Automatic identification and picking system for coal gangue

Abstract

The present application relates to a kind of coal gangue automatic identification picking system.For overcoming prior art defects, the coal gangue automatic identification picking system includes belt conveyor, visual recognition device, sorting device, gangue containing box and control device, control device is electrically connected with belt conveyor, visual recognition device and sorting device, under the control of control device, visual recognition device can identify the gangue in coal flow on belt conveyor, sorting device picks out the identified gangue, and shifts to gangue containing box, characterized in that: infrared explosion-proof lamp is provided above the belt conveyor upstream of the visual recognition device, a reflector is provided above the infrared explosion-proof lamp, the infrared explosion-proof lamp is provided with control circuit, and the control circuit is electrically connected with the control device, under the control of the control device, infrared explosion-proof lamp and belt conveyor are linked control, and synchronous switch is opened.The coal gangue automatic identification picking system of the present application can more accurately identify large gangue, suitable for use in various coal mines.

Description

Technical Field

[0001] This invention relates to an automatic identification and sorting system for coal gangue. Background Technology

[0002] Coal gangue is a by-product of coal mining, accounting for approximately 15% to 20% of raw coal production. Previously, coal preparation plants relied heavily on manual methods to separate coal from gangue, which resulted in low efficiency, high labor intensity, harsh working conditions, and a high risk of equipment blockage or damage.

[0003] The authorization announcement dated December 3, 2021, with announcement number CN112791933B, discloses a high-efficiency coal and gangue sorting system based on microwave radiation. The coal and gangue primary sorting mechanism includes a frame, an upper vibrating screen, a lower vibrating screen, a feeding buffer unit B, a collection hopper, and a collection box. The upper vibrating screen is configured with a left-high, right-low orientation, and the lower vibrating screen is configured with a left-low, right-high orientation. The coal and gangue identification mechanism includes a belt conveyor, camera A, camera B, a microwave heating device, and a temperature sensor. The discharge ends of the upper and lower vibrating screens are each fed to the feed ends of the belt conveyors in the two coal and gangue identification mechanisms by a single-layer material distributor. The sorting execution mechanism includes a jetting cylinder with a spray gun inside. The spray gun is connected to an air source via a sliding block, a rigid pipe, and a flexible hose slidably disposed within the jetting cylinder. The sliding position of the sliding block is adjusted by a cylinder.

[0004] Chinese invention patent CN110624850B, authorized on August 6, 2024, discloses an automatic sorting device for lump coal and large gangue, including an industrial control computer, a controller, a raw coal hopper screening device, a sorting conveyor belt, a queuing device, a density detection device, an air-blowing material sorting unit, and a material sorting temporary storage unit. The screening device is located at the discharge port of the raw coal hopper, and the output end of the screening device corresponds to the input end of the sorting conveyor belt. The queuing device is used to sort the material conveyed by the sorting conveyor belt by thickness, and the density detection device is used to detect the density of the sorted material on the sorting conveyor belt. The material output from the output end of the conveyor belt is sorted by air-blowing material sorting unit and temporarily stored in the material sorting temporary storage unit.

[0005] Chinese invention patent CN110756452B, authorized on March 11, 2025, discloses a coal gangue identification and sorting system, including: a conveying device, a feeding hopper, a surface treatment device, a diversion device, a visual recognition device, a sorting device, and a control device; receiving boxes are provided on both sides of the conveying route of the conveying device; the feeding hopper is located at the conveying start end of the conveying device; the control device is electrically connected to the conveying device, the visual recognition device, and the sorting device to control the operation of the conveying device, the visual recognition device, and the sorting device. The visual recognition device of this coal gangue identification and sorting system can identify gangue in the coal flow on the conveying device (belt conveyor), and its sorting device picks out the identified gangue and transfers it to the gangue receiving box.

[0006] The sorting mechanisms (or sorting mechanisms) of the above three types of gangue sorting equipment are different, but they all rely on computer vision and artificial intelligence technology. The gangue in the coal mining process is similar in image and color to the raw coal. The visual recognition devices of the existing gangue sorting equipment have low recognition accuracy and poor sorting accuracy, and the gangue removal rate of raw coal urgently needs to be improved. Summary of the Invention

[0007] The technical problem to be solved by the present invention is how to overcome the above-mentioned defects of the prior art and provide an automatic coal gangue identification and sorting system with higher accuracy and better ability to remove gangue from raw coal.

[0008] Currently, most coal mines install multiple spray dust suppression devices on belt conveyors to keep the raw coal on the conveyor moist, thereby reducing dust pollution. The raw coal and gangue on the belt conveyor are both damp and dark black in color. The inventors, through extensive research, discovered that this is precisely the main reason for the low recognition accuracy of the visual recognition devices in existing gangue sorting equipment.

[0009] Based on the above findings, the following patent proposal is put forward: This automatic coal gangue identification and sorting system includes a belt conveyor, a vision recognition device, a sorting device, a gangue container, and a control device. The control device is electrically connected to the belt conveyor, the vision recognition device, and the sorting device. Under the control of the control device, the vision recognition device can identify gangue in the coal flow on the belt conveyor, and the sorting device picks out the identified gangue and transfers it to the gangue container. The system is characterized by an infrared explosion-proof light installed above the belt conveyor upstream of the vision recognition device. This infrared explosion-proof light has a reflector and a control circuit electrically connected to the control device. Under the control of the control device, the infrared explosion-proof light and the belt conveyor are linked and switched synchronously (i.e., the infrared explosion-proof light is on when the belt conveyor is running and off when the belt conveyor stops). The infrared explosion-proof light and its control circuit are described in CN201413008Y.

[0010] With this design, the raw coal on the belt conveyor passes through infrared explosion-proof lamps before reaching the visual recognition device. The lamps irradiate the coal with infrared light to dry it, causing the surface moisture, or some of it, of the raw coal and gangue to evaporate. After the raw coal surface dries, its color remains largely unchanged, while the gangue surface becomes more grayish-white. The difference between the two is significant. When the coal then passes through the visual recognition device, this greatly improves the device's recognition accuracy and reduces the gangue removal rate.

[0011] In this system, the infrared explosion-proof lamps only operate when the belt conveyor is running. When the belt conveyor is running, the upper belt and the raw coal above it move rapidly, and the raw coal is irradiated for a short time. The infrared explosion-proof lamps only remove moisture or some moisture from the raw coal and gangue, and will not ignite the raw coal.

[0012] As an optimization, a temperature sensor and a smoke sensor are installed below the infrared explosion-proof lamp. Both sensors are electrically connected to the control device. When the temperature sensor detects that the temperature below the infrared explosion-proof lamp exceeds a predetermined temperature, or when the smoke sensor detects smoke, the infrared explosion-proof lamp shuts off. This design effectively prevents the raw coal from being overheated, thus avoiding safety hazards.

[0013] As an optimization, the infrared explosion-proof lights are provided in two sets, which are used alternately at set intervals. This design allows the two sets of infrared explosion-proof lights to serve as backups for each other and effectively prevents the infrared explosion-proof lights from overheating due to prolonged operation.

[0014] As an optimization, the visual recognition device includes a camera and a vision processor. The camera is used to capture images of the coal flow (hereinafter referred to as coal flow) on the upper conveyor belt. The vision processor includes: a visual automatic recognition module for processing the three-dimensional information of the coal flow using a visual automatic recognition algorithm; a coal flow detection module for obtaining coal flow monitoring information based on the three-dimensional information and reference surface information of the coal flow; and a gangue extraction module for detecting large pieces of gangue based on the three-dimensional information of the coal flow on the upper conveyor belt and a light-colored area threshold that differs from the surrounding color. This design is scientific, reliable in operation, and provides good recognition results.

[0015] As an optimization, the visual automatic recognition module further includes a correction unit for correcting images captured by the camera, performing distortion correction and alignment processing on the relevant images. This design ensures the accuracy of 3D information, thereby improving recognition precision and providing a standardized, precisely aligned image for subsequent matching and 3D calculations.

[0016] As an optimization, an industrial computer and display screen are also included. The industrial computer receives the output signal from the gangue extraction module and controls the downstream sorting device to operate. This design facilitates remote and centralized monitoring.

[0017] As an optimization, the visual recognition device and sorting device transmit the monitored coal flow information and gangue extraction information to the industrial computer via a gigabit network port. The industrial computer then sends instructions to the sorting device. This design ensures rapid and efficient information transmission.

[0018] As an optimization, the camera is also equipped with a supplementary light to provide illumination. This design results in clear images that are easy to identify.

[0019] The automatic coal gangue identification and sorting system of this invention first uses infrared explosion-proof lamps to irradiate and dry the coal flow before identifying gangue, thereby reducing the moisture on the surface of the coal and gangue, which can more accurately identify large pieces of gangue, making it suitable for use in various coal mines. Attached Figure Description

[0020] The automatic coal gangue identification and sorting system of the present invention will be further described below with reference to the accompanying drawings: Fig. 1 This is a schematic diagram of the structure of the automatic coal gangue identification and sorting system; Fig. 2 This is a block diagram of the control logic structure of the vision processor in the automatic coal gangue identification and sorting system.

[0021] In the diagram: 1 is a belt conveyor, 2 is a sorting device, 3 is a gangue container, 4 is a control device, 5 is gangue, 6 is an infrared explosion-proof light, 7 is a temperature sensor, 8 is a smoke sensor, 9 is a camera, 10 is a vision processor, 101 is a visual automatic recognition module, 102 is a coal flow detection module, 103 is a gangue extraction module, 11 is a calibration unit, 12 is an industrial computer, 13 is a display screen, 14 is coal, 15 is a reflector, and 16 is the roof of the belt conveyor roadway. Detailed Implementation

[0022] Implementation method one: such as Figs. 1-2 As shown, this automatic coal gangue identification and sorting system includes a belt conveyor 1, a vision recognition device, a sorting device 2, a gangue container 3, and a control device 4. The control device 4 is electrically connected to the belt conveyor 1, the vision recognition device, and the sorting device 2. Under the control of the control device 4, the vision recognition device can identify gangue 5 in the coal flow on the belt conveyor 1. The sorting device 2 picks out the identified gangue 5 and transfers it to the gangue container 3. The system is characterized in that: an infrared explosion-proof lamp 6 is provided above the belt conveyor 1 upstream of the vision recognition device. A reflector 15 is provided above the infrared explosion-proof lamp 6. The infrared explosion-proof lamp 6 is equipped with a control circuit, which is electrically connected to the control device 4. Under the control of the control device 4, the infrared explosion-proof lamp 6 is linked to the belt conveyor 1 and switched synchronously (i.e., the infrared explosion-proof lamp 6 is turned on when the belt conveyor 1 is running and turned off when the belt conveyor 1 is stopped).

[0023] A temperature sensor 7 and a smoke sensor 8 are installed below the infrared explosion-proof lamp 6. Both the temperature sensor 7 and the smoke sensor 8 are electrically connected to the control device 4. When the temperature sensor 7 detects that the temperature below the infrared explosion-proof lamp 6 exceeds a predetermined temperature (e.g., 70°C) or the smoke sensor 8 detects smoke, the infrared explosion-proof lamp 6 is turned off. There are two sets of infrared explosion-proof lamps 6 (set in front and behind) that are used alternately.

[0024] The visual recognition device includes a camera 9 and a visual processor 10. The camera 9 is used to capture images of the coal flow (hereinafter referred to as coal flow) on the upper conveyor belt of the conveyor 1. The visual processor 10 includes: a visual automatic recognition module 101, used to process the three-dimensional information of the coal flow using a visual automatic recognition algorithm; a coal flow detection module 102, used to obtain coal flow monitoring information based on the three-dimensional information and reference surface information of the coal flow; and a gangue extraction module 103, used to detect large pieces of gangue based on the three-dimensional information of the coal flow and a light-colored area threshold that is different from the surrounding color.

[0025] The visual automatic recognition module 101 includes a correction unit 11, which is used to correct the image captured by the camera to ensure the accuracy of the three-dimensional information. This involves image distortion correction, alignment and other processing to improve recognition accuracy and provide a standardized and precisely aligned image pair for subsequent matching and three-dimensional calculation.

[0026] The coal flow detection module 102 obtains the cross-sectional profile of the coal flow in real time by performing differential calculation between the three-dimensional information of the coal flow and the pre-stored belt reference surface information when there is no coal. Based on the cross-sectional profile, it calculates the cross-sectional area, maximum height and lateral width of the coal flow. When the maximum height of the coal flow exceeds the set safe height threshold, it generates an alarm signal for early warning or shutdown control to prevent coal blockage or overflow.

[0027] It also includes an industrial computer 12 and a display screen 13. The industrial computer 12 receives the output signal of the gangue extraction module 103 and controls the downstream sorting device 2 to perform its operation.

[0028] The visual recognition device and sorting device transmit the monitored coal flow information and gangue extraction information to the industrial computer 12 via a gigabit network port. The industrial computer 12 then sends instructions to the sorting device 2. The camera 9 is also equipped with a supplementary light (not shown in the figure) to provide illumination for the camera.

Claims

1. An automatic coal gangue identification and sorting system, comprising a belt conveyor, a vision recognition device, a sorting device, a gangue container, and a control device, wherein the control device is electrically connected to the belt conveyor, the vision recognition device, and the sorting device; under the control of the control device, the vision recognition device can identify gangue in the coal flow on the belt conveyor, and the sorting device picks out the identified gangue and transfers it to the gangue container, characterized in that: An infrared explosion-proof light is installed above the conveyor belt upstream of the visual recognition device. The infrared explosion-proof light is equipped with a reflector and a control circuit. The control circuit is electrically connected to the control device. Under the control of the control device, the infrared explosion-proof light and the conveyor belt are linked and switched on and off synchronously.

2. The automatic coal gangue identification and sorting system according to claim 1, characterized in that: A temperature sensor and a smoke sensor are installed below the infrared explosion-proof light. Both the temperature sensor and the smoke sensor are electrically connected to the control device. When the temperature sensor detects that the temperature below the infrared explosion-proof light exceeds a predetermined temperature or the smoke sensor detects that smoke is generated, the infrared explosion-proof light is turned off.

3. The automatic coal gangue identification and sorting system according to claim 1, characterized in that: There are two sets of infrared explosion-proof lights, which are used alternately.

4. The automatic coal gangue identification and sorting system according to claim 1, characterized in that: The visual recognition device includes a camera and a vision processor. The camera is used to capture images of the coal flow on the upper conveyor belt. The vision processor includes: a visual automatic recognition module, used to process the three-dimensional information of the coal flow on the upper conveyor belt using a visual automatic recognition algorithm; a coal flow detection module, used to obtain coal flow monitoring information based on the three-dimensional information and reference surface information of the coal flow on the upper conveyor belt; and a gangue extraction module, used to detect large pieces of gangue based on the three-dimensional information of the coal flow on the upper conveyor belt and a light-colored area threshold that differs from the surrounding color.

5. The automatic coal gangue identification and sorting system according to claim 4, characterized in that: The automatic visual recognition module further includes a correction unit, used to correct images captured by the camera and perform distortion correction and alignment processing on the relevant images.

6. The automatic coal gangue identification and sorting system according to claim 4, characterized in that: It also includes an industrial computer and a display screen, wherein the industrial computer receives the output signal of the gangue extraction module and controls the downstream sorting device to perform its operation.

7. The automatic coal gangue identification and sorting system according to claim 1, characterized in that: The visual recognition device and the sorting device send the monitored coal flow information and gangue extraction information to the industrial computer via a gigabit network port, and the industrial computer sends instructions to the sorting device.

8. The automatic coal gangue identification and sorting system according to claim 7, characterized in that: The camera is also equipped with a fill light to provide illumination for the camera.

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