Secondary sorting device and secondary sorting method for mistakenly-picked coal in gangue
By combining the sound detection module and the flip-plate mechanism, automated secondary sorting after the sorting robot is achieved, which solves the problem of coal waste caused by misidentification by the sorting robot, improves sorting efficiency and accuracy, and extends the service life of the equipment.
Patent Information
- Application Number
- CN202511206056.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-27
- Publication Date
- 2025-11-21
AI Technical Summary
In existing technologies, coal sorting robots are prone to misidentification when sorting coal and gangue, leading to waste of coal resources. Existing secondary sorting methods are inefficient and easily affected by environmental factors.
A secondary sorting device for mispicked coal in gangue is adopted. The device uses a sound detection module to identify the material type and performs automatic sorting through a first flipping mechanism and a second flipping mechanism to achieve batch continuous secondary sorting.
It improved sorting efficiency and accuracy, reduced labor intensity, reduced coal resource waste, and extended equipment lifespan.
Smart Images
Figure CN120984579A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coal sorting technology, specifically to the field of gangue sorting equipment technology, and particularly to a secondary sorting device and method for sorting coal that has been mistakenly picked up in gangue. Background Technology
[0002] In coal mining and processing, gangue sorting is a crucial step, aiming to separate coal from gangue and improve the purity and quality of the coal. Currently, gangue sorting robots are widely used in gangue sorting operations, employing technologies such as image recognition and sensor detection to identify and sort coal and gangue.
[0003] However, due to the sometimes similar appearance of coal and gangue, coupled with the complexity of the working environment, gangue sorting robots inevitably make misidentifications during operation, sorting some coal as gangue into the gangue hopper, resulting in a waste of coal resources. To reduce this waste and improve the accuracy of gangue sorting, secondary sorting of the material in the gangue hopper is required to separate the missorted coal.
[0004] Existing secondary sorting methods typically involve a sorting robot first separating large quantities of coal, followed by manual sorting or a second round of centralized sorting using image recognition. However, manual sorting is inefficient and labor-intensive when dealing with large volumes; image recognition, on the other hand, is easily affected by environmental factors, resulting in inconsistent recognition performance. Therefore, a new secondary sorting device and method are urgently needed to address these issues. Summary of the Invention
[0005] The technical problem to be solved by this invention is: in order to solve the technical problem of the difficulty of centralized secondary sorting of coal in the prior art, this invention provides a secondary sorting device and method for mispicked coal in gangue. After the gangue sorting robot sorts out the coal, it immediately performs secondary sorting in small batches to improve sorting efficiency and sorting effect.
[0006] The technical solution adopted by this invention to solve its technical problem is: a secondary sorting device for mispicked coal in gangue, comprising: a material discharge channel, the upper end of which receives materials sorted by a gangue sorting robot, and the lower end for material discharge; a sound detection module, located inside the material discharge channel, which acquires the collision sound of the material with the material discharge channel; a control module, which identifies the material type based on the collision sound; and a first flip-plate mechanism and a second flip-plate mechanism controlled by the control module, the first flip-plate mechanism and the second flip-plate mechanism being located on the material hopper and spaced apart, the first flip-plate mechanism or the second flip-plate mechanism being opened according to the type of material, or the first flip-plate mechanism and the second flip-plate mechanism being closed simultaneously.
[0007] The present invention provides a secondary sorting device for mispicked coal in gangue. After the gangue sorting robot sorts the material, it immediately performs secondary sorting on the material. It adopts batch continuous secondary sorting instead of centralized secondary sorting, thereby improving sorting efficiency and reducing sorting difficulty.
[0008] Furthermore, both the first and second flip-plate mechanisms include a driving device, a driving rod, and a driven rod. One end of the driven rod is hinged to the flip-plate of the material discharge channel, and the other end is connected to the driving rod. The driving rod is connected to the output shaft of the driving device, and the end of the driving rod away from the driving device is hinged to the fixed bracket.
[0009] Furthermore, the flap is hinged to the material discharge channel. When the flap is fully open or fully closed, the intersection point of the driving rod and the driven rod, the connection point of the driving rod and the output shaft, and the connection point of the driven rod and the rotating shaft of the flip are located on the same straight line.
[0010] Furthermore, a return belt is provided below the second flipping mechanism, into which the material output from the second flipping mechanism falls.
[0011] Furthermore, the material feeding channel has a corner section below the entrance, and the material impacts the corner section after falling. The sound detection module is located at the corner section.
[0012] Furthermore, the sound detection module includes multiple microphones arranged in a row.
[0013] The technical solution adopted by this invention to solve its technical problem is: a secondary sorting method for mispicked coal in gangue, which involves detection using the aforementioned secondary sorting device, specifically including the following steps:
[0014] S1. The sorting robot will sort out the materials and send them into the entrance of the material discharge channel;
[0015] S2. The material falls and impacts the material feeding channel, and the collision sound is obtained through the sound detection module;
[0016] S3. The control module identifies the type and batch of materials based on the collision sound.
[0017] S4. The control module opens the first or second flip-plate mechanism according to the type of material in the same batch, or closes the first and second flip-plate mechanisms simultaneously.
[0018] Furthermore, in step S3, the batches of materials are distinguished based on the time interval between the two collision sounds.
[0019] Furthermore, in step S4:
[0020] The material is coal. When the second flap mechanism is opened and the first flap mechanism is closed, the coal is discharged from the second flap mechanism.
[0021] The material is gangue. When the first and second flap mechanisms are closed, the gangue is discharged directly along the discharge channel.
[0022] The material is a coal-gangue mixture. The first flap mechanism is opened and the second flap mechanism is closed, and the coal-gangue mixture is discharged from the first flap mechanism.
[0023] Furthermore, after the coal and gangue mixture falls into the return conveyor belt through the first flipping mechanism, the control module controls the return conveyor belt to transport the coal and gangue mixture to the sorting robot for sorting again.
[0024] Compared with the prior art, the beneficial effects of the present invention are:
[0025] 1. The present invention provides a secondary sorting device and method for missorting coal in gangue, which immediately performs secondary sorting on the materials sorted by the gangue sorting robot. The material type is detected by a sound detection module, which is not affected by the appearance characteristics of the material and the ambient light, and has a high recognition accuracy. It can sort out the coal that was missorted by the gangue sorting robot in real time without the need for manual intervention, reducing labor intensity and achieving high sorting accuracy and efficiency.
[0026] 2. The secondary sorting device and method for mispicked coal in gangue of the present invention utilizes the different impact sounds of coal and gangue with the material discharge channel to identify the types of materials entering the material discharge channel. In conjunction with the opening and closing of the first and second flap mechanisms, secondary sorting of coal, gangue, and coal-gangue mixtures is achieved. For coal-gangue mixtures, they can be returned to the conveyor belt for further sorting, which further improves the accuracy of gangue selection, avoids and reduces the waste of coal resources, and improves economic efficiency.
[0027] 3. The secondary sorting device and method for mispicked coal in gangue of the present invention uses high-strength materials, high-precision drive devices and connecting rod singularity locking structure for the flipping mechanism. When the flipping is fully opened or closed, it forms a dead point self-locking, which can effectively withstand the impact of materials, prevent the flipping from rotating in the opposite direction and damaging the drive device, ensure the accuracy and reliability of the flipping action, extend the service life of the equipment and reduce maintenance costs. Attached Figure Description
[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0029] Figure 1 This is a schematic diagram of the secondary sorting device for mis-picked coal in gangue according to the present invention;
[0030] Figure 2 This is a schematic diagram of the first flipping mechanism;
[0031] Figure 3 This is a schematic diagram showing the first flipping mechanism in the open state.
[0032] In the diagram: 1. Material feeding channel, 2. Sound detection module, 3. First flipping mechanism, 31. Drive device, 32. Active rod, 33. Driven rod, 34. Flipping plate, 4. Second flipping mechanism, 5. Return belt. Detailed Implementation
[0033] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.
[0034] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the 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, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.
[0035] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0036] like Figure 1 As shown, a secondary sorting device for mispicked coal in gangue includes: a material discharge channel 1, a sound detection module 2, a control module (not shown in the figure), a first flipping mechanism 3, and a second flipping mechanism 4.
[0037] Specifically, the upper end of the material discharge channel 1 receives materials sorted by the gangue sorting robot, while the lower end is used for material discharge. The inlet of material discharge channel 1 has a corner section, where materials impact after falling. Since the gangue sorting robot is constantly operating, the sorted materials immediately fall into material discharge channel 1. Upon impact with the corner section, a sound signal is emitted; different materials produce different sound signals, which are acquired by a sound detection module 2. Material discharge channel 1 is part of the gangue funnel.
[0038] Specifically, the sound detection module 2 is located near the corner of the material feeding channel 1 and acquires the collision sound of the material with the material feeding channel 1. The sound detection module 2 can immediately receive different sound signals and send them to the control module to determine the type of material. Material feeding channel 1
[0039] Preferably, the sound detection module 2 includes multiple microphones arranged in a row. The microphones have a frequency response range of 20Hz–20kHz and a sensitivity ≥-38dBV / Pa, enabling them to accurately acquire sound signals generated by the collision of different materials. Simultaneously, the sound detection module 2 is also equipped with a noise reduction processing unit, which uses an adaptive filtering algorithm to reduce noise in the acquired sound signals, removing interference from ambient noise. The filtering coefficient can be adjusted in real time according to the ambient noise intensity. The sound detection module is existing technology and will not be described in detail here.
[0040] Specifically, the control module identifies the material type based on the collision sound. The control module uses an ARM Cortex-A9 architecture processor with a clock speed ≥1GHz and memory ≥512MB to receive and analyze the sound signals transmitted from the sound detection module. It internally stores a database of sound characteristic parameters generated by coal, gangue, and coal-gangue mixtures under different collision forces and angles. This database contains more than 20 characteristic parameters, including sound frequency, amplitude, and spectral distribution. After processing the received sound signal using Fourier transform and wavelet analysis, the characteristic parameters are extracted and then compared with the pre-stored feature parameter database in a multi-dimensional manner. A Support Vector Machine (SVM) algorithm is used for pattern recognition to determine the material type (coal, gangue, or coal-gangue mixture). Based on the determination result, control commands are then issued to other modules such as the flap mechanism. Similarly, the control module is existing technology and will not be elaborated further here.
[0041] Specifically, the first flap mechanism 3 and the second flap mechanism 4 are located on the hopper passage and are spaced apart. The first flap mechanism 3 or the second flap mechanism 4 is opened, or both are closed, depending on the type of material. In this embodiment, coal enters the second flap mechanism 4, while the coal-gangue mixture enters the first flap mechanism 3. The specific opening and closing states of the first flap mechanism 3 or the second flap mechanism 4 will be detailed below.
[0042] Preferably, both the first flap mechanism 3 and the second flap mechanism 4 include a drive device 31, a driving rod 32, and a driven rod 33. One end of the driven rod 33 is hinged to the flap 34 of the material discharge channel 1, and the other end is connected to the driving rod 32. The driving rod 32 is connected to the output shaft of the drive device 31, and the end of the driving rod 32 away from the drive device 31 is hinged to a fixed bracket. After the flap 34 is opened, the material in the material discharge channel 1 can fall to the outside.
[0043] Preferred, such as Figure 2 and Figure 3 As shown, when the flap 34 is fully open or fully closed, the junction of the driving rod 32 and the driven rod 33, the connection point of the driving rod 32 and the output shaft, and the connection point of the driven rod 33 and the rotating shaft of the flip are all on the same straight line. This creates a dead point position, which puts the driving rod 32, the driven rod 33 and the flap 34 in a self-locking state. This allows the flap 34 to withstand the impact of the material and prevent it from rotating in the opposite direction due to the impact, thereby avoiding damage to the drive device 31 (cylinder or servo motor).
[0044] Preferably, the flip plate 34 is made of high-strength alloy material with a thickness of 8-12mm and a wear-resistant coating with a hardness ≥HRC50. The flip plates 34 are respectively installed inside the material feeding channel 1 via rotating shafts. The first flip plate mechanism 3 is located 100-150mm below the sound detection module 2, and the second flip plate mechanism 4 is located 80-120mm below the first flip plate.
[0045] Specifically, a return belt 5 is also provided below the second flipping mechanism 4, and the material output from the second flipping mechanism 4 falls into the return belt 5. The return belt 5 is also controlled by the control module, and the coal and gangue mixture is transported back to the main belt by the return belt 5 for further sorting by the gangue sorting robot.
[0046] Preferably, there is a signal linkage between the return conveyor belt 5 and the first flapping mechanism 3, which is uniformly controlled by the control module. When the first flapping mechanism 3 is in the closed state, the control module sends a stop command to the return conveyor belt 5, and the return conveyor belt 5 does not run. When the control module determines that the material is a coal-gangue mixture and controls the first flapping mechanism 3 to open, it simultaneously sends a start command to the return conveyor belt 5, and the return conveyor belt 5 starts running. The running time of the return conveyor belt 5 is preset according to the material falling amount and conveying speed, generally 3-10 seconds, to ensure that all the material falling from the first flapping mechanism 3 can be conveyed back to the main conveyor belt. After the preset running time of the return conveyor belt 5, the control module sends a stop command, and the return conveyor belt 5 stops running, waiting for the next linkage signal.
[0047] Before describing the secondary sorting method in detail, it should be noted that since the gangue sorting robot is constantly sorting gangue, it may mistakenly sort coal as gangue during the sorting process, or carry coal along with the gangue while moving it. The amount of coal missorted due to these reasons is relatively small, especially since the amount of material sorted by the gangue sorting robot each time is very small (generally only 2-3 pieces of coal or gangue). Therefore, because the amount of material entering the discharge channel 1 each time is small, accurate identification and sorting can be achieved. At the same time, the existing centralized sorting is refined into multiple fragmented sorting processes, effectively improving sorting accuracy and efficiency.
[0048] A secondary sorting method for mispicked coal in gangue, using the aforementioned secondary sorting device, specifically includes the following steps:
[0049] S1. The sorting robot will send the sorted materials into the entrance of the material discharge channel 1. There will be a certain time interval between the materials sent in by the sorting robot. The time interval can be preset to facilitate the batch identification of materials.
[0050] S2. The material falls and impacts the material drop channel 1, and the sound detection module 2 detects the impact sound. The sound detection module 2 determines the batch of the material based on the length of the time interval between the two impacts. For example, if the time interval between two impacts is greater than 1.5s, it is considered to be two batches of material, and if it is less than 1.5s, it is considered to be the same batch of material. Of course, the time interval between two impacts can be adjusted according to actual needs.
[0051] For example, if the sorting robot first feeds in three materials, and the interval between the collision sounds of the three materials is less than 1.5 seconds, then they are judged to be from the same batch. After these three materials, the sorting robot feeds in two more materials. If the time interval between the third and fourth collision sounds is greater than a set time, then the material with the fourth collision sound is from the second batch, and so on. This allows for quick batch determination of materials.
[0052] S3. The control module identifies the type and batch of materials based on the collision sound. Following the description above, the control module performs Fourier transform and wavelet analysis on the sound signal to extract feature parameters. These parameters are then compared with a pre-stored feature parameter database, and the SVM algorithm is used to determine the type of material.
[0053] S4. The control module opens the first flip-plate mechanism 3 or the second flip-plate mechanism 4 according to the type of material in the same batch, or closes the first flip-plate mechanism 3 and the second flip-plate mechanism 4 at the same time.
[0054] If the control module determines that the material is coal, it opens the second flap mechanism 4 and closes the first flap mechanism 3, and the coal is discharged from the second flap mechanism 4 and enters the coal bunker.
[0055] If the control module determines that the material is gangue, it closes the first flap mechanism 3 and the second flap mechanism 4, and the gangue is discharged directly along the discharge channel 1.
[0056] If the control module determines that the mixture is a coal-gangue mixture, it opens the first flap mechanism 3 and closes the second flap mechanism 4, allowing the coal-gangue mixture to be discharged from the first flap mechanism 3. After the coal-gangue mixture falls into the return conveyor belt 5 through the first flap mechanism 3, the control module controls the return conveyor belt 5 to transport the coal-gangue mixture to the sorting robot for further sorting.
[0057] The present invention provides a secondary sorting device for mispicked coal in gangue. After the gangue sorting robot sorts the material, it immediately performs secondary sorting on the material. It adopts batch continuous secondary sorting instead of centralized secondary sorting, thereby improving sorting efficiency and reducing sorting difficulty.
[0058] The above description is based on the preferred embodiments of the present invention. Through the above description, those skilled in the art can make various changes and modifications without departing from the technical concept of the present invention. The technical scope of the present invention is not limited to the contents of the specification, but must be determined by the scope of the claims.
Claims
1. A secondary sorting device for mis-sorting coal in gangue, characterized in that, include: The material discharge channel (1) has an upper end that receives materials sorted by the sorting robot and a lower end that discharges materials. Sound detection module (2), which is located in the material discharge channel (1) and acquires the collision sound of the material with the material discharge channel (1); The control module identifies the material type based on the collision sound. The first flap mechanism (3) and the second flap mechanism (4) are controlled by the control module. The first flap mechanism (3) and the second flap mechanism (4) are located on the material hopper and are spaced apart. The first flap mechanism (3) or the second flap mechanism (4) can be opened or closed at the same time depending on the type of material.
2. The secondary sorting device for mis-picked coal in gangue according to claim 1, characterized in that, The first flip plate mechanism (3) and the second flip plate mechanism (4) both include a driving device (31), a driving rod (32) and a driven rod (33). One end of the driven rod (33) is hinged to the flip plate (34) of the material discharge channel (1), and the other end is connected to the driving rod (32). The driving rod (32) is connected to the output shaft of the driving device (31), and the end of the driving rod (32) away from the driving device (31) is hinged to the fixed bracket.
3. The secondary sorting device for mis-picked coal in gangue according to claim 2, characterized in that, The flap (34) is hinged to the material discharge channel. When the flap (34) is fully open or fully closed, the intersection point of the driving rod (32) and the driven rod (33), the connection point of the driving rod (32) and the output shaft, and the connection point of the driven rod (33) and the rotating shaft of the flip are located on the same straight line.
4. The secondary sorting device for mis-picked coal in gangue according to claim 1, characterized in that, Below the second flipping mechanism (4) is a return belt (5), and the material output from the second flipping mechanism (4) falls into the return belt (5).
5. The secondary sorting device for mis-picked coal in gangue according to claim 1, characterized in that, The material discharge channel (1) has a corner section below the entrance. The material impacts the corner section after falling. The sound detection module is located at the corner section.
6. The secondary sorting device for mis-picked coal in gangue according to claim 5, characterized in that, The sound detection module includes multiple microphones arranged in a row.
7. A secondary sorting method for mistakenly picked coal in gangue, characterized in that, The detection process using the secondary sorting device according to any one of claims 1-6 specifically includes the following steps: S1. The sorting robot will send the sorted materials into the entrance of the material discharge channel (1); S2. The material falls and impacts the material drop channel (1), and the collision sound is obtained through the sound detection module; S3. The control module identifies the type and batch of materials based on the collision sound. S4. The control module opens the first flip-plate mechanism (3) or the second flip-plate mechanism (4) according to the type of materials in the same batch, or closes the first flip-plate mechanism (3) and the second flip-plate mechanism (4) at the same time.
8. The secondary sorting method for mistakenly picked coal in gangue according to claim 7, characterized in that, In step S3, the batches of materials are distinguished based on the time interval between the collision sounds.
9. The secondary sorting method for mistakenly picked coal in gangue according to claim 7, characterized in that, In step S4: The material is coal. The second flap mechanism (4) is opened and the first flap mechanism (3) is closed, and the coal is discharged from the second flap mechanism (4). The material is gangue. When the first flap mechanism (3) and the second flap mechanism (4) are closed, the gangue is discharged directly along the discharge channel (1). The material is a coal-gangue mixture. The first flap mechanism (3) is opened and the second flap mechanism (4) is closed, and the coal-gangue mixture is discharged from the first flap mechanism (3).
10. The secondary sorting method for mistakenly picked coal in gangue according to claim 9, characterized in that, After the coal and gangue mixture falls into the return belt (5) through the first flipping mechanism (3), the control module controls the return belt (5) to transport the coal and gangue mixture to the gangue sorting robot for sorting again.