Method for detecting material leakage between plow discharger and belt

Abstract

The invention belongs to the technical field of material leakage detection methods. A method for detecting material leakage between a plow discharger and a belt comprises the plow discharger and an adjusting executing mechanism, the plow discharger comprises coulters and a tray, the coulters comprise a main coulter and an auxiliary coulter, and the adjusting executing mechanism is used for synchronously driving the coulters and the tray to be close to or separated from each other. The image acquisition module is used for acquiring a plow discharger discharge end belt image; when the image of the belt at the discharging end of the plow discharger is only black, it is judged that no material is leaked between the plow discharger and the belt; when black and yellow appear in the image of the belt at the discharging end of the plow discharger at the same time, it is judged that material leakage exists between the plow discharger and the belt, an adjusting execution mechanism synchronously drives a coulter and a tray to approach each other till only black exists in the image of the updated plow discharger discharging end belt, and it is indicated that material leakage does not exist. The plow discharger is used for solving the technical problems that leakage detection of an existing plow discharger adopting an anti-blocking switch is inaccurate, and use is inconvenient.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of material leakage detection methods, and particularly relates to a plow-type unloader and a belt leakage detection method. BACKGROUND

[0002] The roller belt machine is widely used in the bulk grain conveying industry. In order to adapt to the need of large silos, a single roller belt machine combined with a plow-type unloader is generally used in the silo loading stage. Compared with the single roller and belt machine loading method:

[0003] 1. The belt machine lap joint method requires a secondary stack bridge to be erected on the silo roof, and the number of machine heads increases, the weight of the machine head is large, multiple power components are required, and the overall cost of the equipment, the cost of the stack bridge, the cost of the electrical appliances, and the installation cost are all greatly increased.

[0004] 2. The feeding method of the scraper machine plus the self-cleaning gate can only be applied to a relatively small output configuration, and the maximum output does not exceed 1000T / H. Moreover, the running power of the scraper machine is extremely high, and the material is severely broken, which is not suitable for most working conditions.

[0005] In summary, the single roller and plow-type unloader method is flexible in arrangement, only one single roller is required for a single-row silo, only one motor is required, the stack bridge is a horizontal stack bridge, the investment cost is greatly reduced compared with the belt machine lap joint method, and the running cost is extremely low compared with the scraper machine.

[0006] The plow-type unloader mainly clamps the belt through the combined action of the upper plow and the lower tray to scrape the material on the belt off the belt. In order to ensure complete scraping, the following points need to be controlled: 1. parallelism of the upper plow and the lower tray; 2. flatness of the upper plow edge; 3. firmness of the plow and the tray under stress; 4. positioning accuracy of the plow when repeatedly opening and closing; and 5. gap between the plow and the tray. The input of the above points is constantly changing during the use of the equipment. For example, the plow edge is often in a worn state, and the flatness of the edge easily deteriorates over time, resulting in material leakage.

[0007] Generally, when the plow leaks (the material is not scraped clean), manual adjustment of the plow is required. For example, when the gap is large due to poor positioning accuracy or severe wear, the plow needs to be further compressed (the gap between the plow and the tray is reduced) to reduce material leakage. However, the wear of the plow and the deviation of the mechanical accuracy are usually uncontrollable, including installation quality, usage habits, and environmental temperature, which means that material leakage will occur at irregular intervals when using the plow-type unloader. In order to ensure the normal use of the equipment, it is necessary to constantly patrol the equipment, otherwise a large amount of material will leak into the end silo, causing serious problems such as material mixing.

[0008] The main means for solving the problem of material leakage of the plow-type unloader at the present stage is to configure a blocking prevention switch on the upper part of the machine head bin. When the intermediate unloader leaks, the material will leak to the machine head position. In the case of configuring a gate, the material will accumulate at the machine head, and finally trigger the blocking prevention switch. However, at this time, a large amount of material has already leaked, and subsequent cleaning is difficult. In addition, the alarm of the blocking prevention switch will trigger a fault shutdown, causing the entire production line to suddenly stop, and the cleaning and restarting work is extremely tedious. Finally, after the alarm signal appears, manual intervention is still required to check the running state of the equipment, determine the adjustment mode and adjustment amount, which is time-consuming and labor-intensive. SUMMARY

[0009] The purpose of the present application is to provide a plow-type unloader and belt leakage detection method to solve the technical problems of inaccurate detection of material leakage and inconvenience of use of the existing plow-type unloader using a blocking prevention switch.

[0010] To solve the above technical problems, the present application adopts the following technical solution: a plow-type unloader and belt leakage detection method, comprising a plow-type unloader and an adjustment execution mechanism. The plow-type unloader comprises a plow and a tray. The plow comprises a main plow and a secondary plow. The adjustment execution mechanism is used to synchronously drive the plow and the tray to approach or separate. The characteristic is that:

[0011] A vision sensor is arranged on the plow-type unloader to obtain a belt image at the discharge end of the plow-type unloader;

[0012] When only black color appears in the belt image at the discharge end of the plow-type unloader, it is determined that there is no leakage between the plow-type unloader and the belt.

[0013] When black and yellow colors appear in the belt image at the discharge end of the plow-type unloader, it is determined that there is leakage between the plow-type unloader and the belt. The adjustment execution mechanism synchronously drives the plow and the tray to approach until the updated belt image at the discharge end of the plow-type unloader shows only black color, indicating no leakage.

[0014] To solve the technical problem of the influence of the tensioning degree of the leather on the smooth completion of unloading, the present application adopts the following technical solution: a first wear plate, a middle notch area, and a second wear plate are sequentially arranged on the tray in the direction of belt conveying. The notch area cooperates with the main plow and the secondary plow to ensure good adhesion of the belt to the plow. A main sensor and a secondary sensor are arranged on the notch area of the tray. The main sensor cooperates with the main plow, and the secondary sensor cooperates with the secondary plow to sense whether the belt has been pressed to the limit position.

[0015] To solve the above technical problems, the present application adopts the following technical solution, which further comprises the following steps:

[0016] Set:

[0017] The real-time tension of the belt is N1, and the real-time tension N1 of the belt is obtained by using a tension sensor; the maximum tension that the belt can withstand is N1 max ;

[0018] The relative stroke of the coulter is H, and when the lower end of the main coulter edge is at the same horizontal plane as the upper end of the first wear plate, H = 0; when the lower end of the main coulter edge is higher than the upper end of the first wear plate, H is negative, and vice versa,

[0019] The horizontal distance of the main coulter edge relative to the corresponding point of the first wear plate is L;

[0020] Step 1: unloading preparation

[0021] When preparing to unload, adjust the position of the coulter, and quickly adjust the relative stroke H of the coulter stroke to 0;

[0022] Step 2: start unloading

[0023] When starting to unload, use a visual sensor to determine whether there is material leakage;

[0024] If there is no material leakage, go to step 3;

[0025] If there is material leakage, N1 < N1 max , the main coulter does not contact the main sensor and the secondary coulter does not touch the secondary sensor, then increase the coulter stroke value h, delay for t seconds, and then use the visual sensor to determine whether there is material leakage; if there is no material leakage, maintain the coulter height and belt tension value unchanged, go to step 3, otherwise, repeat the step;

[0026] If there is material leakage, and N1 < N1 max , the main coulter contacts the main sensor or the secondary coulter touches the secondary sensor, then determine that the belt tension is insufficient, and reduce the coulter stroke by h to the point where the main coulter does not contact the main sensor or the secondary coulter does not touch the secondary sensor; increase the belt tension n, delay for t seconds, and then use the visual sensor to determine whether there is material leakage; if there is no material leakage, maintain the coulter height and belt tension value unchanged, go to step 3; if there is still material leakage, increase the belt tension n under the condition of N1 < N1 max , delay for t seconds, and then use the visual sensor to determine whether there is material leakage until there is no material leakage;

[0027] If N1 ≥ N1 max , there is material leakage, and the main coulter does not contact the main sensor and the secondary coulter does not touch the secondary sensor, then determine that the coulter is severely worn, stop the machine and issue an alarm;

[0028] Step 3: unloading monitoring

[0029] In the normal unloading state, the visual sensor continuously monitors the material leakage state, and the tension sensor continuously monitors the N1 value;

[0030] When the material leakage is monitored, and N1 max , step 2 is entered;

[0031] When N1≥N1 max , and no material leakage is monitored, it is judged that the belt tension is too large at this time, the belt tension is reduced to N1 max , after a delay of t seconds, the visual sensor judges whether the material leaks or not, if no material leakage is monitored, the plough travel and the belt tension value are maintained unchanged; if material leakage is monitored, the machine is stopped and an alarm is sent out;

[0032] When N1≥N1 max and material leakage is monitored, the machine is stopped and an alarm is sent out;

[0033] Wherein, n, h, t are settable values.

[0034] To solve the technical problem that the change of the plough pressing force on the belt affects the smooth completion of the unloading, the plough unloader and the belt leakage detection method between the plough unloader and the belt include the following steps:

[0035] Set:

[0036] The real-time tension of the belt machine is N1;

[0037] The maximum value of the plough pressing force on the belt is N2 max ; the relative travel of the plough is H, when the lower end of the main plough blade is at the same horizontal plane as the upper end of the first wear plate, H=0; when the lower end of the main plough blade is higher than the upper end of the first wear plate, H is a negative value, and vice versa;

[0038] The horizontal distance of the main plough blade relative to the first wear plate is L;

[0039] The plough pressing force on the belt is N2, which is calculated from N1, H and L, and the formula is:

[0040]

[0041] Wherein, k1 and k2 are empirical constants;

[0042] n, h, t are settable values; R(H, L) is the contact equivalent curvature radius obtained by "chord length-arch height"; N1 / R is the normal pressure amount converted from the belt tension through the curvature, and the effective component (cosθ) of the blade angle is also considered.

[0043] Step 1: unloading preparation

[0044] When preparing to unload, the plough position is adjusted, and the relative travel H of the plough travel is quickly adjusted to 0;

[0045] Step 2: start unloading

[0046] When starting to unload, judge whether there is leakage by the visual sensor:

[0047] If there is no leakage, go to step 3;

[0048] If there is leakage, N2<N2 max , the main plow does not contact the main sensor and the auxiliary plow does not contact the auxiliary sensor, increase the plow stroke value h, delay for t seconds, and then judge whether there is leakage by the visual sensor; if there is no leakage, maintain the plow stroke and the belt tension value unchanged, and go to step 2; otherwise, repeat step 2;

[0049] If there is leakage, N2<N2 max , the main plow contacts the main sensor or the auxiliary plow contacts the auxiliary sensor, it is judged that the belt tension is insufficient, the plow stroke is reduced by h to a safe position; increase the belt tension n, delay for t seconds, and then judge whether there is leakage by the visual sensor; if there is no leakage, maintain the plow stroke and the belt tension value unchanged, and go to step 3; if there is still leakage, under the condition of N2<N2 max , repeat increasing the belt tension n, delay for t seconds, and then judge whether there is leakage by the visual sensor until there is no leakage any more;

[0050] If N2≥N2 max , there is still leakage, the main plow does not contact the main sensor and the auxiliary plow does not contact the auxiliary sensor, it is judged that the plow is seriously worn, stop the machine and issue an alarm;

[0051] Step 3: Unloading monitoring

[0052] In the normal unloading state, the visual sensor continuously monitors the leakage state, and the tension sensor continuously monitors the N2 value;

[0053] When leakage is monitored, and N2<N2 max , go to step 2;

[0054] When N2≥N2 max , and there is no leakage, the downward pressure of the plow on the belt is too large, reduce the belt tension n, so that the downward pressure of the plow on the belt is N2<N2 max -n, delay for t seconds, and then judge whether there is leakage by the visual sensor; if there is no leakage, maintain the plow stroke and the belt tension value unchanged; if there is leakage, stop the machine and issue an alarm;

[0055] If N2≥N2 max , and there is leakage, stop the machine and issue an alarm.

[0056] Further improvement is made to the technical scheme of the application, and the first wear-resistant plate is in a V-shaped structure.

[0057] Further improvement is made to the technical scheme of the application, and the middle gap area is in a V-shaped structure.

[0058] The second wear plate is in V-shaped structure.

[0059] The visual sensor is a camera.

[0060] The main sensor or the auxiliary sensor is a contact pressure sensor, a micro switch or an inductive sensor.

[0061] The shape of the main sensor is matched with the shape of the main plough blade, and the shape of the auxiliary sensor is matched with the shape of the auxiliary plough blade. BRIEF DESCRIPTION OF DRAWINGS

[0062] Figure 1 is a structural schematic view of the plough discharger of the present application;

[0063] Figure 2 is a structural schematic view of the internal structure of the plough discharger of the present application;

[0064] Figure 3 is a working principle view of the plough discharger of the present application;

[0065] Figure 4 is a structural schematic view of the adjusting actuator of the present application;

[0066] Figure 5 is a structural schematic view of the plough blade and the tray of the plough discharger of the present application;

[0067] Figure 6 is a structural schematic view of the plough blade of the plough discharger of the present application;

[0068] Figure 7 is a structural schematic view of the tray of the plough discharger of the present application;

[0069] In the figure:

[0070] The plough discharger 100; the adjusting actuator 200. DETAILED DESCRIPTION

[0071] The present application will be further described below in combination with the figures.

[0072] Example 1

[0073] As shown in the figure, the plough discharger and the belt gap material detection device, including the plough discharger 100, the adjusting actuator 200. Figure 1

[0074] The plough discharger 100 includes a shell 110, a plough blade 120, a tray 130 and a discharge port 140. The shell 110 includes a bottom groove 111, a side plate 112 and a top cover 113.​

[0075] As shown in Figure 6 , the coulter 120 includes a main coulter 121, a sub-coulter 122, a coulter mounting frame 124, and a coulter fixing shaft 123. The main coulter 121 includes a main coulter edge 1210. The sub-coulter 122 includes a sub-coulter edge 1220.

[0076] As shown in Figure 4 , the adjusting actuator 200 is used to synchronize the approach or separation of the coulter and the tray. The adjusting actuator 200 includes a servo motor 201, a lifting machine 202, a reverser 203, a transmission rod 204, a shaft coupling 205, a lead screw 206, a right-handed nut 207, a left-handed nut 208, an upper sliding plate 209, and a lower sliding plate 210. The unloader accurately transmits the action of the servo motor to the four lifting machines through the transmission shaft and the two reversers. The upper part of each lifting machine is a right-handed lead screw, and the lower part is a left-handed lead screw, which are respectively connected with the upper sliding plate body and the lower sliding plate body. The four upper sliding plate bodies are firmly fixed with the four corners of the upper coulter, and the four lower sliding plate bodies are firmly fixed with the four corners of the lower tray.

[0077] As shown in FIG. 2, a visual sensor 300 is arranged on the plow unloader to obtain the image of the belt at the discharge end of the plow unloader. The visual sensor 300 is preferably a camera. In this embodiment, the intelligent vision technology is used to detect the surface of the belt at the discharge end of the plow unloader.

[0078] When the image of the belt at the discharge end of the plow unloader is only black, it is determined that there is no material leakage between the plow unloader 100 and the belt 400. When the image of the belt at the discharge end of the plow unloader simultaneously appears black and yellow, it is determined that there is material leakage between the plow unloader and the belt. The adjusting actuator synchronously drives the coulter 120 and the tray 130 to approach each other until the updated image of the belt at the discharge end of the plow unloader is only black, indicating that there is no material leakage.

[0079] In this embodiment, the color difference between most grain particles and the belt (grains are mostly yellow, and the belt is black) is used to extract the material leakage information and timely feedback to the adjusting actuator, which is a servo motor. The servo motor drives a precision transmission mechanism to drive the tray and the coulter to approach each other, thereby reducing the gap. The gap is extremely small (such as 0.5 mm) each time. After adjustment, a response time of about 1s is waited. If the material continues to leak, the process is repeated until the material no longer leaks.

[0080] The tray 130 is provided with a tray fixing shaft 131 and a tray redirecting drum 132.

[0081] In one embodiment, as shown in Figure 3 , Figure 5 , Figure 7As shown, the first wear plate 140, the middle notch area 150, and the second wear plate 160 are sequentially arranged on the tray 130 along the conveying direction of the belt 400. The notch area 150 is matched with the main plow 121 and the auxiliary plow 122, and is used to ensure that the belt is well matched with the plow. The main sensor 171 and the auxiliary sensor 172 are arranged on the notch area of the tray. The main sensor 171 is matched with the main plow 121, and the auxiliary sensor 172 is matched with the auxiliary plow 122, and is used to sense whether the belt has been pressed to the limit position.

[0082] Preferably, the first wear plate 140 is a V-shaped structure. Preferably, the middle notch area 150 is a V-shaped structure. Preferably, the second wear plate 160 is a V-shaped structure.

[0083] Preferably, the main sensor 171 is a contact pressure sensor, a microswitch, or an inductive sensor. The shape of the main sensor 171 is matched with the shape of the main plow 122. The auxiliary sensor 172 is a contact pressure sensor, a microswitch, or an inductive sensor. The shape of the auxiliary sensor 172 is matched with the shape of the auxiliary plow 122.

[0084] The surface of the tray of the plow-type discharger is generally covered with a high-molecular material which has good wear resistance and good self-lubricating performance. Moreover, the high-molecular material is not a complete plane, but has a middle notch area at the position corresponding to the plow. The main function of the middle notch area is to ensure that the belt is well matched with the plow.

[0085] Under the tension of the belt itself, the belt is taut upward and is well matched with the main plow and the auxiliary plow in the middle notch area, so as to avoid leaving a small gap for the material to pass through, thereby ensuring that the material is scraped off the belt. When the plow is worn or the surface is uneven, the plow needs to be further pressed down, and the greater tension of the belt compensates for the slight unevenness of the plow. When the plow is seriously worn, the tension of the belt cannot compensate for the unevenness of the surface of the plow. At this time, even if the plow is further pressed down, the material leakage problem cannot be solved. At this time, new plow accessories need to be replaced. The limit of the pressing down of the plow is that the belt touches the tray body. By installing a pressure sensor (or a touch sensor) on the tray body, it can be sensed whether the belt has been pressed to the limit position. At this time, a signal needs to be sent to the system to remind the maintenance personnel to replace the accessories. At this time, if the visual sensor is triggered, the machine is stopped in turn.

[0086] The material leakage detection device between the plow-type discharger and the belt also has a belt tension adjusting mechanism and a belt tension monitoring function, which are used to assist in adjusting the discharging.

[0087] The application can save manpower and reduce labor load without personnel on-line observation during the life of the coulter edge replacement, avoid equipment downtime caused by a large amount of material leakage, material mixing and other problems, predict the service life of the discharger coulter edge through the count of the servo motor depression amount, remind the user to prepare the spare parts in advance, and ensure continuous production, and avoid personnel skill differences from causing under-pressing or over-pressing, thereby greatly reducing the service life.

[0088] Embodiment 2

[0089] During the operation of the long belt conveyor, the belt inevitably elongates and the tightness of the belt changes due to various reasons such as the load bearing of the belt. When the belt conveyor tension becomes large during the unloading process, the coulter will cause excessive downward pressure on the belt, which will aggravate the wear of the coulter and the belt. Therefore, the belt tension needs to be adjusted in time.

[0090] The embodiment provides a method for detecting material leakage between a plow-type discharger and a belt, comprising the following steps:

[0091] Set:

[0092] The real-time tension of the belt is N1, the real-time tension N1 of the belt is obtained by using a tension sensor, and the maximum tension that the belt can bear is N1 max ;

[0093] The relative stroke of the coulter is H, when the lower end of the main coulter edge and the upper end of the first wear plate are at the same horizontal plane, H = 0; when the lower end of the main coulter edge is higher than the upper end of the first wear plate, H is negative, and vice versa,

[0094] The horizontal distance between the main coulter edge and the corresponding point of the first wear plate is L;

[0095] Step 1: unloading preparation

[0096] When preparing to unload, the position of the coulter is adjusted, and the relative stroke H of the coulter stroke is quickly adjusted to 0;

[0097] Step 2: start unloading

[0098] When starting to unload, whether there is material leakage is judged by using a visual sensor;

[0099] If there is no material leakage, step 3 is entered;

[0100] If there is material leakage, N1 < N1 max , the main coulter does not contact the main sensor, and the auxiliary coulter does not contact the auxiliary sensor, the coulter stroke value h is increased, and after a delay of t seconds, whether there is material leakage is judged by using a visual sensor, if there is no material leakage, the coulter height and the belt tension value are maintained unchanged, step 3 is entered, otherwise the step is cycled;

[0101] If there is material leakage, and N1 max , the main plow contacts the main sensor or the secondary plow touches the secondary sensor, it is judged that the belt tension is insufficient, the plow stroke is reduced h to the main plow does not contact the main sensor or the secondary plow does not touch the secondary sensor; increase the belt tension n, after a delay of t seconds, use the visual sensor to judge whether there is material leakage, if there is no material leakage, maintain the plow height and the belt tension value unchanged, enter step 3, if there is still material leakage, in the case of N1 max , the belt tension is increased by n, after a delay of t seconds, the visual sensor judges whether there is material leakage, until there is no material leakage;

[0102] If N1≥N1 max , there is material leakage, and the main plow does not contact the main sensor and the secondary plow does not touch the secondary sensor, it is judged that the plow is severely worn, the machine is stopped and an alarm is issued;

[0103] Step 3: unloading monitoring

[0104] In the normal unloading state, the visual sensor continuously monitors the material leakage state, and the tension sensor continuously monitors the N1 value;

[0105] When material leakage is monitored, and N1 max , enter step 2;

[0106] When N1≥N1 max , and there is no material leakage, it is judged that the belt tension is too large at this time, the belt tension is reduced to N1 max , after a delay of t seconds, the visual sensor judges whether there is material leakage, if there is no material leakage, the plow stroke and the belt tension value are maintained unchanged; if there is material leakage, the machine is stopped and an alarm is issued;

[0107] When N1≥N1 max and material leakage is monitored, the machine is stopped and an alarm is issued;

[0108] Wherein, n, h, t are settable values.

[0109] Example 3

[0110] The size of the plow pressure on the belt is an important factor in whether the unloading can be successfully completed. When the belt conveyor tension is too small, it will cause the plow stroke to touch the bottom, but still not enough pressure. At this time, if the plow stroke is still increased, it will cause the plow and the belt to be squeezed by the bottom sensor, causing the plow and the belt to be worn.

[0111] The embodiment provides a material leakage detection method between a plow type unloader and a belt, comprising the following steps:

[0112] Set:

[0113] The real-time tension of the belt conveyor is set as N1;

[0114] Maximum value of the downward pressure of the coulter on the belt N2 max ; the relative stroke of the coulter is H, when the lower end of the main coulter blade is set at the same level as the upper end of the first wear plate, H = 0; when the lower end of the main coulter blade is higher than the upper end of the first wear plate, H is negative, and vice versa;

[0115] The horizontal distance of the main coulter blade relative to the first wear plate is L;

[0116] The downward pressure of the coulter on the belt is N2, which is calculated from N1, H, and L, and the formula is:

[0117]

[0118] where k1 and k2 are empirical constants;

[0119] n, h, and t are settable values; R(H, L) is the equivalent curvature radius of contact obtained by "chord length-arch height"; N1 / R represents the normal pressure amount "converted" from the belt tension through the curvature, while considering the effective component (cos θ) of the blade angle.

[0120] Step 1: Preparation for unloading

[0121] When preparing for unloading, adjust the position of the coulter, and quickly adjust the relative stroke H of the coulter to 0;

[0122] Step 2: Start unloading

[0123] When starting unloading, determine whether there is a material leakage by combining the visual sensor:

[0124] If there is no material leakage, proceed to Step 3;

[0125] If there is a material leakage, N2 < N2 max , the main coulter does not contact the main sensor and the secondary coulter does not touch the secondary sensor, then increase the coulter stroke value h, delay for t seconds, and then determine whether there is a material leakage by the visual sensor. If there is no material leakage, maintain the coulter height and belt tension value unchanged, proceed to Step 3, otherwise, repeat Step 2;

[0126] If there is a material leakage, N2 < N2 max , the main coulter contacts the main sensor or the secondary coulter touches the secondary sensor, then determine that the belt tension is insufficient, and decrease the coulter stroke by h to a safe position; increase the belt tension by n, delay for t seconds, and then determine whether there is a material leakage by the visual sensor. If there is no material leakage, maintain the coulter height and belt tension value unchanged, proceed to Step 3. If there is still a material leakage, repeat the increase of the belt tension n under the condition of N2 < N2 max , delay for t seconds, and then determine whether there is a material leakage by the visual sensor until there is no material leakage;

[0127] If N2 ≥ N2max When the material leakage still exists, the main plow does not contact the main sensor and the sub-plow does not contact the sub-sensor, it is judged that the plow is seriously worn, the machine is stopped and an alarm is sent out;

[0128] Step 3: unloading monitoring

[0129] Normal unloading state, the visual sensor continuously monitors the material leakage state and the tension sensor continuously monitors the N2 value;

[0130] When the material leakage is monitored and N2 max , step 2 is entered;

[0131] When N2≥N2 max and there is no material leakage, the down pressure of the plow on the belt is too large, the belt tension n is reduced, so that the down pressure of the plow on the belt N2 max -n, after the delay t, the visual sensor judges whether there is material leakage, if not, the plow stroke and the belt tension value are maintained; if there is material leakage, the machine is stopped and an alarm is sent out;

[0132] When N2≥N2 max and there is material leakage, the machine is stopped and an alarm is sent out.

[0133] The above embodiments are only for illustrating the technical features and concepts of the present application, the purpose is to enable the skilled in the art to understand the content of the present application and implement it, and cannot limit the protection scope of the present application, any equivalent changes or modifications according to the spirit and embodiments of the present application should be covered in the protection scope of the present application.

Claims

1. A method for detecting material leakage between a plow-type unloader and a belt conveyor, comprising a plow-type unloader and an adjusting actuator, wherein the plow-type unloader includes plow blades and a tray, the plow blades including a main plow blade and a secondary plow blade, and the adjusting actuator is used to synchronously drive the plow blades and the tray to move closer together or separate from each other, characterized in that: The plow-type unloader is equipped with a vision sensor to acquire images of the conveyor belt at the discharge end of the plow-type unloader. If the image of the conveyor belt at the discharge end of the plow-type unloader is only black, it is determined that there is no leakage between the plow-type unloader and the conveyor belt. When both black and yellow appear in the image of the discharge end belt of the plow unloader, it is determined that there is material leakage between the plow unloader and the belt. The actuator is adjusted to synchronously drive the plow blade and the tray to approach each other until only black appears in the updated image of the discharge end belt of the plow unloader, indicating that there is no material leakage.

2. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 1, characterized in that, The pallet is sequentially arranged with a first wear-resistant plate, a central notch area, and a second wear-resistant plate along the belt conveying direction. The notch area cooperates with the main plow blade and the auxiliary plow blade to ensure good contact between the belt and the plow blade. The notch area of ​​the pallet is equipped with a main sensor and an auxiliary sensor. The main sensor cooperates with the main plow blade, and the auxiliary sensor cooperates with the auxiliary plow blade to sense whether the belt has been pressed down to its limit position.

3. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 2, characterized in that, It also includes the following steps: set up: The real-time belt tension is set to N1, which is obtained using a tension sensor; the maximum tension the belt can withstand is N1. max ; The relative stroke of the plow blades is H. When the lower end of the main plow blade's cutting edge is at the same horizontal plane as the upper end of the first wear-resistant plate, H = 0; when the lower end of the main plow blade's cutting edge is higher than the upper end of the first wear-resistant plate, H is a negative value, and vice versa. The horizontal distance between the main plow blade and the corresponding point of the first wear-resistant plate is set as L; Step 1: Preparation for unloading When preparing to unload, adjust the position of the plow blade and quickly adjust the relative stroke H of the plow blade to 0; Step 2: Begin unloading When unloading begins, a visual sensor is used to determine if there is any leakage. If there is no leakage, proceed to step 3; If leakage occurs, N1 < N1 max If the main plow blade does not contact the main sensor and the auxiliary plow blade does not contact the auxiliary sensor, the plow blade stroke value h is increased. After a delay of t seconds, the visual sensor is used to determine whether there is material leakage. If there is no material leakage, the plow blade stroke and belt tension value are kept unchanged, and the process proceeds to step 3. Otherwise, the process is repeated. If there is material leakage, and N1 < N1 max If the main plow blade contacts the main sensor or the auxiliary plow blade contacts the auxiliary sensor, it is determined that the belt tension is insufficient, and the plow blade stroke is reduced by h until the main plow blade does not contact the main sensor or the auxiliary plow blade does not contact the auxiliary sensor. Increase the belt tension n, and after a delay of t seconds, use a visual sensor to determine if there is material leakage. If there is no leakage, maintain the plow stroke and belt tension value unchanged, and proceed to step 3. If there is still material leakage, then when N1 < N1 max In this case, the belt tension n is increased cyclically, and after a delay of t seconds, the vision sensor determines whether there is material leakage, until there is no more material leakage; If N1≥N1 max If material leakage occurs, and the main plow blade does not contact the main sensor and the auxiliary plow blade does not contact the auxiliary sensor, it is determined that the plow blade is severely worn, the machine is stopped and an alarm is issued; Step 3: Unloading Monitoring During normal unloading, the vision sensor continuously monitors for material leakage, and the tension sensor continuously monitors the N1 value. When leakage is detected, and N1 < N1 max Proceed to step 2; When N1≥N1 max If the belt tension is too high and there is no material leakage, then reduce the belt tension to N1 < N1. max After a delay of t seconds, the vision sensor determines whether there is material leakage. If there is no material leakage, the plow stroke and belt tension remain unchanged; if there is material leakage, the machine stops and an alarm is issued. When N1≥N1 max And when leakage is detected, the machine will stop and an alarm will be issued; Where n, h, and t are configurable values.

4. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 2, characterized in that, It also includes the following steps: set up: The real-time tension of the belt conveyor is set to N1; The maximum downward force N2 exerted by the plow blade on the belt. max The relative stroke of the plow blade is set to H. When the lower end of the main plow blade is at the same horizontal level as the upper end of the first wear-resistant plate, H = 0; when the lower end of the main plow blade is higher than the upper end of the first wear-resistant plate, H is a negative value, and vice versa. The horizontal distance between the main plow blade and the first wear-resistant plate is set as L; The downward pressure of the plow blade on the belt is set as N2, which is calculated from N1, H, and L using the following formula: Where k1 and k2 are empirical constants; n, h, and t are settable values; R(H,L) is the contact equivalent radius of curvature obtained using "chord length - bow height"; Step 1: Preparation for unloading When preparing to unload, adjust the position of the plow blade and quickly adjust the relative stroke H of the plow blade to 0; Step 2: Begin unloading When unloading begins, visual sensors are used to determine if there is any leakage: If there is no leakage, proceed to step 3; If leakage occurs, N2 < N2 max If the main plow blade does not contact the main sensor and the auxiliary plow blade does not contact the auxiliary sensor, the plow blade stroke value h is increased. After a delay of t seconds, the visual sensor determines whether there is material leakage. If there is no material leakage, the plow blade stroke and belt tension value are kept unchanged and the process proceeds to step 2. Otherwise, the process repeats step 2. If leakage occurs, N2 < N2 max If the main plow blade contacts the main sensor or the auxiliary plow blade contacts the auxiliary sensor, it is determined that the belt tension is insufficient. The plow blade stroke is reduced by h to a safe position. The belt tension n is increased, and after a delay of t seconds, the visual sensor determines whether there is material leakage. If there is no material leakage, the plow blade stroke and belt tension are maintained unchanged, and the process proceeds to step 3. If there is still material leakage, then when N2 < N2 max In this case, the belt tension n is increased cyclically, and after a delay of t seconds, the vision sensor determines whether there is material leakage, until there is no more material leakage; If N2≥N2 max If material leakage still occurs, and the main plow blade does not contact the main sensor and the auxiliary plow blade does not contact the auxiliary sensor, it is determined that the plow blade is severely worn, the machine is stopped and an alarm is issued; Step 3: Unloading Monitoring During normal unloading, the vision sensor continuously monitors for material leakage, and the tension sensor continuously monitors the N2 value. When leakage is detected, and N2 < N2 max Proceed to step 2; When N2≥N2 max If there is no material leakage, the downward pressure of the plow blade on the belt is too large. By reducing the belt tension n, the downward pressure of the plow blade on the belt N2 < N2. max -n, after a delay t, the vision sensor determines whether there is material leakage. If there is no material leakage, the plow stroke and belt tension remain unchanged; if there is material leakage, the machine stops and an alarm is issued. If N2≥N2 max Furthermore, if material leaks, the machine will stop and an alarm will be triggered.

5. The method for detecting material leakage between the plow-type unloader and the belt according to claim 2, characterized in that, The first wear-resistant plate has a V-shaped structure.

6. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 5, characterized in that, The central gap area has a V-shaped structure.

7. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 6, characterized in that, The second wear-resistant plate is a V-shaped structure.

8. The method for detecting material leakage between the plow-type unloader and the belt according to claim 1, characterized in that, The visual sensor is a camera.

9. The method for detecting material leakage between the plow-type unloader and the belt as described in claim 1, characterized in that, The main sensor or the auxiliary sensor is a contact pressure sensor, a micro switch, or an inductive sensor; The shape of the main sensor matches the shape of the main plow blade; the shape of the secondary sensor matches the shape of the secondary plow blade.

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