Intelligent medium adding method and system for dense medium coal dressing

Abstract

The invention provides an intelligent medium adding method and system for dense medium coal preparation. The technical problems that an existing automatic medium adding system is high in hardware computing power cost, weak in interference resistance and tedious in operation and maintenance and has potential safety hazards are solved. The method comprises the following steps: acquiring a plane image of a medium stack, dividing the plane image into a plurality of blocks, performing gray imaging, comparing the blocks with large gray values with preset block numbers, and acquiring two-dimensional coordinates of high-point blocks of the medium stack; acquiring the current position of a travelling crane, controlling an electromagnetic chuck to descend according to the numerical value of a weighing sensor when the travelling crane moves to a high-point block of a medium stack, realizing dynamic positioning and medium suction, conveying the medium into a concentrated medium barrel, and calculating the medium adding mass through the weighing sensor; preparing the medium in the concentrated medium barrel, judging whether the liquid level of the medium liquid reaches the upper limit or not, if yes, stopping preparing the medium, conveying the medium liquid in the concentrated medium barrel to the dense medium system, and when the medium liquid in the concentrated medium barrel is lower than the critical liquid level, stopping conveying and continuing to prepare the medium. The method can be widely applied to the technical field of coal.

Description

Technical Field

[0001] This application belongs to the field of coal technology, and more specifically, relates to an intelligent method and system for heavy media coal preparation. Background Technology

[0002] Currently, the addition and preparation of concentrated media in the heavy medium systems of most coal preparation plants in China is still mainly done manually. Specifically, after the central control operator determines that media needs to be added based on production conditions, they notify the media addition operator. The operator then manually prepares the media and controls the make-up medium pump to supply media to the heavy medium system. This entirely manual method of adding media results in high labor intensity for the operators, severe dust pollution in the working environment, and is detrimental to occupational health. At the same time, the extensive manual media preparation process makes it difficult to accurately control the liquid density of the medium and to calculate the actual consumption of the medium.

[0003] The existing Chinese invention patent with publication number CN109718945A proposes an intelligent medium addition system and method for heavy media coal preparation plants. By setting up multiple camera devices, a crane, a grab bucket, a medium pile, a medium tank, a conveying pump, and a controller connected to each component, it realizes automatic medium addition in heavy media coal preparation plants, which solves the problem of high manpower and material costs caused by manual medium addition. However, it has poor operational stability, cannot meet production needs, and is not conducive to efficient separation.

[0004] Moreover, this patent uses multiple camera devices and 3D modeling to achieve positioning and identification. This process is costly in terms of hardware computing power, has weak anti-interference capabilities, and is cumbersome to maintain. Specifically, it requires the deployment of multiple high-definition industrial camera devices and uniform calibration, resulting in high hardware procurement costs. At the same time, 3D mesh modeling requires pixel matching and spatial reconstruction of images from multiple devices simultaneously, which involves complex algorithm logic. In industrial scenarios such as dust in the media storage and light fluctuations, image distortion is prone to occur, leading to misjudgment of the highest point of the media pile and deviations in total weight estimation, affecting the grabbing efficiency of the grab bucket. In subsequent maintenance, the displacement of a single camera device or lens contamination requires overall recalibration, which is cumbersome and costly to maintain, making it difficult to adapt to the landing requirements of coal preparation plants and the long-term stable operation requirements of complex industrial environments.

[0005] Furthermore, the media storage area is a cross-operation zone where personnel inspections and vehicle transportation take place. However, this patented design lacks any safety protection equipment. During personnel inspections, collisions and injuries from falling media are highly likely. The vehicle also lacks multiple limit switches, increasing the risk of collisions, reel spills, and overshooting accidents. Summary of the Invention

[0006] The purpose of this application is to provide an intelligent medium addition method and system for heavy medium coal preparation, so as to solve the technical problems of high hardware computing cost, weak anti-interference, cumbersome operation and maintenance, and safety hazards in the existing automatic medium addition system.

[0007] To achieve the above objectives, a first aspect of this application provides a method for intelligent media addition in heavy media coal preparation, comprising the following steps: A planar image of the media stack is acquired, divided into several blocks, and grayscale imaging is performed on each block. The blocks with larger grayscale values ​​are compared with preset block numbers. The two-dimensional coordinates of the high point blocks of the media stack are obtained through the correspondence between the preset block numbers and the two-dimensional coordinates of the block center. The current position of the crane is obtained. When the crane moves to the high point of the medium stack, the electromagnetic chuck is controlled to descend according to the value of the weighing sensor to achieve dynamic positioning and medium suction, and transport it into the concentrated medium tank. The amount of medium added is calculated by the weighing sensor. Prepare the medium in the concentrate tank and determine if the liquid level of the medium has reached the upper limit. If so, stop preparing the medium and transfer the liquid in the concentrate tank to the heavy medium system. When the liquid level of the medium in the concentrate tank is lower than the critical level, stop the transfer and continue preparing the medium.

[0008] Preferably, before acquiring a planar image of the media stack, the media library area needs to be divided proportionally, and the divided blocks are assigned unique numbers as preset block numbers. The two-dimensional coordinates of the vehicle moving to the center of each block are recorded. After obtaining a planar image of the media stack, the planar image of the media stack is divided into blocks corresponding to the media library area according to the proportion.

[0009] Preferably, the process of calculating the amount of medium added by the weighing sensor includes: obtaining the weight of the medium drawn down by the electromagnetic chuck and the weight of the electromagnetic chuck after it is transported to the concentrated medium tank and the medium is released by the electromagnetic chuck, and the difference between the two is the amount of medium added.

[0010] The second aspect of this application provides an intelligent medium addition system for heavy medium coal preparation, including: a laser rangefinder, a first camera device, a second camera device, a crane, an electromagnetic chuck, a thickening tank, a medium stack, a replenishing pump, and a controller and a host computer connected to each other; The first camera device is located on the top of the media stack, with the lens pointing vertically downwards. The trolley is connected to the electromagnetic chuck. The concentrated medium tank is located on one side of the media stack. The outlet of the concentrated medium tank is connected to the replenishing pump. The controller and the host computer are connected to the laser rangefinder, the first camera device, the second camera device, and the trolley.

[0011] Preferably, safety light curtains are provided on both sides of the medium stack to detect whether a person or vehicle has entered; An audible and visual alarm is installed above the safety light curtain and below the second camera device to issue an alarm when the safety light curtain is blocked or when the second camera device detects a person or vehicle entering the loading area.

[0012] Preferably, a pull-rope encoder and a weighing sensor are provided between the electromagnetic chuck and the crane; A drawstring encoder is used to record the rising and falling positions of an electromagnetic chuck. Laser rangefinders are used to record the movement positions of large and small vehicles during operation; The load cell is used to control the lifting and lowering of the electromagnetic chuck and to record the weight of the electromagnetic chuck after it picks up and releases the medium.

[0013] Preferably, a counterweight limit switch is also provided between the electromagnetic chuck and the trolley, and the trolley is equipped with a limit switch, a photoelectric switch and a flame cut-off device; The counterweight limit switch, together with the flame cut-off device and the pull rope encoder, forms a progressive multi-limit system to limit the vertical upward movement of the electromagnetic chuck. The fire stop and the pull rope encoder form a progressive multi-limit system to limit the vertical downward movement of the electromagnetic chuck 3.

[0014] Preferably, the traveling crane uses limit switches and photoelectric switches to form a progressive multi-limit system to limit the running position of the trolley and the carriage. When the traveling crane reaches the limit position of the limit switches and photoelectric switches, the controller controls the traveling crane to stop moving.

[0015] Preferably, the feed inlet of the concentrate tank is connected to the blower channel and the water supply pipe, a level gauge is installed on the top of the concentrate tank, and a level switch is installed inside the concentrate tank. The blower channel is inserted into the bottom of the thickener tank to stir the medium inside the tank; The water supply pipe is used to replenish water into the concentrate tank according to the control of the controller; A level gauge is used to detect the liquid level inside a concentrated medium tank; The level switch is used to interlock and shut off the water supply pipe when the liquid level in the concentrate tank is too high.

[0016] Preferably, an electric blower valve is provided between the feed inlet of the concentrate tank and the blower channel, and an electric water supply valve and a water supply flow meter are provided between the feed inlet of the concentrate tank and the water supply pipe. Electric blower valves are used to control the opening and closing of the blower duct; The electric water supply valve is used to control the opening and closing of the water supply pipeline; The water supply flow meter is used to detect the amount of water supplied to the water supply pipeline.

[0017] The beneficial effects of this application are as follows: This application provides an intelligent medium-addition method and system for heavy media coal preparation. It obtains a grayscale image from a planar image of the media pile, then performs partitioning processing to obtain the two-dimensional coordinates of the high-point blocks of the media pile. Relying on a weighing sensor, it achieves dynamic positioning of the electromagnetic chuck for medium absorption, thus replacing the traditional multi-camera 3D modeling method. This significantly reduces hardware computing costs and operational complexity. The algorithm logic is simple, avoiding positioning deviations caused by modeling errors and data redundancy. Simultaneously, by aiming the lens of the first camera device vertically downwards at the top of the media pile, it directly acquires vertical images of the media pile, reducing interference from media dust, equipment shadows, and lighting fluctuations on the images. This avoids image distortion problems caused by oblique shooting from multiple cameras, ensuring the stability and efficiency of the medium absorption and release processes. Furthermore, this application also constructs a safety protection system that includes safety light curtains, audible and visual alarms, camera visual recognition, triple limit switches for electromagnetic chuck upward movement, double limit switches for electromagnetic chuck downward movement, double limit switches for horizontal movement of the trolley and carriage during operation, and dual liquid level control. This system can effectively avoid industrial risks such as personnel intrusion, equipment collisions, top overflow, reel rolls, and media spillage, and comprehensively ensure operational safety and stable equipment operation. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A flowchart of a heavy media coal preparation intelligent media addition method provided in an embodiment of this application; Figure 2 A schematic diagram of a heavy media coal preparation intelligent media addition system provided in an embodiment of this application; Figure 3 This is a schematic diagram illustrating the working principle of an intelligent medium addition system for heavy medium coal preparation, provided in one embodiment of this application.

[0020] In the diagram: 1. First camera device; 11. Second camera device; 2. Crane; 3. Electromagnetic chuck; 4. Laser rangefinder; 5. Audible and visual alarm; 6. Concentrated medium tank; 7. Medium stack; 8. Safety light curtain; 9. Controller; 10. Host computer; 21. Photoelectric switch; 22. Limit switch; 23. Flame cut-off device; 31. Pull rope encoder; 32. Weighing sensor; 33. Counterweight limit switch; 61. Blower electric valve; 62. Water supply flow meter; 63. Water supply electric valve; 64. Blower channel; 65. Water supply pipe; 66. Level gauge; 67. Level switch; 68. Medium supply pump; 69. Grate; A. Upper limit of liquid level; B. Lower limit of liquid level. Detailed Implementation

[0021] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0022] Please see Figure 1 The first embodiment of this application provides a method for intelligent media addition in heavy media coal preparation, comprising: S1: Obtain a planar image of the media stack, divide it into several blocks, perform grayscale imaging on each block, compare the block with the preset block number with the block with the larger grayscale value, and obtain the two-dimensional coordinates of the high point block of the media stack through the correspondence between the preset block number and the two-dimensional coordinates of the block center.

[0023] After receiving the media addition command, the host computer issues a media addition instruction. At this time, the camera above the media stack acquires a planar image of the media stack in real time and transmits it to the host computer. The host computer performs grayscale imaging processing on the planar image using a built-in depth recognition algorithm. The block with the larger grayscale value is the block number of the highest point of the media stack. The mapping relationship between the block number and the two-dimensional coordinates of the media library is retrieved, and the two-dimensional coordinates of the highest point block of the media stack are obtained by comparison and parsing. These two-dimensional coordinates are then sent to the controller.

[0024] Specifically, the media storage area is divided into several proportionally sized blocks, each slightly smaller than the suction cup area. Each block is assigned a unique number, and the trolley is controlled to move sequentially to the center of each block, recording the sensor data (i.e., two-dimensional coordinates (X, Y) of the laser ranging sensors on both the main and auxiliary trolleys. The system's host computer acquires a planar image of the media stack area via a camera device and uses a depth recognition algorithm to delineate the extent of the media stack within the planar image. Subsequently, the planar image of the media stack area is divided proportionally into blocks corresponding to the media storage area, and each block is assigned the same number as the media storage area. The depth recognition algorithm performs grayscale imaging processing on the planar image of each block, where the point with the highest grayscale value corresponds to the highest point of the media stack. The two-dimensional coordinates (X, Y) of the highest point of the media stack within the media storage area can be obtained using the block number of the block containing this highest point.

[0025] S2: Obtain the current position of the crane, control the crane to move to the high point of the medium stack, control the electromagnetic chuck to descend according to the value of the weighing sensor, realize dynamic positioning and medium suction, and transport it into the concentrated medium tank. The amount of medium added is calculated by the weighing sensor.

[0026] Based on the laser rangefinder to obtain the current position of the trolley, control the trolley to move to the highest point of the medium stack, the electromagnetic chuck descends and picks up the medium. After the electromagnetic chuck is full of medium, drive the trolley to move above the concentrated medium tank, and then control the electromagnetic chuck to descend and unload the medium into the concentrated medium tank. The added medium weight is calculated based on the total weight of the medium picked up by the electromagnetic chuck and the weight of the medium after the electromagnetic chuck releases the medium.

[0027] Specifically, the controller obtains the current position information of the traveling crane through a laser rangefinder. After the traveling crane carrying the electromagnetic chuck moves to the target position, the controller controls the electromagnetic chuck to descend and dynamically positions itself based on the changes in the weighing value obtained from the weighing sensor, ensuring that the electromagnetic chuck can smoothly land on the medium pile and be fully saturated with medium. The controller obtains the weight of the medium after the electromagnetic chuck has absorbed it through the weighing sensor, and simultaneously controls the traveling crane to move to the concentrated medium tank position. By reading the value of the pull rope encoder, the controller controls the electromagnetic chuck to descend to the medium release position and controls the electromagnetic chuck to release the medium. The controller obtains the weight of the medium after the electromagnetic chuck has released it through the weighing sensor. At this time, the difference between the weight of the medium after the electromagnetic chuck has absorbed it and the weight of the medium after the electromagnetic chuck has released it is the added medium weight.

[0028] This application uses a high-precision weighing sensor to measure the medium being added, and controls the electromagnetic chuck to descend and position itself to ensure that the electromagnetic chuck can smoothly fall onto the medium pile and fully absorb the medium.

[0029] S3: Configure the medium in the concentrate tank and determine whether the liquid level of the medium has reached the upper limit. If so, stop configuring the medium; otherwise, continue configuring.

[0030] Based on the set media density and flow meter data, the electric valve for water replenishment is controlled to adjust the media liquid in the concentrate tank. When the liquid level in the concentrate tank reaches the upper limit or the set amount of media, the media preparation stops.

[0031] Specifically, the controller opens the water supply pipe valve, replenishing the concentrate tank with water based on the calculated replenishment volume according to the set media density and flow meter data. After replenishment, the water supply pipe valve is closed, and the system continues to identify, absorb, release, and replenish media until the media liquid in the concentrate tank reaches the set replenishment volume. Subsequently, the blower operates continuously for a period of time to ensure thorough mixing of the media and water and prevent media sedimentation. Finally, the controller closes the blower valve, completing the media replenishment process. The flow meter data precisely controls the opening and closing of the water supply electric valve to ensure the media liquid reaches the set concentration. The blower pipe installed on the concentrate tank prevents media sedimentation and ensures thorough mixing of the media and water, guaranteeing the desired concentration effect.

[0032] S4: Transfer the medium liquid in the concentrated medium tank to the heavy medium system. When the medium liquid in the concentrated medium tank is lower than the critical level, stop the transfer.

[0033] After the medium in the concentrate tank is prepared, the make-up medium pump delivers the medium liquid in the concentrate tank to the heavy medium system; when the medium liquid in the concentrate tank is lower than the critical level, the make-up medium pump stops running.

[0034] Specifically, when the heavy medium system requests replenishment and the concentrate tank level is higher than the set value, the replenishment pump starts and begins supplying the medium to the heavy medium system. When the concentrate tank level drops to the warning value, the replenishment pump stops operating through an interlocking mechanism. During the replenishment process, the controller monitors the concentrate tank level in real time via a level gauge to prevent the medium from overflowing due to excessively high levels. Furthermore, to prevent abnormal level gauge data, when the concentrate tank level rises to a certain height, the float switch triggers the interlocking protection mechanism, closing the water supply valve.

[0035] In one optional embodiment, during the media processing, the host computer monitors the media processing area in real time using an AI algorithm embedded in the camera device. If a person or vehicle intrudes, the host computer alarms the media processing system operator, and simultaneously triggers an audible and visual alarm to prompt the person or vehicle in the media storage to move away from the media processing area. The controller detects the operating status of the media processing system through safety light curtains, photoelectric switches, and limit switches on the trolley. If the safety light curtains, photoelectric switches, or limit switches are triggered, the controller stops the trolley. After the host computer operator confirms that the abnormality has been resolved, the operation is reset. The intelligent media processing system can continue to operate after passing the self-test.

[0036] Please see Figure 2 The second embodiment of this application provides an intelligent medium addition system for heavy medium coal preparation, comprising: a laser rangefinder 4, a first camera device 1, a second camera device 11, a traveling crane 2, an electromagnetic chuck 3, a concentrated medium tank 6, a medium stack 7, a supplementary medium pump 68, and a controller 9 and a host computer 10 connected to each other. The controller 9 and the host computer 10 are connected to the laser rangefinder 4, the first camera device 1, the second camera device 11, and the traveling crane 2.

[0037] This application includes multiple camera devices distributed around the media storage inlet and the concentration tank 6. The first camera device 1 is positioned above the media stack 7, with its lens pointing vertically downwards. In this embodiment, the first camera device 1 is a video camera, optionally a standard commercial video camera. In an optional embodiment, this application includes four camera devices. Three of them, known as the second camera device 11, are positioned around the media storage inlet and the concentration tank 6 to monitor the media storage area, while one, the first camera device 1, is positioned above the media stack 7 with its lens pointing vertically downwards. It is noteworthy that the installation height of the camera devices (video cameras) is higher than the height of the media stack 7. Furthermore, the electromagnetic chuck 3 is connected to the traveling crane 2, the concentrated medium tank 6 is located on one side of the medium stack 7, the outlet of the concentrated medium tank 6 is connected to the replenishing pump 68, the inlet of the concentrated medium tank 6 is connected to the blower channel 64 and the water replenishment pipe 65, a level gauge 66 is installed above the concentrated medium tank 6, and a level switch 67 is installed inside the concentrated medium tank 6. A blower electric valve 61 is installed between the inlet of the concentrated medium tank 6 and the blower channel 64, and a water replenishment electric valve 63 and a water replenishment flow meter 62 are installed between the inlet of the concentrated medium tank 6 and the water replenishment pipe 65.

[0038] The controller 9 controls the water supply pipe 65 to add water proportionally according to the weight of the medium. Water and medium form a medium liquid inside the concentrate tank 6. The water supply flow meter 62 detects the water supply volume. The water supply electric valve 63 controls the opening and closing of the water supply pipe 65. The level gauge 66 is used to detect the liquid level in the concentrate tank 6. The level switch 67 is used to interlock and close the water supply electric valve 63 when the liquid level is too high.

[0039] The blower channel 64 is inserted into the bottom of the concentrated medium tank 6 to stir and mix the medium and prevent the medium from settling. The blower electric valve 61 is used to control the opening and closing of the blower channel 64.

[0040] A grate 69 is installed above the interior of the concentrate tank 6. When the medium is unloaded from the electromagnetic chuck 3, it falls into the concentrate tank 6 through the grate 69. In an optional embodiment, the grate 69 is made of steel grating with a pore size of 5cm × 3cm, which is used to filter larger impurities and also to buffer the medium unloaded from the electromagnetic chuck 3 to prevent liquid splashing.

[0041] In one embodiment, the concentrate tank 6 is provided with an upper limit A and a lower limit B for the liquid level. When the liquid level in the concentrate tank 6 reaches the upper limit A, the preparation of the medium liquid is stopped; when the liquid level in the concentrate tank 6 reaches the lower limit B, the delivery of the medium liquid is stopped, and the preparation conditions are triggered. A pull-rope encoder 31 and a weighing sensor 32 are provided between the electromagnetic chuck 3 and the traveling trolley 2. A laser rangefinder 4 is provided on one side of the traveling trolley 2, which is used to measure the current position of the traveling trolley 2. In an optional embodiment, two laser rangefinders 4 are provided for positioning the main trolley and the auxiliary trolley in the traveling trolley 2. The measurement accuracy of the laser rangefinder 4 can reach 5mm.

[0042] The pull-rope encoder 31 is used to record the rising and falling positions of the electromagnetic chuck 3. The pull-rope encoder 31 can ensure that after the electromagnetic chuck 3 rises to a high position, the trolley 2 moves in the horizontal direction. When releasing media, it can ensure that the electromagnetic chuck 3 falls to a suitable height before releasing media, thus achieving stable media loading.

[0043] In one embodiment, the crane 2 is equipped with a pull-rope encoder 31 for positioning the electromagnetic chuck 3 as it rises and for positioning the electromagnetic chuck 3 as it descends to the concentrated medium tank 6. The measurement accuracy of the pull-rope encoder 31 can reach 1 mm.

[0044] A weighing sensor 32 is installed on the steel cable between the traveling crane 2 and the electromagnetic chuck 3. This sensor is used both to measure the weight of the medium picked up by the electromagnetic chuck 3 and to assist the electromagnetic chuck 3 in descending to the medium pile 7 for positioning after it reaches the suction area. This ensures that the electromagnetic chuck 3 contacts the medium pile 7 and is fully loaded with medium, while maintaining a certain tension in the steel cable of the traveling crane 2 to prevent the cable from winding up.

[0045] Specifically, the load cell 32 is used to record the weight of the electromagnetic chuck 3 after it picks up and releases the medium. The controller 9 controls the electromagnetic chuck 3 to descend and stop based on the changes in the value of the load cell 32, ensuring that the electromagnetic chuck 3 can stably contact the medium pile 7 and be fully loaded with medium. The maximum measured value of the load cell 32 is greater than the maximum weight of the electromagnetic chuck 3 after it picks up the medium.

[0046] Furthermore, the traveling crane 2 is equipped with a limit switch 22, a photoelectric switch 21, and a fire stop 23. A counterweight limit switch 33 and a pull rope encoder 31 are installed on the steel cable between the traveling crane 2 and the electromagnetic chuck 3. The traveling crane 2 forms a progressive multi-limit system through the limit switch 22 and the photoelectric switch 21 to limit the running position of the trolley and the carriage in the traveling crane 2. When the traveling crane 2 runs to the limited position of the limit switch 22 and the photoelectric switch 21, the controller 9 controls the traveling crane 2 to stop moving.

[0047] The counterweight limit switch 33, the flameout device 23, and the pull rope encoder 31 are used to limit the vertical movement of the electromagnetic chuck 3. Specifically, the counterweight limit switch 33, the flameout device 23, and the pull rope encoder 31 form a progressive multi-limit system to limit the vertical upward movement of the electromagnetic chuck 3. At the same time, the flameout device 23 and the pull rope encoder 31 can also form a progressive multi-limit system to limit the vertical downward movement of the electromagnetic chuck 3.

[0048] Safety light curtains 8 are installed on both sides of the media stack 7 to detect whether a person or vehicle has entered. An audible and visual alarm 5 is installed above the safety light curtains 8 and below the second camera device 11 to issue an alarm when the safety light curtains 8 are blocked or when the second camera device 11 detects a person or vehicle entering the media processing area.

[0049] In an optional embodiment, the traveling crane 2 is equipped with two limit switches 22, six photoelectric switches 21 and a flame cut-off device 23. The two limit switches 22 are respectively located on both sides of the main carriage of the traveling crane 2. Of the six photoelectric switches 21, four are distributed on both sides of the trolley of the traveling crane 2 and the remaining two are distributed on both sides of the main carriage of the traveling crane 2.

[0050] Please see Figure 3 During the process of identifying, absorbing, configuring, and pumping the medium, various sensing components, such as the first camera device 1, the second camera device 11, the weighing sensor 32, the rope encoder 31, the laser rangefinder 4, the water supply flow meter 62, the level gauge 66, the counterweight limit switch 33, the flameout device 23, the photoelectric switch 21, the limit switch 22, the level switch 67, and the safety light curtain 8, are used. The depth recognition algorithm in the host computer 10 identifies the planar image of the medium pile 7 obtained by the first camera device 1. The controller 9 reads the signal from the level gauge 66 in the concentrated medium tank 6 and receives the control signal from the host computer 10 to control the start of medium addition. Based on the signals from the weighing sensor 32, the level gauge 66, and the water supply flow meter 62, the controller controls the operation of the trolley 2, the electromagnetic chuck 3, the water supply electric valve 63, the blower electric valve 61, and the medium addition pump 68. During medium addition, the safety status of the medium addition system is monitored in real time through the limit switch 22, the photoelectric switch 21, the safety light curtain 8, and the first camera device 1.

[0051] Specifically, after the host computer 10 acquires a planar image of the first camera device 1 positioned vertically downwards above the media stack 7, the depth recognition algorithm in the host computer 10 uses the planar image information from the first camera device 1 to parse the block number of the high point of the media stack 7. Then, based on the preset correspondence between the block number and two-dimensional coordinates, it parses the two-dimensional planar coordinates of the high point block of the media stack 7. The host computer 10 sends these two-dimensional planar coordinates to the controller 9. The controller 9 uses the laser rangefinder 4 to obtain the current position of the trolley 2, and then controls the trolley 2, carrying the electromagnetic chuck 3, to move to the high point of the media stack 7. At this time, the controller 9 controls the electromagnetic chuck 3 to descend, while simultaneously performing dynamic positioning based on the data from the weighing sensor 32. Upon reaching the suction position, the electromagnetic chuck 3 is energized, sucking up the media from the media stack 7, and rises to the high point according to the data from the pull rope encoder 31. After acquiring data from the weighing sensor 32, the controller 9 controls the trolley 2 to move above the concentrated medium tank 6. Based on the data from the pull rope encoder 31, it controls the electromagnetic chuck 3 to descend to the medium release position, releasing the medium from the electromagnetic chuck 3 into the concentrated medium tank 6. The controller then reads the weighing data from the weighing sensor 32 again and calculates the single medium addition amount based on the weight difference between the medium suction and release values. Before adding the medium, the controller 9 opens the blower valve 61; after adding the medium and ensuring the liquid is fully mixed, the controller 9 closes the blower valve 61.

[0052] After the medium is added to a certain amount, the controller 9 controls the water replenishment electric valve 63 to replenish water according to the set ratio. When the medium addition amount is reached or the upper limit A of the liquid level in the concentrate tank 6 is reached, the medium addition stops. The concentrate tank 6 mixes the medium and water to form a medium liquid, and then delivers the medium liquid to the heavy medium system through the replenishment pump 68 until the delivered medium liquid is sufficient or the liquid level in the concentrate tank is lower than the lower limit B.

[0053] A second camera 11, an audible and visual alarm 5, a safety light curtain 8, a photoelectric switch 21, a limit switch 22, a flameout device 23, a counterweight limit switch 33, and a level switch 67, installed around the medium storage inlet and the concentrated medium tank 6, are used to ensure the safety of the medium filling system and personnel / vehicles. When the second camera 11 around the medium storage inlet and the concentrated medium tank 6 detects that a person or vehicle has entered the medium filling area or that the safety light curtain 8 is obstructed, the audible and visual alarm 5 sounds an alarm to warn the operator to stay away from the medium filling area, and the host computer 10 displays a dialog box prompting the operator to pay attention to the medium filling area to prevent danger. If the photoelectric switch 21, the limit switch 22, or the counterweight limit switch 33 is triggered during the operation of the crane 2, the controller 9 controls the crane 2 to stop running in the corresponding direction to achieve safety control.

[0054] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0055] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for intelligent media addition in heavy media coal preparation, characterized in that, Includes the following steps: A planar image of the media stack is acquired and divided into several blocks. Grayscale imaging is performed on each block. The blocks with larger grayscale values ​​are compared with preset block numbers. The two-dimensional coordinates of the high point blocks of the media stack are obtained through the correspondence between the preset block numbers and the two-dimensional coordinates of the block center. When the current position of the crane is obtained and the crane is moved to the high point of the medium stack, the electromagnetic chuck is controlled to descend according to the value of the weighing sensor to achieve dynamic positioning and medium suction, and transport it into the concentrated medium tank. The amount of medium added is calculated through the weighing sensor. Configure the medium in the concentrated medium tank, determine whether the liquid level of the medium has reached the upper limit. If so, stop configuring the medium and transfer the liquid in the concentrated medium tank to the heavy medium system. When the liquid level of the medium in the concentrated medium tank is lower than the critical level, stop the transfer and continue configuring the medium.

2. The intelligent medium addition method for heavy medium coal preparation as described in claim 1, characterized in that, Before obtaining a planar image of the media stack, the media library area needs to be divided proportionally, and the divided blocks are assigned unique numbers as the preset block numbers. The two-dimensional coordinates of the vehicle moving to the center of each block are recorded. After obtaining the planar image of the media stack, the planar image of the media stack is divided into blocks corresponding to the media library area according to the proportion.

3. The intelligent medium addition method for heavy medium coal preparation as described in claim 1, characterized in that, The process of calculating the amount of medium added using the weighing sensor includes: obtaining the weight of the medium drawn down by the electromagnetic chuck and the weight of the electromagnetic chuck after it is delivered to the concentrated medium tank and the medium is released by the electromagnetic chuck, and the difference between the two is the amount of medium added.

4. A heavy media coal preparation intelligent media addition system, applied to the heavy media coal preparation intelligent media addition method according to any one of claims 1-3, characterized in that, include: Laser rangefinder, first camera device, second camera device, crane, electromagnetic chuck, concentrated medium tank, medium stack, replenishing pump, and interconnected controller and host computer; The first camera device is located on the top of the medium stack with its lens pointing vertically downwards. The trolley is connected to the electromagnetic chuck. The concentrated medium tank is located on one side of the medium stack. The outlet of the concentrated medium tank is connected to the replenishing pump. The controller and the host computer are connected to the laser rangefinder, the first camera device, the second camera device, and the trolley.

5. The intelligent medium addition system for heavy medium coal preparation as described in claim 4, characterized in that, Safety light curtains are installed on both sides of the media stack to detect whether a person or vehicle has entered. An audible and visual alarm is provided above the safety light curtain and below the second camera device, which is used to issue an alarm when the safety light curtain is blocked or when the second camera device detects a person or vehicle entering the loading area.

6. The intelligent medium addition system for heavy medium coal preparation as described in claim 4, characterized in that, A pull-rope encoder and a weighing sensor are provided between the electromagnetic chuck and the trolley. The pull-wire encoder is used to record the rising and falling positions of the electromagnetic chuck. The laser rangefinder is used to record the running position of the large vehicle and the small vehicle during operation; The weighing sensor is used to control the lifting and lowering of the electromagnetic chuck and to record the weight of the electromagnetic chuck after it picks up and releases the medium.

7. The intelligent medium addition system for heavy medium coal preparation as described in claim 6, characterized in that, A counterweight limit switch is also provided between the electromagnetic chuck and the trolley, and the trolley is equipped with a limit switch, a photoelectric switch and a flame cut-off device. The counterweight limit switch, together with the flame cut-off device and the pull rope encoder, forms a progressive multi-limit system to limit the vertical upward movement of the electromagnetic chuck. The flame cut-off device and the pull-rope encoder form a progressive multi-limit system to limit the vertical downward movement of the electromagnetic chuck.

8. The intelligent medium addition system for heavy medium coal preparation as described in claim 7, characterized in that, The traveling crane uses limit switches and photoelectric switches to form progressive multiple limit positions, which limit the running positions of the main trolley and the auxiliary trolley. When the traveling crane reaches the limit position of the limit switches and photoelectric switches, the controller controls the traveling crane to stop moving.

9. The intelligent medium addition system for heavy medium coal preparation as described in claim 4, characterized in that, The feed inlet of the concentrated medium tank is connected to the blower channel and the water supply pipe. A level gauge is installed above the concentrated medium tank, and a level switch is installed inside the concentrated medium tank. The blower channel is inserted into the bottom of the concentrate tank for stirring the medium inside the concentrate tank; The water supply pipe is used to supply water to the concentrate tank according to the control of the controller; The level gauge is used to detect the liquid level in the concentrated medium tank; The liquid level switch is used to interlock and shut off the water supply pipe when the liquid level in the concentrated medium tank is too high.

10. The intelligent medium addition system for heavy medium coal preparation as described in claim 9, characterized in that, An electric blower valve is provided between the feed inlet of the concentrated medium tank and the blower channel, and an electric water supply valve and a water supply flow meter are provided between the feed inlet of the concentrated medium tank and the water supply pipe. The blower electric valve is used to control the opening and closing of the blower channel; The electric water supply valve is used to control the opening and closing of the water supply pipeline; The water supply flow meter is used to detect the amount of water supplied to the water supply pipe.

Images