Collector ring carbon powder cleaning system

Abstract

The embodiment of the invention provides a collecting ring carbon powder cleaning system. According to the collecting ring carbon powder cleaning system, three-dimensional carbon powder distribution data in a collecting ring chamber are obtained through a dual-mode detection module composed of an optical sensor and an electrostatic sensor; the control module generates a cleaning instruction according to the three-dimensional carbon powder distribution data, wherein the cleaning instruction comprises a partition cleaning strategy and a dynamic parameter set; the execution module comprises a negative pressure dust collection unit and a mechanical brush unit, the negative pressure dust collection unit adjusts the frequency of the vortex generator according to the dynamic parameter set, and the mechanical brush unit adaptively adjusts the rotating speed and the downward pressure according to the carbon powder adhesion strength; the carbon powder collecting container monitors the collecting amount in real time through the weighing sensor and the 3DDoF distance measuring device, and a maintenance signal is triggered when the collecting amount reaches a capacity threshold value. According to the scheme, the spatial sensing network is constructed through the optical-electrostatic dual-mode sensing array, real-time quantitative monitoring of the carbon powder accumulation thickness and density is realized for the first time, and the detection precision is improved.

Description

Technical Field

[0001] The embodiments in this specification relate to the field of equipment operation and maintenance technology, and in particular to a collector ring toner cleaning system. Background Technology

[0002] Traditional toner cleaning of slip rings mainly relies on regular manual inspections and mechanical vacuuming devices, which suffers from three major technical bottlenecks: First, single-point sensors cannot accurately detect the three-dimensional distribution of toner, resulting in blind spots in cleaning; second, cleaning mechanisms with fixed parameters struggle to cope with the different toner adhesion characteristics under varying operating conditions, easily leading to over-cleaning that damages the slip ring or incomplete cleaning that causes arcing; third, existing collection containers lack status monitoring functions, making it impossible for maintenance personnel to predict the risk of overflow. Although automated cleaning equipment based on timed control has emerged in recent years, its rigid operating mode does not consider the actual fluctuations in toner generation rate, resulting in energy waste or protection failure.

[0003] Therefore, a better solution is urgently needed. Summary of the Invention

[0004] In view of this, embodiments of this specification provide a collector ring toner cleaning system to address the technical deficiencies existing in the prior art.

[0005] According to a first aspect of the embodiments of this specification, a current collector ring toner cleaning system is provided, characterized in that it includes: Three-dimensional toner distribution data inside the collector ring chamber is acquired through a dual-mode detection module composed of optical and electrostatic sensors. The control module generates cleaning instructions based on the three-dimensional toner distribution data. The cleaning instructions include a partition cleaning strategy and a dynamic parameter set. The execution module includes a negative pressure suction unit and a mechanical brush unit. The negative pressure suction unit adjusts the frequency of the vortex generator according to the dynamic parameter set, and the mechanical brush unit adaptively adjusts the rotation speed and downward pressure according to the toner adhesion strength. The toner collection container monitors the collection volume in real time using a weighing sensor and a 3DToF ranging device, and triggers a maintenance signal when the capacity threshold is reached.

[0006] In one possible implementation, the dual-mode detection module has a scanning frequency of 200Hz and establishes a toner accumulation thermogram by weighted calculation of the scattered light intensity and the electrostatic field distortion value, wherein the weighting coefficient of the electrostatic field distortion value is 0.63±0.05.

[0007] In one possible implementation, the mechanical brush unit includes a high-frequency vibration module that initiates 28kHz vibration when clumps of carbon powder are detected, while the mechanical brush rotation speed is adjusted accordingly. The values ​​increase gradually, where v is the rotation speed, t is the cleaning duration, and e is the natural constant.

[0008] In one possible implementation, the parameter 0.2 in the speed regulation formula is obtained by training with historical data, specifically expressed as follows: in Let be the temperature difference before and after the i-th cleaning. This refers to the amount of toner collected during the corresponding cleaning cycle. The area of ​​mechanical brush wear is represented by the summation range i=1 to n, which represents the most recent 30 valid cleaning records.

[0009] In one possible implementation, the condition for the local cyclone effect of the negative pressure dust collection unit to be generated is satisfied: Where P is the eddy current intensity coefficient and Q is the airflow rate. d is the density of the toner, and d is the diameter of the nozzle. Where L is the air viscosity and L is the distance from the nozzle to the slip ring.

[0010] In one possible implementation, when a methane concentration > 1% LEL is detected, the gas flow rate Q is automatically limited to: in ΔT is the volume of the collector ring chamber, and ΔT is the difference between the current temperature and the ambient temperature.

[0011] In one possible implementation, the filter replacement condition of the toner collection container satisfies a pressure difference Δp > 500 Pa. The pressure difference is obtained by the difference between the front and rear pressure sensors and compensated by a temperature correction value of 0.15 Pa / ℃.

[0012] In one possible implementation, the digital twin system of the control module predicts brush wear through motor current ripple analysis, and triggers a replacement warning when the current harmonic distortion rate (THD) is greater than 7%.

[0013] In one possible implementation, the dynamic parameter set comprises a three-dimensional matching matrix of suction negative pressure, mechanical brush contact pressure, and cleaning duration.

[0014] In one possible implementation, the system generates a cleanliness assessment report after cleaning is completed. This report is calculated by comparing the Euclidean distance ED between sensor data before and after cleaning. in To determine the toner concentration value at the i-th detection point before cleaning, The summation range is from i=1 to n, representing all valid detection points, and the corresponding concentration values ​​after cleaning are calculated.

[0015] This specification provides an embodiment of a collector ring toner cleaning system, which includes: a dual-mode detection module composed of optical and electrostatic sensors to acquire three-dimensional toner distribution data within the collector ring chamber; a control module to generate cleaning instructions based on the three-dimensional toner distribution data, the cleaning instructions including a zoned cleaning strategy and a dynamic parameter set; an execution module including a negative pressure suction unit and a mechanical brush unit, the negative pressure suction unit adjusting the vortex generator frequency according to the dynamic parameter set, and the mechanical brush unit adaptively adjusting the rotation speed and downward pressure according to the toner adhesion strength; and a toner collection container monitoring the collection volume in real time through a weighing sensor and a 3D ToF ranging device, triggering a maintenance signal when the capacity threshold is reached. This solution constructs a spatial sensing network through an optical-electrostatic dual-mode sensor array, achieving real-time quantitative monitoring of toner accumulation thickness and density for the first time, thus improving detection accuracy. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a collector ring toner cleaning system provided in one embodiment of this specification. Detailed Implementation

[0017] Many specific details are set forth in the following description to provide a full understanding of this specification. However, this specification can be implemented in many other ways than those described herein, and those skilled in the art can make similar extensions without departing from the spirit of this specification. Therefore, this specification is not limited to the specific implementations disclosed below.

[0018] The terminology used in one or more embodiments of this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the one or more embodiments of this specification. The singular forms “a” and “the” as used in one or more embodiments of this specification and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in one or more embodiments of this specification refers to and includes any or all possible combinations of one or more associated listed items.

[0019] It should be understood that although the terms first, second, etc., may be used to describe various information in one or more embodiments of this specification, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, first may also be referred to as second without departing from the scope of one or more embodiments of this specification, and similarly, second may also be referred to as first. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to a determination."

[0020] This specification provides a collector ring toner cleaning system, which will be described in detail in the following embodiments.

[0021] See Figure 1 , Figure 1 This diagram illustrates a toner cleaning system for a collector ring according to an embodiment of this specification. Specifically, it includes a dual-mode detection module composed of an optical sensor and an electrostatic sensor to acquire three-dimensional toner distribution data within the collector ring chamber; a control module to generate cleaning instructions based on the three-dimensional toner distribution data, the cleaning instructions including a zoned cleaning strategy and a dynamic parameter set; an execution module including a negative pressure suction unit and a mechanical brush unit, the negative pressure suction unit adjusting the frequency of the vortex generator according to the dynamic parameter set, and the mechanical brush unit adaptively adjusting the rotation speed and downward pressure according to the toner adhesion strength; and a toner collection container monitoring the collection volume in real time via a weighing sensor and a 3DToF ranging device, triggering a maintenance signal when a capacity threshold is reached.

[0022] Among these, optical sensors can refer to devices that detect changes in light signals, such as those that emit beams of light at specific wavelengths and receive the intensity of light scattered by toner, used to construct a thermal map model of toner distribution, enabling non-contact detection of micron-level particles. Electrostatic sensors can refer to devices that measure changes in electric fields, such as those that monitor the electrostatic field distortion around a collector ring, quantifying the abnormal charge distribution caused by toner accumulation, and supplementing the data blind spots of optical detection in humid environments. Dual-mode detection modules can refer to systems that integrate multiple sensing technologies, such as simultaneously processing optical scattering and electrostatic signal data, generating a three-dimensional toner concentration gradient map through a weighted algorithm, improving the anti-interference capability of detection results. Three-dimensional toner distribution data can refer to a collection of spatial concentration information, such as reconstructing raw data collected by a sensor array using an interpolation algorithm, used to accurately identify the location and thickness of toner accumulation, guiding targeted operations by cleaning agencies. Control modules can refer to the system's decision-making center, such as running dynamic coupling algorithms to analyze toner distribution data to generate an instruction set containing partition priorities and parameter matching schemes, used to coordinate the collaborative work of various execution units. A zoned cleaning strategy can refer to a differentiated operating plan, such as dividing high / low concentration areas based on a heat map and configuring the suction negative pressure level and mechanical brush movement trajectory accordingly, which can optimize cleaning efficiency and reduce energy consumption. A dynamic parameter set can refer to real-time adjusted operating parameters, such as variables including vortex frequency (8-15kHz) and brush speed (300-1200rpm), to adapt to the cleaning needs of toner with different adhesion strengths. A negative pressure suction unit can refer to a pneumatic toner collection device, such as generating adjustable negative pressure airflow through a variable frequency fan, combined with a vortex generator to create a local cyclone effect, which can capture suspended toner particles with low energy consumption. A mechanical brush unit can refer to a physical cleaning mechanism, such as using a servo motor to drive a multi-axis brush body, dynamically adjusting the downward pressure (5-20N) based on pressure sensor feedback, which can effectively remove caked toner without damaging the surface of the collector ring. Toner collection containers can refer to enclosed storage devices, such as those integrating weighing sensors and 3D ToF ranging modules. They calculate real-time capacity through mass-volume cross-validation to prevent secondary pollution caused by toner spills. Maintenance signals can refer to early warning information, such as triggering audible and visual alarms and remote notifications when the container capacity reaches a design threshold (95%), ensuring maintenance personnel can replace the collection unit promptly.

[0023] When implemented in a thermal power plant, the system first scans the collector ring chamber every five minutes using a dual-mode sensor, detecting that the carbon powder concentration in a certain area has risen to 4.2 mg / cm³. 3Afterwards, the control module marked the area as a priority cleaning zone and sent a command to start the negative pressure suction unit (12kPa negative pressure, 10kHz vortex frequency) and the mechanical brush unit (800rpm speed, 15N downward pressure). During the cleaning process, the weighing sensor detected that the mass of the collection container increased to 14.7kg, and the system automatically triggered a maintenance signal and activated the shutdown protection program. The entire process took 6 minutes and 23 seconds, and the temperature of the collector ring dropped to within the normal threshold range after cleaning.

[0024] This technical solution constructs a fully closed-loop system for toner management through the deep integration of multimodal sensing and intelligent decision-making. In the detection phase, dual-mode sensing technology overcomes the limitations of a single signal source, enabling environmentally robust toner status identification. The dynamic parameter matching mechanism in the execution phase achieves a leap from extensive cleaning to precise operation. The real-time capacity monitoring function of the collection system completely changes the traditional passive maintenance model that relies on manual inspections. This solution not only significantly extends the equipment maintenance cycle but also reduces energy consumption by decreasing the frequency of ineffective cleaning, forming a new paradigm for toner management that combines economy and reliability.

[0025] In one possible implementation, the dual-mode detection module has a scanning frequency of 200Hz and establishes a toner accumulation thermogram by weighted calculation of the scattered light intensity and the electrostatic field distortion value, wherein the weighting coefficient of the electrostatic field distortion value is 0.63±0.05.

[0026] The dual-mode detection module refers to a system that integrates optical and electrostatic sensing. For example, by simultaneously acquiring light scattering signals and electric field distortion data, it can construct a multi-dimensional toner distribution model, improving detection accuracy in a complementary manner. The 200Hz scanning frequency refers to the data acquisition rate, such as completing a full-area scan every 5 milliseconds. A high-speed ADC converter digitizes the signal, capturing the transient characteristics of dynamic toner accumulation. Scattered light intensity refers to the diffuse reflection energy value of light. For example, after irradiating the toner layer with a 650nm laser, a photodiode array receives the scattered light flux to quantify the surface toner density distribution. Electrostatic field distortion value refers to the degree of electric field distribution anomaly. For example, measuring the potential gradient change around the collector ring using a ring electrode array can reflect changes in partial discharge characteristics caused by toner accumulation. Weighted calculation refers to a multi-source data fusion algorithm, such as assigning a weight of 0.37 to optical data and 0.63 to electrostatic data, using Kalman filtering to eliminate sensor noise and generate a more reliable thermal map. A toner accumulation heat map can refer to a visualized concentration distribution map. For example, the weighted calculation results can be mapped to an RGB color space, displaying a gradient from blue (low concentration) to red (high concentration), which can intuitively guide the priority allocation of cleaning operations. The weighting coefficient 0.63±0.05 can refer to the contribution of electrostatic data. For example, the coefficient value can be dynamically adjusted based on environmental humidity (0.68 for dry environments and 0.58 for humid environments) to adapt to the detection needs under different working conditions.

[0027] In a wind power collector ring monitoring scenario, the system continuously scans at a frequency of 200Hz. When it detects a sudden increase in the electrostatic field distortion value of a certain sector to 12kV / m (with the weight automatically adjusted to 0.68), and the scattered light intensity drops to 30% of the baseline value, it determines that there is dense carbon dust accumulation in that area. The control module immediately generates a red warning heat map, triggering the cleaning robotic arm to perform directional operations. The entire detection-decision cycle takes only 8 milliseconds, a 60% improvement in response speed compared to traditional single-mode detection methods. Post-maintenance retesting shows that the electric field distortion value in the area has returned to the normal range (4.5±0.3kV / m), verifying the effectiveness of the solution.

[0028] This technical solution achieves a qualitative leap in toner condition detection through the synergistic optimization of high-frequency scanning and intelligent weighted algorithms. The dual-mode sensing architecture effectively overcomes the limitations of single detection methods, enabling the system to maintain stable performance under complex operating conditions. The dynamic weight adjustment mechanism balances the intuitiveness of optical detection with the penetrating power of electrostatic detection, significantly improving the reliability of thermal maps. This technical approach, integrating physical sensing and data mining, not only provides precise guidance for cleaning operations but also lays the data foundation for predictive maintenance, driving the transformation of toner management from experience-based judgment to scientific decision-making.

[0029] In one possible implementation, the mechanical brush unit includes a high-frequency vibration module that initiates 28kHz vibration when clumps of carbon powder are detected, while the mechanical brush rotation speed is adjusted accordingly. The values ​​increase gradually, where v is the rotation speed, t is the cleaning duration, and e is the natural constant.

[0030] The high-frequency vibration module can refer to a component that generates mechanical vibration, such as a 28kHz high-frequency vibration wave generated by a piezoelectric ceramic sheet. This vibration wave is used to break the molecular bonding forces between toner particles, enabling the loosening and pre-treatment of agglomerated toner with low energy consumption. Agglomerated toner can refer to densely adhered toner clumps, such as hardened deposits formed under long-term high temperature and pressure. The vibration module's elastic wave conduction causes the internal structure to break down, reducing the resistance of subsequent mechanical brush cleaning. The 28kHz vibration can refer to mechanical fluctuations at a specific frequency, such as those generated by a piezoelectric transducer driven by a Class D amplifier. This creates a shear stress field in the toner layer, specifically breaking down the crystal structure of agglomerated toner. The rotational speed v can refer to the dynamically adjusted brush body angular velocity, for example, gradually increasing from 300rpm to 1200rpm according to an exponential function. The motor current is adjusted in real time by a software PID controller to match the toner removal requirements of different cleaning stages. The cleaning duration t can refer to the operation time variable, such as the time from the start of the vibration module. As an input parameter of the speed adjustment algorithm, it ensures that the cleaning intensity is positively correlated with the degree of toner adhesion. The natural constant e can refer to the irrational number basis in mathematics, such as the exponential function model used to construct the speed increase curve. It is calculated by calling the mathematical library through the embedded system, which makes the speed change conform to the physical laws of material removal.

[0031] Specifically, when the system detects caking carbon powder (hardness level III) in a certain area, it first activates the high-frequency vibration module, applying a continuous 28kHz frequency for 12 seconds to induce microcracks in the carbon powder layer. Then, the mechanical brush unit starts, with an initial speed set to 300rpm, followed by... The algorithm adjusts the rotation speed once per second. During the cleaning process, a pressure sensor monitors the brush resistance in real time. When the resistance value drops below the threshold (15N), the cleaning of that area is considered complete. After a total time of 41 seconds, the system automatically switches to the next working area. Actual measurements show that the amount of residual toner in this mode is reduced by 73% compared to the traditional method, and the surface temperature fluctuation of the collector ring is controlled within ±5 degrees Celsius.

[0032] This technical solution pioneers a new mode of toner cleaning through the synergistic effect of high-frequency vibration and intelligent speed regulation. The vibration module precisely targets the special structure of clumped toner, significantly reducing the workload of traditional mechanical brushes; the dynamic speed adjustment algorithm intelligently and gradually changes the cleaning intensity over time, avoiding toner splashing caused by high-speed rotation in the initial stage while ensuring effective removal of stubborn deposits in the later stages. This combination of rigidity and flexibility improves cleaning efficiency while significantly extending the service life of mechanical components, providing an innovative solution for slip ring maintenance under high-load conditions.

[0033] In one possible implementation, the parameter 0.2 in the speed regulation formula is obtained by training with historical data, specifically expressed as follows: in Let be the temperature difference before and after the i-th cleaning. This refers to the amount of toner collected during the corresponding cleaning cycle. The area of ​​mechanical brush wear is represented by the summation range i=1 to n, which represents the most recent 30 valid cleaning records.

[0034] The speed regulation formula can refer to a dynamic control algorithm, such as through parameterized equations. The description of rotational speed variation is used to achieve adaptive gradual changes in cleaning intensity, balancing the needs of initial splash prevention and efficient cleaning in the later stages. Historical data training refers to the model optimization process, such as collecting data on temperature difference, toner quantity, and wear area from the last 30 cleaning operations, and using least squares fitting to obtain coefficients to make the formula parameters adaptable to different operating conditions. Valid cleaning records refer to standardized operation data, such as selecting operation records with a duration exceeding 15 seconds and a toner quantity greater than 50g, removing outliers through data cleaning to ensure the reliability of the training data.

[0035] When implemented on Unit 2 of a thermal power plant, the system automatically retrieved the 30 most recent valid records and calculated the results. =4280℃·kg, =15.3cm 2 Substituting the values ​​into the formula yields a new parameter of 0.21. After applying this parameter, the cleaning operation showed that maintaining an initial speed of 300 rpm effectively suppressed carbon dust emission, and gradually increasing the speed to 1150 rpm effectively removed the last clump of carbon dust. The overall time was reduced by 18% compared to the original parameters, and brush wear decreased by 22%. This case demonstrates the superiority of the dynamic parameter adjustment strategy.

[0036] This technical solution achieves self-evolution of the cleaning strategy through a data-driven parameter optimization mechanism. Based on coefficient training using multi-dimensional historical data, the speed adjustment formula dynamically adapts to different equipment states and environmental conditions. A comprehensive consideration of temperature difference, toner quantity, and wear area constructs an evaluation system that balances cleaning efficiency and equipment protection. This approach, integrating physical models and data science, not only significantly improves the accuracy of cleaning operations but also continuously optimizes operating parameters through continuous learning, providing a sustainable improvement path for intelligent operation and maintenance systems.

[0037] In one possible implementation, the condition for the local cyclone effect of the negative pressure dust collection unit to be generated is satisfied: Where P is the eddy current intensity coefficient and Q is the airflow rate. d is the density of the toner, and d is the diameter of the nozzle. Where L is the air viscosity and L is the distance from the nozzle to the slip ring.

[0038] The negative pressure suction unit refers to a vacuum adsorption device used to efficiently collect and transport toner through negative airflow. The local cyclone effect refers to the rotating vortex formed by the airflow, which enhances the separation of toner particles and prevents nozzle clogging.

[0039] As a specific example: In a wind power collector ring cleaning system, the negative pressure dust collection unit is equipped with a titanium alloy nozzle with a diameter d=8mm and a standard airflow rate Q=12m³ / h. 3 / min. When the detected toner density ρ ≥ 1.2 g / cm³ 3 At this time, the suction nozzle distance L is automatically adjusted to 3mm, and the eddy current intensity coefficient P is calculated to be 9.1 (satisfying the condition P>8.5). After the system starts, the local cyclone effect decomposes the slab carbon powder layer into suspended particles, which are then transported to the filter chamber through a negative pressure pipeline. Actual measurements show that the carbon powder recovery rate in a single operation reaches 95%, and there is no secondary pollution on the surface of the collector ring.

[0040] This technical solution achieves precise and efficient toner cleaning by quantitatively controlling the cyclone effect generation conditions. The dynamic adjustment mechanism enables the system to adapt to different toner properties and operating conditions, ensuring thorough adsorption while avoiding energy waste caused by excessive dust collection. This design approach based on fluid dynamics principles provides reliable technical support for equipment maintenance in high-dust environments, significantly improving the automation level and sustainability of cleaning operations.

[0041] In one possible implementation, when a methane concentration > 1% LEL is detected, the gas flow rate Q is automatically limited to: in The current collector ring volume is expressed in cubic meters, and ΔT is the difference between the current temperature and the ambient temperature.

[0042] Methane concentration refers to the volume percentage of methane gas in the air, used to monitor the risk of flammable gas accumulation in the collector ring chamber. 1%LEL can refer to one percent of the lower explosive limit of methane, serving as a safety threshold to trigger airflow restriction mechanisms.

[0043] As a specific example: the collector ring room of an offshore wind farm ( =15m 3 On a certain day and at a certain time, a methane concentration of 1.2% LEL was detected, and the equipment temperature was 8°C higher than the ambient temperature. The system automatically calculates... =0.25×15×(1+0.02×8)=4.35m 3 / min, immediately reduce the original operating flow rate of 8m 3 The flow rate dropped to this safe level. Continuous monitoring showed that after 30 minutes, the methane concentration dropped below 0.8% LEL, and the system gradually returned to normal flow. This process avoided the risk of explosion while maintaining basic dust removal functionality.

[0044] This technical solution achieves a dynamic balance between safety and efficiency by establishing a gas concentration-flow coupled control model. A temperature compensation mechanism enhances adaptability under different climatic conditions, and the volumetric parameterization design ensures that control measures are precisely matched to the actual spatial characteristics. This preventative safety strategy effectively reduces the risk of explosions caused by the accumulation of flammable gases, providing intelligent safety assurance for operations in confined spaces.

[0045] In one possible implementation, the filter replacement condition of the toner collection container satisfies a pressure difference Δp > 500 Pa. The pressure difference is obtained by the difference between the front and rear pressure sensors and compensated by a temperature correction value of 0.15 Pa / ℃.

[0046] Among these, "carbon powder collection container" refers to a dust recovery device used to store carbon powder particles adsorbed during cleaning operations and achieve solid-gas separation. "Filter replacement condition" refers to a maintenance trigger threshold, which uses quantitative indicators to determine the degree of filter clogging to ensure filtration efficiency. "Pressure difference Δp" refers to the pressure difference across the filter, used to monitor the real-time degradation of filter permeability. "Pressure sensor" refers to a pressure sensing element that accurately measures changes in airflow resistance at the filter inlet and outlet. "Temperature correction value" refers to an environmental compensation coefficient to eliminate the influence of temperature fluctuations on the pressure sensor readings.

[0047] As a concrete example: A laser printer toner recovery system detected an initial differential pressure of 480 Pa on a certain day, at which time the equipment's operating temperature was 20°C higher than the standard ambient temperature. The system automatically calculated a compensation value of 20°C × 0.15 Pa / °C = 3 Pa, resulting in a corrected differential pressure Δp of 483 Pa (not reaching the replacement threshold). Three days later, the differential pressure rose to 510 Pa (Δp = 513 Pa after temperature compensation), triggering a replacement command. After maintenance personnel replaced the filter, the system differential pressure returned to the normal level of 120 Pa, and the dust removal efficiency improved significantly.

[0048] This technical solution achieves scientific assessment of filter condition through a dynamic compensation mechanism, avoiding resource waste caused by premature replacement and preventing system failures due to excessive clogging. The temperature correction function significantly improves the reliability of monitoring data, providing accurate data for predictive maintenance. This intelligent maintenance strategy extends filter lifespan while ensuring the continuous and efficient operation of the toner collection system.

[0049] In one possible implementation, the digital twin system of the control module predicts brush wear through motor current ripple analysis, and triggers a replacement warning when the current harmonic distortion rate (THD) is greater than 7%.

[0050] The control module can refer to the equipment's operational hub, used to coordinate the data interaction between motor operating parameters and the digital twin system. The digital twin system can refer to a virtual simulation platform, capable of monitoring the entire lifecycle of physical equipment through real-time data mapping. Motor current ripple analysis refers to electrical signal fluctuation detection technology, which can identify abnormal current characteristics caused by mechanical wear. Brush wear can guide the wear status of electrical materials, used to assess the remaining service life of the motor's carbon brush assembly. Current harmonic distortion rate (THD) is a quantitative indicator of waveform distortion, reflecting the health of the motor's operating status. Replacement warnings refer to maintenance decision signals, which can provide early indication of the need to replace critical components to avoid equipment failure.

[0051] As a concrete example: On a certain day, the digital twin system of a subway traction motor detected a THD value consistently exceeding 7.2%. The system automatically retrieved historical data for comparison and found that the fifth harmonic component in the current ripple of motor No. 3 had increased by 30%. The digital twin model simulation showed that this anomaly matched the simulation curve of 65% brush wear, immediately triggering a red alert. After maintenance personnel replaced the carbon brushes as instructed, the THD value dropped to 4.8%, avoiding a potential motor stall accident.

[0052] This technical solution achieves early identification and accurate prediction of mechanical wear by integrating digital twins and current characteristic analysis. The setting of a harmonic distortion rate threshold avoids resource waste caused by false alarms while ensuring timely maintenance of critical components. This data-driven early warning mechanism significantly improves the operational reliability of equipment, provides intelligent decision support for preventative maintenance, and effectively reduces the risk of operational interruptions due to sudden failures.

[0053] In one possible implementation, the dynamic parameter set comprises a three-dimensional matching matrix of suction negative pressure, mechanical brush contact pressure, and cleaning duration.

[0054] Among these, the **dynamic parameter set** refers to an adjustable combination of operating parameters used to optimize the performance of cleaning equipment under different operating conditions. The **vacuum negative pressure value** refers to the vacuum level generated by the airflow, determining the balance between dust adsorption efficiency and energy consumption. The **mechanical brush contact pressure** refers to the force between the cleaning components and the surface being cleaned, adjustable to achieve a balance between surface protection and cleaning effectiveness. The **cleaning duration** refers to the length of a single operation, tailored to different levels of contamination. The **three-dimensional matching matrix** refers to a multi-parameter relational database used to store and retrieve optimal parameter combinations.

[0055] As a concrete example: A photovoltaic panel cleaning robot, at a certain time, automatically retrieved the "dust storm" mode from the 3D matching matrix using its dynamic parameter set: the suction negative pressure was set to 12 kPa, the mechanical brush contact pressure was adjusted to 8 N, and the cleaning duration was set to 90 seconds / ㎡. Actual operation showed that this combination improved the dust removal rate by 25% compared to the default parameters while maintaining zero damage to the panel surface, and simultaneously reduced energy consumption by 15%. The system fine-tuned the parameters every ten minutes based on dust sensor data, achieving continuous optimization.

[0056] This technical solution achieves dual optimization of cleaning efficiency and equipment protection by establishing a multi-dimensional parameter collaborative control mechanism. The data-driven mode of the three-dimensional matrix significantly improves environmental adaptability, enabling the equipment to autonomously cope with various complex working conditions. This intelligent parameter matching strategy not only extends the life of key components but also reduces energy consumption through dynamic adjustment, providing a universal solution for automated cleaning equipment.

[0057] In one possible implementation, the system generates a cleanliness assessment report after cleaning is completed. This report is calculated by comparing the Euclidean distance ED between sensor data before and after cleaning. in To determine the toner concentration value at the i-th detection point before cleaning, The summation range is from i=1 to n, representing all valid detection points, and the corresponding concentration values ​​after cleaning are calculated.

[0058] Among these, a cleanliness assessment report refers to a document that quantifies cleaning effectiveness, used to objectively record the quality compliance of cleaning operations. Sensor data refers to raw environmental monitoring information, providing real-time and accurate input for cleanliness calculations. Euclidean distance (ED) reflects the overall change in contamination levels before and after cleaning. Toner concentration refers to the particulate matter content per unit volume, characterizing the contamination level at a specific location. Valid detection points refer to calibrated monitoring locations used to ensure the representativeness and comprehensiveness of data collection.

[0059] As a specific example: the system collected toner concentration data from 20 valid detection points. The average concentration before cleaning was 85 μg / m³. 3 After cleaning, the concentration dropped to 12 μg / m³. 3 The ED value was calculated to be 137.6 using the Euclidean distance formula. This value was compared with the preset threshold of 150 to generate an "Excellent" cleaning report. Based on the report's conclusions, maintenance personnel extended the next cleaning cycle, ensuring equipment hygiene while saving labor costs.

[0060] This technical solution achieves quantitative evaluation of cleaning effectiveness through a spatial distance algorithm, making maintenance decisions more scientifically based. The multi-point data acquisition mode effectively avoids incomplete localized cleaning, ensuring the comprehensiveness of the evaluation results. This data-driven reporting mechanism not only improves the accuracy of equipment maintenance but also provides a reliable reference for optimizing cleaning cycles through historical data accumulation, ultimately achieving a dual improvement in operational efficiency and hygiene standards.

[0061] It should be noted that, for the sake of simplicity, the foregoing method embodiments are all described as a series of actions. However, those skilled in the art should understand that the embodiments in this specification are not limited to the described order of actions, because according to the embodiments in this specification, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in this specification are all preferred embodiments, and the actions and modules involved are not necessarily essential to the embodiments in this specification.

[0062] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0063] The preferred embodiments disclosed above are merely illustrative of this specification. The optional embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the embodiments described herein. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the embodiments, thereby enabling those skilled in the art to better understand and utilize this specification. This specification is limited only by the claims and their full scope and equivalents.

Claims

1. A collector ring toner cleaning system, characterized in that, include: Three-dimensional toner distribution data inside the collector ring chamber is acquired through a dual-mode detection module composed of optical and electrostatic sensors. The control module generates a cleaning instruction based on the three-dimensional toner distribution data. The cleaning instruction includes a partition cleaning strategy and a dynamic parameter set. The execution module includes a negative pressure suction unit and a mechanical brush unit. The negative pressure suction unit adjusts the frequency of the vortex generator according to the dynamic parameter set, and the mechanical brush unit adaptively adjusts the rotation speed and downward pressure according to the toner adhesion strength. The toner collection container monitors the collection volume in real time using a weighing sensor and a 3DToF ranging device, and triggers a maintenance signal when the capacity threshold is reached.

2. The collector ring toner cleaning system according to claim 1, characterized in that, The dual-mode detection module has a scanning frequency of 200Hz. It establishes a toner accumulation thermal map by weighting the scattered light intensity and the electrostatic field distortion value, wherein the weighting coefficient of the electrostatic field distortion value is 0.63±0.

05.

3. The collector ring toner cleaning system according to claim 1, characterized in that, The mechanical brush unit includes a high-frequency vibration module that activates 28kHz vibration when it detects clumps of carbon powder, while simultaneously adjusting the mechanical brush rotation speed. The values ​​increase gradually, where v is the rotation speed, t is the cleaning duration, and e is the natural constant.

4. The collector ring toner cleaning system according to claim 3, characterized in that, The parameter 0.2 in the speed regulation formula is obtained from historical data training, specifically expressed as follows: in Let be the temperature difference before and after the i-th cleaning. This refers to the amount of toner collected during the corresponding cleaning cycle. The area of ​​mechanical brush wear is represented by the summation range i=1 to n, which represents the most recent 30 valid cleaning records.

5. The collector ring toner cleaning system according to claim 1, characterized in that, The conditions for the local cyclone effect generated by the negative pressure dust collection unit are met: Where P is the eddy current intensity coefficient and Q is the airflow rate. d is the density of the toner, and d is the diameter of the nozzle. Where L is the air viscosity and L is the distance from the nozzle to the slip ring.

6. The collector ring toner cleaning system according to claim 5, characterized in that, When a methane concentration > 1% LEL is detected, the gas flow rate Q is automatically limited to: in ΔT is the volume of the collector ring chamber, and ΔT is the difference between the current temperature and the ambient temperature.

7. The collector ring toner cleaning system according to claim 1, characterized in that, The filter replacement condition of the toner collection container meets the pressure difference Δp > 500 Pa. The pressure difference is obtained by the difference between the front and rear pressure sensors and compensated by a temperature correction value of 0.15 Pa / ℃.

8. The collector ring toner cleaning system according to claim 1, characterized in that, The digital twin system of the control module predicts brush wear through motor current ripple analysis, and triggers a replacement warning when the current harmonic distortion rate (THD) is greater than 7%.

9. The collector ring toner cleaning system according to claim 1, characterized in that, The dynamic parameter set includes a three-dimensional matching matrix of suction negative pressure value, mechanical brush contact pressure, and cleaning duration.

10. The collector ring toner cleaning system according to claim 1, characterized in that, The system generates a cleanliness assessment report after cleaning is completed. This report calculates the Euclidean distance (ED) by comparing sensor data before and after cleaning. in To determine the toner concentration value at the i-th detection point before cleaning, The summation range is from i=1 to n, representing all valid detection points, and the corresponding concentration values ​​after cleaning are calculated.

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