Coal drop pipe blockage dredging system, dredging method and assembly method of dredging system

Abstract

The invention relates to the technical field of equipment blockage clearing, in particular to a coal drop pipe blockage dredging system and method and an assembling method of the dredging system.The system comprises a detachable nozzle assembly of a target type; the air cannon assembly is installed in the material blocking prone area of the coal falling pipe and used for storing gas and discharging the gas through the detachable nozzle assembly; the compressed air supply assembly is used for supplying air to the air cannon assembly; and the control device is used for controlling the air cannon assembly in the blockage easily-occurring area to execute a first target action based on the blockage clearing instruction and controlling the compressed air supply assembly to execute a second target action so as to realize blockage dredging of the coal drop pipe. Therefore, the problems of low blockage clearing efficiency, high safety risk, high blockage clearing cost, poor environmental protection property and the like in the prior art are solved.

Description

Technical Field

[0001] This application relates to the field of equipment unblocking technology, and in particular to a coal chute blockage clearing system, clearing method, and assembly method of the clearing system. Background Technology

[0002] In the production processes of industries such as power, coal, and steel, the coal chute is the core conveying channel connecting equipment such as raw coal bunkers, coal feeders, and belt conveyors. Its smoothness directly determines the continuity and stability of the entire production process. However, the coal chute is prone to blockage, which can lead to the shutdown of the coal conveying system. A single blockage can cause an average downtime of 1-4 hours, resulting in huge economic losses for enterprises. Therefore, it is necessary to clear the blockage in the coal chute.

[0003] The main methods for clearing blockages in coal chutes in related technologies include manual clearing, mechanical clearing, and chemical clearing. However, manual clearing has high labor costs, low efficiency, and serious safety risks. Mechanical clearing usually uses devices such as agitators, vibrators, or scrapers, which can damage the coal chutes in the long run. Chemical clearing agents are expensive, and the residue can contaminate the coal quality. In addition, some agents are corrosive, which can damage pipelines and equipment, and may also react chemically with coal, creating safety hazards. Summary of the Invention

[0004] This application provides a coal chute blockage clearing system, clearing method, and assembly method for the clearing system to solve the problems of low clearing efficiency, high safety risk, high clearing cost, and poor environmental performance in related technologies.

[0005] The first aspect of this application provides a coal chute blockage clearing system, comprising: a detachable nozzle assembly, the detachable nozzle assembly being of target type; an air cannon assembly, the air cannon assembly being installed in the blockage-prone area of ​​the coal chute for storing gas and discharging gas through the detachable nozzle assembly; a compressed air supply assembly for supplying air to the air cannon assembly; and a control device for controlling the air cannon assembly to perform a first target action based on a blockage clearing command, and controlling the compressed air supply assembly to perform a second target action, so as to clear the blockage in the coal chute.

[0006] Optionally, the target type may include a first type or a second type, and the target type is determined based on the physical properties of the material in the coal chute.

[0007] Optionally, the control device includes: a local control module, which generates a clearing command based on at least one of the user's operation, the material accumulation height of the target blockage area, and the material flow rate; a remote control module, which uploads at least one of the material accumulation height and the material flow rate to a host computer and receives the clearing command from the host computer, wherein the host computer generates the clearing command based on at least one of the material accumulation height and the material flow rate; and a controller, which controls the air cannon assembly in the target blockage area to perform a first target action according to the clearing command, and controls the compressed air supply assembly to perform a second target action.

[0008] Optionally, the clearing command includes an inflation command or an venting command, with the first target action being venting and the second target action being inflation.

[0009] Optionally, the local control module is further configured to: determine the blockage level based on the material stack height and / or material flow rate; determine the target unblocking air pressure based on the blockage level; generate an inflation command based on the target unblocking air pressure; and generate an venting command based on at least one of the user's operation, material stack height, and material flow rate.

[0010] Optionally, the air cannon assembly includes an air tank for storing gas and a solenoid valve for receiving unblocking commands.

[0011] The second aspect of this application provides a method for clearing blockages in a coal chute. The method is based on the implementation of the coal chute clearing system described in the above embodiment and includes the following steps: obtaining at least one of the following: material accumulation height, material flow rate, and user operation in at least one blockage-prone area of ​​the coal chute; generating a clearing command based on at least one of the following: material accumulation height, material flow rate, and user operation; controlling an air cannon assembly in the blockage-prone area to perform a first target action and controlling a compressed air supply assembly to perform a second target action based on the clearing command.

[0012] The third aspect of this application provides an assembly method for a coal chute unblocking system. The assembly method is used to assemble the coal chute unblocking system of the above embodiment. The method includes the following steps: acquiring historical operating data of the coal chute; simulating the flow process of materials in the coal chute based on fluid dynamics simulation software, and identifying the flow field risk area of ​​the coal chute based on the simulation results; determining the blockage-prone area based on the flow field risk area and historical operating data; and fixing the coal chute blockage unblocking system to the blockage-prone area using a target bracket. The detachable nozzle assembly of the coal chute blockage unblocking system forms a target angle with the center of the blockage-prone area.

[0013] Therefore, this application has at least the following beneficial effects: This application provides a coal chute blockage clearing system, including a detachable nozzle assembly, an air cannon assembly, a compressed air supply assembly, and a control device. The control device, based on a clearing command, controls the air cannon assembly to perform a first target action and the compressed air supply assembly to perform a second target action. The compressed air supply assembly supplies high-pressure gas to the air cannon assembly, which then ejects the high-pressure gas through the detachable nozzle assembly. The ejected high-pressure gas clears blockages in prone areas, resulting in high clearing efficiency. Utilizing high-pressure gas as a clean power source makes it more environmentally friendly and energy-efficient, lowers clearing costs, eliminates the need for manual cleaning, and reduces safety risks. This solves the technical problems of low clearing efficiency, high safety risks, high clearing costs, and poor environmental performance in related technologies.

[0014] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0015] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic diagram of a coal chute blockage clearing system provided according to an embodiment of this application; Figure 2 This is a schematic diagram of the composition of the coal chute blockage clearing system provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the coal chute blockage clearing system provided in the embodiments of this application; Figure 4 This is a flowchart of a method for clearing blockages in a coal chute according to an embodiment of this application; Figure 5 This is a flowchart of the assembly method of the coal chute plugging system provided in the embodiments of this application; Figure 6 This is a flowchart illustrating the installation and application of the coal chute blocking system provided in the embodiments of this application. Detailed Implementation

[0016] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0017] Before describing the solution of this application, the relevant technologies of this application will be introduced first.

[0018] Coal chute blockage is the primary cause of coal conveying system shutdowns, with a single blockage resulting in an average downtime of 1-4 hours, causing significant economic losses to enterprises. During coal transportation, blockages are easily caused by multiple factors: First, uneven coal particle size, with large-diameter coal lumps (≥200mm) easily causing jamming in narrow pipe sections; second, moisture fluctuations, where coal moisture content exceeding 12% easily adheres to the pipe walls and accumulates, with higher moisture content leading to stronger adhesion and faster caking; third, abrupt changes in pipe structure, such as bends and diameter changes, causing turbulent flow fields and significant loss of coal kinetic energy, easily leading to eddy current accumulation; and fourth, deposition in long horizontal sections, where coal dust accumulates to a thickness of 5-10mm daily due to gravity in horizontal coal chute lengths exceeding 15 meters, easily forming a hard caking layer over long-term operation, with a blockage rate exceeding 80%. These blockage problems directly lead to coal conveying interruptions, affecting subsequent production processes.

[0019] The main methods for clearing blockages in coal chutes include manual clearing, mechanical clearing, and chemical clearing. However, each method has its own insurmountable technical drawbacks: manual clearing is the most traditional method, requiring workers to enter the coal chutes with tools or knock on the outside, which is extremely labor-intensive and poses serious safety risks. According to a safety report from the power industry, accidents caused by manual clearing, such as falls from heights and material collapses, account for more than 35% of safety accidents in coal conveying systems each year. Mechanical clearing typically uses devices such as agitators, vibrators, or scrapers. Agitators can easily break up large coal blocks, but they can also cause blockages. The inner wall of the pipeline is worn down. After one year of operation, the actual wall thickness of the pipeline has decreased by 1-2 mm. The high-frequency vibration of the vibrator can cause the pipeline weld to crack. The scraper is easily stuck by the hard slab layer and the cleaning response is slow. It takes 20-30 minutes from the discovery of the blockage to the start of the cleaning. Chemical cleaning reduces the viscosity of the material by spraying chemical agents, but the cost of the agents is high (the cost of processing each ton of coal increases by 5-10 yuan), and the agent residue will contaminate the quality of the coal. At the same time, some agents are corrosive and will damage the pipeline and equipment. They may also react chemically with the coal and create safety hazards.

[0020] Therefore, in response to the technical defects of related technologies in unblocking materials, such as low efficiency (long time for each unblocking operation), high safety risks (significant risks of manual operation and mechanical vibration damage to equipment), poor economic efficiency (high mechanical wear and maintenance costs, high chemical agent costs), and insufficient environmental protection (chemical agent pollution), this application provides a coal blockage unblocking system and method, integrating four core units: an air cannon assembly, a compressed air supply device, an intelligent control device, and an adaptable nozzle assembly. Among them, the air cannon assembly, as the core of unblocking execution, adopts a high-strength steel air tank to ensure safe and stable operation under a wide range of working air pressure of 0.4-0.8MPa. The nozzle assembly adopts a detachable structure, and the appropriate type can be selected according to the physical characteristics of the conveyed material, such as humidity and particle size distribution. For dry, free-flowing coal, a circular nozzle is selected to form a penetrating airflow, and for sticky or damp, lumpy coal, a fan-shaped nozzle is selected to expand the impact coverage area. The unblocking method includes the following key steps: Locating the prone-to-blockage areas in the coal chute through fluid dynamics simulation and on-site condition analysis, and precisely deploying air cannons; scientifically selecting nozzle components based on material characteristics and completing sealed installation; controlling the compressed air supply device to inflate the air cannons to the target pressure and then releasing it instantly; utilizing the kinetic energy impact force generated by the rapid expansion of the high-pressure airflow to disperse the blockage material. This invention features a rapid unblocking response, requiring only 2-3 seconds from blockage detection to the start of release. The impact force can be dynamically adjusted according to the degree of blockage, supporting both automated local operation and remote centralized control modes. Because compressed air is used as the power source, there is no risk of sparks or static electricity generation during operation, effectively improving the continuous operating efficiency of the coal conveying system while completely eliminating the safety hazards associated with manual unblocking.

[0021] Specifically, Figure 1 This is a schematic diagram of a coal chute blockage clearing system provided in an embodiment of this application.

[0022] like Figure 1 As shown, the coal chute blockage clearing system 10 includes: a detachable nozzle assembly 11, an air cannon assembly 12, a compressed air supply assembly 13, and a control device 14.

[0023] Among them, the detachable nozzle assembly 11 is the target type; the air cannon assembly 12 is installed in the blockage-prone area of ​​the coal chute to store gas and discharge the gas through the detachable nozzle assembly 11; the compressed air supply assembly 13 is used to supply air to the air cannon assembly; the control device 14 is used to control the air cannon assembly 12 in the blockage-prone area to perform the first target action based on the blockage clearing command, and to control the compressed air supply assembly 13 to perform the second target action, so as to achieve the unblocking of the coal chute.

[0024] It is understood that the embodiments of this application construct a coal chute blockage clearing system 10, including a detachable nozzle assembly 11, an air cannon assembly 12, a compressed air supply assembly 13, and a control device 14. The control device 14 controls the air cannon assembly 12 to perform a first target action based on a blockage clearing command, and controls the compressed air supply assembly 13 to perform a second target action. The compressed air supply assembly 13 is used to charge the air cannon assembly 12 with high-pressure gas. The air cannon assembly 12 sprays the high-pressure gas through the detachable nozzle assembly 11. The high-pressure gas sprays out the blockage in the blockage area, which has a high clearing efficiency. Since high-pressure gas is used as the cleaning power source, it is more environmentally friendly and energy-saving, the blockage clearing cost is lower, and no manual cleaning is required, resulting in low safety risks.

[0025] In this application embodiment, areas prone to material blockage may include bends (especially 90° bends, where coal flow impacts the pipe wall due to inertia and accumulates when turning), diameter transition sections (such as the sudden reduction in diameter from DN800 to DN500, where the coal flow velocity increases abruptly from 1.5m / s to 3.0m / s, easily forming eddy currents at the diameter transition), the junction of horizontal and vertical sections (when the coal flow changes from vertical descent to horizontal conveying, the kinetic energy loss is about 40%, easily leading to stagnation due to insufficient kinetic energy), and long horizontal sections with a length >15 meters (where coal powder gradually deposits due to gravity during horizontal conveying, with an average daily deposition thickness of 5-10mm, which accumulates over a long period to form caking), etc.

[0026] Furthermore, in one embodiment of this application, the unblocking command includes an inflation command or an venting command, with the first target action being venting and the second target action being inflation.

[0027] Among them, the exhaust command is the command issued by the control device 14 to the air cannon assembly, which can be generated according to the user's operation, that is, the user manually sets the exhaust command, or determines the exhaust command according to the material flow rate; the inflation command is the command issued by the control device to the compressed air supply device, which can be triggered automatically according to the user's operation, that is, the user manually sets it, or determines the automatic triggering based on the material accumulation height.

[0028] Furthermore, in one embodiment of this application, the target type includes a first type or a second type, and the target type is determined based on the physical properties of the material in the coal chute.

[0029] The first type can be a circular nozzle, and the second type can be a fan-shaped nozzle. The material characteristics can include moisture content, viscosity coefficient, particle size, etc.

[0030] It is understood that the type of detachable nozzle assembly in the embodiments of this application can be determined based on the characteristics of the basic material, so as to improve the targeting of unblocking, adapt to different scenarios, and improve unblocking efficiency.

[0031] For example, considering only moisture content and viscosity coefficient, if the moisture content is below a certain threshold and the viscosity coefficient is also low, it indicates that the material is relatively dry and has low viscosity. A circular nozzle can be used to form a high-speed, concentrated penetrating airflow. Conversely, if the moisture content is high and the viscosity coefficient is high, a fan-shaped nozzle can be used to form a wide-area airflow impact.

[0032] Specifically, this application embodiment can analyze the physical characteristics of the material conveyed in the coal chute by sampling and testing, focusing on the moisture content and viscosity coefficient of the material: if the material is dry (moisture content ≤8%, viscosity coefficient <0.3Pa·s), its fluidity is good, and a circular nozzle is selected as the nozzle assembly. This type of nozzle can focus the airflow energy and form a penetrating impact; if the material is viscous (moisture content ≥15%, viscosity coefficient ≥0.8Pa·s) or if the dry material has become damp (moisture content 10%-15%, viscosity coefficient 0.3-0.8Pa·s), its fluidity decreases significantly and it is easy to stick to the wall and clump. A fan-shaped nozzle is selected as the nozzle assembly to improve the unblocking effect by expanding the airflow action area; after selecting the nozzle, it is connected to the exhaust port of the air cannon assembly through a flange. When connecting, sealant is applied and the bolts are tightened, and then an airtightness test is performed to ensure that the seal is installed in place.

[0033] Furthermore, in one embodiment of this application, the control device 14 includes: a local control module, a remote control module, and a controller.

[0034] The local control module generates a clearing command based on at least one of the user's operation, the material accumulation height of the target blockage area, and the material flow rate. The remote control module uploads at least one of the material accumulation height and the material flow rate to the host computer and receives the clearing command from the host computer, wherein the host computer generates the clearing command based on at least one of the material accumulation height and the material flow rate. The controller is used to control the air cannon component in the target blockage area to perform a first target action according to the clearing command, and to control the compressed air supply component to perform a second target action.

[0035] The host computer can be a central control system; the target blockage area can be a specific blockage area determined by location; and the controller can be a PLC (Programmable Logic Controller).

[0036] It is understood that the control device 14 in this application embodiment includes a local control module and a remote control module. The local control module can generate a clearing command based on at least one of the user's operation, the material accumulation height of the target blockage area, and the material flow rate, so as to support manual triggering or timed automatic triggering. The remote control module can upload at least one of the material accumulation height and the material flow rate to the host computer and receive the clearing command from the host computer to realize remote control.

[0037] It is understood that the embodiments of this application can automatically generate venting or inflation commands based on user operations, or automatically generate venting commands based on material flow rate and inflation commands based on material accumulation height, so as to improve the flexibility of triggering unblocking commands.

[0038] Specifically, the embodiments of this application can use manual selection of unblocking instructions, or manual setting of timed automatic generation of unblocking instructions, or automatic generation of instructions based on material flow rate and material accumulation height, to expand the application scenarios.

[0039] Furthermore, in one embodiment of this application, the local control module is further configured to: determine the blockage level based on the material accumulation height and / or material flow rate; determine the target unblocking air pressure based on the blockage level; generate an inflation command based on the target unblocking air pressure; and generate an venting command based on at least one of the user's operation, the material accumulation height, and the material flow rate.

[0040] It is understood that the embodiments of this application can determine the blockage level based on the material accumulation height and material flow rate, determine the target unblocking air pressure based on the blockage level, generate an inflation command based on the target unblocking air pressure, and accurately match the unblocking air pressure by the blockage level to avoid equipment impact caused by high air pressure unblocking light blockages or unblocking failure caused by low air pressure unblocking heavy blockages. Furthermore, an exhaust command is generated based on at least one of the user's operation, material accumulation height, and material flow rate to control the air cannon assembly to spray gas for unblocking.

[0041] For example, the blockage level in this application embodiment can be divided into three levels: Level 1 (severe), Level 2 (moderate), and Level 3 (slight). Different unblocking air pressures are matched according to different blockage levels. When the blockage is severe, at Level 1 (e.g., material accumulation height ≥ 1 / 2 of the coal drop pipe diameter, or material flow rate drop exceeding 80%, or interruption exceeding 5 minutes), a higher air pressure of 0.6-0.8 MPa can be selected to ensure sufficient impact force to break up the caking. When the blockage is moderate, at Level 2 (material flow rate drop of 50%-80%, not completely interrupted), a lower air pressure of 0.4-0.6 MPa is selected. When the blockage is slight, at Level 3 (material flow rate drop less than 50%), a lower air pressure of 0.2-0.4 MPa is selected, thereby reducing energy consumption and equipment impact while achieving unblocking.

[0042] It should be noted that the execution logic of the host computer in this application embodiment, which generates unblocking instructions based on the material accumulation height and material flow rate, is the same as that of the local control module.

[0043] Specifically, the control device 14 in this embodiment includes a local control module and a remote control module. Both adopt a dual-CPU architecture to achieve data synchronization and redundant control. The local control module is set in the operating area 1-2 meters away from the air cannon assembly and integrates an emergency stop button, a manual / automatic switch, a pressure display screen, and status indicator lights for on-site manual operation and equipment status monitoring. The remote control module communicates with the central control system of the coal conveying system through the MODBUS-RTU or PROFINET communication protocol. The communication distance can reach 1000 meters (wired) or 500 meters (wireless). It supports remote monitoring of key data such as air tank pressure, solenoid valve status, and number of air filling operations, as well as remote start / stop of unblocking operations.

[0044] Furthermore, in one embodiment of this application, the air cannon assembly 12 includes an air tank and a solenoid valve, wherein the air tank is used to store gas and the solenoid valve is used to receive a clearing command.

[0045] It is understood that the air cannon assembly 12 in this application embodiment includes an air tank and a solenoid valve. The air tank is used to store gas, and the solenoid valve is used to receive a clearing command, specifically an exhaust command, to clear the blockage area with nozzle gas.

[0046] Specifically, in this embodiment, the gas storage tank and solenoid valve can be integrated into a single design. The effective gas storage volume of the gas storage tank is not less than 70L. The main body material is Q345R pressure vessel special steel that meets relevant standards and has passed the 1.38MPa water pressure test. It can operate stably for a long time under a working gas pressure of 0.4-0.8MPa. The material of the gas storage tank can also be aluminum alloy or alloy steel that meets relevant standards. Among them, the weight of the aluminum alloy gas storage tank can be reduced to less than 50Kg, which is suitable for lightweight installation requirements. The alloy steel gas storage tank can withstand high pressure above 1.0MPa, which is suitable for high blockage risk scenarios. The solenoid valve adopts a pilot-operated structure, with a rated working voltage of 24VDC safety voltage. The working pressure covers the entire working range of 0.15-0.8MPa, and the response time is ≤50ms, ensuring that the gas release command can be executed quickly and ensuring timely clearing of blockages.

[0047] In this embodiment, the solenoid valve and control device 14 can be electrically connected via a shielded cable to avoid electromagnetic interference in the industrial environment affecting control accuracy. After the unblocking command is triggered, the control device immediately sends an action signal to the solenoid valve. The solenoid valve responds quickly within 50ms, opening the exhaust channel and allowing the compressed air in the storage tank to be released instantaneously through the nozzle assembly. The high-pressure airflow generated during the release process overcomes the static friction of the material through the kinetic energy generated by the rapid expansion of the gas, quickly breaking up the arched or piled coal and restoring the material to a state of gravity flow. After the release is completed, the control device automatically records the unblocking time, air pressure, and other data for subsequent operation and maintenance analysis.

[0048] Furthermore, in this embodiment, if a single release fails to effectively clear the blockage (determined by a flow recovery rate <80% detected by a flow sensor), the control device 14 will activate an intelligent retry mechanism. After an interval of 30-60 seconds, the control device will control the gas storage tank to release again. The interval can be automatically adjusted according to the ambient temperature (extended to 60 seconds in low-temperature environments <10℃ to avoid pipe icing affecting airflow). The control device activates the intelligent retry mechanism, strictly controlling the number of repeated releases to no more than 3 times. If the flow recovery rate is still <80% after 3 releases, it is determined that the blockage has failed. The system 10 immediately triggers an audible and visual alarm signal (alarm volume ≥85dB, light flashing frequency 2 times / second) and uploads the fault information (including blockage location, inflation pressure, and number of releases) to the central control system, prompting staff to intervene and check for problems such as excessive material caking or equipment malfunction. At the same time, a fault log is recorded for traceability and analysis.

[0049] The coal chute blockage clearing system of this application embodiment is described below through a specific example. Its structural composition is as follows: Figure 2 and Figure 3 As shown, Figure 2 This is a block diagram of the coal chute blockage clearing system. Figure 3 This is a structural diagram of a coal chute blockage clearing system, specifically including: 1. Air cannon assembly.

[0050] As the core component for clearing blockages, it adopts an integrated design of air tank and solenoid valve, which is compact and easy to install.

[0051] The gas storage tank is made of Q345R pressure vessel steel that meets relevant standards. This material is heat-treated, with a yield strength ≥345MPa and a tensile strength ≥510MPa. It has excellent compressive strength, fatigue resistance, and weldability, and can operate stably under working pressure of 0.4-0.8MPa for a long time with a service life of more than 10 years. The inner diameter of the gas storage tank is designed to be 500mm, with an effective gas storage volume of not less than 70L. With an impact force output of 14200N under the rated working condition of 0.7MPa, it has been verified by drop hammer impact test that it can effectively disperse coal lumps with a particle size ≤200mm and caking layers with a thickness ≤300mm. The bottom of the gas storage tank is equipped with a drain valve to periodically drain the condensate in the tank and prevent internal corrosion.

[0052] The solenoid valve is a pilot-operated high-pressure solenoid valve, powered by a safe 24VDC voltage to avoid the risk of electric shock in industrial environments. It operates within a pressure range of 0.15-0.8MPa, with a response time of ≤50ms, ensuring rapid execution of airflow release commands. The exhaust port uses a conical sealing structure for excellent sealing performance. The air inlet uses a 1 / 2-inch NPT (National Pipe Thread) standard thread interface, equipped with a high-pressure sealing gasket, allowing for quick connection to compressed air pipelines. The overall weight of the equipment is strictly controlled to within 70Kg, and it can be fixedly installed using angle steel brackets, adapting to the installation load-bearing conditions of most coal chutes.

[0053] The air cannon assembly of this application releases an impact force during the instantaneous airflow explosion under a rated operating condition of 0.7MPa. This impact force has been verified by a drop hammer impact test and can effectively disperse coal lumps with a particle size ≤200mm. In addition to Q345R, the material of the air storage tank can also be aluminum alloy or alloy steel that meets relevant standards. The weight of the aluminum alloy air storage tank can be reduced to less than 50Kg, which is suitable for lightweight installation requirements. The alloy steel air storage tank can withstand high pressure above 1.0MPa, which is suitable for high blockage risk scenarios. Furthermore, the air inlet of the air storage tank can adopt a 1 / 2-inch NPT standard threaded interface to connect with the compressed air pipeline. The overall weight of the equipment is strictly controlled within 70Kg, which can be adapted to the installation load-bearing conditions of most coal chutes.

[0054] The air cannon assembly in this embodiment is installed using a bracket fixing method. The nozzle axis of the air cannon assembly is arranged at an angle of 30°-45° with the core blockage area to ensure that the airflow can directly act on the core accumulation area of ​​the blockage material. The bracket is made of angle steel and is fixed to the outer wall of the coal chute by expansion bolts. The load-bearing capacity is not less than 200Kg.

[0055] 2. Compressed air supply device (i.e., compressed air supply assembly).

[0056] As a power source support unit, it is sealed to the air intake of the air cannon assembly through a high-pressure rubber tube (working pressure ≥1.0MPa) or a 304 stainless steel tube. The connection part adopts a double compression fitting, which has reliable sealing performance and can effectively prevent air pressure loss.

[0057] The core of the device is configured with screw or piston air compressors depending on the number of air cannons. A single 70L air cannon is compatible with an air compressor with an exhaust volume ≥0.3m³ / min and a rated exhaust pressure ≥1.0MPa. When there are multiple devices, air compressor clusters can be used for air supply, and the airflow is distributed through a manifold.

[0058] The device has a built-in pressure regulation module and a 100L air storage buffer tank. The pressure regulation module can stabilize the output air pressure at 0.8-1.0MPa, and the buffer tank can absorb pressure fluctuations in the air compressor exhaust to ensure stable air supply pressure. The device also integrates safety functions such as temperature protection and overload protection. When the air compressor temperature exceeds 100℃ or the current exceeds the rated value, it will automatically shut down to ensure safe operation of the equipment. The device can adaptively adjust the inflation rate according to the instructions of the control device to ensure that the air cannon components can quickly complete energy storage. Even in scenarios where multiple devices are inflation at the same time, the inflation efficiency of each device can be guaranteed through a batch inflation strategy, and it has the ability to continuously respond to high-frequency unblocking needs.

[0059] 3. Control device.

[0060] It can use a PLC controller as the core, and has multiple functions such as inflation control, release control, status monitoring, and fault diagnosis. It also supports two independent operation modes: local control and remote control. The two modes can be seamlessly switched and have an interlock function to prevent misoperation.

[0061] The local control module integrates an emergency stop button, a manual / automatic switch, an inflation button, a release button, a pressure display screen, and status indicator lights (power, running, fault). It is deployed in the operating area 1-2 meters away from the air cannon assembly and uses a waterproof and dustproof shell (IP65 protection level) to adapt to harsh industrial environments. It allows on-site personnel to directly view equipment pressure, working status, and other information and perform operations.

[0062] The remote control module communicates with the central control system of the coal conveying system via MODBUS-RTU (wired) or LoRa (wireless) communication protocols. The communication distance can reach 1000 meters (wired) or 500 meters (wireless). It can upload data such as air cannon pressure, solenoid valve status, air filling frequency, and fault information in real time, and receive clearing commands from the central control system to achieve remote monitoring and automated control of blocked materials. The control device also has a built-in data storage module that can record more than one year of operating data, which is convenient for subsequent operation and maintenance analysis and fault tracing.

[0063] 4. Nozzle assembly (i.e., detachable nozzle assembly).

[0064] As an airflow guiding and efficiency enhancement unit, it is made of high-strength aluminum alloy (tensile strength ≥300MPa) with precision machining. It is lightweight and wear-resistant. It can be detachably and sealed to the exhaust port of the air cannon assembly through a flange or quick connector. The sealing surface uses a nitrile rubber sealing ring and is coated with high-temperature resistant sealant to ensure that there is no leakage of high-pressure airflow.

[0065] The nozzle assembly can be flexibly selected with different structural types according to the physical characteristics (humidity, particle size, viscosity, etc.) of the material in the coal chute, forming a "one-shot, multiple-nozzle" adaptation solution: For dry materials (moisture content ≤8%, viscosity coefficient <0.3 Pa·s), which have good flowability, a circular nozzle with an outlet diameter of 15-25 mm is selected, which can form a high-speed concentrated penetrating airflow with an airflow velocity of 300-400 m / s, which can quickly penetrate loose and clogged materials, with a penetration depth of 1-1.5 meters; for viscous materials (moisture content ≥15%, viscosity coefficient ≥0.8 Pa·s), the nozzle assembly can be selected with different structural types according to the physical characteristics (moisture content ≤8%, viscosity coefficient ≥0.8 Pa·s), which have good flowability, forming a high-speed concentrated penetrating airflow with an airflow velocity of 300-400 m / s, which can quickly penetrate loose and clogged materials, with a penetration depth of 1-1.5 meters; for viscous materials (moisture content ≥15%, viscosity coefficient ≥0.8 Pa·s), the nozzle assembly can be selected with different structural types according to the physical characteristics (moisture content ≤15%, viscosity coefficient ≥0.8 Pa·s), which have good flowability. When dry materials become damp (moisture content 10%-15%, viscosity coefficient 0.3-0.8 Pa·s), their fluidity decreases significantly, making them prone to sticking and caking. Using a fan-shaped nozzle with an outlet width of 50-80 mm and a spray angle of 60°-90° creates a wide-area airflow impact, ensuring the impact force is evenly applied to a 300-500 mm material area. This effectively solves the problem of material sticking and caking, ensuring the overall fluidity of the material is restored. Both nozzle types have been optimized through fluid dynamics simulation, with airflow resistance loss ≤5%, ensuring maximum impact force transmission.

[0066] The coal chute blockage clearing system of this application can achieve the following: 1. Excellent Clearing Efficiency: The air cannon assembly delivers a precise impact force of 14200N at its rated pressure of 0.7MPa. Verified by drop hammer impact tests, it effectively disperses coal lumps ≤200mm in diameter and caking layers ≤300mm in thickness. The exhaust time is only 0.34 seconds, and the entire process from triggering clearing to airflow release takes only 0.1 seconds, a response speed far faster than mechanical clearing (20-30 minutes) and manual clearing (30-60 minutes). Combined with precise installation (airflow directly targets the blockage core) and material-adaptive nozzles (circular focusing / wide fan-shaped), the single-time clearing success rate is ≥90%, and even in complex blockage scenarios, the success rate reaches 100% after three repeated releases. Actual application data shows that after adopting the clearing system described in this application, the single blockage handling time of the coal conveying system is reduced from 40-60 minutes using traditional methods to less than 1 minute, and downtime is reduced by more than 98%, significantly improving the continuous operation efficiency of the coal conveying system and reducing production losses caused by downtime.

[0067] 2. High safety and reliability: Using compressed air as the sole energy source, there are no sparks, static electricity, or short circuit risks during the entire operation, making it fully suitable for conveying flammable and explosive materials such as coal, and meeting the explosion-proof requirements of relevant regulations. The air cannon component adopts an intermittent working mode, and through fluid dynamics optimization design, the airflow impact force is evenly applied to the material, without causing damage to the coal drop pipe structure. After 5 years of actual operation, the pipe wall thickness showed no significant wear (wear ≤0.1mm), far superior to mechanical blockage clearing (1-2mm wear per year). At the same time, the system achieves fully automated blockage clearing, completely replacing manual entry into dangerous areas, fundamentally avoiding the safety risks of falls from heights and material collapses during manual blockage clearing, and meeting the requirements of the occupational health and safety management system.

[0068] 3. High degree of automation: The system uses a PLC controller as its core, supporting both local and remote control modes. These two modes are interlocked to prevent misoperation. The local control module integrates complete operation and monitoring functions. Operators can view the air tank pressure in real time via a pressure display screen and quickly determine the equipment's operating status via status indicator lights. The remote control module seamlessly connects with the central control system of the coal conveying system via industrial communication protocols, enabling remote monitoring of blockages, automatic triggering of clearing, and uploading of operational data. It supports integration with enterprise MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) systems for intelligent management of the entire process. The equipment installation adopts a modular design; air cannon components and control devices are all standardized modules. On-site installation only requires fixing, pipeline connection, and wiring. Installation time for a single unit is ≤4 hours, far faster than traditional mechanical clearing equipment (1-2 days). The operation process is simple; operators can master basic operation after 1 hour of training, effectively reducing manual maintenance costs and improving management efficiency.

[0069] 4. Environmentally Friendly and Energy-Saving Characteristics: The system consumes only compressed air during operation, generating no solid, liquid, or gaseous pollutants. Compressed air leakage is ≤0.02MPa / 5min, far below national environmental protection standards. Compressed air can be stored in the storage tank for a long time (pressure drop ≤0.05MPa after 24 hours of pressure maintenance). The inflation process is started on demand, avoiding ineffective energy consumption. Actual measurements show that a single 70L air cannon consumes only 0.05KWh for inflation and approximately 0.001KWh / cycle for clearing blockages, far lower than mechanical clearing equipment (consuming 5-10KWh per clearing cycle). The equipment has a long service life, with core components such as the air cannon and control devices designed for a service life of ≥10 years. The average annual maintenance cost is only 500-1000 yuan (mainly for seal replacement), far lower than chemical clearing (increasing the cost by 5-10 yuan per ton of coal) and mechanical clearing (average annual maintenance cost of 10,000-20,000 yuan), demonstrating significant economic and environmental benefits.

[0070] The coal chute blockage clearing system proposed in this application includes a detachable nozzle assembly, an air cannon assembly, a compressed air supply assembly, and a control device. The control device controls the air cannon assembly to perform a first target action based on a blockage clearing command, and controls the compressed air supply assembly to perform a second target action. The compressed air supply assembly is used to fill the air cannon assembly with high-pressure gas. The air cannon assembly sprays the high-pressure gas through the detachable nozzle assembly. The high-pressure gas is used to clear the blockage in the blockage area, resulting in high clearing efficiency. Since high-pressure gas is used as the cleaning power source, it is more environmentally friendly and energy-saving, with lower blockage clearing costs. Moreover, no manual cleaning is required, resulting in low safety risks.

[0071] Next, with reference to the accompanying drawings, a method for clearing blockages in coal chutes according to embodiments of this application is described.

[0072] Figure 4 This is a flowchart of a method for clearing blockages in a coal chute according to an embodiment of this application.

[0073] This method for clearing blockages in the coal chute is based on the aforementioned coal chute blockage clearing system.

[0074] like Figure 4 As shown, the method for clearing blockages in the coal chute includes the following steps: In step S101, at least one of the following is obtained: material accumulation height, material flow rate, and user operation in the coal drop pipe of at least one area prone to blockage.

[0075] In step S102, a blockage clearing command is generated based on at least one of the following: material accumulation height, material flow rate, and user operation.

[0076] In step S103, the air cannon assembly in the blockage-prone area is controlled to perform the first target action according to the blockage clearing command, and the compressed air supply assembly is controlled to perform the second target action.

[0077] It should be noted that the foregoing explanation of the coal chute blockage clearing system embodiment also applies to the coal chute blockage clearing method of this embodiment, and will not be repeated here.

[0078] This application also provides an assembly method for a coal chuting system.

[0079] The assembly method of the coal chute dredging system is used to assemble the coal chute dredging system described above.

[0080] Figure 5 This is a flowchart of the assembly method of the coal chute unblocking system provided according to the embodiments of this application.

[0081] like Figure 5 As shown, the assembly method of this coal chute unblocking system includes the following steps: In step S201, historical operating data of the coal chute is obtained.

[0082] Historical operating data can be field operating data from the past year, including statistics on the frequency, location, and causes of material blockage, in order to identify areas prone to blockage.

[0083] In step S202, the flow process of materials in the coal chute is simulated using fluid dynamics simulation software, and the flow field risk areas of the coal chute are identified based on the simulation results.

[0084] The fluid dynamics simulation software can be Fluent software.

[0085] It is understood that the embodiments of this application can simulate the flow process of materials in the coal chute based on fluid dynamics simulation software in order to analyze the distribution of coal flow velocity field and pressure field under different working conditions and identify the risk areas of the flow field.

[0086] In step S203, the blockage-prone area is determined based on the flow field risk zone and historical operating data. The coal chute blockage clearing system is fixed in the blockage-prone area using the target bracket. The detachable nozzle assembly of the coal chute blockage clearing system is at a target angle to the center of the blockage-prone area.

[0087] The target support can be a fixed support, which can be fixed by expansion bolts; the target angle can be 30°-45° to ensure that the airflow can directly act on the core accumulation area of ​​the blockage material and avoid damage caused by the airflow impacting the pipe wall.

[0088] It is understood that the embodiments of this application can accurately determine the areas prone to blockage based on the flow field risk zone and historical operating data, and use the target support to fix the coal chute blockage clearing system in the areas prone to blockage, thereby improving the efficiency of subsequent blockage clearing.

[0089] In addition, it should be noted that before installation, the embodiments of this application require on-site surveying to determine the installation space and load-bearing conditions.

[0090] Specifically, the assembly process of the coal chute blockage clearing system according to this application embodiment is as follows: Step S1: Build a 1:1 three-dimensional simulation model of the coal chute on site. Use SolidWorks software to draw the complete structure of the coal chute and input the key dimensional parameters of the coal chute on site, including the total length of the pipe, the diameter of each section, the bend angle, the length of the horizontal and vertical sections and the fillet size at the junction, and the roughness of the inner wall of the coal chute, to ensure that the model is completely consistent with the actual equipment. Step S2: Import the Fluent fluid dynamics simulation software, optimize the mesh generation, and use a combination of structured and unstructured meshes to refine the mesh in key areas prone to blockages, such as bends, diameter changes, and intersections of horizontal and vertical sections, while using conventional meshes in other areas. Step S3: Set boundary conditions. The inlet boundary is set as the mass flow rate boundary based on the actual coal conveying volume on site, the outlet boundary is set as the pressure outlet, and the pipe wall is set as a non-slip wall. Based on the physical characteristics of the coal being conveyed on site, set the medium parameters of the coal flow, including density and dynamic viscosity. The simulated coal flow is an incompressible viscous fluid. The simulation calculation uses a turbulence model, and the number of iteration steps can be set to 10,000. The convergence criterion can be set to residual ≤1e-5. Enable the energy equation to monitor the change in coal kinetic energy.

[0091] Step S4: Extract simulation results for multi-dimensional analysis: First, velocity field analysis, focusing on the velocity distribution cloud map of coal flow in each region, identifying areas of sudden velocity increases and decreases, and eddy currents, where turbulent coal flow is prone to accumulation; second, pressure field analysis, examining the pressure distribution contour map, identifying areas of concentrated pressure, which easily leads to coal block compression and accumulation; third, kinetic energy loss analysis, calculating the kinetic energy loss rate of coal flow in each section using the energy equation, highlighting areas with kinetic energy loss ≥30%, where insufficient kinetic energy easily leads to coal flow stagnation; fourth, particle trajectory analysis, importing discrete phase particles with the same particle size as the coal blocks on site, simulating particle motion trajectories, identifying areas with high particle impact frequency and long residence time on the pipe wall, which are high-risk blockage areas, and combining the simulation analysis results to mark high-risk blockage areas and generate a preliminary simulation analysis report (i.e., simulation results).

[0092] Step S4: Collect on-site operation data from the past year, statistically analyze the frequency, location and causes of material blockage, combine with simulation analysis reports, correct the high-risk area markings, and form a complete material blockage risk map.

[0093] Step S5: Conduct on-site surveying of the coal drop pipe. Use tools such as laser rangefinders and calipers to accurately measure the spatial dimensions of the installation area and the flatness of the outer wall of the pipe. Use a tensile tester to test the load-bearing capacity of the pipe installation location, confirm the installation space and load-bearing conditions, and ensure that the air cannon assembly does not affect the coal flow and does not exceed the pipe's load-bearing range after installation.

[0094] Step S6: Based on the above comprehensive analysis, accurately locate the areas prone to blockage, specifically including: bends, diameter changes, intersections of horizontal and vertical sections, and long horizontal sections with a length greater than 15 meters. During installation, use custom angle steel brackets for fixation. The brackets are fixed to the outer wall of the coal chute with expansion bolts. Arrange the nozzle axis of the air cannon assembly at an angle to the core blockage area to ensure that the airflow can directly act on the core accumulation area of ​​the blockage material and avoid damage caused by airflow impacting the pipe wall.

[0095] According to the assembly method of the coal chute unblocking system proposed in the embodiments of this application, the flow process of materials in the coal chute is simulated using fluid dynamics simulation software, and the flow field risk area of ​​the coal chute is identified based on the simulation results. Based on the historical operating data of the coal chute and the flow field risk area, the blockage-prone area is accurately determined. The coal chute blockage unblocking system is installed in the blockage-prone area, and the detachable nozzle assembly is positioned at a target angle with the center of the blockage-prone area to ensure that the airflow can impact the core of the blockage area.

[0096] Specifically, the embodiments of this application describe the installation and application process of the coal chute unblocking system as follows: Figure 6 As shown below: Step 1: Precise positioning and installation of the air cannon assembly, i.e., blockage detection, is used to detect areas prone to material blockage.

[0097] Before installation, three preparatory tasks need to be completed: First, the material flow process of the coal chute is simulated using fluid dynamics simulation software such as Fluent to analyze the distribution of coal flow velocity field and pressure field under different working conditions and identify turbulent areas in the flow field; second, field operation data from the past year is collected to statistically analyze the frequency, location and cause of material blockage and form a material blockage risk map; third, the coal chute is surveyed on-site to confirm the installation space and load-bearing conditions. Based on the above analysis, the areas prone to blockage are precisely located, including: bends (especially 90° bends, where the coal flow impacts the pipe wall due to inertia when turning, with an impact force of over 500N, easily leading to accumulation), diameter change sections (such as the sudden reduction in diameter from DN800 to DN500, where the coal flow velocity increases abruptly from 1.5m / s to 3.0m / s and the Reynolds number increases from 5000 to 10000, easily forming eddy currents at the diameter change), the junction of horizontal and vertical sections (when the coal flow changes from vertical descent to horizontal transport, the kinetic energy loss is about 40%, and the velocity drops from 3.0m / s to 1.8m / s, easily leading to stagnation due to insufficient kinetic energy), and long horizontal sections with a length >15 meters (coal powder gradually deposits due to gravity during horizontal transport, with an average daily deposition thickness of 5-10mm, and a caking layer with a thickness ≥100mm can be formed within 3 months). During installation, a custom-made angle steel bracket is used for fixation. The bracket is fixed to the outer wall of the coal chute with M16 expansion bolts, with a load-bearing capacity of not less than 200Kg. The nozzle axis of the air cannon assembly is arranged at an angle of 30°-45° with the core blockage area to ensure that the airflow can directly act on the core accumulation area of ​​the blockage material and avoid damage caused by airflow impacting the pipe wall. After installation, the horizontal and vertical alignment is calibrated, with a deviation of ≤2°.

[0098] Step 2: Material analysis and nozzle selection.

[0099] First, the physical properties of the material conveyed in the coal chute were comprehensively analyzed by sampling and testing. The test items included: moisture content (tested by drying method, accuracy ±0.1%), particle size distribution (tested by sieving method, screen aperture 5-200mm), viscosity coefficient (tested by rotational viscometer, accuracy ±0.01Pa·s) and bulk density (tested by volumetric method, accuracy ±10Kg / m³). Based on the test results, the nozzle type is selected as follows: If the material is dry (moisture content ≤8%, viscosity coefficient <0.3Pa·s, etc.), its flowability is good, so a round nozzle is selected. This type of nozzle can focus the airflow energy to form a penetrating impact, which is suitable for breaking loose accumulations. If the material is viscous (moisture content ≥15%, viscosity coefficient ≥0.8Pa·s, bulk density 1300-1500Kg / m³, etc.) or if the dry material has become damp (moisture content 10%-15%, viscosity coefficient 0.3-0.8Pa·s, etc.), its flowability decreases significantly and it is easy to stick to the wall and clump. A fan-shaped nozzle is selected, which can improve the unblocking effect by expanding the airflow action area, and is suitable for breaking clumps that stick to the wall. After selecting the nozzle, connect it to the air cannon exhaust port via a flange. When connecting, apply high-temperature resistant sealant (temperature range -40℃ to 200℃) to the sealing surface and tighten the bolts evenly (torque value 50-60 N·m). Then, conduct an airtightness test: close the drain valve, inflate to 0.8 MPa and hold the pressure for 5 minutes. Monitor the pressure change through a pressure sensor. A pressure drop ≤ 0.02 MPa is acceptable. Ensure the seal is properly installed to prevent air leakage from causing impact force loss.

[0100] Step 3: Clear the blockage.

[0101] 1. Intelligent inflation and energy storage control.

[0102] First, the target working air pressure is set through the control device's operating interface (touchscreen or button panel). The target air pressure can be preset to three levels according to the blockage risk level: light blockage (0.4-0.6MPa), medium blockage (0.6-0.7MPa), and heavy blockage (0.7-0.8MPa). Then, the compressed air supply device is activated. The device monitors the air pressure changes in the storage tank in real time through a high-precision pressure sensor (measuring range 0-1.0MPa, accuracy ±0.01MPa), feeding the data back to the control device to achieve closed-loop inflation control. During inflation, the control device automatically adjusts the inflation flow rate according to the storage tank volume and current air pressure: maximum flow rate is used in the initial inflation stage (air pressure < 0.5MPa) to improve efficiency; the flow rate is reduced in the later inflation stage (air pressure ≥ 0.5MPa) to avoid abnormal temperature rise inside the tank due to excessively rapid inflation (real-time monitoring by a temperature sensor; temperature ≤ 60℃ is within the safe range). When the air is inflated to the target working pressure, the pressure sensor sends a signal to the control device, which immediately cuts off the inflation circuit (closes the intake solenoid valve) and issues an inflation completion notification via indicator light and buzzer. If multiple air cannon assemblies are present on site, the control device can perform batch inflation (starting one unit every 5 seconds) to prevent a sudden increase in grid load caused by simultaneous inflation (the starting current of a single air compressor is approximately 3-5 times its rated current), thus ensuring grid stability.

[0103] 2. Instantly release the blockage clearing action.

[0104] When a blockage occurs in the coal chute, the system supports three triggering methods to meet different scenario requirements: First, on-site personnel manually press the release button via the local control module, suitable for manually discovered blockages; second, the central control system of the coal conveying system automatically sends a clearing command after detecting a sudden drop in material flow (a drop of ≥50% lasting for 10 seconds) through an electromagnetic flow sensor (measurement range 0-500t / h, accuracy ±1%), suitable for automated production lines; third, in timed clearing mode, it is triggered at a preset time (configurable from 5-60 minutes), suitable for scenarios with high blockage frequency. After the clearing is triggered, the control device immediately sends an action signal to the solenoid valve through the high-speed IO module. The solenoid valve responds quickly within 50ms, causing the compressed air in the air tank to be released instantaneously through the nozzle assembly. During the release process, the high-pressure airflow forms a high-speed airflow jet through the nozzle (300-400m / s for circular nozzles, 200-300m / s for fan-shaped nozzles). The kinetic energy generated by the rapid expansion of the airflow overcomes the static friction of the material, quickly breaking up the arched or accumulated coal, allowing the material to return to a state of gravity flow. After release, the control device automatically records data such as clearing time, inflation pressure, and release duration, and stores them in the built-in data module for subsequent operation and maintenance analysis and optimization.

[0105] Step 4: Effect evaluation and iterative optimization.

[0106] After the blockage is cleared, the clearing effect is confirmed in two ways: first, the electromagnetic flow sensor detects a material flow recovery rate of ≥80% and automatically sends a clearing success signal; second, on-site personnel manually send a clearing success signal after confirming the blockage is cleared through an observation window or camera. Upon receiving the success signal, the control device automatically adjusts the compressed air supply device to refill the air tank to a standby air pressure of 0.6MPa (lower than the working air pressure to save energy and reduce equipment standby load), putting the system in a real-time standby state, with a response time of ≤35s for the next blockage clearing request.

[0107] If a single release fails to effectively clear the blockage (flow recovery rate <80%), the control device will activate the intelligent retry mechanism, controlling the gas storage tank to release again after an interval of 30-60 seconds. The interval can be automatically adjusted according to the ambient temperature (extended to 60 seconds in low-temperature environments <10℃ to avoid condensation in the pipeline affecting the airflow jet effect; shortened to 30 seconds in high-temperature environments >35℃ to prevent the material from further caking due to high temperature).

[0108] The number of repeated releases must be strictly controlled to no more than 3 times. If the flow recovery rate is still <80% after 3 releases, it is determined that the blockage has failed. The system will immediately trigger an audible and visual alarm signal (alarm volume ≥85dB, red alarm light flashing frequency 2 times / second) and upload the fault information (including blockage location, inflation pressure, number of releases, and sensor data) to the central control system. At the same time, the fault log (including time and operating parameters) will be recorded for easy traceability and analysis, prompting staff to intervene and check for problems such as excessive material caking, nozzle blockage, or equipment failure.

[0109] The installation and application of the coal chute blockage clearing system according to the present application are described below through specific embodiments.

[0110] Example 1: Application of a coal chute blockage clearing system in a power plant.

[0111] A large thermal power plant (installed capacity 2×660MW) uses a DN800→DN500 variable diameter coal chute structure in its coal conveying system. This chute connects the raw coal bunker to the coal feeder, with a conveying capacity of 400t / h. The coal conveyed is bituminous coal (moisture content 10%-12%, average particle size 20-80mm). In the initial stage of operation, blockages frequently occurred at the variable diameter section and the junction of the horizontal and vertical sections, averaging 8-10 blockages per month. Each blockage required 2-3 workers to clear it using a combination of manual tapping and mechanical vibration, with an average processing time of 40-60 minutes. Each blockage resulted in insufficient coal supply to the boiler, necessitating the use of backup fuel oil, with a single loss of approximately 50,000 yuan. Furthermore, there was a minor injury accident caused by material collapse during manual blockage clearing.

[0112] To solve this problem, the power plant adopted the solution proposed in this application for renovation, and the specific implementation plan is as follows: 1. System Configuration: Based on the on-site working condition analysis, two air cannon components with a storage capacity of 70L and made of Q345R material were selected. They were installed respectively at the DN800→DN500 diameter transition section (1.5 meters from the transition point) and the junction of the horizontal and vertical sections (1 meter from the junction). The air cannon weighs 65Kg and is fixed with a custom-made angle steel bracket. The bracket is fixed to the outer wall of the coal chute using M16 expansion bolts, with a load-bearing capacity of 200Kg and an installation angle of 35° to ensure that the airflow directly hits the core blockage area. The solenoid valve is a 24VDC powered pilot-operated high-pressure solenoid valve with a working pressure range of 0.15-0.8MPa and a response time of 50ms. Compressed air... The supply unit uses a screw air compressor with a rated pressure of 1.0MPa and a discharge capacity of 0.6m³ / min, equipped with a 100L air storage buffer tank to ensure stable air supply. Considering the characteristic of the coal conveyed by this power plant with a moisture content of 10%-12% (slightly damp), a fan-shaped nozzle with an outlet width of 60mm and a spray angle of 80° is selected. The control unit adopts a Siemens S7-200SMART PLC controller, which integrates a local operation panel (IP65 protection level) and an Ethernet communication module. It communicates and links with the power plant's coal conveying central control system (Siemens PCS7) through the PROFINET protocol, and can upload equipment status in real time and receive automatic unblocking commands.

[0113] 2. Clearing Process: After the modification, the system enters automatic operation mode. When blockage occurs in the variable diameter section, the central control system of the coal conveying system detects a sudden drop in material flow rate from 400t / h to 150t / h (a decrease of 62.5%) via an electromagnetic flow sensor (measuring range 0-500t / h). After 10 seconds, it automatically sends a clearing command to the control device. The control device immediately adjusts the compressed air supply device to inflate the corresponding air cannon component, with the target air pressure set at 0.7MPa. During the inflation process, the pressure sensor provides real-time feedback data. Inflation is completed after 34 seconds (pressure...). (Force reaches 0.7MPa, temperature 55℃); then the control device sends an action signal to the solenoid valve, which responds quickly to open the exhaust channel. Compressed air is released instantaneously through the fan-shaped nozzle, generating a wide-amplitude impact force of 14200N within 0.34 seconds, directly acting on the blockage material at the change of diameter; after the release is complete, the flow sensor detects that the material flow rate gradually recovers, returning to 380t / h after 10 seconds (recovery rate 95%), indicating successful unblocking; the system automatically adjusts the air compressor to recharge the air cannon to a standby pressure of 0.6MPa, awaiting the next unblocking demand. The entire process requires no manual intervention, taking only 45 seconds from blockage detection to unblocking completion.

[0114] 3. Application Results: After the system was put into operation, statistical data from one year of operation showed that the frequency of coal duct blockage decreased from 8-10 times per month to 1-2 times per month, and the time for a single blockage clearing was shortened from 40-60 minutes for traditional manual clearing to less than 1 minute. The continuous operating efficiency of the coal conveying system increased from 85% to 98%, an increase of 15 percentage points. Annual downtime was reduced by approximately 400 hours, and approximately 80 tons of spare fuel were avoided (at a cost of 8,000 yuan per ton of fuel), directly reducing downtime losses by approximately 640,000 yuan. Combined with the cost savings from manual clearing (originally requiring two dedicated clearing personnel at an annual labor cost of 150,000 yuan), the overall annual economic benefit was approximately 790,000 yuan. Simultaneously, the safety hazards associated with manual clearing were completely eliminated. No safety accidents occurred during the first year of system operation, and equipment maintenance costs were only 800 yuan per year (mainly for replacing seals), earning high praise from the power plant's safety and maintenance departments.

[0115] Example 2: Application of wet coal chutes in a coal mine.

[0116] The underground coal conveying system of a large coal mine (roadway width 3 meters, height 3.5 meters) uses a 20-meter-long, DN600 diameter horizontal coal drop pipe to transport raw coal mined underground (moisture content 18%-22%, average particle size 10-50mm, viscosity coefficient 1.2Pa·s). Because the coal is directly transported after mining, it has high moisture content and strong viscosity, and frequent caking and blockage occur in long horizontal sections. The thickness of the caking layer can reach 100-200mm, with an average of 5-6 blockages per week. Traditionally, mechanical scrapers are used to clear the blockage, but each clearing requires a 2-3 hour shutdown, which not only affects the output of raw coal (average daily reduction of 1000 tons), but also makes the scrapers prone to clogging and jamming.

[0117] 1. System Configuration: Four air cannon components are installed every 5 meters along a 20-meter horizontal section. The enhanced equipment with a 75L air storage capacity is selected, and the material is a composite structure of Q345R and alloy steel, which has passed the 1.38MPa water pressure test. Considering the strong stickiness of wet coal, fan-shaped nozzles are selected to expand the airflow area. The control device is set to a timed inspection mode, which detects the material flow status every 30 minutes through the flow rate sensor.

[0118] 2. Unblocking process: During the scheduled inspection, when the flow rate sensor detects that the material flow rate is lower than the threshold, the control device immediately starts the unblocking program, and adjusts the four air cannon components to be charged to 0.8MPa in sequence (charge time 36 seconds), and then released in sequence at 5-second intervals according to the installation order; the fan-shaped nozzles form a wide airflow to impact the caking coal, causing the caking layer to break up and restore flow; if the flow rate is still not up to standard after a single release, the system releases again at 40-second intervals to achieve complete unblocking.

[0119] 3. Application effect: After treatment, the frequency of coal duct blockage was reduced to twice a month, and the success rate of clearing blockage reached 100%; the wide airflow impact effectively prevented the aggravation of wet coal caking, reduced the corrosion of the inner wall of the pipeline by wet coal, and reduced equipment maintenance costs by 30%.

[0120] This application also provides a computer-readable storage medium storing a computer program or instructions thereon. When the computer program or instructions are executed by a processor, they implement the above-mentioned method for clearing blockages in a coal chute or the assembly method for a coal chute clearing system.

[0121] This application also provides a computer program product, including a computer program or instructions, which, when executed, implement the above-mentioned method for clearing blockages in a coal chute, or the assembly method for a coal chute clearing system.

[0122] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0123] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0124] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0125] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or more of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (FPGAs), field-programmable gate arrays (FPGAs), etc.

[0126] Those skilled in the art will understand that all or part of the steps of the methods described in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, it includes one or a combination of the steps of the method embodiments.

Claims

1. A coal chute blockage clearing system, characterized in that, include: A detachable nozzle assembly, wherein the detachable nozzle assembly is of the target type; An air cannon assembly is installed in the blockage-prone area of ​​the coal chute to store gas and discharge the gas through the detachable nozzle assembly. A compressed air supply assembly is used to supply air to the air cannon assembly; The control device is used to control the air cannon assembly to perform a first target action based on the blockage clearing command, and to control the compressed air supply assembly to perform a second target action, so as to clear the blockage in the coal chute.

2. The coal chute blockage clearing system according to claim 1, characterized in that, The target type includes a first type or a second type, and the target type is determined based on the physical properties of the material in the coal chute.

3. The coal chute blockage clearing system according to claim 1, characterized in that, The control device includes: The local control module generates the unblocking command based on at least one of the user's operation, the material accumulation height in the target blockage area, and the material flow rate. The remote control module uploads at least one of the material accumulation height and material flow rate to the host computer and receives the unblocking command from the host computer, wherein the host computer generates the unblocking command based on at least one of the material accumulation height and material flow rate. The controller is used to control the air cannon assembly in the target blockage area to perform a first target action according to the unblocking command, and to control the compressed air supply assembly to perform a second target action.

4. The coal chute blockage clearing system according to claim 3, characterized in that, The unblocking command includes an inflation command or an venting command, where the first target action is venting and the second target action is inflation.

5. The coal chute blockage clearing system according to claim 4, characterized in that, The local control module is further used for: The blockage level is determined based on the material accumulation height and / or the material flow rate; Determine the target unblocking air pressure based on the blockage level, and generate an inflation command based on the target unblocking air pressure; An exhaust command is generated based on at least one of the user's operation, the material stack height, and the material flow rate.

6. The coal chute blockage clearing system according to claim 1, characterized in that, The air cannon assembly includes an air tank and a solenoid valve. The air tank is used to store the gas, and the solenoid valve is used to receive the unblocking command.

7. A method for clearing blockages in a coal chute, characterized in that, The method is based on the implementation of the coal chute clearing system as described in any one of claims 1-6, wherein the method includes the following steps: Obtain at least one of the following in at least one of the following areas prone to material blockage: material accumulation height, material flow rate, and user operation. A blockage clearing command is generated based on at least one of the user's operation, the material stacking height, and the material flow rate. According to the unblocking command, the air cannon assembly in the blockage-prone area is controlled to perform the first target action, and the compressed air supply assembly is controlled to perform the second target action.

8. An assembly method for a coal chute unblocking system, characterized in that, The assembly method is used to assemble the coal chute unblocking system as described in any one of claims 1-6, wherein the method includes the following steps: Obtain the historical operating data of the coal chute; The flow process of materials in the coal chute is simulated using fluid dynamics simulation software, and the flow field risk areas of the coal chute are identified based on the simulation results. Based on the flow field risk zone and the historical operating data, the blockage-prone area is determined. The coal chute blockage clearing system is fixed in the blockage-prone area using a target bracket. The detachable nozzle assembly of the coal chute blockage clearing system is at a target angle to the center of the blockage-prone area.

9. A computer-readable storage medium having a computer program or instructions stored thereon, characterized in that, The computer program or instructions are executed by a processor to implement the coal chute blockage clearing method as described in claim 7, or the coal chute clearing system assembly method as described in claim 8.

10. A computer program product, comprising a computer program or instructions, characterized in that, When the computer program or instructions are executed, they implement the coal chute blockage clearing method as described in claim 7, or the coal chute clearing system assembly method as described in claim 8.

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