the steps of the anti-blocking and anti-mixing method for coal sampling equipment as described in any one of claims 1-7.