Intelligent anti-overflow system for coal mine transfer bin and control method

Abstract

The application provides an intelligent anti-overflow system and control method for a coal mine transfer bin, which comprises a multi-source monitoring module, an intelligent control module, a rapid execution module and a secondary protection module; the multi-source monitoring module is used for collecting coal flow state parameters in real time; the intelligent control module is in communication connection with the multi-source monitoring module and is used for risk judgment according to the coal flow state parameters and outputting a control instruction; the rapid execution module is connected with the intelligent control module and is used for driving the main gate to act according to the control instruction; and the secondary protection module is connected with the intelligent control module and is used for starting a standby barrier when the main gate fails to close. The technical scheme provided by the application realizes the whole-process intelligent management and control of the anti-overflow risk in the aspects of "prevention, interruption and recovery".

Description

Technical Field

[0001] This application relates to the field of coal mining and storage safety technology, and in particular to an intelligent anti-collapse storage system and control method for coal mine transit storage. Background Technology

[0002] In large-scale coal mine production, the transfer bin, as a key node in coal transportation, plays a crucial role in the temporary storage and buffering of coal produced from the mining face. Its operational safety directly determines the continuity of coal mine production and the safety of workers. Currently, coal mine transfer bin collapses have become one of the core risks restricting underground safety. The root cause lies in the dynamic fluctuations in coal moisture content—factors such as coal seam burial depth, seasonal rainfall, and groundwater infiltration can all lead to significant changes in the moisture content of coal within the bin. When the moisture content reaches the range of 18%-25%, the coal transforms from a loose solid into a "solid-liquid mixture," which, under the influence of gravity, surges out at high speed along the feeder outlet or gate gaps, resulting in a bin collapse accident.

[0003] In existing technologies, the hazards of coal bin collapse accidents are mainly reflected in two dimensions: First, the direct damage of the initial collapse, where the gushing coal flow can instantly bury equipment such as feeders and conveyor belts, causing equipment jamming, motor burnout, and even burying and suffocating workers; Second, the secondary collapse during the disposal process, where the material structure inside the coal bin becomes unstable after the initial collapse, and the remaining high-moisture coal body is prone to collapse again during manual cleaning or equipment maintenance, posing a fatal threat to rescue and disposal personnel.

[0004] Although existing coal mines have taken preliminary protective measures against the risk of mine collapse, there are still many key technical deficiencies that make it difficult to meet safety requirements. The specific problems are as follows:

[0005] 1. Low monitoring accuracy and high false alarm / missed alarm rates. Existing anti-collapse systems mostly use single-point infrared coal pile sensors, which can only monitor the coal flow height within a fixed angle (usually 30-60°) and a fixed range (0.3-2m). These sensors are easily affected by underground dust and humidity. In particular, dust adhering to the sensor probe shortens the detection distance, and high humidity causes infrared signal attenuation, leading to false alarms and missed alarms. Statistics show that traditional single-point sensors have a false alarm rate as high as 18% and a missed alarm rate of about 5%, affecting normal production and failing to effectively prevent the risk of coal pile collapse.

[0006] 2. Slow response time, unable to cope with sudden market crashes. The existing hydraulic drive units generally suffer from the problem of "power transmission delay": on the one hand, the distance between the hydraulic station and the gate cylinder is usually more than 15m, and the pressure build-up time is 0.8-1.2 seconds when using ordinary high-pressure hoses for transmission; on the other hand, the hydraulic station is not equipped with an efficient energy storage device, and when the power is cut off, it relies solely on gravity to drive the gate to close, with a closing time of 3-5 seconds. In the event of a sudden collapse, the coal flow velocity can reach 1.5m / s, which can bury the feeder within 3 seconds. The existing response speed is completely unable to stop the coal flow.

[0007] 3. Lack of secondary protection mechanisms can easily lead to the escalation of accidents. The existing system relies solely on a single maintenance gate as a protective barrier, without considering extreme situations such as gate failure (e.g., cylinder seal failure, gate jamming). When the main gate cannot be fully closed, coal will continue to flow out, which can easily trigger a secondary collapse. Manual intervention can only be carried out after the coal flow stabilizes, further prolonging the accident response time and increasing the probability of casualties.

[0008] 4. Low level of automation, lack of intelligent prediction and linkage The existing system can only implement the simple logic of "monitoring-alarm-closing" and is not linked with the underground personnel positioning system, the ground monitoring center, and the equipment management system: the collapse alarm only provides sound and light prompts and cannot accurately notify nearby workers to evacuate; it cannot collect key parameters such as humidity and coal flow velocity in the coal bunker in real time, making it difficult to predict the risk of collapse; the equipment operating status (such as cylinder pressure and sensor accuracy) requires manual inspection and investigation, making it impossible to detect potential faults in advance.

[0009] 5. Poor weather resistance of materials, resulting in a shorter equipment lifespan. The underground environment is characterized by high dust, high humidity, and corrosive gases (such as hydrogen sulfide). Existing system components mostly use ordinary steel and rubber seals, which are prone to steel corrosion and seal aging. The average service life of hydraulic cylinders is only 1.5 years, high-pressure hoses need to be replaced every 6 months, and sensor probes need to be disassembled and cleaned every 3 months. This not only increases maintenance costs but may also lead to equipment failure due to untimely maintenance.

[0010] In summary, existing anti-collapse technologies for coal mine transfer silos have significant shortcomings in monitoring accuracy, response speed, protection redundancy, intelligent linkage, and material weather resistance, making them ineffective in addressing the collapse risk of transfer silos in high-moisture coal seams. Therefore, there is an urgent need for an anti-collapse system with multi-source precise monitoring, millisecond-level response, secondary protection, intelligent prediction, and long lifespan. Summary of the Invention

[0011] This application provides an intelligent anti-collapse system and control method for coal mine transfer silos, which at least solves the technical problems of existing coal mine transfer silo anti-collapse systems, which cannot effectively predict, block and prevent silo collapse accidents due to inaccurate monitoring, slow response, single protection, and lack of intelligent early warning.

[0012] The first aspect of this application proposes an intelligent anti-collapse system for coal mine transfer warehouses, the system comprising: a multi-source monitoring module, an intelligent control module, a rapid execution module, and a secondary protection module; The multi-source monitoring module is used to collect coal flow status parameters in real time; The intelligent control module is communicatively connected to the multi-source monitoring module and is used to determine the risk based on the coal flow state parameters and output control commands. The rapid execution module is connected to the intelligent control module and is used to drive the main gate to move according to the control command. The secondary protection module is connected to the intelligent control module and is used to activate the backup barrier when the main gate fails to close.

[0013] Preferably, the multi-source monitoring module includes: a dual-mode coal pile sensor and a multi-point humidity sensor; The dual-mode coal stacking sensor adopts a fusion of millimeter-wave radar and infrared sensor and is installed above the feeder outlet; The multi-point humidity sensors are distributed along the height of the inner wall of the transfer warehouse.

[0014] Furthermore, the multi-source monitoring module also includes: A coal flow velocity sensor, which is a laser Doppler velocity meter, is non-contactly installed above the feeder conveyor belt.

[0015] Furthermore, the intelligent control module includes: an explosion-proof PLC controller and an edge computing unit; The edge computing unit is equipped with an AI image recognition model and an LSTM-based risk prediction model to identify coal flow patterns and predict the risk of coal mine collapse.

[0016] Furthermore, the fast execution module includes: Explosion-proof hydraulic station and main gate cylinder; The explosion-proof hydraulic station has a built-in bladder accumulator and a supercapacitor to provide emergency power in the event of a power outage. The explosion-proof hydraulic station is installed at a distance of less than or equal to 10 meters from the main gate cylinder.

[0017] Furthermore, the closing time of the main gate from fully open to fully closed is less than or equal to 0.5 seconds.

[0018] Furthermore, the secondary protection module includes: A foldable carbon fiber buffer baffle and a spare hydraulic cylinder for driving the buffer baffle; The buffer baffle unfolds within 0.3 seconds to form a V-shaped barrier in an emergency.

[0019] Furthermore, the system also includes: The humidity control module is used to monitor and control the humidity inside the warehouse within the range of 10% to 12%. The linkage alarm module is linked with the underground personnel positioning system to realize directional audible and visual alarms and personnel evacuation notifications; The digital twin module is used to build a 3D model of the transit warehouse and to visualize the equipment status and simulate risks.

[0020] A second aspect of this application provides an intelligent anti-collapse control method for coal mine transfer bins, the method comprising: Real-time data on coal flow height, humidity inside the silo, and coal flow velocity are collected using multi-source sensors. The data on coal flow height, humidity inside the silo, and coal flow velocity are fused and processed, and the risk level is determined based on a preset risk threshold. When the risk level is greater than or equal to the preset emergency threshold, the main gate is controlled to perform an emergency closing action and trigger a linkage alarm. The system monitors the closing status of the main gate. If the closure is not completed within a preset time, it controls the backup protective barrier to deploy to block the coal flow.

[0021] Furthermore, the method also includes: Based on the long short-term memory network model, the trend of coal flow height and humidity change in historical periods is predicted and analyzed to obtain the probability of collapse risk in the next 5 to 10 minutes. A risk warning is triggered when the predicted probability of a margin call exceeds a preset probability threshold.

[0022] The technical solutions provided by the embodiments of this application bring at least the following beneficial effects: This application proposes an intelligent anti-collapse system and control method for coal mine transfer bins. The method includes: a multi-source monitoring module, an intelligent control module, a rapid execution module, and a secondary protection module. The multi-source monitoring module is used to collect coal flow status parameters in real time. The intelligent control module is communicatively connected to the multi-source monitoring module and is used to determine risks based on the coal flow status parameters and output control commands. The rapid execution module is connected to the intelligent control module and is used to drive the main gate to operate according to the control commands. The secondary protection module is connected to the intelligent control module and is used to activate a backup barrier when the main gate fails to close. The technical solution proposed in this application realizes intelligent management and control of the entire process of "prevention before collapse, blocking during collapse, and recovery after collapse" of bin risk.

[0023] 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

[0024] 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 application provides a first structure for an intelligent anti-collapse storage system for a coal mine transfer warehouse according to one embodiment; Figure 2 This is an overall schematic diagram showing the installation positions of various components in an intelligent anti-collapse bin system for coal mine transfer bins according to an embodiment of this application; Figure 3 This is a schematic diagram of the bottom structure of an intelligent anti-collapse warehouse system according to an embodiment of this application; Figure 4 This is a schematic diagram of the top structure of an intelligent anti-collapse warehouse system according to an embodiment of this application; Figure 5 This is a second structure of an intelligent anti-collapse bin system for a coal mine transfer bin, according to one embodiment of this application; Figure 6 This is a flowchart illustrating an intelligent anti-collapse control method for a coal mine transfer warehouse according to an embodiment of this application; Figure Labels Multi-source monitoring module 100, intelligent control module 200, rapid execution module 300, secondary protection module 400, humidity control module 500, linkage alarm module 600, digital twin module 700, dual-mode coal pile sensor 1, multi-point humidity sensor 2, coal flow velocity sensor 3, rope displacement sensor 4, explosion-proof PLC controller 5, edge computing unit 6, explosion-proof hydraulic station 7, hydraulic pressure sensor 7.1, main gate 8, main gate cylinder 8.1, carbon fiber buffer baffle 9, spare cylinder 9.1, explosion-proof humidity monitoring sensor stroke 10. Switch, 11. Explosion-proof drainage pump, 12. Spraying device, 13. Directional sound and light alarm, 14. Ground terminal, 15. Explosion-proof power distribution chamber, 16. Water sump, 17. Under-bin conveyor belt, 18. Coal bunker body, 19. Top conveyor belt of transfer bunker, 20. Iron remover, 21. Under-bin roadway roof, 22. Under-bin roadway floor, 23. Feeder, 24. Limit switch, 25. Coal feeder outlet, 26. Coal bunker top motor, 27. Coal bunker top coal flow, 28. Coal bunker top monitoring camera, 29. Belt conveyor unloading port protective cover, 30. Coal bunker wall, 31. Cable, 32. High-pressure hydraulic pipe. Detailed Implementation

[0025] 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.

[0026] This application proposes an intelligent anti-collapse system and control method for coal mine transfer bins. The method includes: a multi-source monitoring module, an intelligent control module, a rapid execution module, and a secondary protection module. The multi-source monitoring module is used to collect coal flow status parameters in real time. The intelligent control module is communicatively connected to the multi-source monitoring module and is used to determine risks based on the coal flow status parameters and output control commands. The rapid execution module is connected to the intelligent control module and is used to drive the main gate to operate according to the control commands. The secondary protection module is connected to the intelligent control module and is used to activate a backup barrier when the main gate fails to close. The technical solution proposed in this application realizes intelligent management and control of the entire process of "prevention before collapse, blocking during collapse, and recovery after collapse" of bin risk.

[0027] The following description, with reference to the accompanying drawings, describes an intelligent anti-collapse storage system and control method for a coal mine transfer storage facility, according to an embodiment of this application.

[0028] Example 1 Figure 1 This is a structural diagram of an intelligent anti-collapse bin system for a coal mine transfer bin according to an embodiment of this application, as shown below. Figure 1As shown, the system includes: a multi-source monitoring module 100, an intelligent control module 200, a rapid execution module 300, and a secondary protection module 400; The multi-source monitoring module 100 is used to collect coal flow status parameters in real time; The intelligent control module 200 is communicatively connected to the multi-source monitoring module 100 and is used to determine the risk based on the coal flow state parameters and output control commands. The rapid execution module 300 is connected to the intelligent control module 200 and is used to drive the main gate 8 to move according to the control command; The secondary protection module 400 is connected to the intelligent control module 200 and is used to activate the backup barrier when the main gate fails to close.

[0029] In the embodiments disclosed herein, such as Figure 2 As shown, the multi-source monitoring module 100 includes: a dual-mode coal pile sensor 1 and a multi-point humidity sensor 2; The dual-mode coal stacking sensor 1 adopts a fusion method of millimeter-wave radar and infrared sensor and is installed above the feeder outlet; It should be noted that the dual-mode coal pile sensor 1 is specifically installed 1.2-1.5m above the feeder outlet, with two units installed symmetrically along the coal flow direction, covering a detection angle of 0-120°.

[0030] The parameters of the dual-mode coal pile sensor 1 can be as follows: millimeter-wave radar: detection distance 0.5-5m, accuracy ±1mm, frequency 77GHz, strong resistance to dust attenuation; infrared detection: detection distance 0.3-3m, accuracy ±2mm, using an anti-fog lens to prevent water vapor adhesion; protection level: IP68, suitable for underground humidity 95% (RH) and temperature -20℃-60℃ environment; data output: 4-20mA analog quantity + RS485 digital quantity, sampling frequency 10Hz to ensure real-time performance.

[0031] Millimeter-wave radar detects the three-dimensional contour (height, width, and velocity) of the coal flow, while infrared detection supplements the details of the coal flow at close range. The data from both are fused through edge computing unit 6 to remove outliers caused by dust and moisture, and output a precise coal flow height signal.

[0032] The multi-point humidity sensors 2 are distributed along the height of the inner wall of the transfer warehouse.

[0033] It should be noted that if the dust concentration underground is extremely low (such as in a surface transfer silo), the dual-mode coal pile sensor can be replaced with a laser + ultrasonic dual-mode sensor. Laser detection has higher accuracy, while ultrasonic detection has strong anti-interference capabilities and is suitable for clean environments.

[0034] It should be noted that the multi-point humidity sensor 2 can be a capacitive humidity sensor with temperature compensation function, and its installation location is as follows: Figure 2 The diagram shows six detectors evenly distributed along the height of the inner wall of the transit warehouse (two at the bottom, two in the middle, and two at the top) to avoid detection deviations at a single location.

[0035] The parameters of the multi-point humidity sensor 2 can be: measurement range: 0-100%RH, accuracy ±2%RH (at 25℃), temperature measurement range -40℃-85℃; response time: ≤5 seconds (25℃, 63%RH step); protective structure: stainless steel shell, explosion-proof design, to prevent coal block impact and corrosion. The multi-point humidity sensor 2 collects humidity data at different heights inside the chamber in real time and transmits it to the intelligent control module 200. When the average humidity exceeds 16%RH, the humidity control module 500 is triggered to start.

[0036] Furthermore, the multi-source monitoring module 100 also includes: The coal flow velocity sensor 3 is a laser Doppler velocity meter, which is non-contactly installed above the feeder conveyor belt.

[0037] It should be noted that the coal flow velocity sensor 3 can be a laser Doppler velocity meter, which is a non-contact measurement to avoid wear caused by direct contact with the coal flow; like Figure 2 As shown, the coal flow velocity sensor 3 is installed 0.8m above the feeder conveyor belt, at a 45° angle to the width direction of the conveyor belt. Its parameters are: measurement range: 0.1-3m / s, accuracy ±0.01m / s, sampling frequency 5Hz; laser wavelength: 650nm (visible red light), spot diameter 5mm, which is convenient for alignment with the conveyor belt. Laser irradiation of the coal flow surface and calculation of the velocity of coal particles using the Doppler effect help determine the risk of coal collapse when the flow velocity suddenly increases.

[0038] It should be noted that, as Figure 2 and Figure 3 As shown, the system also includes: a hydraulic pressure sensor 7.1 and a rope displacement sensor 4; The hydraulic pressure sensor 7.1 is installed at the outlet of the hydraulic station and the rodless chamber of the cylinder, with a measurement range of 0-31.5MPa, to monitor whether the system pressure is normal. The pull rope displacement sensor 4 is installed at the end of the piston rod of the main gate cylinder. The measurement range is adapted according to the gate stroke and provides real-time feedback on the gate opening degree (0% is fully open, 100% is fully closed). It should be noted that the system also includes: a motor temperature sensor; The motor temperature sensor is embedded in the stator winding of the hydraulic station motor, with a measurement range of -50℃ to 150℃, to prevent the motor from burning out due to overload.

[0039] In the embodiments disclosed herein, such as Figure 2 As shown, the intelligent control module 200 includes: an explosion-proof PLC controller 5 and an edge computing unit 6; The edge computing unit 6 is equipped with an AI image recognition model and an LSTM-based risk prediction model, which are used to identify coal flow patterns and predict the risk of coal mine collapse.

[0040] It should be noted that the explosion-proof PLC controller 5 can be an underground explosion-proof model (ExdIMb), with safety certification and support for fail-safe functions. Its hardware configuration includes a processor, storage capacity, and interfaces that are adapted as needed. The software functions are: first, a data fusion algorithm. A weighted average method is used to fuse dual-mode sensor data, with the weights dynamically adjusted based on the ambient dust concentration (increasing the weight of the millimeter-wave radar when the dust concentration is high); second, risk assessment logic. Three levels of early warning thresholds are set (e.g., early warning: coal flow height 0.4m / humidity 14%; alarm: 0.45m / 16%; emergency: 0.5m / 18%) to avoid misjudgments caused by a single threshold.

[0041] The edge computing unit 6 can be configured with explosion-proof hardware and supports AI model deployment. Its specific functions include: 1) AI image recognition: Running a lightweight CNN (Convolutional Neural Network) model to analyze coal flow images and data collected by the silo camera and humidity monitoring sensor in real time, identifying the coal flow morphology (loose / fluid state), and comparing it with sensor data to reduce false alarm rates; 2) Risk prediction: Based on an LSTM (Long Short-Term Memory) model, inputting the humidity and coal flow height change trends over the past hour, predicting the risk of silo collapse 5-10 minutes in advance, and outputting the prediction results to the ground monitoring center; 3) Data preprocessing: Filtering and denoising the raw data collected by the sensors to ensure data accuracy.

[0042] In the embodiments disclosed herein, such as Figure 2 and Figure 3 As shown, the fast execution module 300 includes: Explosion-proof hydraulic station 7 and main gate cylinder 8.1; The explosion-proof hydraulic station 7 has a built-in bladder-type accumulator and a supercapacitor to provide emergency power in the event of a power outage. The explosion-proof hydraulic station 7 is installed at a distance of less than or equal to 10 meters from the main gate cylinder 8.1.

[0043] It should be noted that the closing time of the main gate from fully open to fully closed is less than or equal to 0.5 seconds.

[0044] It should be noted that the explosion-proof hydraulic station 7 is installed at a distance of ≤10m from the feeder to reduce the pressure transmission distance and shorten the response time; The components of the explosion-proof hydraulic station 7 include: a motor – a variable frequency explosion-proof motor that supports speed adjustment, operating at low speed under light loads to achieve energy saving, and outputting at high speed under heavy loads; an oil pump – an axial piston pump, adaptable to displacement, rated pressure, and pressure fluctuations; an accumulator – a bladder-type accumulator that can provide hydraulic power for two gate closures in the event of a power outage; an electro-hydraulic directional valve – an electromagnetic pilot type with a response time ≤0.1 seconds to ensure rapid switching of the oil circuit; a supercapacitor – connected in parallel with the accumulator to provide 10 minutes of emergency power to the solenoid valve and PLC in the event of a power outage; and a cooling system – an air-cooled radiator equipped with a temperature sensor that automatically starts when the oil temperature exceeds 55℃ to prevent the oil from overheating and deteriorating.

[0045] The explosion-proof hydraulic station 7 monitors the pressure in real time based on a pressure detection sensor. When the pressure is lower than the set value, the motor automatically starts to replenish the pressure; when the set value is reached, the motor stops to avoid energy waste caused by continuous operation.

[0046] It should be noted that the main gate is an arc-shaped low-temperature toughness steel gate with a width that matches the feeder outlet. Wear-resistant lining plates are pasted on the inner side of the gate to reduce the erosion and wear caused by the coal flow. like Figure 3 As shown, the main gate cylinder 8.1 can be a double-acting single-piston rod cylinder with compatible cylinder diameter, rod diameter, and stroke. When the system pressure is greater than the set value, it can easily overcome the coal flow pressure to push the gate to close. The main gate cylinder 8.1 can be installed by using lug-type connections at both ends of the cylinder, which are hinged to the gate to ensure flexible and unobstructed operation.

[0047] It should be noted that by increasing the hose diameter, shortening the pipeline length, and optimizing the valve flow rate, the time for the gate to go from fully open to fully closed can be controlled within 0.5 seconds, which is much faster than the 3-5 seconds of the existing system.

[0048] It should be noted that if the coal mine has a compressed air system (pressure ≥ 0.8MPa), the hydraulic drive system can be replaced with a pneumatic drive system, the main gate cylinder can be replaced with a pneumatic cylinder, and the hydraulic station can be replaced with a pneumatic triplet (filter + pressure reducing valve + oil mist lubricator) to reduce system costs, but the closing time will be extended accordingly.

[0049] If the transit warehouse is small, the main gate can be replaced with a flat gate instead of an arc-shaped gate to simplify the structure, reduce installation difficulty, and keep the gate closing time ≤0.6 seconds.

[0050] In the embodiments disclosed herein, such as Figure 2 and Figure 3 As shown, the secondary protection module 400 includes: A foldable carbon fiber buffer baffle 9 and a spare hydraulic cylinder 9.1 for driving the buffer baffle; The buffer baffle 9 unfolds within 0.3 seconds to form a V-shaped barrier in an emergency.

[0051] It should be noted that the secondary protection module 400 is the system's "backup defense line," activated when the main gate fails, and specifically includes: The foldable carbon fiber buffer baffle 9 can be made of carbon fiber composite material, which is impact-resistant, wear-resistant and corrosion-resistant. Its structure can be a foldable structure. Under normal conditions, it can be folded and stored under the feeder without affecting the coal flow. In an emergency, it can be unfolded into a "V" shape to cover the full width of the feeder outlet. The dimensions are 1.5m width, 1.2m height, 20mm thickness, and approximately 30kg weight per baffle, making it easy to install and maintain.

[0052] It should be noted that the configuration parameters of the backup cylinder 9.1 can be adapted to the cylinder diameter, rod diameter, and stroke, and the thrust can meet the baffle deployment requirements. The power source can share the oil circuit with the main hydraulic station, but a separate directional valve is set to ensure that the backup oil circuit can drive the system in case of failure of the main oil circuit. When the rope displacement sensor detects that the main gate has been closed for more than 1 second (or the opening degree has not reached 100%), the intelligent control module immediately activates the backup hydraulic cylinder, pushing the buffer baffle to unfold within 0.3 seconds to block the coal flow from gushing out.

[0053] It should be noted that if the underground space is limited and a foldable buffer baffle cannot be installed, the secondary protection module can be replaced with a "rapid-inflating airbag". The airbag is inflated by a high-pressure gas cylinder (inflation time ≤ 0.5 seconds), and after unfolding, it forms a columnar barrier to block the coal flow. The airbag can be reused and has low maintenance costs.

[0054] It should be noted that, Figure 2 Component 10 is the limit switch for the explosion-proof humidity monitoring sensor, 14 is the ground terminal, 17 is the conveyor belt under the coal bunker, 18 is the coal bunker body, 20 is the iron separator, 21 is the roof of the underground roadway, 22 is the floor of the underground roadway, 25 is the coal feeder outlet, 26 is the motor at the top of the coal bunker, 27 is the coal flow at the top of the coal bunker, 28 is the monitoring camera at the top of the coal bunker, 29 is the protective cover for the conveyor belt unloading port, 30 is the coal bunker wall, and 32 is the high-pressure hydraulic pipe. All components work together to achieve intelligent full-process control of the risk of coal bunker collapse, including "prevention before the event, interruption during the event, and recovery after the event".

[0055] It should be noted that, as Figure 4 The diagram shows the top structure of the intelligent anti-collapse warehouse system.

[0056] In the embodiments disclosed herein, such as Figure 5As shown, the system also includes: The humidity control module 500 is used to monitor and control the humidity inside the warehouse within the range of 10% to 12%. It should be noted that, as Figure 2 As shown, the humidity control module 500 reduces the risk of coal collapse at the source by controlling the moisture content of coal through monitoring the humidity inside the coal bin. Specifically, it includes: 1. Explosion-proof dehumidifier fan; the model can be an explosion-proof humidity monitoring sensor. The installation location can be the front end of the unloading roller of the conveyor belt machine on the top of the transfer warehouse; The system monitors the moisture content of the coal entering the silo in real time. When it detects that the coal containing mud and water has entered the silo, it automatically cuts off the power to the conveyor belt on the top of the silo.

[0057] 2. Explosion-proof drainage pump 11, the model can be an explosion-proof submersible pump, with flow rate, head and power adapted to meet normal drainage requirements; The installation location can be the water collection pit at the bottom of the transfer warehouse, equipped with an automatic coupling device for easy maintenance; A liquid level sensor is installed in the sump. When the liquid level exceeds the set value, the drainage pump will start automatically to discharge the accumulated water to the underground drainage main pipeline; when the liquid level is lower than the set value, the pump will stop running.

[0058] 3. For example Figure 2 As shown, the humidity balancing spray device 12 can be designed to have an annular spray pipe installed on the top of the warehouse wall, with an atomizing nozzle set at certain intervals. When the humidity inside the silo is below 8% (coal is prone to dust), the PLC starts the spray device 12 to spray atomized water into the silo, maintaining the humidity in the range of 10%-12%, which prevents coal dust from flying and avoids the silo from collapsing due to excessive humidity.

[0059] The linkage alarm module 600 is linked with the underground personnel positioning system to realize directional audible and visual alarms and personnel evacuation notifications; It should be noted that the linkage alarm module 600 is responsible for accident early warning and personnel safety evacuation, realizing multi-dimensional linkage: The linkage alarm module 600 includes: like Figure 2 As shown, the directional sound and light alarm 13 can be installed at two locations: one 50m before and after the feeder, facing the main passage direction of the workers. The audio-visual parameters can be: lighting: red LED strobe light, with adaptive flashing frequency, brightness, and visibility distance to meet on-site requirements; sound: directional speaker, with appropriate volume, capable of playing custom voice messages, such as "The transit warehouse is at risk of collapse, nearby personnel should evacuate immediately"; Adjust the alarm intensity according to the risk level. For example: when the warning is given, the lights stay on and the voice plays once every 30 seconds; when the alarm is triggered, the lights flash frequently and the voice plays once every 10 seconds; when the emergency occurs, the lights flash frequently and the voice plays continuously.

[0060] The linkage alarm module 600 can realize the linkage of underground personnel positioning, and the interface protocol can support the connection with the existing personnel positioning system in the coal mine via the OPCUA protocol. The linkage function can automatically query the location information of personnel within a 50m range when the system triggers an emergency alarm, push evacuation instructions to relevant personnel through the positioning system terminal (such as underground base station, personnel positioning card), and transmit the personnel location to the ground monitoring center in real time to facilitate command and evacuation.

[0061] The linkage alarm module 600 can realize alarms at the ground monitoring center: The data transmission method involves transmitting alarm information (including coal flow data, equipment status, and personnel location) to the ground monitoring center via a dedicated underground network. The alarm methods are a pop-up alarm window on the monitoring center's large screen and an audible and visual alarm.

[0062] The Digital Twin Module 700 is used to build a 3D model of the transit warehouse and to visualize the equipment status and simulate risks.

[0063] It should be noted that the digital twin module 700 is a "digital mirror" of the system, enabling status visualization and intelligent prediction, as detailed below: (1) Digital model construction Modeling software: Constructs a 3D digital model of the transfer warehouse, which can display details such as gates, cylinders, and sensors; Data mapping: Real-time transmission of physical equipment status data (such as gate opening, cylinder pressure, and coal flow height) via a dedicated underground network is synchronized and updated in the digital model to achieve real-time linkage between "physical entity and digital mirror".

[0064] (2) Risk prediction and simulation Predictive function: Based on the LSTM model, input historical humidity, coal flow data and real-time data, predict the probability of silo collapse risk in the next hour, for example, trigger an early warning when the risk probability is >80%; Simulation function: Supports simulation of different breach scenarios (such as mild breach, severe breach, main gate failure), and outputs emergency response plans (such as whether to activate the buffer barrier and personnel evacuation routes), providing support for daily training and emergency drills.

[0065] (3) Equipment operation and maintenance management Status monitoring: Display the equipment operating status (such as motor temperature, cylinder seal wear) in real time in the digital model; when equipment parameters exceed the normal range, maintenance work orders are automatically generated. Lifespan prediction: Based on equipment operating data (such as the number of cylinder actions and sensor sampling frequency), models are used to predict the remaining lifespan of the equipment, arrange maintenance in advance, and avoid sudden failures.

[0066] It should be noted that if the hardware configuration of the coal mine ground monitoring center is limited, the digital twin module can be replaced from "Unity3D real-time rendering" to "visual interface". The interface displays the equipment status, data curves and alarm information, which can meet basic monitoring needs and reduce hardware investment.

[0067] The specific implementation details of this system are as follows: 1) Installation of multi-source monitoring module 100: Dual-mode coal pile sensor 1: Installed 1.4m above the feeder outlet via an angle adjustment bracket. Two sensors are symmetrically arranged, with the detection angle adjusted to 0-120°. Cable 31 is connected to the underground intrinsically safe circuit via an explosion-proof sealing joint. Multi-point humidity sensor 2: Six sensors are welded and installed along the inner wall of the transfer silo. The bottom two are 1m from the bottom of the silo, the middle two are 5m from the bottom of the silo, and the top two are 1m from the top of the silo. The sensor probes face inward to avoid impact from coal blocks. Coal flow velocity sensor 3: installed 0.8m above the conveyor belt 17 of feeder 23, with the laser spot aligned with the center line of the conveyor belt and at a 45° angle to the width direction of the conveyor belt; The pull rope displacement sensor 4 is fixed to the main gate cylinder 8.1 by a bracket, and the end of the pull rope is connected to the piston rod of the cylinder to ensure that the pull rope extends and retracts synchronously when the gate moves.

[0068] 2) Installation of the intelligent control module 200: like Figure 2 As shown, the explosion-proof PLC controller 5 is installed in the explosion-proof power distribution chamber 15 near the transfer warehouse, 5m away from the hydraulic station, and is connected to the edge computing unit 6 through a dedicated cable; The edge computing unit (explosion-proof version) 6 is installed in the same location as the PLC5 and is connected to the underground 5G base station via Ethernet. It deploys a CNN image recognition model (the training dataset contains 10,000 coal flow images) and an LSTM prediction model.

[0069] It should be noted that if the coal mine does not have a 5G network, the data transmission method can be replaced from "5G+LoRa" to "Industrial Ethernet+ZigBee". Industrial Ethernet is used for communication between the ground and the underground chamber, and ZigBee is used for short-range communication between sensors and PLCs to ensure stable data transmission.

[0070] 3) Quickly execute module 300 installation: Hydraulic station 7: Placed on a concrete foundation 8m away from feeder 23, with the foundation 0.3m above the ground (to prevent water accumulation), and the accumulator pre-charge pressure is adjusted to 10MPa; Main gate 8 and main gate cylinder 8.1: The main gate (arc-shaped, 1.2m wide) is installed above the feeder outlet via hinges. The main cylinder (125mm diameter, 500mm stroke) is hinged to the bin body and the gate at both ends respectively. The high-pressure hose (25mm diameter, material: inner layer PTFE + outer layer nickel-plated alloy) connects the hydraulic station and the cylinder. The hose is fixed to the tunnel wall with a pipe clamp to avoid dragging and wear.

[0071] 4) such as Figure 2 As shown, the secondary protection module 400 is installed: Buffer baffle (size: 1.5m×1.2m×20mm) 9: is installed on the side of feeder 23 by hinge, and a 5mm thick wear-resistant ceramic liner is pasted on the inside of the baffle. The spare oil cylinder 9.1 (cylinder diameter 80mm, stroke 300mm) is installed next to the baffle, and the oil cylinder piston rod is hinged to the baffle connecting lug. Limit switch 24: Installed at the limit position of the baffle when it is fully extended. When the baffle is fully extended, the limit switch is triggered and sends a signal to the PLC controller 5.

[0072] 5) such as Figure 2 As shown, the humidity control module 500 is installed: An explosion-proof humidity monitoring sensor 10 is installed at the front end of the unloading drum of the conveyor belt 19 on the top of the transfer silo, facing the direction of coal flow, and is equipped with a waterproof cover. The drainage pump 11 is installed in the sump pit 16 at the bottom of the silo and adopts an automatic coupling device. The pump outlet pipeline is connected to the underground drainage main pipeline (DN100). The spray device has 12 ring spray pipes (DN50, 316L stainless steel) welded to the top of the silo wall, and one atomizing nozzle is installed every 300mm. The water source is connected to the underground purified water pipeline (pressure ≥0.6MPa).

[0073] 6) Installation of the linkage alarm module 600: Directional sound and light alarm 13: Two alarms are installed on the side of the tunnel 50m before and after the feeder 23, at a height of 2.5m. The preset voice content is "There is a risk of collapse in the transfer warehouse. Personnel in the surrounding area should evacuate immediately." Personnel location linkage: It connects with the existing personnel location system in the coal mine through the OPCUA protocol. When an alarm is triggered, it automatically queries personnel information within 50m and pushes the command to the personnel location card through the location base station.

[0074] 7) Deployment of the Digital Twin Module 700: Digital Model: The 3D model of the transfer warehouse was built using Autodesk Revit, imported into Unity3D for rendering, and equipment status animations (such as gate opening and closing, and cylinder actions) were added. Terminal Deployment 14: The ground monitoring center is equipped with two industrial computers to receive real-time data from downhole via a dedicated network, enabling synchronous updates of the model.

[0075] 8) System debugging: Power-on debugging: First, power on the PLC and edge computing unit, then start the hydraulic station and check whether the power supply to each module is normal; 9) Function debugging: Monitoring accuracy adjustment: Artificially simulate coal flow height and adjust the weight of dual-mode sensor to ensure that the detection error is ≤±2mm; Response speed test: Trigger an emergency alarm, record the gate closing time, and ensure that the closing time is ≤0.5 seconds by adjusting the hydraulic station pressure and valve flow rate; Secondary protection test: Manually simulate main gate jamming and check whether the buffer baffle unfolds within 0.3 seconds; Linkage test: Trigger the early warning and confirm whether the audible and visual alarm, personnel positioning system, and ground control center respond synchronously.

[0076] Compared with existing coal mine transshipment silo anti-collapse technologies, the system proposed in this embodiment has beneficial effects in four dimensions: safety, economy, technology, and production, and possesses significant novelty and inventiveness. 1. Safety benefits: Comprehensive improvement in warehouse collapse protection capabilities The monitoring accuracy has been greatly improved: by adopting millimeter wave + infrared dual-mode sensors + AI image fusion, the false alarm rate has been reduced from 18% to below 3%, and the false alarm rate has been reduced from 5% to below 0.5%, avoiding "false alarm shutdown" and "false alarm accidents" and ensuring accurate risk identification; Response speed is improved exponentially: Through hydraulic system optimization (short distance, large diameter hose, accumulator), the gate closing time is reduced from 3-5 seconds to less than 0.5 seconds, which can block the coal flow before it surges out of the dam, reducing the risk of equipment burial and personnel casualties; Double protection prevents secondary collapse: A carbon fiber buffer baffle is added, which unfolds within 0.3 seconds in the event of main gate failure, completely solving the defect of "single protection" in the existing system and preventing secondary collapse from threatening the personnel. More precise personnel evacuation: In conjunction with the underground personnel positioning system, it can accurately locate personnel within 50m and send instructions, avoiding the problem of "vague range" of traditional sound and light alarms, improving the efficiency of personnel evacuation and reducing the probability of casualties.

[0077] 2. Economic benefits: Reduced costs and improved production continuity Equipment maintenance costs reduced by 60%: By adopting new materials, the lifespan of hydraulic cylinders has been extended from 1.5 years to 3 years, the maintenance cycle of sensors has been extended from 3 months to 1 year, the replacement cycle of high-pressure hoses has been extended from 6 months to 2 years, and the annual maintenance cost has been reduced from 200,000 yuan to 80,000 yuan. Energy consumption reduced by 30%: The hydraulic station uses a variable frequency motor, which operates at low speed under light load; the humidity control module starts and stops as needed to avoid the equipment running idle. Significantly reduced accident losses: Under current technology, the average time for equipment repair after a warehouse collapse is 72 hours. This system can completely prevent warehouse collapses, avoiding equipment damage and production stoppages. Reduced labor costs: The system automates the entire process, eliminating the need for manual inspection of sensors and manual control of gates, thus reducing the number of dedicated inspection personnel by two and saving labor costs.

[0078] 3. Technological Benefits: Promoting the Upgrading of Coal Mine Storage Safety Technology Multi-source fusion monitoring technology innovation: Combining millimeter-wave radar with infrared detection and introducing AI image recognition to solve the monitoring accuracy problem in underground dust and humid environments, providing a new solution for "intelligent sensing" in coal mines; Breakthrough in hydraulic system emergency response technology: By combining "variable frequency motor + accumulator + supercapacitor", millisecond-level door closing is achieved in the event of a power outage, breaking through the technical bottleneck of "power failure" in existing hydraulic systems; Digital twin technology empowers safety management: Constructing a digital twin model of a transit warehouse enables risk prediction, scenario simulation, and equipment operation and maintenance visualization, promoting the transformation of coal mine safety management from "post-event handling" to "pre-event prevention"; New material applications are being expanded: high-performance materials are being applied to underground equipment to improve its weather resistance and lifespan, providing a reference for "material upgrades" of coal mine equipment.

[0079] 4. Production benefits: Improves industry safety levels and has broad application value. Ensuring the safety of miners' lives: By implementing precise protection and rapid evacuation, the risk of casualties caused by mine collapse accidents can be fundamentally reduced; Wide range of application scenarios: This system is not only suitable for coal mine transit warehouses, but also for ground raw coal warehouses, metal mine ore warehouses, port bulk cargo warehouses and other storage scenarios that are prone to collapse, with broad application prospects; Promote industry standardization: The technical parameters of this system (such as monitoring accuracy, response time, and protection level) can serve as a reference for coal mine transfer warehouse anti-collapse systems, leading the industry towards technical standardization; Facilitating the construction of "smart mines": The system is deeply integrated with new technologies such as 5G, digital twins, and AI, providing key support for the intelligent transformation of coal mines.

[0080] In summary, the intelligent anti-collapse system for coal mine transfer warehouses proposed in this embodiment realizes intelligent management and control of the entire process of "prevention before collapse, interruption during collapse, and recovery after collapse" of the risk of collapse.

[0081] Based on the aforementioned intelligent anti-collapse bin system for coal mine transfer bins, this embodiment also proposes an intelligent anti-collapse bin control method for coal mine transfer bins, such as... Figure 6 As shown, the method includes: Step 1: Collect real-time data on coal flow height, humidity inside the silo, and coal flow velocity using multi-source sensors; Step 2: The data on coal flow height, humidity inside the silo, and coal flow velocity are fused and processed, and the risk level is determined according to the preset risk threshold; Step 3: When the risk level is greater than or equal to the preset emergency threshold, control the main gate to perform an emergency closing action and trigger a linkage alarm; Step 4: Monitor the closing status of the main gate. If the closing is not completed within the preset time, control the backup protective barrier to deploy to block the coal flow.

[0082] In this embodiment of the disclosure, the method further includes: Based on the long short-term memory network model, the trend of coal flow height and humidity change in historical periods is predicted and analyzed to obtain the probability of collapse risk in the next 5 to 10 minutes. A risk warning is triggered when the predicted probability of a margin call exceeds a preset probability threshold.

[0083] Specifically, taking a risk management case caused by increased underground water seepage in a coal mine as an example, the system operation process is explained in detail: (1) Real-time monitoring phase (S1): One day, the water seepage in a coal mine increased, and the moisture content of the coal in the transfer warehouse rose. Multiple humidity sensors detected that the average humidity in the warehouse reached 14.5% (exceeding the warning threshold of 14%). The dual-mode coal pile sensor detected a coal flow height of 0.35m (normal) and a flow velocity of 0.4m / s (normal). The data is transmitted to the edge computing unit in real time. After filtering, the PLC stops the conveyor belt machine on the warehouse, the digital twin module updates the humidity data in the warehouse, and the ground monitoring center displays "early warning level risk".

[0084] (2) Risk prediction stage (S2): At 8:30, the humidity rose to 16.2% (alarm threshold 16%), the coal flow height rose to 0.42m, and the flow velocity rose to 0.65m / s; The edge computing unit LSTM model predicts that within the next 10 minutes, the humidity will rise to 17.8%, the coal flow height will reach 0.48m, the probability of a collapse will be 85%, triggering an alarm. The directional sound and light alarm is activated (the light flashes and the voice plays once every 10 seconds). The personnel positioning system detects two inspection personnel within 50m and immediately sends out an evacuation order.

[0085] (3) Emergency Response Phase (S3): At 8:38, the dual-mode coal pile sensor detected a sudden increase in the coal flow height to 0.52m (emergency threshold 0.5m), and AI image recognition confirmed that the coal flow was in a "fluid state," determining that a collapse had occurred. The PLC immediately activated the emergency response: The directional sound and light alarm flashes at a high frequency (10Hz) and continuously plays evacuation instructions. When the electro-hydraulic directional valve of the hydraulic station is energized, high-pressure oil enters the main gate cylinder, and the gate begins to close. An emergency alarm popped up at the ground monitoring center, and mine leaders received a text message notification. At 8:38:04, the rope displacement sensor reported that the gate opening was 100% (completely closed), and the coal flow was blocked.

[0086] (4) Recovery and maintenance phase (S5): At 8:45, on-site personnel confirmed that the collapse had stabilized and remotely controlled the hydraulic station through the ground monitoring center to open the main gate (opening degree 20%) and clear the small amount of overflowing coal flow. PLC automatically detects the status of the equipment: hydraulic pressure 22MPa (normal), sensor accuracy is within tolerance, and cylinder seals are leak-free; At 9:30, the humidity inside the warehouse dropped to 12.5%, the multi-source monitoring module confirmed no risk, and the system resumed normal operation; The PLC automatically stores the data for this event (8:00-9:30), and the digital twin module saves the scene for subsequent analysis.

[0087] In summary, the intelligent anti-collapse system for coal mine transfer warehouses proposed in this embodiment realizes intelligent management and control of the entire process of "prevention before collapse, interruption during collapse, and recovery after collapse" of the risk of collapse.

[0088] 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.

[0089] Any process or method description in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more 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.

[0090] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. An intelligent anti-collapse bin system for coal mine transfer bins, characterized in that, The system includes: a multi-source monitoring module, an intelligent control module, a rapid execution module, and a secondary protection module; The multi-source monitoring module is used to collect coal flow status parameters in real time; The intelligent control module is communicatively connected to the multi-source monitoring module and is used to determine the risk based on the coal flow state parameters and output control commands. The rapid execution module is connected to the intelligent control module and is used to drive the main gate to move according to the control command. The secondary protection module is connected to the intelligent control module and is used to activate the backup barrier when the main gate fails to close.

2. The system as described in claim 1, characterized in that, The multi-source monitoring module includes: a dual-mode coal pile sensor and a multi-point humidity sensor; The dual-mode coal stacking sensor adopts a fusion of millimeter-wave radar and infrared sensor and is installed above the feeder outlet; The multi-point humidity sensors are distributed along the height of the inner wall of the transfer warehouse.

3. The system as described in claim 2, characterized in that, The multi-source monitoring module also includes: A coal flow velocity sensor, which is a laser Doppler velocity meter, is non-contactly installed above the feeder conveyor belt.

4. The system as described in claim 3, characterized in that, The intelligent control module includes: an explosion-proof PLC controller and an edge computing unit; The edge computing unit is equipped with an AI image recognition model and an LSTM-based risk prediction model to identify coal flow patterns and predict the risk of coal mine collapse.

5. The system as described in claim 4, characterized in that, The fast execution module includes: Explosion-proof hydraulic station and main gate cylinder; The explosion-proof hydraulic station has a built-in bladder accumulator and a supercapacitor to provide emergency power in the event of a power outage. The explosion-proof hydraulic station is installed at a distance of less than or equal to 10 meters from the main gate cylinder.

6. The system as described in claim 5, characterized in that, The closing time of the main gate from fully open to fully closed is less than or equal to 0.5 seconds.

7. The system as described in claim 6, characterized in that, The secondary protection module includes: A foldable carbon fiber buffer baffle and a spare hydraulic cylinder for driving the buffer baffle; The buffer baffle unfolds within 0.3 seconds to form a V-shaped barrier in an emergency.

8. The system as described in claim 7, characterized in that, The system also includes: The humidity control module is used to monitor and control the humidity inside the warehouse within the range of 10% to 12%. The linkage alarm module is linked with the underground personnel positioning system to realize directional audible and visual alarms and personnel evacuation notifications; The digital twin module is used to build a 3D model of the transit warehouse and to visualize the equipment status and simulate risks.

9. A method for controlling the intelligent anti-collapse system of a coal mine transfer silo, based on the intelligent anti-collapse system for coal mine transfer silos described in claims 1-8, characterized in that, The method includes: Real-time data on coal flow height, humidity inside the silo, and coal flow velocity are collected using multi-source sensors. The data on coal flow height, humidity inside the silo, and coal flow velocity are fused and processed, and the risk level is determined based on a preset risk threshold. When the risk level is greater than or equal to the preset emergency threshold, the main gate is controlled to perform an emergency closing action and trigger a linkage alarm. The system monitors the closing status of the main gate. If the closure is not completed within a preset time, it controls the backup protective barrier to deploy to block the coal flow.

10. The method as described in claim 9, characterized in that, The method further includes: Based on the long short-term memory network model, the trend of coal flow height and humidity change in historical periods is predicted and analyzed to obtain the probability of collapse risk in the next 5 to 10 minutes. A risk warning is triggered when the predicted probability of a margin call exceeds a preset probability threshold.

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