A destructive iron piece sorting system in an iron ore mining process

Abstract

This invention discloses a destructive iron component sorting system for iron ore mining. The system includes: a machine vision recognition module for real-time image acquisition of materials on a conveyor belt and for identifying and locating destructive iron components mixed in the ore; a robot sorting execution module that moves to the location of the iron component based on the positioning information provided by the machine vision recognition module and performs gripping and moving operations; a central control module electrically connected to the machine vision recognition module, the robot sorting execution module, and the conveyor belt drive device for coordinating the linkage control of each module; and an early warning and shutdown control module that triggers an alarm and stops the conveyor belt when an iron component is detected. High efficiency and high reliability: It achieves 24-hour uninterrupted automatic sorting, with sorting speed and accuracy far exceeding manual operation, significantly reducing the missed detection rate and ensuring a smooth production process.

Description

Technical Field

[0001] This invention relates to the field of foreign object sorting technology in iron ore mining and beneficiation processes, and particularly to a destructive automatic identification and sorting system and method for iron parts based on machine vision and robotics technology. Background Technology

[0002] During the mining and processing of iron ore, large iron components from mining equipment, such as iron plates, reinforcing bars, steel fibers, and shovel teeth, are often mixed in with the ore during blasting, loading, and transportation. These iron components enter subsequent processes such as conveying, crushing, and grinding along with the ore, and can easily cause blockages, wear, or even serious damage to critical equipment such as crushers and grinders. This leads to unplanned downtime of the production line, high maintenance costs, and seriously affects production efficiency and economic benefits.

[0003] Currently, the industry mainly relies on manual inspection and sorting along the conveyor belt. This method has significant drawbacks: First, manual identification is prone to missed detections due to visual fatigue, resulting in poor reliability; second, the production environment is harsh, posing occupational health and safety hazards such as dust and noise; finally, manual sorting is inefficient and usually requires machine downtime, affecting production continuity.

[0004] To address the aforementioned issues and achieve safe production and intelligent management, there is an urgent need to develop a technology and equipment capable of automatically, accurately, and efficiently sorting destructive iron parts. Summary of the Invention

[0005] The present invention aims to overcome the shortcomings of the prior art and provide a destructive iron sorting system in iron ore mining process to solve the problems of low efficiency, poor safety, high missed detection rate and damage to production equipment caused by iron parts in manual sorting.

[0006] A destructive iron component sorting system for iron ore mining processes, the system comprising: The machine vision recognition module is used to acquire image information of materials on the conveyor belt in real time, and to identify and locate destructive iron parts mixed in the ore; The robot sorting execution module moves to the location of the iron piece and performs gripping and moving operations based on the positioning information provided by the machine vision recognition module; The central control module is electrically connected to the machine vision recognition module, the robot sorting execution module, and the conveyor belt drive device, respectively, and is used to coordinate the linkage control of each module. The early warning and shutdown control module triggers an alarm and stops the conveyor belt when it detects an iron object.

[0007] Preferably, the machine vision recognition module is equipped with a foreign object screening unit, which is configured to set a sorting threshold based on the weight, size and shape characteristics of the iron parts, and trigger the sorting process only for iron parts that exceed the preset threshold.

[0008] Preferably, the sorting threshold is set to the iron part weighing more than 8kg and having a size greater than 50cm*10cm.

[0009] Preferably, the end effector of the robot sorting execution module integrates an auxiliary vision positioning unit for secondary precise positioning of the iron parts before gripping.

[0010] Preferably, the central control module includes an intelligent decision-making unit. When the foreign object identified by the machine vision recognition module is determined to be a non-target object, the intelligent decision-making unit controls the conveyor belt to automatically resume operation and release the foreign object.

[0011] Preferably, the system further includes a data recording and analysis module for recording historical data of sorting events, including sorting time, images of iron parts, and feature data.

[0012] A method for sorting destructive iron parts in an iron ore mining process, the method comprising the following steps: S1: Continuously monitor the conveyor belt in operation using a machine vision system to acquire material images; S2: Process and analyze the image to identify the iron parts and determine whether they meet the sorting conditions; S3: If the conditions are met, trigger an early warning and control the conveyor belt to stop, while sending the position information of the iron piece to the robot system; S4: The robot system moves to the target position, performs a gripping action, and removes the iron piece from the conveyor belt; S5: After the sorting action is completed, the control system confirms and restarts the conveyor belt to resume production.

[0013] Preferably, in step S4, the robot performs secondary positioning using a vision device integrated at the end effector before grasping, in order to improve grasping accuracy.

[0014] Preferably, in step S2, the sorting conditions are determined based on preset thresholds for the weight and size of the iron parts.

[0015] Preferably, in step S2, if the identified foreign object does not meet the sorting conditions, the system does not trigger a shutdown process, and the conveyor belt continues to run.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. High efficiency and high reliability: Enables 24-hour uninterrupted automatic sorting, with sorting speed and accuracy far exceeding manual operation, significantly reducing the missed detection rate and ensuring smooth production process.

[0017] 2. Enhanced safety: Completely replaces manual sorting operations in hazardous environments, fundamentally eliminating corresponding safety and occupational health hazards.

[0018] 3. Reduce production costs: Effectively prevent large iron components from damaging expensive downstream equipment, significantly reduce equipment maintenance costs and downtime losses, and save labor costs.

[0019] 4. High intelligence and adaptability: Through parameter settings, the system can intelligently determine sorting priorities and optimize production rhythm. Simultaneously, data-driven analysis and optimization support predictive maintenance and lean manufacturing. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the layout of the iron parts sorting system described in this invention on an ore conveying line. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1 As shown in the figure, the machine vision system is installed above the conveyor belt, the robot sorting system is located on the side of the conveyor belt, and the central control cabinet is arranged nearby. The entire system forms a closed loop with the conveyor belt.

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1 The present invention provides a technical solution: The present invention adopts the following technical solution: A destructive iron component sorting system for iron ore mining processes is deployed at key locations on ore conveyor belts (such as belt #1) and mainly consists of four parts working in concert: a machine vision system, a robot sorting system, a central control system, and an early warning system.

[0025] Machine vision system: As the "eyes" of the system, it is responsible for acquiring image information of materials on the conveyor belt in real time. The system uses advanced image recognition algorithms (such as deep learning object detection algorithms) to distinguish between ore and iron parts in the image, accurately identify the position, outline, size and other information of the iron parts, and send this data to the central control system.

[0026] Robotic sorting system: The "hand" of the system typically employs a high-degree-of-freedom, high-precision industrial robot (robotic arm). Based on coordinate information provided by a vision system, the robotic arm moves above the workpiece. To improve gripping accuracy, an auxiliary vision camera can be integrated into the end effector for secondary precise positioning. Subsequently, the robotic arm performs the gripping action, removing the workpiece from the conveyor belt and placing it into a designated waste collection device.

[0027] Central control system: As the "brain" of the system, it uses a programmable logic controller (PLC) or industrial computer (IPC) to coordinate the operation of the entire system. It receives the recognition results from the vision system, decides the sorting strategy, controls the movement trajectory of the robotic arm, and links with the drive unit of the conveyor belt.

[0028] Early warning system: When the vision system detects a metal object, the early warning system immediately activates, issuing an audible and visual alarm signal to alert the operator. Simultaneously, it controls the conveyor belt to temporarily stop via I / O signal output, creating safe and stable operating conditions for the robot sorting. After sorting is completed, the system automatically resumes conveyor belt operation.

[0029] Preferred implementation scheme: Foreign object screening mechanism: To balance sorting efficiency and production continuity, the system can set sorting thresholds. For example, only large, destructive iron parts weighing more than 8kg and with irregular shapes larger than 50cm*10cm are automatically sorted, thereby reducing downtime and achieving critical protection for the core equipment of medium and fine crushing.

[0030] Intelligent sorting process: After the vision system initially identifies a suspected iron object, the system automatically stops the conveyor belt until the target moves into the working range of the robotic arm. An auxiliary camera at the end of the robotic arm performs a second identification and confirmation. If it is confirmed to be the target iron object to be picked up, the picking process is executed; if it is a misjudgment or a non-target foreign object, the system automatically releases it and restarts the conveyor belt to continue production.

[0031] Human-machine interaction: The system is equipped with a human-machine interface (HMI) for setting sorting parameters, displaying equipment status, recording historical sorting data, and supporting manual intervention.

[0032] The following will combine Figure 1 A specific embodiment of the present invention will be described.

[0033] In this embodiment, the system is deployed at the No. 1 belt conveyor transfer point of the ore conveying system. The vision system uses a high-resolution industrial camera and a dust-resistant lighting system to ensure image acquisition quality. The image recognition algorithm has been trained on a large number of ore and ironwork images and has a high recognition rate.

[0034] During operation, ore flows along conveyor belt #1, which is continuously monitored by the vision system. Once a large iron piece that meets the criteria is detected, the control system immediately issues an alert and stops the conveyor belt. The robotic arm moves to the approximate location of the iron piece based on the vision positioning data, and its end effector camera performs secondary precise positioning, guiding the robotic arm to successfully grasp the iron piece and place it into a nearby waste bin. After completion, the control system receives a confirmation signal, automatically restarts the conveyor belt, and resumes normal production.

[0035] The system can also record information about the iron parts sorted each time (such as time, size estimation, etc.), forming a data log for production analysis and equipment status assessment.

Claims

1. A destructive iron component sorting system in iron ore mining, characterized in that, The system includes: The machine vision recognition module is used to acquire image information of materials on the conveyor belt in real time, and to identify and locate destructive iron parts mixed in the ore; The robot sorting execution module moves to the location of the iron piece and performs gripping and moving operations based on the positioning information provided by the machine vision recognition module; The central control module is electrically connected to the machine vision recognition module, the robot sorting execution module, and the conveyor belt drive device, respectively, and is used to coordinate the linkage control of each module. The early warning and shutdown control module triggers an alarm and stops the conveyor belt when it detects an iron object.

2. The destructive iron component sorting system in an iron ore mining process according to claim 1, characterized in that, The machine vision recognition module is equipped with a foreign object screening unit, which is configured to set a sorting threshold based on the weight, size and shape characteristics of the iron parts, and trigger the sorting process only for iron parts that exceed the preset threshold.

3. The destructive iron component sorting system in an iron ore mining process according to claim 2, characterized in that, The sorting threshold is set as follows: the weight of the iron piece is greater than 8kg and the size is greater than 50cm*10cm.

4. The destructive iron component sorting system in an iron ore mining process according to claim 1, characterized in that, The end effector of the robot sorting execution module integrates an auxiliary vision positioning unit, which is used to perform secondary precise positioning of the iron parts before grasping.

5. The destructive iron component sorting system in an iron ore mining process according to claim 1, characterized in that, The central control module includes an intelligent decision-making unit. When the foreign object identified by the machine vision recognition module is determined to be a non-target object, the intelligent decision-making unit controls the conveyor belt to automatically resume operation and release the foreign object.

6. The destructive iron component sorting system in an iron ore mining process according to claim 1, characterized in that, The system also includes a data recording and analysis module for recording historical data of sorting events, including sorting time, images of iron parts, and feature data.

7. A method for sorting destructive iron parts in an iron ore mining process according to any one of claims 1 to 6, characterized in that, The method includes the following steps: S1: Continuously monitor the conveyor belt in operation using a machine vision system to acquire material images; S2: Process and analyze the image to identify the iron parts and determine whether they meet the sorting conditions; S3: If the conditions are met, trigger an early warning and control the conveyor belt to stop, while sending the position information of the iron piece to the robot system; S4: The robot system moves to the target position, performs a gripping action, and removes the iron piece from the conveyor belt; S5: After the sorting action is completed, the control system confirms and restarts the conveyor belt to resume production.

8. A method for sorting destructive iron parts in an iron ore mining process according to claim 7, characterized in that, In step S4, the robot performs secondary positioning using the vision device integrated at the end effector before grasping, in order to improve grasping accuracy.

9. A method for sorting destructive iron parts in an iron ore mining process according to claim 7, characterized in that, In step S2, the sorting conditions are determined based on preset thresholds for the weight and size of the iron parts.

10. A method for sorting destructive iron parts in an iron ore mining process according to claim 7, characterized in that, In step S2, if the identified foreign object does not meet the sorting conditions, the system will not trigger a shutdown process, and the conveyor belt will continue to run.

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