Grain warehousing automatic sampling device and sampling operation method

Abstract

The invention discloses an automatic sampling device for grain warehousing and a sampling operation method. The automatic sampling device comprises a machine body and a lifting seat located at the upper end of the machine body, a telescopic material taking arm with a tooth groove in the side face is transversely arranged in the lifting seat, a motor is arranged in the lifting seat, and the telescopic material taking arm is driven by the motor to achieve left-right horizontal movement; one end of the telescopic material taking arm is fixedly connected with a material taking groove, a material receiving groove is formed in the side face of the lifting base, the material receiving groove is a feeding port for sampling, the material receiving groove corresponds to the lower portion of the telescopic material taking arm, and when the telescopic material taking arm drives the material taking groove to move to the position above the material receiving groove, a taken sample is discharged into the material receiving groove, and a sample outlet is formed in the lower end of the lifting base. The sample outlet is communicated with the material receiving groove, and a basin receiving sample is placed in the sample outlet. When grain is discharged on the belt conveyor, grain sampling can be automatically achieved through telescopic driving, and sampling can be achieved by setting a time value, for example, the sampling machine can automatically stretch out of the arm every several minutes to receive the grain back.

Description

Technical Field

[0001] This invention relates to the field of automatic sampling operations during grain storage, and more specifically to an automatic sampling device and sampling operation method for grain storage. Background Technology

[0002] In the grain storage industry, quality control of incoming grain is a core element in ensuring the safe storage, circulation, and processing quality of grain, directly impacting the implementation of the national food security strategy, enterprise storage efficiency, and end-consumer quality. According to industry regulations such as the "Grain Storage Management Measures" and the "Grain Quality and Safety Supervision Measures," key indicators such as moisture, impurities, particle size, and bulk density of each batch of grain must be tested in real time upon entering storage. Scientific and standardized sampling is a prerequisite for ensuring the authenticity and validity of the test data; its accuracy and timeliness directly determine the success or failure of quality control.

[0003] Currently, the most common method for grain sampling in the industry is manual sampling: during the process of grain being transported into the warehouse via belt conveyor, on-site warehouse workers need to be close to the high-speed conveyor to manually collect grain samples, which are then sent to the testing area for indicator analysis. However, this traditional sampling method has many insurmountable technical drawbacks and is no longer suitable for the large-scale, continuous operation requirements of modern grain storage, specifically in the following aspects: 1. High labor intensity and low operational efficiency: During peak periods of concentrated grain storage, the amount of a single batch can reach hundreds or even thousands of tons. Warehouse keepers need to continuously bend over and reach out to grab the grain, and they need to monitor and follow up on the transportation process of each truckload of grain throughout the entire process. This not only consumes a lot of physical strength and energy, but also easily leads to unstable sampling frequency and excessively long sampling intervals due to personnel fatigue. It is difficult to meet the needs of modern warehousing for continuous and high-frequency sampling and testing, which seriously restricts the overall efficiency of storage operations.

[0004] 2. Insufficient accuracy and standardization in sampling: Manual sampling is greatly affected by operating habits, subjective judgment, and fatigue, resulting in significant randomness and subjectivity. Some operators collect only surface samples of grain to simplify the process, or the sampling quantity and location are inconsistent, leading to samples that cannot reflect the true quality of the entire batch of grain and easily causing quality misjudgments. At the same time, manual sampling lacks standardized operating procedures, and the differences in sampling methods among different operators further exacerbate the dispersion of test data, affecting the accuracy of quality control.

[0005] 3. Significant operational safety risks: When the belt conveyor is running, the belt surface moves at high speed. When the warehouse keeper manually samples at close range, their hands, clothing, etc. are easily caught in the equipment, posing safety hazards such as mechanical injury and falls. Especially when working at night or in bad weather conditions, the visibility is limited, further amplifying the safety risks and posing a serious threat to the personal safety of the operators.

[0006] 4. Difficult to adapt to the needs of large-scale warehousing: With the modernization of the grain storage industry, the storage scale of large grain depots and grain processing enterprises continues to expand. The conveying speed and single-pass volume of belt conveyors have increased significantly. The drawbacks of traditional manual sampling methods, such as high manpower costs and low operating efficiency, have become increasingly prominent and can no longer match the operating rhythm of large-scale and automated warehousing systems.

[0007] In summary, existing manual sampling methods have significant shortcomings in terms of labor intensity, sampling accuracy, operational safety, and scalability. The industry urgently needs a solution that can overcome these technical bottlenecks. Against this backdrop, developing an automated grain storage sampling device that combines automation, precision, efficiency, and safety to achieve standardized and continuous sampling has become an urgent need to promote the upgrading of quality control in the grain storage industry and adapt to modern operational models. Summary of the Invention

[0008] Therefore, to address the aforementioned shortcomings of existing methods, this invention provides an automatic grain sampling device and sampling operation method for grain storage. This application provides an automatic grain sampling device for grain storage. When grain is released from a belt conveyor, it can automatically sample the grain through a telescopic mechanism. It can also automatically extend its arm to retrieve the grain by setting a time value, such as every few minutes, to achieve sampling. The height of the sampling machine is also adjustable. When the sampling machine touches the stop bar of the receiving trough, the bottom plate opens, and the grain sample flows into the inlet and into the sample container. Now, personnel only need to change the container each time.

[0009] This invention is implemented as follows: An automatic grain sampling device for storage is constructed, characterized by comprising a body and a lifting base located at the upper end of the body. A telescopic sampling arm with toothed grooves on its side is horizontally arranged within the lifting base. A motor is installed inside the lifting base, and a gear meshing with the toothed grooves is installed at the rotating end of the motor. The motor drives the telescopic sampling arm to achieve horizontal left-right movement; this is gear-driven telescopic sampling. One end of the telescopic sampling arm is fixedly connected to a sampling trough. A receiving trough is provided on the side of the lifting base, serving as the inlet for the sample return. The receiving trough is located below the telescopic sampling arm. When the telescopic sampling arm moves the sampling trough to above the receiving trough, the sample is released into the receiving trough. A sample outlet is provided at the lower end of the lifting base, communicating with the receiving trough. A basin is placed at the sample outlet to collect the sample.

[0010] According to the present invention, an automatic sampling device for grain storage is characterized in that: the lifting seat is located inside the machine body to achieve lifting and lowering, a motor is installed inside the machine body, the outer side of the lifting seat has a toothed groove, and the lifting seat is also lifted and lowered by the motor driving the gear; that is, the raising and lowering of the lifting seat is also achieved by gear transmission.

[0011] According to the present invention, an automatic grain sampling device for storage is characterized in that: a touch screen and a control button area are provided on the upper surface of the machine body; the touch screen can set parameters such as sampling speed, sampling time interval, and telescopic sampling length; the control button area includes an alarm button, a run button, a start / stop button, and buttons for adjusting the raising and lowering of the lifting seat.

[0012] According to the present invention, an automatic sampling device for grain storage is characterized in that: the sampling trough includes a sampling trough body, the bottom of the sampling trough body has a discharge port, a movable discharge stop is provided at the discharge port, the two ends of the discharge stop are provided with through holes, the two ends of the discharge stop are inserted into two connecting columns at the bottom of the sampling trough body through the through holes, springs are provided on the connecting columns, the discharge stop can move horizontally along the connecting columns, and the springs can return the discharge stop to its original position.

[0013] According to the present invention, an automatic grain sampling device for warehousing is characterized in that: a stop bar is provided in the inner cavity of the receiving trough to control the opening of the discharge stop block. The stop bar and the discharge stop block are at the same horizontal position. When the telescopic feeding arm drives the entire feeding trough to take a sample and moves to the right to the receiving trough, the stop bar blocks and limits the discharge stop block, thereby exposing the discharge port at the bottom of the feeding trough. The sample in the feeding trough is released into the receiving trough through the discharge port. When the telescopic feeding arm drives the entire feeding trough to move to the left, the spring can return the discharge stop block to its original position, and the discharge stop block will cover the discharge port again. That is, the bottom plate automatically opens when the sample returns and hits the stop bar. After the feeding trough extends, the spring force resets the device. The device is closed by the spring force, and it opens when the sample returns and hits the stop bar.

[0014] According to the present invention, an automatic grain sampling device for warehousing is characterized in that a laser sensor is provided on the side of the lifting seat, and the laser sensor corresponds to the sampling direction. The sampling is controlled according to a set time only when the laser sensor detects that grain has been released.

[0015] A sampling operation method for the aforementioned automatic grain sampling device for warehousing is characterized in that: the operation process involves pressing the "Run" button in the control button area, the device entering automatic sampling mode, the laser sensor continuously monitoring the grain conveying situation in the sampling direction, and when normal grain conveying is detected, the device automatically starts the sampling process according to the set sampling time interval. The motor drives the gear to rotate, causing the telescopic feeding arm to extend horizontally to the left. The feeding trough extends into the grain layer of the belt conveyor along with the telescopic arm. At this time, the discharge stop block blocks the discharge port under the elastic force of the spring, and the grain sample is scooped into the feeding trough. After sampling is completed, the motor reverses and drives the telescopic feeding arm to return horizontally to the right. When the feeding trough moves to the top of the receiving trough, the stop bar in the receiving trough contacts and limits the discharge stop block, forcing the discharge stop block to slide horizontally along the connecting column, compressing the spring, and the discharge port at the bottom of the feeding trough is exposed. The grain sample in the feeding trough falls into the receiving trough through the discharge port, and then flows into the sample collection basin below through the connecting channel between the receiving trough and the sample outlet. After the sample is discharged, the telescopic feeding arm continues to reset to the left, the discharge stop block disengages from the limit of the stop bar, and slides in the opposite direction along the connecting column under the return force of the spring, covering the discharge port again, waiting for the next sampling command.

[0016] This invention has the following advantages: Currently, when grain is stored, each truckload of grain requires a warehouse keeper to manually grab a sample on the conveyor belt for testing, in order to monitor the quality of the stored grain. This application provides a sampling machine that automatically samples the grain as it is released from the conveyor belt via a telescopic mechanism. The machine can also automatically extend its arm to collect the grain at set intervals, such as every few minutes. The height of the sampling machine is adjustable. When the sampler touches the stop bar of the receiving trough, the bottom plate opens, and the grain sample flows into the sample container. Now, personnel only need to change the container each time. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this application; Figure 2 This is a schematic diagram showing the location of the sample outlet at the lower end of the lifting seat in this application; Figures 3-4 This is a schematic diagram of the material feeding trough in this application; Figure 5 This is a schematic diagram of the receiving trough in this application; Figure 6 This is a schematic diagram of the sampling device of this application being located on the side of the belt conveyor to achieve sampling; Figure 7 This is a schematic diagram of the material feeding state from the sampling trough to the receiving trough in the sampling device of this application.

[0018] The components include: 1. Body, 2. Lifting seat, 3. Telescopic material handling arm, 4. Material handling trough, 4-1. Material trough body, 4-2. Material outlet, 4-3. Material outlet block, 4-4. Through hole, 4-5. Connecting column, 4-6. Spring, 4-6. Material receiving trough, 5. Stop bar, 5-1. Sample outlet, 6. Touch screen, 7. Control button area, 8. Laser sensor, 9. Belt conveyor, 10. Detailed Implementation

[0019] The following will be combined with the appendix Figures 1-7This invention will be described in detail, and the technical solutions in the embodiments of this invention will be clearly and completely described. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0020] Now, when grain is put into storage, each truckload of grain is sampled by hand on the conveyor belt to take back for testing, so as to keep track of the quality of the grain entering the storage.

[0021] In an embodiment, to improve the method of grain sampling, the present invention provides an automatic grain sampling device for grain entering storage, such as... Figures 1-7 As shown, it can be implemented in the following manner; including a machine body 1, and a lifting seat 2 located at the upper end of the machine body 1 (the operating height of grain sampling can be adjusted by adjusting the height of the lifting seat 2), and a telescopic picking arm 3 with toothed grooves on the side is arranged horizontally in the lifting seat 2. The lifting base 2 is equipped with a motor, and the rotating end of the motor is equipped with a gear that meshes with the tooth groove. The motor drives the telescopic material picking arm 3 to achieve horizontal movement left and right. This is gear telescopic sampling.

[0022] like Figures 1-2 As shown, one end of the telescopic feeding arm 3 is fixedly connected to the feeding trough 4. The side of the lifting seat 2 is provided with a receiving trough 5, which is the inlet for the sample to return. The receiving trough 5 is located below the telescopic feeding arm 3. When the telescopic feeding arm 3 moves the feeding trough 4 to the position above the receiving trough 5, the sample is released into the receiving trough 5. The lower end of the lifting seat 2 is provided with a sample outlet 6, which is connected to the receiving trough 5. A basin is placed at the sample outlet 6 to receive the sample.

[0023] The lifting seat 2 is located inside the body 1 to achieve lifting. A motor is installed inside the body 1. The outer side of the lifting seat 2 has toothed grooves. The lifting seat 2 also achieves lifting by the motor driving the gears; that is, the raising and lowering of the lifting seat 2 is also achieved by gear transmission.

[0024] like Figures 1-2 As shown, a touch screen 7 and a control button area 8 are provided on the upper surface of the machine body 1. The touch screen can set parameters such as sampling speed, sampling time interval, and telescopic material feeding length. The control button area 8 includes an alarm button, a run button, a start / stop button, and an adjustment button for raising and lowering the lifting seat 2.

[0025] like Figures 1-4As shown, the material receiving trough 4 includes a material receiving trough body 4-1. The bottom of the material receiving trough body 4-1 has a discharge port 4-2. A movable discharge block 4-3 is provided at the discharge port 4-2. The two ends of the discharge block 4-3 have through holes 4-4. The two ends of the discharge block 4-3 are inserted into two connecting posts 4-5 at the bottom of the material receiving trough body 4-1 through the through holes 4-4. A spring 4-6 is provided on the connecting posts 4-5. The discharge block 4-3 can move horizontally along the connecting posts 4-5. The spring 4-6 can return the discharge block 4-3 to its original position.

[0026] like Figures 1-5 As shown, the inner cavity of the receiving trough 5 is equipped with a stop rod 5-1 to control the opening of the discharge stop 4-3. The stop rod 5-1 and the discharge stop 4-3 are at the same horizontal position. When the telescopic feeding arm 3 moves the entire feeding trough 4 to the right to the receiving trough 5 after sampling, the stop rod 5-1 blocks and limits the discharge stop 4-3, thereby exposing the discharge port 4-2 at the bottom of the feeding trough 4-1. The sample in the feeding trough 4 is released into the receiving trough 5 through the discharge port 4-2. When the telescopic feeding arm 3 moves the entire feeding trough 4 to the left, the spring 4-6 can return the discharge stop 4-3 to its original position, and the discharge stop 4-3 will then block the discharge port 4-2 again. Figure 7 As shown, the bottom plate automatically opens when the sample returns and hits the stop bar 5-1. After the material trough 4 extends out, the spring force resets the device. The device is closed by the spring force, and it opens when the sample returns and hits the stop bar 5-1.

[0027] In this application, a laser sensor 9 is provided on the side of the lifting seat 2. The laser sensor 9 corresponds to the sampling direction. The laser sensor detects that grain has been released and then controls the sampling according to the set time.

[0028] In the implementation of this application, the alarm will automatically sound if two consecutive sampling attempts fail and no sample is obtained.

[0029] The following is a detailed description of the usage process of the automatic grain sampling device for warehousing according to the present invention; I. Preparation stage before use Device Inspection: Check whether the device body 1 is securely installed in the designated position next to the belt conveyor, and ensure that all connecting parts (such as telescopic picking arm 3, picking trough 4, receiving trough 5, connecting column 4-5, etc.) are not loose or deformed; check whether the discharge block 4-3 of the picking trough 4 can slide flexibly along the connecting column 4-5, and whether the spring 4-6 is intact and can provide normal return force; confirm that the stop bar 5-1 is firmly installed and its position is horizontally aligned with the discharge block 4-3; check whether the laser sensor 9 is clean, installed at the correct angle, and without any obstructions affecting the sensing.

[0030] Sample collection preparation: Place a clean sample collection basin below the sample outlet 6 at the lower end of the machine body 1, ensuring that the sample collection basin is directly opposite the sample outlet 6 to avoid sample spillage.

[0031] Power connection: Connect the device to a compliant power source and check whether the touch screen 7 and control button area 8 are powered on normally, whether the display screen is clear, and whether the buttons are stuck.

[0032] II. Parameter Setting Stage Press the power start button in control button area 8 to activate the device control system, and the touch screen 7 will enter the operation interface.

[0033] Based on the actual needs of grain storage (such as grain flow rate of the belt conveyor, grain particle size, sampling frequency requirements, etc.), the core parameters can be set via touch screen 7: Sampling speed: Adjust the left and right movement speed of the telescopic feeding arm 3 to ensure that the feeding trough 4 can fully scoop up the grain sample, while avoiding excessive speed that may cause sample splashing or excessive load on the device; Sampling time interval: Set the time interval between two sampling operations (e.g., sampling once every 5 minutes) to adapt to the continuous operation rhythm of grain storage. Telescopic material handling length: Adjust the extension distance of the telescopic material handling arm 3 to ensure that the material handling trough 4 can accurately extend into the grain layer of the belt conveyor to obtain a representative sample (avoiding only taking the surface layer or not touching the grain).

[0034] After setting the parameters, confirm and save via touchscreen 7 to return to the main operation interface.

[0035] III. Equipment Commissioning Phase Press the "Lifting seat up / down" adjustment button in control button area 8 to adjust the height of lifting seat 2 through gear transmission mechanism so that the height of the material trough 4 matches the height of the grain layer on the belt conveyor (the opening end of the material trough 4 is slightly lower than the surface of the grain layer to ensure that the material can be effectively contained when sampling).

[0036] Start the belt conveyor and allow the grain to be transported normally. Observe whether the laser sensor 9 can accurately detect the grain on the belt conveyor (the touch screen 7 will display "Grain detection normal" after successful detection). If the laser sensor does not detect the grain, check the sensing angle, whether there are any obstructions, or adjust the height of the lifting seat 2 so that the sensing direction is aligned with the grain conveying area.

[0037] Press the "Trial Run" button in the control button area 8 to test whether the telescopic feeding arm 3 can extend and retract smoothly, and whether the feeding trough 4 can accurately move above the receiving trough 5 after sampling; observe whether the discharge block 4-3 can open normally under the action of the stop rod 5-1, and whether the sample can fall smoothly into the receiving trough 5 and flow into the sample receiving basin through the sample outlet 6; confirm that after sampling is completed, the discharge block 4-3 accurately returns to its original position under the action of the spring 4-6, blocking the discharge port 4-2.

[0038] If problems such as sampling position deviation, sample spillage, or failure of the discharge baffle to open and close properly occur during trial operation, adjust the sampling parameters via the touch screen or manually fine-tune the position of the components until the device operates normally.

[0039] IV. Automatic Sampling Operation Phase After the trial run is successful, press the "Run" button in control button area 8, and the device will enter the automatic sampling mode.

[0040] Laser sensor 9 continuously monitors the grain conveying in the sampling direction. When it detects normal grain conveying, the device automatically starts the sampling process according to the set sampling time interval. The motor drives the gear to rotate, causing the telescopic feeding arm 3 to extend horizontally to the left. The feeding trough 4 extends into the grain layer of the belt conveyor along with the telescopic arm. At this time, the discharge block 4-3 blocks the discharge port 4-2 under the elastic force of the spring 4-6, and the grain sample is scooped into the feeding trough 4-1. After sampling is completed, the motor reverses and drives the telescopic feeding arm 3 to return horizontally to the right. When the feeding trough 4 moves above the receiving trough 5, the stop bar 5-1 in the receiving trough 5 contacts and limits the discharge stop block 4-3, forcing the discharge stop block 4-3 to slide horizontally along the connecting column 4-5, compressing the spring 4-6, and exposing the discharge port 4-2 at the bottom of the feeding trough 4-1. The grain sample in the feeding trough 4 falls into the receiving trough 5 through the discharge port 4-2, and then flows into the sample collection basin below through the connecting channel between the receiving trough 5 and the sample outlet 6. After the sample is released, the telescopic feeding arm 3 continues to reset to the left, the discharge block 4-3 disengages from the limit of the stop bar 5-1, and slides in the opposite direction along the connecting column 4-5 under the return force of the spring 4-6, covering the discharge port 4-2 again, waiting for the next sampling command.

[0041] During the sampling process, the operator can view the number of samplings, sampling parameters, device operating status and other information in real time through the touch screen 7; if the device fails to collect a sample in two consecutive samplings (empty sampling), the system will automatically trigger the alarm function, the alarm indicator light in the control button area 8 will light up and an alarm sound will be emitted.

[0042] Alarm handling: After hearing the alarm, the operator presses the "alarm button" to clear the alarm, checks whether the belt conveyor is interrupted, whether the extension length of the feeding chute 4 is insufficient, whether the laser sensor 9 is malfunctioning, etc. After troubleshooting and resolving the problem, the automatic sampling mode is restarted.

[0043] V. Sample Collection and Testing Stage Operators regularly collect grain samples from the sample collection basin below sample outlet 6 according to inspection needs, ensuring the basin is clean during collection to avoid cross-contamination between different batches of samples.

[0044] The collected samples are sent to the testing area for testing of indicators such as moisture, impurities, particle size, and quality. The test results are recorded to assess the quality of the grain entering the warehouse.

[0045] After the samples are collected, clean the sample collection container in a timely manner to prevent residual samples from getting damp or moldy, which could affect the accuracy of subsequent sampling.

[0046] VI. Shutdown and Maintenance Phase When the grain storage operation is completed or sampling is no longer required, press the "Start / Stop Button" in control button area 8 to stop the automatic sampling operation.

[0047] Disconnect the power supply to the device and clean and maintain the equipment: clean the residual grain in the feeding trough 4, receiving trough 5, and sample outlet 6 to prevent the grain from accumulating and clumping and affecting the next use; check whether the elasticity of springs 4-6 is normal, and whether the connecting column 4-5 is rusted or stuck, and apply lubricating oil if necessary; clean the sensing surface of laser sensor 9 to ensure sensing sensitivity; check whether the gear transmission mechanism, motor and other components are operating normally, and whether there is any abnormal wear or abnormal noise.

[0048] After maintenance, close the protective cover of the device and keep a record of the equipment usage, including running time, number of samplings, alarm status, maintenance content, etc., for future traceability and repair.

[0049] The operating parameters of the relevant components involved in this application can be configured as follows; (a) Power and transmission components: Lifting motor / telescopic motor: Both adopt 57HS22 stepper motor (rated speed 1500rpm, reduction ratio 1:10, rated torque 2.2N·m). Gear transmission parameters: module 2mm, number of teeth 20, center distance 40mm, clearance between tooth space and gear tooth thickness 0.15-0.2mm; Guide structure: The lifting seat guide adopts SK16 linear slide rail (500mm stroke, 50kg slider load); the telescopic material handling arm guide adopts 45 steel guide shaft with a diameter of 12mm and a length of 800mm, and is matched with linear bearing (model LM12UU).

[0050] Material handling and unloading mechanism: Spring 4-6: Cylindrical helical compression spring (material 65Mn), elastic coefficient k=5N / mm, free length 50mm, installation pre-compression 10mm; Discharge stop 4-3: travel stroke 15mm, connecting post 4-5 length 30mm, through hole 4-4 and connecting post 4-5 clearance fit (gap 0.1-0.2mm). Material feeding trough 4-1: Dimensions are 150mm long × 80mm wide × 60mm high; Material discharge port 4-2: Dimensions are 80mm long × 50mm wide.

[0051] Sensing and control components: Laser sensor 9: E3Z-LS63 type diffuse reflection laser sensor, sensing distance 50-500mm, trigger threshold is "grain blocking the beam for ≥0.5s", power supply voltage 12-24V DC; Controller: S7-200 SMART PLC (model ST20), Touch screen 7 is MT6071IP type (connected to PLC via RS485 communication protocol); Motor driver: DM542 stepper motor driver, microstepping set to 16 microsteps, compatible with 57HS22 motor.

[0052] Body and fixed structure: The main body is made of 304 stainless steel, with dimensions of 600mm (length) × 400mm (width) × 1200mm (height). It has four M16 adjustable anchor bolts at the bottom (adjustment range 0-100mm) and is fixed to the belt conveyor frame with expansion bolts (fixing hole spacing 300mm). Material receiving trough 5: Inclined at 30°, bottom channel size 100mm×80mm, inner wall of the channel is coated with polytetrafluoroethylene (0.1mm thick), sample outlet 6 inner diameter 100mm, with a material receiving basin support below (compatible with material receiving basins with diameter 200-300mm).

[0053] (ii) Control logic and parameter linkage (to ensure that automatic functions can be implemented) Sampling length and motor revolutions: For every 1 revolution of the motor, the telescopic arm moves 5mm (calculated by gear ratio). The PLC controls the telescopic length by recording the number of motor pulses (e.g., if the telescopic length is set to 300mm, the motor needs to rotate 60 times, corresponding to 60 × 1600 (16 microsteps per revolution) = 96000 pulses). Sampling speed control: The motor pulse frequency is adjusted by PLC, and the sampling speed range is 100-500mm / s (corresponding pulse frequency = speed ÷ 5mm / revolution × 1600 pulses / revolution, such as 300mm / s corresponding pulse frequency = 300 ÷ 5 × 1600 = 96000Hz). Sampling time interval: Implemented by the PLC's internal timer, ranging from 1 to 60 minutes (accurate to 1 second). The sampling process starts after the timer is triggered.

[0054] The core timing sequence of the control program is as follows: power-on → parameter initialization → laser sensor monitoring → grain obstruction ≥ 0.5s → trigger sampling timer → timer expires → telescopic motor rotates forward (feeding arm extends to the set length) → delay 0.5s (sampling) → telescopic motor reverses (feeding arm retracts) → feeding trough triggers stop bar → material discharge → feeding arm reset → wait for the next timer trigger.

[0055] (III) Exception handling logic (to ensure operational stability) Motor jamming: When the motor operating current exceeds 1.5 times the rated current (via driver feedback signal), the PLC immediately stops the motor and triggers an alarm (indicator light + buzzer). Manual reset and troubleshooting of the jamming cause are required. Laser sensor malfunction: If no grain is detected for 60 consecutive seconds (and the belt conveyor is running normally), it is determined to be a sensor malfunction, and an alarm message "Sensor abnormal" will be displayed. Spring failure (discharge stop not reset): The position of the discharge stop is detected by the proximity switch (newly added, model SN04-N). If no stop closure signal is detected within 3 seconds after the sample reset, the alarm "unloading mechanism failure" is triggered. Gear wear: Determined by motor current fluctuations (fluctuations exceeding ±30%), triggering an alarm message "Transmission mechanism abnormal".

[0056] Alarm linkage operation: After all alarms are triggered, the device will stop operating immediately, and the touch screen will display the fault type. The device can only be restarted after the "Alarm Reset Button" is pressed and the fault is cleared.

[0057] The practical value of the automatic grain warehousing sampling device of this application is explained below; First, it can solve the pain points of traditional manual sampling and establish a safety production line. Traditional grain sampling at storage facilities relies on warehouse keepers manually grabbing samples next to the conveyor belt, posing two major safety hazards: First, the high-speed operation of the conveyor belt increases the risk of hand entanglement and falls during close-range manual operation, directly threatening the personal safety of workers. Second, manual sampling requires constant monitoring, involving repetitive bending and reaching movements, resulting in high labor intensity and increasing the risk of occupational injuries such as lumbar muscle strain over time. This device completely replaces manual contact with automated mechanical sampling. Operators only need to change the sample container in a safe area, eliminating the risk of mechanical injury at its source and significantly reducing labor intensity, providing a solid guarantee for safe grain storage operations.

[0058] II. Improve the standardization and accuracy of sampling to ensure the precision of grain quality control; Manual sampling is inherently subjective and random: some operators, for convenience, only take samples from the surface of the grain, or the sampling frequency and quantity are inconsistent, resulting in samples that cannot reflect the true quality of the entire batch of grain; furthermore, manual sampling is susceptible to factors such as fatigue and operating habits, leading to significant errors. This device addresses these issues through standardized design: Sampling parameters are controllable: Sampling speed, time interval, and extension length can be precisely set via touch screen to ensure that the sampling frequency and sample volume are consistent for each batch, avoiding human differences. Highly representative samples: The height of the lifting seat is adjustable, and the telescopic feeding arm can penetrate deep into the grain layer. Combined with the laser sensor, it can accurately identify the grain conveying status and start sampling only when there is grain. It can obtain representative samples at different depths and positions, effectively avoiding quality misjudgment caused by "surface sampling". Samples are free from contamination: The enclosed transmission design of the feeding trough and receiving trough prevents sample spillage and contamination with impurities, ensuring the purity of the test samples. This provides accurate data for the detection of key indicators such as moisture, impurities, and particle size, helping grain depots to accurately control the quality of incoming grain and prevent unqualified grain from entering the storage process.

[0059] Third, improve the efficiency of warehousing operations and reduce labor and management costs; Traditional manual sampling requires dedicated personnel to monitor the entire process, necessitating multiple interruptions or simultaneous sampling during each grain truck's entry into the warehouse. This not only incurs high labor costs but also slows down the conveyor belt's transport speed, impacting overall warehousing efficiency. This device offers the following efficiency advantages: Fully automated continuous operation: After setting parameters, no manual intervention is required. It can automatically complete the entire process of "sampling-sampling-unloading-resetting" according to preset time intervals, which is suitable for the 24-hour continuous operation requirements of grain storage and greatly improves storage efficiency. Reduced manpower input: One device can replace 1-2 full-time sampling personnel. Especially during peak periods of large-scale and concentrated grain storage, it can significantly reduce manpower and lower the labor costs of grain depots. Streamline management processes: Avoid sampling interruptions caused by staff shifts or leave. Sampling data can be recorded and traced through a touch screen, reducing omissions and errors in manual recording and lowering communication costs and traceability difficulties in quality management.

[0060] IV. Easy to operate and adaptable to various practical needs in multiple scenarios; This device takes into full account the operating habits of grain depot workers, and its design combines professionalism with ease of use: Low barrier to entry: It adopts a dual mode of "touch screen parameter setting + physical button control", and the core parameters such as sampling speed, interval, and extension length can be visually adjusted. Key operations such as rising / falling, starting / stopping, and alarm can be triggered with one click. No professional technical training is required, and ordinary warehouse keepers can quickly master it. Low maintenance cost: The core transmission structure of the device adopts gear transmission, and the unloading of the material chute relies on the spring force and mechanical stop lever. The structure is simple and reliable with a low failure rate. Routine maintenance only requires cleaning residual grain and checking the spring elasticity and the tightness of the connecting parts, without the need for complicated repairs. High adaptability to different scenarios: The height of the lifting seat is adjustable and the length of the telescopic material picking arm is controllable, which can be adapted to different models of belt conveyors and different grain sizes (such as wheat, corn, rice, etc.). At the same time, it supports flexible adjustment of sampling frequency according to the storage rhythm, meeting the sampling needs of different scenarios such as small and medium-sized grain depots and large grain processing plants.

[0061] V. Real-time monitoring and early warning ensure a smooth warehousing process; The device is equipped with a laser sensor and an automatic alarm function, enabling intelligent monitoring of the sampling process: the laser sensor accurately identifies the grain conveying status, avoiding invalid sampling when there is no grain and ensuring targeted sampling; the automatic alarm design after two consecutive empty samples promptly reminds operators to check for problems such as material breakage on the belt conveyor or insufficient extension length of the sampling arm, avoiding quality control loopholes caused by missed inspections, while ensuring uninterrupted warehousing processes. This function allows grain depot managers to monitor the sampling status in real time, anticipate potential problems, and improve the stability and controllability of warehousing operations.

[0062] VI. Facilitate digital management of grain storage and improve industry standardization; The automated design of this device aligns with the trend of digital and standardized management in modern grain depots: sampling parameters can be precisely set and recorded, and data such as sampling frequency, time, and abnormal alarms are traceable, providing objective and accurate raw data for establishing grain quality records; the standardized sampling process avoids interference from human factors in quality judgment, making the quality assessment of grain entering the warehouse more credible, helping grain depots pass quality system certification and enhance their industry competitiveness. At the same time, the widespread application of this device can promote the transformation of the grain storage industry from "manual experience-based" to "intelligent standardization," improving the overall level of operational standardization.

[0063] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automatic sampling device for grain entering a warehouse, characterized in that; Includes a machine body (1) and a lifting seat (2) located at the upper end of the machine body (1). A telescopic material-taking arm (3) with toothed grooves on the side is arranged horizontally in the lifting seat (2). A motor is installed inside the lifting seat (2). A gear that meshes with the toothed groove is installed at the rotating end of the motor. The telescopic material-taking arm (3) is driven by the motor to achieve horizontal movement left and right. This is gear telescopic sampling. One end of the telescopic feeding arm (3) is fixedly connected to the feeding trough (4). The side of the lifting seat (2) is provided with a receiving trough (5). The receiving trough (5) is the inlet for the sample to come back. The receiving trough (5) is located below the telescopic feeding arm (3). When the telescopic feeding arm (3) moves the feeding trough (4) to the top of the receiving trough (5), the sample is released into the receiving trough (5). The lower end of the lifting seat (2) is provided with a sample outlet (6). The sample outlet (6) is connected to the receiving trough (5). A basin is placed at the sample outlet (6) to receive the sample.

2. The automatic grain sampling device for grain storage according to claim 1, characterized in that; The lifting seat (2) is located inside the machine body (1) to achieve lifting. A motor is installed inside the machine body (1). The outer side of the lifting seat (2) has a toothed groove. The lifting seat (2) is also lifted by the motor driving the gear. That is, the lifting and lowering of the lifting seat (2) is also achieved by gear transmission.

3. The automatic grain sampling device for warehousing according to claim 1, characterized in that; The upper surface of the machine body (1) is provided with a touch screen (7) and a control button area (8). The touch screen (7) can set the sampling speed, sampling time interval and telescopic material length. The control button area (8) includes an alarm button, a run button, a start / stop button and a rise and fall adjustment button for the lifting seat (2).

4. The automatic grain sampling device for warehousing according to claim 1, characterized in that; The material receiving trough (4) includes a material receiving trough body (4-1), the bottom of which has a discharge port (4-2). A movable discharge stop (4-3) is provided at the discharge port (4-2). The discharge stop (4-3) has through holes (4-4) at both ends. The two ends of the discharge stop (4-3) are inserted through the through holes (4-4) onto two connecting posts (4-5) at the bottom of the material receiving trough body (4-1). A spring (4-6) is provided on the connecting post (4-5). The discharge stop (4-3) can move horizontally along the connecting post (4-5), and the spring (4-6) can return the discharge stop (4-3) to its original position.

5. The automatic grain sampling device for warehousing according to claim 1, characterized in that; The inner cavity of the receiving trough (5) is equipped with a stop rod (5-1) to control the opening of the discharge stop (4-3). The stop rod (5-1) and the discharge stop (4-3) are at the same horizontal position. When the telescopic feeding arm (3) drives the entire feeding trough (4) to take samples and moves to the right to the receiving trough (5), the stop rod (5-1) blocks and limits the discharge stop (4-3), thereby exposing the discharge port (4-2) at the bottom of the feeding trough (4-1). The sample in the feeding trough (4) is then... The material outlet (4-2) is released into the receiving trough (5). When the telescopic material taking arm (3) drives the material taking trough (4) to move to the left, the spring (4-6) can make the material outlet block (4-3) return to its original position. The material outlet block (4-3) then blocks the material outlet (4-2). That is, when the sample returns and hits the stop bar (5-1), the bottom plate automatically opens. After the material taking trough (4) extends out, the spring force resets the device. The device is closed by the spring force. When the sample returns and hits the stop bar (5-1), it opens.

6. The automatic grain sampling device for warehousing according to claim 1, characterized in that; A laser sensor (9) is provided on the side of the lifting seat (2). The laser sensor (9) corresponds to the sampling direction. The laser sensor will control the sampling according to the set time when it detects that grain has been released.

7. A sampling operation method for the automatic grain warehousing sampling device according to claim 1, characterized in that; The operation process is as follows: Press the "Run" button in the control button area (8), and the device enters the automatic sampling mode. The laser sensor (9) continuously monitors the grain conveying in the sampling direction. When normal grain conveying is detected, the device automatically starts the sampling process according to the set sampling time interval. The motor drives the gear to rotate, causing the telescopic feeding arm (3) to extend horizontally to the left. The feeding trough (4) extends into the grain layer of the belt conveyor along with the telescopic arm. At this time, the discharge block (4-3) blocks the discharge port (4-2) under the elastic force of the spring (4-6), and the grain sample is scooped into the feeding trough (4-1). After sampling is completed, the motor reverses and drives the telescopic feeding arm (3) to return horizontally to the right. When the feeding trough (4) moves above the receiving trough (5), the stop bar (5-1) in the receiving trough (5) contacts and limits the discharge stop block (4-3), forcing the discharge stop block (4-3) to slide horizontally along the connecting column (4-5), compressing the spring (4-6), and the discharge port (4-2) at the bottom of the feeding trough body (4-1) is exposed. The grain sample in the feeding trough (4) falls into the receiving trough (5) through the discharge port (4-2), and then flows into the sample collection basin below through the connecting channel between the receiving trough (5) and the sample outlet (6); After the sample is released, the telescopic feeding arm (3) continues to reset to the left, the discharge block (4-3) disengages from the limit of the stop bar (5-1), and slides in the opposite direction along the connecting column (4-5) under the return force of the spring (4-6), covering the discharge port (4-2) again, waiting for the next sampling command.

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