A transfer point dust removal linkage device and linkage control method based on a noise sensor

Abstract

The present application relates to a kind of based on noise sensor's transfer point control dust removal linkage device and linkage control method, belong to industrial dust control and automation control technical field.The device includes linkage control unit, noise sensor, actuator and power module;Linkage control unit is connected between noise sensor, actuator by communication cable;Linkage control unit and power module are connected by power cable.Actuator is spray dust suppression mechanism or closed dust removal mechanism, and selection is carried out according to application scene.The present application can distinguish the working condition of transfer point transport belt by the composite criterion of double threshold value and duration analysis, realizes adaptive control dust removal adjustment, and can effectively filter transient noise interference, reduces the probability of equipment false start or miss start, and reliability is high;In addition, the present application uses noise sensor non-contact signal acquisition, avoids the problems such as sensor wear, collision damage, and improves economic benefit.

Description

Technical Field

[0001] This invention belongs to the field of industrial dust control and automation control technology, and relates to a dust removal linkage device and linkage control method based on noise sensors at transfer points. It is mainly applicable to two typical operating scenarios at transfer points: open spray dust suppression and closed dust removal. Background Technology

[0002] In bulk material conveying systems such as mines and mineral processing plants, transfer points are critical locations for dust generation and diffusion. Currently, common dust control devices typically employ the following linkage methods: 1. Touch-based sensor linkage: This method triggers spraying or dust removal equipment by detecting the mechanical vibration of the belt or materials. This method requires direct contact with moving parts, making the sensor susceptible to damage from material impact and mechanical wear, resulting in frequent maintenance and poor long-term reliability.

[0003] 2. Timed control method: The dust suppression equipment is started and stopped according to a preset time cycle. It cannot identify whether the belt is in an unloaded state in real time, which often leads to the equipment continuing to run when there is no material, resulting in waste of water and electricity resources. It may also cause problems such as belt slippage and increased material moisture content due to excessive spraying.

[0004] 3. Dust Concentration Sensor Linkage: This system controls equipment startup and shutdown based on whether the dust concentration in the air exceeds the limit. Dust concentrations at transfer points are typically low and fluctuate little; sensors are not sensitive to minute concentration changes, making them prone to misjudgments and causing untimely equipment startup and shutdown or frequent malfunctions.

[0005] Furthermore, although recent studies have employed non-contact detection technologies such as radar and lasers to identify material conditions, their high equipment costs and limited environmental adaptability have prevented large-scale application in industrial settings. Therefore, there is an urgent need to develop a cost-effective, non-contact, accurate, and suitable technology for linking transfer point condition identification with dust removal in harsh industrial environments. Summary of the Invention

[0006] In view of this, the purpose of this invention is to provide a dust suppression linkage device and linkage control method based on a noise sensor at the transfer point. By collecting noise signals at the transfer point in real time and analyzing the difference in sound pressure level characteristics between the belt under no-load and material conveying conditions, the dust suppression equipment can achieve adaptive and precise control, realizing the intelligent operation effect of "starting when there is material and stopping when there is no material", significantly improving dust removal efficiency and reducing resource consumption.

[0007] To achieve the above objectives, the present invention provides a dust removal linkage device based on a noise sensor at a transfer point, which includes a linkage control unit, a noise sensor, an actuator, and a power module; the linkage control unit is connected to the noise sensor and the actuator via a communication cable; and the linkage control unit is connected to the power module via a power supply cable.

[0008] Furthermore, the actuator can be either a spray dust suppression system or a closed dust removal system, depending on the application scenario.

[0009] The dust suppression spray mechanism is used for dust reduction in open spaces and includes an infrared pedestrian detection sensor, an electric valve, an inlet pipe, an outlet pipe, and a spray device. The infrared pedestrian detection sensor and the electric valve are connected to the linkage control unit. The inlet pipe and the outlet pipe are connected through the electric valve. The spray device is connected to the outlet pipe.

[0010] The sealed dust removal mechanism is used for dust collection and purification in a closed space, and includes a sealed cover, a dust removal fan, an electromagnetic starter, and a dust extraction pipeline; wherein, the electromagnetic starter is connected to the linkage control unit; the dust removal fan is connected to the electromagnetic starter; the sealed cover is connected to the dust removal fan through the dust extraction pipeline; a transfer point conveyor belt is set in the sealed cover to limit the spread of dust during material transportation.

[0011] Another aspect of the present invention provides a dust control linkage method for transfer point dust removal applicable to the device described in the first aspect. The method includes a linkage control unit receiving a noise signal collected in real time by a noise sensor, and determining whether to start the actuator for dust removal based on a comparison of the noise signal with a preset threshold and in conjunction with whether the conveyor belt at the transfer point is set to an idling mode.

[0012] Furthermore, under the premise that the conveyor belt at the transfer point is set to idle mode, if the noise signal is less than the first threshold and continues for a period of time, it is determined that the material transportation has ended, and the linkage control unit controls the shutdown of the actuator; if the noise signal is greater than or equal to the first threshold but less than the second threshold and continues for a period of time, it is determined that the conveyor belt at the transfer point is unloaded, and the linkage control unit controls the start of the actuator; if the noise signal is greater than or equal to the second threshold and continues for a period of time, it is determined that the material has arrived and transportation has begun, and the linkage control unit controls the start of the actuator. If the noise signal is less than the second threshold and persists for a period of time when the conveyor belt at the transfer point is not set to an idle mode, the linkage control unit will shut down the actuator; if the noise signal is greater than or equal to the second threshold and persists for a period of time, the linkage control unit will start the actuator.

[0013] Furthermore, when the actuator is a spray dust suppression mechanism, the linkage control unit needs to make a judgment based on the signal of the infrared pedestrian detection sensor before controlling the start of the actuator. If the infrared pedestrian detection sensor detects a pedestrian passing by, the actuator will not be started for a period of time until no pedestrian signal is detected, at which point the linkage control unit will start the actuator.

[0014] The beneficial effects of this invention are as follows: (1) Non-contact accurate identification: The noise sensor collects signals in a non-contact manner, without mechanical contact with materials or equipment, which fundamentally avoids problems such as sensor wear and collision damage, resulting in a long equipment life and low maintenance workload.

[0015] (2) High reliability adaptive control: Through the composite criteria of "dual threshold + duration analysis", it can accurately distinguish different working conditions such as belt idling and material conveying, and effectively filter instantaneous noise interference, greatly reducing the probability of equipment false start or missed start, and the system has high reliability.

[0016] (3) Significant energy saving and consumption reduction: The dust suppression equipment and the material flow are precisely synchronized and only started when needed, avoiding idling operation caused by some working conditions (when the belt starts and the spray system or dust removal system is turned on), saving water and electricity, and the economic benefits are obvious.

[0017] (4) Integrated safety protection: In the spray dust suppression mechanism, an infrared pedestrian detection and safety delay mechanism is set up, which can automatically stop the operation of the spray device when people approach, effectively preventing people from getting wet and improving the safety of the workplace.

[0018] (5) Flexible deployment and cost advantage: Noise sensors are common monitoring equipment in mines, with low cost, and can be quickly deployed using existing infrastructure. The overall device adopts a modular design, which can be adapted to new projects and is also easy to upgrade and transform existing dust removal systems, making it easy to promote and apply.

[0019] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0020] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a structural block diagram of the transfer point control dust removal linkage device proposed in this invention; Figure 2 A schematic diagram of the linkage device when the actuator is a spray dust suppression mechanism; Figure 3 A schematic diagram of the linkage device when the actuator is a closed dust removal mechanism; Figure 4 A schematic diagram of the linkage control method when the actuator is a spray dust suppression mechanism; Figure 5This is a schematic diagram of the linkage control method when the actuator is a closed dust removal mechanism. Detailed Implementation

[0021] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0022] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0023] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0024] Example 1 like Figure 2 and Figure 3 As shown in the figure, this embodiment provides a noise sensor-based dust removal linkage device for transfer points, which mainly includes a noise sensor, a linkage control unit, an actuator, an infrared pedestrian detection sensor, a power module, and connecting cables.

[0025] The noise sensor is an intrinsically safe noise sensor for mining, with a range of 50-130 dB(A). It is installed about 1.5 meters to the side of the unloading chute at the transfer point and fixed by a windproof and shockproof bracket. It is used to collect the noise signal of the transfer point in real time.

[0026] The linkage control unit, as the core control module, integrates a microprocessor, signal conditioning circuitry, and communication interface. It is responsible for receiving and processing noise sensor signals, performing logical operations such as dual-threshold judgment, duration analysis, and infrared safety signal integration, and outputting control commands to the actuators.

[0027] Based on the application scenario, the implementing agencies are divided into two categories: a) Spray dust suppression mechanism: including electric valves, spray pipelines, nozzles, etc., suitable for spray dust suppression in open spaces; b) Enclosed dust removal mechanism: including enclosed hood, dust extraction pipeline, dust removal fan and its electromagnetic control switch, suitable for dust collection and purification in enclosed spaces.

[0028] Infrared pedestrian detection sensors are installed near personnel passageways in the work area to detect whether people are approaching or passing through in real time. When the infrared pedestrian detection sensor detects a person, it sends a signal to the linkage control unit, triggering the equipment to pause or delay its start-up to ensure work safety.

[0029] The power module is used to power the entire system. It can use an intrinsically safe explosion-proof lithium battery pack or be connected to a low-voltage power supply on site, and supports continuous power supply and low-power standby mode.

[0030] Cable conduits are used for power supply, water supply, and signal transmission between various devices. They are equipped with protection ratings and are suitable for harsh environments such as underground mines or industrial sites. They mainly include communication cables, power supply cables, transmission cables, water supply cables, dust extraction pipes, etc. The linkage control unit is connected to noise sensors, infrared pedestrian detection sensors, and actuators via communication cables, while the power supply cables are connected to the linkage control unit via power supply cables.

[0031] In addition, in the actuator, the spray dust suppression mechanism is supplied with water for spraying via a water supply cable. In the closed dust removal mechanism, the closed hood is connected to the dust removal fan via a dust extraction pipe, the dust removal fan is connected to the electromagnetic control switch via a power transmission cable, the electromagnetic control switch is connected to the power module via a power supply cable, and the electromagnetic control switch is connected to the linkage control unit via a communication cable.

[0032] In this embodiment, based on the need for long-term monitoring, the first threshold (noise under no-load condition) is set to 85dB(A), and the second threshold (noise under loaded condition) is set to 92dB(A).

[0033] The duration parameter is set as follows: loading determination time is 5 seconds, no-load determination time is 5 seconds, and operation end stabilization time is 10 seconds.

[0034] In addition, when using a spray dust suppression system, a safety delay is set, that is, when the infrared pedestrian detection sensor detects a pedestrian passing by, the spray dust suppression system will be paused for 1 minute, during which time spraying will stop.

[0035] In this embodiment, the working process of the linkage device is as follows: After the system is powered on, the noise sensor continuously monitors the noise signal and transmits it to the linkage control unit. When the noise at the transfer point exceeds 92 dB(A) for 5 seconds, it is determined that material has arrived, and the linkage control unit immediately activates the actuator for dust control or removal. During operation, if the noise drops below 85 dB(A) for 10 seconds, it is determined that material conveying has ended, and the linkage control unit shuts down the actuator. If the system is set to belt idling mode, there may be situations where the noise signal is between 85 and 92 dB(A). If the noise signal is between 85 and 92 dB(A) for more than 5 seconds, it is determined that the belt is currently in idling mode, and the actuator needs to be activated for dust control or removal.

[0036] If the actuator is a spray dust suppression mechanism, it is also necessary to control it based on the real-time monitoring signal of the infrared pedestrian detection sensor. Specifically, if the infrared pedestrian detection sensor detects a person, the spray dust suppression operation will be interrupted immediately and a safety delay will be entered. After the delay time is over, the infrared pedestrian detection sensor will be used to detect whether there are any people.

[0037] Example 2 This embodiment provides a dust removal linkage control method based on a noise sensor at a transfer point. The method mainly includes: 1. Signal acquisition and transmission: The noise sensor continuously collects the sound pressure level signal at the transfer point and transmits it to the linkage control unit in real time via analog or digital communication.

[0038] 2. Dual threshold condition identification: The linkage control unit presets two noise thresholds: the first threshold (85dB(A)) corresponds to the background noise level when the belt is running unloaded, and the second threshold (92dB(A)) corresponds to the typical noise level when materials are being conveyed. The linkage control unit makes a preliminary judgment on the current operating condition based on the range of real-time noise values ​​collected by the noise sensors.

[0039] 3. Duration-based filtering for interference suppression: To avoid false triggering caused by transient noise (such as impacts or abnormal sounds), the linkage control unit performs duration analysis on noise signals exceeding the threshold. That is, only when the duration of the noise signal exceeds the set duration is it considered a valid operating condition signal; otherwise, it is regarded as interference and ignored.

[0040] Specifically, when the noise level at the transfer point exceeds 92 dB(A) for 5 consecutive seconds, it is considered a valid operating condition signal, indicating that material has arrived, and the linkage control unit activates the actuator. During device operation, if the noise signal drops below 85 dB(A) and remains below for 10 seconds, it is determined that material conveying has ended, and the linkage control unit shuts down the actuator.

[0041] 4. Infrared safety interlock: Infrared sensor signals are incorporated into the control logic. If personnel are detected approaching during equipment startup or operation, the equipment (primarily affecting the spray dust suppression mechanism) is immediately paused, and a safety delay (e.g., 1 minute) is initiated. After the delay, the personnel status is rechecked, and spray dust suppression operations can only resume after confirming that no personnel are present.

[0042] 5. Adaptive Equipment Start / Stop: Based on the final determined operating condition, the control unit outputs corresponding commands: a) If the noise signal remains above the second threshold for more than 5 seconds, it is determined to be a material handling state, and the spray or dust removal device is activated. b) If the noise signal is between the first threshold and the second threshold, and the system is in "belt idling mode" (applicable to some factories and mines where the spray system or dust removal system is required to start when the belt is started), then the actuator will be activated; c) If the noise signal is below the first threshold and continues for a certain period of time, such as 10 seconds, it is determined that the operation is over or in standby mode, and the device is turned off.

[0043] 6. Multiple operation modes available: The linkage control unit supports multiple control modes to adapt to different on-site management needs, as described below. a) Fully automatic mode: operates automatically based entirely on signals from the noise sensor and the infrared pedestrian detection sensor; b) Idle-running linkage mode: meets the requirements of special processes where the equipment can be started immediately when the belt is running; c) Manual remote control mode: Remote start and stop via wireless remote control, facilitating maintenance and debugging.

[0044] In this embodiment, control methods for different actuators are described separately.

[0045] I. When the actuator is a spray dust suppression mechanism, the control method is as follows: Figure 4 As shown: ① The linkage control unit reads the monitoring signal from the noise sensor in real time and compares the read noise signal with the preset threshold to make a judgment.

[0046] ②If the noise signal is less than the first threshold and the duration exceeds 10 seconds, the material conveying is determined to be finished, and the linkage control unit controls the closing of the electric valve to stop spraying.

[0047] When the noise signal is greater than or equal to the first threshold and less than the second threshold, first determine whether the linkage device has a belt idle mode set. If it is set, then if the duration of the noise signal between the first and second thresholds exceeds 5 seconds, pedestrian detection is performed; if it is not set, then the electric valve is closed and spraying stops when the noise signal is greater than or equal to the first threshold and less than the second threshold.

[0048] If the noise signal is greater than or equal to the second threshold and lasts for more than 5 seconds, it is determined that the material has arrived and pedestrian detection is performed.

[0049] ③ Based on the infrared signal from the infrared pedestrian detection sensor, if there are no pedestrians, the linkage control unit will open the electric valve to start spraying to reduce dust; otherwise, the electric valve will be closed, the spraying will be paused for one minute, and pedestrian detection will be performed again after one minute.

[0050] II. When the actuator is a closed dust removal mechanism, the control method is as follows: Figure 5 As shown: ① The linkage control unit reads the monitoring signal from the noise sensor in real time and compares the read noise signal with the preset threshold to make a judgment.

[0051] ② If the noise signal is less than the first threshold and the duration exceeds 10 seconds, the material conveying is determined to be finished, and the linkage control unit controls the electromagnetic starter to shut down the dust removal fan and stop dust extraction.

[0052] ③ When the noise signal is greater than or equal to the first threshold and less than the second threshold, first determine whether the linkage device has a belt idle mode set.

[0053] If configured, if the noise signal remains between the first and second thresholds for more than 5 seconds, the linkage control unit will control the electromagnetic starter to start the dust removal fan and begin dust extraction.

[0054] If not set, the dust collector fan will be shut down via electromagnetic starter to stop dust extraction when the noise signal is greater than or equal to the first threshold and less than the second threshold.

[0055] ④ If the noise signal is greater than or equal to the second threshold and lasts for more than 5 seconds, it is determined that the material has arrived, and the linkage control unit controls the electromagnetic starter to start the dust removal fan and begin dust extraction.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A dust removal linkage device for transfer points based on noise sensors, characterized in that, It includes a linkage control unit, a noise sensor, an actuator, and a power module; the linkage control unit is connected to the noise sensor and the actuator via a communication cable; the linkage control unit is connected to the power module via a power supply cable.

2. The transfer point control dust removal linkage device according to claim 1, characterized in that, The actuator can be either a spray dust suppression system or a closed dust collection system, depending on the application scenario.

3. The transfer point control dust removal linkage device according to claim 2, characterized in that, The dust suppression spray mechanism is used for dust reduction in open spaces and includes an infrared pedestrian detection sensor, an electric valve, an inlet pipe, an outlet pipe, and a spray device. The infrared pedestrian detection sensor and the electric valve are connected to the linkage control unit. The inlet pipe and the outlet pipe are connected through the electric valve. The spray device is connected to the outlet pipe.

4. The transfer point control dust removal linkage device according to claim 2, characterized in that, The sealed dust removal mechanism is used for dust collection and purification in a closed space, and includes a sealed cover, a dust removal fan, an electromagnetic starter, and a dust extraction pipeline; wherein, the electromagnetic starter is connected to the linkage control unit; the dust removal fan is connected to the electromagnetic starter; the sealed cover is connected to the dust removal fan through the dust extraction pipeline; a transfer point conveyor belt is set in the sealed cover to limit the spread of dust during material transportation.

5. A transfer point dust removal linkage control method applicable to the device described in any one of claims 1 to 4, characterized in that, The linkage control unit receives noise signals collected in real time by the noise sensor, compares the noise signal with a preset threshold, and determines whether to start the actuator for dust control based on whether the conveyor belt at the transfer point is set to an idle mode.

6. The method according to claim 5, characterized in that, If the conveyor belt at the transfer point is set to idle mode, and the noise signal is less than the first threshold and continues for a period of time, it is determined that the material transportation has ended, and the linkage control unit controls the shutdown of the actuator; if the noise signal is greater than or equal to the first threshold but less than the second threshold and continues for a period of time, it is determined that the conveyor belt at the transfer point is unloaded, and the linkage control unit controls the start of the actuator; if the noise signal is greater than or equal to the second threshold and continues for a period of time, it is determined that the material has arrived and transportation has begun, and the linkage control unit controls the start of the actuator. If the noise signal is less than the second threshold and persists for a period of time when the conveyor belt at the transfer point is not set to an idle mode, the linkage control unit will shut down the actuator; if the noise signal is greater than or equal to the second threshold and persists for a period of time, the linkage control unit will start the actuator.

7. The method according to claim 6, characterized in that, When the actuator is a spray dust suppression mechanism, the linkage control unit needs to make a judgment based on the signal of the infrared pedestrian detection sensor before controlling the start of the actuator. If the infrared pedestrian detection sensor detects a pedestrian passing by, the actuator will not be started for a period of time until no pedestrian signal is detected, at which point the linkage control unit will start the actuator.

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