Automatic powder sample processing system and method thereof

Abstract

The invention relates to the technical field of industrial automation and quality detection, in particular to a full-automatic powder sampling system and method. The method and system are used for full-automatic sampling, marking, packaging and information tracing in the pneumatic conveying (flushing) process of powdery materials (such as cement, coal ash and mineral powder), unmanned operation of the whole process of monitoring, sampling, temporary storage, barreling, capping, marking and warehousing is achieved, the manual labor intensity and cost are greatly reduced, and the production efficiency is improved. The problems that an existing manual sampling mode is low in efficiency, poor in representativeness, difficult to trace and the like are solved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation and quality inspection technology, specifically to a fully automated powder sampling system and method. Background Technology

[0002] In industries such as building materials, metallurgy, and chemicals, the quality inspection of powdered materials is crucial, and the scientific accuracy of sampling is a prerequisite for ensuring the validity of test results. Currently, after powder transport vehicles arrive at the plant, the powder is mainly conveyed into the silo through a pneumatic conveying system. The sampling process in this step generally relies on manual operation, which presents several challenges: Technicians are required to frequently take manual samples during the material processing, working in harsh environments. When dealing with multiple shipments and large batches of powder, labor costs are high, and fatigue can easily lead to operational errors. The timing, location, and depth of manual sampling are random and subjective, making it difficult to guarantee that the samples accurately reflect the quality of the entire batch, increasing the risk of misjudging "qualified samples, unqualified materials." Sample information is typically recorded using paper labels or manual data entry, which is prone to errors, omissions, and damage, causing a break in the information chain between "sample-batch-shipment-supplier." Once a quality problem occurs, rapid and accurate traceability is difficult, increasing the complexity and risk of quality control.

[0003] While some automated sampling equipment has been reported, most focus on single mechanical sampling actions and fail to deeply integrate with material information flow to form a closed-loop automated management system covering sampling, labeling, circulation, and traceability. Therefore, developing a fully automated powder sampling system that can completely replace manual labor, ensure sample representativeness, and achieve full-process digital traceability is urgently needed and of great significance. Summary of the Invention

[0004] In view of this, the present invention provides a fully automatic powder sampling system and method, which can realize fully automatic sampling, labeling, packaging and information traceability of powdery materials (such as cement, fly ash, mineral powder, etc.) during pneumatic conveying (feeding) process.

[0005] To achieve the above objectives, the present invention provides an automated powder sample processing system, comprising: The material feeding monitoring module is installed on the outer wall of the powder feeding pipe to monitor the working status of the feeding pipe in real time. An automatic sampling module is connected to the powder feeding pipe via a sampling branch, and is used to automatically sample according to preset rules during the feeding process; The encapsulation and labeling module, located after the automatic sampling module, is used to seal the sample storage container and write electronic tag information. The inbound / outbound management module, located in the sample retention room, is used to read the electronic tag information of the sample storage containers and manage the inbound / outbound data; The control module is used to receive information from external systems and control the coordinated operation of various modules.

[0006] The sensors provided in the material handling monitoring module include one or more of the following: vibration sensors, pressure sensors, or dust concentration sensors.

[0007] The automatic sampling module includes: Multiple sampling branches, each branch is connected to a powder flushing pipe and equipped with an automatic sampling valve; Sample storage container, used for temporary storage of samples taken; Automatic sample unloading valve is used to control the transfer of samples from the temporary storage container to the sample storage bucket; A weight sensor is used to monitor the sampling weight and control the sampling process; the multiple sampling branches share a single sampling host, and sampling operations on different pipelines are achieved by switching valves.

[0008] The encapsulation and identification module includes: The capping mechanism has a transverse push rod and a longitudinal push rod, which are used for transferring the bucket cap and pressing and sealing it, respectively. Electronic tag reading and writing equipment is used to write sample information into electronic tags on sample storage containers.

[0009] The sample storage container is equipped with an electronic tag and uses RFID technology to store and read information.

[0010] The control module includes: The data transceiver unit is used to receive incoming powder information from external systems. The control unit is used to control the sampling, packaging, and labeling process according to a preset program.

[0011] This invention also provides an automated method for processing powder samples, based on the system described in this invention, comprising: Real-time monitoring and acquisition of incoming powder information and planned material feeding pipeline numbers; Monitor the operational status of the planned material conveying pipeline; When a material rushing state is detected, the sampling valve is opened to take a sample according to the preset rules. Monitor the sample weight and close the valve once the preset value is reached; After transferring the sample into the storage container, it is sealed and labeled with information. The sample storage container is transferred to the sample retention room and the storage information is registered; the preset sampling rules include one or more of the following methods: random time sampling, multi-location sampling, or multi-point sampling.

[0012] The label information includes one or more of the following: powder manufacturer, type, grade, batch, truck number, and sampling time.

[0013] Beneficial effects: 1. The system of this invention is a fully automated system for sampling, labeling, packaging and information traceability of powdery materials (such as cement, fly ash, mineral powder, etc.) in the pneumatic conveying (feeding) process. It realizes unmanned operation of the entire process from monitoring, sampling, temporary storage, drum filling, capping, labeling to warehousing, which greatly reduces the intensity and cost of manual labor and solves the problems of low efficiency, poor representativeness and difficulty in traceability of existing manual sampling methods.

[0014] 2. In the system of the present invention, random or multi-point multi-time sampling logic controlled by a program, supplemented by high-precision weight sensing control, ensures that the sampled material can truly reflect the quality of the entire batch of materials, thereby improving the reliability of the test results.

[0015] 3. In this invention system, RFID technology is used to automatically and seamlessly bind sample and material information (manufacturer, type, batch, vehicle number, time, etc.), eliminating errors from manual recording and establishing a "one barrel, one code" full life cycle digital traceability system, which facilitates rapid location and traceability of quality problems.

[0016] 4. The system of this invention can be integrated with the factory's existing ERP, MES and other management systems to achieve data exchange, providing a solid data foundation for quality big data analysis and supplier performance evaluation, and promoting the informatization and intelligent upgrading of enterprise quality management.

[0017] 5. The system of this invention reduces the overall cost and maintenance cost of the system by using a single sampling host and intelligent valve switching for multiple pipelines, and is suitable for various industrial scenarios.

[0018] 6. The method of the present invention is based on the system of the present invention, realizing unmanned operation of the entire process from monitoring, sampling, temporary storage, barrel filling, capping, labeling to warehousing, which greatly reduces the intensity and cost of manual labor and solves the problems of low efficiency, poor representativeness and difficulty in traceability of existing manual sampling methods. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of a system according to an embodiment of the present invention.

[0020] Figure 2 This is a schematic diagram of the method flow of an embodiment of the present invention. Detailed Implementation

[0021] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0022] This invention provides an automated powder sample processing system, an intelligent equipment system designed to address the pain points of sampling during the powder transport vehicle flushing process, aiming to achieve automated sampling, digital labeling, and information-based traceability. The system embodiment of this invention is as follows: Figure 1 As shown, the system includes a material flushing monitoring module, an automatic sampling module, a packaging and labeling module, an inbound / outbound management module, and a control module. The material flushing monitoring module is installed on the outer wall of the powder flushing pipe and uses sensors to monitor the working status of the flushing pipe in real time. The automatic sampling module is connected to the outer wall of the powder flushing pipe through a sampling branch. This module includes a sampling branch, an automatic sampling valve, a sample storage container, an automatic unloading valve, a sample storage bucket, and sensors. The packaging and labeling module is located after the automatic sampling module. This module includes a capping mechanism and an electronic tag reader / writer. The inbound / outbound management module is located in the powder sample retention room. This module includes an electronic tag reader / writer and an inbound / outbound management system. The control module includes a data transceiver unit and a control unit. The data transceiver unit receives key information about incoming powder from external systems in real time, while the control unit automates the processing of powder samples according to the set sampling, packaging, and labeling procedures.

[0023] Specifically, one of the material flushing monitoring modules is installed in each material flushing pipeline, and the sensors it is equipped with include, but are not limited to, vibration sensors, pressure sensors, dust concentration sensors, etc.

[0024] The automatic sampling module is connected to at least one sampling branch, each sampling branch is connected to one powder flushing tube, and each sampling branch is equipped with an automatic sampling valve. The automatic sampling valve switches between multiple powder flushing tubes to share a single automated powder sample processing system. The sensor is used to determine whether the sampling quantity meets the preset requirements and triggers the automatic valve to automatically stop sampling. The sample storage container is equipped with an electronic tag. In this embodiment, the automatic sampling module, through the linkage of sensors and mechanical actuators, automatically completes sampling according to preset logic (such as random time, multi-location triggering) during the powder flushing process, replacing manual operation, reducing manpower input, and ensuring sample representativeness through standardized procedures, avoiding deviations caused by subjective human factors.

[0025] The encapsulation and identification module works in conjunction with a capping mechanism and an electronic tag reader / writer to automatically write sample information into the electronic tag of the sample storage container while the capping mechanism completes the capping of the container. In this embodiment, the capping mechanism includes two push rods: a horizontal push rod that moves the sample storage container cap above the container and aligns it with the container, and a vertical push rod that presses the cap and container together to achieve a complete seal.

[0026] In this embodiment, the packaging and identification module uses RFID smart identification and traceability. Each collected sample is automatically associated with a unique RFID electronic tag, which stores key information such as material type, transport vehicle number, flushing time, and sampling location. With the help of RFID reading and writing equipment, it can automatically record the entire lifecycle data of the sample, including its entry and exit from the warehouse, testing status, and storage location, forming a digital traceability chain of "sample-material-batch-supplier" to facilitate rapid tracing of quality issues. The system can be integrated with enterprise quality control platforms, ERP systems, and other systems to integrate sampling data and traceability information into a unified data platform, providing data support for quality analysis and supplier evaluation, and promoting the transformation of powder quality control from manual to digital and intelligent, thereby improving overall management efficiency and accuracy.

[0027] This invention also provides an automated method for processing powder samples, implemented based on the system of this invention, with the process as follows: Figure 2 As shown, it includes the following steps: Step 1: The data transceiver unit in the control module monitors the incoming powder information from the external system in real time. After detecting the incoming powder, it obtains the planned flushing pipeline number and key information of the incoming powder from the external system. The key information includes, but is not limited to, the powder manufacturer, powder type, grade number, etc. Step 2: The material flushing monitoring module is activated to monitor in real time whether the planned material flushing pipeline has entered the material flushing state; Step 3: After the flushing monitoring module detects that the planned flushing pipeline has entered the flushing state, the automatic sampling valve on the sampling branch connected to the planned flushing pipeline will be opened continuously or intermittently according to the preset sampling rules, so that the powder in the powder flushing pipe enters the sample storage container through the sampling branch. Step 4: The sensor equipped with the automatic sampling module obtains the weight of the sampled powder in real time and matches it with the preset sampling weight. Once the preset sampling weight is reached, the automatic sampling valve closes, and the sampling is temporarily stored. Step 5: The automatic sampling module's unloading valve opens, and the powder sample enters the storage bucket by its own weight; Step 6: The sealing and marking module starts the capping mechanism to complete the sealing of the sample storage container. At the same time, the electronic tag reading and writing device writes the key information of the incoming powder obtained in Step 1 into the electronic tag of the sample storage container. Step 7: The sample storage container is transferred to the sample retention room via a conveyor or unmanned vehicle. The electronic tag reader of the inbound and outbound management module reads the electronic tag information of the sample storage container and writes it into the inbound and outbound management system to complete the automated processing of powder samples.

[0028] In summary, the above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automated powder sample processing system, characterized in that, include: The material feeding monitoring module is installed on the outer wall of the powder feeding pipe to monitor the working status of the feeding pipe in real time. An automatic sampling module is connected to the powder feeding pipe via a sampling branch, and is used to automatically sample according to preset rules during the feeding process; The encapsulation and labeling module, located after the automatic sampling module, is used to seal the sample storage container and write electronic tag information. The inbound / outbound management module, located in the sample retention room, is used to read the electronic tag information of the sample storage containers and manage the inbound / outbound data; The control module is used to receive information from external systems and control the coordinated operation of various modules.

2. The system according to claim 1, characterized in that, The sensors equipped in the material handling monitoring module include one or more of the following: vibration sensors, pressure sensors, or dust concentration sensors.

3. The system according to claim 1, characterized in that, The automatic sampling module includes: Multiple sampling branches, each branch is connected to a powder flushing pipe and equipped with an automatic sampling valve; Sample storage container, used for temporary storage of samples taken; Automatic sample unloading valve is used to control the transfer of samples from the temporary storage container to the sample storage bucket; A weight sensor is used to monitor the sampling weight and control the sampling process; the multiple sampling branches share a single sampling host, and sampling operations on different pipelines are achieved by switching valves.

4. The system according to claim 1, characterized in that, The packaging and identification module includes: The capping mechanism has a transverse push rod and a longitudinal push rod, which are used for transferring the bucket cap and pressing and sealing it, respectively. Electronic tag reading and writing equipment is used to write sample information into electronic tags on sample storage containers.

5. The system according to any one of claims 1-4, characterized in that, The sample storage container is equipped with an electronic tag and uses RFID technology to store and read information.

6. The system according to claim 5, characterized in that, The control module includes: The data transceiver unit is used to receive incoming powder information from external systems. The control unit is used to control the sampling, packaging, and labeling process according to a preset program.

7. An automated method for processing powder samples, implemented based on the system described in any one of claims 1-6, characterized in that, include: Real-time monitoring and acquisition of incoming powder information and planned material feeding pipeline numbers; Monitor the operational status of the planned material conveying pipeline; When a material rushing state is detected, the sampling valve is opened to take a sample according to the preset rules. Monitor the sample weight and close the valve once the preset value is reached; After transferring the sample into the storage container, it is sealed and labeled with information. The sample storage container is transferred to the sample retention room and the storage information is registered; the preset sampling rules include one or more of the following methods: random time sampling, multi-location sampling, or multi-point sampling.

8. The method according to claim 7, characterized in that, The label information includes one or more of the following: powder manufacturer, type, grade, batch, truck number, and sampling time.

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